Smart EZ Modulevel Displacer Transmitter Instruction Manual BE48

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]