834A. Microwave Solids Flow Indicator. M o d e l SFI

Transcription

1 BUL L E T I N 834A I N S T A L L A T I O N & O P E R A T I O N Microwave Solids Flow Indicaor M o d e l SFI Thank you for purchasing a qualiy produc manufacured by Monior Technologies LLC. We realize ha you do have a choice of vendors when procuring Microwave Solids Flow Indicaors and we sincerely appreciae your business! This manual conains he informaion necessary o ensure a safe and successful insallaion. Please read and comply wih he secion on page 7 of his manual peraining o SAFETY. Doing so will ensure proper operaion of he equipmen and he safey of all personnel. Before discarding shipping conainer, please inspec i horoughly and verify ha all pars ordered are accouned for. Someimes smaller pars become suck under caron flaps and oher packaging maerials. In he even ha informaion conained herein does no compleely saisfy your requiremens or answer your quesions, you may conac Technical Suppor on our websie by elephone a ( ), or by fax a If your Microwave Solids Flow Indicaor ever requires service eiher in or ou of warrany, please conac us and obain an RMA number prior o shipping he uni o us.

2 A P P L I C A T I O N S The SFI provides deecion of flow in solid maerial handling applicaions including graviy chues and pneumaic pipelines. Typical indusries for he SFI include chemicals, feed, plasics, uiliies, cemen and food processing. By furnishing an analog oupu he SFI provides more informaion for he user han a on-off flow deecor. The SFI can be used o indicae he relaive amoun of flowing maerial. The accuracy of his indicaion will vary from applicaion o applicaion and will ypically provide a very rough esimae of mass flow. Facors which influence he accuracy of he SFI: Paricle Size Disribuion Dielecric Consan Variaion Moisure Conen Variaion Dispersion of Produc Flow wihin Conveying Line Velociy of Produc Flow Locaion of Produc Flow wih respec o SFI Auxiliary Equipmen Movemen (feeders, mechanical conveyors, ec.) Temperaure Variaion Type of Conveying Sysem SFI provides mass flow indicaion o help ensure flow rae from feeders and conveyors is wihin accepable range. Type of Conveying Sysem vs. Qualiy of Indicaion Free Falling in Graviy Chues bes indicaion Dilue Phase Pneumaic Lines can achieve good flow indicaion if velociy remains consan Sliding down Graviy Chue quesionable Air Slides quesionable Dense Phase Pneumaic Lines quesionable T Y P I C A L A P P L I C A T I O N S I N C L U D E : SFI signals underfeed or overfeed condiions ha may resul from malfuncioning process equipmen such as a diverer valve. Chemical Indusry flow indicaion for blending, loading, discharging, ec. Feed Mills indicae flow of ingrediens and addiives Plasics blending applicaions for color or hardness characerisics Power Indusry measuring flow of pulverized coal o burners/boiler Cemen Indusry baching, loading, off-loading Food Processing Indicae flow of ingrediens and addiives. SFI indicaes he esimaed relaive flow of pneumaically conveyed pelles, granules and powders. 2

3 P R E - I N S T A L L A T I O N C O N S I D E R A T I O N S Pre-insallaion planning is he mos criical elemen in achieving a successful SFI applicaion. The following issues all influence he effecive sensiiviy and qualiy of he flow indicaion. Whenever possible, he seleced mouning locaion should be he one which maximizes he sensor s abiliy o see maerial flow. INSTALLATION ISSUES INFLUENCING SENSITIVITY 1) Mouning Angle: Whenever possible selec a mouning locaion where mouning can be made a a 25 o 45 degree angle wih respec o maerial flow. Angle-mouned sensors are more sensiive han hose aimed perpendicular o maerial flow. 2) Mouning Orienaion: Selec an orienaion on he pipe/chue by which he process seal will be exposed o he full moion of maerial flow under normal process condiions. Avoid mouning immediaely afer a bend, elbow or oher irregular pahway. The closer he maerial flow is o he locaion of he sensor face, he beer. 3) Pipe/Chue Maerial: Whenever possible selec a mouning locaion where he pipe/chue is meallic. When microwave energy is enrapped wihin meal conainers, inernal reflecions are produced herefore increasing he probabiliy o see maerial moion. For non-meallic pipes such as glass, plasics and concree, inernal reflecions are no as prevalen. Therefore, sensors in applicaions uilizing meallic pipes/chues inherenly are more sensiive han hose in applicaions uilizing non-meallic pipes/chues. Noe: Since microwave energy can propagae hrough non-meallic maerial, he sensor can be ruly non-conac if direced hrough a non-meallic window. 4) Pipe/Chue Diameer: Whenever possible selec a mouning locaion where he pipe/chue diameer is smalles. As he diameer of he pipe/chue increases, he effecive sensiiviy of he sensor decreases. Inernal reflecions are no as significan. In addiion he ransmied microwave energy loses is power densiy as i ravels hrough greaer disances. Therefore, sensors in applicaions uilizing small diameer pipes/chues inherenly are more sensiive han hose in applicaions uilizing large diameer pipes/chues. 5) Targe Movemen: Whenever possible, selec a mouning locaion wih minimal vibraion, away from feeders, conveyors and augers, so he SFI's oupu is no falsely influenced by apparaus movemen or he relaed vibraion. Elecronic signal condiioning is designed o ignore very slow moving objecs, bu respond o greaer velociies ypically associaed wih moving maerial. The sensor is capable of deecing objecs moving in excess of 1.7 f/sec (51.8 cm/sec). Figure 1 MATERIAL ISSUES INFLUENCING SENSITIVITY 1) Maerial Densiy in he Pipe/Chue: As more produc is placed in moion, he amoun of disurbance which is analyzed as moion also increases. Therefore, sensors in applicaions which have significan maerial flow inherenly are more sensiive han hose in applicaions wih minimal maerial flow. 2) Maerial Dielecric Consan: Microwave propagaion is affeced by he dielecric consan of he maerial being sensed. Typically, low dielecric or dry maerials end o absorb/pass he energy while high dielecrics or mois maerials end o reflec he energy. The SFI will sense maerial beer when energy is refleced. Therefore, sensors in applicaions wih high dielecric or mois maerials (e.g. grains, feed, ores) inherenly are more sensiive han hose in applicaions wih low dielecric or dry maerials (e.g. plasics, soap, cemen). 3) Maerial Paricle Size: Microwaves have a paricular wavelengh and herefore are more easily refleced when hiing larger paricle sizes. Therefore, sensors in applicaions wih large paricle sizes such as granulars are inherenly more sensiive han hose in applicaions wih small paricle sizes such as powders. 3

4 M E C H A N I C A L I N S T A L L A T I O N Before insalling he SFI, be sure o read he Pre-Insallaion Consideraions. Proper mouning selecion is criical o achieving a successful insallaion. Generally, here are hree mouning echniques which can be used: angular mouning a 25 o 45 degree, coupling moun a 90 degrees and saddle coupling moun a 90 degrees. Angular moun (20-45 degree) (see Figure 2): 1.) Creae a y in he maerial handling line by cuing a hole and welding a suiable ube/pipe a a 25 o 45 degree angle wih respec o he maerial flow. 2.) Posiion ube poining downsream o help preven plugging of he ube. The welded end of he ube should no projec ino he maerial flow. The ube should be kep as shor as possible while sill providing clearance for sensor mouning. The opposie end of he ube should have a fiing which will accep a 1-1/4" NPT (1-1/2" if using he sainless seel adaper) male connecion found on he SFI sensor housing. 3.) Tighen he sensor ino place ensuring he condui connecion is facing downward. insalled ino a sandard 1-1/4" half coupling (1-1/2" coupling if using he sainless seel adaper). Tighen he sensor ino he appropriae welded coupling ensuring he condui connecion is facing downward. Saddle coupling (90 degree) (see Figure 4): Alhough angled mouning is preferable, 90 degree mouning is accepable in some applicaions. Monior s saddle coupling can be used o overcome he difficuly of welding o he curvaure of he maerial handling line. The aluminum saddle coupling is hreaded o permi engagemen of he 1-1/4" NPT connecion on he SFI. Using he supplied gaske, accepable mouning can be achieved for pipe/chue diameers ranging from 4" o 10" (101mm o 254mm). 1.) Afer selecing he appropriae locaion, cu a 1 1/2"(38mm) diameer hole in he pipe/chue. 2.) Posiion/cener he saddle coupling over he hole while placing he gaske in beween. 3.) Fasen he saddle coupling o he pipe/chue using indusrial grade hose clamps. 4.) Tighen he sensor ino he saddle coupling ensuring he condui connecion is facing downward. The saddle coupling can also be fasened o a pipe/chue wih sandard screw/nu faseners by simply creaing mouning holes in he saddle coupling s ears and fasening o he pipe/chue. I is also feasible o flaen he profile of he saddle coupling (via bel sander, mill, ec.) and use i as a sandard half coupling. Figure 2 Coupling moun (90 degree) (see Figure 3): Alhough angled mouning is preferable, 90 degree mouning is accepable in some applicaions. The SFI sensor housing incorporaes an aluminum 1-1/4" NPT connecion. The connecion is specially machined o provide flush moun insallaion when Figure 4 Special Noe for Mouning o Non-Meallic Chues: When sensing hrough non-meallic maerials, he energy can ravel hrough he pipe/chue o he backside of he insallaion. The sensor mus be posiioned o avoid having moion of nearby equipmen or personnel inerpreed as a disurbance. Backing he nonmeallic pipe/chue wih a meallic shield will grealy reduce he possibiliy of false signals. Figure 3 4

5 E L E C T R I C A L I N S T A L L A T I O N 1) Power (see Figure 5): Two wire enries are provided for wiring convenience, especially if separaion of power and oupu is required. Roue wires hrough enry. While observing polariy, connec he DC volage source o he + and - erminals locaed on he PCB. Improper inerconnecion may resul in circui damage. Connec he shield of your shielded cable o eiher he volage source s earh ground, or he ground pos provided in he sensor. Connec only one end of he shield, leaving he oher end unaached. 2) Oupu (see Figure 5): Roue wires hrough condui enry and connec he posiive end of he analog oupu load o he SIG erminal and he negaive end of he analog oupu load o he - erminal of he power supply. Noe ha he power source - and he analog oupu - are he same poin. The sensor is acing as a curren sourcing device. Isolaion is provided beween he sensor s housing ground and he - erminal on he sensor s PCB. See specificaions for isolaion value. The power source herefore provides he energy o operae he sensor and he energy needed o generae he curren loop. Z Zero Adjusmen: A muli-urn poeniomeer is provided o fine une he oupu curren when in he no-flow condiion. The inenion of his adjusmen is o make minor curren changes when no moion is deeced. The range of he adjusmen is limied o +/- 10%. If he applicaion s low moion limi is greaer han 4.5mA, his adjusmen will no be capable of reducing he oupu curren o he desired 4.0mA. Successful use of he SFI is sill possible wih proper signal analysis by he user s conrol sysem. S Span Adjusmen: A muli-urn poeniomeer is provided o fine une he oupu curren when in he full-flow condiion. The inenion of his adjusmen is o make minor curren changes when full moion is deeced. The range of adjusmen is limied o +/- 10%. If he applicaion s maximum moion limi is less han 18.4mA, his adjusmen will no be capable of increasing he oupu curren o he desired 20.0mA. Successful use of he SFI is sill possible wih proper signal analysis by he user s conrol sysem. SIG AVG Signal Average Adjusmen: A single-urn poeniomeer is provided o permi he user o se he ime period over which he oupu signal should be averaged. Reacion o a sep simulus can be adjused from 100mS up o 5 seconds. This is paricularly useful for applicaions in which periodic surges are ypical of he conveying process. The funcion operaes as a moving average and herefore he oupu curren may move sluggishly if SIG AVG is se relaively high. Indicaors: Figure 5 C A L I B R A T I O N Accepable calibraion is applicaion dependen. I is expeced ha a good percenage of applicaions will no achieve an oupu ranging from 4-20mA. Alhough here are on-board adjusmens designed o generae such, an accepable applicaion would include hose whose curren oupu may range from 4-10mA, 6-13mA, 10-19mA, ec. Noe: A 4mA oupu always represens a no-flow condiion. The user s conrol apparaus mus make decisions from he curren limis achievable by he applicaion. The following adjusmens can be uilized o opimize he curren oupu. Sensiiviy: The swich selecion chosen deermines he amoun of gain o be applied o he sensed signal. Adjusmen is done via a slide swich which permis selecion of HI or LO seings. Ideal selecion can be deermined only afer he full flow saus is creaed and analyzed. The sensor is provided wih he sensiiviy swich placed in he LO seing. If insufficien oupu curren is observed a full flow condiion, gain can be increased by reposiioning slide swich o HI. Conversely, if oupu curren is excessive a full flow condiion, gain can be decreased by reposiioning slide swich o LO. 1) Green LED: Illuminaion of he green LED indicaes ha power is properly conneced o he sensor. Lack of illuminaion could be from lack of supplied power or reversed polariy of he inpu connecions. 2) Yellow LED: Any illuminaion of he yellow LED indicaes ha he SIG connecion loop is correcly insalled. Lack of illuminaion could be from improper connecion beween he sensor and he oupu apparaus. Deeced moion will cause he yellow LED o more inensely illuminae. Figure 6 5

6 Calibraion Sequence: 1) Sensiiviy Seing: Place he sensiiviy seing in he LO posiion o sar he process. I may be necessary o change o HI bu i will become eviden laer in his sequence. 2) SIG ADJ Seing: Place SIG ADJ adjusmen fully clockwise o achieve maximum averaging. During he following seps, allow 5 seconds of seling ime afer any adjusmen before making conclusions. 3) Z Seing: While he sysem is operaing (conveyors, feeders) and no maerial is flowing, adjus Z zero adjusmen unil oupu curren reads 4.0mA. If machinery movemen or equivalen minimum flow saus creaes significan moion, i may be impossible o aain he 4.0mA reading. 4) S Seing: Wih he maerial flowing in maximum condiion, adjus he S span adjusmen unil oupu curren reads 20.0mA. If deeced moion is oo lile, i may be impossible o aain he 20.0mA reading. 5) Sensiiviy Seing: Deermine if he range beween no flow and full flow condiions provide enough curren oupu change. If no, readjus sensiiviy seing o HI and repea seps 3 and 4. 6) SIG ADJ Seing: Make final decision regarding placemen of he signal averaging. If i is desirable o have he oupu curren respond more quickly o aciviy a he sensor face, roae he adjusmen couner-clockwise. T R O U B L E S H O O T I N G PROBLEM: The SFI oupu curren does no change wih process flow changes. 1) Insufficien circui gain for he deeced moion. Increase he sensor sensiiviy by selecing HI posiion. 2) Mouning locaion does no provide enough microwave disurbance. Consider wheher a differen mouning locaion or angle may presen a beer arge and hereby increase he microwave disurbance/oupu curren. PROBLEM: The SFI oupu curren changes erraically herefore creaing unusable informaion. 1) Sensor is reacing oo fas o he insananeous disurbance deeced. Increase he signal averaging by roaing he SIG AVG poeniomeer clockwise. 2) Mouning locaion sees inconsisen flow paerns generally associaed wih he applicaion. Consider wheher a differen mouning locaion or angle may presen a more consisen arge for he deerminaion of maerial flow. PROBLEM: The SFI oupu curren always remains below 10mA (e.g. no maerial flow is represened by 4mA and full flow is represened by <10mA). 1) Insufficien circui gain for he deeced moion. Increase he sensor sensiiviy by selecing he HI posiion. 2) Circui scaling facor is no maximized. Increase he scaling facor (span) by roaing he S poeniomeer clockwise. 3) Mouning locaion does no provide enough microwave dis urbance. Consider wheher a differen mouning locaion or angle may presen a beer arge and hereby increase microwave disurbance/oupu signal. PROBLEM: The SFI oupu curren always remains above 12mA (e.g. no maerial flow or minimum maeral flow is represened by >12mA and full flow is represened by 20mA). 1) Circui offse facor is excessive. Decrease he offse facor (zero) by roaing he Z poeniomeer couner-clockwise. 2) Deermine if equipmen such as feeders or conveyors are being sensed when no flow or minimum flow is presen resuling in a greaer oupu curren. Do so by evaluaing oupu curren wih he sysem operaing wihou maerial. If necessary, moun he sensor a new locaion. 3) Mouning locaion provides excessive maerial disurbance deecion. Consider wheher a differen mouning locaion or angle may presen a arge which would no creae as much microwave disurbance/oupu signal. PROBLEM: The SFI oupu curren his maximum level of 20+mA prior o ime when maerial flow is a maximum. 1) Excessive circui gain for he deeced moion. Decrease he sensor sensiiviy by selecing he LO posiion. 2) Mouning locaion provides excessive microwave disubance. Consider wheher a differen mouning locaion or angle may presen a arge which would no creae as much maerial disurbance/oupu signal. M A I N T E N A N C E The SFI is a mainenance-free produc and shall be serviced by Monior Technologies LLC only. Consul he facory when operaion appears inappropriae. The following warning is required by he Federal Communicaions Commission (FCC). WARNING: Changes or modificaions o he SFI no expressly approved by Monior Technologies LLC could void he user s auhoriy o operae he produc. NOTE: This equipmen has been esed and found o comply wih he limis for a Class B digial device, pursuan o Par 15 of he FCC Rules. These limis are designed o provide reasonable proecion agains harmful inerference in residenial and indusrial insallaions. This equipmen generaes, uses and can radiae radio frequency energy and, if no insalled and used in accordance wih he insrucions, may cause harmful inerference in radio communicaions. However, here is no guaranee ha inerference will no occur in a paricular insallaion. If his equipmen does cause harmful inerference o radio or elevision recepion, which can be deermined by urning he equipmen off and on, he user is encouraged o ry o correc he inerference by one or more of he following measures: Reorien or relocae he receiving anenna Increase he separaion beween he SFI and he receiver Connec he SFI o a circui differen from which he receiver is conneced Consul he dealer or an experienced radio/tv echnician for help 6

7 S A F E T Y Radiaed Energy: OSHA has adoped regulaions designed o preven possible harmful effecs in human being from exposure o elecromagneic fields in he frequency range of 300 KHz o 100 GHz. The SFI generaes energy wihin his band. OSHA permis human exposure o power densiies up o 10mW/cm 2 for a one-half hour coninuous duraion. The SFI produces a power densiy less han 1mW/cm 2 a he sensor face and herefore poses no healh danger o operaors or he general public. M E C H A N I C A L S W A R R A N T Y Monior Technologies LLC warrans each solids flow indicaor i manufacures o be free from defecs in maerial and workmanship under normal use and service wihin wo (2) years from he dae of purchase wihin Norh America, and wihin one (1) year from dae of purchase ouside of Norh America. The purchaser mus give noice of an defec o Monior Technologies LLC wihin he warrany period, reurn he produc inac and prepay ransporaion charges. The obligaion of Monior Technologies LLC under his warrany is limied o repair or replacemen a is facory. This warrany shall no apply o any produc which is repaired or alered ouside of he Monior Technologies LLC facory, or which has been subjec o misuse, negligence, acciden, incorrec wiring by ohers or improper insallaion. S P E C I F I C A T I O N S Power Requiremens: VDC, 100mA max. Enclosure: die cas aluminum, polyeser powder coaed (beige) Enclosure Proecion: NEMA 4 / ENCLOSURE TYPE 4, IP66 Operaing Temperaure: -13 o o 185 o F (-25 o o 85 o C) Process Temperaure: 250 o F (121 o C) if ambien air emp. below 150 o F (65 o C) Process Seals: TFE Teflon ; Ryon -Equivalen Pressure Raings: TFE Teflon : 75psi (5 bar) inermien Ryon -Equivalen: 300psi (20 bar) Process Connecion: 1-1/4" NPT (1-1/2" wih sainless seel adaper) Condui Connecions: (2) 1/2" NPT Deecion Range: 0 o 10f (3.05m) free air, environmen and arge dependen Sensiiviy: swich selecable HI/LOW Min. Velociy: 1.7 f/sec 45 o moun o direcion of flow Oupu: 4-20mA oupu (full span may no be achievable in some applicaions), curren sourcing device (signal reurn common o user power supply); magniude proporional o disurbance deeced; 175 ohm load max, zero and span adjusable Isolaion: 750 vpk isolaion beween sensor ground and user power supply/ 4-20mA analog signal Indicaors: Green LED - power Yellow LED - loop, inensifies wih disurbance deeced Emission: GHz, FCC and IC cerified, energy levels less han 1mW/cm 2 (OSHA limi of 10mW/cm 2 ) Approvals: CSA US/C ; Class II, Div. 1, Groups E, F, G; CE Marking (ordinary locaions only) Teflon is a regisered rademark of Dupon Chemical Co. Ryon is a regisered rademark of Solvay Specialy Polymers. Monior Technologies LLC reserves he righ o change he design and/or specificaions wihou prior noice. 7

8 B U L L E T I N 834 Monior Technologies LLC 44W320 Keslinger Rd. Elburn, IL USA Fax: GDR JSC JUN DOC A 10