Universal IV CM Water Cut Meter Manual

Universal IV CM Water Cut Meter Manual
A Leader in Level Measurement
Installation and
Operating Instructions
For the
Universal IV™ CM Model
2-Wire, 4-20 mA, Water Cut Meter
with HART® Protocol
For Assistance Call + 215-674-1234
AMETEK Drexelbrook makes no warranty of any kind with regard to the material contained in this manual, including, but
not limited to, implied warranties or fitness for a particular purpose. Drexelbrook shall not be liable for errors contained
herein or for incidental or consequential damages in connection with the performance or use of material.
© Copyright AMETEK Drexelbrook
EDO# 01-17-105
UIVCM-LM
Issue # 4
Universal IV™ CM Model
2-Wire, 4-20 mA
Water Cut Meter
with HART® Protocol
An ISO 9001 Certified Company
205 Keith Valley Road, Horsham, PA 19044
Telephone:
+1 215-674-1234
Fax:
+1 215-674-2731
E-mail:
drexelbrook.info@ametek.com
Website:
www.drexelbrook.com
Contents
Contents
Section 1:
1.1
1.2
1.3
Introduction
System Description ........................................................................................................... 1
Unpacking ......................................................................................................................... 1
Model Numbering .............................................................................................................. 2
Section 2:
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Installation
Installation Guide............................................................................................................... 5
Installation Considerations ................................................................................................ 7
Sensing Element Insertion and Active Lengths ................................................................. 8
Mounting the Electronic Unit ............................................................................................. 9
Wiring the Electronic Unit ................................................................................................ 12
Wiring the Sensing Element ............................................................................................ 13
Surge Voltage (Lightning) Protection............................................................................... 15
RFI (Radio Frequency Interference) Filters ..................................................................... 15
Section 3:
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
Configuration and Calibration with Drexelbrook Software, HRTWin
Installing The USB Modem .............................................................................................. 19
Install the Windows Version HRTWin Software ............................................................... 20
Description of Function Keys........................................................................................... 22
Configuration ................................................................................................................... 23
Calibration ....................................................................................................................... 24
Set D/A Trim .................................................................................................................... 28
Save/Print Entries............................................................................................................ 29
Calibration & Configuration via Display/Keypad .............................................................. 30
HART® - Multi-drop mode ............................................................................................... 32
Section 4: Specifications
4.1
Transmitter Specifications ............................................................................................... 35
Section 5: Normal Maintenance
5.1
Viewport Cleaning ........................................................................................................... 37
Section 6:
6.1
6.2
6.3
Hazardous Location Approval Supplementary Instructions
General safety information .............................................................................................. 39
The Compartment Cover ................................................................................................. 40
Standards and Approvals ................................................................................................ 41
Section 7:
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
7.12
7.13
Troubleshooting
Identifying a Problem/Symptom ...................................................................................... 46
Troubleshooting Loop Connection................................................................................... 46
Radio Frequency interference ......................................................................................... 46
Transmitter Does Not Communicate with HRTWin Software .......................................... 47
Transmitter Function Test ................................................................................................ 48
Transmitter Drift Test ....................................................................................................... 48
Testing the Sensing Element/Cable ................................................................................ 51
Status Messages ............................................................................................................. 53
Factory Assistance .......................................................................................................... 56
Field Service.................................................................................................................... 56
Customer Training ........................................................................................................... 56
Return Equipment ........................................................................................................... 57
Universal IV Cut Monitor Troubleshooting Guide ............................................................ 58
Section 8: Control Drawings
8.1
ATEX / IECEX ................................................................................................................ 61
8.2
FM US / FMC .................................................................................................................. 69
Section 9:
9.1
9.2
9.3
9.4
9.5
Approval Certificates
FM US Approval Certificate ............................................................................................. 91
FM Canada Approval Certificate ..................................................................................... 97
IECEx Approval Certificate ............................................................................................ 103
ATEX Approval Certificate ............................................................................................. 107
CE Mark Declaration of Conformity ................................................................................114
Page Has No Content
Section 1
Introduction
Universal IV™ CM Model
Section 1:
1.1
Introduction
System Description
The instructions in this manual are for the AMETEK Drexelbrook Universal IV CM
Model Water Cut Meter for measurement of the percentage of water in oil. Each
AMETEK Drexelbrook Universal IV CM system consists of a two-wire, 4-20 mA
electronic unit and a 700 series sensing element. Communication with the device
is done by either an onboard keypad or with a laptop via HART® protocol.
AMETEK Drexelbrook has been measuring water cut with capacitive technology for
over 40 years. Using capacitance to measure water cut is widely successful because
of the large difference between the dielectric constants of oil (k≈2.3) and water
(k≈80). The sensing element and the pipe wall form the necessary two plates of
the concentric capacitor. The system electronics transmit a radio frequency voltage
to the sensing element that measures changes in capacitance. As the amount of
water in the flowing oil increases, the net dielectric of the fluid increases which
causes the capacitance to increase. The onboard electronics can then compute the
relationship between capacitance change and water cut.
It is termed a two-wire transmitter because the same two wires that are used to
power the unit also indicate the change in Cut (4-20 mA).
1.2
Unpacking
Carefully remove the contents of the carton and check each item against the packing
list before destroying any packing material. If there is any shortage or damage,
report it immediately to the factory.
1
Introduction
1.3
Model Numbering
System Electronics and Probe Model
Technology
U
Universal IV
Measurement Type / Frequency and Phasing
C0 Water Cut Monitor Electronics
T0 Water Cut Monitor with Temperature Compensation Electronics
Digital Protocols
1
HART®
Future Use
0
Future Use
Approvals
0
Unapproved
1
FM/FMc IS
2
FM/FMc XP
3
ATEX ia
4
ATEX d [ia]
5
IECEx ia
6
IECEx d
Electrical Connection
0
3/4" NPT without external ground lug
1
M20 with external ground Equipotential Bonding
2
3/4 with external ground Equipotential Bonding
Surge / Noise Suppression
0
No additional filtering required
1
Signal RFI (Integral or Remote)
2
Signal RFI - XP (Integral or Remote)
3
Probe RFI (Remote only)
4
Probe RFI - XP (Remote only)
5
Signal & Probe RFI (Remote only)
6
Signal & Probe RFI - XP (Remote only)
7
Signal Surge Filter (Integral or Remote)
8
Probe HDSP - Heavy Duty Spark Protection (Remote only)
9
Signal Surge and Probe HDSP (Remote only)
A
RFI (signal & probe) and Surge filtering (Remote only)
B
RFI (signal & probe) and Surge filtering - XP (Remote only)
D
Desalter Filter
Integral / Remote options
0
Integral configuration
1
Remote configuration without cable
2
Remote configuration with 10 ft General Purpose Cable
3
Remote configuration with 25 ft. General Purpose Cable
4
Remote configuration with 35 Ft. General Purpose Cable
5
Remote configuration with 50 ft. General Purpose Cable
6
Remote configuration with 75 ft. General Purpose Cable
7
Remote configuration with 100 ft. General Purpose Cable
8
Remote configuration with 10 ft. Triax Cable
9
Remote configuration with 25 ft. Triax Cable
A
Remote configuration with 35 ft. Triax Cable
B
Remote configuration with 50 ft. Triax Cable
C
Remote configuration with 75 ft. Triax Cable
D
Remote configuration with 100 ft Triax Cable
E
Remote configuration with 10 ft Hi Temp Cable
F
Remote configuration with 25 ft. Hi Temp Cable
G
Remote configuration with 35 ft. Hi Temp Cable
H
Remote configuration with 50 ft. Hi Temp Cable
J
Remote configuration with 75 ft. Hi Temp Cable
K
Remote configuration with 100 ft Hi Temp Cable
L
Remote configuration with 10 ft Hi Temp Composite Cable
M Remote configuration with 25 ft. Hi Temp Composite Cable
N
Remote configuration with 35 ft. Hi Temp Composite Cable
O
Remote configuration with 50 ft. Hi Temp Composite Cable
P
Remote configuration with 75 ft. Hi Temp Composite Cable
Q
Remote configuration with 100 ft Hi Temp Composite Cable
Z
Remote configuration with custom cable
Dual seal option
0
Without Dual Seal option
1
With Dual Seal option
Sensing Element Code
### Sensing element 3-digit code (Refer to probe selection table)
000 Remote System without a probe
ZZZ Special sensing element
R## Retrofit kit upgrade with probe dependent adapters R02, R04 or R12 (Refer to table)
Cut Monitor Software
0
None
A
Light Oil -- 0 - 1%
B
Light Oil -- 0 - 5%
C
Light Oil -- 0 - 10%
D
Light Oil -- 0 - 30%
E
Light Oil -- 0 - 50%
F
Heavy Oil -- 0 - 1%
G
Heavy Oil -- 0 - 5%
H
Heavy Oil -- 0 - 10%
I
Heavy Oil -- 0 - 30%
J
Heavy Oil -- 0 - 50%
M Heavy Oil -- 0 - 80%
Z
Special Software
U
0 1 0
2
Universal IV™ CM Model
1.3
Model Numbering (Continued)
Dimensions and Process Connection
Process gland wetted part (X)
B
316/316L SS
Process connection (XX)
A0 3/4" NPT
B0 1" NPT
BA 1" 150# RF Carbon Steel
BB 1" 150# RF 316/316L Stainless Steel
CB 1" 300# RF 316/316L Stainless Steel
BD 1" 150# RF 316/316L SS TFE
C2 1 1/2" Tri-Clamp
E2 2" Tri-Clamp
FA 2" 150# RF Carbon Steel
FB 2" 150# RF 316/316L Stainless Steel
GB 2" 300# RF 316/316L Stainless Steel
FC 2" 150# RF CS TFE Face
FD 2" 150# RF 316/316L SS TFE
FE 2" 150# RF CS Inserted TFE
FH 2" 150# RF 316L SS Seal-Tyte
G0 1/2" NPT
IA 3" 150# RF Carbon Steel
IB 3" 150# RF 316/316L Stainless Steel
J2 3" Tri-Clamp
JB 3" 300# RF 316/316L Stainless Steel
KB 4" 150# RF 316/316L SS
KC 4" 150# RF CS TFE Face
KD 4" 150# RF 316/316L SS TFE
KG 4" 150# RF CS Seal-Tyte
LA 4" 300# RF Carbon Steel
LB 4" 300# RF 316/316L Stainless Steel
WB 6" 600# RF 316/316L Stainless Steel
2B 8" 600# RF 316/316L Stainless Steel
XX* Many more options available upon request (ANSI, DIN, JIS)
Insertion Length in MM
XXXXXX Length of the probe in millimeters from process connection to the bottom of the probe. Ranges from 13.875" to
39.275" (352.425mm to 997.585mm) I.L. depending on pipe size and sensing element - Refer to pipe size look up table
Cote-Shield™ Length in MM
XXXXXX Length of the Cote-Shield in millimeters. Typical 3.5", 6" or 10" (88.9mm, 152.4mm, 254 mm)
depending on pipe size and sensing element- Refer to pipe size look up table
Inactive Length in MM
XXXXXX Length of the inactive part of the probe that is not measured.
This option does not apply to Cut Monitors
Inactive Material
N
Not Applicable to Cut Monitors
B
0 0 0 0 0 0 N
3
Section 2
Installation
Universal IV™ CM Model
Section 2:
2.1
Installation
Installation Guide
Use the following mounting and installation instructions so that the sensing element
will operate properly and accurately:
• The insertion style sensing element should be mounted in a section of pipe as
close to the center and as parallel to the pipe as possible. Factory calibration
assumes mounting on the pipe centerline and in the correct size pipe.
• Vertical mounting, with the tip down, is preferred for the insertion style sensing
elements, but not essential.
• Gas bubbles must be excluded from the active area by maintaining pressure
and, if necessary, a degasser upstream from the sensing element. Gas
bubbles (whether from natural gas, air or steam) decrease the accuracy of the
measurement.
• Do not take the sensing element apart or loosen the packing glands.
• In large pipe installations (greater than eight inches), the length of the cote
shield section must be long enough (i.e. length of nozzle short enough) that the
cutout in the concentric tube is in the actual flow of oil.
• For large pipes with no bends (18 inch and larger), it is possible to mount the
sensing element at a 45 degree angle to provide sufficient flow through the shield
of the sensing element.
5
Installation
2.1
Installation Guide (Continued)
Installation in a Pipe 8 inches or larger
Installation in a Pipe 18 inches or larger
6
Universal IV™ CM Model
2.2
Installation Considerations
The insertion style sensing element must be mounted at an existing or created,
90 degree bend in the pipe. It can be installed through a tee or a weld-o-let to a 90
degree elbow. The vertically downward mounting attitude is preferred for ease of
inspection or cleaning, since draining of the pipe is not required. Regardless, the
probe will function in any attitude, as long as the pipe is completely full in the active
probe area. See the figure below for ideal installation orientation.
The probe is active from its tip to the end of the Cote-Shield element. In the area
of the Cote-Shield, it is completely inactive.
In all cases, the presence of gas bubbles, whether from air, petroleum vapor, steam,
or natural gas, will reduce accuracy, producing lower readings . One of the most
common causes of gas bubbles is abrupt pressure drops in high temperature streams,
which can allow water and light ends to flash.
An in-line mixer just upstream of the Water Cut Meter is highly recommended for
streams which go above 10% water cut. Accuracy is based on uniform, oil-continuous
emulsion, so any unplanned separation will cause errors.
All instruments are factory calibrated. If calibration trimming is required, it may
be done through the Keypad or with AMETEK Drexelbrook PC software. The
proprietary software allows one shot calibration trimming with one reading and
sample. The Real-time View window is useful for observing transmitter function
and troubleshooting.
Active Probe Area
FLOW
Suggested Installation
7
Installation
2.3
Sensing Element Insertion and Active Lengths
The Water Cut Meter sensing element varies with pipe size. The larger the pipe
diameter size, the longer the sensing element active length must be. The CoteShield length is sized so the sensing element is fully extended into the fluid beyond
nozzles and elbows. Below are some standard sensor dimensions.
NACE MR0175 Certification is available upon request.
700-1202-0XX Series Sensing
Elements (Peek™ Insulation)
700-0201-0XX Series Sensing Elements
(TFE Insulation)
Pipe
Size
Cote-Shield
Length
Insertion
Length
Pipe
Size
Cote-Shield Insertion
Length
Length
Model Number
2"
3.5"
21.25"
2"
6"
28.1"
700-0201-052
2"
6"
23.75"
3"
10"
2.9"
700-0202-053
2"
10"
27.75"
4"
10"
32.1"
700-0202-054
12"
38.4"
700-0202-056
3"
3.5"
25.5"
6"
3"
6"
28"
8" and >
18"
37"
700-0201-058
3"
10"
32"
In Tank
8"
27"
700-0201-059
4"
6"
31.125"
4"
10"
35.125"
6"
6"
35.375"
6"
10"
39.375"
8" and >
10"
25.5"
In Tank
3.5"
19"
In Tank
6"
21.5"
In Tank
10"
25.5"
Size
Dimension "A"
Sensing Element Dimensions
Insulation, PEEK or TFE
CSL
Cote Shield Length
IL
Insertion Length
Dimension "B"
Dimension "C" Dimension "D"
Flange
2 inch
17.0" (432)
13.4" (340)
8.5" (216)
2.125" (54)
150#/300#
3 inch
32.0" (813)
13.9" (353)
19.0" (429)
3.125" (79)
150#/300#
4 inch
32.0" (813)
14.3" (363)
21.8" (554)
4.625"(117)
150#/300#
5.25 (133)
4 (102)
5.88(149)
2 (51)
CABLE ENTRIES (2)
3/4 NPT or
M20 x 1.5
.875 (22)
6.45 (164)
"B"
"D"
"C"
"A"
8
Universal IV™ CM Model
2.4
Mounting the Electronic Unit
The integral electronic unit is mounted with the sensing element. The remote
electronic unit is designed for field mounting, but it should be mounted in a location
as free as possible from vibration, corrosive atmospheres, and any possibility
of mechanical damage. For convenience at start-up, mount the instrument in a
reasonably accessible location. Ambient temperatures should be between -40°F
and 167°F (-40°C and 75°C).
When installing conduit to the electronic unit, be sure that vertical conduit runs
will not cause water to enter the electronic unit housing, as shown in Figure Below.
Figure 2-1
Recommended Conduit Installation
9
Installation
2.4
Mounting the Electronic Unit (Continued)
Integral System Mounting
Figure 2-2
Integral Mounting Dimensions
10
Universal IV™ CM Model
2.4
Mounting the Electronic Unit (Continued)
Remote System Mounting
SENSING
ELEMENT
DEPENDENT
Figure 2-3
Remote Mounting Dimensions
11
Installation
2.5
Wiring the Electronic Unit
The signal connections are made to the three-terminal block on the front of the
chassis. Due to the low power consumption of the instrument, the wiring need only
be light gauge (e.g. 20 AWG). Shielded twisted pair cables are recommended.
Integral units are pre-wired to the sensing element at the factory. Figure 2-5
shows the wiring of the integral unit.
See Figure 2-6 for wiring connections of the remote unit. The cable from
the sensing element is connected to the terminal strip below the instrument
chassis. The cable connections are sensing element (prb), center wire (cw),
ground (gnd), and shield (shd).
CAUTION!
Before using Intrinsic Safety Barriers, read manufacturer's instruction for
barrier operation.
The Universal IV has a built-in current limiter which holds the signal current to
a maximum of 28 mA.
Figure 2-4
Universal IV Wiring Connections
12
Universal IV™ CM Model
2.6
Wiring the Sensing Element
The cable connections to the remote sensing element are shown in Figure 2-6
• Do not connect the cable to the sensing element until after the sensing element
has been installed in the vessel and the condulet / housing has been secured.
Only cables supplied by Drexelbrook should be used to connect the transmitter to
the sensing element. Use of other cables can result in unstable performance.
Integral System Sensing Element Wiring
Figure 2-5
Universal IV Wiring Connections Integral Mounting
13
Installation
2.6
Wiring the Sensing Element (Continued)
Remote System Sensing Element Wiring
Figure 2-6
Universal IV Wiring Connections, Remote Mounting
14
Universal IV™ CM Model
2.7
Surge Voltage (Lightning) Protection
Optional surge protection can be supplied with transmitters that are expected to
be exposed to surge voltages or surges due to lightning near the two-wire loop. A
Drexelbrook Model 401-0016-028 Signal Filter Assembly affords additional protection
to the transmitter but is not absolute in its protection against a very close lightning
strike. Refer to Figure 2-9 to properly connect the Signal Filter Assembly. You
must insure the transmitter housing is well connected to an earth ground.
2.8
RFI (Radio Frequency Interference) Filters
When installing the Universal IV transmitter, follow these recommendations to
avoid problems with Radio Frequency Interference (RFI).
• Choose a location to mount the electronic unit at least 6 feet (2m) from a walkway
where personnel using walkie talkies may pass.
• For remotely-mounted electronic units connect the sensor to the electronic unit
by placing the coaxial cable in grounded metal conduit. Integrally mounted
electronic unit sensor connections and triaxial cables are already shielded.
• Use Shielded Twisted Pair wiring for all loop wiring. Loop wiring should also
be in grounded metallic conduit.
• Ground the electronic unit and housing with a minimum of 14 gauge wire to a
good earth ground. Make sure that conduits entering and leaving the housing
have a good electrical ground connection to the housing
If the recommendations listed are followed, it is usually not necessary to add
RFI filtering to protect against signal strengths of 10 Volts/ Meter or less. This
degree of protection is usually sufficient to protect against walkie talkies that
are used 3 feet (1m) or more from a typical electronic unit. If greater protection
is required, or filters have already been provided, install RFI filters as shown
in Figure 2-8.
CE Mark Certification:
Triaxial Cable - Systems with remote mounted electronics that connect to the
sensing element via a triaxial cable do not need a sensing element RFI filter or
metal conduit to maintain CE Mark certification.
15
Installation
2.8
RFI Filters (Continued)
Figure 2-8
Sensing element Radio Frequency Interference (RFI) Filters
Part # 401-0016-029
Figure 2-9
Signal Radio Frequency Interference (RFI) Filters / Surge Protection
Part # 401-0016-028
16
Page Has No Content
Section 3
Configuration & Calibration
Universal IV™ CM Model
Section 3:
Configuration and Calibration with
Drexelbrook Software, HRTWin
This section instructs the user how to use the AMETEK Drexelbrook PC calibrator
software to configure and calibrate the Universal IV (RF Admittance) Transmitter.
3.1
Installing The USB Modem
HART® Modems are available from third party vendors.
Refer to directions supplied by modem manufacturer.
Figure 3-1
USB Modem Assembly & Loop Connection
19
Configuration and Calibration
3.2
Install the Windows Version HRTWin Software
Installation is quite simple.
A. Download the software from www.drexelbrook.com.
B. If program does not "Auto-Run", select the location where the file was saved
and run the set-up program manually.
C. Follow "On-Screen" instructions in Setup to create program file.
D. Once loaded, double click "HRTWin" icon and the program will run under its
own window.
E. Select communication port [Com 1, Com 2, etc.] and then click “OK.” See Figure
3-2.
F. If you are not sure which communication port you are using (such as when first
using a USB modem), select “Search Ports,” then OK. The software automatically
will seek out the correct one. In either case the software begins to communicate
with the HART protocol transmitter and returns with a view (below) containing
“name plate data,” Tag ID and all default or existing configuration information.
This is the same as if you clicked on the Read Transmitter function button.
G. The next view, shown in Figure 3-3, appears automatically, displaying current
transmitter data for calibration set-up for your selected Tag ID. The Scratch
Pad will automatically show the last message (last user, last calibration, etc.) up
to 32 characters. If this is a new transmitter, the Tag ID is user-defined. Serial
number, transmitter software version, range, etc. is automatically entered from
the “name plate data” embedded in the transmitter:
Figure 3-2
Selecting COM ports during software installation
20
Universal IV™ CM Model
3.2
Install the Windows Version HRTWin Software (Continued)
Figure 3-3
PC Software Menu Screen automatically communicates all "name plate data" from transmitter
21
Configuration and Calibration
3.3
Description of Function Keys
The following paragraphs describe the function buttons. The data fields are described
in Section 3.7 Configuration.
Read Transmitter [F3 on keyboard]
Reads all pertinent data from the transmitter and displays it on the screen. The
Read function also updates the real time window. Keep in mind that it takes several
seconds to load the information from the transmitter. When the load is complete,
the screen shows the data parameters, except any user-defined strapping table
information. This command is also used when connecting to another transmitter.
Write to Transmitter [F5 on keyboard]
Sends new or edited configuration data to the transmitter. Data fields that have
been edited but not sent to the transmitter are displayed in red.
Real Time View [F4 on keyboard]
Displays the real time values of water percentage, capacity, loop current, and status.
D/A Trim
Allows for correction of transmitter output current. Requires a calibrated current
meter in the signal loop.
See Section 3.9.
Strapping Table
Displays the values of the input (pF) vs. output (% water) in a table of up
to 21-points. Allows points to be adjusted when actual data deviated from the
theoretical input/output curve.
See Section 3.8.4
Configure Meter
Configures the Digital Integral Meter (440-44-3) used for local indication. See
Section 3.10
Water Cut Meter Calibration (One-Shot®)
Used to adjust calibration to specific oil and temperature that the transmitter
monitors. See Section 3.8.1
HRTWin Tool Bar
22
Universal IV™ CM Model
3.4
Configuration
Configuration involves downloading information to the HART protocol transmitter
that is specific to the application that is being measured.
A. Begin configuration by using Tag ID (8 characters) to identify the unit or vessel.
Use the Scratchpad (32 characters) to record the date of calibration or other
similar notes. Press Tab or Enter on your keyboard.
B. Edit Damping Time from 0-90 seconds, if desired.
C. Click on Write to Transmitter.
HRTWin Main Screen
23
Configuration and Calibration
3.5
Calibration
All Drexelbrook Universal IV CM Water Cut Meter instruments are calibrated at
the factory according to:
• Size of pipe, and
• Density of oil
Specific factors could cause the factory calibration to be less accurate than is
required. For example,
A. Pipe I.D. is smaller than nominal size (Sched. 80, 160, or extra heavy pipe)
B. Sensing element is not centered (parallel to axis) in pipe. This condition causes
higher (never lower) readings.
C. Oil may be heavier (higher readings) or lighter (lower readings) than expected.
D. Major temperature deviations.
Do not change the factory calibration without obtaining data that indicates a
calibration change is necessary. If the output reading is low because of gas, steam,
or air in the stream, then no amount of calibration will produce satisfactory
performance.
Once the gas is gone, an accurate calibration check can be made. The following
equipment is required to check the calibration of a Water Cut Meter application
and record sample data:
• A centrifuge (or other API-approved standard) to sample water content.
• If the stream temperature is greater than 150ºF (65ºC), a sampling bomb with
a minimum capacity of 500 ml.
• Temperature stabilization bath.
24
Universal IV™ CM Model
3.5.1 One Shot ® Calibration Trim Using HRTWin Software
A. With a PC connected to the signal loop, click on the Real Time View button to
open the “Real Time View” Screen.
B. Take a sample of the fluid from as close to the probe as possible. Use a sampling
bomb if the stream temperature is greater than 150°F. Stabilize at 150°F before
determining water content.
C. Read and record water percentage from the “Real Time View” as the sample is
being taken.
D. After determining the actual water percentage in the sample, close the “Real
Time View” window and open the “Calibration Screen” by clicking on the Cut
Monitor Calibration button.
E. Enter the % water reading, recorded at the time of sampling in the “Indicated
Water” box. Enter the result of the sample test in the “Sampled Water” box and
click on the Calibrate button.
F. Click on the Write To Transmitter button to install the revised calibration in
the transmitter.
G. Depending on the range, if the original calibration and the measured sample
differed by more than 2.5% water, another iteration will probably be required.
Unless there is an overwhelming discrepancy, it is best to monitor the
performance with this new calibration for a few days before making a second
change.
Calibration Window
RTV Window
25
Configuration and Calibration
3.5.2 Range Change
It is possible to reduce the span of an existing calibration simply by lowering the
% water URV on the “Menu Screen”. If the reduction in span fall within a lower
Input/Output curve, the lower curve should be selected.
When changing ranges on the Universal IV CM it is important to understand that
the shape of the input/output curve may require revision, as well as the 100% point.
The simplest way to re-range an instrument is to select a different input curve.
Captures from Main Screen
26
Universal IV™ CM Model
3.5.3 Strapping Table
If none of the available input/output curves are adequate for the application, a
user defined table may have to be created. This is accomplished by editing the
strapping table.
A. Whith a PC connected to the signal loop (as in section 3.4) click on the strapping
table button
B. Click on Write Strapping Table button to re-range the transmitter to the new
values.
C. Click on the Exit to return to the “Menu Screen” It may be necessary to do a
“One Shot” calibration on the installed instrument.
For user defined tables it will be necessary to adjust the URV (20 mA) point to
the desired range (See section 3.8.3) and adjust the local indicator so that the
maximum value is equal to the maximum % water in viewing % water is desired.
3.5.4 Linearity Correction
On high water ranges (greater than 10%) the shape of the % Water/Capacitance
curve will typically vary somewhat from one field to another. If it is determined
that the output is accurate at high and low water levels, but incorrect at some
intermediate area, it is possible to manipulate the break points in the strapping
table to improve accuracy.
A step-by-step procedure is beyond the scope of this publication. Several AWT users
have successfully trimmed the theoretical curve and in one case determined their
own curve to satisfy particular conditions in their installation.
When attempting to optimize the input/output curve there are 3 precautions to
keep in mind:
A. Try to err on the side of under compensation for perceived deviations
B. The top three points are designed to clip the output at 20 mA and should not
be disturbed. They have no significant effect on the curve below 20 mA.
C. Before beginning, be sure have a record of the starting curve, in case it becomes
necessary to start over.
27
Configuration and Calibration
3.6
Set D/A Trim
D/A Trim is NOT a calibration! This is a pre calibrated alignment to
precision factory settings and is rarely in need of change. The procedure is
intended only as a slight "meter" adjustment to a known external reference.
The Digital to Analog (D/A) Trim adjusts the transmitter mA (current) output.
Since the smart transmitter performs a digital to analog conversion, there may
be a discrepancy in the 4-20 mA output loop as measured with a reliable external
milliampere meter.
For example: perhaps after calibration you observe that the tank is empty and
a hand-held mA meter reads only 3.94 mA, while the Real Time View in the PC
Menu shows 4.00 mA. By adjusting the D/A trim, you may digitally manipulate the
output current to equal 4.00. You may also wish to adjust the high end to 20.00 mA.
To make these adjustments, click on D/A Trim on the PC software Menu Screen
and follow the pop-up window
instructions.
Setting D/A Trim Menu Screen
Windows
28
Universal IV™ CM Model
3.7
Save/Print Entries
In addition to your own convenience, many regulatory agencies are requiring a
record of the values being used during certain processes. All of the values developed
in this configuration and calibration procedure may be saved to be reloaded into
another (or replacement) transmitter. All of the values may likewise be printed
out as hard copy, including the Serial Number, Transmitter Software Version, Tag
ID, Scratch Pad, Instrument Calibration, all of the Real Time View numbers, and
all of the Strapping Table entries.
Pop-up screens come from selections in the FILE pull down at the top left of the
PC menu Screen.
Copies are saved in both .Universal IV CM file and .txt files.
The .Universal IV CM file will download into a transmitter through the OPEN
command. The text file may be printed out, or reformatted.
PRINT command provides a pre-formatted hard copy.
AMETEK Drexelbrook
205 Keith Valley Road
Horsham, PA 19044
Telephone: 215-674-1234
FAX: 215-674-2731
Service: 800-527-6297
Tag-ID:
Scratch Pad:
Damping Time:
LT-DEMO
DEMO CALIBRATION
0 sec.
Serial Number:
Software Version:
Range Position:
Instrument Configuration
Input/Output Curve:
Range Endpoints
M - 0 To 80% Heavy Oil Range 4
Print Pop-up from Menu
LRV (4 mA):
URV (20 mA):
Real Time View
Percent Water:
Capacitance:
Loop Current:
Percentage:
Status:
55.00 %
600.00 pF
15.00 mA
68.75 %
OK
Input/Output Table
Number of Points:
Input
pF
40.00
56.20
79.00
122.20
189.00
256.00
395.00
600.00
750.00
900.00
1100.00
2400.00
2700.00
2900.00
3450.00
29
123456
6.0
4
15
Output
% Water
0.00
10.00
23.00
35.00
40.00
42.00
50.00
55.00
57.00
60.00
65.00
70.00
75.00
80.00
83.00
0.00 % Water
80.00 % Water
Configuration and Calibration
3.8
Calibration & Configuration via Display/Keypad
To enter the Configuration Menu:
• Press and Hold the "Enter" Button for approximately 5 seconds.
• Use the "Up" and "Down" Buttons to scroll through the available menu selections.
• Press "Enter" to access sub-menu items.
• Use the "Up" and "Down" Buttons to adjust settings.
Settings that can be adjusted will be "flashing".
• Press "Enter" to accept the adjustment...Or...
• Press and Hold the "Enter" Button for approximately 5 seconds to exit to the
previous menu level.
Menu Function
(display abbreviation)
"Values
(display abbreviation)"
Description
"Fct 1.00
Water Cut Ranges
(RANGE)"
Select the water cut range for optimal measurement
0 to 1% water in Light Oil (LIGHT A)
Light Oil is defined as oil with API Gravity greater than 25.
Heavy Oil is defined as oil with API Gravity less than 25.
0 to 5% water in Light Oil (LIGHT B)
0 to 10% water in Light Oil (LIGHT C)
0 to 30% water in Light Oil (LIGHT D)
0 to 50% water in Light Oil (LIGHT E)
0 to 1% water in Heavy Oil (HEAVY F)
0 to 5% water in Heavy Oil (HEAVY G)
0 to 10% water in Heavy Oil (HEAVY H)
0 to 30% water in Heavy Oil (HEAVY I)
0 to 50% water in Heavy Oil (HEAVY J)
0 to 80% water in Heavy Oil (HEAVY M) Default
CUSTOM
Custom range requires a custom strapping table. See Fct 3.00
"Fct 2.01
Last Cal Point
(LST CAL)
Value of last cut enetered for calibration - read
only
User can view the last % cut entered
"Fct 2.02
Actual Cal Point
(ACT CAL)
Water cut % from actula cut % - 0.0 (Default)
Enter the actual water cut reading verified by another method of
water cut measurement
"Fct 2.00 Point Cal
"Fct 3.00
Calibration (CAL)"
Enter this menu to calibrate the unit
"Fct 3.01
Indicated Calibration Point
(IND CAL)"
% water - 0.0 Default
Enter the water cut reading captured at the time of taking the
sample for calibration measurement
"Fct 3.02
Actual Calibration Point
(ACT CAL)"
% water - 0.0 Default
Enter the actual water cut reading verified by another method of
water cut measurement
30
Universal IV™ CM Model
3.8
Calibration & Configuration via Display/Keypad (Continued)
"Fct 4.00
Strapping table
(STRAP)"
Use this strapping table menu to define a custom range if
selected in FCT 1.00. Otherwise the correct strapping table
is automatically loaded when range is selected in FCT 1.00.
Default values are for 'HEAVY M' range
"Fct 4.01
Maximum points
(MAX PNT)"
15 (Default)
Enter the total number of points in the strapping table which is
range dependent
"Fct 4.02
Point number index (INDEX)"
"1..MAX PNT
1 (Default)"
Enter the point number index
"Fct 4.03
Input value in PF
(INPT #)
"
Value in PF
Enter the capacitance value in pF
"Fct 4.04
Output value in water cut%
(OUT #)"
Value in % water
Enter the cut value associate with the capacitance in pF and
point index. Repeat FCT 3.02 to FCT 3.04 until all points are
entered in the strapping table
"Fct 5.00
Output
(OUTPUT)"
Configure the output from the unit including LRV, URV, damping
and fixed output
"Fct 5.01
Lower Range Value
(LRV)"
0.0 (Default)
Enter the lower range value in % water equivalent to 4mA
output
"Fct 5.02
Upper Range Value
(URV)"
80.0 (Default)
Enter the upper range value in % water equivalent to 20mA
output
"Fct 5.03
Damping in Seconds
(DAMPING)"
0.0 (Default)
Enter damping in seconds to delay and filter (software RC filter)
the output in case of rapid water cut variations
"Fct 5.04
4mA Trim
(TRIM 4)"
4.00 (Default)
Use this menu to calibrate the 4 mA output which is not
common practice. Requires calibrated meter to measure actual
current output
"Fct 5.05
20mA Trim
(TRIM 20)"
20.00 (Default)
Use this menu to calibrate the 20 mA output which is not
common practice. Requires calibrated meter to measure actual
current output
"Fct 5.06
Fixed Output
(LOCK mA)"
0.00 (Default)
Use this menu to fix the output to a certain mA value regardless
of the measurement. Enter the value in mA. The output will
stay at this value until exiting the menu of if display times out in
approx. 30 seconds
"Fct 5.07
Device ID
(POLL)"
0 (Default)
Enter the device ID to be used on the HART loop. Each device
on the loop must have a unique device ID. Change only for
multi-drop configuration
"Fct 5.08
Water Cut Clamping
(H2O CLP)
ENABLE (Default)
Clamps the indicated water cut to values of 0.0% and above
"Fct 6.00
Display (DISPLAY)"
Setup the parameter(s) to be displayed on the unit during
operation
"Fct 6.01
Toggle the display
(TOGGLE?)"
NO (Default)
Toggle between enabled parameters. YES or NO
"Fct 6.02
Water Cut (H2O)"
ENABLE (Default)
Enable or disable water cut measurement display
"Fct 6.03
Density Corrected Water Cut
(DC H2O)
ENABLE (Default)
Enable or disable the automatic display of the density corrected
water cut ONLY when connected to a DCM.
"Fct 6.03
Capacitance (CAP)"
DISABLE (Default)
Enable or disable capacitance measurement in pF
"Fct 6.04
Calculated current (4-20)"
DISABLE (Default)
Enable or disable the calculated current output
31
Configuration and Calibration
"Fct 7.00
Service (SERVICE)"
Use this menu for troubleshooting and service
"Fct 7.01
Restore factory default
(RST FAC)"
NO (Default)
Select YES to restore factory default in which case all
paramaters will be replaced with factory default setting.
Restoring the factory default will initiate this message on the
display 'DEFAULT PARAMS SET' until power is cycled.
"Fct 7.02
Pad Capcitor in PF
(PAD CAP)"
15.0 (Default)
Enter the value of an external capacitor that must be connected
to the unit. Padding capacitors are used to reduce the
sensing element standing capacitance in order to improve the
measurement resolution
"Fct 7.03
Contrast
(CONTRST)"
0 (Default)
0 is the highest contrast. 20 is the lowest contrast
"Fct 7.04
Parameter Number
(PAR NUM)"
0
Contact factory
"Fct 7.05
Parameter Offset
(PAR OFS)"
0
Contact factory
"Fct 7.06
Parameter Value
(PAR VAL)"
44
Contact factory
"Fct 7.07
Select Decimal Value
(H2O DEC)
0
1
2 Default
Allows the user the select the number of decimal places
displayed for % water
3.9
HART® - Multi-drop mode
All AMETEK Drexelbrook HART protocol transmitters default to a polling address
of "0".
In order to put the transmitter in the "Multi-drop" mode, the polling address must
be changed from "0".
A polling address of "1 - 15" is acceptable under "Hart revision 5". The transmitter
will set the output to a fixed current of "6 mA". All Multi-drop transmitters are
placed in parallel on the Loop.
32
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Section 4
Specifications
Universal IV™ CM Model
Section 4:
4.1
Specifications
Transmitter Specifications
Technology
RF Admittance / Capacitance
Process Pressure (Sensing Element)
Up 103 bar (1,500 psi), probe dependent
Supply Voltage
13-30VDC, 2-wire loop powered
Process Connection (Sensing Element)
NPT, ANSI, and more upon request
Ouput/Digital Protocol
4-20mA, HART
Compatible with HART®
Integral or Remote Configuration
25 ft max cable length for remote configuration
Accuracy and Resolution
Water Cut
Nominal Water Cut
Range
Variance*
Resolution**
0 to 1%
+/- 0.03
0 to 5%
+/- 0.04
0 to 10%
+/- 0.04
0 to 30%
+/- 0.12
0 to 50%
+/- 0.35
0 to 80% (Heavy Oil) +/- 0.25
*
Water Cut
Supply Voltage Effect
0.2% of full scale max
0.0002
0.0009
0.0009
0.0030
0.0080
0.0035
The measurement accuracy of an inline, dynamic water cut
measurement is dependent upon many process variables including:
oil dielectric consistency, fluid velocity at the sample point, mounting
geometry and homogeneity of the oil/water emulsion. The values
above represent nominal water cut measurement variances for
a properly installed sensor under consistent measurement point
conditions.
** The smallest water cut step that the instrument can resolve
Load Resistance
Maximum 550 ohms at 24 VDC
Minimum 250 ohms for HART protocol
Response Time
350 msec nominal (no damping applied)
1-90 seconds programmable damping time
Temperature Effect
0.5% per 100°F (37.7°C) change
Start-Up Time
< 12 seconds
Configuration and Calibration
Standard LCD display and keypad are built-in
HRTWIN™ PC-based software (free download)
Emission and Surge Protection
Compliant with IEC6100-4.2, 3, 4, 6, 8
Compliant with CISPR11 Group I, Class B
Approvals
Intrinsically Safe (IS)
Explosion Proof (XP) without IS barrier
Ambient Temperature
-40°C to 75°C (-40°F to 167°F)
Process Temperature (Sensing Element)
Up 232°C (450°F)
35
Section 5
Normal Maintenance
Universal IV™ CM Model
Section 5:
5.1
Normal Maintenance
Viewport Cleaning
The viewport (if supplied) is made of Borosilicate glass and can be cleaned with
any common glass cleaning product (e.g.: Windex™, Isopropyl alcohol, etc.) that is
suitable for the Class and Division rating of the specific system installation.
37
Section 6
Hazardous Locations
Universal IV™ CM Model
Section 6:
6.1
Hazardous Location Approval Supplementary Installation
& Operating Instructions
General safety information
This document contains installation instructions for potentially explosive atmosphere
applications.
The Universal U IV is approved for use in hazardous locations when properly installed.
Control drawings detailing installation guidelines are available in Section 8.
Always Install to Local Codes / Requirements / Directives as Mandated by the
Authority Having Jurisdiction.
The aluminum enclosure must be protected from mechanical friction and impact
that could cause ignition capable sparks.
6.1.2 Warning
• Installation, Start-Up, and Service should only be performed by personnel
trained in explosive atmosphere installations.
• Substitution of Components May Impair Intrinsic Safety.
6.1.3 Device Description
The Universal IV is a Continuous Level Measurement System.
Measurements are displayed via remote communications or an integrated display
screen.
6.1.4 Electrical connection
WARNING! Read the following information carefully.
• Live Maintenance should only be carried out by Skilled Personnel trained in
explosion protection methods.
• Test Equipment used to perform “Live Maintenance” must be certified to use
in the associated hazardous area.
Intrinsically Safe Installations
When the Universal IV is installed as an intrinsically safe device per the agency
control drawings, the housing cover may be safely opened. For system configuration,
remove the view port housing cover to access the display keypad for local system
configuration.
Explosionproof or Flameproof Installations
No Live maintenance is permitted.
Disconnect power to the device and check that the atmosphere is clear of hazardous
substances.
39
Hazardous Locations
6.1.5 Commissioning
Start-up checklist
Do not connect power until you have gone through the checklist below
1. Are the wetted components (gasket, flange and sensing element) resistant to
the corrosive properties of the tank product?
2. Does the information given on the nameplate correspond with the application?
3. Ex d applications: Have you connected the equipotential bonding system
correctly?
4. Ex i applications: Are you using an intrinsic barrier within the correct parameters?
5. Did you install cable entries of the correct internal diameter so that there is
a good seal around the cable? Are the cable glands suitably certified per the
application and the hazardous area parameters?
6. Do not use the earth terminal in the wiring compartment: use the equipotential
bonding system.
6.2
The Compartment Cover
Viewport Cleaning: The viewport is made of Borosilicate glass and can be cleaned
with any common glass cleaning product (e.g.: Windex™, Isopropyl alcohol, etc.)
that is suitable for the Class and Division rating of the specific system installation.
6.2.1 Opening the cover
Procedure
1. Unscrew cover stop, if applicable
2. Unscrew terminal compartment cover
6.2.2 Closing the cover
Warning: Ex d [ia] applications
Check that the terminal compartment cover is screwed tight and the cover stop (if
applicable) is fastened tightly to the cover.
40
Universal IV™ CM Model
6.3
Standards and Approvals
6.3.1 FM US Approvals - Install per 420-0004-412-CD
The Universal IV Level Transmitter is rated as Intrinsically Safe for Class I, II and
Ill, Groups A-G and Class I, Zone 0, Group IIC, in accordance with drawing 4200004-412-CD; Nonincendive Class I, Division 2, Groups A-D Hazardous (Classified)
Locations.
Furthermore, the Integral version is rated as Explosionproof for Class I, Division
1, Groups C & D; Dust lgnitionproof for Class II & Ill, Division 1, Groups E-G
and Class I, Zone 1, Group lIB Hazardous (Classified) Locations with an integral
sensor that is Intrinsically Safe for Class I, II & Ill, Groups A-G and Class I, Zone
1 Hazardous (Classified) Locations. The Remote version is rated as Explosionproof
Class I, Division 1, Groups C & D; Dust-lgnitionproof for Class II & Ill, Division 1,
Groups E-G and Class I, Zone 1, Group lIB Hazardous (Classified) Locations with
connections to a 700 Series sensor that is Intrinsically Safe for Class I, II & Ill,
Groups A-G and Class I, Zone 1 Hazardous (Classified) Locations.
6.3.2 FM Canada Approvals - Install per 420-0004-412-CD
The Universal IV Level Transmitter is rated as Intrinsically Safe for Class I, II
and Ill, Groups A-G and Class I, Zone 0, Group IIC, in accordance with drawing 4200004-412-CD; Nonincendive Class I, Division 2, Groups A-D Hazardous Locations.
Furthermore, the Integral version is rated as Explosionproof for Class I, Division
1, Groups C & D; Dust lgnitionproof for Class II & Ill, Division 1, Groups E-G and
Class I, Zone 1, Group lIB Hazardous Locations with an integral sensor that is
Intrinsically Safe for Class I, II & Ill, Groups A-G and Class I, Zone 1 Hazardous
Locations. The Remote version is rated as Explosionproof Class I, Division 1,
Groups C & D; Dust-lgnitionproof for Class II & Ill, Division 1, Groups E-G and
Class I, Zone 1, Group lIB Hazardous Locations with connections to a 700 Series
sensor that is Intrinsically Safe for Class I, II & Ill, Groups A-G and Class I, Zone
1 Hazardous Locations.
41
Hazardous Locations
6.3
Standards and Approvals (Continued)
6.3.3 ATEX Approvals - Install per 420-0004-424-CD
Universal IV Level Transmitter – Integral
II 1 G Ex ia IIC T4 Ga -40°C ≤ Tamb ≤ +75°C; IP66 (For models U**103**00-*-*)
II 2 G Ex d ia IIB T4 Gb -40°C ≤ Tamb ≤ +75°C; IP66 (For models U**104**00-*-*)
II 2 D Ex tb ia IIIC Db T90°C -40°C ≤ Tamb ≤ +75°C; IP66 (For models U**104**00*-*)
Universal IV Level Transmitter – Remote (excluding models U**10***00-*-*)
II 1 G Ex ia IIC T4 -40°C ≤ Tamb ≤ +75°C; IP66 (For models U**103***0-*-*)
II 2 (1) G Ex d [ia] IIB T4 -40°C ≤ Tamb ≤ +75°C; IP66 (For models U**104***0-*-*)
II 2 (1) D Ex tb [ia] IIIC T90°C -40°C ≤ Tamb ≤ +75°C; IP66 (For models U**10****0*-*)
700-*, Universal IV Sensors
II 1 G Ex ia IIC T2…T5 Ga -40°C ≤ Tamb ≤ +75°C
II 1 D Ex ia IIIC T300°C…T90°C Da -40°C ≤ Tamb ≤ +75°C
6.3.4 IECEx Approvals - Install per 420-0004-424-CD
Integral:
Ex ia IIC T4 Ga; Ex d ia IIB T4 Gb; Ex tb ia IIIC T90°C Db; -40°C ≤ Ta ≤ +75°C; IP66
Input Voltage: 13-30Vdc; 1W
Remote:
Ex ia IIC T4 Ga; Ex tb [ia] IIIC T90°C Db; Ex d [ia] IIB T4 Gb; Ex tb [ia] IIIC T90°C
Db; -40°C ≤ Ta ≤ + 75°C; IP66
Input Voltage: 13-30Vdc; 1W
Remote Sensor:
Ex ia IIC T5 ... T2 Ga; Ex ia IIIC T90°C ... T300°C Da; -40°C ≤ Ta ≤ +75°C; IP66
42
Page Has No Content
Section 7
Troubleshooting
Universal IV™ CM Model
Section 7:
Troubleshooting
Problem/Symptom
Tests in order of probability
Reference Section(s)
Comments
Can’t communicate with transmitter
using Drexelbrook PC Software
Check modem connections
Check for 250 Ω resistance
(min.) in the loop.
Check voltage at transmitter
Try another modem
Power from a battery source
7.2 and 7.3
Often a result of loop connection
problems or output current > 20
mA
0 mA output all the time
(no measurable output current at
any time)
Check voltage at transmitter
Check polarity of loop
7.2
Probable loop problem.
Faulty connection in loop
More than 20 mA output all the time
Check for moisture in housing
Check transmitter
Verify sensing element wiring
is correct
Test Sensing Element
Check Calibration
Output drifts (output accuracy varies
slowly over time…e.g. hours or
days)
Test transmitter without sensing 7.5
element (drift test)
Output erratic - (output jumps
around noticeably in terms of
seconds or minutes)
Check probe and cable
Check for radio interference
Check for noise on loop
7.6
7.7
Erratic readings often show
actual process conditions. Look
for bubbles or stratification, etc.
Output intermittent (output jumps
quickly usually between >4mA and
some “on scale” value
Check signal loop connections
Possible water slug
7.2
Intermittent Loop Connection
Inaccurate readings (% water
readings are incorrect compared to
sample)
Check calibration
Check method of comparison
3
Reading does not change with level
Check cables
Check sensing element
7.6
Verify % water reading.
Output goes in opposite direction
from level change
Check LRV/URV
3
Probable LRV/URV reversal.
Application related problems
Comments
Gas bubbles
The presence of gas bubbles
will decrease the dielectric
constant of the liquid and
therefore the reading. Bubbles
must be eliminated for proper
operation. Situations that can
result in pressure drops, such
as changing pipe diameters,
should be avoided.
Separation of oil and water
A homogeneous mixture is
required for proper operation.
Consider using an upstream
mixer if separation is
suspected.
7.4
7.6
Table 7-1 Problem / Symptom Chart
45
Troubleshooting
7.1
Identifying a Problem/Symptom
Use Table 7-1 as a guide to find and correct a problem when it occurs. Most problems
are not related to transmitter failure. It is important to be methodical when tracking
down a problem. If you experience a problem that you cannot solve using this guide,
call Drexelbrook Service at 215-674-1234. You may also E-mail us at the Internet
address: drexelbrook.service@ametek.com. Further service information may be
found at our World Wide Web address www.drexelbrook.com.
When you contact us, be prepared to give the service person as much information
as you can about the model numbers, serial numbers, application requirements,
and the materials being measured.
7.2
Troubleshooting Loop Connection
Specific transmitter loop connections will vary from installation to installation
but in general will be connected in a similar manner to typical transmitter loop in
Figure 2-3. When troubleshooting the loop connection, verify the following items.
1. Loop devices are wired in series.
2. There is at least 250 ohms total loop resistance for HART communications.
3. There is at least 13 VDC available for the transmitter when a loop current of
20 mA is flowing.
4. The open circuit voltage does not exceed 30 VDC
5. Power the unit from a portable source. 3 – 9 volt batteries in series will produce
27 VDC
7.3
Radio Frequency interference
All Drexelbrook transmitters have a significant amount of RFI protection built in.
However, there are situations where the standard protection is inadequate. RFI
filters are available to provide additional protection for the 4-20 mA loop from
unusually difficult sources of interference. Proper grounding and careful attention
to installation practices can usually make them unnecessary. Some recommended
installation practices are referenced in Section 2.
If RFI continues to be a problem, contact the Drexelbrook service department for
the proper filters and assistance.
46
Universal IV™ CM Model
7.4
Transmitter Does Not Communicate with HRTWin Software
Start
Transmitter
does not
communicate
with computer
Verify calibrator is connected properly. Reference Fig 3-1
Check for noise and ripple on loop. Maximum noise level for HART
communications is 1.2 mV rms (500 Hz – 10 kHz) Maximum
ripple 0.2 v p-p (47 – 125 Hz). If noise is found eliminate source such as
VFD wiring in close proximity to transmitter loop wires. Sometimes can
be reduced by increasing the loop resistance.
Verify there is 13 VDC minimum at the terminals @ 20 mA
No
Loop current
3.7 mA to
22 mA
No
Current > 22 mA: Disconnect probe and recheck current.
If current 3.7 mA – 22 mA check probe and cable per
section 7.7. Attempt to connect with probe disconnected.
If current is not 3.7 – 22 mA check transmitter per section 7.5.
Current = 0 mA: Verify there is 13 – 24 VDC at the terminals and
polarity is correct.
Current > 0 mA and < 3 mA: Possible bad transmitter.
Contact factory.
No
Check power source resistance. 250 ohms may be built-in.
Add resistor to loop to achieve 250 ohm minimum.
Yes
250 ohms
min. loop
resistance?
Communicating?
Yes
Connected to
DCS?
No
Yes
No
Verify correct COM port is selected
Check for software redirecting COM port
Possible bad cable or modem.
Verify modem is isolated from ground. If a
computer is used switch to battery power.
Try connecting with a different computer
Yes
Is DCS polling?
Yes
Disable polling or
power from
different source
Contact
Factory
Communicating?
Yes
47
Finish
Troubleshooting
7.5
Transmitter Function Test
If the unit is reading an incorrect value it is necessary perform the following steps .
1. Verify the transmitter power is correct. (10-30 VDC, 13 VDC-22mA or 18VDC22mA with 250 Ohms)
2. Disconnect power
3. Remove the transmitter from the housing.
4. Apply power
5. Perform a factory reset using Fct 6.01
6. Reset Water Cut range to 0-5% Light Fct 1.01
A. Unit should display 13.xx pf. If not correct, contact factory
B. If (A) is correct, remove probe wires from the mounting board and install
transmitter in housing. Unit should now show 7.xx pf. If this is correct, tranmitter
is operating properly. If this is not correct, contact factory.
7.6
Transmitter Drift Test
If symptoms point toward calibration drift, it is important to determine if the
apparent drift is coming from the transmitter, the sensing element, or the
application of the equipment. The following test determines if the transmitter
is stable. In most cases, no drift will be found in the transmitter.
1. Disconnect the coaxial cable from the transmitter terminals.
2. Without changing any data stored in the transmitter;
A. Connect a Drexelbrook capacitance substitution box (401-0006-008) or an
NPO test capacitor from the "PROBE" terminal to the Left "GND" terminal
on the transmitter "Figure 7-1" on page <OT>. (Select a capacitance value that
produces between 4 and 20 mA of loop current.)
3. Observe the loop current See "Figure 7-2" on page 46 over a 12-hour period
to confirm the stability of the unit. If the readings remain stable for this period,
then the problem is not in the transmitter. If the loop current has changed more
than 1% during the test period, then the unit is defective. Please contact the
Service department for further instructions regarding repair or replacement.
48
Universal IV™ CM Model
7.6
Transmitter Drift Test (Continued)
Electronic unit removed to access sensing element board terminal block. Sensing
element wires removed.
Figure 7-1
49
Troubleshooting
7.6
Transmitter Drift Test (Continued)
Figure 7-2
50
Universal IV™ CM Model
7.7
Testing the Sensing Element
1. With the sensing element installed normally, remove electronic unit from
housing.
2. Test in an empty pipe or pipe filled with oil. Use an analog meter.
3. Ref Figure 7-3 on page 52. Remove probe and shield wires. Measure from Probe
center wire (Blue) to GRD terminal, Probe center wire (blue) to Shield wire (Red)
and Shield wire (Red) to GRD terminal. All reading should be open.
4. Any measurement less than 1 Meg Ohm and probe must be removed from the
pipe and retested per #3.
5. If resistance reading was low when it was installed in the pipe and now reads
open when removed from pipe, then the probe (sensing element) was touching
the pipe wall. Inspect installation for the proper fit keeping the probe (sensing
element) centered in the pipe and parallel to the pipe wall.
6. If the resistance reading is still low after removal, check for paraffin buildup
on probe and pipe and clean. Retest per #3. If an unsuccessful test is concluded
then run the Cable Test below.
7.71 Testing the Cable
1. Integral system
A. Probe center Wire (Blue) should be shorted to the tip of the probe (listed as
center rod (active)) in Fig 7-3.Probe center wire (Blue) should be open to ground
and the the Shield wire (Red).
B. Shield wire (Red) should be shorted to the probe shield (listed as Cote Shield
Element in Fig 7-3.) and open to probe (Center Rod Active) and ground screws.
*Any bad reading indicates that there is a faulty probe or wires. Consult Factory.
2. Remote system cables
A. Disconnect wires from the probe and electronic mounting board. PErform
an end to end continuilty test of each wire and check to insure that they are
isolated from one another.
*Any bad reading indicates that there are faulty wires. Repair or replace cable.
Table 7-2
51
Troubleshooting
7.7 Testing the Sensing Element - RF Admittance (Continued)
Figure 7-3
52
Universal IV™ CM Model
7.8
Status Messages
The Universal IV CM has two types of error conditions, critical and non-critical.
Critical error conditions cause device to go to a fault state loop current and scroll a
message across the display. Non-critical error conditions allow the unit to continue
normal operations, but scroll a message across the display to indicate to the user
the nature of the non-critical faults. Most non-critical errors are the result of a
transient condition affecting a very small number of readings and are not indicative
of a failure but informational only.
Critical Errors
Below is a list of all the critical errors that can occur in the U-IV Cut Monitor:
Error Message:
SENSOR CRITICAL SHIELD ERROR
Cause:
The preamp has failed to take a shield reading for 10 consecutive attempts.
Action:
Contact factory
Error Message:
SENSOR CRITICAL PROBE ERROR
Cause:
The preamp has failed to take a probe reading for 10 consecutive attempts. Most likely
cause is a capacitance reading above the calibrated range
Action:
Perform sensing element and cable tests in troubleshooting section. Verify calibration
and configuration parameters are set correctly. Contact factory
Error Message:
SENSOR CRITICAL REF CAP ERROR
Cause:
The preamp has failed to take a reference cap reading for 10 consecutive attempts.
Action:
Contact factory
Error Message:
SENSOR CRITICAL COMM ERROR
Cause:
The output module has failed to communicate with the preamp for 20 consecutive
readings.
Action:
Contact factory.
Error Message:
SENSOR STACK OVERFLOW
Cause:
An error has occurred during operation that corrupted the SRAM.
Action:
Contact factory.
Error Message:
SENSOR FLASH CKSM ERROR
Cause:
The preamp failed the checksum test on power-up.
Action:
The unit needs to be replaced. Contact factory.
Error Message:
SENSOR SPI ERROR
Cause:
Preamp could not communicate with A2D through SPI bus.
Action:
Contact factory.
Error Message:
SENSOR INVALID PROFILE
Cause:
An invalid profile has been downloaded to the preamp.
Action:
Contact factory.
Error Message:
POWER UP FAILURE
Cause:
The output module failed to download all startup parameters to the preamp.
Action:
Cycle power to the system to attempt power-up procedure again. Contact factory
Error Message:
FLASH CKSM ERROR
53
Troubleshooting
7.8
Status Messages (Continued)
Cause:
The output module failed the checksum test on power-up.
Action:
The unit needs to be replaced. Contact factory.
Error Message:
STACK OVERFLOW
Cause:
An error occurred during operation that corrupted the SRAM.
Action:
Contact factory.
Error Message:
FORCED RANGE MODE
Cause:
The output module is in forced range mode because of HART command 215.
Action:
Contact factory.
Error Message:
CALIBRATION SETUP ERROR
Cause:
Calibration parameters produce calculated max capacitance above max range
Incorrect configuration or calibration entry
Action:
Review calibration and configuration data
Contact factory
Error Message:
BEYOND MAX CAP ERROR
Cause:
Live capacitance has exceed the max capacitance of the unit
Probe or sensing element shorted
Action:
Review calibration and configuration data
Perform sensing element and cable tests per section 5.5 and 5.6
Contact factory
54
Universal IV™ CM Model
7.8
Status Messages (Continued)
Noncritical Errors
The following is a list of all the non critical error messages that could be displayed
on the U-IV Cut Monitor:
Error Message:
SENSOR NONCRITICAL SHIELD ERROR
Cause:
The preamp encountered an error when attempting to take a shield reading.
Action:
If error persists, contact factory.
Error Message:
SENSOR NONCRITICAL PROBE ERROR
Cause:
The preamp encountered an error when attempting to take a probe reading.
Action:
If error persists see actions for SENSOR CRITICAL PROBE ERROR.
Error Message:
SENSOR NONCRITICAL REF CAP ERROR
Cause:
The preamp encountered an error when attempting to take a ref cap reading.
Action:
If error persists, contact factory.
Error Message:
SENSOR NONCRITICAL LEVEL VALID ERROR
Cause:
The preamp encountered an error when attempting to take a test cap reading.
Action:
If error persists, contact factory.
Error Message:
SENSOR NONCRITICAL COMM ERROR
Cause:
Communication between the output module and the preamp are intermittently timing out.
Action:
If error persists, contact factory.
Error Message:
FIXED CURRENT MODE SET
Cause:
The output module is in fixed current mode because of HART command 40.
Action:
Consult factory.
Error Message:
OVERRANGE
Cause:
% range is over 105%, Level > URV, Cable shield open circuit, Cable or sensing element
shorted
Action:
Verify level is within specified operating range, Perform sensing element and cable tests
per section 9.8, Contact factory
Error Message:
UNDERRANGE
Cause:
% range is under -5 %, Level < LRV, Cable or sensing element open circuit
Action:
Verify oil does not have gas bubbles, Perform sensing element and cable tests per section
9.8, Contact factory
Error Message
INVALID CAP
Cause:
Unit has calculated a negative capacitance
Action:
Verify the sensing element is fully covered in oil, Verify sensing element is connected
properly, Perform sensing element and cable tests per section 9.8
55
Troubleshooting
7.9
Factory Assistance
AMETEK Drexelbrook can answer any questions about your level measurement
system.
For Technical Support and Customer Assistance: + 215-674-1234
If you require assistance and attempts to locate the problem have failed:
• For Technical Assistance call + 215-674-1234,
• FAX: + 215-443-5117,
• E-mail: drexelbrook.service@ametek.com
Please complete the troubleshooting guide, section 7.14, and include any checkout
procedures performed with the results.
7.10 Field Service
Trained field service engineers are available on a time-plus-expense basis to assist
in start-ups, diagnosing difficult application problems, or in-plant training of
personnel. Contact the service department for further details.
7.11 Customer Training
Periodically, AMETEK Drexelbrook instrument training seminars for customers
are held at the factory. These sessions are guided by Drexelbrook engineers and
specialists, and provide detailed information on all aspects of level measurement,
including theory and practice of instrument operation. For more information
about these valuable workshops, write to AMETEK Drexelbrook, attention:
Communications/ Training Group, or call direct + 215-674-1234.
56
Universal IV™ CM Model
7.12 Return Equipment
Any equipment being returned for evaluation or credit must be pre-approved by
the factory.
In many applications, sensing elements are exposed to hazardous materials.
• OSHA mandates that our employees be informed and protected from
hazardous chemicals.
• Material Safety Data Sheets (MSDS) listing the hazardous materials
to which the sensing element has been exposed MUST accompany any
repair.
• It is your responsibility to fully disclose all chemicals and
decontaminate the sensing element.
To obtain a return authorization (RA#), contact the Service department at + 215674-1234.
Please provide the following information:
•
•
•
•
•
•
•
Model Number of Return Equipment
Serial Number
Process Materials to which equipment has been exposed
MSDS sheets for any hazardous materials
Billing Address
Shipping Address
Purchase Order No. for Replacement / evaluation
Please include a purchase order even if the returned unit is under warranty. If
repair is covered under warranty, you will not be charged.
Ship equipment freight prepaid to:
AMETEK Drexelbrook
205 Keith Valley Road
Horsham, PA 19044-1499
COD shipments will not be accepted.
57
Troubleshooting
7.13 Universal IV Cut Monitor Troubleshooting Guide
AMETEK Drexelbrook
Universal IV™ CM Model Troubleshooting Guide
Service Department (215) 674-1234 FAX (215) 443-5117
Service Dept. Contact
Customer Name
Company
City/State
Phone #
Fax #
Email
Electronic Unit Model #
Serial #
Sensing Element Model #
Serial #
Insertion Length
Cote Shield Length
Process Material
Temp.
Press.
Other
Provide as much of the following information as possible. All of the information is available from the
Drexelbrook Calibration Software. Information with an asterisk is available from the display.
Vessel Sketch
AMETEK Drexelbrook HRTWin Protocol Software Version
Tag ID
Serial Number
Scratch Pad
Software Version
*Damping Time
Span Range
Range Endpoints
Press F4 for Real-Time View
*LRV (4mA)
*Temperature
*URV (20mA)
*Water %
*Capacitance
*Loop Current
*Percentage
Instrument Configuration
*Status
*Oil Type
*Temperature Units
*Analog Loop Assign.
*Temperature Compensation
Show principal tank dimensions, including vessel construction, mounting
location, nozzle, LRV, URV, present level, etc.
Detailed description of problem:
58
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Section 8
Control Drawings
Universal IV™ CM Model
Section 8:
8.1
Control Drawings
ATEX / IECEX
61
Control Drawings
8.1
ATEX / IECEX (Continued)
62
Universal IV™ CM Model
8.1
ATEX / IECEX (Continued)
63
Control Drawings
8.1
ATEX / IECEX (Continued)
64
Universal IV™ CM Model
8.1
ATEX / IECEX (Continued)
65
Control Drawings
8.1
ATEX / IECEX (Continued)
66
Universal IV™ CM Model
8.1
ATEX / IECEX (Continued)
67
Control Drawings
8.1
ATEX / IECEX (Continued)
68
Universal IV™ CM Model
8.2
FM US / FMC
69
Control Drawings
8.2
FM US / FMC (Continued)
70
Universal IV™ CM Model
8.2
FM US / FMC (Continued)
71
Control Drawings
8.2
FM US / FMC (Continued)
72
Universal IV™ CM Model
8.2
FM US / FMC (Continued)
73
Control Drawings
8.2
FM US / FMC (Continued)
74
Universal IV™ CM Model
8.2
FM US / FMC (Continued)
75
Control Drawings
8.2
FM US / FMC (Continued)
76
Universal IV™ CM Model
8.2
FM US / FMC (Continued)
77
Control Drawings
8.2
FM US / FMC (Continued)
78
Universal IV™ CM Model
8.2
FM US / FMC (Continued)
79
Control Drawings
8.2
FM US / FMC (Continued)
80
Universal IV™ CM Model
8.2
FM US / FMC (Continued)
81
Control Drawings
8.2
FM US / FMC (Continued)
82
Universal IV™ CM Model
8.2
FM US / FMC (Continued)
83
Control Drawings
8.2
FM US / FMC (Continued)
84
Universal IV™ CM Model
8.2
FM US / FMC (Continued)
85
Control Drawings
8.2
FM US / FMC (Continued)
86
Universal IV™ CM Model
8.2
FM US / FMC (Continued)
87
Control Drawings
8.2
FM US / FMC (Continued)
88
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Section 9
Approval Certificates
Universal IV™ CM Model
Section 9:
9.1
Approval Certificates
FM US Approval Certificate
91
Approval Certificates
9.1
FM US Approval Certificate (Continued)
92
Universal IV™ CM Model
9.1
FM US Approval Certificate (Continued)
93
Approval Certificates
9.1
FM US Approval Certificate (Continued)
94
Universal IV™ CM Model
9.1
FM US Approval Certificate (Continued)
95
Approval Certificates
9.1
FM US Approval Certificate (Continued)
96
Universal IV™ CM Model
9.2
FM Canada Approval Certificate
97
Approval Certificates
9.2
FM Canada Approval Certificate (Continued)
98
Universal IV™ CM Model
9.2
FM Canada Approval Certificate (Continued)
99
Approval Certificates
9.2
FM Canada Approval Certificate (Continued)
100
Universal IV™ CM Model
9.2
FM Canada Approval Certificate (Continued)
101
Approval Certificates
9.2
FM Canada Approval Certificate (Continued)
102
Universal IV™ CM Model
9.3
IECEx Approval Certificate
103
Approval Certificates
9.3
IECEx Approval Certificate (Continued)
104
Universal IV™ CM Model
9.3
IECEx Approval Certificate (Continued)
105
Approval Certificates
9.3
IECEx Approval Certificate (Continued)
106
Universal IV™ CM Model
9.4
ATEX Approval Certificate
107
Approval Certificates
9.4
ATEX Approval Certificate (Continued)
108
Universal IV™ CM Model
9.4
ATEX Approval Certificate (Continued)
109
Approval Certificates
9.4
ATEX Approval Certificate (Continued)
110
Universal IV™ CM Model
9.4
ATEX Approval Certificate (Continued)
111
Approval Certificates
9.4
ATEX Approval Certificate (Continued)
112
Universal IV™ CM Model
9.4
ATEX Approval Certificate (Continued)
113
Approval Certificates
9.5
CE Mark Declaration of Conformity
114
Form 440-0001-001
3/1/2006
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If a delay excused per the above extends for more than ninety (90) days and the parties have
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any and all prior discussions, and negotiations on its subject matter.
Page Has No Content
An ISO 9001 Certified Company
205 Keith Valley Road, Horsham, PA 19044
Telephone:
+1 215-674-1234
Fax:
+1 215-674-2731
E-mail:
drexelbrook.info@ametek.com
Website:
www.drexelbrook.com
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