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TX6023/4 User Manual
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1. SENSOR Red V a 5546 18 i Interface b Black Sig Unit ov Supply E t E Black Sig TX6114 PRESSURE SENSOR www trolex com TX6023 4 UM EN 01 15 TROLEX lt 3 5 3 TX6024 to TX9042 Connections Flow Module Pressure Module P5423 556 P5423 508 pa Tro TX6147 FLOW SEN H Red V p aw Black Sig eS TX6114 PRESSURE SENSOR Black Sig 3 b 4 TX6024 to TX9131 Connections 7 8 9 1011112 7 81 9 10 1112 rip Amplifier Assembly includes TX9131 Trip Optional TX9131 TX9131 Trip Amplifier Amplifier and P5546 18 Trip Amplifier Pressure Interface Unit Monitoring TX6147 FLOW SENSOR T P5546 18 demam seasg W 1 E TX6114 PRESSURE SENSOR 16 TX6023 4 UM EN 01 www trolex com 1X6023 TX6024 User Manual 4 Configuration In order to get the best performance out of the 1X6023 4 Liquid Flow Pressure Monitoring System it should be used in conjunction with the 1 9042 Programmable Sensor Controller or the 9131 Programmable Trip Amplifier Some set up of these controllers will be required in order to linearise and compensate the flow reading 4 1 TX6023 Configuration 4 1 1 6023 to TX9042 Configuration Checkpoint Ensure that the TX9042 has a P5423 553 flow module installed Checkpoint display and control of pressure is required ensure that a separate P5423 508 p
2. Europe Ex Certificate number Baseefa 0021 Ex Certification code M1 Ex ia 20 C lt Ta lt 60 C Specific Conditions of Use 1 When installing the apparatus please note that the screen of the integral cable must be connected internally to the frame of the apparatus 2 Also during installation please note that Pin 4 of the optional plug socket arrangement is connected internally to the frame of the apparatus 3 When the absolute version is used the electrical circuit is not capable of withstanding 500 V RMS to earth or frame and this must be taken into account when installing General Conditions of Use Prior to installation it is essential that user refers to the above certificate to ensure that the termination and cable parameters are fully complied with and are compatible with the application Copies of certificates are available from Trolex ATEX Directive 94 9 EC EMC Directive 2004 108 EC C 10 TX6023 4 UM EN 01 www trolex com TX6023 TX6024 User Manual 2 Australia ANZEx JAS ANZ Ex Certificate number ANZEx 12 3024X Ex Certification Code ia 20 C lt lt 60 C iA E 1 Conditions of Certification 1 Prior to installation it is essential that the user refers to the above certificate to ensure that the termination and cable parameters are fully complied with and are compatible with the application Co
3. contact your local Trolex service agent or service trolex com for advice on repair or replacement 5 After the completion of all maintenance update the maintenance records e 20 TX6023 4 UM EN 01 www trolex com 1X6023 TX6024 User Manual 5 1 2 Liquid Flow Pressure Monitoring System Calibrate 1 Under normal circumstances the calibration of the Liquid Flow Pressure Monitoring System will not change significantly 2 Check the accuracy by comparing the display reading with a reference value of flow velocity OR 2 Alternatively the Liquid Flow Pressure Monitoring System can be removed and returned to your local Trolex service agent for checking and calibration across the full operating spectrum Contact service trolex com for further information 3 After the completion of all maintenance update the maintenance records 6 Support If you need technical support to operate this product or would like details of our after sales technical support packages please contact your local Trolex service agent or service trolex com 7 Disposal Part of the ethos of Trolex is sustainable design The Liquid Flow Pressure Monitoring System contains materials that can be recovered recycled and reused At the end of its useful life ensure that the Liquid Flow Pressure Monitoring System Is recycled in accordance with local laws and bylaws for the geographic area where it is located The end of its useful life is to be determined
4. in Group hazardous areas mining when used with approved equipment eg 9042 Programmable Sensor Controller or TX9131 Trip Amplifiers The complete system both sensors and monitoring devices can be mounted in the hazardous area Both the sensors and the monitoring equipment should be powered from the same certified power supply Checkpoint Ensure that the sensors are the intrinsically safe versions Group 14 TX6023 4 UM EN 01 www trolex com TX6023 TX6024 User Manual 3 b Connections The flow and pressure sensors and the venturi can be mounted in any attitude however a slight zero shift may be noticed due to gravity acting on the flow sensor diaphragm This can be zeroed via the X9042 or 9131 refer to respective User Manuals for details The venturi can be mounted utilising standard proprietary pipe clamps The venturi diameters are 63 5 mm and 89 mm equivalent pipe diameters are 21 2 3 5 1 TX6023 to TX9042 Connections Flow Module Pressure Module P5423 553 P5423 508 pa Teo TX6145 FLOW SENSOR Red V 21 n Sig Black Sig TX6114 PRESSURE SENSOR 3 5 2 TX6023 to TX9131 PD779 Connections 718 9 10 1112 7 8 910 1112 P5438 91 Trip Amplifier Optional TX9131 Assembly includes 1X9131 PD779 Trip Amplifier TX91 31 PD779 Trip Amplifier Pressure Trip Amplifier and itori Monitoring P5546 18 Interface Unit ppp TX6145
5. operating pressure of the TX6114 may cause permanent damage or de calibration of the output signal For Intrinsically Safe applications the instrument must be used with an Approved Intrinsically Safe power supply source All interconnecting cables to monitoring equipment must comply with the requirements of the particular monitoring device being used in order to preserve the Intrinsically Safe integrity of the system Out of balance pressure or high pressure surges can cause permanent damage to the sensing elements inside the instruments Never operate the instrument without both process connections being connected If maintenance work or testing is being carried out on the hydraulic circuits of the machine then the instruments should be protected against pressure surges or the application of reverse pressure Ensure that the correct modules are fitted in the 9042 www trolex com TX6023 4 UM EN 01 13 TROLEX lt 3 2 Tools and Test Equipment Required No special tools are needed 3 3 Preparation 1 Check that the supply voltage is correct for the application and is from an approved supply Check that the certification code is correct Check that the pressure range 1 correct Check that the flow range 1 correct refer to venturi details Check that the mechanical fittings are correct E a 3 4 Connecting in Group Hazardous Areas Mining The output signals of the sensors are certified Intrinsically Safe for use
6. read zero Refer to the 9042 User Manual for instructions on how to enter this figure 4 1 2 TX6023 to T X9131 PD779 Configuration Checkpoint display and control of pressure is required ensure that a separate X9131 is also used 1 Ensure the pressure and flow sensors have been correctly wired to the TX9131 refer to Section 3 5 2 for information 2 From the venturi used determine the Flow Constant and program it into the TX9131 PD779 refer to the User Manual for instructions on how to enter this figure 3 Note the full scale pressure range of the associated 6114 and program this value into the 9131 connected to the 1X6114 pressure sensor refer to the TX9131 User Manual for instructions on how to enter this figure 4 Note the full scale flow range of the venturi being used and program this value into Upper on the TX9131 PD7789 refer to the 9131 User Manual for instructions on how to enter this figure 5 Now with the unit correctly wired and hydraulically connected the display should read the correct flow Due to mechanical constraints and mounting attitude there may be a little zero drift this can be removed by setting DP Zero the TX9131 PD7789 refer to the TX9131 User Manual for instructions on how to enter this figure Checkpoint Note that the DP Zero should only be carried out at zero flow otherwise it will invalidate the sensor calibration 6 In order that the display on the TX913
7. 1 PD779 does not display a small amount of flow due to further zero drift Flow Mask on the TX9131 PD779 can be set to a flow value below which the display will read zero Refer to the 9131 User Manual for instructions on how to enter this figure 18 TX6023 4 UM EN 01 www trolex com 1X6023 TX6024 User Manual 4 2 TX6024 Configuration 4 2 1 TX6024 to TX9042 Configuration Checkpoint Ensure that the TX9042 has a P5423 556 flow module installed Checkpoint display and control of pressure is required ensure that a separate P5423 508 pressure module is installed 1 Ensure the pressure and flow sensors have been correctly wired to the X9042 refer to Section 3 5 3 for information 2 Note the full scale pressure range of the associated TX6114 and program this value into channel of the 9042 that has the 6114 connected to it refer to the TX9042 User Manual for instructions on how to enter this figure 3 Note the full scale flow range of the venturi being used and program this value into Upper on the T X9042 refer to the 9042 User Manual for instructions on how to enter this figure 4 2 2 TX6024 to TX9131 Configuration Checkpoint display and control of pressure is required ensure that a separate X9131 is also used 1 Ensure the pressure and flow sensors have been correctly wired to the TX9131 refer to Section 3 5 4 for information 2 Note the full scale flow range of the venturi being use
8. Checkpoint Higher pressure ranges are available please contact Trolex for details 6 TX6023 4 UM EN 01 www trolex com TX6023 TX6024 User Manual 1 4 Dimensions i iji T 309 i ER 179 1000 37 Venturi Diameter A and Flow Rate Venturi Diameter A Flow Rate 63 5 mm to 20 l min 63 5 mm to 30 l min 63 5 mm to 50 l min 63 5 mm 120 l min 89 mm to 200 l min 99 mm to 300 l min www trolex com TX6023 4 UM EN 01 7 TROLEX lt 1 5 Technical Information Flow measuring range 20 30 50 120 200 and 300 l min venturi options dependent Pressure range options to 50 to 100 and 0 to 200 bar Higher pressure ranges are available Maximum pressure drop 0 9 to 2 0 bar Accuracy 2 of full scale Repeatability 1 of full scale Ambient temperature range 20 to 60 C Supply voltage 12 V dc nominal Output signals Flow 4 to 20 mA Pressure 4 to 20 mA Protection classification 66 TX6114 PRESSURE SENSOR TX6145 7 FLOW SENSOR 8 TX6023 4 UM EN 01 Red E Red V P PEE Blue Sig V Black Sig www trolex com 1X6023 TX6024 User Manual 2 Certification 2 1 Intrinsically Safe 2 1 1 TX6145 and TX6147 1 Europe ATEX Ex Certificate number Baseefa ObATEXO193U Ex Certification code M1 Ex ial 60 C Ta lt 70 C Specific Condition of Use The connector pins of the component must be protected to IP54 minimum wh
9. TX6023 TX6024 2 TROLE _ Liquid Flow Pressure Monitoring System User Manual TX6023 TX6024 Contents 1 Product Overview 1 1 Operating Features 12 Application 13 Product Options 14 Dimensions 15 Technical Information 2 Certification 2 1 Intrinsically Safe 3 Installation 3 1 Safety Precautions 3 2 Tools and Test Equipment Required 3 9 Preparation wwW trolex com 1X6023 TX6024 User Manual Liquid Flow Pressure Monitoring System cO ON gt A 3 4 X Connecting in Group Hazardous Areas Mining 3 5 Connections 4 Configuration 4 1 6023 Configuration 4 2 6024 Configuration 5 Maintenance 5 1 Introduction 6 Support 7 Disposal Disclaimers Trademarks Contact Details Document History TX6023 4 UM EN 01 14 12 17 19 20 20 21 21 22 22 22 22 3 TROLEX lt 1 Product Overview 2x4 to 20 mA calibrated analogue output signal TX6023 4 Protected to IP66 1 1 Operating Features e For use on cutters shearers power packs road headers etc in the mining and tunnelling industry e Precision monitoring of both flow and pressure to improve integrity on heavy duty machinery results in less downtime and more productivity e Versatile high flow capability at high static pressure for use with water and oil e Low maintenance clear bore hole path with no invasive components no springs no levers and no mechanical shuttle
10. by the owner operator of the equipment and not Trolex Ensure that the Liquid Flow Pressure Monitoring system is recycled by licenced waste contractors with the appropriate licences for handling metallic and electronic waste in the geographic area where the Liquid Flow Pressure Monitoring System is located Checkpoint Consult your local Trolex service agent or the Trolex Product Support Department If you require assistance with disposal service trolex com www trolex com TX6023 4 UM EN 01 21 TROLEX lt Disclaimers The information provided in this document contains general descriptions and technical characteristics of the performance of the product It is not intended as a substitute for and is not to be used for determining suitability or reliability of this product for specific user applications It is the duty of any user or installer to perform the appropriate and complete risk analysis evaluation and testing of the products with respect to the relevant specific application or use Trolex shall not be responsible or liable for misuse of the information contained herein If you have any suggestions for improvements or amendments or find errors in this publication please notify us at marketing trolex com No part of this document may be reproduced in any form or by any means electronic or mechanical including photocopying without express written permission of Trolex All pertinent state regional and local safety regulati
11. d and program this value into Upper on the X9131 refer to the 9131 User Manual for instructions on how to enter this figure 3 Note the full scale pressure range of the associated 6114 and program this value into the 9131 connected to the 1X6114 pressure sensor refer to the TX9131 User Manual for instructions on how to enter this figure www trolex com TX6023 4 UM EN 01 19 TROLEX lt 5 Maintenance 5 1 Introduction To keep your Liquid Flow Pressure Monitoring System in the best possible condition and minimise downtime Trolex strongly recommends that you carry out regular planned preventative maintenance and keep records of the maintenance carried out The planned preventative maintenance for Liquid Flow Pressure Monitoring System consists of a number of tasks carried out at regular intervals These tasks are listed in the maintenance schedule below Equipment Name Task Type Mm muc Liquid Flow Pressure Monitoring GE 511 12 months oystem Liquid Flow Pressure Monitoring 512 12 months System 5 1 1 Liquid Flow Pressure Monitoring System Check 1 Check the exterior of the Liquid Flow Pressure Monitoring System for cracks penetration and any other signs of damage 2 Check that the wiring is secure and free trom damage Check that the Liquid Flow Pressure Monitoring System is securely mounted 4 f any part of the Liquid Flow Pressure Monitoring System shows any signs of damage deformation or missing parts
12. en installed General Conditions of Use Prior to installation it is essential that user refers to the above certificate to ensure that the termination and cable parameters are fully complied with and are compatible with the application Copies of certificates are available from Trolex ATEX Directive 94 9 EC EMC Directive 2004 108 EC C 2 Australia JAS ANZ Ex Certificate number AUSEx 02 1519X Ex Certification Code Ex ia 60 lt Ta lt 70 C A A p 1 Specific Condition of Use The connector pins of the component must be protected to 54 minimum when installed General Conditions of Use Prior to installation it is essential that user refers to the above certificate to ensure that the termination and cable parameters are fully complied with and are compatible with the application Copies of certificates are available from Irolex www trolex com TX6023 4 UM EN 01 9 TROLEX lt 3 South Africa Ex certificate number MASC M 13 575U Ex certification codes Ex ia 60 lt Ta lt 70 C Specific Condition of Use The connector pins of the component must be protected to 54 minimum when installed General Conditions of Use Prior to installation it is essential that user refers to the above certificate to ensure that the termination and cable parameters are fully complied with and are compatible with the application Copies of certificates are available from Trolex 2 1 2 TX6114 1
13. ns of Use Prior to installation it is essential that user refers to the above certificate to ensure that the termination and cable parameters are fully complied with and are compatible with the application Copies of certificates are available from Trolex c Conditions of Use Prior to installation it is essential that user refers to the above certificate for any specific conditions of use The user must ensure that the termination and cable parameters are fully complied with and are compatible with the application Copies of certificates are available from Trolex 2 1 3 6023 4 1 Russia GOST R Ex certificate number GB 5 03981 Ex certification code PO Ex ia 2 India CIMFR Test Report Test report CIMFR TC P H796 available Please contact Trolex 12 TX6023 4 UM EN 01 www trolex com 3 3 1 1X6023 TX6024 User Manual Installation Safety Precautions Ensure sensor ranges are compatible with the application Ensure that appropriately rated pressure couplings are used for the installation of the sensors Where the sensors are to be used on high pressure systems take care to isolate and relieve the system pressure before installation or removal Ensure all fittings are secure before applying pressure to the system Do not insert sharp or metallic objects into any sensor pressure orifice as this may cause internal damage to the sensors otatic line pressures in excess of 2 times the rated
14. ons must be observed when installing and using this product For reasons of safety and to ensure compliance with documented system data only Trolex or its affiliates should perform repairs to components When devices are used for applications with technical safety requirements the relevant instructions must be followed Trademarks 2014 Irolex amp Limited Trolex is a registered trademark of Trolex Limited The use of all trademarks in this document is acknowledged Document History Issue 01 21 March 2014 Original publication of this document Contact Details Trolex Ltd Newby Road Hazel Grove Stockport Cheshire SK7 5DY UK 44 0 161 483 1435 salesQtrolex com 22 TX6023 4 UM EN 01 www trolex com _ Trolex Ltd Newby Road Hazel Grove Stockport Cheshire SK7 5DY UK t 44 0 161 483 1435 e salesQtrolex com www trolex com
15. pies of certificates are available from Trolex 2 Itis a condition of safe use that when installing the apparatus the screen of the integral cable must be connected internally to the frame of the apparatus 3 It is a condition of safe use that Pin 4 of the optional plug socket arrangement is connected internally to the frame of the apparatus 4 tis a condition of safe use that the apparatus measures high process pressures but shall be exposed to the hazardous gas at atmospheric pressure only General Conditions of Use Prior to installation it is essential that user refers to the above certificate to ensure that the termination and cable parameters are fully complied with and are compatible with the application Copies of certificates are available from Trolex 3 South Africa Ex certificate number MASC 11 421 Ex certification codes Ex ia 20 lt Ta lt 60 C Specific Conditions of Use 1 When installing the apparatus please note that the screen of the integral cable must be connected internally to the frame of the apparatus 2 Also during installation please note that Pin 4 of the optional plug socket arrangement is connected internally to the frame of the apparatus 3 When the absolute version is used the electrical circuit is not capable of withstanding 500 V RMS to earth or frame and this must be taken into account when installing www trolex com TX6023 4 UM EN 01 11 TROLEX lt General Conditio
16. ressure module is installed 1 Ensure the pressure and flow sensors have been correctly wired to the X9042 refer to Section 3 5 1 for information 2 From the venturi used determine the Flow Constant and program it into the flow channel of the TX9042 refer to the 9042 User Manual for instructions on how to enter this figure 3 Note the full scale pressure range of the associated 6114 and program this value into channel of the 9042 that has the TX6114 connected to it refer to the TX9042 User Manual for instructions on how to enter this figure 4 Note the full scale flow range of the venturi being used and program this value into Upper on the 1 9042 refer to the 9042 User Manual for instructions on how to enter this figure 5 With the unit correctly wired and hydraulically connected the display should read the correct flow Due to mechanical constraints and mounting attitude there may be a little zero drift this can be removed by setting DP Zero on the TX9042 refer to the 9042 User Manual for instructions on how to enter this figure Checkpoint Note that the DP Zero should only be carried out at zero flow otherwise it will invalidate the sensor calibration www trolex com TX6023 4 UM EN 01 17 TROLEX lt 6 In order that the display on the TX9042 does not display a small amount of flow due to further zero drift Flow Mask on the 9042 be set to a flow value below which the display will
17. s e Robust corrosion resistant pressure capsule for accurate analogue pressure monitoring gives high overpressure capability and superior long term stability 4 TX6023 4 UM EN 01 www trolex com 1X6023 TX6024 User Manual 1 2 Application The flow and pressure output signals from the X6023 4 Liquid Flow Pressure Monitoring System sensors can be connected to a 9042 Programmable Sensor Controller or TX9131 Programmable Trio Amplifiers When used in conjunction with 9042 or TX9131 the values of flow velocity and line pressure indicate minute changes in flow delivery to spray heads or hydraulic systems on cutting and shearing machines road headers continuous miners and dust suppression systems etc Monitoring line pressure together with volumetric flow means that precise flow rates can be determined where there are fluctuations in line pressure The flow sensor combines a high accuracy differential pressure sensor and a stainless steel diaphragm pressure sensor with a high precision venturi for mounting into small bore fluid lines The system can be connected directly into oil or water circuits on heavy mining machinery providing a flow path for the fluid with no mechanical intrusions In combination with the venturi the differential pressure sensor gives an output proportional to flow When connected to the 9042 Programmable Sensor Controller a linearised compensated display of flow is shown The line pressure is also di
18. splayed The flow and pressure signals can be used to control the state of up to 4 output relays PRESSURE SIGNAL FLOW SIGNAL TX6145 7 Underground Mining and Tunnelling TX6145 and TX6147 Type of protection M1 Ex ia Intrinsically safe Ex ia TX6114 Category M1 Ex ia Ma IM1 www trolex com TX6023 4 UM EN 01 5 TROLEX lt 13 Product Options TX6023 Liquid Flow Pressure Monitoring System for use with TX9042 Programmable Sensor Controller or P5438 91 Programmable Trip Amplifier Order Reference Flow Range Pressure Range 0 to 50 bar 0 to 100 bar 0 to 200 bar 20 l min TX6023 76 81 TX6023 7781 TX6023 78 81 to l min TX6023 76 82 140023 7792 TX6023 78 82 to 50 l min TX6023 76 83 TX6023 77 83 TX6023 78 63 to 120 l min TX6023 76 84 TX6023 7784 TX6023 78 84 to 200 l min TX6023 76 85 TX6023 7785 TX6023 78 85 to 300 l min 1X6023 76 86 1X6023 77 86 TX6023 78 86 TX6024 Liquid Flow Pressure Monitoring System with Pre conditioned Flow Sensor Output Order Reference Flow Range Pressure Range 0 to 50 bar 0 to 100 bar 0 to 200 bar to 20 l min TX6024 76 81 TX6024 7781 TX6024 78 81 to l min TX6024 76 82 TX6024 7782 TX6024 78 82 to 50 l min TX6024 76 83 TX6024 77 83 TX6024 78 83 to 120 l min TX6024 76 84 TX6024 7784 TX6024 78 84 to 200 l min TX6024 76 85 TX6024 7785 TX6024 78 85 to 300 l min 1 6024 76 86 TX6024 77 86 TX6024 78 86 Checkpoint l min litres per minute
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