Ametek Universal III 509-7X Series User manual

A Leader in
Level Measurement
Series 509-7X
Universal III™ Transmitter
with HART® Protocol
using 409-1000 Electronics
U.S. and Canada: 1-800-553-9092
24-Hour Service: 1-800-527-6297
International: [phone]
Fax: [phone]
E-mail: drexelbrook.ser[email protected]
Website: www.drexelbrook.com
Installation and
Operating Instructions
For Assistance Call 1-800-527-6297
Outside North America + 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

Series 509-7X
Universal III™ Transmitter
with HART® Protocol
using 409-1000 Electronics
EDO# 02-08-101
409-1000-000-LM
Issue #10
205 Keith Valley Road, Horsham, PA 19044
U.S. and Canada: 1-800-553-9092
24-Hour Service: 1-800-527-6297
International: [phone]
Fax: [phone]
E-mail: drexelbrook.inf[email protected]
Website: www.drexelbrook.com
An ISO 9001 Certified Company

Form 440-0001-001 3/1/2006
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SERVICES, COST OF CAPITAL, COST OF SUBSTITUTE GOODS, FACILITIES,
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installation or in connection with the use or handling of nuclear material, or for any hazardous
activity or critical application, where failure of a single component could cause substantial
harm to persons or property, unless the goods have been specifically approved for such a use
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accordance with U.S. Export Law, that goods sold hereunder shall not be destined for
facilities or activities involving nuclear, chemical or biological weapons, or related missile
delivery systems in named prohibited regions or countries.
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any order. All matters relating to interpretation and effect of these terms and any authorized
changes, modifications or amendments thereto shall be governed by the laws of the
Commonwealth of Pennsylvania. No government contract regulations or clauses shall apply
to the goods or services, this agreement, or act to bind Seller unless specifically agreed to by
Seller in writing.
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conditions shall not be construed as a waiver of any other breach.
SEVERABILITY AND ENTIRE AGREEMENT: If any provision of these terms and conditions
is unenforceable, the remaining terms shall nonetheless continue in full force and effect. This
writing, together with any other terms and conditions Seller specifically agrees to in writing,
constitutes the entire terms and conditions of sale between Buyer and Seller and supercedes
any and all prior discussions, and negotiations on its subject matter.

Contents
Section 1: Introduction..................................................................................................................... 1
1.1 System Description........................................................................................................... 1
1.2 Technology........................................................................................................................ 1
1.3 Model Numbering ............................................................................................................. 2
1.4 Sensing Element Reference Number ............................................................................... 3
1.5 Area Classifications ........................................................................................................ 4
Section 2: Installation ...................................................................................................................... 5
2.1 Unpacking......................................................................................................................... 5
2.2 Mounting the Electronic Unit............................................................................................. 5
2.3 Wiring the Electronic Unit ............................................................................................... 10
2.4 Wiring the Sensing Element ........................................................................................... 12
2.5 Spark (Static Electricity) Protection ................................................................................ 13
2.6 Surge Voltage (Lightning) Protection .............................................................................. 15
2.7 RFI (Radio Frequency Interference) Filters..................................................................... 16
2.8 Electrostatic Filters ......................................................................................................... 18
2.9 Digital Integral Meter....................................................................................................... 19
Section 3: Configuration & Calibration with Drexelbrook PC Software..................................... 21
3.1 General Description ........................................................................................................ 21
3.2 Model Number ................................................................................................................ 21
3.3 System Requirements .................................................................................................... 21
3.4 Installing The RS232 Modem.......................................................................................... 22
3.5 Install the Windows Version HARTWin Software on Hard Drive ..................................... 24
3.6 Description of Function Keys .......................................................................................... 24
3.7 Configuration................................................................................................................... 26
3.8 Calibration....................................................................................................................... 28
3.9 PC Status Messages ...................................................................................................... 32
3.10 Set D/A Trim.................................................................................................................... 33
3.11 Strapping Table ............................................................................................................... 33
3.12 Digital Integral Meter Configuration ................................................................................ 35
3.13 Save/Print Entries ........................................................................................................... 35
3.14 Validation ........................................................................................................................ 36
3.15 Calibration & Configuration via 401-44-3 Display/Keypad .............................................. 39
Section 4: Configuration & Calibration Using the Rosemount™ Model 275 Communicator
with Drexelbrook Device Description.......................................................................... 41
4.1 Drexelbrook Device Description...................................................................................... 41
4.2 Start-up........................................................................................................................... 41
4.3 Configuration................................................................................................................... 42
4.4 Calibration....................................................................................................................... 44
Section 5: Configuration and Calibration Using the Rosemount™ Model 275 Communicator
without a Drexelbrook Device Description................................................................. 49
5.1 Range / Span Control ..................................................................................................... 49
5.2 Rules & Conventions of HART Configuration Software (Model 275) .............................. 50
5.3 Tag ID.............................................................................................................................. 50
5.4 Set Up Procedures ......................................................................................................... 51
5.5 Reading Input and Output............................................................................................... 54
5.6 Calibration Using Actual Tank Level................................................................................ 55
5.7 Bench Calibration (if needed) ......................................................................................... 56
5.8 Point Calibration.............................................................................................................. 58
5.9 Handheld Calibrator Error Messages.............................................................................. 59

Section 6: Troubleshooting............................................................................................................ 61
6.1 Identifying a Problem/Symptom...................................................................................... 62
6.2 Troubleshooting Loop Connection .................................................................................. 62
6.3 Rosemount Mod. 268 or 275 Calibrator cannot identify or find device .......................... 63
6.4 Rosemount Mod. 275 with device description cannot identify or find device .................. 63
6.5 Transmitter does not communicate with Drexelbrook PC software................................. 64
6.6 Troubleshooting Transmitter ............................................................................................ 65
6.7 Troubleshooting Sensing Element.................................................................................. 67
6.8 Troubleshooting Coaxial Cable ....................................................................................... 68
6.9 Static Electricity .............................................................................................................. 70
6.10 Radio Frequency Interference......................................................................................... 70
6.11 Factory Assistance.......................................................................................................... 70
6.12 Field Service ................................................................................................................... 71
6.13 Customer Training ........................................................................................................... 71
6.14 Return Equipment........................................................................................................... 72
6.15 Universal III Troubleshooting Guide ................................................................................ 73
Section 7: Specifications ............................................................................................................... 75
7.1 Transmitter Specifications ............................................................................................... 75
7.2 Coaxial Cable Specifications .......................................................................................... 76
Section 8: Normal Maintenance..................................................................................................... 77
8.1 Viewport Cleaning........................................................................................................... 77
Section 9: Drawings........................................................................................................................ 79
9.1 FM / CSA APPROVAL DRAWINGS................................................................................ 79
9.2 KEMA APPROVAL DRAWINGS ..................................................................................... 83

Introduction
1
Section 1: Introduction
1.1 System Description
The instructions in this manual are for the Drexelbrook
509-7X-XXX Series Universal III™ for level measurement
in liquids, slurries, interfaces and granulars.
Each Drexelbrook 509-7X-XXX system consists of a
Universal III™ (409-1000) series two-wire, 4-20 mA
electronic unit and a 700 series sensing element (probe). A
380 series connecting cable is also supplied for connection
of the sensing element to the electronic unit.
The 509-7X-XXX is an admittance-to-current transducer.
A change in level produces a change in admittance which
results in a change of current. It is termed a two-wire
transmitter because the same two wires that are used to
power the unit also indicate the change in level (4-20 mA).
1.2 Technology
In a simple capacitance probe, when the level rises and
material covers the sensing element, the capacitance within
the circuit between the probe and the medium (conductive
applications) or the probe and the vessel wall (insulating
applications) increases. This is due to the dielectric constant
(k) of the material, which causes a bridge misbalance. The
signal is demodulated (rectied), amplied and the output
is increased. There are drawbacks, however, especially
when there is coating of the probe.
An RF Admittance level transmitter is the next generation.
Although similar to the capacitance concept, Universal
III™ employs a radio frequency signal and adds the Cote-
Shield™ circuitry within the Electronics Unit.
Built-in oscillator buffer and chopper drive circuits permit
separate measurement of resistance and capacitance.
Since the resistance and the capacitance of any coating are
of equal magnitude (by physical laws), the error generated
by a coating can be measured and subtracted from the total
output.
This patented Cote-Shield™ circuitry is designed into
Universal III™ series and enables the instrument to ignore
the effect of buildup or material coating on the sensing
element. The sensing element is mounted in the vessel and
provides a change in RF admittance indicating presence of
material.
The Cote-Shield™ element of the sensor prevents the
transmission of RF current through the coating on the
sensing element. The only path to ground available for the
RF current is through the material being measured.
The result is an accurate measurement regardless of the
amount of coating on the probe, making it by far the most
versatile technology, good for very wide range conditions
from cryogenics to high temperature, from vacuum to
10,000psi pressure, and works with all types of materials.
Figure 1-1 Capacitance
Sensing Element
k
air
A
d
Ck
media
C=kA
d
C = k A
d
A
k
air
d
C
k
media
Tank Wall
Coating
High Resistance
Little to No Resistance
TFE Insulation
Sensing Element
(More Coating is
Easier to Ignore)
R
Xc
Xc
R
Oscillator circuitry through phase shift
cancels small amounts of RF current
flow (both Resistive and Capacitive)
caused by coating
Figure 1-2
RF Admittance Sensing
Element with Cote-Shield

509-7X Series Universal III™ Transmitter
2
1.3 Model Numbering
Universal III System
509 - 007
Application
5 Conductive Liquids
6 Interface
7 Insulating Liquids
9 Granular Solids
Package
7 Remote
9 Integral
Sensing Element Reference Number (Next Page)
509 - 007 X - X X X
Universal III Electronic Unit
409 - 10
Type
0 0 Insulating or Conducting Material
3 0 Coating Material
Agency Approvals
O No Approvals
F FM
C CSA
K KEMA
I FM, CSA, and KEMA
Frequency
0 100 KHz
1 15 KHz
Housing
1 Chassis Only
4 Remote Type 4X Explosion-Proof
6 Remote Type 4X Explosion-Proof with DrexelCote
7 Type 4X Fiberglass
8 Integral Type 4X Explosion-Proof with DrexelCote
9 Integral Type 4X Explosion-Proof
409 - 10 X 0 - X X X

Introduction
3
Sensing
Element
Reference
Number
Typical
Application
Sensing
Element
Model #
Material of
Construction
O.D. and
Mounting
Temperature and
Pressure
0075-X09 Water-like
Conductive
Liquids
700-001-22 TFE-covered rod Probe
3/8” OD
3/4” NPT
100°F @ 1000 PSI
300°F @ 500 PSI
0077-X06 Concentric
Water-like
Insulating
Liquids
700-001-24 TFE-covered rod with
carbon steel
concentric Shield
Concentric
Shield
1.66” OD
1 1/2” NPT
100°F @ 1000 PSI
300°F @ 500 PSI
0075-X07 Low Viscosity
Conducting
Liquids
700-002-24 TFE-covered rod Probe
3/4” OD
3/4” NPT
100°F @ 1000 PSI
450°F @ 500 PSI
0076-X02 Interface of
Liquids
Containing
Ketones and
Esters
700-002-27 FEP-covered rod Probe
.56” OD
3/4” NPT
100°F @ 1000 PSI
300°F @ 500 PSI
0075-X05 Thick
Conducting
Liquids
700-002-37 “X”*-covered rod Probe
.54” OD
3/4” NPT
100°F @ 1000 PSI
250°F @ 500 PSI
0075-X06 Conducting
Liquids and
Interfaces
700-002-57 “X”*-covered rod Probe
.84” OD
1” NPT
100°F @ 1000
PSI
250°F @ 500 PSI
0079-X20 Agitated
Conducting
Liquids and
Granulars
700-005-18 “X”*-covered cable Cable Probe
5/16” OD
3/4” NPT
100°F @ 1000 PSI
250°F @ 500 PSI
0079-X09 Heavy-duty for
Abrasive
Granulars
700-005-19 Urethane-covered
cable
Cable Probe
3/4” OD
2” NPT
150°F @ 5 PSI
150°F @ 5 PSI
0077-X25 Long Lengths of
Conducting
Liquids
700-005-54 PFA-covered cable Cable Probe
.093” OD
3/4” NPT
100°F @ 1000 PSI
300°F @ 500 PSI
0079-701
0077-714
Insulating
Liquids and
Granulars
700-205-78 “X”* covered cable Cable Probe
5/16” OD
1” NPT
250°F @ 5 PSI
250°F @ 5 PSI
*“X” is a fluorocarbon-type insulation
1.4 Sensing Element Reference Number

509-7X Series Universal III™ Transmitter
4
1.5 Area Classifications
The standard electronic unit in a Type 4X housing (409-
10XX-XX7) meets the following classications:
• Type 4X Waterproof/Corrosion Resistant.
The standard electronic unit mounted in the explosionproof
housing (409-10XX-XX4) is dual-rated and meets the
following conditions:
• Type 4X Waterproof/Corrosion Resistant
• Type 7 Explosionproof FM Approved for CI.I Gr. A,B,C
& D, CI.II Gr. E, F, & G CI. III.
See Section 1.4 for detailed specications of sensing elements
that are most often recommended with a 509-7X-XXX
system. Contact the factory or your local representative if
additional information is required.
The electronic unit and sensing element are connected by
a three-terminal coaxial cable. Drexelbrook cables are
available in:
• General Purpose: 380-XXX-12
• High Temperature: 380-XXX-11
• Composite: 380-XXX-18
(rst 10 feet high temperature)
The XXX in the model number indicates the length of the
cable in feet. 25 feet is standard (e.g., 380-025-12). Longer
and shorter lengths are available. Cable can also be
purchased in bulk lengths with termination kits. Consult
factory for maximum recommended lengths per specic
application.

Installation
5
Section 2: Installation
2.1 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.
2.2 Mounting the Electronic Unit
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.
The Universal IIITM (409-1000) Series system was designed
for eld 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 185°F (–40°C and 85°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 2-1.
• Always install to NEC® and/or local requirements/
codes/directives as mandated by the authority having
jurisdiction.
• Forelectronicunits withdisplayoption,the meter display
can be rotated to the proper viewing orientation after
installation. Refer to Section 2.16 for instructions.
• Cable ttings supplied are weather-resistant. They are
NOT certied as explosionproof (XP) or ameproof (d)
unless they are specically marked.
Figure 2-1 shows the recommended conduit installation.
See Figure 2-2 for dimensions when installing conduit to
the electronic unit.

509-7X Series Universal III™ Transmitter
6
Figure 2-2
Mounting Dimensions
Inches (mm)
2.2 Mounting the Electronic Unit (Continued)
Figure 2-1
Recommended Conduit
Connection
WRONG CORRECT
CONDUIT
BREATHER
DRAIN
WRONG CORRECT
* *
Allows Moisture Infiltration Use only cable
supplied by
AMETEK
Drexelbrook
All conduit connections
are sealed.
Gaskets are in place.
Fill Pipe Ends with
silicone sealant.
CONDULET
Packing Gland
Assembly
Do Not Disturb!
Hold here while
tightening condulet.
Hold here to install
or remove sensing
element from vessel.
*

Installation
7
2.2 Mounting the Electronic Unit (Continued)
The mounting location for the sensing element (probe) is
often determined by whether there is a suitable location
inside a vessel. An external side arm or stilling well can be
considered.
The following sensing element mounting and installation
instructions should be followed so that the equipment will
operate properly and accurately:
A. In applications requiring an insulated sensing element,
use particular care during installation. There is always
the danger of puncturing the insulation, especially with
the thin-walled probes.
B. Sensing elements should be mounted in such a manner
that they are not in the direct stream of a lling nozzle
or chute. If this is not possible, a deecting bafe should
be installed between the probe and the ll.
C. Do not take the sensing element apart or loosen the
packing glands. Follow instructions in Figure 2-3.
D. Avoid installing the sensing element with any of the
common mistakes shown in Figure 2-4.
E. If a stilling well is used, ensure that "vent" holes are
large enough to allow free passage of both air and process
material. Holes should be 5/8" or larger, 120° apart,
every 2-3 feet along the length of the stilling well.
F. Sensing elements that are mounted in agitated vessels
usually require brackets and supports to control the
position of the sensor during agitation. See Figure 2-5.
G. For non-metallic vessels without Drexelbrook self-
grounding sensing elements, choose one of the grounding
recommendations shown in Figure 2-6.

509-7X Series Universal III™ Transmitter
8
Figure 2-4
Common Installation Mistakes
PROBE
CONTACTS
SIDE OF STILLING
WELL
SLUDGE
SLUDGE
MAY CLOG
PIPE
LACK OF PROPER GROUND
(EARTH) CONNECTION
BETWEEN SENSOR MOUNTING
AND VESSEL WALL
NOZZLE DIAMETER
TOO SMALL
OR
LENGTH TOO LONG
DAMAGE
MAY
OCCUR
HERE
DAMAGE
MAY
OCCUR
HERE
PROBE
MAY
FLEX
INSIDE
PIPE
FILL LINE
AVOID
FILL
STREAM
WALL BUILD-UP
TOUCHES SENSOR
STILLING
WELL
LACKS
VENT
HOLES
Figure 2-3
Installing Sensing Element
Packing Gland
Assembly
Do Not Turn One
Relative to The
Other
Place Wrench Here
When Tightening
Condulet
Place Wrench
Here to Install or
Remove From
Vessel
2.2 Mounting the Electronic Unit (Continued)

Installation
9
FLEXIBLE
BOTTOM
ANCHOR
PART# 727-XX-X
CUSTOMER
SUPPLIED
SUPPORT
RECOMMENDED FLEXIBLE
SENSOR INSTALLATION
FLEXIBLE
CABLE TYPE
SENSOR
ROD
STYLE
SENSOR
CUSTOMER
SUPPLIED
SUPPORT
BRACKET
INSULATED
SUPPORT
BUSHINGS
PART # 713-XX-X
RECOMMENDED RIGID
SENSOR INSTALLATION
AVOID WEIGHTED
FLEXIBLE SENSORS IN
HEAVILY AGITATED
VESSELS
Figure 2-5
Installing Sensing Element
in Agitated Vessel
Figure 2-6
Providing Ground
Reference*
*This is a sensing
element ground
reference and possibly
different from an
electrical power ground.
GROUND
CLAMP
CLAMP
RUN 14 AWG. WIRE FROM FABRICATED
GROUND TO GREEN SENSOR GROUND
SCREW
PLASTIC
TANK
SENSOR
A B
C
E
D
PUMP
WEIGHT
F
METAL
C
MOUNT SENSOR IN METAL PIPE
Mounting the level sensor inside a metal
pipe provides an excellent ground
reference.
Use only if the process material is
greter than 1000 uMHOS/cm such as acids
and caustic.
A
GROUND ROD
A ground rod can be fabricated out of any
metal compatible with the process. Use
material that is at least 3/8inch dia. such as
pipe, All-Thread, or tubing. The ground rod
must be parallel and relatively close to the
sensor.
B
GROUND WIRE
1/4 inch or larger dia. stainless steel rope
that is anchored or weighted can be used.
E
SUBMERGED METAL STRUCTURE
Use any constantly submerged metal
object such as: pumps, agitators, or
thermowells.
F
METAL FLANGE
A submerged metal flange or orifice plate
can be used.
Use only if the process material is greater
thatn 1000 uMHOS/Cm. such as acids and
caustic.
D
METAL PIPING
Metal piping that connects to the tank
bottom can be used as a ground
reference. Use only if the process material
is greter than 1000 uMHOS/cm such as
acids and caustic.
If the vessel is non metallic see grounding sketch below. sensors
with factory supplied concentric shield or ground rod do not need
additional grounding.
Measure ground continuity from housing ground screw to metal
wall of vessel. A good ground will measure less than 5 ohms.
2.2 Mounting the Electronic Unit (Continued)

509-7X Series Universal III™ Transmitter
10
Figure 2-7
Wiring Connections Integral Mounting
Figure 2-8Wiring Connections, Remote Mounting
2.3 Wiring the Electronic Unit
Integral units are pre-wired at the factory. Figure 2-7
shows the wiring of the integral unit.
For remote units, 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). Twisted shielded pair
cables are recommended for lengths over 200 feet.
The cable from the sensing element is connected to the four-
terminal strip on the back side of the instrument chassis.
The cable connections are probe (prb)or Center Wire (cw),
ground (gnd), and shield (shd). See Figure 2-8 for wiring
connections of the remote unit.

Installation
11
Figure 2-8
Universal III Wiring Connections
Remote Mounting
2.3 Wiring the Electronic Unit (Continued)

509-7X Series Universal III™ Transmitter
12
2.4 Wiring the Sensing Element
CAUTION !
Before using Intrinsic Safety Barriers, read
manufacturer's instruction for barrier operation.
The 409-1000 has a built-in current limiter which
holds the signal current to a maximum of 28 mA.
The cable connections to the sensing element are shown in
Figure 2-9 and 2-10
• 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.
• If the sensing element does not have a shield connection,
(the most common condition for a 2-terminal sensing
element) be sure to clip and /or tape the shield wire
at the sensing element end of the cable only. See
Figure 2-9.
Only coaxial cables supplied by Drexelbrook should be used
to connect the transmitter to the sensing element. Use of
other cables can result in unstable performance.
Clipped Shield wire on two-wire versions must NOT touch
housing.
Figure 2-9
Three-Terminal Cable Connections
to Two-Terminal Sensing Element
Figure 2-10
Three-Terminal Cable Connections
to Three-Terminal Sensing Element