TROLEX TX5921 Vortex Air Flow Sensor User Manual

TROLEX TX5921 Vortex Air Flow Sensor

Product Information

Specifications

• Product Name: Vortex Air Flow Sensor
• Model Numbers: TX5921, TX5922, TX5923
• Application: Fixed point airflow velocity measurement in pipes, ducts, and open roadways
• Output Data: Linearly proportional to airflow velocity

Product Overview
The Vortex Air Flow Sensor comes in three configurations:

1. TX5921: Rear projecting sensing probe for duct monitoring
2. TX5922: Side projecting sensing probe for open flow monitoring in tunnels, roadways, and process systems
3. TX5923: Remote mounted sensor for limited or difficult access spaces

Product Usage Instruction

Installation

Tools and Test Equipment Required
Ensure you have the following tools handy before installation:

• Screwdrivers
• Wrenches
• Measuring tape

Siting Recommendations

• Fitting in Pipes and Ducts
  Make sure to position the sensor securely in the pipe or duct using appropriate brackets or clamps.

• Fitting in Roadways and Tunnels
  Install the sensor at a suitable height and angle to capture accurate airflow data.

• Orientation of the Housing
  Ensure the sensor housing is oriented correctly as per the installation guidelines to avoid any interference with airflow.

Setup and Calibration

• Controls and Indicators
  Familiarize yourself with the controls and indicators on the sensor to operate it effectively.

• Software Menus
  Access the setup menu on the sensor to configure various parameters based on your requirements.

Output Signal Check

• Sensing Probe Function Test
  Perform a sensing probe function test to ensure accurate data output.

• Sensing Probe Clean
  Clean the sensing probe regularly to maintain optimal performance.

FAQ

• Q: What is the maximum cable length for TX5923?
  A: The maximum cable length for TX5923 is 10 meters.

• Q: Can the sensing head be replaced separately?
  A: Yes, the sensing head can be replaced separately. Refer to the user manual for specific part numbers.

Product Overview

Vortex air flow sensor with rear projecting sensing probe suitable for duct monitoring

Vortex air flow sensor with side projecting sensing probe for open flow monitoring in tunnels, roadways, and process systems.

Vortex air flow sensor with remote-mounted sensor. For use where fitting space is limited or is difficult to access.

Operating Features

• High stability airflow monitoring
• Vortex monitoring principle with no moving components
• Output signal linearly proportional to flow velocity
• Integral LCD screen with large easy to read characters and backlight illumination
• Easily programmable function and display configuration
• Choice of output signals:
  • 0.4 to 2 V
  • 4 to 20 mA
• Manageable flow velocity from 0.5 m/sec to 30 m/sec

Application

Fixed point airflow velocity measurement in pipes, ducts, and open roadways. Ventilation, cooling systems, and process condition monitoring in heavy-duty industrial applications and hazardous areas. Output data is linearly proportional to airflow velocity.

Product Options

Vortex Air Flow Sensor

Vortex Air Flow Sensor

Sensor Configuration| Product Code
Rear projecting sensor| TX5921
Side projecting sensor| TX5922
Remote sensor| TX5923
Certification|  | Option Code
---|---|---
General Purpose|  | .00
ATEX| Grp I| .01
MASC| Grp I| .05
ANZEx| Grp I| .10
EAC| Grp I| .14
CIMFR| Grp I| .21
ATEX| Grp II| .02
MASC| Grp II| .16
ANZEx| Grp II| .11
EAC| Grp II| .15
Ukraine| Grp I| .24
Output Signal| Option Code
---|---
0.4 – 2 V| .11| Grp I Only
4 – 20 mA| .12|
Process Fitting| Option Code
---|---
None| .00
50 mm ANSI flange| .21
11½ ” BSP bush| .22
Probe Length| Option Code
---|---
165 mm (standard)| .00
500 mm| .02
1000 mm| .03
1800 mm| .04
Velocity Range| Option Code
---|---
5 m/s| .01
10 m/s| .02
15 m/s| .03
20 m/s| .04
25 m/s| .05
30 m/s| .06
Cable Length (TX5923 Only)|  | Option Code
---|---|---
0 m|  | .00
1 m|  | .01
2 m (standard)|  | .02
3 m|  | .03
4 m|  | .04
5 m|  | .05
6 m|  | .06
7 m|  | .07
8 m|  | .08
9 m|  | .09
10 m| (max)| .10

Vortex Air Flow Sensor – Replacement Sensing Head Only

Dimensions

TX5921 Rear Projecting Sensor

TX5922 Side Projecting Sensor

TX5923 Remote Mounted Sensor

Technical Information

2

• 50 mm ANSI mounting flange

Cable entry| • Rear projecting sensing probe – 2 x M20

• Side projecting sensing probe – 1 x M20

• Remotely mounted sensing probe – 1 x 2M20

Net weight| •                    Rear projecting sensing probe – 1.5 kg

•                    Side projecting sensing probe – 1.5 kg

• Remotely mounted sensing probe – 2.5 kg

Information display| 128 x 64 dot graphic backlit LCD screen
Vibration limits| •                    10 to 30 Hz – 1.00 mm total excursion

•                    31 to 150 Hz – 19.6 m/s2 acceleration peak

Impact limits| 20 joules (housing)
Output Signals

Programmable Information

| • 0.4 to 2 V
• 4 to 20 mA

• zero & span
• signal offset
• volumetric calculations
• engineering units
• turndown & damping
• display contrast & suppression
• fault mode & signal clamp

Electrical Details

General Purpose Applications

 | Output signal:| 4 to 20mA
Max load:| 600 0 at 24 V dc
Power supply:| 10 to 30 V dc
Max current:| 40 mA
Group I applications (when powered from approved apparatus)

 | Output signal:| 4 to 20 mA| 0.4 – 2 V dc
Max load:| 300 0 at 12 V dc| 10 k Ohms at 12 V dc
Power supply:| 6.5 to 16.5 V d| 6.5 to 16.5 V dc
Max current:| 15 mA| 15 mA
Group II applications (when powered from approved safety barriers)

 | Output signal:| 4 to 20 mA
Max load:| 600 0 at 24 V dc
Power supply:| 10 to 30 V dc
Max current:| 40 mA

Connections

4 to 20 ma output signal

• The output signal is a standard 4 to 20 mA current-regulated signal loop.
• The sensor also requires a separate power supply feed and can be connected in either the 3-wire or 4-wire mode.

0.4 to 2 V output signal

• A low-impedance output requires a separate power supply.
• The 3-wire connection mode works well up to about 100 meters.
• Use the 4-wire mode for longer distances or increase the size of the cable cores.

Group II hazardous area

• Sensor versions with 4 – 20 mA output are certified intrinsically safe for use in Group II hazardous areas, Zone 0, Zone 1, and Zone 2 when used in conjunction with approved safety barriers.
• Only the sensor may be mounted in the hazardous area.

Group I hazardous areas

• All versions of the sensor are certified intrinsically safe for use in Group I hazardous areas (Mining) when used with approved apparatus.
• The complete systems, both sensor and monitoring device can be mounted in the hazardous area.

Certification & Conformity

European Union

Intrinsic safety parameters
For intrinsic safety parameters associated with certificates listed above, please refer to individual certificates. Copies of certificates are available on www.trolex.com. The following intrinsic safety parameters apply the equipment listed above.

Note:

1. In some applications, T1 and T2 are inputs, in which case these output parameters are not relevant.
2. For Group I builds, the connections to terminals T1/T2 and T3/T4 shall be from the same power supply. The user should note that the power to terminals T1/T2 must be limited to 1.72 W via a supply with a minimum source resistance of 40 Ohm. There is no specific power limitation to terminals T3/T4, so terminals T1/T2 and T3/T4 should be regarded as separate intrinsically safe circuits.
3. The user should refer to the parameters of the equipment connected to terminals T1/T2 and compare these to the parameters listed in the table. A more onerous set of parameters should be used.
4. Terminals T5, T6, and T8 are connections to the Vortex Head which may be integral with the main part of the apparatus (TX5921 and TX5922) or connected by a cable not exceeding 10 m in length (TX5923). T7 is not connected.

The following Special Conditions for Use apply to the certificates listed above:

1. The only sensor that may be used with the TX5923 (remote sensor head version) is that supplied by Trolex. The maximum length of cable allowed is 10 m.
2. The plastic enclosure and the polycarbonate window are non-conducting and may generate an ignition-capable level of static under certain extreme conditions. The user should ensure that the equipment is not installed in a location where it may be subjected to external conditions (such as high-pressure steam) which might cause a build-up of static on non-conducting surfaces. Additionally, cleaning of the equipment should be done only with a damp cloth.

Australia

Intrinsic safety parameters
For intrinsic safety parameters associated with certificates listed above, please refer to individual certificates. Copies of certificates are available on www.trolex.com. The following intrinsic safety parameters apply the equipment listed above.

Note:

1. In some applications, T1 and T2 are inputs, in which case these output parameters are not relevant.
2. For Group I versions, the connections to terminals T1/T2 and T3/T4 shall be from the same power supply. The user should note that the power to terminals T1/T2 must be limited to 1.72W via a supply with a minimum source resistance of 40 Ohm. There is no specific power limitation to terminals T3/T4, so terminals T1/T2 and T3/ T4 should be regarded as separate intrinsically safe circuits.
3. Terminals T5, T6, and T8 are connections to the sensor head which may be integral with the main part of the apparatus (TX5921 and TX5922) or connected by a cable, not exceeding 10 m in length (TX5923) with cable inductance and capacitance of not more than 15uH and 15nF. T7 is not connected.
4. The installer should refer to the parameters of the equipment connected to terminals T1/T2 and compare these to the parameters listed in the table.
5. The user should note that the current and power to these terminals must be limited via a supply with a minimum source resistance of 233 Ohm.

The following Special Conditions for Use apply to the certificates listed above:

1. The apparatus shall only be cleaned with a damp cloth.

Installation of equipment
The installation of the product must only be carried out by competent personnel. Each installation needs to be considered concerning the local safety regulations and authorities. Refer to the following standards for additional guidance:

• IEC/EN 60079-14
• IEC/EN 60079-25

Refer to the Certification Section of this User Manual and to the relevant certificates for any installation parameters and special conditions of safe use.

Commissioning/verification tests before first use.
Before commissioning and first use, the product shall be inspected for any visible damages and integrity of the enclosure. Never use a product that has damaged housing in hazardous locations.

Maintenance
The maintenance of the product must only be carried out by competent personnel. Maintenance shall be considered by the local safety regulations and authorities. Refer to the following standards for additional guidance:

• IEC/EN 60079-17

It is recommended to periodically check the condition of the product. The product shall only be serviced and repaired by Trolex Ltd. or a local Trolex service agent approved by Trolex Ltd to maintain the explosion protection of the product.

Installation

Tools and Test Equipment Required

No special tools are required:

• Metric spanner set
• Metric hexagon key set
• Standard electrical test meter

Checkpoint
Where the process cannot be interrupted to remove the Vortex from a pipeline, an isolating ball valve may be fitted to the process connection at the installation. This is also useful in installations that have a high level of contamination or moisture in the gas stream. The build-up of debris or water vapor will cause deterioration of the output signal.

Siting Recommendations

Fitting in Pipes and Ducts

• To attain the best accuracy of response, select a position that is at least twenty pipe diameters downstream from bends or obstructions, and approximately five pipe diameters from down-stream intrusions.

• Similarly, the sensor should be mounted at least fifteen pipe diameters from a pipe reducer and fifty pipe diameters from valves.

• If this is not possible then the installation of a standard flow straightener will improve performance.

• Fit a corresponding threaded boss or flange at the monitoring point and install the sensor, ensuring an airtight seal.

Checkpoint
High-pressure versions, above 2 bar, will be supplied with a welded bush or flange and will require dedicated process fittings.

• Release the clamping ring on the mounting bush or flange.
• The center of the flow path of the sensing head should be positioned as shown.

Checkpoint
Ensure that pressurized systems have been completely vented before installation or removal of the sensor.

• Position the sensing head with the smaller opening facing the flow, within a rotational deviation of no more than 12.5° from the axis of flow.
• Tighten the clamping ring with moderate force.
• Avoid fitting the sensor at low points in pipework structures to prevent the sensing head from being affected by large accumulations of moisture.

Fitting in Roadways and tunnels
To attain the best accuracy of response, select a position away from adjacent structures with a clearance of 200 mm.

The version with a side projecting sensor can be mounted on to a suitable support using the mounting holes.

Alternatively, use a standard mounting bush or flange for fitting to a suitable bracket.

Orientation of the Housing

• The housing of the Vortex can be turned to any position about the axis of the sensing probe and locked in position for the preferred mounting attitude or cable routing access.
• Release the locking ring by turning anti-clockwise as far as it will go.
• Rotate the sensing probe or the sensor housing to the desired position.

Checkpoint
Rotation is limited to approximately 300° so do not force the housing beyond the limit stops.

Setup and Calibration

Controls and Indicators

Software Menus

Switch On

• The processor will initialize all the default settings or new data that have been previously programmed.
• After two seconds the display will switch to the Main Display signal and Display magnitude mode.

The bar graph will also show an indication of signal level with a Signal Overrange alert marker.

Menu

• Press to enter
• Press or o scroll the menu
• Press to confirm
• A key code will be requested if the active

Messages

• Entry saved: when new data is entered
• Not saved: when data is not entered

Exit
Press to exit any position in the menu and step back to the Main Display.

Self-Test

• The processor will perform a regular self-test routine to check all the system elements.
• Any malfunction will prompt a Fail message.

Keycode
Enter a four-digit keycode if security is active

• Press to traverse the digits
• Press to scroll the digit
• Press to confirm

Set Keycode
Enter a new security keycode.

Set the status of the keycode:

• Not active: –

• Active +

• Press to traverse the digits

• Press to scroll the digit

• Press to confirm

Scaling
The scaling values can be programmed

• Press or to select the function
• Press to confirm

Turndown
When the sensor is used to monitor a lower velocity range then the calibrated range, the complete response range of the sensor can be utilized by reducing the gain value.

Adjustable range: 5 to 30 m/s

• Press to traverse the digits
• Press to scroll the digit
• Press to confirm

Units
Select the preferred engineering units of flow velocity

• Press or to scroll
• Press to confirm

If a volumetric unit is selected it will be necessary to enter a cross- sectional multiplier relating to the flow path (see scale factor)

Scale factor
Enter a cross-sectional multiplier when using volumetric units

The multiplier must be entered using the same units:

• meters cubed/second: square meters
• meters cubes/hour: square meters
• feet cubes/second: square feet
• feet cubes/hour: square feet
• Press to traverse the digits
• Press to scroll the digit
• Press to confirm

Setup
The output signal parameters and operating functions can be programmed

• Press or to select
• Press to confirm

Damping
The immediacy of response can be adjusted to suppress spurious changes in flow velocity.

• Delay in seconds to reach 63% of scale
• Range: 0 to 1000 seconds
• Press to traverse the digits
• Press to scroll the digit
• Press to confirm

Language
Choice of English, French, Spanish, or German

• Press or to select
• Press to confirm

Contrast

• Press or to SET the contrast
• Press to confirm

Decimal places
When the sensor is measuring a rapidly fluctuating signal, the position of the decimal point can be moved.

• press to traverse the decimal point
• press to confirm

Fix output
If the process being monitored is shut down for maintenance, then to prevent an alarm condition being transmitted by the sensor the output signal can be flxed at any % value of the output signal range.

• The fixed level selected is a calibrated value so this feature can also be used to test the integrity of the signal loop and any remote monitoring equipment by simulating an output signal of defined value.
• Remote display systems can be calibrated and any alarm setpoint levels can be checked for function and accuracy.
• Press to traverse the cursor
• Press to increment the value of the digit above the cursor
• Press to confirm

The signal will be released when the menu position is vacated.

Master reset
All data will be re-initialized equivalent to removing the power. All user settings will be retained.

• Press to reset
• The display will return to the signal display mode.

Output Signal Check

1. Using a test meter check that the value of the output signal agrees with the value of the display reading
2. After the completion of all maintenance, update the maintenance records

Sensing Probe Function Test

1. Under normal circumstances, the calibration of the sensing probe will not change significantly.

2. Check the accuracy by comparing the display reading with a reference value flow velocity.
   Alternatively:
   The Vortex can be removed and returned to your Trolex service agent for checking and calibration across the full operating spectrum. Contact service@trolex.com for further information.

3. After completion of all maintenance, update the maintenance records.

Sensing Probe Clean

1. Remove the sensor and clean the sensing head with a soft brush or cloth.

Checkpoint
Do not use sharp tools as this may cause damage to the ultrasound transducers and the transverse strut.

Disposal
Part of the ethos of Trolex is sustainable design. Vortex contains materials that can be recovered, recycled, and reused. At the end of its useful life ensure that the Vortex is recycled per local laws and bylaws for the geographic area where it is located. The end of its useful life is to be determined by the owner/operator of the equipment and not Trolex. Ensure that the Vortex is recycled by licensed waste contractors with the appropriate licenses for handling metal, plastic, and electronic waste in the geographic area where the Vortex is located.

Checkpoint
Consult your local Trolex service agent or the Trolex Product Support Department if you require assistance with disposal: service@trolex.com.

Maintenance

Maintenance Records

• Implement a planned preventative maintenance process and keep good maintenance records.
• Consult your local Trolex service agent or the Trolex Product Support Department: service@trolex.com for help in implementing a planned preventative maintenance process.
• The ‘Maintenance Log’ gives an example of a typical maintenance record system.

Maintenance Log

Order Reference:

Serial Number:| Date Purchased:
Location:| Flow Rate:
Date| Scheduled Check| Fault| Recalibrate| Return to Trolex| Comments
---|---|---|---|---|---
 |  |  |  |  |

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 the suitability or reliability of this product for specific user applications. Any user or installer must perform the appropriate and complete risk analysis, evaluation, and testing of the products concerning 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 regulations must be observed when installing and using this product. For reasons of safety and to help 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
© 2024 Trolex® Limited.

Trolex is a registered trademark of Trolex Limited. The use of all trademarks in this document is acknowledged.

Document History

• Issue 01 30 September 2014 Original publication of this document – 6th draft
• Rev A 07 March 2024 P5431.1600

Contact Details

• Trolex Ltd, Newby Road, Hazel Grove, Stockport, Cheshire, SK7 5DY, UK
• +44 (0) 161 483 1435
• sales@trolex.com.

Trolex Ltd.

• Newby Road, Hazel Grove, Stockport, Cheshire SK7 5DY, UK
• t: +44 (0)161 483 1435
• e: sales@trolex.com
• W: www.trolex.com.

References

• Trolex – At Trolex, we save lives. 60 years of our pioneering safety technology has helped keep workers protected in even the most challenging environments.

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