ES/EZ Modulevel® Top Hat Assembly Design Installation and Operating Manual Digital ES II Modulevel with HART ® Communication and Analog EZ Modulevel Electronic Liquid Level Transmitters Read this Manual Before Installing This manual provides information on the Digital ES II and Analog EZ Modulevel Electronic Transmitters. It is important that all instructions are read carefully and followed in sequence. Detailed installation, wiring and calibration instructions are included in this manual. Conventions Used in this Manual Certain conventions are used in this manual to convey specific types of information. General technical material, support data, and safety information are presented in narrative form. The following styles are used for notes, cautions, and warnings. NOTES Notes contain information that augments or clarifies an operating step. Notes do not normally contain actions. They follow the procedural steps to which they refer. Cautions Cautions alert the technician to special conditions that could injure personnel, damage equipment, or reduce a component’s mechanical integrity. Cautions are also used to alert the technician to unsafe practices or the need for special protective equipment or specific materials. In this manual, a caution box indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. WARNINGS Warnings identify potentially dangerous situations or serious hazards. In this manual, a warning indicates an imminently hazardous situation which, if not avoided, could result in serious injury or death. Safety Messages Follow all standard industry procedures for servicing electrical and computer equipment when working with or around high voltage. Always shut off the power supply before touching any components. Electrical components are sensitive to electrostatic discharge. To prevent equipment damage, observe safety procedures when working with electrostatic sensitive components. WARNING! Explosion hazard. Do not connect or disconnect equipment unless power has been switched off or the area is known to be non-hazardous. Low Voltage Directive For use in Category II installations. If equipment is used in a manner not specified by manufacturer, protection provided by equipment may be impaired. Notice of Trademark, Copyright and Limitations Magnetrol & Magnetrol logotype and STI & STI logotype, and Modulevel are registered trademarks of Magnetrol International, Incorporated. Digital ES II, Digital ES II Modulevel, Analog EZ & Analog EZ Modulevel, Smart EZ & Smart EZ Modulevel are tradenames of Magnetrol International, Incorporated. Copyright © 2007 Magnetrol International, Incorporated. All rights reserved. Performance specifications are effective with date of issue and are subject to change without notice. Magnetrol/STI reserves the right to make changes to the product described in this manual at any time without notice. Magnetrol/STI makes no warranty with respect to the accuracy of the information in this manual. Warranty All Magnetrol/STI electronic level and flow controls are warranted free of defects in materials or workmanship for one full year from the date of original factory shipment. If returned within the warranty period; and, upon factory inspection of the control, the cause of the claim is determined to be covered under the warranty; then, Magnetrol/STI will repair or replace the control at no cost to the purchaser (or owner) other than transportation. Magnetrol/STI shall not be liable for misapplication, labor claims, direct or consequential damage or expense arising from the installation or use of equipment. There are no other warranties expressed or implied, except special written warranties covering some Magnetrol products. Quality assurance The quality assurance system in place at Magnetrol/STI guarantees the highest level of quality throughout the company. Magnetrol/STI is committed to providing full customer satisfaction both in quality products and quality service. Magnetrol’s quality assurance system is registered to ISO 9001 affirming its commitment to known international quality standards providing the strongest assurance of product/service quality available. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) Electronic Modulevel (Top Hat Assembly Design) Displacer Level Transmitter Installation, Operation and Maintenance Manual Table of Contents 1.0 Complete Installation 1.1 Unpacking.............................................................1 1.2 Electrostatic Discharge (ESD) ...............................1 1.3 Before you begin....................................................2 1.3.1 Site Preparation ..........................................2 1.3.2 Equipment and Tools..................................2 1.3.3 Operational Considerations ........................3 1.4 Mounting ..............................................................3 1.4.1 Installing a Tank Top Mounted Modulevel...................................................3 1.4.2 Installing a Chamber Type modulevel.........4 2.0 Analog EZ Modulevel Wiring and Calibration 2.1 Integral Transmitter Wiring ...................................6 2.2 Remote Transmitter Wiring...................................7 2.3 Hazardous Location Wiring ..................................7 2.4 Calibrating the Analog EZ Modulevel.................10 2.4.1 Direct Acting Field Calibration.................10 2.4.2 Reverse Acting Field Calibration...............11 2.4.3 Bench Calibration.....................................11 3.0 Digital ES II Modulevel Wiring and Calibration 3.1 Integral Transmitter Wiring .................................14 3.2 Remote Transmitter Wiring.................................15 3.3 Hazardous Location Wiring ................................16 3.4 Digital ES II Push-button Calibration.................16 3.4.1 Push-button Field Calibration ..................16 3.4.2 Push-button Bench Calibration ................17 3.4.3 Digital Meter Calibration .........................18 3.4.4 Interface Calibration.................................19 3.4.4.1 Calibration in Process Liquids .....20 3.4.4.2 Calibration in water only for interface of another liquid over water............................................20 3.4.4.3 Calibration in water only for interface of two other liquids .......20 3.4.4.3.1 Lower S.G. less than or equal to 1.0 .............20 3.4.4.3.2 Lower S.G. greater than 1.0.......................21 3.5 Configuration Using HART................................22 3.5.1 Connections .............................................22 3.5.2 Display Menu ...........................................22 3.5.3 Basic Field Calibration Using Hart HHC ..22 3.5.4 Hart Menu ...............................................23 4.0 Reference Information 4.1 Description..........................................................25 4.2 Theory of Operation ...........................................26 4.2.1 Displacer Buoyancy ..................................26 4.2.2 LVDT.......................................................26 4.3 Troubleshooting...................................................26 4.4 Maintenance of Analog EZ Modulevel ................28 4.4.1 Replacing Transmitter PC Board ..............28 4.4.2 Replacing Power Supply PC Board ...........28 4.4.3 Replacing LVDT ......................................29 4.4.4 Checking the LVDT Winding Resistance .29 4.5 Maintenance of Digital ES II Modulevel .............29 4.5.1 Replacing Transmitter PC Board ..............29 4.5.2 Replacing LVDT ......................................30 4.5.3 Checking the LVDT Winding Resistance .30 4.6 Agency Approvals ................................................31 4.6.1 FM (Factory Mutual)................................31 4.6.2 CSA (Canadian Standards Association).....31 4.6.3 CENELEC (Comiteí Européen de Normalisation Electotechnique)................32 4.7 Parts ....................................................................33 4.7.1 Replacement PC Boards ...........................33 4.7.2 Transmitter Head Parts .............................34 4.7.3 Recommended Spare Parts........................34 4.7.4 Mechanical Replacement Parts..................35 4.7.5 Upgrade to ESII Electronics .....................37 4.7.5.1 ES to ES II Conversion ...............37 4.7.5.2 EZ to ES II Conversion...............38 4.8 Specifications.......................................................39 4.8.1 Functional ................................................39 4.8.2 Performance..............................................40 4.8.3 Physical.....................................................41 4.9 Model Numbers ..................................................43 4.9.1 Models for Steam Applications (max. 600 lbs.)..........................................43 4.9.2 Models for Steam Applications (900-2500 lbs.).........................................45 4.9.3 Models for Non-Steam Applications (max. 600 lbs.)..........................................47 Glossary .................................................................49 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 1.0 Mechanical Installation This section provides detailed procedures for properly installing the Electronic Modulevel Displacer Level Transmitter. 1.1 Unpacking Unpack the instrument carefully. Take care not to bend the displacer stem or enclosing tube. Ensure all components have been removed from the packing material. Check all the contents against the packing slip and report any discrepancies to the factory. • • Before proceeding with the installation, do the following: Inspect all components for damage. Report any damage to the carrier within 24 hours. On chambered units, remove the shipping strap and wire assembly holding the displacer in place. This assembly must be removed through the bottom chamber connection before start-up. Caution: If reshipping to another location, the displacer must again be secured using the same strap and wire assembly. • • Check that the model number on the nameplate matches the packing slip and purchase order. Record the model and serial numbers for future reference when ordering parts. Model Number Serial Number 1.2 Electrostatic Discharge (ESD) Handling Procedure Magnetrol’s electronic instruments are manufactured to the highest quality standards. These instruments use electronic components which may be damaged by static electricity present in most work environments. • • 1 The following steps are recommended to reduce the risk of component failure due to electrostatic discharge. Ship and store circuit boards in anti-static bags. If an antistatic bag is not available, wrap the board in aluminum foil. Do not place boards on foam packing materials. Use a grounding wrist strap when installing and removing circuit boards. A grounded workstation is recommended. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) • • 1.3 Handle circuit boards only by the edges. Do not touch components or connector pins. Ensure that all electrical connections are completely made and that none are partial or floating. Ground all equipment to a good, earth ground. Before You Begin 1.3.1 Site Preparation Each Modulevel transmitter is built to match the specific physical specifications of the required installation. Ensure that the process connection(s) on the vessel matches the Modulevel’s process connection(s). See Mounting, Section 1.4. Ensure that the wiring between the power supply and Modulevel transmitter are complete and correct for the type of installation. See Specifications, Section 4.8. When installing the Modulevel transmitter in a general purpose or hazardous area, local, state and federal regulations and guidelines must be observed. See Wiring, Sections 2.0 & 3.0. 1.3.2 Equipment and Tools • • • • • • • No special equipment or tools are required to install the Electronic Modulevel. The following items are recommended: Wrenches, flange gaskets and flange bolting appropriate for process connection(s) Flat-blade screwdriver Level 1 ⁄8" Allen wrench Power supply which matches voltage identification on nameplate Multimeter with maximum sensitivity of 100 millivolts for 120 or 240 VAC transmitters 250 to 450 ohm resistor for transmitters with HART communication 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 2 1.3.3 Operational Considerations The Modulevel transmitter should be located for easy access for service, configuration, and monitoring. There should be sufficient headroom to allow installation and removal of the transmitter head and, in cases of tank top configuration, the displacer. Special precautions should be made to prevent exposure to corrosive atmosphere, excessive vibration, shock, or physical damage. The operating temperature range for the transmitter electronics is -40° to +160° F (-40° to +70° C). The operating temperature range for the digital display is -4° to +160° F (-20° to +70° C). Operation of all buoyancy type level devices should be done in such a way as to minimize the action of dynamic forces on the float or displacer sensing element. Good practice for reducing the likelihood of damage to the control is too equalize pressure across the device very slowly. 1.4 Mounting The Modulevel transmitter can be mounted to a tank using a variety of configurations and process connections. Generally, either a threaded, welded or flanged connection is used with an external cage. A flanged connection is always used on a tank top model. For information about the sizes and types of connections available, see Model Numbers, Section 4.9. Liquid Level Displacer Ensure all mounting connections are in place on the tank and properly sized for the specific unit being installed. Compare the model on the nameplate with the product information to ensure the Modulevel transmitter is correct for the intended installation. Figure 1 Tank Top Mounted Installation 1.4.1 Installing a Tank Top Mounted Modulevel (E61, E62, E51 and E52 models) Figure 1 illustrates a typical tank top installation. • • • 3 Before installing, ensure that: There is adequate headroom for the installation of the Modulevel head and displacer and that it has unobstructed entry into the vessel. Using a level, the mounting flange is horizontal within 3°. If the adjustable hanger assembly (P/N 32-3110-001) is used, it is cut to the required length and attached to the displacer stem. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) Note: The adjustable hanger assembly is used when the top of the displacer and, therefore, the top of the measurement range must be positioned in the vessel more than 5" (127 mm) below the mounting flange in the case of models 600# or less, or more than 9.31" below the mounting flange on models 900# or greater. The maximum hanger cable length is 8 feet. • A stilling well is installed for applications where continuous agitation is present. The stilling well must be vertically level so as not to restrict displacer movement. See Figure 2 for a typical stilling well installation. • The process temperature, pressure and specific gravity are within the unit’s specifications for installation. See Specifications, Section 4.8. To install: Use stilling well in case of turbluent medium Figure 2 Tank Top Mounted with Stilling Well 1. Carefully place the displacer in the vessel. Align the gasket on the flange. 2. Align the Modulevel flange with the flanged connection on the vessel. 3. Make sure the flange gasket is seated properly. Install flange bolts and nuts. 4. Tighten alternating flange bolts in a star pattern. Caution: All Modulevels are shipped from the factory with the enclosing tube tightened and the transmitter head set screws locked to the enclosing tube. Failure to loosen the set screws prior to repositioning the supply and output connections may cause the enclosing tube to loosen, resulting in the possible leakage of the process liquid or vapor. Size 1/8" Always unlock for repositioning or removal of head assembly and always relock, after final positioning 5. Loosen the transmitter head lock screws (socket type) and position conduit outlet in the desired direction. See Figure 3. 6. Retighten lock screws. Note: Figure 3 Transmitter Head Lock Screws Since the transmitter head is rotatable through 360º, it is important to make certain that the controller locking screws are tight before making electrical connections. 1.4.2 Installing a Chamber Type Modulevel (E63, E64, E65, E66, E53, and E55) The chamber type Modulevel is mounted on the side of the vessel with either a side/side or side/bottom connection, as furnished. Figure 4 on page 5 illustrates a typical chamber type installation. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 4 • • • Liquid Level Figure 4 Chamber Type Installation Side-Side Process Connections • Before installing, ensure that: There is adequate room for the installation of the Modulevel. Using a level, the vessel mounting connections are level within 3° of vertical. The process temperature, pressure and specific gravity are within the unit’s specifications for installation. See Specifications, Section 4.8. If not already done, remove the shipping strap and wire assembly holding the displacer in place in the chamber. This assembly must be removed through the bottom chamber connection or drain before start-up. To install: 1. Carefully align the Modulevel chamber process connections with the vessel connections. 2. Attach the process connections accordingly, based on the type of connection. Appropriate gaskets and bolting will be required if using flanged process connections. Note: It is recommended that shut-off valves be installed in each equalizing line to the chamber, along with a blow-down valve (refer to Figure 4). Equalizing lines should be sized at least as large as the connections provided at the chamber. 3. Make sure that the chamber is vertically level within 3° in each direction to ensure frictionless operation of the internal displacer. Caution: All Modulevels are shipped from the factory with the enclosing tube tightened and the transmitter head set screws locked to the enclosing tube. Failure to loosen the set screws prior to repositioning the supply and output connections may cause the enclosing tube to loosen, resulting in the possible leakage of the process liquid or vapor. 4. Loosen the transmitter head lock screws (socket type) and position conduit outlet in the desired direction. See Figure 3 on page 4. 5. Retighten lock screws. Note: Since the transmitter head is rotatable through 360º, it is important to make certain that the controller locking screws are tight before making electrical connections. 5 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 2.0 Analog EZ Modulevel Wiring and Calibration Caution: The Analog EZ Modulevel Transmitter operates at voltages 12–36 VDC, 120 VAC or 240 VAC. Incorrect voltages will damage the transmitter. AC, Ground (green) AC, High (black) (+) 4-20 mA output To Transmitter Housing (–) 4-20 mA output AC, Low (white) WARNING! Turn off all power before making any electrical connection. Series EZB, EZC, GZR, GZS, GZ2 and GZ3 Blind Transmitters 120 and 240 VAC Supply Conduit Junction Box 2.1 Figure 5 0 40 20 60 8 0 1 00 All wiring between the power supply and the Modulevel transmitter on 24 VDC units should be made using 18-22 AWG shielded twisted pair instrument cable or on 120 VDC and 240 VAC units should be made using a quantity of 14-16 AWG conductors and ground. All wiring connections to the transmitter are made in the attached junction box. NO WIRING CONNECTIONS ARE REQUIRED INSIDE THE TRANSMITTER HOUSING ON INTEGRAL UNITS. Instructions for wiring the Modulevel transmitter depend on type of mounting, integral or remote, and the area classification required, intrinsically safe, explosion proof or non-incendive. Integral Transmitter Wiring Note: Before connecting the power supply to the transmitter, be sure that the voltage identification on the nameplate matches the power supply. Do NOT attempt to operate this unit at voltages other than as identified as it will damage the unit. M+ M– 1. Remove the cover to the junction box of the transmitter. Meter 2. If unit is supplied with meter, access terminal board by removing the two screws securing the meter/bracket assem+ VE – VE bly to the junction box housing and moving meter/bracket meter 4-20 mA meter assembly out of the way. Do not disconnect wires. If unit output AC, Ground (green) has no meter, terminal board is already accessible. AC, High (black) 3. Install an approved conduit seal within 18" of the junction box for explosion proof installation. For IS installation, see To Transmitter page 9. Housing 4-20 mA output 4. Pull the supply wires and connect to the terminals as indicated in the wiring diagram for the unit having the approAC, Low (white) priate voltage and meter configuration, see Figures 5, 6, 7 & 8 on pages 6-7. 5. Replace meter/bracket assembly, if supplied, by positioning Series EZL, EZN, GZU, GZV, the holes in the bracket assembly over those in the junction GZ5 and GZ6 Transmitters with Meter box housing and replacing the two screws. 120 and 240 VAC Supply Conduit Junction Box 6. Replace the junction box cover. Ensure that the cover is Figure 6 tightened down sufficiently to compress o-ring seal. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 6 Note: When operated from a 24 VDC source, the maximum allowable loop resistance is 480 ohms for Analog EZ Modulevels. See Figure 9. DC+ When operated from a 120 or 240 VAC source, the Analog EZ current can only be monitored from the meter terminals (M+ and M-) using a multimeter with maximum sensitivity of 100 millivolts. (+) 24 VDC M– Red Caution: Instrument and conduit junction box covers must be in place and tightly sealed at all times during operation. DC– 2.2 Remote Transmitter Wiring Black EZA, EZD, EZE, EZH, GZH, GZQ, RZQ and RZW Blind Transmitter 24 Vdc Supply Conduit Junction Box Figure 7 0 40 20 60 8 0 1 00 Meter – VE meter Red M– Black DC– DC+ + VE meter Note: Before connecting the power supply to the transmitter, be sure that the voltage identification on the nameplate matches the power supply. Do NOT attempt to operate this unit at voltages other than as identified as it will damage the unit. (–) 24 VDC 1. Remove the cover of the remote transmitter and of the LVDT housing. 2. Connect one end of the six conductor cable (P/N 037-3218-xxx or 037-3220-xxx) to the LVDT terminal block and the other end to the terminal block within the remote transmitter housing. Be sure to match the six discrete numbered wires with the numbers on each terminal block. See Figure 10. 3. Wire the power supply to the terminal board in the junction box and seal the conduit per the instructions in Section 2.1. Note: When operated from a 24 VDC source, the maximum allowable loop resistance is 480 ohms for Analog EZ Modulevels. See Figure 9. (+) 24 vDC When operated from a 120 or 240 VAC source, the Analog EZ current can only be monitored from the meter terminals (M+ and M-) using a multimeter with maximum sensitivity of 100 millivolts. (–) 24 vDC Caution: Instrument and conduit junction box covers must be in place and tightly sealed at all times during operation. EZG, EZI, EZF, EZK, GZK, GZT, RZT and RZX Transmitter with Meter 24 Vdc Supply Conduit Junction Box Figure 8 2.3 Hazardous Location Wiring Figure 11 illustrates the proper installation for Intrinsically Safe wiring. Figure 12 illustrates Intrinsically Safe Connections/Non-incendive wiring. See page 9. NOTE: Intrinsically Safe Connections require that the remote mount electronics and LVDT housings must be installed explosion proof. 7 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) Loop Resistance vs. Power Supply Voltage MAXIMUM LOOP RESISTANCE (Ohms) (Including Barrier Resistance) 1100 1000 960 ohms @ 36V 900 800 700 600 500 400 480 ohms at 24 VDC (Analog EZ Modulevel) 300 200 100 0 12 14 16 18 20 22 24 26 28 30 32 34 36 38 Power Supply Voltage (VDC) Figure 9 Analog EZ Maximum Loop Resistance Transmitter Housing Terminal Block Red Blue Black Green Brown Yellow 1 2 1 2 Yel Brn 1 5 Red 6 3 Grn 3 4 2 4 4 5 Blk Blu 6 3 5 6 Transmitter Housing Terminal Block Detail Integral LVDT Housing Terminal Block white white/yellow To Integral LVDT Housing Remote Transmitter Housing 1 1 black brown green white/green 2 2 3 3 black white/black red blue black white/red 4 4 5 To Transmitter PC Board 5 6 6 Figure 10 Analog EZ Remote Mounted Transmitter Wiring 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 8 ON S REVISI ECLUSIVE PROPERT Y THIS DRAW ING IS TH E X OF MAGNETROL INTERNATIONA L. NOUSE W HATSOEVER OF TH E INFORMAT ION CON TAINED HEREON, NOR REPROD UCTION IN W HOLE ORIN PART MA Y BE MADEW ITHOUT THE X EPRESSW RITTEN PERM ISSI ON OF: THIRD ANGLE PROJECTION SYM HAZARDO US LOCATION ,IIIIDV 1 INTRINSICALLY SAFE CONNECTION S CLASSI,II NON -INCENDIVE BY & DATE W N ONCAD. PG. 1: REDRA ADDED: PG .2, /P N -002. J PG 1: ADDED: NOTE 8, RMVD: EXPLOSION PROOF & DUST IGNITION PROOF FROM HAZARDOUS LOCATION,CHGD: GW AS 6; W PG 2 CHGD TO PG3, ADDED NE PG 2; PG3 ADDED:SMART ESII MOD ULEVEL & ES9 TOHAZARDOUS LOCATION S & RMVD GSH, SK, G G S4, G SQ, R ST, R SZ; R GSQ, ST, ADDED:ILLUS TRATION & NOTE9, CHGD NON HAZARDOUS LOCATION: Vt& ItW ERE +V & Ie RESP. K PG.1 & 2: ADDEDSEIITO TITLE, 4T Ta=71°C & EZ TO TO SMART ES IIMODULEVEL CALLOUT. ENTITY CIW AS 5pF. REVISED MODELS APPROVED. DRW G.W AS 3 PAGES. (mm ) MAGNETRO L INTERNATIONA L DESCRIPTION H IN CLASSI CLASSII DIV 2 DIV 2 SAFE LOCATION UPS GRO B,C,D,E, F& G 4 Ta = T71°C GROUPS A, B,C,D GROUPS E, F,G (F & G ON LY FOR FM ) THE VOLTAGE (Vmax) ANDCURRENT(Imax) W HICH TH E TRAN SM ITTERCAN RECEIVE M UST BE Q E UAL TO OR GREATER HANT THE MAXIM UM OPENCIRCUIT VOLTAGE T MAXIM UM SHORT CIRCUIT (Voc OR tV) AND HE CURRENT(Isc ORIt)W HICH CAN BE DELIVERED BY TH E SOURCE DEV ICE.IN ADDITION, HE T MA XIM UM CAPACITANCE (Ci) ANDIND UCTANCE H E CAPACITANCE (Li) OF TH E LOAD AND T AND IND UCTANCE OF TH E INTERCONNECTING W IRING, MUST BE Q E UAL TO ORLESS TH AN T IND UCTANCE THE CAPACITANCE (Ca) OR HE (La)W HICH CAN BE DRIVEN BY TH E SOURCE DEVICE. SMART ES II/ EZ MODULEVEL TRANSM ITTER INSTRUMENT SEALED NIPPLE (EPOXY FILL ED) COND UIT JUNCTION FITTING L PAGE 1-CHG'D:LIM ITING VALUES 5nF W AS 5pF,434µH W AS 434nF.BOTH PAGES ITY 434µH W AS CHG'D: ENT 434nH. PAGE 2 - ADDED TO NOTE 7 SECOND CSA W ARNING. CHANGE NO. DPP 3/99 5057-008 SC 6-99 3057-986 JS 11 -99 3057-994 JM JARAS 1-18-00 3051-004 M ADDED: 3051-020 RC 01-02 "ALTERNATIVELY -FM ONLY" REMOVED: MODELSKSQ,KST, KSZ,KZQ ANDKZT INTRINSICALLY SAFE BARRIER W ITHOUT METER W ITH METER (W INDO W ED) MODE LS APPROVED x Exx-xxxx- RSQ, ST, R SZ R FOR SMART ES II ZQ, ZT, R FOR R EZ MODULEVEL M M ENT ITY Vmax = 28.6V Imax = 140m A Ci = 5nF Li = 434µH Pmax = 1W LIM ITING VALUES Voc≤ 28.6V Ca ≥ 5nF Isc ≤ 140m A La ≥ 434µH M ALTERNATIVELY -FM ONLY Vmax = 22V Imax = 165 m A Ci = 5nF Li = 43µH Pmax = 1W LTERNAT A IVELY -FM ONLY Voc≤ 22V Ca ≥ 5nF Isc ≤ 140m A La ≥ 434µH C DW G SIZE NOTE: 9. NRT L LIS TED DUST T IGHT SEALS MUST BE USED W HEN INSTALLED IN CLASSII& III ENV IRONMENT S. AGENCY LIS TED DRAW ING ALL REV ISI ON S TO HIS T DRAW ING REQUIRE QA APPROVA L P/N 99-5031-000 MATERIAL RAW MATL PART NO . HEAT TREAT Figure 11 UNLESS OTHERW ISE SPECIFI ED: PLAIN DIMEN SION S IN INCHES;()OR METERS "mm " DIMEN SION S IN MILLI REMOVE ALLBURRS ANDSHARP EDGES, MAX. ALLOW ED .032(0,81) )R. INSIDE RADII.032(0,81 ALLFINISHES 125 OR BETTER TOLERANCES: 2 PL.IN. DEC.± 0.015 IN.(0,4mm ) 3 PL.IN. DEC.± 0.005IN.(0,2mm ) ANGULAR ± 2° FINISH 99-5031 8. REMOTE MO UNT LVDT & ELECTRONICS HOUSING UST M BE INSTALLED E XPLOSION PROOF. T DRAW ING MUST BE SUBM ITTED TOFACTORY MUTUAL & CSA 1. ANY CHANGES TO HIS PER SPISE0-006. 2. MANUFACTURE'S INSTRUCTION S SUPPLIED W ITH THE PROTE CTIVE BARRIER,CEC (CSA) ORHET NE C MUST BE FOLLOW ED W HEN INSTALLI NG THIS EQUIPMENT. 3.FOR INSTALLATION GUIDAN CE,SEE AN SI/ISA RP1 2.6. EA INTRINSICALLY SAFE/SECURITEINTRINSEQUE. 4.FOR CSA: XI 5.FOR CSA:W ARNING -EXPLOSION HAZARD-SUBSTITUTION OF COMPONENT S MAY IMPA IR SUITABILI TY FOR HAZARDO US LOCATION S. FOR CSA:W ARNING -EXPLOSION HAZARD- DO NOT IS DCONNECT E Q UIPMENT UNLESS POW ER HAS BEEN SW ITCHED OFF OR HE T AREAISKNO W N TOBE NON -HAZARDO US. 6.FOR SUPPLY CONNECTION S USE W IRE SUITABLE FOR THE OPERAT ING TEMPERAT URE.FOR 71°C AMBIENT USE W IRE W ITH A M INIM UM TEMPERAT URE RAT ING OF 75°C. 7. THE TRAN SM ITTER MA Y ALSO BE INSTALLED IN CLASSI, IDV.2, GRO UPS A, B,C,& D;CLASSII , IDV.2, GRO UPS E, F,& G(F & G ON LY FOR FMR C);CLASSIII , IDV.2,LOCATION S AND DOE S NOT RE QUIRE CONNECTION TO A PROTE CTIVE BARRIER W HEN INSTALLED PERCEC (FOR CSA) OR NE C (FOR FMR C) ANDW HEN CONNECTED TO A W POER SOURCE NOT XCEEDI E NG 30 VDC. TITLE SYSTEM DRAW ING ES II/ EZ MODULEVEL DRAW N D.PASHOLK DATE CHKD J.M .JARAS DATE APPD P.S.SNIDER 3057-515 DATE PROJ NO. R 5300 BELMONT ROAD, DO W NERS GROVE, ILLI NO IS60515 / AREA630 /969-4000 3/8/99 4/28/99 5-14-99 SCALE PAGE NONE DW G SIZE 1 2 OF 99-5031 C SKETCH NO. Intrinsically Safe Wiring REVISIONS THIS DRAW ING IS THE EXCLUSIVE PROPERTY OF M AGNETROL INTERNATIONAL. ON USE W HATSOEVER OF THE INFORM ATION CONTAINED HEREON, NOR REPRODUCTION IN W HOLE OR IN PART M AY BE M ADE W ITHOUT N PERM ISSION OF: THE EXPRESSW RITTE THIRD ANGLE PROJECTION SYM M IN DESCRIPTION BY & DATE SEESHEET 1FOR REV. CHANGE NO. 3051-0 20 RC 1-0 2 (mm ) M AGNETROL INTERNATIONAL HAZARDOUS LOCATIONS NON HAZARDOUS LOCATIONS SM ART ES II/EZ M ODULEVEL Lim iting Values x M ODEL Exx-xxxx -ESD,ESI,ESJ,ESH,ESK,ES8 OR ES9 FOR SM ART ES II EZD,EZI,EZH,OR EZK FOR EZ M ODULEVEL Intr insicall y SafeforCL I,Div. 1GroupsA B C D CL II ,Div. 1GroupsE F G CL IIIEM N A 4X (FM )TYPE 4X (CSA) T4 Ta = 71°C nt(Imax)whichthe tr ansm itter can receive The voltage (Vmax)and curre m ustbe equaltoorgreaterthan the maxim um open circuitvoltage (Voc orVt)and the maxim um shortcircuitcurre nt(Isc orIt)which can be deliveredby the sour ce device.In addition,the maxim um capacitance (Ci)and inductance (Li)ofthe load and the capacitance and inductance ofthe inter connecting w iring,m ustbe equaltoor lessthan the capacitance (Ca)orthe inductance (La)whichcan be driven by the sour ce device. TRANSM ITTE R INSTRUM ENT SEALED NIPPLE (EPOXY FILLED) CONDUITJUNCTION FITTI NG INTRINSICALLY SAFE BARRIER W ITHOUT M ETER W ITH M ETER (W INDOW ED) NOTES: ENTITY Vmax = 28.6V Imax = 140m A Ci = 5nF Li = 434µH Pmax = 1W ALTERNATIVELY -FM ONLY Vmax = 22V Imax = 165m A M Ci = 5nF Li = 434µH Pmax = 1W M Lim iting Values Voc <= 28.6V Ca >= 5nf+ Ccable Isc <= 140 m A La >= 434 uH + Lcable ALTERNATIVLY -FM ONLY Voc <= 22V Ca >= 5nf+ Ccable Isc <= 165 m A La >= 434 uH + Lcable 1)Barr iersm ustbe CSA Cert ified and FM approved . 2)M anufacturers install ation instru ctionssupplied w ith the prote ctivebarr ierand the CEC (forCSA)orthe NEC and ANSI/ISA RP 1 2.6(ForFM RC)m ustbe foll ow ed when install ing the equipm ent. 3)Contro lequipm entconnectedtoprote ctivebarr iersm ustnotuseorgeneratem ore than 250 Vdc orVrm s. C ClassII & III environm ents. 99-5031 5) No revisionstothisdraw ing w ithoutFM RC and CSA approv al. 6)ForCSA:Exia Intr insicall y Safe /SecuriteIntr inseque 7)ForCSA:W arning Explosion Hazard Subst itut ion ofcom ponentsma y im pair suitability forhazardousLocations. ForCSA:W arning Explosion Hazard Do notdisconnectequipm entunless AGENCY LISTED DRAW ING pow erhasbeen sw itched offorthe area isknow n tobe non-hazardous . 8)Forsupply connections,usew iresuitable foroperating tem perature . ALLREVISIONS TO THIS DRAW ING REQUIRE QA APPROVAL For71°C am bient,usew irew ith a m ini m um tem peraturerating of75°C. 9)The tr ansm itter ma y alsobe install ed inClassIDiv 2 groupsA,B,C,D, P/N 99-5031000 ClassII ,Div 2 GroupsE,F & G (F&G only forFM RC); ClassIII ,Div 2 locationsand doesnotrequireconnection toa prote ctivebarr ierwhen M ATERIAL install ed perCEC (forCSA)or NEC (forFM RC)and when connectedtoa pow ersour ce notexceeding 30 VDC. RAW M ATL PART NO. HEAT TREAT FINISH Figure 12 9 DW G SIZE 4) NRTL listeddusttightsealsm ustbe usedwhen device isinstall ed in UNLESSOTHERW ISE SPECIFIED: PLAIN DIM ENSIONS IN INCHES;()OR "mm "DIM ENSIONS IN M ILLIM ETERS REM OVE ALLBURRS AND SHARP EDGES,M AX.ALLOW ED .032(0,81) INSIDE RADII.032(0,81)R. ALLFINISHES 125 OR BETTER TOLERANCES: 2 PL.IN.DEC.± 0.015IN.(0,4mm ) 3 PL.IN.DEC.± 0.005IN.(0,2mm ) ANGULAR ± 2° TIT LE SYSTEM DRAW ING ES II/EZ M ODULEVEL DRAW N CHKD APPD PROJ NO. D.PASHOLK DATE J.M .JARAS DATE P.S.SNIDER 3057-515 DATE SKETCH NO. R 5300BELM ONT ROAD,DOW NERS GROVE, ILLINOIS 60515 AREA / 630 /699 4000 3/8/99 4/28/99 5-14-99 SCALE NONE DW G SIZE C PAGE 2 OF 2 99-5031 Intrinsically Safe Connections/Non-incendive wiring 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 2.4 Calibrating the Analog EZ Modulevel The Analog EZ Modulevel must be calibrated for each unique application. It may be calibrated in service or on a bench calibration stand. Bench calibration provides a convenient way to set up the transmitter before going to the tank site to complete the installation. Bench calibration, however, does not compensate for elevated process temperatures. For convenience during the calibration of a blind transmitter, a DC milliameter may be connected to terminals (M+) and (M-) in the junction box, see Figure 5 on page 6. 2.4.1 Direct Acting Field Calibration Zero and Span Controls Replace Covers After Calibration 100% Level, 20 mA Output 100% Level, 4 mA Output Desired Level Range (Reverse Acting) Desired Level Range (Direct Acting) Zero Level, 4 mA Output 100% Level, 20 mA Output Bottom of Displacer Figure 13 Analog EZ Modulevel Field Calibration 1. Bring process up to operating temperature. 2. Unscrew and remove protective covers from zero and span controls. See Figure 13. 3. Rotate the span control counterclockwise fully, approximately 20 turns. 4. Rotate the zero control counterclockwise fully, approximately 20 turns. 5. Establish liquid level at the desired 4 mA (0%) level on the displacer. 6. Adjust the zero control until the output signal is 4.00 mA (0% on transmitter with analog meter). 7. Replace cover on zero control. 8. Establish liquid level at the desired 20 mA (100%) level on the displacer. 9. Adjust the span control until the output signal is 20.00 mA (100% on transmitter with analog meter). In the case that 20 mA (100%) level cannot be established: 10. After setting the zero point, establish liquid level as close to the 20 mA level as possible. 11. Adjust the span control until the output signal corresponds with the % of actual level (e.g. 80 % level should equal (20 mA – 4 mA) x 80% + 4 mA = 16.8 mA). 12. Replace cover on span control. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 10 2.4.2 Reverse Acting Field Calibration (—) (+) P4 P3 4 mA SET — TB1 + R8 ¤ J2 E Z MODULEVEL ¤ 5300 BELMONT ROAD, DOWNERS GROVE, IL 60515, USA. 1. 2. 3. HEIKENSSTRAAT 6, B 9240 ZELE, BELGIUM. www.magnetrol.com 4. 5. REFER TO MODULEVEL MANUAL, BULLETIN 48-615, FOR INSTALLATION AND OPERATION INSTRUCTIONS. TP2 ASSEMBLY PART NO. R13 30-2163 REV. AGC 6. 7. S1 DIR. J1 TP1 8. 05-9118-001 Direct/Reverse Switch Figure 14 Analog EZ Transmitter PC Board 9. 10. 11. 12. 13. 14. Analog EZ Modulevels are factory set for direct action (rising level increases output signal). The following adjustment is required for reverse action. Remove power from unit. Remove transmitter housing cover. Locate the Direct/Reverse switch on the PC board. See Figure 14. Move the Direct/Reverse switch to “REV.” Replace and tighten the transmitter housing cover until the o-ring is compressed. Bring process up to operating temperature. Unscrew and remove protective covers from zero and span controls. See Figure 13 on page 10. Rotate the span control counterclockwise fully, approximately 20 turns. Rotate the zero control counterclockwise fully, approximately 20 turns. Establish liquid level at the desired 4 mA (100%) level on the displacer. Adjust the zero control to until the output signal is 4.00 mA (0% on transmitter with analog meter). Replace cover on zero control. Establish liquid level at the desired 20 mA (0%) level on the displacer. Adjust the span control until the output signal is 20.00 mA (100% on transmitter with analog meter). 2.4.3 Bench Calibration The Analog EZ Modulevel can be bench calibrated using the calibration stand (P/N 31-6107-001) (except units that have been calibrated for interface service. Bench callibration cannot be performed on interface models). The fixture includes an open-topped enclosing tube upon which the transmitter head is mounted and an adjustment rod which simulates level movement of liquids with various S.G.s. 1. 2. 3. 4. 5. 11 To remove transmitter head from control: Disconnect field wiring at the junction box. Loosen the housing base lock screws. See Figure 3 on page 4. Remove transmitter housing cover. Remove c-ring from enclosing tube using snap ring pliers. Slide transmitter on housing base upward until clear of the enclosing tube. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) To install transmitter head on calibration stand, carefully slide the white teflon spacer and LVDT assembly down over the open topped enclosing tube. Be certain that both the LVDT assembly and the housing base are fully seated on the fixture. See Figure 15 on page 13. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. To bench calibrate the Analog EZ transmitter: Connect appropriate supply voltage and meter, if necessary, to terminals in junction box. See Figure 5, 6, 7 & 8 on pages 6-7. Unscrew and remove protective covers from zero and span controls. See Figure 13 on page 10. Rotate the span control counterclockwise fully, approximately 20 turns. Rotate the zero control counterclockwise fully, approximately 20 turns. Push the adjustment rod completely down into the enclosing tube to simulate low level. See Figure 15 on page 13. Adjust the zero control until the output signal is 4.00 mA (0% on transmitter with analog meter). Replace cover on zero control. Lift the adjustment rod until the top of the enclosing tube is aligned with the marking on the rod that corresponds to the S.G. of your process liquid. Adjust the span control until the output signal is 20.00 mA (100% on transmitter with analog meter). Replace cover on span control. Disconnect power and meter (if used) and remount transmitter head onto control by reversing the removal procedure. Note: Bench calibration does not compensate for elevated process temperatures. Note: To bench calibrate for reverse action, after moving the Direct/Reverse Switch to “Rev” position, adjust the zero control with the adjustment rod positioned at the S.G. marking on the rod. Adjust the span control with the adjustment rod down until firmly seated on calibration tube (see “Bench Calibration” procedure above). 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 12 C-ring Located Here on Process Level Sensors Adjustment Rod .2 .4 .6 .8 LVDT 1.0 P.C. Board “O” Rings S P .2 .4 Enclosing Tube .6 .8 1.0 Enlarged Detail of Adjustment Rod LVDT Core Base and Junction Box White Teflon Spacer Must Be Installed Stand Calibration Tube Figure 15 Bench Calibration Stand (part number 31-6107-001) % Note: For units with meter, pull meter out to access wiring terminals Figure 16 Digital Meter Removal 13 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 3.0 Digital ES II Modulevel Wiring and Calibration. Caution: The Digital ES II Modulevel Transmitter operates at voltages of 12-36 VDC. Incorrect voltages will damage the transmitter. Loop Resistance vs. Power Supply Voltage 1090 ohms @ 36V MAXIMUM LOOP RESISTANCE (Ohms) (Including Barrier Resistance) 1100 1000 All wiring between the power supply and the Modulevel transmitter should be made using 18-22 AWG shielded twisted pair instrument cable. All wiring connections to the transmitter are made in the attached junction box. NO WIRING CONNECTIONS ARE REQUIRED INSIDE THE TRANSMITTER HOUSING ON INTEGRAL UNITS. Instructions for wiring the Modulevel transmitter depend on type of mounting, integral or remote, and the area classification required, intrinsically safe, explosion proof or non-incendive. 900 800 545 ohms at 24 VDC (Digital ES II) 700 600 500 400 300 200 100 0 12 14 16 18 20 22 24 26 28 30 32 34 36 38 WARNING! Turn off all power before making any electrical connection. Figure 17 Digital ES II Maximum Loop Resistance 3.1 Integral Transmitter Wiring Note: Before connecting the power supply to the transmitter, be sure that the voltage identification on the nameplate matches the power supply. Do NOT attempt to operate this unit at voltages other than as identified as it will damage the unit. AW3175 1. Remove the cover to the junction box of the transmitter. 2. If unit is supplied with meter, access terminal board by pulling meter straight out until it unplugs. See Figure 16. If unit has no meter, terminal board is already accessible. D1 TB2 – P1 JP1 D2 + P2 meter hook-ups – L5 C5 C4 L4 L6 C6 + L3 + – + DC+ – C1 L2 C3 DC- } 3. Install an approved seal within 18" of the junction box conduit. 4. Pull the supply wires and connect to the terminals as indicated in the wiring. See Figure 18. 5. Replace meter, if supplied, by pushing banana plugs firmly into receptacles. Signal Power Supply min 12 VDC max 36 VDC 6. Replace junction box cover. Ensure that the cover is tightened down sufficiently to compress o-ring seal. TB1 Figure 18 Digital ES II Terminal Board Note: When operated from a 24 VDC source, the maximum allowable loop resistance is 545 ohms for Digital ES II Modulevels. See Figure 17. When using HART, a loop resistance of 250 to 450 ohms must be placed in series with the Digital ES II Modulevel. Caution: Instrument and conduit junction box covers must in place and tightly sealed at all times during operation. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 14 3.2 Remote Transmitter Wiring Note: Before connecting the power supply to the transmitter, be sure that the voltage identification on the nameplate matches the power supply. Do NOT attempt to operate this unit at voltages other than as identified as it will damage the unit. 1. Remove the cover of the remote transmitter and of the LVDT housing. 2. Connect one end of the six conductor cable (P/N 037-3218-xxx or 037-3220-xxx) to the LVDT terminal block and the other end to the terminal block within the remote transmitter housing. Be sure to match the six discrete numbered wires with the numbers on each terminal block. See Figure 19. 3. Wire the power supply to the terminal board in the junction box and seal the conduit per the instructions in Section 3.1. Note: When operated from a 24 VDC source, the maximum allowable loop resistance is 545 ohms for Digital ES II Modulevels. When using HART, a loop resistance of 250 to 450 ohms must be placed in series with the Digital ES II Modulevel. See Figure 17 on page 14. Caution: Instrument and conduit junction box covers must be in place and tightly sealed at all times during operation. Remote Transmitter Housing PC Board SPAN (+) P1 – TB1 + ZERO ERROR (–) P2 ® UP ® white/yellow 2 brown 2 green 3 white/green black 4 white/black 3 4 5 blue 6 white/red 6 Red 6 3 Grn ENTER www.magnetrol.com 3 4 5 DOWN REFER TO MODULEVEL MANUAL, BULLETIN 48-615, FOR INSTALLATION AND OPERATION INSTRUCTIONS. Junction Box Terminal Board TP1 6 6 D1 + TB2 Remote Transmitter Housing Terminal Block – P1 + P2 C6 TP2 + – L5 L6 2 1 5 Yel Brn 2 1 2 HEIKENSSTRAAT 6, B 9240 ZELE, BELGIUM. 3 4 5 Blk Blu 4 red black 5 1 L3 1 black AW3175 white 1 E S MODULEVEL 5300 BELMONT ROAD, DOWNERS GROVE, IL 60515, USA. JP1 D2 Green Brown Yellow L4 ASSEMBLY PART NO. C5 C4 Red Blue Black – C3 15 – C1 J1 Digital ES II Remote Mounted Transmitter Wiring L2 + Figure 19 Integral LVDT Housing Terminal Block TB1 05-9123-001 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 3.3 Hazardous Location Wiring See Figure 11 on page 9 for proper installation of Digital ES II for intrinsically safe locations. Proper installation of Digital ES II with intrinsically safe connections and nonincendive wiring is illustrated in Figure 12 on page 9. 3.4 Digital ES II Push-Button Calibration The Digital ES II Modulevel must be calibrated for each unique application. It may be calibrated using the pushbuttons on the PC board or using a HART communicator. The HART hand-held communicator allows advanced calibration. The Digital ES II Modulevel may be calibrated in service or on a bench calibration stand (P/N 31-6107-001) (except units that have been calibrated for interface service. Bench callibration cannot be performed on interface models). Bench calibration provides a convenient way to set up the transmitter before going to the tank site to complete the installation. Bench calibration, however, does not compensate for elevated process temperatures and must be fine tuned in the field. 3.4.1 Push-button field calibration Red LED Pushbuttons Zero LED Span LED Error LED ... ENT ENT 100% level, 20 mA output Desired level range (direct acting) Zero level, 4 mA output, bottom of displacer Figure 20 Digital ES II Push-button Calibration 1. Bring process up to operating temperature. 2. Establish liquid level at desired 4 mA (0%) level on displacer. If 4 mA level is at the bottom of the displacer, 4 mA point may be set with displacer hanging free in vapor. 3. With unit power on, remove cover. 4. Press the ENTER key to start calibration. The ZERO LED will light. Loop will go to 22 mA. See Figure 20 on page 16. 5. Press the DOWN key to lock in the 4 mA value. The ZERO LED will flash and remain on. Loop will stay at 22 mA. 6. Press ENTER to confirm the setting. The ZERO LED will go off. Loop will go to 4 mA. 7. Establish liquid at the 20 mA (100%) level on the displacer. 8. Press ENTER to start calibration. The ZERO LED will light. Loop will go to 22 mA. 9. Press UP to lock in the 20 mA value. The ZERO LED will go off. The SPAN LED will be on. Loop will go to 20 mA. 10. Press ENTER to confirm the setting. The SPAN LED will go off. Loop will stay at 20 mA. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 16 In the case that 20 mA (100%) level cannot be established: 11. After setting the zero point, establish the liquid level as close to the 20 mA level as possible (must be more than 50% of the total span). 12. Press ENTER to start 20 mA calibration. The ZERO LED will light. Loop will go to 22 mA. 13. Press UP to lock in 20mA value. The ZERO LED will go off. The SPAN LED will be on. Loop will go to 20 mA. 14. Toggle UP and DOWN until the loop signal corresponds with the % of actual level (e.g. 80 % level should equal (20 mA – 4 mA) x 80% + 4 mA = 16.8 mA). 15. Press ENTER to confirm the setting. The SPAN LED will go off. Loop will stay at value chosen in step 14 above. 16. Replace cover. Note: When calibrating for reverse action (4 mA at high level, 20 mA at low level) step 2 will be establishing high level at the 4 mA level and step 7 will be bringing the level down to the 20 mA level. 3.4.2 Push-button Bench Calibration The Digital ES II Modulevel can be bench calibrated using the calibration stand (P/N 31-6107-001) (except units that have been calibrated for interface service. Bench callibration cannot be performed on interface models). The fixture includes an open topped enclosing tube upon which the transmitter head is mounted and an adjustment rod which simulates level movement of liquids with various S.G.s. Bench calibration does not compensate for elevated process temperatures and must be fine tuned in the field. 1. 2. 3. 4. 5. To remove transmitter head from control: Disconnect field wiring at the junction box. Loosen the housing base lock screws. See Figure 3 on page 4. Remove transmitter housing cover. Remove c-ring from enclosing tube using snap ring pliers. Slide transmitter on housing base upward until clear of the enclosing tube. To install transmitter head on calibration stand, carefully slide the white teflon spacer and LVDT assembly down over the open topped enclosing tube. Be certain that both the LVDT assembly and the housing base are fully seated on the fixture. See Figure 15 on page 13. 17 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. To bench calibrate the Digital ES II transmitter: Connect supply voltage and meter, if necessary, to terminals in junction box. See Figure 18 on page 14. Slide the electronics head over the open topped enclosing tube of the calibration stand, making sure that the white plastic washer is in place below the electronics head. See Figure 15 on page 13. Push the adjustment rod completely down into the enclosing tube to simulate low level. Press the ENTER key to start calibration. The ZERO LED will light. Loop will go to 22 mA. Press the DOWN key to lock in the 4 mA value. The ZERO LED will flash and remain on. Loop will stay at 22 mA. Press ENTER to confirm the setting. The ZERO LED will go off. Loop will go to 4 mA. Lift the adjustment rod until the top of the enclosing tube is aligned with the marking on the rod that corresponds to the S.G. of your process liquid. Press ENTER to start calibration. The ZERO LED will light. Loop will go to 22 mA. Press UP to lock in the 20 mA value. The ZERO LED will go off. The SPAN LED will be on. Loop will go to 20 mA. Press ENTER to confirm the setting. The SPAN LED will go off. Loop will stay at 20 mA. Note: To calibrate for reverse action, follow the same procedures as above, but calibrate 4 mA as 100% (adjustment rod at your S.G.) and 20 mA as 0% (adjustment rod all the way down). 3.4.3 Digital Meter Calibration The digital meter on the Digital ES II Modulevel is set at the factory to display 00.0% when the loop current is 4.0 mA and 100.0% when the loop current is 20.0 mA. The following instructions may be followed if a different configuration is required. Regardless of the configuration of the numeric display, the analog bar graph represents 4 – 20 mA directly. Meter configuration does not affect the loop current and is easily done with no additional equipment. 1. Remove transmitter junction box housing cover. 2. Unscrew and remove the transparent meter cover. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 18 3.4.3 Digital Meter Calibration (cont.) Digital Display % Bar Graph Left Configuration Button Right Configuration Button Figure 21 Digital Meter To position the decimal point and choose meter function: 3. Simultaneously press and immediately release the left and right configuration buttons. See Figure 21. 4. To move the decimal point, press the left button until decimal point is in desired location. 5. To choose meter function, press right button until desired function is displayed. L in=linear, L inF=linear with five second filter, Srt = Square root and SrtF = Square root with five second filter. 6. Simultaneously press both configuration buttons for two seconds to store chosen configurations. To set 4 mA reading: 7. Press left button for two seconds. 8. Using the left button to decrease the reading and the right to increase the reading, set display to the desired 4 mA reading. 9. Simultaneously press both buttons to store the 4 mA reading. To set 20 mA reading: 10. Press right button for two seconds. 11. As in step 8 above, set display to desired 20 mA reading. 12. Simultaneously press both buttons to store the 20 mA reading. 13. Replace transparent meter cover and transmitter junction box cover. 3.4.4 Interface Calibration 3.4.4.1 Calibration in Process Liquids IMPORTANT: Displacer must always be completely submerged in one or both process liquids. 1. Bring process up to operating temperature. 2. Establish interface level at desired 4 mA (10%) level on the displacer. If 4 mA level is at the bottom of the displacer, 4 mA point may be set with displacer immersed in upper liquid only. 3. With unit power on, remove cover. 4. Press the ENTER key to start calibration. The ZERO LED will light. Loop will go to 22 mA. 5. Press the DOWN key to lock in the 4 mA value. The ZERO LED will flash and remain on. Loop will stay at 22 mA. 6. Press ENTER to confirm the setting. The ZERO LED will go off, and the loop will go to 4 mA. 19 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 3.4.4 Interface Calibration (cont.) 7. Establish interface level at desired 20 mA (100%) level on the displacer. 8. Press the ENTER key. The ZERO LED will light. Loop will go to 20 mA. 9. Press UP to lock in the 20 mA value. The ZERO LED will go off. The SPAN LED will light. Loop will go to 20 mA. 10. Press ENTER to confirm setting. The SPAN LED will go off, and the loop will go to 20 mA. 3.4.4.2 Calibration in water only for interface of another liquid over water. The example calibration below assumes an upper specific gravity of 0.80. For liquid with another S.G., immerse displacer by the percentage equal to that S.G. (EX: S.G. = 0.73, immerse displacer 73%) 1. Bring process up to operating temperature. 2. Establish water level at 80% level on displacer. 3. With unit power on, remove cover. 4. Press the ENTER key to start calibration. The ZERO LED will light. Loop will go to 22 mA. 5. Press the DOWN key to lock in the 4 mA value. The ZERO LED will flash and remain on. Loop will stay at 22 mA. 6. Press ENTER to confirm the setting. The ZERO LED will go off, and the loop will go to 4 mA. 7. Immerse displacer completely in water. 8. Press the ENTER key. The ZERO LED will light. Loop will go to 20 mA. 9. Press UP to lock in the 20 mA value. The ZERO LED will go off. The SPAN LED will light. Loop will go to 20 mA. 10. Press ENTER to confirm setting. The SPAN LED will go off, and the loop will go to 20 mA. 3.4.4.3 Calibration in water only for interface of two other liquids. 3.4.4.3.1 Lower S.G. less than or equal to 1.0. When S.G. of lower liquid is less than or equal to 1.0, calibrate as follows (this example assumes upper S.G. = 0.78 and lower S.G. = 0.98): 1. Bring process up to operating temperature. 2. Establish water at the point on displacer equal to the upper S.G. × 100% (EX. 0.78 × 100% = 78%). 3. Ensure there is no explosion hazard. With unit power on, remove cover. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 20 4. Press ENTER key to start calibration. ZERO LED will light. Loop will go to 22 mA. 5. Press DOWN key to lock in 4 mA value. Zero LED will flash and remain on. Loop will stay at 22 mA. 6. Press ENTER to confirm setting. ZERO LED will go off, and loop will go to 4 mA. 7. Establish water at the point on displacer equal to the lower S.G. × 100% (EX. 0.98 × 100% = 98%). 8. Press ENTER key. ZERO LED will light. Loop will go to 20 mA. 9. Press UP key to lock in 20 mA value. ZERO LED will go off. SPAN LED will light. Loop will go to 20 mA. 10. Press ENTER to confirm setting. ZERO LED will go off, and loop will go to 20 mA. 3.4.4.3.2 Lower S.G. greater than 1.0. When S.G. of lower liquid is greater than 1.0, calibrate as follows (this example assumes upper S.G. = 0.78 and lower S.G. = 1.20): 1. Bring process up to operating temperature. 2. Establish water at the point on displacer equal to the upper S.G. × 100% (EX. 0.78 × 100% = 78%). 3. Ensure there is no explosion hazard. With unit power on, remove cover. 4. Press ENTER key to start calibration. ZERO LED will light. Loop will go to 22 mA. 5. Press DOWN key to lock in 4 mA value. Zero LED will flash and remain on. Loop will stay at 22 mA. 6. Press ENTER to confirm setting. ZERO LED will go off, and loop will go to 4 mA. 7. Immerse displacer completely in water. 8. Determine the proper current setting for this calibration step using the following calculation: [(20 mA - 4 mA) × (1.00 - upper S.G.)/(lower S.G upper S.g.)] + 4 mA (EX. [(20 mA - 4 mA) × (1.00 - 0.78)/(1.20 - 0.78)] + 4 mA = 12.38 mA). 9. Press ENTER key. ZERO LED will light. Loop will go to 20 mA. 10. Press UP key to lock in 20 mA value. ZERO LED will go off. SPAN LED will light. Loop will go to 20 mA. 11. Using UP and DOWN keys, toggle until loop signal reads 12.38 mA. 12. Press ENTER to confirm setting. The SPAN LED will go off. 21 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 3.5 Configuration Using HART A HART (Highway Addressable Remote Transducer) remote unit, such as a HART handheld terminal (HHT) can be used to provide a communication link to the Digital ES II Modulevel Transmitter. When connected to the control loop, the same system measurement readings shown on the transmitter are shown on the HHT. In addition, the HHT can be used to calibrate the transmitter. SPAN (+) P1 – TB1 + ZERO ERROR (–) P2 If your HART communicator (HHT) has not been updated since January 1999, it will need to be updated to include the ES II Modulevel V2 software (Device Descriptors). Contact your local HART Service Center if this is required. ® UP ® E S MODULEVEL 5300 BELMONT ROAD, DOWNERS GROVE, IL 60515, USA. DOWN HEIKENSSTRAAT 6, B 9240 ZELE, BELGIUM. 3.5.1 Connections ENTER www.magnetrol.com REFER TO MODULEVEL MANUAL, BULLETIN 48-615, FOR INSTALLATION AND OPERATION INSTRUCTIONS. A HART communicator can be operated from a remote location by connecting to a remote junction or by connecting directly to the (+) and (-) terminal points at TB1 on the amplifier board in the electronics housing of the Digital ES II Modulevel Transmitter. TP1 TP2 ASSEMBLY PART NO. J1 HART uses the Bell 202 frequency shift key technique of high-frequency digital signals. It operates on the 4-20 mA loop and requires 250 ohms of minimum load resistance. A typical connection between a HHT and the Digital ES II Transmitter is illustrated in Figure 22. 05-9123-001 Junction 3.5.2 Display Menu - Control Room Display + A typical communicator display is an 8 line by 21 character LCD. When connected, the top line of each on line menu displays the model (ES MOD) and its tag number or address. Usually, the bottom line is reserved for software defined function keys (F1-F4). For detailed operating information, consult the instruction manual provided with the HART communicator. 3.5.3 Basic Field Calibration Using Hart HHC Power Supply Current Meter Figure 22 1. Connect HART HHT per Figure 22. 2. Start up the unit. 3. Refer to the next page for the transmitter online menu. Open the menu by pressing the alphanumeric key 1, Device Setup, to display the second level menu. Digital ES II/HART Communicator Connections 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 22 3.5.4 HART Menu 1 Enter Password password set at factory = 1 1 Device Setup 2 Calibration 1 Set Points 2 Damping 2 Level 3 Fault State view level in % select 3.6 mA–down button or 22 mA–up button 3 Current view level in mA 4 Date/Time/Initials enter this info as customer record of recalibration 4 Date displays date entered in Calibration>Date/Time/initials 5 Loop Test 3 Basic Setup 1 Tag enter tag # of unit 2 Descriptor 16 place customer descriptor for unit 3 Message 32 place customer message 4 Final Assembly Number 5 Poll Adr value is 0 unless for multidrop use 4 Advanced Setup 5 Review review all existing parameters 23 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 1 Set as 4 mA value current level will be new 4 mA level 1 4 mA apply new 4 mA input 2 20 mA apply new 20 mA input 2 Read new value introduce a value that will match 4 mA 3 Leave as found keep old 4 mA level 3 20 mA by % enter % of span vs. actual level 4 End 1 Set as 20 mA value current level will be new 20 mA level 2 Read new value Introduce a value that will match 20 mA 3 Leave as found 1 4 mA keep old 20 mA value unit blocks at 4 mA 2 20 mA unit blocks at 20 mA 3 Other enter a value between 3.6 and 22 mA 4 End 1 Set Dry Point for use when SG will be changed, dry point set with displacer hanging free completely out of liquid. 2 LVDT % read out % 3 Spec Grav set SG value 4 Error Codes if value other than 0000, consult factory 5 New password enter new password, or enter value “0” to disable password function 6 Trim 4 mA Point factory set 1 Model 2 Manufacturer 3 Set Magnetrol S/N 4 Dev id 5 Tag 6 Descriptor 7 Trim 20 mA Point 7 Message factory set 8 Damping 8 4 mA Trim Point factory set 9 20 mA Trim Point factory set 10 Set Serial Number factory set 9 Fault State 10 Date 11 Final Assembly 12 Universal rev 13 Fld dev rev 14 Software rev 15 Poll addr 16 Number req preams 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 24 4.0 Reference Information This section presents an overview of the operation of the Electronic Modulevel Displacer Level Transmitter, information on troubleshooting common problems, listings of agency approvals, lists of replacement and recommended spare parts, and detailed physical, functional, and performance specifications. 4.1 Description The Digital ES II and Analog EZ Modulevels are advanced, intrinsically safe or explosion proof twowire or four-wire instruments utilizing simple buoyancy principles to detect and convert liquid level changes into a stable 4–20 mA output signal. The linkage between the level sensing element and the output electronics provides a simple mechanical design and construction. The vertical in-line design of the transmitter results in low instrument weight and simplifies installation. The instrument comes in a variety of configurations and pressure ratings for varied applications. The Digital ES II Modulevel has micro-processor based electronics with HART compatible output, in addition to the standard 4–20 mA DC output. The Analog EZ Modulevel provides a simple 4–20 mA output. Electronic enclosure Moving LVDT core Printed circuit board LVDT External span and zero adjustment (EZ models only) Enclosing Tube Range spring Terminal junction box Potted entrance seal Displacer External cage Figure 23 Electronic Modulevel Components 25 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 4.2 Theory of Operation The Electronic Modulevel Displacer Level Transmitter relies on the principles of buoyancy to convert mechanical movement to an electronic output. See Figure 23. 4.2.1 Displacer Buoyancy The buoyancy force acting on an object is equal to the weight of the liquid displaced by the object. As the level changes, and more or less of the displacer is submerged in liquid, the buoyancy force on the displacer changes. This change is detected by the range spring from which the displacer hangs. The compression or elongation of the range spring, in turn, causes movement of the LVDT core mounted on the rigid stem attached to the spring. 4.2.2 LVDT An LVDT is a linear variable differential transformer made up of a primary winding, two secondary windings and a special magnetic steel core. The primary winding and the two secondary windings form an open transformer. The secondary windings are positioned, one above each other, opposite the primary winding. The primary winding is powered so that when the magnetic steel core is positioned between the primary and one or both of the secondary windings, a current is induced in the secondary winding(s). By comparing the currents in the two secondary windings, the exact position of the core, and therefore the liquid level, can be measured. 4.3 Troubleshooting The Electronic Modulevel Displacer Level Transmitter is designed and engineered for trouble-free operation over a wide range of operating conditions. Common transmitter problems are discussed in terms of their symptoms and corrective actions as recommended. WARNING! Explosion hazard. Do not connect or disconnect equipment unless power has been switched off or the area is known to be non-hazardous. The table on the next page provides information on how to troubleshoot transmitter-level problems. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 26 Symptom Problem Solution No loop current Power supply not turned on. Turn on power. Insufficient source voltage. The ES II requires a minimum of 12 VDC at terminals TB1 and TB2 while the EZ requires a minimum of 12 VDC at terminals P3 and P4 on amplifier board. Wires broken/improperly connected. Check wiring. Defective PC board. Replace PC board. See Section 4.4.1 or 4.5.1. Incorrect supply. Check power supply. Zero incorrectly set. Recalibrate 0% level. Zero point cannot be set to 4.00 mA at low level. Displacer hanging up. Verify proper and level installation. Incorrect supply. Check power supply. Span incorrectly set. Recalibrate unit. Displacer hanging up. Verify proper and level installation. Excessive loop resistance. Increase power supply voltage, or decrease loop resistance (For Digital ES II, max 545 ohms @ 24 VDC, 450 ohms for HART; for Analog EZ, max 480 ohms @ 24VDC). Span point cannot be decreased to 20.00 mA at high level. Span incorrectly set. Recalibrate unit. Displacer hanging up. Verify proper and level installation. Loop current oscillates or hunts. Waves or disturbances in medium. Adjust damping via HART (ES II) or install stilling well. See Section 3.5.4. Loop current randomly unstable. Waves or disturbances in medium. Adjust damping via HART. Power supply unstable. Repair or replace power supply. Electrical interference (RFI). Consult factory for assistance. Incorrect calibration. Recalibrate unit. Material level greater than 100%. No action required. Supply voltage out of limits at transmitter. Check power supply. Allowable voltage for ES II or EZ is between 12 and 36 VDC, Excessive temperature at transmitter electronics. Use remote transmitter mounting. Loop current exceeds 22.00 mA. Check power supply (+) and (-) for reverse wiring. Incorrect calibration. Recalibrate unit. Material level less than 0%. No action required. Supply voltage out of limits at transmitter. Adjust power supply or reduce loop resistance. Excessive temperatures at transmitter electronics. Use remote transmitter mounting. Loop current 22 mA or 3.6 mA fault indication (ES II only). Stem is broken, LVDT core is missing, LVDT wire is broken or unplugged or circuitry failure has occurred. Verify the unit. Non-linear output. Incorrect calibration. Excessive loop resistance. Recalibrate unit. Increase power supply voltage or decrease loop resistance. Verify proper and level installation. Span point cannot be increased to 20.00 mA at high level. Loop current exceeds 20.00 mA. Loop current less than 4.00 mA. Displacer hanging up. 27 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 4.4 Maintenance of Analog EZ Modulevel Mounting Screws (4) P4 P3 4.4.1 Replacing Transmitter PC Board Refer to Figure 24 during this procedure. 1. Remove power from the unit. 2. Remove transmitter housing cover. (—) (+) P4 P3 4 mA SET — TB1 + R8 ¤ J2 E Z MODULEVEL ¤ 5300 BELMONT ROAD, DOWNERS GROVE, IL 60515, USA. Potentiometer Cable Connector Pins (J2) HEIKENSSTRAAT 6, B 9240 ZELE, BELGIUM. www.magnetrol.com REFER TO MODULEVEL MANUAL, BULLETIN 48-615, FOR INSTALLATION AND OPERATION INSTRUCTIONS. 3. 4. TP2 5. ASSEMBLY PART NO. R13 30-2163 AGC REV. S1 LVDT Eight Pin Connector (J1) DIR. J1 6. TP1 05-9118-001 Figure 24 Analog EZ Transmitter PC Board Connections 7. 8. 9. 10. Spade connectors P5 P4 P3 To remove old transmitter board: Remove the two wires from spade connectors P3 and P4 and shield wire from the board mounting screw on the transmitter PC board. Unplug the potentiometer cables from the PC board connector pins at J2. Unplug the LVDT eight pin connector from the socket at J1. Clip the plastic tie wrap which holds the cable to the PC board. Remove two screws which secure the PC board bracket to housing base and carefully remove board / bracket assembly. Remove the four screws which hold the PC board to the bracket. Carefully remove the transmitter PC board from the transmitter housing. Install new PC board by reversing above steps. Be certain that the red wire is attached to P3 and the black wire is attached to P4. 4.4.2 Replacing Power Supply PC Board (120 and 240 VAC controls only) 1. 2. 3. P2 P1 Mounting Screws (4) Spade Connectors 4. 5. Figure 25 Analog EZ Power Supply PC Board Connections 6. Refer to Figure 25 during this procedure. Remove power from the unit. Remove transmitter housing cover. To remove old power supply board: Mark the five wires connected to P1 through P5 and then remove the wires from these connectors. Remove the four screws which hold the PC board to the bracket. Carefully remove the power supply PC board from the transmitter housing. Install new PC board by reversing above steps. Be certain that each wire is connected to the same spade connector as on the original PC board. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 28 4.4.3 Replacing LVDT 1. Remove power from the unit. 2. Remove the transmitter housing cover. To remove old LVDT: 3. Locate the black wire which runs from the top of the LVDT to the lower right hand corner of the transmitter PC board. Remove the eight pin connector on this wire from J1 on the transmitter PC board. 4. Remove the c-ring above the LVDT on the enclosing tube using a snap ring pliers. 1 2 3 4 8765 5. Carefully slide the LVDT from the enclosing tube. If necessary, clip the plastic tie wrap on the transmitter PC board. 6. Install new LVDT by reversing the above steps. 4.4.4 Checking the LVDT Winding Resistance 1. 2. 3. Figure 26 4. LVDT Eight Pin Connector 5. 6. 4.5 Refer to Figure 26 during this procedure. Remove power from the unit. Remove the transmitter housing cover. Locate the black wire which runs from the top of the LVDT to the lower right hand corner of the transmitter PC board. Remove the eight pin connector on this wire from J1 on the PC board. Using a multimeter, check the primary winding by verifying that pins 2 and 6 of the eight pin connector have approximately 78 to 117 ohms resistance. Check the secondary winding by verifying that pins 1 and 5 or pins 4 and 8 of the eight pin connector have approximately 72 to 109 ohms resistance. If the winding resistance is out of range, replace LVDT. Maintenance of Digital ES II Modulevel 4.5.1 Replacing Transmitter PC Board Refer to Figure 27 during this procedure. 1. Remove power from the unit. 2. Remove transmitter housing cover. To remove old board: 3. Remove two screws which secure the PC board bracket to the housing base. 4. Remove two wires from TB1 on the PC board. 29 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) C-ring TBI SPAN (+) P1 — TB1 + ZERO ERROR (—) P2 5. Unplug the LVDT eight pin connector from the socket at P1 on the PC board. 6. Clip the plastic tie wraps which hold the cable to the PC board. 7. Remove the four screws which hold the PC board to the bracket. 8. Remove the c-ring from LVDT using snap ring pliers. 9. Carefully remove the transmitter PC board from the transmitter housing. 10. Install new PC board by reversing above steps. Be certain that the red wire is attached to the (+) terminal at TB1 and the black wire is attached to the (-) terminal at TB1. ¤ UP ¤ E S MODULEVEL 5300 BELMONT ROAD, DOWNERS GROVE, IL 60515, USA. HEIKENSSTRAAT 6, B 9240 ZELE, BELGIUM. DOWN ENTER www.magnetrol.com REFER TO MODULEVEL MANUAL, BULLETIN 48-615, FOR INSTALLATION AND OPERATION INSTRUCTIONS. TP1 4.5.2 Replacing LVDT TP2 ASSEMBLY PART NO. J1 J1 1. Remove power from the unit. 2. Remove the transmitter housing cover. 05-9123-001 Bracket Screws 3. Figure 27 Digital ES II Transmitter PC Board Mounting 4. 5. 6. To remove old LVDT: Locate the black wire which runs from the top of the LVDT to the lower right hand corner of the transmitter PC board. Remove the eight pin connector on this wire from J1 on the PC board. Remove the c-ring above the LVDT on the enclosing tube using a snap ring pliers. Carefully slide the LVDT from the enclosing tube. If necessary, clip the plastic tie wrap on the transmitter PC board. Install new LVDT by reversing the above steps. 4.5.3 Checking the LVDT Winding Resistance 1. 2. 3. 4. 5. 6. Refer to Figure 26 during this procedure. Remove power from the unit Remove the transmitter housing cover. Locate the black wire which runs from the top of the LVDT to the lower right hand corner of the transmitter PC board. Remove the eight pin connector on this wire from J1 on the PC board. Using a multimeter, check the primary winding by verifying that pins 2 and 6 of the eight pin connector have approximately 78 to 117 ohms resistance. Check the secondary winding by verifying that pins 1 and 5 or pins 4 and 8 of the eight pin connector have approximately 72 to 109 ohms resistance. If the winding resistance is out of range, replace LVDT. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 30 4.6 Agency Approvals 4.6.1 FM (Factory Mutual) Model XEXX-XXXX with transmitter codes: Approval EZA, B, C, E, F, G, L, N Explosion Proof ESA, E, F, G, 7, 9 Class I, Div. 1; Groups A, B, C, D GZH, K, Q, R, S, T, U, V, 2, 3, 5, 6 Class II, Div. 1; Groups E, F, G GSH, K, Q, T, 4, 7 Class III, NEMA 4X RZW, X RSW, X, 4 XEXX-XXXX with transmitter codes: RZQ, T Explosion Proof with RSQ, T, Z Intrinsically Safe Connections Class I, II, III, Div. 1; Groups B, C, D, E, F, G Nema 4X Entity EXX-XXXX with transmitter codes: EZD, H, I, K Intrinsically Safe ESD, H, I, J, K, 8, 9 Class I, Div. 1; Groups B, C, D Class II, Div. 1; Groups E, F, G Class III, NEMA 4X Entity EXX-XXXX with transmitter codes: EZA, G Non-Incendive ESA, E, F, G, 7, 9 suitable for: GZH, K, Q, T GSH, K, Q, T, 4, 7 Class I, Div. 2; Groups A, B, C, D Class II, Div. 2; Groups F, G Class III, Div. 2; NEMA 4X RZW, X RSW, X, 4 31 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 4.6.2 CSA (Canadian Standards Association) Model Approval XE5X-XXXX with transmitter codes: EZA, B, C, E, F, G, L, N Explosion Proof ESA, E, F, G, 7, 9 Class I, Div. 1; Groups B, C, D GZH, K, Q, R, S, T, U, V, 2, 3, 5, 6 Class II, Div. 1; Groups E, F, G GSH, K, Q, T, 4, 7 Class III, Type 4X RZW, X RSW, X, 4 E5X-XXXX with transmitter codes: EZD, H, I, K Intrinsically Safe ESD, H, I, J, K, 8 Class I, Div. 1; Groups A, B, C, D GZH, K, Q, T GSH, K, Q, T, 4, 7 RZQ, T Class II, Div. 1; Groups E, F, G Class III, Type 4X Entity RSQ, T, Z E5X-XXXX with transmitter codes: EZD, H, I, K Non-Incendive ESD, H, I, J, K, 8 suitable for: GSH, K, Q, T, 4, 7 Class II, Div. 2; Groups E, F, G RZQ, T Class III, Type 4X GZH, K, Q, T Class I, Div. 2; Groups A, B, C, D RSQ, T, Z 4.6.3 ATEX (European Directive for Explosion Protection Model ATEX Approval XEXX-XXXX, EXX-XXXX with transmitter codes Explosion Proof EZA, E, F, G ATEX Ex II 1/2 G EEx d IIC T6 ESA, E, F, G, 7, 9 RZW, X RSW, X, 4 EXX-XXXX with transmitter codes Intrinsically Safe ESD, I, H, K ATEX Ex II 1 G EEx ia IIC T6 RSQ, T EXX-XXXX with transmitter codes Intrinsically Safe ESJ, 8 ATEX Ex II 1 G EEx ia IIC T5 RSZ Field wiring must be installed in conduit. If IS or NI CSA nameplate is required, this must be specified at time These units have been tested to EN 50081-2 and EN 50082-2 and are in compliance with the EMC Directive 89/336/EEC. of order placement. ATEX EP approval available on standard 900#, 1500#, and 2500# models. 150#, 300#, and #600 models require modification for ATEX EP approval and must be “X’d” for a heavy wall e-tube. Entity parameters for ATEX EEx ia installation: Ci = 5 nF, Li = 800 µH Ui = 28.4 V, Pi = 0.67 W or Ui = 26.4 V, Li = 99 mA, Pi = 0.66 W 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 32 4.7 Parts 4.7.1 Replacement P.C. Boards 1 Replacement Electronic Modulevel Boards Digital ES Supply Voltage Transmitter Mounting Integral 24 VDC Remote HT-Integral Analog EZ Serial Number Format Date of Manufacture P.C. Board Description Transmitter Code ESA/ESD/ESG/ESI/ESE/ESH/ESF ESJ/ES9/ESK/ES7/ES8 ES1/ES4/GSH/GSK GS7 ESQ/EST/GSQ/GST GS4 RSQ/RSW/RST/RSX/RS4/RSZ (6 digits)-(2 digits)-(3 digits) 1998 - present Potted module Serial Number Format Date of Manufacture (6 digits)-(2 digits)-(3 digits) 1996 - present Six pin potentiometer connector 6 or 7 digits 1984 - 1997 Ten pin potentiometer connector New EZ board Original EZ board P.C. Board Description Supply Voltage 24 VDC 24 VDC 120 VAC 240 VAC 24 VDC 120 VAC 240 VAC 24 VDC 120 VAC 240 VAC 24 VDC Transmitter Mounting Integral Remote HT-Integral Transmitter Code EZA/EZG/EZE/EZF EZD/EZI/EZH EZB/EZL EZC/EZN EZ1/EZ4/GZH/GZK EZ2/EZ5/GZ2/GZ5 EZ3/EZ6/GZ3/GZ6 EZQ/EZT/GZQ/GZT/GZZ EZR/EZU/GZR/GZU EZS/EZV/GZS/GZV RZW/RZX/RZQ/RZT 6 or 7 digits 1995 - 1999 Through hole ES II board ES I board 89-9113-001 89-7826-004 89-7826-004 89-7826-005 89-7826-006 89-7826-004 89-7826-005 89-7826-006 89-7826-004 89-7826-005 89-7826-006 89-7826-004 89-7826-001 89-7826-001 89-7826-002 89-7826-003 89-7826-001 30-2163-002 89-7826-003 89-7826-001 89-7826-002 89-7826-003 n/a All digital ES boards are to be replaced with ES II transmitter boards as indicated. CENELEC IS units require complete transmitter head replacement if PC board or LVDT is required. 33 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 4.7 Parts 4.7.2 Transmitter Head Parts 2 ESA ESG ES9 EZA EZB EZC EZG EZL EZN ESE ESF ES7 EZE EZF GSH GSK GS7 GSQ GST GS4 GZH GZ2 GZ3 GZK GZ5 GZ6 GZQ GZR GZS GZT GZU GZV RSW RSX RS4 RZW RZX ESD ESH RSQ* ESI ESK RST ESJ ES8 RSZ* EZD EZH RZQ* EZI EZK RZW* LVDT Assembly 89-7827-001 3 Meter Assembly N/A 37-3308-001 37-3310-001 4 Transmitter/ LVDT Housing 89-7830-002 5 Junction 6 Housing O-rings Junction/Meter Board (not shown) 89-6562-001 Z30-2194-001 89-6562-001 N/A 89-6562-001 N/A 89-6562-001 Z30-2194-001 89-6562-001 N/A 89-6562-001 QTY 2 Z30-2194-001 89-6562-001 QTY 2 Z30-2194-001 89-6562-001 QTY 2 N/A 89-6562-001 QTY 2 N/A 89-6562-001 QTY 2 N/A 89-6562-001 QTY 2 N/A 89-7828-006 89-6562-001 QTY 2 Z30-2194-001 89-7828-001 89-7828-003 89-6562-001 QTY 2 N/A Box 89-7828-005 89-7828-006 89-7828-001 89-7827-001 N/A 89-7830-001 89-7827-001 37-3145-002 89-7830-001 89-7828-002 89-7828-003 89-7827-006 30-2135-002 89-7827-003 89-7827-004 N/A 37-3308-001 37-3310-001 N/A 37-3145-002 N/A 37-3308-001 37-3310-001 N/A 37-3308-001 37-3310-001 89-7827-003 N/A 89-7827-003 37-3145-002 89-7827-004 N/A 89-7827-004 37-3145-002 89-7827-004 89-7827-004 89-7827-001 89-7827-006 89-7827-004 89-7827-001 89-7827-006 89-7827-004 89-7827-001 89-7827-006 89-7827-004 89-7827-001 30-2135-002 89-7827-004 89-7827-001 30-2135-002 89-7827-004 N/A 37-3308-001 37-3310-001 N/A 37-3145-002 89-7828-004 89-7828-005 89-7830-002 89-7830-001 89-7830-002 and 89-7830-003 89-7830-002 and 89-7830-003 89-7830-001 and 89-7830-003 89-7830-001 and 89-7830-003 89-7830-001 and 89-7830-003 89-7830-001 and 89-7830-003 89-7830-004 and 89-7830-003 89-7830-005 & 89-7830-003 89-7828-006 89-7828-001 89-7828-003 89-7828-005 89-7828-006 89-7828-005 89-7828-006 89-7828-001 89-7828-002 89-7828-003 89-7828-004 89-7828-001 89-7828-002 89-7828-003 89-7828-004 89-7828-005 N/A 04-9111-001 cover only 04-9113-001 cover only 89-6562-001 Z30-2194-001 37-3308-001 04-9111-001 cover only 36-3908-003 cover only 89-6562-001 Z30-2194-001 37-3310-001 04-9111-001 cover only 36-3908-003 cover only 89-6562-001 Z30-2194-001 N/A 04-9111-001 cover only 04-9113-001 cover only 89-6562-001 N/A 04-9111-001 cover only 36-3908-001 cover only 89-6562-001 N/A 37-3145-002 N/A * Requires quantity 2 of Transmitter/LVDT Housing and Housing O-rings 4.7.3 Recommended Spare Parts Item Description Part Number 1 Transmitter PC board assembly See replacement parts chart, Section 4.7.1. 2 Displacer See replacement parts chart, Section 4.7.4. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 34 4.7.4 Mechanical Replacement Parts 7 E-tube kit CS to 600# SS to 600# CS - 900# CS 1500# & up Standard High Temperature 89-5944-001 89-5944-002 89-5944-002 89-5944-005 89-5944-004 89-5944-007 89-5944-003 89-5944-006 8 E-tube Gasket All Pressures 12-1204-001 9 Flange/Flange Assembly 150# 3" CS 0.5 89-4217-001 3" CS 1.0/2.0 89-4218-001 4" CS 0.5 Z31-4804-007 4" CS 1.0/2.0 Z31-4804-010 6" CS 0.5 Z31-4804-013 6" CS 1.0/2.0 Z31-4804-016 3" SS 0.5 89-4238-001 3" SS 1.0/2.0 89-4238-002 4" SS 0.5 Z31-4806-007 4" SS 1.0/2.0 Z31-4806-010 6" SS 0.5 Z31-4806-013 6" SS 1.0/2.0 Z31-4806-016 300# 89-4219-001 89-4220-001 Z31-4804-008 Z31-4804-011 Z31-4804-014 Z31-4804-017 89-4238-003 89-4238-004 Z31-4806-008 Z31-4806-011 Z31-4806-014 Z31-4806-017 600# 89-4221-001 89-4222-001 Z31-4804-009 Z31-4804-012 Z31-4804-015 Z31-4804-018 89-4238-005 89-4238-006 Z31-4806-009 Z31-4806-012 Z31-4806-015 Z31-4806-018 900# n/a n/a n/a Z04-8606-001 n/a Z04-8606-004 n/a n/a n/a n/a n/a n/a 1500# n/a n/a n/a Z04-8606-002 n/a Z04-8606-005 n/a n/a n/a n/a n/a n/a 2500# n/a n/a n/a Z04-8606-003 n/a Z04-8606-006 n/a n/a n/a n/a n/a n/a 10 Stem Assembly Pressure 600# or less 600# or less 4" 900# 4" 900# 6" 900# 6" 900# 4" 1500# 4" 1500# 6" 1500# 6" 1500# 4" 2500# 4" 2500# 6" 2500# 6" 2500# E-tube standard High Temp standard High Temp standard High Temp standard High Temp standard High Temp standard High Temp standard High Temp 0.5 SG 32-5841-003 32-5841-005 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 1.0 SG 32-5841-004 32-5841-006 32-5855-001 32-5855-006 32-5855-002 32-5855-007 32-5855-002 32-5855-007 32-5855-004 32-5855-009 32-5855-003 32-5855-008 32-5855-005 32-5855-010 2.0 SG 32-5841-004 32-5841-006 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 0.5 SG 32-8129-003 32-8129-004 32-8129-008 1.0 SG 32-8129-001 32-8129-002 32-8129-007 2.0 SG 32-8129-005 32-8129-006 32-8129-009 Hi Press 1.0 SG 32-8120-002 n/a 32-8120-002 11 Spring Assembly CS Low Temp SS Low Temp CS/SS Hi Temp Head Flange- Gasket Only (not pictured) 150# 300# 3" 12-1301-17 12-1301-018 4" n/a n/a 35 600# 12-1204-021 n/a 900# n/a 12-1204-009 1500# n/a 12-1204-010 2500# n/a 12-1204-011 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 1 Transmitter P.C. Board Assembly and Bracket LVDT Core Stem 10 4 Housing Base and Cover 2 LVDT Assembly 5 Junction Box 3 Meter Only 6 Housing O-Rings 11 Range Spring 13 Cotter Pins 7 Enclosing Tube 8 Gasket Flange 9 or Flange Assembly 12 12 Displacer Displacer 14" 32" 48" 60" 72" 84" 96" 108" 120" Low Pressure 0.5/1.0 2.0 89-6125-001 89-6126-001 89-6125-002 89-6126-002 89-6125-003 89-6126-003 89-6125-004 89-6126-004 89-6125-005 89-6126-005 89-6125-006 89-6126-006 89-6125-007 89-6126-007 89-6125-008 89-6126-008 89-6125-009 89-6126-009 High Pressure 1.0 89-6125-010 89-6125-011 89-6125-012 89-6125-013 n/a n/a n/a n/a n/a 13 Cotter pins All Units 10-5203-001 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 36 4.7.5 Upgrade to ESII Electronics 4.7.5.1 Procedure for Conversion of Smart ES Electronics to Digital ES II Electronics REMOVAL OF THE ES TRANSMITTER BOARD: 1. Remove power from the Smart ES unit. 2. Remove the transmitter housing cover. 3. Remove the two screws that secure the PC board and bracket assembly to the housing base. Save these screws. 4. Using snap ring pliers, remove the c-ring on the enclosing tube above the LVDT. 5. Slide the board/bracket assembly up and off of the e-tube. 6. Remove the shield over the transmitter PC board by removing the two screws in the upper corners of the board that hold it in place. Discard the shield and screws. 7. Remove the power wires from terminal TB1 on the board. 8. Remove the LVDT eight pin connector from socket P1 on the board. 9. Clip the plastic tie-wrap that holds the cable to the board. 10. Remove and discard the PC board and bracket assembly. INSTALLATION OF THE ES II REPLACEMENT BOARD: 1. Have on hand an ES II replacement board kit, p/n 89-9113-001. 2. Connect the power wires to the board at terminal TB1. Ensure that the red wire is attached to the (+) terminal and the black wire to the (-) terminal. 3. Plug the LVDT eight pin connector into the new board at socket J1. 4. Slide the board and bracket assembly down on the e-tube until the bracket rests in the housing base. 5. Secure the bracket to the housing base using the two screws that originally held it in place. 6. Replace the c-ring on the enclosing tube above the LVDT. 7. Replace the transmitter housing cover. 8. Apply power and check for output signal. 9. Recalibrate the transmitter as described in Sections 3.4 & 3.5. 37 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 4.7.5.2 Procedure for Conversion of EZ Electronics to Digital ES II Electronics REMOVAL OF THE EZ TRANSMITTER: 1. Remove power from the EZ unit. 2. Remove the transmitter and terminal housing covers. C-ring 3. Disconnect the field wiring in the terminal strip housing. TBI 4. Unplug the LVDT wiring from the 8-pin connector at P1. 5. Remove the c-ring on the enclosing tube above the LVDT using snap ring pliers. SPAN (+) P1 — TB1 + ZERO ERROR (—) P2 ¤ UP 6. Slide the LVDT up, off the enclosing tube. It may be necessary to clip the wiring tie-wrap from the PC board. ¤ E S MODULEVEL 5300 BELMONT ROAD, DOWNERS GROVE, IL 60515, USA. HEIKENSSTRAAT 6, B 9240 ZELE, BELGIUM. DOWN ENTER www.magnetrol.com REFER TO MODULEVEL MANUAL, BULLETIN 48-615, FOR INSTALLATION AND OPERATION INSTRUCTIONS. 7. Remove the white plastic positioner ring at the base of the enclosing tube. TP1 8. Loosen the set screws in the hub of the housing base, and carefully lift the entire assembly off the enclosing tube. TP2 ASSEMBLY PART NO. J1 J1 INSTALLATION OF THE ES II REPLACEMENT: 05-9123-001 Bracket Screws Figure 28 1. Remove the dummy enclosing tube (if provided) from the new ES II housing assembly. 2. Remove the transmitter and terminal housing covers. 3. Lower the complete ES II assembly onto the existing enclosing tube, being careful not to bend the enclosing tube. Make sure the housing set screws are loose so that the assembly fits tightly to the enclosing tube nut. As you lower the assembly, guide the PC board assembly mounting bracket onto the enclosing tube. 4. Replace the white plastic positioner on the enclosing tube making sure it is snug against the enclosing tube base; then, slide the LVDT down the enclosing tube until it rests firmly on the white plastic positioner. 5. Replace the c-ring at the top of the enclosing tube. 6. Connect the 8-pin LVDT into the socket at J1. 7. Connect the field wiring to the terminals in the terminal housing. Check the terminal markings for +/- polarity. 8. Replace the transmitter housing cover. 9. Apply power and check for output signal. 10. Calibrate the transmitter as described in Sections 3.4 & 3.5. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 38 4.8 Specifications 4.8.1 Functional Measurement principle Buoyancy – continuous displacement utilizing a precision range spring Input Measured variable Level, determined by LVDT core movement affected by buoyancy force changes on continuous displacer Physical Range Up to 120" (300 cm) based on displacer length Output (Digital ES II) Type Range Loop Resistance (maximum) Fault Damping Sampling Rate Analog 4 to 20 mA direct or reverse acting with HART® digital signal Analog 3.8 to 20.5 mA useable Digital 0 to 100% 545 Ohms @ 24 VDC 3.6 or 22 mA, selectable Adjustable 0-60 seconds Transmitter 15 times per second Digital Meter 1.33 times per second User Interface (Digital ES II) Keypad 3 calibration buttons (up, down, enter) Indication 3 LED’s on PCB for calibration and functional checks Digital communication HART Version 5.x compatible Power (Digital ES II) Measured at instrument 12 to 36 VDC terminals Output (Analog EZ) Type Analog 4 to 20 mA direct or reverse acting Range Analog 4 to 20 mA useable Loop Resistance (maximum) 480 ohms @ 24 VDC Fault User Interface (Analog EZ) Potentiometers Action Power (Analog EZ) Measured at instrument terminals 22 mA Housing Material Cable entry 39 Zero + Span controls Direct/Reverse switch 12 to 36 VDC 120 VAC, 50/60 Hz 240 VAC, 50/60 Hz Polymer coated cast iron 1" NPT 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) Chamber Materials Carbon steel 316/316L stainless steel Wetted parts 304/304L and 316/316L (900# and greater) and Inconel (spring) 316/316L (600# and less) and Inconel (spring) Process connections Tank Top: 3", 4", 6" ANSI Flange Chambered: 11⁄2", 2" NPT 11⁄2", 2" Socketweld 11⁄2", 2" ANSI Flanges Process Conditions Process temperature range * Steam applications: -20° F to +500° F (+260° C) Non-steam applications: -20° F to +600° F (-29°C to +315° C) Process pressure range 4265 psig @ +100° F (294 bar @ +38° C) Environmental Electronics operating temperature -40° F to +160° F (-40° C to +70° C) Display function operating temperature -4° F to +160° F (-20° C to +70° C) Storage temperature -40° F to +185° F (-40° C to +85° C) Electromagnetic compatibility Meets CE Requirements (EN 50081-2, EN 50082-2) 4.8.2 Performance Linearity (independent) LVDT: +/- 0.25% of full span Mechanical/electrical: +/- 0.25% of full span Repeatability +/-0.20% of full span Resolution 0.05 % of range ± 1 digit Ambient temperature effect Maximum zero shift is 0.031% of effect/°F Operating Temp. range: -40° to +160° F (-40° to +70° C) Digital Meter Temp. Range: -4° to +160° F (-20° to +70° C) Storage Temp. Range: -40° to +185° F (-40° to +85° C) Electromagnetic Compatibility: Meets CE Requirements (EN 50081-2, EN 50082-2) * Maximum process temperatures are based on ambient temperatures less than or equal to +120° F (+49° C). Higher ambient temperatures require reduced process temperatures. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 40 4.8.3 Physical Dimensional specifications for standard pressure models E61, E62, E63, E64, E65, E66 19.10 (485) 8.62 (219) Range Spring Specific Gravity Rating A B C .11 to .54 14.06 (357) 19.06 (484) 23.25 (591) .55 to 1.09 1.10 to 2.20 12.12 (308) 17.12 (435) 21.31 (541) C ± .19 (5) Outlet Size 11⁄2" 2" D E 3.19 (81) 3.31 (84) 6.25 (159) 6.25 (159) Level range plus 3.50 (89) Level range plus 8.62 (219) 10.75 (273) D 8.62 (219) E Figure 29 HT Integral Side/Bottom Mount Fourth Digit Codes 7, 8, 9 1" NPT conduit connector B 10.75 (273) 8.62 (219) 1" NPT conduit connector Level range A 3.00 (76) 5.00 (127) Adjustable hanger cable available (specify 032-3110-001) D E Level range 1" NPT drain (plug not provided) Figure 31 Integral Side/Side Mount Fourth Digit Codes 1, 2, 3 Figure 30 Integral Top Mount 41 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) Dimensional specifications for high pressure models E51, E53, E55 10.75 (273) 10.75 (273) 8.62 (219) 8.62 (219) 1" NPT conduit connector B 1" NPT 1/2" N 1" NPT conduit connector NPT 2.00 (51) 3.50 (89) 2.75 (70) C ANSI standard flange Up to 75' (23 m) of Connecting Cable, part number 037-3218-0XX or 037-3220-0XX, run in conduit. Cable must be ordered separately. F Level range Level range Dia. Figure 32 E51 Series with Integral Top Mounting 900, 1500, 2500 lb. Class (2) 11/2" or 2" ANSI standard flange (Refer to chart for class and size.) Mid Range 5.00 (127) J 3.00 (76) (2) 11/2" or 2" NPT or socket weld L 1" NPT drain G 10.75 (273) Remote Mount Bracket Figure 33 8.62 (219) 1" NPT conduit connector B E E55 Series with Side/Side Connections, Remote Mount 900, 1500, 2500 lb. Class K Dimensions Flange Size & Class F 11⁄2" – 900 lb. 2" – 900 lb. Level range 11⁄2" – 1500 lb. Mid Range 2" – 1500 lb. 11⁄2" – 2500 lb. M 2" – 2500 lb. H B C E F G H J K N 7.25 8.43 16.38 9.31 25.81 9.31 (184) (214) 3.44 11.50 20.57 (416) (236) (655) (236) 8.18 9.38 (87) (292) (522) (208) (238) 7.93 9.13 16.75 9.31 26.19 9.31 (201) (232) 3.44 12.25 20.94 (425) (236) (665) (236) 8.87 10.13 (87) (311) (532) (225) (257) 9.06 10.25 17.62 9.31 27.06 9.31 (230) (267) 3.44 14.00 21.81 (447) (236) (687) (236) 9.87 11.13 (87) (356) (554) (251) (283) 11/2" (2) or 2" NPT or socket weld L G (2) 11/2" or 2" ANSI standard flange (Refer to chart for class and size.) Outlet Size Figure 34 11⁄2" NPT or Socket Weld E53 Series with Upper Side/Bottom Connections, Integral Mount 900, 1500, 2500 lb. Class 2" NPT or Socket Weld 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) Dimensions L M 4.00 (102) 4.38 (111) 3.44 (87) 3.50 (89) 42 4.9 Model Numbers 4.9.1 Models for Steam applications (max. 600 lbs.) DESIGN TYPE E 6 Standard design EZ Modulevel MOUNTING AND CHAMBER MATERIALS flanged top cage side/bottom cage side/side tank connection chamber material steel 316 SS steel 316 SS steel 316 SS 1 2 3 4 5 6 code Adjustable 8' hanger cable (p/n 32-3110-001), required when distance from flange face to top of displacer must be greater than 5.00" SPECIFIC GRAVITY AND PROCESS TEMPERATURE HT integral transmitter mounting integral remote or remote +300° F (+150° C) +400° F (+200° C) +500° F (+260° C) maximum temperature 1 7 7 0.11 - 0.54 specific gravity 2 8 8 0.55 - 1.09 specific gravity 3 9 9 1.10 - 2.20 specific gravity Consult factory for lower specific gravity design TANK CONNECTION Top mounted connection type ANSI HEAD Flange rating RF 150 lbs RF 300 lbs RF 600 lbs External cage models ANSI Cage rating Size RF 150 lbs RF 300 lbs RF 600 lbs Size / Type G3 G4 G5 3" C5 C7 C9 11⁄2" NPT H3 H4 H5 4" C6 C8 C0 11⁄2" S.W. K3 K4 K5 6" P3 P4 P5 11⁄2" flanged D5 D7 D9 2" NPT LEVEL RANGE 14 32 356 813 A B D6 D8 D0 2" S.W. Q3 Q4 Q5 2" flanged 48 1219 60 1524 72 1829 84 2134 96 2438 108 2743 120 3048 inches mm C D E F G H I code TRANSMITTER – ELECTRONICS (see opposite page) E 6 43 complete order code for Standard EZ Modulevel transmitter 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) TRANSMITTER TYPE & MOUNTING E Electronic Integral Mount G Electronic Remote Mount R Electronic High-temp Integral Mount TRANSMITTER OUTPUT Z 4-20 mA only (Analog) S 4-20 mA with HART (Digital) HART communicator sold separately 24 VDC, 120 VAC or 240 VAC 24 VDC only TRANSMITTER CONFIGURATION AND ACCESSORIES Code Display Input Voltage Integral Mount Fourth Digits 1, 2, 3 only Eighth Digit E only +300° F max. Remote Mount A None B None C EP – FM, CSA, CENELEC None 240 VAC EP – FM, CSA IS/NI – FM, CSA, CENELEC None 24 VDC Analog 24 VDC EP – FM, CSA, CENELEC I Analog 24 VDC IS/NI – FM, CSA, CENELEC L Analog N Analog 240 VAC EP – FM, CSA 24 VDC IS/NI – FM, CSA Digital J 9 Digital H None None 3 None 7, 8, 9 only K Analog Eighth Digit G only 5 Analog 6 Analog Fourth Digits 7 ,8, 9 only 7 Digital Q None 120 VAC EP – FM, CSA, CENELEC 24 VDC EP – FM, CSA 240 VAC EP – FM, CSA 24 VDC EP – FM, CSA 240 VAC EP – FM, CSA 120 VAC 120 VAC EP – FM, CSA EP – FM, CSA 24 VDC EP – FM, CSA 24 VDC IS/NI – FM, CSA, CENELEC W None 24 VDC EP – FM, CSA, CENELEC T Analog 24 VDC IS/NI – FM, CSA, CENELEC X Analog 24 VDC EP – FM, CSA, CENELEC Digital 4 +500° F max. Z Digital Q None R None 120 VAC 240 24 VDC EP – FM, CSA, CENELEC 24 VDC IS/NI – FM, CSA 24 VDC EP – FM, CSA VAC Fourth Digits 7, 8, 9 only S None T Analog Eighth Digit G only U Analog 120 VAC V Analog 240 4 Digital 24 VDC +500° F max. EP – FM, CSA 24 VDC Eighth Digit R only Remote Mount EP – FM, CSA D 2 HT-Integral Mount 120 VAC G Fourth Digits +400° F max. Agency Approval 24 VDC 24 VDC VAC EP – FM, CSA EP – FM, CSA EP – FM, CSA EP – FM, CSA EP – FM, CSA EP – FM, CSA 120 & 240 VAC available on Analog unit only (ninth digit Z) Digital meter available on Digital Hart compatible unit only (ninth digit S) REMOTE CONNECTING CABLE Up to +400° F, specify cable 037-3218-0XX, where last two digits are cable length in feet from 1-75 feet. Last 3 Digits of Model Number Up to +500° F, specify cable 037-3220-0XX, where last two digits are cable length in feet from 1-75 feet. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 44 4.9.2 Models for Steam applications (900 to 2500 lbs.) DESIGN TYPE E 5 Standard design EZ Modulevel MOUNTING AND CHAMBER MATERIALS flanged top cage side/bottom cage side/side 1 3 5 tank connection with steel chamber material code Adjustable 8' hanger cable (p/n 32-3110-001), required when distance from flange face to top of displacer must be greater than 9.31" SPECIFIC GRAVITY AND PROCESS TEMPERATURE HT integral transmitter mounting integral remote or remote +300° F (+150° C) +400° F (+200° C) +500° F (+260° C) 2 8 8 maximum temperature 0.55 - 1.09 specific gravity TANK CONNECTION Top mounted connection type ANSI HEAD Flange rating RF 900 lbs RF 1500 lbs RF 2500 lbs External cage models ANSI Cage rating RF 900 lbs RF 1500 lbs RF 2500 lbs Size / Type Size H6 H7 H8 4" L5 L7 L9 11⁄2" NPT K6 K7 K8 6" M5 M7 M9 11⁄2" S.W. P6 P7 P8 11⁄2" flanged L6 L8 L0 2" NPT M6 M8 M0 2" S.W. Q6 Q7 Q8 2" flanged LEVEL RANGE 14 32 356 813 A B 48 1219 60 1524 inches mm C D code TRANSMITTER – ELECTRONICS (see opposite page) E 5 45 complete order code for Standard EZ Modulevel transmitter 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) TRANSMITTER TYPE & MOUNTING E Electronic Integral Mount G Electronic Remote Mount R Electronic High-temp Integral Mount TRANSMITTER OUTPUT Z 4-20 mA only (Analog) S 4-20 mA with HART (Digital) HART communicator sold separately 24 VDC, 120 VAC or 240 VAC 24 VDC only TRANSMITTER CONFIGURATION AND ACCESSORIES Code Display Input Voltage Integral Mount Fourth Digit 2 only Eighth Digit E only +300° F max. Remote Mount Fourth Digit 8 only Eighth Digit G only +400° F max. HT-Integral Mount Fourth Digit 8 only Eighth Digit R only +500° F max. Remote Mount Fourth Digit 8 only Eighth Digit G only +500° F max. A None B None C Agency Approval 24 VDC EP – FM, CSA, CENELEC None 240 VAC EP – FM, CSA IS/NI – FM, CSA, CENELEC 120 VAC EP – FM, CSA D None 24 VDC G Analog 24 VDC EP – FM, CSA, CENELEC I Analog 24 VDC IS/NI – FM, CSA, CENELEC L Analog N Analog 240 VAC EP – FM, CSA 24 VDC IS/NI – FM, CSA Digital J 9 Digital H None 2 None 3 None K Analog 5 Analog 6 Analog 120 VAC EP – FM, CSA 24 VDC EP – FM, CSA, CENELEC 24 VDC EP – FM, CSA 240 VAC EP – FM, CSA 24 VDC EP – FM, CSA 240 VAC EP – FM, CSA 120 VAC 120 VAC EP – FM, CSA EP – FM, CSA 7 Digital 24 VDC EP – FM, CSA Q None 24 VDC IS/NI – FM, CSA, CENELEC W None 24 VDC EP – FM, CSA, CENELEC T Analog 24 VDC IS/NI – FM, CSA, CENELEC X Analog Digital 4 24 VDC EP – FM, CSA, CENELEC 24 VDC EP – FM, CSA, CENELEC 24 VDC IS/NI – FM, CSA 24 VDC EP – FM, CSA Z Digital Q None R None 120 VAC S None 240 T Analog U Analog 120 VAC V Analog 240 4 Digital 24 VDC VAC 24 VDC VAC EP – FM, CSA EP – FM, CSA EP – FM, CSA EP – FM, CSA EP – FM, CSA EP – FM, CSA 120 & 240 VAC available on Analog unit only (ninth digit Z) Digital meter available on Digital Hart compatible unit only (ninth digit S) REMOTE CONNECTING CABLE Up to +400° F, specify cable 037-3218-0XX, where last two digits are cable length in feet from 1-75 feet. Last 3 Digits of Model Number Up to +500° F, specify cable 037-3220-0XX, where last two digits are cable length in feet from 1-75 feet. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 46 4.9.3 Models for Non-Steam applications (max. 600 lbs.) DESIGN TYPE E 6 Standard design EZ Modulevel MOUNTING AND CHAMBER MATERIALS flanged top cage side/bottom cage side/side tank connection chamber material steel 316 SS steel 316 SS steel 316 SS 1 2 3 4 5 6 code Adjustable 8' hanger cable (p/n 32-3110-001), required when distance from flange face to top of displacer must be greater than 5.00" SPECIFIC GRAVITY AND PROCESS TEMPERATURE HT integral transmitter mounting integral remote or remote +400° F (+200° C) +500° F (+290° C) +600° F (+315° C) maximum temperature 1 7 7 0.23 - 0.54 specific gravity 2 8 8 0.55 - 1.09 specific gravity 3 9 9 1.10 - 2.20 specific gravity Consult factory for lower specific gravity design TANK CONNECTION Top mounted connection type External cage models ANSI HEAD Flange rating ANSI Cage rating RF 150 lbs RF 300 lbs RF 600 lbs Size RF 150 lbs RF 300 lbs RF 600 lbs Size / Type G3 G4 G5 3" C5 C7 C9 11⁄2" NPT H3 H4 C8 C0 11⁄2" S.W. K4 4" 6" C6 K3 H5 K5 P3 P4 P5 11⁄2" flanged D5 D7 D9 2" NPT LEVEL RANGE 14 32 356 813 A B D6 D8 D0 2" S.W. Q3 Q4 Q5 2" flanged 48 1219 60 1524 72 1829 84 2134 96 2438 108 2743 120 3048 inches mm C D E F G H I code TRANSMITTER – ELECTRONICS (see opposite page) E 6 47 complete order code for Standard EZ Modulevel transmitter 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) TRANSMITTER TYPE & MOUNTING E Electronic Integral Mount G Electronic Remote Mount R Electronic High-temp Integral Mount TRANSMITTER OUTPUT Z 4-20 mA only (Analog) S 4-20 mA with HART (Digital) HART communicator sold separately 24 VDC, 120 VAC or 240 VAC 24 VDC only TRANSMITTER CONFIGURATION AND ACCESSORIES Code Display Input Voltage A Integral Mount Fourth Digits 1, 2, 3 only Eighth Digit E only +400° F max. None B None None 240 VAC EP – FM, CSA None 24 VDC IS/NI – FM, CSA, ATEX Analog 24 VDC EP – FM, CSA, ATEX I Analog 24 VDC IS/NI – FM, CSA, ATEX L Analog N Analog Digital J None Remote Mount 2 None Fourth Digits 7, 8, 9 only 3 None K Analog Eighth Digit G only 5 Analog 6 Analog 120 VAC EP – FM, CSA 24 VDC IS/NI – FM, CSA 24 VDC EP – FM, CSA, ATEX 24 VDC EP – FM, CSA 240 VAC EP – FM, CSA 24 VDC EP – FM, CSA 240 VAC EP – FM, CSA 120 VAC 120 VAC EP – FM, CSA EP – FM, CSA 7 Digital 24 VDC EP – FM, CSA Q None 24 VDC IS/NI – FM, CSA, ATEX W None 24 VDC EP – FM, CSA, ATEX T Analog 24 VDC IS/NI – FM, CSA, ATEX X Analog 24 VDC EP – FM, CSA, ATEX 24 VDC EP – FM, CSA, ATEX 24 VDC IS/NI – FM, CSA 24 VDC EP – FM, CSA Digital 4 +600° F max. Z Digital Q None R None 120 VAC 240 VAC Fourth Digits 7, 8, 9 only S None T Analog Eighth Digit G only U Analog 120 VAC V Analog 240 4 Digital 24 VDC +600° F max. EP – FM, CSA 240 VAC Eighth Digit R only Remote Mount EP – FM, CSA D H Fourth Digits 7 ,8, 9 only G Digital HT-Integral Mount 120 VAC Agency Approval EP – FM, CSA, ATEX C 9 +500° F max. 24 VDC 24 VDC VAC EP – FM, CSA EP – FM, CSA EP – FM, CSA EP – FM, CSA EP – FM, CSA EP – FM, CSA 120 & 240 VAC available on Analog unit only (ninth digit Z) Digital meter available on Digital Hart compatible unit only (ninth digit S) ATEX EP approval requires modification of unit. Model must be “X’d” for a heavy-wall e-tube. REMOTE CONNECTING CABLE Up to +500° F, specify cable 037-3218-0XX, where last two digits are cable length in feet from 1-75 feet. Last 3 Digits of Model Number Up to +600° F, specify cable 037-3220-0XX, where last two digits are cable length in feet from 1-75 feet. 48-618 ES/EZ Modulevel Displacer Level Transmitter (Top Hat Assembly Design) 48 ASSURED QUALITY & SERVICE COST LESS Service Policy Return Material Procedure Owners of Magnetrol/STI controls 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. Controls returned under our service policy must be returned by Prepaid transportation. Magnetrol/STI will repair or replace the control at no cost to the purchaser (or owner) other than transportation if: So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorization” (RMA) number be obtained from the factory, prior to the material's return. This is available through Magnetrol/STI’s local representative or by contacting the factory. Please supply the following information: 1. Returned within the warranty period; and 2. The factory inspection finds the cause of the claim to be covered under the warranty. If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labor 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, labor, direct or consequential damage will be allowed. 1. 2. 3. 4. 5. Company Name Description of Material Serial Number Reason for Return Application Any unit that was used in a process must be properly cleaned in accordance with OSHA standards, before it is returned to the factory. A Material Safety Data Sheet (MSDS) must accompany material that was used in any media. All shipments returned to the factory must be by prepaid transportation. All replacements will be shipped F.O.B. factory. NOTE: See Electrostatic Discharge Handling Procedure on page 1. NOTE: If unit needs to be returned, the displacer must be secured to prevent damage in transit. 5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4000 • Fax 630-969-9489 • www.magnetrol.com 145 Jardin Drive, Units 1 & 2 • Concord, Ontario Canada L4K 1X7 • 905-738-9600 • Fax 905-738-1306 Heikensstraat 6 • B 9240 Zele, Belgium • 052 45.11.11 • Fax 052 45.09.93 Regent Business Ct r., Jubilee Rd. • Burgess Hill, Sussex RH15 9TL U.K. • 01444-871313 • Fax 01444-871317 5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4028 • Fax 630-969-9489 • www.sticontrols.com Copyright © 2007 Magnetrol International, Incorporated. All rights reserved. Printed in the USA. BULLETIN: 48-618.4 EFFECTIVE: August 2007 SUPERSEDES: October 2002