Smart EZ Modulevel® Installation and Operating Manual Displacer Operated Level/Interface Measurement 7xxx 6xxx 5xxx 4xxx 3xxx I VE GOT 2xxx ABILITY ® VE L LE 1xxx FE T Y I EGRITY NT SA Refer to bulletin 48-615 for Analog EZ Modulevel UNPACKING These units are in conformity with the provisions of: 1. The EMC Directive: 2004/108/EC. 0038 The units have been tested to 0344 EN 61326: 1997 + A1 + A2. 2. Directive 94/9/EC for Equipment or protective system for use in potentially explosive atmospheres. EC-type examination certificate number ISSeP00ATEX003X (intrinsic safe units) or ISSeP01ATEX018 (EEx d units). 3. The PED directive 97/23/EC (pressure equipment directive). Safety accessories per category IV module H1. TOP MOUNTED UNITS After unpacking, inspect all components to see that no damage has occurred during shipment. Care should be taken not to bend the displacer stem or enclosing tube during unpacking or installation. CHAMBERED UNITS A strap and wire assembly retains and protects the displacer within the chamber during shipment. This assembly must be removed through bottom chamber connection before startup. Inspect instrument as described for top mounting units. Nameplate Caution: If re-shipping to another location, displacer must again be secured using same strap and wire assembly. MOUNTING -40°C (-40°F) to +70°C (160°F) calibration vent is recommended Liquid level max 1° tolerance 2 Use stilling well in case of turbulent medium Shut-off valves are recommended Size 1/8" Always unlock for repositioning or removal of head assembly and always relock, after final positioning max 360 ° WIRING INTEGRAL UNITS IMPORTANT FOR HART® USERS A MAXIMUM LOAD RESISTANCE OF 450 Ω MAY BE INSERTED INTO SUPPLY LINE FOR CURRENT MONITORING. IMPORTANT INSTRUMENT AND ELECTRICAL JUNCTION FITTING COVERS MUST BE KEPT TIGHT AT ALL TIMES DURING OPERATION. NO WIRING CONNECTIONS ARE REQUIRED INSIDE THE TRANSMITTER ELECTRONIC ENCLOSURE. – TB1 + ® ENTER AW3175 TP1 L6 + – P2 L5 L4 C5 C3 – – C1 L2 REMOTE UNITS (+) P1 – TB1 + 3 Grn LVDT housing 5 6 3 4 5 6 Transmitter housing 1 2 3 www.magnetrol.com REFER TO MODULEVEL MANUAL, BULLETIN 48-615, FOR INSTALLATION AND OPERATION INSTRUCTIONS. ENTER TP1 4 ASSEMBLY PART NO. + C6 TP2 + – TB2 5 6 Junction box + – L5 C5 C3 P2 – J1 05-9123-001 D1 P1 L3 Yel Brn 1 2 4 2 HEIKENSSTRAAT 6, B 9240 ZELE, BELGIUM. + Red 5 6 2 Blk Blu 1 3 6 5 4 2 3 1 UP DOWN – ® 1 4 ® E S MODULEVEL 5300 BELMONT ROAD, DOWNERS GROVE, IL 60515, USA. AW3175 Green ZERO SPAN ERROR Yellow Signal/Power Supply min 12 V DC – ATEX Exd/Exi max 36 V DC – ATEX Exd max 28,4 V DC – ATEX Exi JP1 D2 (–) P2 Black } The 6 discrete conductors are tagged 1 through 6, and should be secured to their respective terminals on both terminal blocks. The wiring of the EZ Modulevel transmitter assembly, to the LVDT assembly, is pre-wired from factory by 6 conductor cables. When transmitter housing is remote mounted by means of a cable, use the following cables: Brown DC- TB1 05-9123-001 Bleu DC+ + J1 Red D1 P1 C4 ASSEMBLY PART NO. + C6 TP2 + – TB2 L6 REFER TO MODULEVEL MANUAL, BULLETIN 48-615, FOR INSTALLATION AND OPERATION INSTRUCTIONS. L4 www.magnetrol.com NOTE: For units with meter, pull meter out before wiring terminals can be reached. DOWN C4 HEIKENSSTRAAT 6, B 9240 ZELE, BELGIUM. UP C1 E S MODULEVEL 5300 BELMONT ROAD, DOWNERS GROVE, IL 60515, USA. ® L2 ZERO SPAN ERROR % L3 (+) P1 JP1 D2 (–) P2 POWER TERMINALS AND LOCAL METER (IF APPLICABLE) ARE LOCATED IN THE JUNCTION BOX TB1 3 CALIBRATION – LEVEL CALIBRATION USING PUSHBUTTONS NOTE: Default Error signal setting from factory = 22 mA. Direct action 4 to 20 mA at rising level: 1. Calibrate 4 mA/0 % level Push = start calibration – loop will go to 22 mA. Push = lock 4 mA value – red ZERO LED must be ON. Push = red ZERO LED turns OFF, after ± 5 s LED flashes 1x to confirm the new 4 mA setting. Note: DO NOT move level/push any buttons before the LED has flashed. Restart the procedure if any of these occurred. 2. Calibrate 20 mA/100 % level: Establish liquid level at desired 20 mA level Push = start calibration Push = lock 20 mA value – red SPAN LED must be ON Push = red SPAN LED turns OFF, after ± 5 s LED flashes 1x to confirm the new 20 mA setting. Note: DO NOT move level/push any buttons before the LED has flashed. Restart the procedure if any of these occurred. 3. In case 100 % level cannot be established: Establish liquid level at highest possible level Push = start calibration Push = lock 20 mA value – red SPAN LED will turn ON Toggle / = untill loop signal corresponds with % of actual level. Each two toggles correspond with 0.1 mA eg. 80 % level should match: (20 mA – 4 mA) x 80 % + 4 mA = 16.8 mA Push = red SPAN LED turns OFF, after ± 5 s LED flashes 1x to confirm the new 20 mA setting. Note: DO NOT move level/push any buttons before the LED has flashed. Restart the procedure if any of these occurred. Red LED ZERO led Span led Error led Pushbuttons ... ENT 100 % level, 20 mA output TESTING on BENCH CALIBRATOR The EZ Modulevel bench calibrator is designed to test the electronics of the unit. The bench calibrator can also be used for calibration purpose but the calibration requires fine tuning versus actual levels in the field. Slide the electronic head over the open topped enclosing tube, making sure that the white plastic washer is in place. 1. Calibrate 4 mA/0 % level: Slide the adjustment rod completely down into the enclosing tube Push = start calibration – loop will go to 22 mA. Push = lock 4 mA value – red ZERO LED must be ON = red ZERO LED turns OFF, after ± 5 s LED Push flashes 1x to confirm the new 4 mA setting. Note: DO NOT move the adjustment rod/push any buttons before the LED has flashed. Restart the procedure if any of these occurred. 2. Calibrate 20 mA/100 % level: Align the scale of the adjustment rod with the SG of your medium Push = start calibration Push = lock 20 mA value – red SPAN LED will turn ON Push = red SPAN LED turns OFF, after ± 5 s LED flashes 1x to confirm the new 20 mA setting. Note: DO NOT move the adjustment rod/push any buttons before the LED has flashed. Restart the procedure if any of these occurred. Ordering code: 031-6107-001 Adjustment rod For non-Exi units: Grip ring located here on process level sensors LVDT PC board "O" rings ENT LVDT core White plastic washer must be installed Base & junction box Desired level range (direct acting) Zero level, 4 mA output, bottom of displacer Stand NOTE: Reverse action: Maintain the same procedure as above described but calibrate 4 mA as 100 % level (adjustement rod aligned with specific gravity) and 20 mA as 0 % level (adjustement rod entirely in LVDT core) IMPORTANT BENCH CALIBRATION DOES NOT COMPENSATE FOR ELAVATED TEMPERATURES SEE HAND HELD CALIBRATION PROCEDURE Specific gravity needs to be set in function of selected unit (see partnumber) to establish 100 % level output: E8x-J/M/A/D/Qxxx-Exx = align adjustment rod with real specific gravity E8x-K/B/N/E/Rxxx-Exx = align adjustment rod with real specific gravity multiplied by 2 (density = 0.3 - align with 0.6) E8x-L/C/P/F/Txxx-Exx = align adjustment rod with real specific gravity divided by 2 (density = 1.30 - align with 0.65) 4 CALIBRATION – LEVEL CALIBRATION USING HART® IMPORTANT (–) P2 (+) P1 SPAN – TB1 + ZERO ERROR CHECK WHETHER YOUR HART® COMMUNICATOR IS EQUIPED WITH THE EZ MODULEVEL DEVICE DESCRIPTION (DDʼS). OLDER PURCHASED DEVICES MAY REQUIRE AN UPDATE – CONSULT YOUR LOCAL HART SERVICE CENTRE OR MAGNETROL FOR FURTHER ASSISTANCE. ® ® HEIKENSSTRAAT 6, B 9240 ZELE, BELGIUM. www.magnetrol.com CONNECTIONS Connection of your Hart communicator • At TB1 terminals (+) and (-) at amplifier board • At first junction box between unit and control room. IMPORTANT THE DIGITAL HART® COMMUNICATION IS SUPERIMPOSED ON THE 4-20 mA LOOP AND REQUIRES A MIN. LOAD RESISTANCE OF 250 Ω AND A MAX LOAD RESISTANCE OF 450 Ω. UP E S MODULEVEL 5300 BELMONT ROAD, DOWNERS GROVE, IL 60515, USA. DOWN REFER TO MODULEVEL MANUAL, BULLETIN 48-615, FOR INSTALLATION AND OPERATION INSTRUCTIONS. ENTER TP1 ASSEMBLY PART NO. TP2 J1 05-9123-001 Junction 250 Ω < RL < 450 Ω NOTE: Manual calibration should not be attempted while HART® communication is active. - + Control Room Display Power Supply Current Meter 5 CALIBRATION – HART® MENU ACTION SCREEN/COMMENT I/O Start Up the unit 컄 2 컄 1 컄 1 컄 컄 컄 컄 2 컄 컄 컄 컄 3 컄 4 컄 2 컄 3 Enter Calibration Set Points 4 mA: apply new 4 mA input: Set as 4 mA value: current level will be new 4 mA level Read new value: introduce a value that will match 4 mA Leave as found: keep old 4 mA value 20 mA Set as 20 mA value: current level will be new 20 mA level Read new value: introduce a value that will match 20 mA Leave as found: keep old 20 mA value 20 mA by %: enter % of span versus actual level End Damping Fault state (select via and pushbuttons) 3.6 mA 22 mA Date/Time/Initials: details about the last change of data Loop Test 4 mA: unit blocks at 4 mA 20 mA: unit blocks at 20 mA Other: enter a value between 3.6 and 22 mA End Enter Device Setup: press one of the following numeric keys to proceed Enter Password 1 컄 1 컄 4 컄 5 컄 컄 컄 컄 컄 컄 3 컄 컄 컄 컄 컄 4 컄 1 컄 컄 컄 컄 컄 컄 컄 컄 컄 컄 2 3 4 6 1 2 3 4 5 5 2 3 4 5 6 7 8 9 ➨ 1 2 3 4 1 2 3 1 2 3 Enter Basic Setup TAG: enter the tag N° of the unit Descriptor: 16 characters – customer description for transmitter Message: 32 characters – for customer message Final Asmbly num: final assembly N° of the unit Poll addr: only to be used when multiple units are connected in the same loop – leave value “0” when used as a single transmitter Enter Advanced Setup Set dry Point: only needed when the Specific Gravity setting will be changed. Dry point is set when the displacer free hanging not in contact with the medium LVDT %: read out % Spec Grav: set Specific Gravity value Error codes: consult factory when another value than “0000” is displayed New Password: enter new password “Factory default value 0” will disable the Password function Trim 4 mA Point: coarse match for 4 mA loop current Trim 20 mA Point: coarse match for 20 mA loop current 4 mA trim point: fine match for 4 mA loop current 20 mA trim point: fine match for 20 mA loop current set Serial Number: Serial N° is factory set and cannot be changed in the field Enter Review: Review all parameters set Model Spec Grav Manufacturer Date Magnetrol S/N Final asmbly Num Dev id Universal Rev Tag Fld Dev Rev Descriptor Software Rev Message Poll Adress Damping Num Req Preams Fault state Level: view level in % Current: view level in mA Date PACTware – Configuration and Troubleshooting For more details about the use of PACTware® and FDT, refer to instruction manual 59-601 WHAT IS FDT, PACTware® AND DTM • FDT (Field Device Tool) is a new interface code that describes the standardization between frame programs (e.g., PACTware) and DTMs (Device Type Manager). • PACTware® (Process Automation Configuration Tool) is a frame program. It is a device-independent software program that communicates with all approved DTMs. • DTM (Device Type Manager) is not a stand-alone program but a device-specific software driver designed to operate within a frame program such as PACTware. It includes all special information needed to communicate with a specific device (e.g., Pulsar RX5). There are two basic categories of DTMs—Communication (HART, Fieldbus®, Profibus®, etc.) and Field Device (e.g. Pulsar RX5 Radar transmitter). MINIMUM SYSTEM REQUIREMENTS Following are general requirements for proper operation of this program: Pentium® II 500 MHz processor. 128 MB RAM. 120 MB free hard disk space. Windows® XP/2000 (Service Pack 1) / NT 4.0 (Service Pack 6). Graphic Resolution 1024x768 (16-bit color). Internet Explorer 5.0. RS232 serial interface. RS232-HART or USB-HART serial interface for point-topoint connection or RS232-RS485 converter for connection to Hart Multiplexer. HART communication DTM. MOST COMMONLY USED SCREENS • Online parameterization: allows the user to configure the unit online. • Offline parameterization: allows the user to configure the unit offline. • Tank view: displays a common operating window graphically showing % output of level. • Echo curve: shows the actual waveform. The echocurve is an extremely useful tool for advanced configuration and troubleshooting. • Process trend: all key data (Level, % Output, Loop) can be trended and saved, scales can be adapted. • Device/diagnosis: the diagnosis: the diagnosis screen allows examination of all faults, warnings and international messages. TROUBLESHOOTING This program offers a wealth of information critical to effective troubleshooting. If a problem should arise and factory assistance is necessary for analysis, be prepared to save and email the following files: • ONLINE PARAMETERS: the complete list of configuration data. • PROCESS TREND information that includes the time of upset/error condition. • Diagnostics: list of possible error messages. See page 9. • ERROR MONITOR (VIEW/ERROR MONITOR) including upset/error condition. Transmitter with current HART revision. CONNECTIONS The following diagram shows a typical hardware configuration. Observe all safety codes when attaching to instrument loops in hazardous areas or when measuring flammable media. Computers are not intrinsically safe devices. 24 V DC HART connections Power Transmitter PC with HART Serial Interface HART Interface Adapter (RS232 or USB) 7 CALIBRATION – INTERFACE: all interface transmitters are pre-calibrated from factory INTERFACE ANY MEDIA - USING THE REAL MEDIA FOR CALIBRATION IMPORTANT DISPLACER MUST REMAIN ALWAYS IMMERGED IN THE UPPER LIQUID Calibrate 4 mA/0 % level Bring interface at lowest level Push = start calibration – loop will go to 22 mA. Push = lock 4 mA value – red ZERO LED must be ON Push = red ZERO LED turns OFF, after ± 5 s LED flashes 1x to confirm the new 4 mA setting. Note: DO NOT move level/push any buttons before the LED has flashed. Restart the procedure if any of these occurred. air/gases Calibrate 20 mA/100 % level: Bring interface at highest level Push = start calibration Push = lock 20 mA value – red SPAN LED must be ON Push = red SPAN LED turns OFF, after ± 5 s LED flashes 1x to confirm the new 20 mA setting. Note: DO NOT move level/push any buttons before the LED has flashed. Restart the procedure if any of these occurred. air/gases upper liquid interface upper liquid interface set 4 mA lower liquid set 20 mA lower liquid INTERFACE WATER (S.G. 1)/OTHER LIQUID - USING WATER FOR CALIBRATION NOTE: Below procedure is based upon an interface water/liquid (S.G. 0.8). When the density of the upper liquid is different e.g. 0.78, immerge the displacer for 78 % in the example) Calibrate 4 mA/0 % level Immerge displacer for 80 % in water Push = start calibration – loop will go to 22 mA. Push = lock 4 mA value – red ZERO LED must be ON Push = red ZERO LED turns OFF, after ± 5 s LED flashes 1x to confirm the new 4 mA setting. Note: DO NOT move level/push any buttons before the LED has flashed. Restart the procedure if any of these occurred. air/gases = Calibrate 20 mA/100 % level: Immerge displacer for 100 % in water Push = start calibration Push = lock 20 mA value – red SPAN LED must be ON Push = red SPAN LED turns OFF, after ± 5 s LED flashes 1x to confirm the new 20 mA setting. Note: DO NOT move level/push any buttons before the LED has flashed. Restart the procedure if any of these occurred. S.G. 0.8 S.G. 1.0 air/gases set 4 mA water 8 water = set 20 mA S.G. 0.8 S.G. 1.0 CALIBRATION – INTERFACE: all interface transmitters are pre-calibrated from factory INTERFACE ANY MEDIA - USING WATER FOR CALIBRATION NOTE: Below procedure is based upon an interface liquid (S.G. 1.2)/liquid (S.G. 0.8). When the density of the upper liquid is different e.g. 0.78, immerge the displacer for 78 % in the water – see example) Calibrate 4 mA/0 % level Immerge displacer for 80 % in water Push = start calibration – loop will go to 22 mA. Push = lock 4 mA value – red ZERO LED must be ON = red ZERO LED turns OFF, after ± 5 s LED Push flashes 1x to confirm the new 4 mA setting. Note: DO NOT move level/push any buttons before the LED has flashed. Restart the procedure if any of these occurred. = air/gases S.G. 0.8 S.G. 1.2 Calibrate 20 mA/100 % level: Immerge displacer for 100 % in water Push = start calibration Push = lock 20 mA value – red SPAN LED must be ON Toggle / = untill loop signal corresponds with, in our example, 12 mA Calculation: Push set 4 mA 100 x (1 - Upper S.G.) = % Span Lower S.G. - Upper S.G. 100 x (1 - 0,8) 1.2 - 0,8 = 50 % [(20 mA - 4 mA) x 50 %] + 4 mA = 12 mA = red SPAN LED turns OFF, after ± 5 s LED flashes 1x to confirm the new 20 mA setting. Note: DO NOT move level/push any buttons before the LED has flashed. Restart the procedure if any of these occurred. water air/gases = S.G. 0.8 S.G. 1.2 set 18.5 mA water MAINTENANCE ERROR MESSAGES - HART® Message Description/Problem Solution 0020 LVDT Analog/Digital input values out of range Replace PC board, partn° 030-2163-003 – see replacement procedure at page 10 or consult factory. 0010 0040 0080 EEPROM fault LVDT wire broken Core dropped out of range Replace PC board, partn° 030-2163-003 – see replacement procedure at page 10 or consult factory. Replace LVDT, check Replacement Parts list for the proper spare and follow the replacement procedure at page 10 or consult factory Consult factory for assistance. 9 MAINTENANCE TROUBLESHOOTING Symptom No loop current Problem Power supply not turned on. Insufficient source voltage. Wires broken/improperly connect. Defective PC board. Zero point cannot be set to 4.00 mA at low level. Span point cannot be increased to 20.00 mA at high level. Incorrect supply Zero incorrectly set. Displacer hanging-up. Incorrect supply. Span incorrectly set. Displacer hanging-up. Excessive loop resistance. Span point cannot be decreased to 20.00 mA at high level. Span incorrectly set. Loop current oscillates or hunts. Waves or disturbances in medium. Loop current randomly unstable. Loop current 22 mA or 3.6 mA fault indication ➀. Loop current between 3.8 mA and 4 mA or 20 mA and 20.5 mA. Non-linear output. Displacer hanging-up. Waves or disturbances in medium. Power supply unstable. Electrical interference (RFI). Stem is broken, LVDT core is missing, LVDT wire is broken or unplugged or a circuitry failure occured. Solution Turn on power. A minimum of 12 V DC is required at terminal TB1 (see wiring on page 3). Check wiring. Replace PC board (see procedure on page 10). Check power supply. Recalibrate 0 % level. Verify proper and level installation. Check power supply. Recalibrate unit. Verify proper and level installation. Increase power supply voltage, or decrease loop resistance (max 545 Ω @ 24 V DC, 450 Ω for HART®). Recalibrate unit. Verify proper and level installation. Adjust damping via Hart®. Adjust damping via Hart®. Repair or replace power supply. Consult factory for assistance. Verify the unit. Level is out of calibrated span but still is within safety band before fault indication. No action is required. Displacer hanging-up. Verify proper and level installation. Incorrect calibration. Recalibrate unit. ➀ In case of fault indication Red ERROR LED will only be ON when unit is set for 22 mA fault indication. When unit is set for 3.6 mA, Red ERROR LED will NOT go ON. 10 MAINTENANCE REMOVAL OF TRANSMITTER HEAD CAUTION: BENDING THE ENCLOSING TUBE WILL PERMANENTLY DAMAGE THE UNIT. REPLACING LINEAR VARIABLE DIFFERENTIAL TRANSFORMER (LVDT) ➄ Lift LVDT ➂ Remove grip ring & PC board ➁ Remove grip ring (–) P2 (+) P1 SPAN (+) P1 ® ZERO ERROR SPAN – TB1 + ® ® transmitter head over enclosing tube HEIKENSSTRAAT 6, B 9240 ZELE, BELGIUM. UP www.magnetrol.com REFER TO MODULEVEL MANUAL, BULLETIN 48-615, FOR INSTALLATION AND OPERATION INSTRUCTIONS. DOWN HEIKENSSTRAAT 6, B 9240 ZELE, BELGIUM. REFER TO MODULEVEL MANUAL, BULLETIN 48-615, FOR INSTALLATION AND OPERATION INSTRUCTIONS. UP ➀ Remove power DOWN ENTER ➅ Unplug LVDT TP1 ENTER www.magnetrol.com black (-) and red (+) ® E S MODULEVEL 5300 BELMONT ROAD, DOWNERS GROVE, IL 60515, USA. E S MODULEVEL 5300 BELMONT ROAD, DOWNERS GROVE, IL 60515, USA. ➃ Lift ZERO ERROR (–) P2 ➁ Remove wires: – TB1 + TP1 ASSEMBLY PART NO. + J1 + – L5 L6 C6 P2 05-9123-001 – C1 L2 + C4 L4 05-9123-001 J1 – C5 C3 TP2 D1 P1 JP1 D2 TB2 L3 ASSEMBLY PART NO. AW3175 TP2 TB1 ➂ Unlock for repositioning or removal of head assembly and always relock, after final positioning Size 1/8" ➃ Remove bracket screws ➀ Disconnect ➆ Remove LVDT Power NOTE: Re-install transmitter head on process level sensor. Be sure housing base is fully seated downward. White plastic washer is in place and LVDT assembly is fully seated downward. Replace grip ring. REPLACING TRANSMITTER BOARD ➄ Lift LVDT ➂ Remove grip ring & PC board (–) P2 (+) P1 black (-) and red (+) SPAN – TB1 + ZERO ERROR ➁ Remove wires: ® E S MODULEVEL 5300 BELMONT ROAD, DOWNERS GROVE, IL 60515, USA. ® HEIKENSSTRAAT 6, B 9240 ZELE, BELGIUM. www.magnetrol.com REFER TO MODULEVEL MANUAL, BULLETIN 48-615, FOR INSTALLATION AND OPERATION INSTRUCTIONS. UP DOWN ENTER ➀ Remove power ➆ Clip plastic tie-wraps TP1 ASSEMBLY PART NO. TP2 J1 05-9123-001 ➃ Remove bracket screws ➅ Unplug LVDT CHEKING THE LVDT WINDING RESISTANCE 1. Using a multimeter, check primary winding. Pins 2 and 6 should have approximately 78 to 117 ohms. 2. Secondary winding (pins 1 and 5 or 4 and 8) should have approximately 72 to 109 ohms. If not in this range, replace the LVDT. 1 2 34 87 65 ➇ Remove 4 screws ➈ Remove transmitter PC board from housing NOTE: Re-install by reversing the above procedure. NOTE: Replace LVDT if the secondary winding is out of range 11 REPLACEMENT PARTS Specify replacement parts from table below by reference to transmitter identification letters. Example: E85-KQ3A- ESD Item 1 Transmitter PC board Item 2 LVDT assembly Item 3 Meter assembly ESD 030-2135-001 N/A ESA 030-2135-001 N/A ESH 030-2135-002 N/A ESE 030-2135-002 N/A ESI 030-2135-001 037-3308-001 ESG 030-2135-001 037-3308-001 ESK 030-2135-002 037-3308-001 ESF 030-2135-002 037-3308-001 030-2135-001 037-3310-001 ES9 030-2135-001 037-3310-001 ES8 030-2135-002 037-3310-001 ES7 030-2135-002 037-3310-001 Item 4 Housing 'O'-rings Item 5 Junction box PC board 089-6562-001 ESJ 030-2163-003 Z30-2194-001 RSQ 030-2154-002 N/A RSW 030-2154-002 N/A RST 030-2154-002 037-3308-001 RSX 030-2154-002 037-3308-001 RSZ 030-2154-002 037-3310-001 RS4 030-2154-002 037-3310-001 Item 6 Item Description 7 8 9 11 Low pressure enclosing tube – max 600 lbs / PN 100 032-6401-007 – Exi 032-6401-010 – Exd High pressure enclosing tube – 900 lbs / 1500 lbs / 2500 lbs 032-6401-010 – Exi/Exd 089-6562-001 quantity = 2 Description Housing cover Junction box cover E-tube gasket Stem assembly consult factory consult factory 012-1204-001 consult factory Chamber ring joint Flange type 10 Item Chamber gasket / ring joint Chamber gasket 012-1301-017 – – 3" 300 lbs RF 012-1301-018 – – 3" 600 lbs RF 012-1204-021 – – 3" 900 lbs RJ –> 012-1904-002 012-1906-002 3" 1500 lbs RJ –> 012-1904-003 012-1906-003 4" 2500 lbs RJ –> 012-1904-011 012-1906-011 Description Item Low pressure range spring – max 600 lbs / PN 100 089-5340-002 From +230 °C 089-5340-003 Up to (+450 °F) 0.55-1.09 +230 °C 089-5340-005 089-5340-006 to +315 °C (+450 °F) 1.10-2.20 089-5340-008 (+600 °F) 089-5340-009 1.10-2.20 From +230 °C Up to (+450 °F) +230 °C 089-5340-010 089-5340-010 to +315 °C (+450 °F) (+600 °F) Cotter pins 010-5203-001 (standard stainless steel cotter pins) – (qty: 2) 0.55-1.09 13 NOTE: 12 WHEN ORDERING PARTS SPECIFY COMPLETE PART AND SERIAL NUMBERS OF THE INSTRUMENT. Description Displacer kits. Consult factory for other S.G. ranges Low pressure High pressure Length 150-300-600 lbs 900 - 1500 - 2500 lbs mm inches 0.23-0.54 & 0.55-1.09 1.10-2.2 0.55-1.09 High pressure range spring – 900 lbs / 1500 lbs / 2500 lbs 0.23-0.54 316 / 316L SST 3" 150 lbs RF 0.23-0.54 12 Body material Carbon steel 356 14 089-6125-001 089-6126-001 089-6125-010 813 32 089-6125-002 089-6126-002 089-6125-011 1219 48 089-6125-003 089-6126-003 089-6125-012 1524 60 089-6125-004 089-6126-004 089-6125-013 1829 72 089-6125-005 089-6126-005 Consult factory 2134 84 089-6125-006 089-6126-006 Consult factory 2438 96 089-6125-007 089-6126-007 Consult factory 2743 108 089-6125-008 089-6126-008 Consult factory 3048 120 089-6125-009 089-6126-009 Consult factory 14 REPLACEMENT PARTS 1 Transmitter P.C. board assembly 7 Housing cover Stem assembly 11 2 LVDT assembly 8 Junction box cover 3 Meter assembly 4 Housing "O"-rings 5 Junction box PC board 6 12 Range spring in protector (incl. spring assembly screws and lock washer) Enclosing tube 13 Cotter pins 9 “E” tube gasket 10 Chamber gasket / ring joint 14 Displacer kit (displacer and cotter pins) 13 SPECIFICATIONS PHYSICAL/ELECTRONICAL SPECIFICATIONS Description Power (at terminals) Signal output ATEX intrinsically safe: 12 to 28,4 V DC (@ 94 mA) ATEX explosion proof / Non Ex: 12 to 36 V DC 4 – 20 mA (direct / reverse action) 3,8 to 20,5 mA usable (meets NAMUR NE 43) with Hart® and AMS® supported Span 356 mm up to 3048 mm (14" up to 120") (other ranges at request) Loop resistance 600 Ohm at 24 V DC Max 545 Ohm when used in combination with 22 mA error signal Diagnostic alarm 3,6 mA or 22 mA Damping 0 to 60 s Zero/span and error LEDʼs 3-button keypad and/or HART® / AMS® PACTware® User interface Display Housing material Wetted materials Cage materials Spring Displacer Approvals SIL (Safety Integrity Level) Electrical data Equivalent data Net and gross weight PERFORMANCE None (blind), or with local analog or digital meter IP 66, polyester coated cast iron - 1 x 1" NPT cable entry IP 66, stainless steel - 1 x M20 x 1,5 cable entry IP 66, polyester coated cast aluminium - 2 x M20 x 1,5 cable entries (one plugged off) Inconel (other materials at request) 316/316L SST (1.4401/1.4404) or 304 SST (1.4301) Carbon steel or 316/316L SST (1.4401/1.4404) (other materials at request) ATEX II 1G EEx ia II C T6, intrinsically safe ATEX II 1/2G EEx d II C T6, explosion proof FM/CSA/SAA, explosion proof GOST-K/GGTN-K – ROSTECH/FSTS: Russian Authorisation Standards LRS, Lloyds Register of Shipment (marine applications) Other approvals are available, consult factory Functional safety to SIL 1 / SIL 2 in accordance to IEC 61508 - SFF 66,5 %. – full FMEDA reports and declaration sheets available at request. Ui = 28,4 V; Ii = 94 mA; Pi = 0,68 W Ci = 5 nF; Li = 800 µH 14 kg (31 lbs) (cast iron housing with meter) - integral unit 6,3 kg (13,80 lbs) (cast aluminium housing with meter) - integral unit 15 kg (33 lbs) (stainless steel housing with meter) - integral unit Description Specifications Resolution 0,05 % of range ± 1 digit Linearity Accuracy Repeatability Response time Sampling rate Ambient temperature Process temperature Process pressure Max. ambient temp. effect Density range Humidity ➀ Specifications Electromagnetic compatibility ± 0,25 % of full span for level measurement 0,5 % ± 0,20 % of full span Less than 1s (electronics) 15 times / s (digital meter: 1.33 / s) -40 °C to +70 °C (-40 °F to +160 °F) -30 °C to +315 °C (+260 °C for steam) (-20 °F to +500 °F (+600 °F for steam)➀ Max. temp. needs to be derated in case of higher ambient temperature. For lower process temperature – use Stainless steel constructions. Max 355 bar (5150 psi) Flanged models are downrated to the design pressure of the selected flange. < 0,056 % / °C (< 0,031 % / °F) Min 0,23 S.G. – Max 2,20 S.G. 0-99 %, non condensing Meets CE requirements (EN-50081-2, EN 50082-2) For E82, E84 and E86 (SST units): -40 °C (-40 °F) to +315 °C (+500 °F) [+260 °C (+600 °F) for steam] 14 OPERATING TEMPERATURES The following charts lists combinations of process and ambient temperatures that should not be exceeded, with standard instruments Non-steam applications 350 Process temperature °C 300 250 200 150 100 50 0 30 35 40 45 50 55 60 65 70 75 60 65 70 75 Ambient temp. °C Steam applications 350 Process temperature °C 300 250 200 150 100 50 0 30 35 40 45 Digit 4 = J/K/L Digit 4 = A/B/C Digit 4 = M/N/P 50 55 Ambient temp. °C Digit 4 = D/E/F Digit 4 = Q/R/T 15 DIMENSIONS IN mm (inches) Top Mounted E81/E82 - J/K/L Side/bottom cage E83/E84 - J/K/L 273 (10.75) 273 (10.75) 367 (14.45) cast iron: 1 x 1" NPT stainless steel: 1 x M20 x 1,5 367 (14.45) cast aluminium: 2 x M20 x 1,5 (one entry plugged off) A A Level Range Level Range 133 (5.24) C B Side/bottom cage E83/E84 - J/K/L Side/side cage E85/E86 - J/K/L 273 (10.75) Side/side cage E85/E86 - J/K/L 273 (10.75) 273 (10.75) 367 (14.45) 367 (14.45) 367 (14.45) A A Level Range Level Range 133 (5.24) 133 (5.24) 1" NPT-F drain (plug not supplied) B TEMPERATURE EXTENSIONS Models E8x-A/B/C Models E8x-M/N/P B A Level Range 133 (5.24) 1" NPT-F drain (plug not supplied) Models E8x-D/E/F B Models E8x-Q/R/T 485 (19.1) 469 (18.45) 16 570 (22.45) 672 (26.45) 570 (22.45) DIMENSIONS IN mm (inches) Dimension A for all models Cage rating 150 / 300 / 600 lbs PN 16 .. PN 100 900 / 1500 lbs 2500 lbs SG range 4 th digit Dimension A 1.10 - 2.20 L/C/P/F/T 186 (7.32) 0.23 - 0.54 0.55 - 1.09 0.55 - 1.09 J/A/M/D/Q K/B/N/E/R K/B/N/E/R 236 (9.29) 186 (7.32) 236 (9.29) 315 (12.40) Dimensions B and C for external cage models (E83/E84/E85/E86) Flanged process connections Flange size 1 1/2" 2" DN 40 DN 50 Flange rating 150 / 300 / 600 lbs 600 lbs 900 / 1500 lbs 2500 lbs 150 / 300 / 600 lbs 600 lbs 900 / 1500 lbs 2500 lbs PN 16 .. PN 100 PN 16 .. PN 100 Threaded / Socket weld process connections Size 1 1/2" 2" Cage rating 150 / 300 / 600 lbs 900 / 1500 lbs 900 lbs 1500 lbs 2500 lbs 150 / 300 / 600 lbs 900 / 1500 lbs 900 lbs 1500 lbs 2500 lbs Connection type Slip on - ANSI RF Weldneck - ANSI RJ Weldneck - ANSI RJ Weldneck - ANSI RJ Slip on - ANSI RF Weldneck - ANSI RJ Weldneck - ANSI RJ Weldneck - ANSI RJ EN/DIN EN/DIN Connection type NPT/SW NPT SW SW NPT/SW NPT/SW NPT SW SW NPT/SW B Dimensions 180 (7.09) 180 (7.09) 193 (7.60) 235 (9.25) 185 (7.28) 185 (7.28) 214 (8.43) 250 (9.84) 180 (7.09) 185 (7.28) B Dimensions 81 (3.19) 81 (3.19) 81 (3.19) 89 (3.50) 102 (4.02) 84 (3.31) 84 (3.31) 84 (3.31) 99 (3.90) 112 (4.41) C 268 (10.55) 268 (10.55) 283 (11.14) 313 (12.32) 273 (10.75) 273 (10.75) 303 (11.93) 328 (12.91) 268 (10.55) 273 (10.75) C _ 17 MODEL IDENTIFICATION – UP TO 600 lbs BASIC MODEL NUMBER E E E E E E 8 8 8 8 8 8 1 2 3 4 5 6 top mounted EZ Modulevel top mounted EZ Modulevel EZ Modulevel with side/bottom cage EZ Modulevel with side/bottom cage EZ Modulevel with side/side cage EZ Modulevel with side/side cage - Carbon steel construction - Stainless steel construction - Carbon steel construction - Stainless steel construction - Carbon steel construction - Stainless steel construction SPECIFIC GRAVITY AND PROCESS TEMPERATURE (consult factory for interface applications) integral +150 °C integral +200 °C integral +230 °C integral +290 °C ➀ remote +315 °C ➁ L C P F T A J M B K N D Q E PROCESS CONNECTION a. For top mounted connection type E81/E82 - ANSI HEAD Flange rating 600 lbs 150 lbs 300 lbs Size RF RF RF RJ G3 G4 G5 G6 3" H3 H4 H5 H6 4" K3 K4 K5 K6 6" b. For external cage models R mounting max. temp. 0.23 - 0.54 specific gravity 0.55 - 1.09 specific gravity 1.10 - 2.20 specific gravity E81/E82 - DIN / EN 1092-1 HEAD Flange rating Type B1 Type B1 Type B2 Type B2 Size PN 16 PN 25/40 PN 63 PN 100 EA FA GA EB FB GB ED FD GD EE FE GE DN 80 DN 100 DN 150 E83 ... E86 - ANSI Flange/Cage rating E83 ... E86 - DIN / EN 1092-1 Flange rating 600 lbs 300 lbs Type B1 Type B1 Type B2 Type B2 Size Size RF PN 16 PN 25/40 PN 63 PN 100 RF RJ P3 P4 P5 P6 11/2" flanged DN 40 Q3 Q4 Q5 Q6 2" flanged CA CB CD CE flanged R3 R4 R5 11/2" NPT-F S3 S4 S5 2" NPT-F DN 50 T3 T4 T5 11/2" S.W. DA DB DD DE flanged U3 U4 U5 2" S.W. 150 lbs RF LEVEL RANGE 356 813 14 32 A B 1219 48 C 1524 60 D 1829 72 Max +290 °C Blind ESD ESA ➀ Not for applications with steam. ➁ Max +260 °C for steam applications ➂ Max +150 °C for steam applications ➃ Only for applications with steam 18 F 2438 96 G 2743 108 H 3048 120 I mm inches code TRANSMITTER – ELECTRONICS Standard codes apply for cast iron housing - use "X" description for stainless steel or cast aluminium housing INTEGRAL MOUNT ELECTRONICS E 8 E 2134 84 ➂ with meter Analog Digital ESI ESJ ESG ES9 Max +230 °C ➃ (steam only) with meter Blind Analog Digital ESH ESK ES8 ESE ESF ES7 REMOTE ELECTRONICS 24 V DC amplifier head Process Temperature Max +315 °C ➁ (codes as per digit 4) (Q, R or T) Local meter with meter Output Blind & Safety approvals Analog Digital RSQ RST RSZ 4 - 20 mA with HART®, intrinsically safe RSW RSX RS4 4 - 20 mA with HART®, explosion proof complete code for EZ Modulevel transmitter – up to 600 lbs MODEL IDENTIFICATION – FROM 900 lbs TO 2500 lbs BASIC MODEL NUMBER E E E E E E 8 8 8 8 8 8 1 2 3 4 5 6 top mounted EZ Modulevel top mounted EZ Modulevel EZ Modulevel with side/bottom cage EZ Modulevel with side/bottom cage EZ Modulevel with side/side cage EZ Modulevel with side/side cage - Carbon steel construction - Stainless steel construction - Carbon steel construction - Stainless steel construction - Carbon steel construction - Stainless steel construction SPECIFIC GRAVITY AND PROCESS TEMPERATURE (consult factory for interface applications) integral +150 °C integral +200 °C K integral +230 °C B integral +290 °C ➀ N remote +315 °C ➁ E R PROCESS CONNECTION (for DIN flanges consult factory) a. For top mounted connection type (E81, E82) - head flange rating 900 lbs RJ 1500 lbs RJ 2500 lbs RJ K7 K8 K9 G7 – H7 – H8 H9 b. For external cage models (E83, ... E86) - ANSI rating 1500 lbs RJ 2500 lbs RJ 900 lbs 1500 lbs 2500 lbs P8 Q8 R7 S7 T7 U7 R8 S8 T8 U8 0.55 - 1.09 specific gravity Type 3" size size 4" size 6" size 900 lbs RJ P7 Q7 mounting max. temp. P9 Q9 Flange rating Cage rating R9 S9 T9 U9 connection 1 1/2" ANSI Flanges 2" ANSI Flanges connection 1 1/2" NPT-F 2" NPT-F 1 1/2" Socket Weld 2" Socket Weld LEVEL RANGE (consult factory for longer level range) 356 14 A 813 32 1219 48 B C mm inches 1524 60 code D TRANSMITTER – ELECTRONICS Standard codes apply for cast iron housing - use "X" description for stainless steel or cast aluminium housing INTEGRAL MOUNT ELECTRONICS Max +290 °C Blind ESD ESA E 8 with meter Analog Digital ESI ESG Max +230 °C ➃ (steam only) ➂ ESJ ES9 Blind ESH ESE with meter Analog Digital ESK ESF ES8 ES7 REMOTE ELECTRONICS Max +315 °C (R only) Blind RSQ RSW with meter Analog Digital RST RSX 24 V DC amplifier head ➁ RSZ RS4 Local meter Process Temperature (codes as per digit 4) Output & Safety approvals 4 - 20 mA with HART®, intrinsically safe 4 - 20 mA with HART®, explosion proof complete code for EZ Modulevel transmitter – from 900 lbs to 2500 lbs ➀ Not for applications with steam ➁ Max +260 °C for steam applications ➂ Max +150 °C for steam applications ➃ Only for applications with steam 19 IMPORTANT SERVICE POLICY Owners of Magnetrol products may request the return of a control; or, any part of a control for complete rebuilding or replacement. They will be rebuilt or replaced promptly. Magnetrol International will repair or replace the control, at no cost to the purchaser, (or owner) other than transportation cost if: a. Returned within the warranty period; and, b. The factory inspection finds the cause of the malfunction to be defective material or workmanship. If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labour and the parts required to rebuild or replace the equipment. In some cases, it may be expedient to ship replacement parts; or, in extreme cases a complete new control, to replace the original equipment before it is returned. If this is desired, notify the factory of both the model and serial numbers of the control to be replaced. In such cases, credit for the materials returned, will be determined on the basis of the applicability of our warranty. No claims for misapplication, labour, direct or consequential damage will be allowed. RETURNED MATERIAL PROCEDURE So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorisation” (RMA) form will be obtained from the factory. It is mandatory that this form will be attached to each material returned. This form is available through Magnetrolʼs local representative or by contacting the factory. Please supply the following information: 1. Purchaser Name 2. Description of Material 3. Serial Number 4. Desired Action 5. Reason for Return 6. Process details All shipments returned to the factory must be by prepaid transportation. Magnetrol will not accept collect shipments. All replacements will be shipped FOB factory. BULLETIN N°: EFFECTIVE: SUPERSEDES: UNDER RESERVE OF MODIFICATIONS www.magnetrol.com ® BE 48-616.7 FEBRUARY 2008 April 2007 BENELUX FRANCE Heikensstraat 6, 9240 Zele, België -Belgique Tél. +32 (0)52.45.11.11 • Fax. +32 (0)52.45.09.93 • E-Mail: [email protected] DEUTSCHLAND Alte Ziegelei 2-4, D-51491 Overath Tel. +49 (0)2204 / 9536-0 • Fax. +49 (0)2204 / 9536-53 • E-Mail: [email protected] INDIA C-20 Community Centre, Janakpuri, New Delhi - 110 0058 Tel. +91 (11) 41661840 • Fax +91 (11) 41661843 • E-Mail: [email protected] ITALIA Via Arese 12, I-20159 Milano Tel. +39 02 607.22.98 (R.A.) • Fax. +39 02 668.66.52 • E-Mail: [email protected] U.A.E. Te DAFZA Office 5EA 722 • PO Box 293671 • Dubai l. +971-4-6091735 • Fax +971-4-6091736 • E-Mail: [email protected] UNITED KINGDOM Unit 1 Regent Business Centre, Jubilee Road Burgess Hill West Sussex RH 15 9TL Tel. +44 (0)1444 871313 • Fax +44 (0)1444 871317 • E-Mail: [email protected]