Solid-State Flow Sensors: User Manual
Solid-State Flow Sensors: User Manual
Solid-State Flow Sensors: User Manual
Flow Sensors
USER MANUAL
839E
Important User Information
Because of the variety of uses for the products described in this publication, those responsible for the
application and use of this control equipment must satisfy themselves that all necessary steps have been
taken to assure that each application and use meets all performance and safety requirements, including
any applicable laws, regulations, codes and standards.
The illustrations, charts, sample programs and layout examples shown in the guide are intended solely for
purposes of example. Since there are many variables and requirements associated with any particular
installation, Rockwell Automation does not assume responsibility or liability (to include intellectual property
liability) for actual use based upon the examples shown in this publication.
Rockwell Automation publication SGI-1.1, Safety Guidelines for the Application, Installation and
Maintenance of Solid-State Control (available from your local Rockwell Automation sales office), describes
some important differences between solid-state equipment and electromechanical devices that should be
taken into consideration when applying products such as those described in this publication.
Reproduction of the contents of this copyrighted publication, in whole or part, without written permission
of Rockwell Automation, is prohibited.
Throughout this manual we use notes to make you aware of safety considerations:
WARNING Identifies information about practices or circumstances that can cause an explosion in
a hazardous environment, which may lead to personal injury or death, property
damage, or economic loss.
IMPORTANT
Identifies information that is critical for successful application and understanding of
the product.
ATTENTION Identifies information about practices or circumstances that can lead to personal
injury or death, property damage, or economic loss. Attentions help you identify a
hazard, avoid a hazard, and recognize the consequences.
SHOCK HAZARD Labels may be on or inside the equipment (for example, drive or motor) to alert people
that dangerous voltage may be present.
BURN HAZARD Labels may be on or inside the equipment (for example, drive or motor) to alert people
that surfaces may reach dangerous temperatures.
It is recommended that you save this user manual for future use.
839E Solid-State Flow Sensors User Manual
Table of contents
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Designated use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation, commissioning and operation . . . . . . . . . . . . . . . . . 2
Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Process connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
On-site programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Programming with personal computer and ReadWin 2000 19
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Configuration kit with ReadWin . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Error and warning codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Change status (release) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Safety instructions
Designated use
The Bulletin 839E is a flow switch for measurement and monitoring of mass flow rates in
industrial processes. The device has been safely built with state-of-the-art technology and
meets the applicable requirements and EC Directives. It can, however, be a source of
danger if used incorrectly or for anything other than the designated use.
Operational safety
• Funtional Safety
The 839E flow switch was developed according to standard IEC 61010.
• Ex-area
The 839E is not approved for use in Ex-areas.
Return
Before returning a device to Rockwell Automation, be sure to remove all fluid residue. This
is particularly important if the fluid is a health hazard, e.g. flammable, toxic, caustic,
carcinogenic, etc.
Product identification
Flow (0.03…3m/s)
–40°F < T < 185°F
839E-DA1BA1A3D4 IP65
53009401032
5 Output 10 Approvals
Notes:
• Specifications and ratings may differ from those shown in Figure 1, depending on
particular model. Refer to product nameplate or catalog for actual ratings and
specifications.
• The series number indicates the version of the switch. A change in the series letter does
not have any effect on the compatibility—see “Change status” section.
• Approvals inlcude 3A authorized for models configured with sanitary adaptors.
Installation
Dimensions
M12 x 1
97.1
(3.82)
42.1
(1.657)
L L
Process connection
The following table illustrates the versions of 839E.
1 2
L
L
Installation instructions
Vm L
Figure 3 Installing Bulletin 839E (example). Sensor length L is completely immersed in the flow
profile.
Mounting instructions:
• Any orientation
• The on-site display can be rotated electronically 180° — see “Operation” section.
• The housing can be rotated up to 310° for optimal readability and ease of wiring.
• Minimum sensor immersion length: L ≥ 10 mm (0.4 in.)
• The sensor tip should not touch the pipe wall.
• If used in a vertical pipe, the flow should be ascending.
• For a horizontal pipe, install sensor from top if pipe is completely filled with medium.
Otherwise, install sensor from side to ensure complete length of sensor is in the medium.
Note!
For correct flow measurement, the complete length of the sensor must be immersed in the
fully developed flow profile.
Installation instructions
Installation conditions
Note!
The sensor requires a fully developed flow profile for correct monitoring. For this reason,
steadying sections (5x DN) must be provided in the pipe after a pump, pipe bend, internal
fittings and cross-sectional changes.
ATTENTION Do not turn the device into the process connection thread
at the housing. Always install the device at the spanner flats
(Figure 4, item 1). Use a suitable open-ended wrench for
this task (see table of page 5).
• The onsite display can be rotated electronically 180°, see “Onsite operation” section.
• The upper housing section can be rotated mechanically up to 310°.
Wiring
• The sensor tip should be completely
surrounded by medium.
• Position the sensor tip in the area of
maximum fluid velocity (pipe center).
• Minimum sensor immersion length:
L1 ±10 mm.
A1 A2
L+ L+
2 1 2 1
3 4 R1 R2 3 4 4…20 mA R2
L- L-
Figure 7 DC voltage version with M12 connector
Mating cables
2 m (6.5 ft) PVC cable with 4-pin micro
(M12x1) connector and ratcheted
epoxy-coated zinc coupling nut.
Catalog number: 889D-F4AC-2
2 m (6.5 ft) PVC cable with 4-pin micro
889D-F4AC-2
(M12x1) right-angle connector and
ratcheted epoxy-coated zinc coupling nut.
Catalog number: 889D-R4AC-2
Note: Other cable lengths are available and
shielded cables may be required for some
analog output applications — refer to the
On-Machine Connectivity catalog for
additional information.
889D-R4AC-2
Operation
On-site programming
The Bulletin 839E is programmed via three push buttons. The digital display and the light
emitting diodes (LEDs) assist in the navigation through the operating menu.
Operating key
E
Digital display
LED for status
Green = ok
Red = error 22.07 bar
Communications jack
for personal computer
Figure 8 Location of operating keys and display elements
ATTENTION Changes take effect only when you choose YES when asked
to save the data.
Figure 10 Navigating the “Learn” function using the Calibration (CAL) function group as an
example
➊ Select the HIF (Learn High Flow) or LOWF (Learn Low Flow) function with the E key
➋ Select the “RUN” function with the + key, learn function is initialized
➌ Select the “WAIT” function with the + key, press for longer than 2 sec.
➍ Accept (“learn”) the current measured value after approx. 10 sec. - “OK” appears on the
display
➎ If “NOK” (not OK) appears on the display after 60 sec., no current measured value was set
➏ Return to the CAL function group (Home position) with the E key
Notes!
1. Programming buttons [E], [-], and [+] may need to be pressed and held for several
seconds before displaying the expected response.
2. When performing a calibration the 839E may require up to 60 seconds to learn the high
or low flow rate. The display will indicate “WAIT” during the learn process.
3. After configuring the 839E to the desired settings, press and hold the [E] key until
“SAVE” appears; press the [+] or [-] key until “YES” appears. Press and hold the [E] key
until “SAVE” appears. Depending on the configuration changes the display may
indicate a number or a blinking “INIT.” Wait for the blinking “INIT” to change to another
value. This indicates the 839E is ready for operation.
1 2
80%
0%
MAX
3.5 8 …
1 2
Basic settings
Function Function
group (display) Description
BASE Display assignment:
(basic OFF
functions) Display of current measured value or of configured
switch point (switch 1)
Display of current measured value or of configured
switch point (switch 1) rotated 180°
Display of current medium temperature
Display of current medium temperature rotated 180°
Factory setting: current measured valued in %
Display medium temperature unit °C or °F
Factory setting: °C
NOTE: Only visible if the current medium
temperature is selected in the DISP mode.
Measured value damping with regard to display
value and output:
0 (no damping) or 9…40 sec. (in increments of 1
second)
Factory setting: 0 sec.
Behavior as per DESINA: The PIN of the M12
connector is assigned in accordance with the
guidelines of DESINA.
(DESINA = DistributEd and Standardized INstAllation
technology for machine tools and manufacturing
systems)
CAL Setting for maximum flow rate occurring.
(Calibration) 100% value
Function
Function group (display) Description
OUT Output switching mode for channel 2: flow or
(Setting for the temperature
1st output) Factory setting: flow
OUT2 (Setting for
Temperature unit selection (°C/°F)
the 2nd output,
NOTE: Function only visible if switching mode
optional)
(MODE) is set to temperature in the 2nd output.
Switch output function:
hysteresis function NC contact or NO contact (see
diagram)
4…20 mA
Function Function
group (display) Description
OUT and Can be set anywhere between 0…99 sec. in
OUT2 increments of 1 second.
(continued) Factory setting: 0 sec.
1 2
USB
3
Figure 14 Programming with PC
➀ Personal computer with ReadWin configuration software
➁ Configuration kit (836E-NSR)
➂ Bulletin 839E with programming port
Accessories
Configuration Kit with ReadWin
The configuration kit (Catalog Number:
836E-NSR) consists of a software CD and a
conversion cable which interfaces the USB
port of the PC to the 4-pin programming
port on the sensor face.
USB
Troubleshooting
Error and warning codes
If an error occurs in the electronics, the color of the status LED changes from green to red
and the background illumination of the digital display changes from white to red. A status
LED flashing red and green displays an error or warning code, as outlined below:
• E-code for errors
In the event of an error message, the measured value is unreliable.
• W-code for warnings
In the event of a warning, the measured value is still reliable.
Error Codes
Code Explanation
E011 Device configuration faulty
E012 Error in measurement or underrange/overrange
E013 Error at heating resistor
E015 Error in EEPROM
E019 Power supply has undervoltage/overvoltage
E020 Error in Flash
E021 Internal memory error
E022 USB power supply
E027 Characteristic does not suit medium
Output current can no longer be generated. Possible cause:
E042
analog output not connected or open circuit.
Warning Codes
Code Explanation
W107 Simulation active
W202 Flow outside the sensor range
W209 Device start-up
W210 Configuration modified
W212 Sensor signal outside the permitted range
W250 Number of switch cycles exceeded
W260 Value for High Flow (HIF) and Low Flow (LOWF) faulty
W270 Short-circuit and overload at output 1
W280 Short-circuit and overload at output 2
Values for high flow (HIF) or low flow (LOWF) could not be
W432 determined with certainty. The device can be operated,
however.
Repair
Bulletin 839E flow switches are not repairable.
Disposal
Please pay particular attention to the local disposal regulations of your country. Ensure the
materials of the device components are separated and processed accordingly.
Technical data
Power supply
Supply voltage
• DC voltage version
18...30 V DC
Current consumption
• < 100 mA (open-circuit operation) at 24 V DC, max. 150 mA (open-circuit operation); with
reverse polarity protection
Power supply failure
• Behavior in case of overvoltage (> 30V)
The device works continuously up to 34V DC without any damage. No damage is caused to
the device in case of a short-term overvoltage up to 1 kV (as per EN 61000-4-5). If the supply
voltage is exceeded, the properties specified are no longer guaranteed.
• Behavior in case of undervoltage
If the supply voltage drops below the minimum value, the device switches off (status as if
not supplied with power = switch open).
Output
Switching capacity
• Switch status ON: Ia ≤ 250 mA
• Switch status OFF: Ia ≤ 1 mA
• Switching cycles: ≤ 10,000,000
• Voltage drop PNP: ≤ 2 V
• Overload protection
Automatic load testing of switching current; output is switched off in case of overcurrent,
the switching current is tested again every 0.5 sec.; max. capacitance load: 14 mF for max.
supply voltage (without resistive load); periodical protective disconnection in event of
overcurrent (f = 2 Hz) and ‘Warning’ display.
Signal on alarm
• Switch outputs: in safe state (switch normally open)
Operating conditions
• Any orientation
• Top housing section can be rotated 310°
Operating conditions: Environment
• Ambient temperature range
–40…+85 °C (–40…185 °F)
• Storage temperature
–40…+85 °C (–40…185 °F)
• Climate class
4K4H as per DIN EN 60721-3-4
• Degree of protection
IP65 complete housing
• Shock resistance
50 g as per DIN IEC 68-2-27 (11 ms)
• Vibration resistance
20 g as per DIN IEC 68-2-6 (10-2000Hz)
4 g as per guidelines of German Lloyd GL
• Electromagnetic compatibility
Interference emission as per IEC 61326, class B equipment
Interference immunity as per IEC 61326, Appendix A (industry) and
NAMUR Recommendation NE21; EMC influence: d 0.5%
Operating conditions: Process
• Process flow limits
Liquids: 0.03…3.0 m/s (0.1…9.84 ft/s)
• Process temperature limits
–20…85 °C (–4…185 °F)
Note!
The sensor can be exposed up to 130°C (266°F) without damage. Monitoring switches shut
off automatically at T ≥ 85°C (185F) and starts again at T ≤ 85°C (185°F).
1000.0
0.1
0. 1 1. 0 10. 0
Flow rate ft/s