Trolex TX5921-2-3 Vortex Air Flow Sensor User Manual
Brand: Trolex
1. Product Overview
The Trolex TX5921-2-3 series offers advanced Vortex Air Flow Sensors designed for accurate and reliable air flow measurement in various industrial applications.
TX5921: Rear Projecting Sensor
The TX5921 is a Vortex air flow sensor with a rear projecting sensing probe, suitable for duct monitoring.
TX5922: Side Projecting Sensor
The TX5922 is a Vortex air flow sensor with a side projecting sensing probe, designed for open flow monitoring in tunnels, roadways, and process systems.
TX5923: Remote Mounted Sensor
The TX5923 is a Vortex air flow sensor with a remote mounted sensor, intended for use where fitting space is limited or difficult to access.
1.1 Operating Features
- High stability air flow 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 or 4 to 20 mA
- Rangeable flow velocity from 0.5 m/sec to 30 m/sec
1.2 Application
Fixed point air flow velocity measurement in pipes, ducts, and open roadways. Used for ventilation, cooling systems, and process condition monitoring in heavy-duty industrial applications and hazardous areas. Output data is linearly proportional to air flow velocity.
1.3 Product Options
| Sensor Configuration | Product Code |
|---|---|
| Rear projecting sensor | TX5921 |
| Side projecting sensor | TX5922 |
| Remote sensor | TX5923 |
| Certification | Group | 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 | Notes |
|---|---|---|
| 0.4 - 2 V | .11 | Grp I Only |
| 4 - 20 mA | .12 |
| Process Fitting | Option Code |
|---|---|
| None | .00 |
| 50 mm ANSI flange | .21 |
| 1½" 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 | Option Code | Notes |
|---|---|---|
| 0 m | .00 | |
| 1 m | .01 | 1m to 10m cable length P5431.6000.03 only |
| 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 |
1.4 Dimensions
1.4.1 TX5921 Rear Projecting Sensor
Diagram showing the dimensions of the TX5921 sensor, including overall length (327 mm), probe insertion range (68-118 mm), housing dimensions (110 mm width, 153 mm height), and flange mounting hole pattern (4 x Ø19 holes on 120.6 PCD).
TX5921 Rear Projecting Sensor
Diagram showing alternative views and dimensions for the TX5921 sensor, including nominal dimensions (33 mm), datum points, and BSP bush fitting details (1½" BSP).
1.4.2 TX5922 Side Projecting Sensor
Diagram showing the dimensions of the TX5922 sensor, including overall height (385 mm), housing dimensions (110 mm width, 84 mm height), and probe length. Notes indicate 2 fixing holes for M6 screws.
1.4.3 TX5923 Remote Mounted Sensor
Diagram showing the dimensions of the TX5923 sensor, including housing dimensions (110 mm width, 84 mm height), and probe dimensions with datum and centre of head indicators. It also shows the remote probe dimensions with flexible conduit connection.
1.5 Technical Information
| Flow measuring range | Rangeable from 0.5 to 5 m/s up to 0.5 to 30 m/s |
| Accuracy | +/- 2% within 12.5° rotation of flow axis |
| Linearity | +/- 1% |
| Ambient temperature limits | -15 °C to +50 °C |
| Sensor temperature limit | -20 °C to +150 °C |
| Humidity | 0 to 95% non-condensing |
| Protection classification | Dust and waterproof to IP65 |
| Process media | Gas, air, steam or saturated vapour |
| Housing material | Electrically dissipative polymer |
| Sensor material | Stainless steel - grade 316 |
| Flexible cable (remote sensor) | PVC coated armoured flexible conduit |
| Maximum static pressure | 20 bar |
| Process fittings |
|
| Cable entry |
|
| Nett weight |
|
| Information display | 128 x 64 dot graphic backlit LCD screen |
| Vibration limits |
|
| Impact limits | 20 joules (housing) |
| Output Signals |
|
Programmable Information
- Zero & span adjustment
- Signal offset
- Volumetric calculations
- Engineering units selection
- Turndown & damping adjustment
- Display contrast & suppression settings
- Fault mode & signal clamp configuration
1.6 Electrical Details
| Output signal: | 4 to 20mA |
| Max load: | 600 Ω at 24 V dc |
| Power supply: | 10 to 30 V dc |
| Max current: | 40 mA |
| Output signal: | 4 to 20 mA | 0.4 - 2 V dc |
| Max load: | 300 Ω 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 |
| Output signal: | 4 to 20 mA |
| Max load: | 600 Ω at 24 V dc |
| Power supply: | 10 to 30 V dc |
| Max current: | 40 mA |
1.7 Connections
Integral sensor
Diagram showing terminal connections for TX5922 integral sensor: Terminal 1 (+V Supply), Terminal 2 (Signal), Terminal 3 (OV Supply), Terminal 4-8 (Supply).
Remote sensor
Diagram showing terminal connections for TX5923 remote sensor: Terminal 1 (+V Supply), Terminal 2 (Signal), Terminal 3 (OV Supply), Terminal 4-8 (Supply). Cable length specifications are Standard: 2 m, Maximum: 10 m.
4 to 20 mA output signal
The output signal is a standard 4 to 20 mA current regulated signal loop. The sensor requires a separate power supply and can be connected in either 3-wire or 4-wire mode.
0.4 to 2 V output signal
A low impedance output requiring a separate power supply. The 3-wire connection mode is suitable for up to 100 meters. Use 4-wire mode for longer distances or larger cable cores.
Diagrams illustrating 3-wire and 4-wire connections for a monitoring device (TX5920) with 4-20mA and 0.4-2V output signals, showing connections to +V Supply, OV Supply, and Signal.
Hazardous Area Considerations
Group II hazardous area
Sensor versions with 4-20 mA output are certified intrinsically safe for use in Group II hazardous areas (Zone 0, 1, 2) when used with approved safety barriers. Only the sensor may be mounted in the hazardous area.
Diagram showing a TX5920 sensor in a hazardous area (HAZ) connected to a monitoring device in a safe area (SAFE) via safety barriers.
Group I hazardous areas
All sensor versions are certified intrinsically safe for use in Group I hazardous areas (Mining) when used with approved apparatus. The complete system (sensor and monitoring device) can be mounted in the hazardous area.
Diagram showing a TX5920 sensor and monitoring device in a hazardous area (HAZ) for Group I applications.
2. Certification & Conformity
1. European Union
Features CE and ATEX (European Union) certification for use in underground mines (Group I) and Industrial (Group II) locations, complying with ATEX Directive 2014/34/EU.
| Product Code | Ex Certificate Number | Ex Certification Code |
|---|---|---|
| TX5921.01(.xx...) TX5922.01(.xx...) TX5923.01(.xx...) | Sira 99ATEX2135X | I M1 Ex ia I Ma Ta = -20°C to +60°C |
| TX5921.02(.xx...) TX5922.02(.xx...) TX5923.02(.xx...) | II 1G Ex ia IIC Ga T4 Ta = -20°C to +60°C |
Intrinsic safety parameters for ATEX certification are detailed in the following tables. Full certificate copies are available at www.trolex.com.
| Version | T3/T4 (supply) | T1/T2 (signal out) |
|---|---|---|
| Group I 4-20 mA version | Ui = 16.5 V Ci = 4 nF Li = 0 | Ui = 16.5 V Pi = 1.72 W Ci = 15 nF Li = 0 Uo = 16.5 V Io = 220 mA Po = 0.91 W Co = 11.9 uF Lo = 2.6 mH |
| Group I 0.4-2 V version | Ui = 16.5 V Ci = 4 nF Li = 0 | Ui = 16.5 V Pi = 1.72 W Ci = 15 nF Li = 0 Uo = 16.5 V Io = 41 mA Po = 0.17 W Co = 11.9 uF Lo = 2.6 mH |
| Group I 5-15 Hz version | Ui = 16.5 V Ci = 4 nF Li = 0 | Ui = 16.5 V Pi = 1.72 W Ci = 0 Li = 0 Uo = 0 |
| Version | T1/T2/T3/T4 (total inputs to 'supply' and 'signal out') |
|---|---|
| Group II 4-20 mA version | Ui = 28 V Ii = 120 mA Pi = 0.84 W Ci = 18.3 nF Li = 0 |
Notes: Refer to the document for detailed notes regarding input parameters, power supply limitations, and terminal connections (T1-T8).
Special conditions for Use: Equipment should be cleaned only with a damp cloth.
2. Australia
Features ANZEX certification for use in underground mines (Group 1) and Industrial (Group II) locations in Australia.
| Product Code | Ex Certificate Number | Ex Certification Code |
|---|---|---|
| TX5921.10(.xx...) TX5922.10(.xx...) TX5923.10(.xx...) | ANZEx 12.3003X | Ex ia I Ta = -20°C to +60°C |
| TX5921.11(.xx...) TX5922.11(.xx...) TX5923.11(.xx...) | Ex ia IIC T4 Ta = -20°C to +60°C |
Intrinsic safety parameters for ANZEX certification are detailed in the following tables. Full certificate copies are available at www.trolex.com.
| Version | T3/T4 (supply) | T1/T2 (signal out) |
|---|---|---|
| Group I 4-20 mA version | Ui = 16.5 V Ci = 4 nF Li = 0 | Ui = 16.5 V Pi = 1.72 W (see Note 2) Ci = 15 nF Li = 0 Uo = 16.5 V Io = 223 mA Po = 0.921 W Co = 7 uF Lo = 0.6 mH |
| Group I 0.4-2 V version | Ui = 16.5 V Ci = 4 nF Li = 0 | Ui = 16.5 V Pi = 1.72 W (see Note 2) Ci = 15 nF Li = 0 Uo = 16.5 V Io = 41 mA Po = 0.17 W Co = 7 uF Lo = 0.6 mH |
| Group I 5-15 Hz version | Ui = 16.5 V Ci = 4 nF Li = 0 | Ui = 16.5 V Pi = 1.72 W (see Note 2) Ci = 0 Li = 0 Uo = 0 |
| Version | T1/T2/T3/T4 |
|---|---|
| Group II 4-20 mA version | Ui = 28 V Ii = 120 mA Pi = 0.84 W Rmin = 233 Ohm (see Note 5) Ci = 18.3 nF Li = 0 |
Notes: Refer to the document for detailed notes regarding input parameters, power supply limitations, and terminal connections.
Installation of equipment
Installation must be carried out by competent personnel, adhering to local safety regulations and standards like IEC/EN 60079-14 and IEC/EN 60079-25.
Commissioning / verification tests prior to first use
Inspect the product for visible damages before commissioning. Do not use if the housing is damaged.
Maintenance
Maintenance must be carried out by competent personnel, following local safety regulations and standards like IEC/EN 60079-17. Periodic checks are recommended. Servicing and repairs should only be performed by Trolex Ltd. or an approved service agent to maintain explosion protection.
3. Installation
3.1 Tools and Test Equipment Required
No special tools are required, only standard metric spanner sets, metric hexagon key sets, and a standard electrical test meter.
Checkpoint
If the process cannot be interrupted, an isolating ball valve can be fitted. This is also beneficial in installations with high contamination or moisture, as debris or water vapour can degrade the output signal.
3.2 Siting Recommendations
3.2.1 Fitting in Pipes and Ducts
For best accuracy, position the sensor at least twenty pipe diameters downstream from bends or obstructions, and approximately five pipe diameters from downstream intrusions. Mount at least fifteen pipe diameters from a pipe reducer and fifty pipe diameters from valves.
Diagrams illustrating recommended sensor placement in pipes and ducts, showing distances in terms of pipe diameter (d) from bends, reducers, and valves (e.g., 20d, 15d, 50d downstream).
If ideal positioning is not possible, a standard flow straightener can improve performance.
Fit a corresponding threaded boss or flange at the monitoring point, ensuring an airtight seal.
Checkpoint
High pressure versions (above 2 bar) require welded bushes/flanges and dedicated process fittings.
Release the clamping ring on the mounting bush or flange.
Diagram showing the sensor head being mounted and secured with a clamping ring, with a note about positioning the sensing head's center of flow path.
Checkpoint
Ensure pressurized systems are completely vented before installation or removal.
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.
Diagram showing the correct orientation of the sensing head relative to the flow, with +/- 12.5 degree tolerance.
Avoid fitting the sensor at low points in pipework to prevent moisture accumulation affecting the sensing head.
3.2.2 Fitting in Roadways and tunnels
For best accuracy, select a position away from adjacent structures with a clearance of 200 mm.
Diagram showing recommended clearance (200 mm minimum) for side-projecting sensors in roadways/tunnels.
The side projecting sensor can be mounted using its mounting holes on a suitable support. Alternatively, a standard mounting bush or flange can be used for fitting to a bracket.
Diagrams illustrating side-projecting sensor mounting options using mounting holes or a bracket with a bush/flange.
3.3 Orientation of the Housing
The housing can be turned to any position around the sensing probe axis and locked for preferred mounting attitude or cable routing. Release the locking ring by turning anti-clockwise [arrow pointing counter-clockwise]. Rotate the probe or housing to the desired position.
Checkpoint
Rotation is limited to approximately 300°; do not force beyond the limit stops.
Diagram showing the housing rotation mechanism and the 300° limit.
4. Setup and Calibration
4.1 Controls and Indicators
The device features an LCD display showing Signal, Display magnitude, Bargraph, and Units. Control buttons allow navigation and adjustment.
Diagram of the LCD display showing numerical readings (e.g., "2 53"), a bargraph, and units (M/S). It also indicates control buttons like UP [Up Arrow], DOWN [Down Arrow], LEFT [Left Arrow], RIGHT [Right Arrow], ENTER [Enter Button].
4.2 Software Menus
Switch On
Upon power-up, the processor initializes settings. After two seconds, the display shows the Main Display signal and magnitude. A bargraph indicates signal level with an overrange marker.
Diagram showing the initial display after power-on, showing "2 53 m/s" and a bargraph.
Menu Navigation
Press the [Menu] button to enter the menu. Use [Up Arrow] or [Down Arrow] to scroll through options. Press [Enter] to confirm selections. A keycode may be required.
Diagram illustrating menu navigation: "MENU" screen, "ENTER SAVED", "NOT SAVED", and "FAIL" messages.
Messages
Indicates if data entry was saved or not saved.
Exit
Press [Menu] to exit any menu position and return to the Main Display.
Self-Test
The processor performs a self-test routine. Any malfunction will display a "FAIL" message.
Diagram showing a "FAIL" message on the display.
Keycode
Enter a four-digit keycode if security is active. Use [Up Arrow] / [Down Arrow] to traverse digits, [Left Arrow] / [Right Arrow] to scroll digits, and [Enter] to confirm.
Diagrams showing keycode entry: "Enter KCode" and "NOGO GO" messages.
Set Keycode
Allows setting a new security keycode and its status (Not active or Active).
Diagram showing keycode setting interface with "+ 1234" and "Enter KCode".
Scaling
The scaling values can be programmed. Use [Left Arrow] / [Right Arrow] to select functions and [Enter] to confirm.
Diagram showing a "SCALE" interface for programming values.
Turndown
Adjusts the gain value to monitor lower velocity ranges. The adjustable range is 5 to 30 m/s.
Diagram showing "Set Turn down" with values "15.00" and "30.00".
Units
Select preferred engineering units for flow velocity (e.g., ft³/h, m³/h, ft/s, m/s).
Diagram showing unit selection options like ft³/h, m³/h, ft/s, m/s.
Scale factor
When using volumetric units, enter a cross-sectional multiplier. The multiplier must use the same units as the flow rate (e.g., square metres for m³/s).
Diagram showing a "SCALE" interface for entering multipliers.
4.2.1 Setup
Output signal parameters and operating functions can be programmed.
Diagram showing a "CALIB" interface, likely for calibration setup.
Damping
Adjusts immediacy of response to suppress spurious changes in flow velocity. Delay can be set from 0 to 1000 seconds.
Diagram showing "Set Damping" with a value "001.0".
Language
Choice of English, French, Spanish, or German. Use [Up Arrow] / [Down Arrow] to select and [Enter] to confirm.
Diagram showing language selection options: E, F, S, GB (English).
Contrast
Adjust the display contrast using the arrow keys.
Diagram showing a contrast adjustment interface.
Decimal places
Move the decimal point position for fluctuating signals.
Diagram showing decimal point adjustment.
Fix output
Allows fixing the output signal at a specific percentage of the range, useful for maintenance or testing. This can simulate a defined output value.
Graph showing a fixed output signal at 20mA.
Use arrow keys to traverse the cursor and increment digits. Press [Enter] to confirm.
Diagram showing cursor movement and digit increment for fixing output.
Master reset
Resets all data to factory defaults, retaining user settings. Press [Reset] button to initiate.
Diagram showing a "RESET" prompt.
4.3 Output Signal Check
- Use a test meter to verify the output signal matches the display reading.
- Update maintenance records after completing any maintenance.
Diagram showing a sensor connected to a test meter for output signal verification.
4.3.1 Sensing Probe Function Test
- Under normal conditions, the sensing probe calibration remains stable.
- Check accuracy by comparing the display reading with a reference flow velocity.
- Alternatively, the sensor can be returned to Trolex service for checking and calibration. Contact service@trolex.com.
- Update maintenance records after all maintenance is completed.
Diagram showing a sensor probe inside a pipe, with an arrow indicating flow, and a callout for function test.
4.3.2 Sensing Probe Clean
- Remove the sensor and clean the sensing head with a soft brush or cloth.
Checkpoint
Do not use sharp tools, as they can damage the ultrasound transducers and transverse strut.
4.4 Disposal
Trolex promotes sustainable design. Vortex sensors contain recyclable materials. At the end of its useful life, ensure the Vortex is recycled according to local laws and bylaws. The owner/operator determines the end of useful life. Use licensed waste contractors for handling metal, plastic, and electronic waste.
Checkpoint
Consult your local Trolex service agent or the Trolex Product Support Department for disposal assistance: service@trolex.com.
4.5 Maintenance Records
Implement a planned preventative maintenance process and maintain good records. Contact Trolex service or Product Support for assistance in implementing a maintenance process. The 'Maintenance Log' provides an example.
4.6 Maintenance Log
A table for recording maintenance activities:
| Order Reference | Serial Number | Date Purchased | Location | Flow Rate | Date | Scheduled Check | Fault | Recalibrate | Return to Trolex | Comments |
|---|---|---|---|---|---|---|---|---|---|---|
Disclaimers
The information provided contains general descriptions and technical characteristics. It is not a substitute for determining suitability or reliability for specific applications. Users/installers must perform their own risk analysis, evaluation, and testing. Trolex is not liable for misuse of information. Suggestions for improvements or error notifications should be sent to marketing@trolex.com.
No part of this document may be reproduced without written permission from Trolex.
State, regional, and local safety regulations must be observed. Only Trolex or its affiliates should perform repairs.
Relevant instructions must be followed for applications with technical safety requirements.
Trademarks
© 2024 Trolex® Limited. Trolex is a registered trademark of Trolex Limited. All trademarks are acknowledged.
Document History
Issue 01: 30 September 2014 (Original publication - 6th draft)
Rev A: 07 March 2024 (P5431.1600)
Contact Details
Trolex Ltd, Newby Road, Hazel Grove, Stockport, Cheshire, SK7 5DY, UK
Tel: +44 (0)161 483 1435
Email: sales@trolex.com
Website: www.trolex.com
Trolex – At Trolex, we save lives. 60 years of our pioneering safety technology has helped keep workers protected in even the most challenging environments.
