NOSHOK KING-GAGE 5900 Operation & Calibration Manual

D/P Module
4 mA to 20 mA Pressure Transmitter
Model 5900
Effective: September, 2010 (replaces February, 1998)
EX-1710-1
Operation/Calibration Manual
User Guide to Range Calculation, Calibration
Procedures, Zero/Span Adjustments
for Differential Pressure Transmitters
Multiple Tank Level Display
KING-GAGE, A NOSHOK Company I 1010 West Bagley Road, Berea, Ohio 44017 I Ph: 855-367-2494 I www.king-gage.com
Model 5900 D/P Module
© 2010 King Engineering Corp. All rights reserved.
The information contained in this manual was accurate at
the time of release. Specifications are subject to change
without notice.
WARRANTY—All King Engineering products are guaranteed
to be free from defects in material and workmanship for
one year from the date of purchase. Any product or part
found to be defective under normal use within one year
of purchase will be repaired or replaced at no charge if
returned to the company in Berea, Ohio within ten days
of discovery of the defect. No other warranties, whether
express, implied or statutory, including the warranties of
fitness for a particular purpose or merchantability, are given
by this agreement. The exclusive remedy for nonconformity
of these goods shall be repair and/or replacement of the
nonconforming goods or parts.
Seller will not be liable for consequential damages resulting
from breach of this agreement. The term "consequential
damages" shall include but shall not be limited to damage
to all machines, equipment and goods other than the goods
sold hereby, interruption of production, loss of profits,
delays of any kind, administrative expense and overhead.
Revisions:
April, 1987 – original release
December, 1987 – revised test equipment specifications
August, 1990 – revised zero/span adjustment
August, 1991 – corrected zero/span positions (pg. 11)
September, 1994 – revised text (update model numbers)
February, 1998 – LP2 3-terminal signal connector (pg. 15)
September, 2010 – revised voltage/load capacity
page 2
EX-1710-1
EX-1710-1
Model 5900 D/P Module
Table of Contents
Specifications.............................................................................................. 4
Span Adjustment Range.............................................................................. 4
Pressure Connections.................................................................................. 5
Power Requirement.................................................................................... 5
Load Capacity at Supplied Voltage.............................................................. 5
Calibration—Zero/Span Adjustment............................................................ 6
Low Pressure Input (for differential pressure)............................................... 8
Calibration Test Setup (Typical).................................................................... 9
Pressure Range Calculation....................................................................... 10
Troubleshooting........................................................................................ 11
Model No. Designations
5900 - 1 - 2
Fittings
1 = none (1/8" NPT connection)
4 = Swagelok 1/4" tube × 1/8" NPT
(compatible with copper or poly tubing)
Range
0 = 0–5 psid / 0 –0.3 bar
1 = 0–10 psid / 0 –0.69 bar
2 = 0–15 psid / 0 –1.03 bar
3 = 0–30 psid / 0 –2.06 bar
4 = 0–50 psid / 0 –3.44 bar
page 3
EX-1710-1
Model 5900 D/P Module
Application
The D/P Module is a pneumatic-to-current, differential pressure transmitter. It provides
a two-wire 4-20 mA output signal suitable for process control or tank level gauging.
Model 5900 D/P Module
This surface mount transmitter is intended for control room or other protected
locations. Modules should typically be mounted within an enclosure or cabinet.
Specifications
4-20 mA
Output
Connection
Pressure Ranges
0–5, 0–10, 0–15, 0–30, 0–50 psid
Output
4–20 milliamperes (mAdc)
KINGGAGE
ZERO
Accuracy
± 0.20% FS (± 0.10% FS, typical)
includes non-linearity, hysteresis, non-repeatability
SPAN
T
E
S
T
Repeatability
± 0.02% of calibrated span
Temperature Range (environmental)
0° F to 180° F / -18° C to 82° C operating
+
-
7-1/8 in
181 mm
D/P
MODULE
4-20 mA
Pressure
Transmitter
Compensated Temperature Range
32°F to 120°F / 0°C to 54° C
Thermal Effects
(over compensated temp. range)
less than .007° F (.011%° C) span shift—sensitivity
less than .007° F (.011%° C) span shift—zero
1/8 in NPT
1 in
25 mm
Power Supply Voltage
14–40 Vdc (unregulated)
Power Supply Stability
(Effect on FSO) less than 0.005% of span change in output
per volt change at input terminals
Burst Pressure
200 psi
Span Adjustment Range
Transmitter adjustment turndown is 3:1 for the 0–15, 0–30, 0–50 psid nominal ranges.
Nominal
0–5 psid
Minimum
0–3 psid
Range of Adjustment
0– 83 in. thru 0–138 in. water / 0–2.1 m thru 0–3.5 m water
0–10 psid
0–3 psid
0– 83 in. thru 0–277 in. water / 0–2.1 m thru 0–7.0 m water
0–15 psid
0–3 psid
0– 83 in. thru 0–415 in. water / 0–2.1 m thru 0–10.5 m water
0–30 psid
0–10 psid
0–277 in. thru 0– 830 in. water / 0–7.0 m thru 0–21.0 m water
0–50 psid
0–15 psid
0–415 in. thru 0–1384 in. water / 0–10.5 m thru 0–35.1 m water
Operating Limit (Maximum Pressure)
Pressure above 300% nominal range (overrange) will result in damage to the transmitter
(200% may cause a shift in calibration).
page 4
(Optional)
1/4 in Fittings
6-3/16 in
81 mm
E
S
Low
Pressure
Ports
High
Pressure
Ports
EX-1710-1
Model 5900 D/P Module
Pressure Connections
Power Requirement
D/P Module Transmitter incorporates two (2) 1/8" NPT
ports for HIGH and LOW differential pressure inputs.
The D/P transmitter requires a source of DC power (14– 40
Vdc) for operation. Minimum excitation voltage must be
no less than 14 Vdc Any receiver installed on the signal
loop (meters, data loggers, controllers, etc.) must be taken
into account when determining the required power supply
voltage to be used. The internal resistance of each device
added together represents the total “load” residing on the
signal loop circuit.
E
vent plug for atmospheric reference (or low pressure
input when measuring differential pressure)
S
connection for pressure input signal (high pressure
input when measuring differential pressure)
Load Capacity = (Supply Voltage −12 Volts)
(ohms)
.02
When application is for psig (gage pressure), the low pressure
port is not used. A vent plug should
be installed in the low
(Optional)
NPT transmitter
1/4 intoFittings
pressure port1/8
to inallow
reference atmosphere.
The low pressure port should never be plugged or sealed!
Load Capacity at Supplied Voltage
S
E
Low
Pressure
Ports
20 Vdc
24 Vdc
400 ohms
600 ohms
28 Vdc
32 Vdc
800 ohms 1000 ohms
36 Vdc
40 Vdc
1200 ohms
1400 ohms
KING-GAGE® tank processors and LevelBAR provide 24 Vdc
excitation to power the signal loop circuit. (If the application
Plug-in Power/Signal
requirement
exceeds 700 ohms, an external power supply
Connector
of appropriate voltage will be required.)
High
Pressure
Ports
+ Ð
Signal Loop Connections
1
A plug-in type terminal connector is furnished for the +
Signal and − Signal inputs. Terminal block can be removed
to make the cable connections and then re-inserted into
the mating socket. Screw clamp terminals are provided
for positive (+) and negative or common (−) sides of the
signal loop.
As is typical of two-wire transmitters, all electrical power
is supplied through the signal loop wiring. Refer to the
following diagram for proper wiring of the 4–20 mA loop
circuit:
2
Signal
Cabling
The 4–20 mA signal loop needs to be run using twisted pair
(two conductor) cable. “Noise” or EMI (electromagnetic
interference) does not generally create a problem since it
is common to both wires in the pair and essentially cancels
itself out. In most applications, non-shielded twisted pair
instrumentation cable (20–22 awg) will be suitable for the
signal+ loop between the LP2 and sensor/transmitter.
K
I
G NG
A G
E
ZE
RO
SP
AN
T
E
S
T
D/
P
M
O
4 DU
-
-2
L
Pr 0 m E
e
Tra ssu A
ns re
m
itt
er
Plug-in Power/Signal
Connector
+ Ð
1
-
2
RL
+
4-20 mA
Output
Connection
VCOM
+VA
K
I
G NG
A G
E
ZE
RO
SP
AN
T
E
S
T
D/
P
M
O
4 DU
+
-
-2
L
Pr 0 m E
e
Tra ssu A
ns re
m
itt
er
page 5
-
+
RL
EX-1710-1
Model 5900 D/P Module
Adjusting Zero Setting
Check zero by measuring the output using the meter
terminal posts (TP1 and TP2) on the transmitter board.
1.
Adjust span potentiometer as necessary to increase
output (clockwise) or decrease output (counterclockwise) until the signal displays as 20.00 or 20.01 mA
on the test meter.
Maximum
25 turns
adjustment
Zero Adjust &
Span Adjust
Potentiometers
3.
page 6
ZERO
3
4
Zero
Adjustment
Span
Adjustment
Meter
Terminals
SPAN
SW 1
+
-
Adjust zero potentiometer as necessary to increase
output (clockwise) or decrease output (counterclockwise) until the signal displays as 4.00 or 4.01 mA on
the test meter.
Adjusting Span Setting
This requires applying pressure to the “S” port of the D/P
transmitter equivalent to the maximum depth (hydrostatic)
pressure. Measure the output using the meter terminal
posts on the transmitter board.
2.
Dip Switch
2
This procedure is intended to recalibrate the existing zero and
span output settings. It is generally recommended that the
zero output be checked at least every 12 months. Generally
speaking, slight adjustment of the zero potentiometer is all
that is needed to maintain transmitter accuracy. However,
since zero is an offset adjustment, shifting this setting
upward or downward will have some corresponding effect
on span.
1
D/P Calibration—Zero/Span Adjustment
In-Process Zero/Span Adjustment
It is possible to make adjustments to the zero setting while
the D/P transmitter is installed at the tank. The meter terminal
posts permit in-process monitoring without disturbing the
loop wiring. Confirm that the tank is empty (or liquid level
is below sensor). Measure the transmitter output using a
milliammeter (multimeter) and adjust zero potentiometer
as required.
ON
Test Point Terminals (TP1, TP2)—Test meter terminals
are provided (see diagram) for measuring the output signal
without disturbing the signal loop. Do not connect any
device or meter whose internal resistance exceeds 20 ohms
across these test points. Also refer to “In-Process Zero/Span
Adjustment” in the following section.
Next step is to re-check the zero output and slightly
adjust if necessary.
Using Multimeter: Set multimeter for DC current, using
mA or .001 amp scale. The internal resistance of the meter
must be 20 ohms or less since higher resistance values will
create incorrect readings. Connect the meter leads to the
TP1 and TP2 posts on the internal circuit board.
Adjusting span settings of an installed transmitter is not a
very precise method for calibration (since the hydrostatic
pressure may not be accurately determined). In-process span
adjustment is not recommended for this reason.
EX-1710-1
Model 5900 D/P Module
D/P Range Adjustment DIP Switch Settings
The D/P transmitter span can be adjusted from 70%
to 140% of the nominal range indicated by the model
number. (Refer to Model No. Designation on page 3.) This
is how the transmitter’s pressure range can be changed
for a specific application. When the D/P transmitter is
used with a KING-GAGE ® digital tank level indicator,
the “Application Datapack” (iButton memory module) is
generally programmed with the nominal range setting. The
indicator programming will correlate the output signal to
tank capacity regardless of whether the maximum tank level
generates less than 20 mA output from the transmitter.
DIP Switch
Maximum mA
Output
ON
1 2 3 4
ON
Increase
1 2 3 4
ON
Decrease
1 2 3 4
ON
WHEN NOT TO CHANGE SPAN—If a KING-GAGE indicator
is part of the system, you should not have to change the
range (span) of the transmitter.
1 2 3 4
ON
1 2 3 4
Coarse Range Setting
An initial coarse range setting is provided by the DIP switches.
Use the previously outlined Zero/Span Calibration to achieve
the final trim setting for precise 4–20 mA output over the
intended pressure range.
The DIP switches on the transmitter circuit board affect
the span (range) of the transmitter. These provide coarse
adjustment in addition to the fine span adjustment of the
potentiometer. Please refer to the individual DIP switch
positions listed for adjusting the existing setting of the
transmitter.
ON
1 2 3 4
ON
1 2 3 4
Increase
1 2 3 4
Decrease
2.
1 2 3 4
ON
1 2 3 4
ON
1 2 3 4
Record the existing setting positions of the DIP
switches.
Adjust the potentiometer to maximum output by
turning clockwise until it “clicks”.
4.
To increase the milliamp output, use a higher switch
setting arrangement; to reduce the milliamp output,
use a lower switch setting arrangement. (The goal is
to achieve a output signal value just slightly above
20 milliamps and then use the potentiometer to
trim the setting.)
5.
ON
Apply the desired maximum pressure to the sensing
diaphragm of the D/P transmitter (requires a pressure
test shell available from King Engineering).
3.
Follow the Zero/Span Calibration procedure to check
both the zero and span output.
ON
1 2 3 4
The four (4) switches provide 16 increments of coarse
adjustment. Prior to changing any switch setting, check
the current output of the transmitter at the desired upper
pressure value. Also note the existing switch setting.
1.
ON
ON
Increase
1 2 3 4
ON
Decrease
1 2 3 4
ON
1 2 3 4
Minimum mA
Output
ON
1 2 3 4
page 7
EX-1710-1
Model 5900 D/P Module
Coarse Range Setting—Alternate Version
Previous versions of the D/P transmitter employ similar DIP
switches, but only offer 5 increments of coarse adjustment.
With these versions, the span potentiometer offers greater
range of adjustment.
Coarse Setting Procedure: The number of switches in
the ON position will increase the milliamp value as each
switch controls an identical fixed resistor. To increase
milliamp output, place additional switches into the ON
position. To decrease milliamp output, move switches
to the off position.
ON
ON
1 2 3 4
ON
1 2 3 4
1 2 3 4
1 2 3 4
Decrease
mA
Increase
mA
17.0
O
Internal Tank Pressure or Vacuum
In a closed, pressurized or evacuated tank, it is necessary to
measure differential pressure. This is achieved by subtracting
the internal pressure condition of the tank above the surface
of the liquid from the total pressure sensed at the bottom
of the tank. When the low pressure is applied to one side
of the transmitter sensing element and the high pressure to
the other side, the internal tank pressure above the liquid
(low pressure) is balanced across the sensing element. This
is also referred to as being “equalized” (which is why we
designate the low pressure connection as “E”).
CAUTION: While the internal pressure above the liquid is
not a factor in determining range (span), there may be
instances where the sum of the liquid and internal pressure
exceeds the 150 psi burst pressure rating of the transmitter.
Also, do not subtract pressure when a vacuum condition
is present within the tank (since loss of vacuum would be
seen as an increase at the high pressure connection of the
transmitter).
N
02
1
Gauge
Air Signal
Gauge
1 Air
2 3 Signal
4
ON
ON
Low Pressure Input
2
Meter
3
4
DIP Switch
P2
DIP Switch—Coarse Adjustment
19.9
S
O
N
70
Surface of Liquid
1
Range Less Than 3.00 PSID
2
3
Meter
4
When the nominal 5 psid
transmitter is used on an
DIP Switch
application whose maximum pressure is less than 3.00 psid,
the full calculated range output will be less than 20 mA.
To determine the actual milliamp output of the transmitter
when the maximum applied pressure is below the lower
span limit,
P2 use the following formula:
(16 × Calculated PSID)
3.0
+ 4 = mA Output
S
E
The above
P1 formula may also be used for other nominal
range transmitters if maximum applied
pressure will be
Sensor
less than the adjustment range allows. Merely divide by
the lower
limit psid value (listed above) in place of
P1 + span
P2
the “3.0” shown in the formula.
page 8
P
E
(P1
Sensor
P1 + P2
S
Surface of Liquid
Note
S
1
High
Pressure
P1 + P2
E
High
Pressure
P1 + P2
Low
Pressure
P2
(P1 + P2) - P2 = P1
EX-1710-1
Model 5900 D/P Module
Calibration Test Setup (Typical)
This D/P transmitter has a specified accuracy of ± 0.15%. To
ensure your calibration maintains this degree of accuracy,
the equipment used to check zero and span settings must
conform to the recommendation listed below. Use of
equipment with less than specified accuracy figures will not
provide acceptable results. King assumes no responsibility
for transmitter accuracy if test equipment does not meet
recommended minimum standards.
20.00
OFF
VOLTS AC
VOLTS DC
300 mV DC
OHMS
Recommended Equipment:
AUDIO
AMPS AC
MILLIAMMETER; 3-1/2 digit minimum, 0.05% accuracy
(20 ohms max. internal resistance)
DC POWER SUPPLY
−
PRESSURE INDICATOR; PSI or IN. OF WATER
0.05% accuracy corresponding to transmitter range
± .0025 psi or .0693" of water
5 psid nominal
± .005 psi or .1385" of water
10 psid nominal
± .0075 psi or .2078" of water
15 psid nominal
± .015 psi or .4156" of water
30 psid nominal
± .025 psi or .6927" of water
50 psid nominal
+
AMPS DC
10 A
300 mA
COM
Meter
−
NOTE—The low pressure port (“E”) of transmitter must be
vented to atmosphere during the calibration and adjustment
procedures.
+
RL
+
VCOM
4-20 mA
Output
Connection
+VA
−
Precision
Pressure
Regulator
Compressed
Air
S
0
160
Precision
Pressure
Indicator
page 9
EX-1710-1
Model 5900 D/P Module
Pressure Range Calculation
There are two simple equations that can be used to
determine the actual range (span) required for the
transmitter. One of these gives the range in psid and the
other in INCHES OF WATER.
(B − A) × C = Range (psid)
27.6807
Where . . .
A = Reserve (inches of depth from low point of tank to
sensor)
B = Full Tank (inches of depth from low point of tank to full)
C = Specific Gravity of Tank Contents
A second tank gauging application is illustrated in Figure 2.
The “reserve” represents the distance from the lowest
point on the bottom of the tank to the installed sensor.
“Full” is the level of contents at which the tank is filled
to desired level (which is less than the actual full capacity
of the tank). The liquid contents in the tank has a specific
Water
gravity of 1.032.
1.00
SP. GR.
B
C = 1.032 (Specific Gravity) Sensor
B = 300" (Upper Level)
A A = 28" (Reserve)
(300 − 28) × 1.032 = 10.14 psid
27.6807
(300 − 28) × 1.032 = 281" water
Converting LBS/GAL to Specific Gravity
If the density of the liquid is expressed as pounds per gallon
(e.g., 8.6 lbs/gal), the specific gravity can be determined
by dividing the value by 8.33 (weight of water per gallon).
Examples—Pressure Range Calculations
A typical tank gauging application is illustrated in Figure
1. The “reserve” represents the distance from the lowest
point on the bottom of the tank to the installed sensor.
“Full” is the level of contents at which the tank is filled
to capacity (or may be some point below the tank top, as
desired). The liquid contents in the tank is water @ 1.00
specific gravity.
C = 1.00 (Specific Gravity)
B = 382" (Full Tank)
A = 30" (Reserve)
B
Sensor
A
Figure 2
(382 − 30) × 1.00 = 12.72 psid
27.6807
NOTE—Should the calculated range exceed the upper span
limits of the transmitter, the next higher range is required.
If the calculated range falls below the lower span limits, a
lower range transmitter is required (to obtain 20 mAdc).
(382 − 30) × 1.00 = 352" water
When Output will be Less Than 20 mA . . .
Water
1.00 SP. GR.
B
Milk
1.032 SP. GR.
Sensor
Maximum Pressure Below 3.00 PSID
When the nominal 5 psid transmitter is used on an
application whose maximum pressure is less than 3.00 psid,
the full calculated range output will be less than 20 mA.
To determine the actual milliamp output of the transmitter
when the maximum applied pressure is below the lower
span limit, use the following formula:
(16 × Calculated PSID)
3.0
A
Figure 1
page 10
Milk
1.032 SP. GR.
+ 4 = mA Output
Other Ranges
The above formula may also be used for other nominal
range transmitters if maximum applied pressure will be
less than the adjustment range allows. Merely divide by
the lower span limit PSID value (see page 4) in place of the
“3.0” shown in the formula.
Model 5900 D/P Module
EX-1710-1
Troubleshooting
No signal
• Check that Vdc power is connected to the signal loop
circuit (V+ at transmitter + signal terminal).
• Polarity reversed- check by reversing the + and - leads
at the input terminals.
Output greater than 20.0 mA
• Check zero output of transmitter—adjust zero to 4.00
mA if necessary.
• Check span setting—adjust to 20.00 mA at nominal
range or calculated full pressure.
Maximum output less than 20.00 mA
• Check that applied pressure is within span limits
for transmitter range. (Transmitter has ± 40% span
adjustment.)
• Check span setting—adjust to 20.00 mA at nominal
range or calculated full pressure.
• Higher resistive load on signal loop may exceed voltage/
load capacity (see page 5).
page 11
">