Installation and Operating Manual Volume measurement of bulk solids and powders in any size or shape of storage vessel Contents 1 ABOUT THIS DOCUMENT ........................................................................................ 5 1.1 1.2 1.3 2 CONTOURᵀᴹ OVERVIEW ......................................................................................... 7 2.1 2.2 2.3 2.4 3 LOCATION AND POSITIONING GUIDELINES ....................................................................... 9 SCANNER ORIENTATION ............................................................................................ 11 SITE PREPARATIONS ................................................................................................. 12 ASSEMBLY AND MOUNTING....................................................................................... 13 WIRING ................................................................................................................. 16 FIRST-TIME ACTIVATION ...................................................................................... 20 4.1 4.2 4.3 4.4 5 THEORY OF OPERATION .............................................................................................. 7 WIDE APPLICATION RANGE ......................................................................................... 7 ADVANTAGES............................................................................................................ 7 MODELS .................................................................................................................. 8 PHYSICAL INSTALLATION ........................................................................................ 9 3.1 3.2 3.3 3.4 3.5 4 SYMBOLS IN USE ........................................................................................................ 5 FOR YOUR SAFETY ...................................................................................................... 5 STORAGE AND TRANSPORT........................................................................................... 6 LOCAL USER INTERFACE ............................................................................................ 20 SWITCHING ON THE SCANNER ..................................................................................... 21 FIRST-TIME ACTIVATION STEPS SUMMARY .................................................................... 22 INITIAL SETUP PROCEDURE......................................................................................... 22 DIFFERENT CONNECTION METHODS .................................................................... 23 5.1 5.2 5.3 5.4 5.5 4-20 MA CONNECTION ............................................................................................ 23 HART® COMMUNICATION ........................................................................................ 23 RS485 COMMUNICATION ......................................................................................... 24 COMMUNICATION USING THE CONTOUR CONNECT ..................................................... 24 TCP/IP COMMUNICATION ........................................................................................ 24 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 3 APPENDIX A: ONBOARD CONFIGURATION .................................................................. 26 OUTPUT SETTINGS .............................................................................................................. 26 DISPLAY SETTINGS .............................................................................................................. 28 DEVICE INFO...................................................................................................................... 29 DEVICE RESET .................................................................................................................... 30 APPENDIX B: ACCESSORIES .......................................................................................... 31 INSTALLATION FLANGES ....................................................................................................... 31 NECK EXTENSIONS .............................................................................................................. 33 HEAD-BODY SEPARATION..................................................................................................... 34 CABLE GLANDS .................................................................................................................. 35 APPENDIX C: MAINTENANCE ....................................................................................... 36 APPENDIX D: RECOMMENDED TOOLS ......................................................................... 37 APPENDIX E: SPECIFICATIONS...................................................................................... 38 TECHNICAL DATA ................................................................................................................ 38 DIMENSIONS ..................................................................................................................... 41 APPENDIX F: STANDARDS & APPROVALS .................................................................... 43 4 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved About this Document ● Symbols in use 1 About this Document This operation manual provides detailed product related information, installation, setup and operation instructions for CONTOUR models 3DS-S, 3DS-M and 3DS-V. The manual is designed for trained personnel. Please read it entirely and carefully before unpacking and installation of the products. 1.1 Symbols in use The following symbols indicate different sections of additional information as follows: IMPORTANT: An indication for additional information, tips, hints or an indication of helpful additional knowledge. WARNING: Indication of a potentially dangerous situation, which could result in serious injury to persons and/or damage to the CONTOUR. EX APPLICATION: An indication of special instructions relevant to installations in hazardous locations. 1.2 For your safety Authorized personnel All operations described in this manual must be carried out by authorized, trained personnel only. For safety and warranty reasons, any internal work on the scanners must be carried out by manufacturer-authorized personnel only. Warning about misuse Inappropriate or incorrect use of the scanner may result in hazards and application-specific malfunctioning such as vessels overfill or damage to system components through incorrect mounting or adjustments. If the CONTOUR is used in a manner not specified in this manual, the protection provided by the CONTOUR will be impaired. CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 5 About this Document ● Storage and transport General safety instructions The CONTOUR is a high-tech device requiring strict observance of standard regulations and guidelines. The user must strictly follow the safety instructions in this operating manual. Local and national electrical codes and all common safety regulations and accident prevention rules should be considered during installation as well. CE conformity The CONTOUR conforms to CE's EMC and NSR standards. CE conformity is as follows: EMC NSR (73/23/EWG) EN 61326-1: 2006 CISPR 11: 2003 Class A IEC 61000-4-2: 2001 Air Discharge, 8kV IEC 61000-4-3: 2002 80-1000MHz, 1V/m; 1.4-2GHz, 1V.m; 2.0-2.7GHz, 1V/m IEC 61000-4-4: 2004 Power Lines: 1kV; Signal Lines: 0.5kV IEC 61000-4-6: 2004 0.15-80MHz 1VRMS, 80% A.M. by 1kHz Power & Signal Lines EN 61010-1: 2001 FCC conformity (EMC) FCC Part 15, Sub-part B, Class A. Safety information for Ex Areas EX-AREAS: Please note the Ex-specific safety information for installation and operation in Ex areas. These safety instructions are part of the operating instructions manual that comes with Ex-approved scanners. WARNING: Substitution of components may impair Intrinsic Safety. WARNING: For preventing ignition of flammable or combustible atmospheres, read, understand and adhere to the manufacturer’s live maintenance procedures. 1.3 Storage and transport The scanner is protected by special packaging during transport, and is guaranteed to handle normal loads during transport. 6 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved CONTOURᵀᴹ Overview ● Theory of Operation 2 CONTOURᵀᴹ Overview 2.1 Theory of Operation ® The MAGNETROL CONTOUR™ is the only device available which delivers accurate measurement of bulk solids and powders – regardless of material type, product characteristics, storage silo type, size, bin or container, and harshness of the storage environment. The CONTOUR incorporates MAGNETROL's unique dust-penetrating technology to achieve an unrivalled degree of process measurement and inventory control. The CONTOUR includes an array of three antennas that generate low frequency acoustic signals and receive echo signals from the contents of the silo, bin, or other container type. Using these antennas, the unit measures not only the time/distance of each echoed signal but also its direction. The built-in Digital Signal Processor digitally samples and analyses the echoed signals and produces accurate measurements of the level, volume, and mass of the stored contents, and generates a 3D representation of the position and form of the material within the container for displaying on remote computer screens. 2.2 Wide Application Range The CONTOUR measures practically any kind of solid material, stored in a variety of containers, including large open bins, bulk solid storage rooms, stockpiles and warehouses, mapping loads that randomly form over time inside silos, and many other challenging applications that were not possible until now. The sensor can measure ranges of up to 70m (230ft) and generate 3D mapping of the material surface. 2.3 Advantages Service and maintenance-friendly - Non-contact measuring principles, the CONTOUR is highly easy to service and maintain The only available device for solid volume measurement applications The only available device that measures minimum and maximum levels Suitable for measuring all solid materials (including ones with low dielectric constants) Operates in dusty and moisture environments Profiles of adhesions of materials to vessel walls Self-cleaning antenna CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 7 CONTOURᵀᴹ Overview ● Models 3-Dimensional mapping visualization tool for filling-point choosing assistance (in vessels with multiple filling points The most reliable sensor available - includes 3 transmitters and 3 receivers 2.4 Models The CONTOUR line of products is consisted of three models: 3DS-S, 3DS-M and 3DS-V. Model 3DS-S The 3DS-S model determines the average level of the stored contents and average distance from the scanner to the surface of the material. Based on a 30° beam angle, The S model is ideal for small and narrow vessels of up to 4m (13ft) in diameter. Model 3DS-M The 3DS-M model yields highly accurate readings of level and volume. It is appropriate for large vessels of up to 15m (50ft) in diameter and at least twice as high (30m / 100ft), open bins and stockpiles. It is based on a 70° beam angle. The M model also presents the minimum and maximum Level/Distance measurements along with the calculated average. Model 3DS-V The 3DS-V model is identical to the 3DS-M model, with the additional capability of generating a 3-dimensional representation of the stored contents on a remote computer. This feature is highly useful for mapping build-up loads that form randomly over time and other irregularities. All three models are available in various modes, such as ATEX approved, FM approved, and non-ATEX (for more information, see Approvals on page 40) and also available with neck extension (see Appendix B: Accessories: Neck on page 33) and compatible with the Head-Body separation kit. The CONTOUR is available in two temperature ranges: The CONTOUR 3DS-xxxx-Axx-xx-xxx is compatible in applications where the maximal temperature in the surroundings inside the vessel is up to 85° C (185° F). The CONTOUR 3DS-xxxx-Hxx-xx-xxx is compatible in applications where the maximal temperature in the surroundings inside the vessel is up to 180° C (356° F). All references in this manual to the CONTOUR can be referred to as CONTOUR or simply the scanner, if nothing else is mentioned it applies to any of the scanner models. 8 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Physical Installation ● Location and positioning guidelines 3 Physical Installation This chapter describes the necessary steps for proper installation of the CONTOUR beginning with important pre-installation considerations such as environmental conditions, correct positioning and orientation, through the mounting and configuration process. 3.1 Location and positioning guidelines When choosing the proper location for the CONTOUR, the installer should consider every aspect of the vessel and contained materials, including the silo or vessel dimensions, type of material and angle of repose, locations of filling and emptying points, maximum level of material, internal construction and moving part and any other consideration which may possibly affect the scanner performance. MAGNETROL strongly recommends installing the CONTOUR according to the CONTOUR Locator PC software for properly choosing installation location and positioning. In case of no satisfying software solution, please contact CONTOUR Customer Support for assistance with the positioning. Moisture and water condensation Use the recommended cable gland and tighten the cable connection. For additional protection against moisture, lead the connection cable downward in front of the cable entry. Rain and condensation water can thus drain off. This applies mainly to mounting in areas where moisture is expected (e.g., by cleaning processes), or on cooled or heated vessels. Measuring range The measuring range is set in the scanner and defined by silo dimensions and the full and empty calibration levels. These levels set the 100% and 0% values relatively. The scanner measurements are calibrated to the top of the body. If the scanner is lowered, or mounted with neck extension or head-body separation, it is important to adjust all measurements to the top of the body. NOTE: If the material level reaches the antenna, build up could form inside the horn over time and cause measurement errors or damage to the membranes. NOTE: the CONTOUR has a 500mm (20”) of dead zone (or blanking zone). CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 9 Physical Installation ● Location and positioning guidelines Pressure The process fitting must be sealed in the case of a low pressured vessel. Before usage, verify that the sealing material is resistant to the stored medium. The maximum allowed pressure (stated in page 38: Appendix E: Specifications) is indicated on the type label of the sensor. Installation location Choosing the proper installation location for the CONTOUR is an important part of the installation process. A wrong location may result in erroneous measurements or loss of performance. The usage of the CONTOUR Locator Software is recommended for finding the optimal location, which is based on various parameters. The following factors must be taken into consideration while choosing the installation position: vessel dimensions, filling and emptying point locations, internal structure or support and other restrictions related to vicinity to noisy devices (such as electrical motor) and any other element which may affect the proper operation of the scanner. IMPORTANT: When mounting the CONTOUR, do not install the scanner near the vessel wall. The installation must consider the vessel dimensions. Installing the scanner near the side wall will result in bad performance and will not be supported by CONTOUR. Installing the CONTOUR at the center of the vessel is not recommended, since the perfect symmetry from all sides toward the scanner may affect the echoes distinction. 10 The scanner cannot be mounted at a distance lower than 500mm (20") from the wall. When choosing the installation location, consider the filling and emptying points. Use the CONTOUR Locator PC software for choosing a proper location. CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Physical Installation ● Scanner Orientation 3.2 Scanner Orientation Mounting direction Mounting of the CONTOUR at a specific direction is important. The ridge on the horn body, and the notch on the top of the thread (representing antenna no.1) should be directed toward the center of the vessel. The 00 label location Mounting direction. 00 indication toward vessel center Standpipe mounting When mounting the scanner using a standpipe it should be assembled and positioned at a height that leaves at least 10mm (0.4”) out of the standpipe, for the antenna end protrudes, as shown in the figure to the right. IMPORTANT: Any obstruction as well as rails, frames or support beams should never interfere with the acoustic beam transmitted and received, as shown in the figure to the right. This comment applies to all CONTOUR models including S model. Wrong CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Correct 11 Physical Installation ● Site Preparations Inflowing material Do not mount the scanners in or above the filling stream, not too far from the stream, and not in the direction of the filling stream in case it is diagonal, to avoid damage to the scanner from the flowing material. The scanner should be located with a clear line of sight to the top of the material at high levels, not to be affected by the filling stream or the noise it creates. Fitting The fitting area should be prepared to maintain the horns/antennas vertically positioned to the ground, as shown at right. Wrong 3.3 Correct Site Preparations IMPORTANT: The site preparations described in this section must be complete and verified prior to installation. For optimal installation, ensure that the CONTOUR can be positioned and fitted according to the guidelines described in the beginning of this chapter. For a list of items recommended to prepare before installing the CONTOUR, refer to page 37: Appendix D: Recommended Tools. Before installing, make sure the following preparations have been completed. Power 12 Connecting the CONTOUR chassis to the facility grounding is important for protection. A 24VDC (1.5 Watt) power supply must be prepared and ready to use near the scanner mounting location. The CONTOUR is a 4-Wire device. The voltage supply and data output (4-20 mA) are carried along two separated two-wire connection cables. CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Physical Installation ● Assembly and Mounting Communications Route communication cables in proper conduits and use a proper cable type. The cable used for RS-485 should be of twisted-pair type, shielded, with 120 Ohm impedance and approved for RS-485 communications. The cable used for 4-20 mA should be rated for analog signals, twisted-pair, low resistance and shielded. 3.4 Assembly and Mounting Package Contents The supplied package includes: CONTOUR sensor Documentation CD with the CONTOUR Configurator software and marketing materials Cable glands accessory kit Ex-specific safety instructions (with Ex versions) Certificates if applicable Included components The CONTOUR includes the following components: CONTOUR Body CONTOUR Head CONTOUR Body: Includes three antennas, transducers and temperature sensor. The flange is mounted on the body and tightened to it. CONTOUR Head: Includes the electronic board with LCD display and all wiring connections. The Head is mounted on the body. CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 13 Physical Installation ● Assembly and Mounting Flange preparation Prior to the installation of the CONTOUR, an installation flange should be prepared. The flange must have a 52mm (2.05”) hole for the scanner body thread insertion. CONTOUR provides two types of standard flanges. Please refer to page 31: Appendix B: Accessories for flange specifications. Installing the Flange 1 Verify existence of the O-Ring on the neck tube remains in place as shown: 2 Use an adjustable 18" wrench to untighten and remove the nut from the neck tube. 3 Place flange over the neck tube, insert until placed as shown: 4 Replace the nut and tighten it over the neck tube to the flange, using an adjustable 18" wrench. Make sure the scanner is well tightened to the flange, for vibrations prevention and proper sealing. When mounting the scanner body and flange to the silo standpipe make sure the scanner is facing the center of the silo as described in Scanner Orientation on page 11. Installing the Scanner Head 1 14 Unpack the scanner head. Untighten the four screws of the housing rear panel using a 4mm hex key, and remove the rear panel. The screws are of captive type and will not fall off. CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Physical Installation ● Assembly and Mounting 2 Remove the cable clamp located at the bottom inside the scanner as shown. 3 Gently insert the antenna cable through the scanner head. Make sure not to damage the (white) cable connector. This connector connects the transmission signal from the electronic board to the transducers. Damage to the connector or to the wires will result with malfunctioning operation of the scanner. 4 Insert the scanner head onto the neck tube. IMPORTANT: When inserting the scanner head onto the neck tube, make sure to push the head all the way down until it fully contacts the top of the neck tube. NOTE: It is recommended to lubricate the O-Ring on the neck tube prior to installing the scanner head. This makes it easier to insert and properly locate the scanner head over the tube neck. NOTE: The CONTOUR head may be installed in six different positions. 5 Tighten the front screw using a 4mm hex key and a 13mm wrench. 6 Replace the cable clamp back to position, between the antenna cable and the electronic board. CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 15 Physical Installation ● Wiring 7 Carefully connect the antenna cable connector back to the electronic board as shown. This connector allows the transmission signal from the electronic board to the transducers. Damaged connector or wires will result with malfunctioning operation of the scanner. 8 Leave the scanner open at this stage in order to complete the wiring. 3.5 Wiring The CONTOUR can be connected in different modes and configurations for different external systems such as PLC or DCS and communications on RS485, ModBus, and HART and also to RS485 bus converting adapters to communication gateways such as CONTOUR Connect for GMS or GPRS data relay and TCP/IP gateway. For in-depth details and explanations on wiring and communication, refer to page 23: Different Connection Methods. Use 8-13mm (20-24 AWG) diameter cables to ensure proper and effective sealing of the cable gland entry opening. Select a cable suitable for application (indoor or outdoor) and safety certified according to national regulations. Communications NOTE: If electromagnetic interference is expected, usage of a screened and twisted wired cable is recommended for the signal lines, which should be connected to the ground reference. CAUTION: Always observe the following safety instructions: Connections must be made only in the complete absence of line voltage. If over-voltage is expected, overvoltage arresters should be installed. Use only a safety-certified power supply with dual insulation between the primary and output for powering the unit. The power supply output rating must be limited to 20-32VDC, 1A for a single CONTOUR device, and not to be connected to a DC distribution network. In hazardous areas you should take note of the appropriate regulations, conformity and type of approval certificates of the sensors and power supply units. Refer to the printed safety manual provided with the ATEX/FM approved CONTOUR. 16 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Physical Installation ● Wiring Power Supply For power supply specifications, refer to page 39: Appendix E: Specifications for full details. 4-20 mA/HART 4-wire: The power supply and signal current inputs must be carried over two separated pairs. Connection Procedure 1 Untighten the four screws of the scanner housing rear panel and remove the rear panel. The screws are of captive type and will not fall off. 3 Insert the cable into the scanner through the cable gland and entry opening. 4 Remove approximately 10cm (4 inches) of the cable mantle and strip approximately 1cm (0.4 inches) the edge of each conductor. 5 Open the terminal block screws located inside the scanner housing using a thin flat (A3/32") screwdriver. Insert the wire edges into the terminals according to the wiring plan detailed next, and fasten the terminal screws. Gently pull the wires to ensure they are securely connected. 2 Loosen the compression nut of the cable gland entry. CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 17 Physical Installation ● Wiring 6 Terminal block wiring plan. The tables below describe the connections. Refer to the following Local Connection and Multi-Drop Connection drawings for details. Left Connector Description Ports 7 PS IN + - Feed in power supply 20 – 32 VDC 4-20 mA - + 4–20 mA / HART Communications terminals Right Connector Description RS-485 / Modbus RTU RS-485 Communications + terminals Ports Connect the external ground terminal with potential equalization to the external ground terminal of the scanner, located as shown. An internal cable grounding connection is also possible using the inner connection as shown. 8 18 Tighten the compression nut over the cable gland entry opening. Verify that the sealing ring completely wraps the cable. IMPORTANT: Gland compression nut tightening provides good sealing. It is necessary for the scanner to maintain IP67 requirements, and for extended scanner lifetime. CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Physical Installation ● Wiring 9 Attach the rear panel back to position at the rear of the scanner housing and tighten the four screws to secure it in place, using a 4mm hex key. The CONTOUR is ready for configuration. IMPORTANT: Use direct connection between the scanners and the plant (PLC/SCADA). IMPORTANT: For a remote connection, use the CONTOUR Connect remote connection module or a local PC/Laptop computer as detailed in the following drawing. CAUTION: Do not connect power supply to the 4-20 mA or to the RS485 ports. The CONTOUR is not a loop powered device but a 4W device. WARNING: The 4-20 mA / HART lines should NOT be connected using multidrop. CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 19 First-Time Activation ● Local User Interface 4 4.1 First-Time Activation Local User Interface Configuration and adjustment of the CONTOUR must be done using the CONTOUR Configurator software, with the optional addition of GSM/GPRS communications using CONTOUR Connect. For detailed configuration procedure, refer to CONTOUR Configurator Software Manual and the CONTOUR Connect Manual. The CONTOUR User Interface The user interface includes a 4-lines LCD display and the four keys located on the front side of the device, marked ESC, +, - and E. Key functions are as follows: Navigates back within a function menu. Continuous 3 second press exits to the default screen. Navigates upwards in the navigation list. Navigates right within a function. Navigates downwards in the navigation list. Navigates left within a function. Navigates to the right when within a function group. Stores a value once configured. The following, simultaneous key-press combinations perform special functions as follows: Increases / decreases the LCD display intensity. Press and hold the button, then use the decrease the intensity of the display. 20 or buttons to increase or CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved First-Time Activation ● Switching on the scanner Operating menu The operating menu consists of two levels: Function groups: The scanner functions are organized groups. Available function groups are: Output Settings, Display Settings, Device Info and Device Reset. Functions: Each function group consists of one or more functions. The functions may perform different actions or modify scanner setting parameters. Numerical values can be entered, and parameters can be selected and saved. 4.2 Switching on the scanner Once the CONTOUR is connected to the power supply and switched on, it initializes a selftest which lasts for approximately 30 seconds. When the initialization is complete, the following content is displayed allowing selecting a language and distance units: 1 The unit is turned on and is initializing for about 30 seconds, during which the display remains blank. 2 The version screen appears: The value in <> describes the scanner model: S, M, or V. FW Ver: Firmware version HW Ver: Hardware version Init. Please wait... CONTOUR <V> FW Ver: 03.00.00 HW Ver: 020 3 Once the startup process is complete, the following screen appears showing the current distance measurement. The forth line displays the scanner tag name. By default, when the name has not been configured yet, this line remains empty. Press to return to the Main Menu. Press for 3 seconds to switch to the basic measurement screen. Measured Parameter 3.45m Dist. ██████████████████████ test CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 21 First-Time Activation ● First-time Activation Steps Summary 4.3 First-time Activation Steps Summary Here is a list of all the actions taken during the first-time activation of the scanner: 1 Connect power to the scanner. Following about 30 seconds duration, the version screen appears. 2 After a little while, the display switches to the current distance measurement screen. 3 Press to enter the Main Menu. 4 In the Main Menu, choose Output Settings, by pressing , and set the polling address. Following completion of the first-time activation tasks, use the CONTOUR Configurator software to establish the connection and to make all the necessary configurations. 4.4 Initial Setup procedure Setting the scanner address The sensor address setting is mandatory when multiple sensors are connected over a RS485-Multidrop (Daisy Chain). Addresses must be set prior to parameter adjustment. 22 1 At the Main Menu, scroll down to Output Settings option using the key and press to switch to the Polling Address configuration screen. 2 Use the key to switch between the two digits. Use the key to modify the value. The default polling address is 00. The polling address ranges from 00 to 63. Press to store the modified address. Main Menu →Output Settings Display settings Device info Polling Address 00 40 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Different Connection Methods ● 4-20 mA Connection 5 Different Connection Methods Using the CONTOUR Configurator for communicating with the CONTOUR allows the user to choose several communication types: RS485, HART, GSM, GPRS and TCP/IP, for more information and details regarding the communications, refer to the CONTOUR Configurator Software Instructions manual. 5.1 4-20 mA Connection The CONTOUR outputs the % of Volume as set in the configuration and between the Full and Empty calibration levels. The 4-20 mA current output is available through ports 3 and 4 of the left green connector (as shown in the drawing to the right). Ports 3 and 4 are the negative and positive poles, respectively. The 4-20 mA line is connected directly from the scanner mounted on the vessel to the PLC/DCS/Display or any other device (as shown below). IMPORTANT: This type of connection is active and not passive, hence the CONTOUR is the active module and the PLC should be the passive module. 5.2 HART Communication The CONTOUR supports HART protocol over the 4-20 mA wires. By connecting a 250 Ohm resistor on one of the wires and a HART modem and communication to and from the scanner can be established from the CONTOUR Configurator software. CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 23 Different Connection Methods ● RS485 Communication 5.3 RS485 Communication The CONTOUR includes an RS485 communication port. This type of connection allows a computer to communicate with the scanner. It also allows a multiple scanner connection on the same RS485 bus and communication with all scanners using a single connection to the computer running the software. In both single or multi scanner connection, it is required to use an appropriate cable rated for RS485, the cable should be of twisted pair, has 120 Ohm impedance and shielded. The total length of the cable should not reach 1000m (3280ft). In case of a multi scanner connection, all scanners must be connected in parallel mode in the RS485 ports. Hence, all the '+' (positive) ports of the RS485 should commonly be connected and all the '-' (negative) ports of the RS485 should be connected commonly. The connection must be of Daisy-Chain type and have at each of the far ends of the chain 120 Ohm resistor (such resistor is provided with the scanner). Each Scanner must be configured with a different polling address. 5.4 Communication using the CONTOUR Connect In both single and multiple scanner installation, the CONTOUR can be connected to a GSM/GPRS modem in order to transfer the data over the cellular network. The CONTOUR Connect should be connected on the RS485 bus as any of the scanners, including cable and resistors as needed. For further details on wiring and establishing a connection, refer to the CONTOUR Connect manual and to the CONTOUR Configurator Software Instructions manual. NOTE: In such communication mode, only one computer running the CONTOUR Configurator software can be connected to the scanners. 5.5 TCP/IP Communication The RS485 bus can be converted to TCP/IP communication. TCP/IP to RS485 converter installation should be done as with any scanner, including the resistors and daisy-chain considerations. 24 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Different Connection Methods ● TCP/IP Communication NOTE: Consult with CONTOUR Technical Support team for assistance on the proper TCP/IP converter to use. CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 25 Appendix A: Onboard Configuration ● Output Settings Appendix A: Onboard Configuration Output Settings This function defines the scanner Polling Address, and further to Measured Parameter settings. Navigate down at the Main Menu screen using the key, select the Output Settings option and press to enter the Output settings menu. The first screen of Output Settings allows setting the scanner polling address. Select the proper Polling Address using the / keys, and press to proceed. Exiting this menu automatically switches to the Measured Params. menu. Polling Address 00 40 The following functions set displayed measurement units for Distance, Level, Volume, Temperature and their maximum allowed values. As well, it allows reading the current measurements for Analog Output, SNR and Temperature. This menu is not accessible from the main menu. It will appear following completion of the Output Settings or the Display Settings menus. Navigate up/down the menu using the / keys, and Press to select the desired option. 1 26 Measurement Distance settings Select the Distance option and press proceed. to Measured Params. →Distance Level Volume 50 Measured Params. →Distance Level Volume 50 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Appendix A: Onboard Configuration ● Output Settings 2 Select the desired Distance Unit using the / keys, and press to store the option and proceed. Distance Unit →m cm mm 62 3 This menu defines how the Measured Distance is displayed: by a minimum value, a maximum value or an average value. Select the desired option using the / keys. Press to store and proceed. Meas. Distance →Min Avg Max. 51 4 Measurement Level settings Meas. Level →Min Avg Max. 52 Measured Params. Distance Level →Volume 50 This menu defines how the Measured Level is displayed: by a minimum value, a maximum value or an average value. Select the desired Meas. Level option using the / keys. Press to store and proceed. Measurement Volume Select the Volume option from the Measured Params. Menu. Press to proceed. The Measured Parameter screen is shown, displaying the Volume percentage. Analog Output Select the Analog Output option from the Measured Params. Menu. Press to proceed. The Measured Parameter screen is shown, displaying the Analog Output value in mA. Measured Parameter 100% Volume ██████████████████████ test Measured Params. Level Volume →Analog Output 50 Measured Parameter 20.0mA Ang. Out. ██████████████████████ test CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 27 Appendix A: Onboard Configuration ● Display Settings SNR Select the SNR option from the Measured Params. Menu. Press to proceed. The Measured Parameter screen is shown, displaying the SNR value in dB. Temperature Select the Temperature option from the Measured Params. Menu. Press to proceed. Select the desired temperature measurement units using the / keys, and press to store and proceed. The Measured Parameter screen is shown, displaying the measured temperature value using the selected units. Measured Params. Volume Analog Output →SNR 50 Measured Parameter 8.0dB SNR ██████████████████████ test Measured Params. Analog Output SNR →Temperature 50 Temperature Unit →°C °F 64 Measured Parameter -49.6C Temp. ██████████████████████ test Display Settings This function allows setting a Tag Name for the current scanner. At the Main Menu, navigate down using the key to select Display Settings, and Press to proceed. 28 Main Menu Extended Calibr. Output Settings →Display Settings CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Appendix A: Onboard Configuration ● Device Info Set the Tag name for the current scanner. Switch between the digits using the key and modify the selected digit using the keys. Press to store the option. The display will switch to the Measured Params menu. Tag Name 60 test Device Info This function allows setting a Tag Name for the current scanner. At the Main Menu, navigate down using the to select Display Settings, and Press proceed. 1 2 3 4 key to Main Menu Output Settings Display Settings →Device Info The screen displays the scanner Serial Number. This is a read-only identifier which is unique to each scanner. Press to proceed. Serial Number The screen displays the Software Version of the scanner. Press to proceed. Software Version The screen displays the Firmware Version of the scanner. Press to proceed. Firmware Version The screen displays the Hardware communications interface information for the scanner. Press to proceed. HW Interface 4...20 mA/HART Modbus RS485 70 709001234 71 03.00.37 72 020 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 73 29 Appendix A: Onboard Configuration ● Device Reset 5 The screen displays the Device Type: S, M or V. Press to exit and switch back to the Main Menu. Device Type CONTOUR <V> 74 Device Reset This function allows selection of different reset options: Reset, Reset to Factory settings and Reset to Lab settings. Use with caution! At the Main Menu, navigate down using the key to select Device Reset, and Press to proceed. 30 Main Menu Display Settings Device Info →Device Reset 1 The Reset menu allows selection of the required Reset option. The Reset option brings the scanner to power-up mode and clears measurements. The Reset to Factory option will reset all parameters to their default values as well as performing the Reset option. The Reset to Lab option is password protected and reserved for factory use. Select the desired Reset option using the key and press to proceed. Reset →Reset Reset to Factory Reset to Lab 80 2 On selecting Reset or Reset to Factory, a confirmation request screen appears. Select Yes? to proceed with the reset and restart process, or No? to cancel reset. Press to proceed and go back to the main menu. Reset the device? →Yes? No? 81 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Appendix B: Accessories ● Installation flanges Appendix B: Accessories Installation flanges The following flanges are available for the CONTOUR. Flange type DN200 Flange thickness: 6.5mm (0.25"). CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 31 Appendix B: Accessories ● Installation flanges Flange type DN250 Flange thickness: 6.5mm (0.25"). Flange preparation and installation guidelines 32 The transducer case must fit in the hole in the vessel. If this cannot be reached, use alternative solutions such as neck extension or lowering the scanner inside the vessel. The widest part of the scanner is the transducers case: 193.3mm (7.61") Insert the flange onto the neck tube Tighten the nut to the neck thread using an 18" adjustable wrench Note: The diameter of the hole in the center of the flange center is 52mm (2.1") CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Appendix B: Accessories ● Neck Extensions Neck Extensions The purpose of using the neck extensions is to lower the scanner body below obstructions, such as standpipes, support beams or other construction which might block the acoustic signals. Neck extensions are available in 2 sizes: 30cm (11.81") 50cm (19.68") The neck extension must be purchased with a compatible scanner. An adjusted antennas cable length is manufactured with the scanner and is compatible with the required neck extension. NOTE: When using the neck extension, the measurements are referenced to the top part of the scanner body. CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 33 Appendix B: Accessories ● Head-Body separation Head-Body separation The head body separation solution allows installing the body inside the vessel and the head in an external location where it is easy to maintain and reach. Head-Body Separators are available in 2 sizes: 3m (9.85ft) 10m (32.8ft) Head-Body separation dimensions: 34 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Appendix B: Accessories ● Cable Glands Cable Glands The CONTOUR is shipped with one M20 cable gland and one M20 Blind plug. When ordering CONTOUR with option N under the ‘Cable Entry / Plug Connection’ section (field V in the Pricelist), it is supplied with accessory kit that includes: 1 x M20 Cable Gland 2 x NPT ½” adaptor The provided glands and accessory kit will allow the installer to use any combination as he sees fit. The available options are: Using one Gland and one blind Using two glands – unscrew the blind and attached the M20 gland Using conduits or ½” glands by unscrewing the existing gland or blind, attaching the NPT ½” and connecting the conduit or gland to the adaptor this can be done using one or both cable entries M20 Blind Gland M20 Cable Gland NPT ½” Adaptor CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 35 Appendix C: Maintenance ● Cable Glands Appendix C: Maintenance Preventive maintenance procedure MAGNETROL recommends the following periodical maintenance procedure for keeping the CONTOUR in proper operating conditions and preventing unnecessary malfunctioning which may be caused by environmental factors during time: Clean the interior part of the antennas (see details bellow) Visually check and ensure the communication and power cables are in good condition and are not damaged Check and ensure proper sealing of cable entry openings Open the rear side of the scanner head and ensure absence of wetness Antenna cleaning guidelines: Use a brush or wet cloth for the purpose of cleaning Disconnect power to the scanner Disassemble the flange and carefully pull out the entire scanner As necessary, water can be used for cleaning Avoid usage of sharp tools such as screwdrivers for cleaning. Such tools may damage the membranes. Preventive maintenance frequency The frequency of the maintenance procedure is subject to the conditions and the type of material stored in the vessel. In the case of materials such as salt, sugar, calcium carbonate etc., treatments should be more frequent. 36 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Appendix D: Recommended Tools ● Cable Glands Appendix D: Recommended Tools The following tools are recommended for the installation process: The site application documents (IPF, AAF), and vessel technical drawings A Set of small precision screwdrivers, to be used with the terminal blocks 13mm open wrench 4mm hex key (preferably with a handle) Large adjustable wrench 18” Stanley knife, Cutter, Pointed pliers, Isolating tape Laser measurement device (or other means to ensure correct positioning and distance to the material) RS485 to USB converter, including drivers 120 Ohm (RS485) and 250 Ohm (HART) resistors PC/Laptop Internet GSM Stick for testing the communications between the installed scanner and the monitoring computer at the center, using the CONTOUR Connect. CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 37 Appendix E: Specifications ● Technical data Appendix E: Specifications Technical data Materials, non-wetted parts Housing & Antenna Inspection window in housing cover Ground terminal Painted Aluminum die casting Polycarbonate Stainless steel 1.4571/1.4435 Physical Weight 5.6kg (12.34 lbs.) Output variables Output signal Resolution 4-20 mA Current limitation Communication 10μA 22 mA RS485 / ModBus RTU Plugs and Cabling 1 x cable entry M20x1.5 (cable 8…13mm with conductor size of 20 to 24AWG, preferable shielded twisted pairs type cable) assembled on the scanner 1 x blind stopper M20x1.5 assembled on the scanner Accessory kit with additional M20x1.5 cable gland and 2 x NPT1/2” adaptors Display panel Display Adjustment elements LCD 4 lines x 20 characters 4 keys (ESC, +, -, E) Load 4-wire sensor Integration time 38 See load diagram bellow 0…9999 s, adjustable CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Appendix E: Specifications ● Technical data Load Diagram 1: HART Load 2: Voltage Limit EEx ia device 3: Voltage limit non-Ex/Exd ia device 4: Supply Voltage Ambient conditions Ambient/storage/transport temperature: -40…85°C (-40…+185°F) [CONTOUR 3DS-xxxx-Axx-xx-xxx] Relative humidity 20…85% 5,000m (16,400ft) Maximum altitude -40…180°C (-40…+356°F) [CONTOUR 3DS-xxxx-Hxx-xx-xxx] Process conditions Vessel pressure -0.5…3bar (-50…300 kPa or -7.25…43.5 Psi) Process temperature Measured on the process fitting: -40…85°C (-40…+185°F) [CONTOUR 3DS-xxxx-Axx-xx-xxx] Vibration resistance: Mechanical vibrations of 2g at 5…200 Hz -40…180°C (-40…+356°F) [CONTOUR 3DS-xxxx-Hxx-xx-xxx] Measurement characteristics Frequency Beam angle with horn antenna Interval Adjustment time 2.65-7 kHz 70 degrees >2 s (depending on parameter adjustment) >3 s (depending on parameter adjustment) Power supply – 4-wire device A safety certified power supply which provides double insulation between the primary and output must be used for powering the unit. The power supply must be a limited power source type with maximum output current 1A and voltage range of 20VDC minimum and 32VDC maximum, and not to be connected to a DC distribution network. CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 39 Appendix E: Specifications ● Power Supply The power supply will not connect to a DC distribution network. Supply voltage 20…32 VDC Power consumption max 1.5W Electrical protective measures Protection Approvals ATEX cFMus NEPSI CE FCC 40 IP 67 according to IEC 60529 II 1/2D, Ex ibD/iaD 20/21 T110°C II 2G Ex ia/ib IIB T4 Intrinsically safe CL I, II, DIV I, GP CDEFG Comply with the following approval standards: CAN/CSA C22.2 No. 25, 1966 CAN/CSA C22.2 No. 157, 1992 CAN/CSA C22.2 No. 1010, 2004 CAN/CSA E61241-1-1, 2002 Ex ibD/iaD 20/21 T110°C Ex ia/ib IIB T4 EMC (2004/108/EC) Emission: EN 61326: 1997 (class B) Susceptibility: IEC/EN 61326:1997 + A1:1998 + A2:2001 + A3:2003 NSR (73/23/EWG) EN 61010-1: 2001 Conformity to part 15 of the FCC regulations FCC 47 CFR part 15:2007, subpart B, class A The CONTOUR 3DS-xxxx-Axx-xx-xxx complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Appendix E: Specifications ● Dimensions CONTOUR dimensions: Front view CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 41 Appendix E: Specifications ● CONTOUR dimensions: Side view 42 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Appendix F: Standards & Approvals ● Appendix F: Standards & Approvals CONTOUR EMC Test Certificate for FCC Part 15, Sub-part B, Class A CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 43 Appendix F: Standards & Approvals ● CONTOUR EMC Test Certificate for: EN 61326-1: 2006 CISPR 11: 2003 Class A IEC 61000-4-2: 2001 Air Discharge, 8kV IEC 61000-4-3: 2002 80-1000MHz, 1V/m; 1.4-2GHz, 1V.m; 2.0-2.7GHz, 1V/m IEC 61000-4-4: 2004 Power Lines: 1kV; Signal Lines: 0.5kV IEC 61000-4-6: 2004 0.15-80MHz 1VRMS, 80% A.M. by 1kHz Power & Signal Lines 44 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved Appendix F: Standards & Approvals ● Read this Manual Before Installing This manual provides information on the MAGNETROL CONTOUR. It is important that all instructions are read carefully and followed in sequence. Notice of Copyright and Limitations MAGNETROL® & MAGNETROL® logotype are registered trademarks of MAGNETROL® International, Incorporated. Copyright © 2013 MAGNETROL® International, Incorporated. All rights reserved. MAGNETROL reserves the right to make changes to the product described in this manual at any time without notice. MAGNETROL makes no warranty with respect to the accuracy of the information in this manual. Warranty All MAGNETROL 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 will repair or replace the control at no cost to the purchaser (or owner) other than transportation. MAGNETROL 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 guarantees the highest level of quality throughout the company. MAGNETROL is committed to providing full customer satisfaction both in quality products and quality service. The MAGNETROL 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. CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 45 W O R L D W I D E L E V E L A N D F L O W S O L U T I O N S sm CORPORATE HEADQUARTERS 5300 Belmont Road • Downers Grove, Illinois 60515-4499 USA • Phone: 630-969-4000 • Fax: 630-969-9489 contour.magnetrol.com • magnetrol.com • [email protected] BULLETIN: 61-601.0 EFFECTIVE: April 2013