R.F. Capacitance Dual-Point Level Control INSTALLATION & OPERATION MANAUL

Transcription

1 CAPTROL MODELS 510 R.F. Capacitance Dual-Point Level Control INSTALLATION & OPERATION MANAUL An L&J Technologies Co Butterfield Road Hillside, IL Phone: Fax:

2 was started in 1976 by a young engineer who had a better idea in tank gauge electronics. His employer at the time,, did not want to invest in state-of-the-art technology, so he started L&J. Ten years later L&J bought GPE. Needless to say, he reorganized GPE s management and its new product development philosophy. Along with GPE, L&J bought, a GPE affiliate that manufactures fittings and valves for the same type of tanks that used the gauging equipment. A short time later, all 3 companies were reorganized under one corporate entity called. In 1994, a brand new, state-of-the-art manufacturing facility was built to bring all of the L&J Technologies manufacturing efforts under one roof. In 1996, L&J bought, a manufacturer of liquid level controls and Hi/Low level switches for the boiler, process, and liquid storage industries. On February 28, 2000, L&J purchased Durlam Associates, (now Durlam Inc.). is located in Houston, Texas and is the leading manufacturer of fiberglass reinforced plastic (FRP) Derakane 470 conservation vents and fittings. On March 31, 2000, L&J purchased Delavan Process Instrumentation in Naugatuck, CT. is a well-established name in ultrasonic, capacitance and microwave point level and continuous level measurement for liquids and solids. Delavan was relocated to L&J Technologies corporate headquarters in Hillside, Illinois. Today, the L&J family of companies is the world s largest manufacturer specializing in the monitoring, management, and control of bulk liquids. L&J provides quality products for the Petroleum, Petrochemical, Chemical, Food, Pharmaceutical, Pipeline, Steel, Water Treatment and Biogas ( ) Industries. Visit L&J Technologies on the internet at 2

3 TABLE OF CONTENTS 1.0 Introduction Description Principle of Operation Specifications Installation Unpacking Mechanical Installation Non-Metallic Tank Electrical Installation Operation General Controls for Analog Output Controls for Relay Adjustment Indicators for Analog or Relay Adjustment Procedure Analog Preparation for Relay Adjustment Relay Adjustment Procedure -- Single Relay Relay #2 Adjustment Procedure Maintenance & Servic Product Warranty

4 1.0 INTRODUCTION The contents in this instruction manual are designed for Delavan's model Captrol 510 R. F. Capacitance "dual-point" level control. Please review the information contained in this instruction manual carefully to ensure proper operation. 1.1 Description Delavan's Captrol model 510 is an adjustable on/off R.F. Capacitance switch with one relay and an adjustable deadband or differential. It may be used in both powder bulk solids and liquids applications. 1.2 Principle of Operation The Captrol model 510 system consists of solid state "Failsafe" electronics mounted in a cast aluminum explosion proof enclosure and a sensing probe. The sensing probe is energized with a R.F. (Radio Frequency) signal, of approximately 2 Mega Hertz. When the process material level changes, a change in capacitance occurs resulting in a change in frequency. The change in frequency is compared with preset values and after amplification is used to actuate a relay contact. Multi-turn potentiometers are used for set point and differential calibration. An important feature of the Captrol 510 is that the set point and differential adjustments are noninteracting and are independent of each other. The amount of capacitance generated in a given application is dependent upon the dielectric constant of the process material, the distance from the sensing probe to earth ground or a ground reference, and by the size (surface area) of the sensing probe. 1.3 Ordering Information Captrol Special Features X = No special Features H = High temp lagging ext. Process Mounting NPT = Nat'l pipe thread 3A = Food Grade fitting T3A = Teflon, food grade fitting K3A = Kynar, food grade fitting FC = Flange, carbon steel FSS = Flange, stainless steel Sensing Probe Type THD KHD TCP BHS TCT BF T BHT TF KF DWW THDD KHDD Enclosure Types G = General Purpose H = Hazardous Location Electronic Control Options 1 = 1 independently adjustable relay 2 = 2 independently adjustable relays Model 510 "Dual-Point" Level Switch Assuming that the dielectric constant of the process material is consistent, and that the sensing elements mounting location in the vessel is fixed, the amount of capacitance generated is based upon the sensing elements overall size or area. When the process material fluctuates in the vessel, the amount of capacitance generated between the sensing element and the vessel wall or ground also fluctuates. 4

5 2.0 PRODUCT SPECIFICATIONS 2.2 Dimensions Electrical Specifications Supply Voltage Power Consumption 115, Hz, 24 VDC 3 VA Sensitivity 0.5 pf or less Output Relay one Form C DPDT VAC Non Ind VAC Non Ind 3 24 VDC Non Ind. Time Delay Standard: Fixed 100 millisecond delay Optional: Adjustable 100 milliseconds to 30 seconds Fail-Safe Temperature Range Enclosure Rating Switch selectable - High level or Low level Electronics: -40 to +71 C -40 to F Die Cast Aluminum with fused Polyester paint finish. Meets NEMA 4,5,7,9, & 12 NEC Class I Division II NEC Class II Division II 3.0 INSTALLATION 3.1 Unpacking Remove the Captrol 510 carefully from the shipping carton. Check to make certain that no damage has occurred to the electronics or to the sensing probe. If the equipment has been damaged, notify the shipping carrier immediately. 3.2 Mounting Location Delavan's Captrol model 510 should be installed and mounted in an environment where temperatures are no less than -40 F. (-40 C.) and no greater than +160 F. (+71 C.). 2.1 Third Party Approvals Thrid Party Approvals Normally, when installed in metallic vessels, the vessel wall serves as the ground reference. It is important to the overall operation of the system that a good connection be made between the sensing probe and the vessel. If in doubt, connect a separate ground strapping wire between the Captrol 510's housing and the metal vessel. CSA Cenelec Approved: Class I, Groups C & D Class II, Groups E,F, &G Pending: Eex d IICT6 5 When installed in vessels containing conductive liquids, the location of the probe in relationship to the vessel wall is not critical. When the Captrol 510 is used to monitor materials that have low dielectric values (non-conductive materials or materials with a dielectric value < 20) special provisions should be made to locate the sensing probe within 10 inches of the vessel wall. If this cannot be accomplished, an artificial ground reference (metal pipe or rod) should be considered. This will enhance the units sensitivity and operation.

6 For applications where the Captrol 510 is being used in nonmetallic vessels i.e. plastic, fiberglass, or concrete, an artificial ground reference that runs parallel to the sensing probe must be used. Typically, this can be accomplished by using a dual probe or a concentric probe available through Delavan. 3.3 Vessels With Nozzles Special consideration should be given to the possibilities of material becoming entrapped around the sensing probe within the recessed area of the nozzle, resulting in false readings. When mounting on nozzles specify a sensing probe that contains an inactive sheath long enough to extend at least 1 inch beyond the vessel wall. See illustration below: 3. Firmly assemble the Captrol 510's electronic control unit to the sensing probe. 4. With the enclosure lid removed from the electronic control unit, locate the red banana plug which is at tached to the electronics. Insert the red banana plug into the top of the sensing probe until firmly secured. NOTE: When handling the red banana plug do not apply excessive force to the coax cable. Insert and remove by holding the plug only. 3.5 Wiring Procedure Power and relay wiring should comply with NEC (National Electrical Code) standards and specifications. When selecting wire for power and relay connections use a light gauge, 16 to 20 AWG insulated wire. Power Wiring 1. Make certain power is disconnected. 2. Run power wires through conduit. RECOMMENDED 3.4 Mounting Instructions NOT RECOMMENDED Delavan's Captrol 510 can be used with both rigid sensing probes and flexible cable style sensing probes. Rigid sensing probes up to 20 inches in length are shipped from the factory pre-assembled to the electronic control unit. Sensing probes over 20 inches in length, as well as, flexible cable style sensing probes, must be assembled in the field Assembly Procedure 1. Install sensing probe into vessel coupling or flange. 2. When tightening, apply wrench to the lower nut only (closest to the sensing probe). Packing Gland Nut (When installing, use wrench on this nut only) 3. Connect the hot wire to the appropriate terminal, 115 VAC to #3, 230 VAC to #4, or 24VDC to #12. Connect the common wire to terminal #2 when using 115 or 230 VAC. When using 24 VDC connect the common to #11. Connect an earth ground wire to terminal #1. (See Wiring Terminal illustration below) Wiring Terminal GND NEUT 115VAC 230VAC N.C C. N.O. N.C. C. N.O. LOW - VOLT INPUT + RELAY CONTACTS NOTE: The relay contacts are form C Dry Contacts. Power must be supplied to the relay contacts, typically, by using a jumper between the power terminal and the common terminal of each relay that is to be used. RIGID PROBE ASSEMBLY 6

7 Power Relay Wiring Truth Table Material Level Failsafe Relay Status Relay Wiring COM to NC COM to NO high high De-energized Closed Open low high Energized Open Closed On high low Energized Open Closed low low De-energized Closed Open high high De-energized Closed Open low high De-energized Closed Open Fail high low De-energized Closed Open low low De-energized Closed Open 4.0 ADJUSTMENT CONTROLS 4.1 Relay and Sensor Status Relay Status: Yellow LED: Illuminates when relays are energized. 4.2 Set Point and Differential Adjustment Set Point Adjustment: This 20 turn pot matches the set (trip) point of the switch to the desired process level. (Lower trip point) S6, S7 Fail-safe Switch Fail-safe high or fail-safe low does not indicate the physical location of the sensor installed in the vessel. The fail-safe switch position determines if the relay is de-energized when the product is above or below the operation point. Relay Status Fail-safe Dip Switch Position Above Set pt. High Level S6 - Open, S7 - Closed De-Energized Low Level S6 - Closed, S7 - Open Energized Time Delay There are two time delay options on the Captrol 510. Standard: Fixed non-adjustable 100 milliseconds non-integrating delay. Optional: Adjustable milliseconds minimum to 10 seconds maximum before relay actuation. 5.0 CALIBRATION 5.1 Board Layout Differential Adjustment: This 20 turn pot matches the differential end point (upper limit) to the desired upper limit of the process level. 4.3 Function Switches S1, S2 Set Point Range Switch These switches match the instrument measuring point required for the specific process. Range Low Medium High Dip Switch Position S1 - Open, S2 - Open S1 - Closed, S2 - Open S1 - Open, S2 - Closed S3, S4 Differential Range Switch These switches match the differential range of the instrument to process requirements. Range Low Medium High Dip Switch Position S3 - Open, S4 - Open S3 - Closed, S4 - Open S3 - Open, S4 - Closed S5 Interlock Switch This switch interlocks the set point and differential point for pump control operation. Switch Position S5 - Open S5 - Closed Status Unlatched - Calibration Latched - Operation 5.2 Set Up Step 1 - Determine the fail-safe mode required for your application. The fail-safe switch position determines if the relay is energized or de-energized when the product is above the set point. 7

8 Step 2 - Pick condition A or B depending on your installation and follow the procedures below. Condition: A Single Point Step 8 -Turn differential potentiometer counter-clockwise until the RED LED just comes ON. Step 9 - Set S5 to CLOSED to activate differential action. Calibration completed. Condition: B Differential adjustment for Pump Control 6.0 TROUBLESHOOTING 1) Check power to unit, is it within the absolute limits 5.3 Procedures Condition: A (Single Point) 2) Is their proper earth ground? (metallic or non-metallic vessel) 3) Are the relay contacts wired correctly? Step 1 - Turn differential potentiometer fully counter-clockwise and set-point potentiometer fully clockwise. Step 2 - Set switches S1 through S5 to OPEN. Step 3 - Raise material to desired detection point on probe. Step 4 - If the RED LED is OFF, setting is within this set-point range, proceed to Step 5. If RED LED is ON, set S1 to CLOSED and if still ON, set S2 to CLOSED before proceeding to Step 5. Step 5 - Turn set-point potentiometer counter-clockwise until the RED LED just comes ON. Calibration completed. Condition: B (Differential adjustment for Pump Control) Step 1 - Turn differential potentiometer fully counter-clockwise and set-point potentiometer fully clockwise. Step 2 - Set switches S1 through S5 to OPEN. Step 3 - Raise material to desired low detection point on probe. Step 4 - If the RED LED is OFF, setting is within this set-point range, proceed to Step 5 If RED LED is ON, set S1 to CLOSED, and if still ON, set S2 to CLOSED before proceeding to Step 5. Step 5- Turn set-point potentiometer counter-clockwise until the RED LED just comes ON, then clockwise slowly until RED LED just goes OFF. Step 6 - Raise material to desired high point. 4) Is their build-up on the probe? 5) Is the probe recessed in the process mounting? 6) Is the probe fractured or cracked? (please see notes 1 & 2 below) Note 1 - To check for a shorted probe, disconnect the coaxial wire from the probe. Connect DMM test leads between the probe and the grounding lug on the enclosure. If thedmm indicates continuity, the probe may be shorted to ground or the probe insulation may have ruptured allowing the process material to contact the internal stainless steel rod. Note 2 - The Captrol 510 is capable of measuring capacitance ranging from 50 picofarads to 30,000 picofarads. Disconnect the coaxial wire from the probe. Using a capacitance meter, verify the capacitance between the probe and electronics enclosure does not exceed 30,000 picofarads. (30,000 picofarad =.03 microfarad) 7.0 SPARE PARTS DESCRIPTION PART NUMBER 510 Final Assembly Electronic Assembly Enclosure Enclosure lid Enclosure base Instruction manual Step 7-Turn differential potentiometer fully clockwise. If the RED LED is OFF, setting is within this set-point range, proceed to Step 8. If the RED LED is ON, set S3 to CLOSED and if still ON, set S4 to CLOSED before proceeding to Step 8. 8

9 8.0 RETURN GOODS PROGRAM When returning equipment to Delavan, it is necessary to first obtain a return goods authorization (RG) number. In order for Delavan to provide the most efficient service regarding any equipment being returned, the following information is necessary: 1) Billing & shipping addresses 2) Contact name & phone number 3) Reason for return 4) Purchase order number (for repairs) 5) Brief, but detailed, description of problem or reason for return Authorization may be obtained by contacting either Delavan or your local Delavan representative. 9.0 PRODUCT WARRANTY Delavan level control products will be replaced, put in good operating condition, or the purchase price refunded, at the option of Delavan, free of charges except transportation, if defective in their manufacture, labeling, packaging, or shipping, and if notice of said defect is received by Delavan within one year from the date of shipment. The cost of such replacement repair or refund or purchase price shall be the exclusive remedy for any breach of any warranty, and Delavan shall not be liable to any person for consequential damages for injury or commercial loss resulting from any breach of any warranty, of fitness for a particular purpose, and makes no other warranty, express or implied, including implied warranty arising from course of dealing or usage or trade. 9

10 REACHING NEW LEVELS IN PROCESS MEASUREMENT 5911 Butterfield Rd. Hillside, IL PH: (708) FAX: (708)