ARJAY ENGINEERING 4100-PRO User manual

MODEL 4100-PRO
Oil/Water Emulsion Profiler
User Manual
Technical Support
Continental North America Toll Free 1-[phone]
Ph: [phone] Fx: [phone]
A Product of Arjay Engineering Ltd.
Oakville, Ontario, Canada
www.ArjayEng.com
MODEL:
HARDWARE NO.:
SOFTWARE NO.:
SERIAL NO.:

Model: 4100-PRO User Manual Rev: 1.0
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TABLE OF CONTENTS

1.0INSTRUMENT OVERVIEW............................................................................................4
1.1Features.............................................................................................................6
1.2Model Numbers..................................................................................................6
1.3Specifications.....................................................................................................7
2.0INSTALLATION...............................................................................................................8
2.1Main and Remote APP Panel Installation..........................................................8
2.2Probe Installation ...............................................................................................8
2.3Electrical Installation ..........................................................................................11
2.4Glossary of Symbols..........................................................................................12
3.0POWER UP INTRODUCTION........................................................................................13
3.1Power Up ...........................................................................................................13
3.2Screen Menu Background Information ..............................................................13
3.2.1Keypad Main Menu Entry....................................................................14
3.2.2Password.............................................................................................14
4.0SETUP AND CALIBRATION (PARAMETER SETTINGS) .............................................15
4.1Configuration Main Screen View........................................................................15
4.2Alarm Setup .......................................................................................................16
4.3Analog Output....................................................................................................18
4.4Date and Time....................................................................................................18
4.4.1Color Setup..........................................................................................18
4.5Calibration..........................................................................................................19
4.5.1Full Calibration (2 Point) (Most Typical)..............................................20
4.5.21 Point Calibration (Not Typical)..........................................................22
4.5.3Manual Calibration (Not Typical).........................................................23
4.6Diagnostic Information .......................................................................................24
5.0TROUBLESHOOTING....................................................................................................25
6.0CONTROLLER SETTINGS SHEET ...............................................................................28
7.0MODBUS MAP AND DETAIL.........................................................................................30
7.1Modbus Commands Supported.........................................................................30
7.2Register Map......................................................................................................30
8.0DETAILED ELECTRICAL AND DIMENSIONAL DRAWINGS........................................31

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TABLE OF FIGURES
Figure 1 – Instrument System Overview.......................................................................................................4
Figure 2 – PMC Installation Overview...........................................................................................................9
Figure 3 – Typical Water In Oil Application Overview.................................................................................10
Figure 4 – Electrical Installation Overview..................................................................................................11
Figure 5 – Main Screen View......................................................................................................................13
Figure 6 – Password Screen View..............................................................................................................14
Figure 7 – Parameter Settings Screen View...............................................................................................15
Figure 8 – Configure Main Screen View.....................................................................................................15
Figure 9 – Alarm Setting Screen Views......................................................................................................16
Figure 10 – Analog Output Screen View.....................................................................................................18
Figure 11 – Pulse Card Set-up Screen View..............................................................................................19
Figure 12 – Calibration Reminder Screen View..........................................................................................19
Figure 13 – 2 Point Calibration Screen View..............................................................................................20
Figure 15 – 1 Point Calibration Set-up Screens View.................................................................................22
Figure 14 – Manual Calibration Set-up Screen View..................................................................................23
Figure 15 – Diagnostic Information Screen View........................................................................................24

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1.0 INSTRUMENT OVERVIEW
The Arjay Model 4100-PRO is a capacitance based monitor used for the measurement of
emulsions, interfaces, and concentrations of water in oil or other mixtures in a pipe or vessel. The
control panel receives input data from one or more Arjay PMC cards installed at the sensing
probes and, through a site calibration, displays a graphic visual profile of the % water in oil
emulsions. The probes are installed at stategic vertical and/or horizontal points in the vessel. The
quantity of probes is fully optional and pre-determined for the application. Proportional analog
outputs and relays are available for each probe. A Modbus communication is standard.
The unit senses the oil /water interface or emulsion concentration using an RF capacitance
measurement technique for high resolution capacitance measurements. The capacitance
change is proportional to the dielectric change of the fluid. The probe capacitance to %
concentration is not a linear relationship over the full concentration range and accuracies are
best at or near the calibration points. The controller allows for two points of calibration. A single
point calibration is also available for out-of-the box use although this will not provide optimum
accuracy. The % indication and corresponding outputs are ideally suited for trending and
process data collection. Best sensitivity is provided in the 0-30% Water in Oil phase.
The panels receive an input from each Arjay PMC card installed in the sensing probe junction box.
Through a site calibration, the unit displays the % oil emulsion. A graphics display of the vessel
with user determined colour shades for % concentration is provided.
The monitoring system is comprised of one main control panel, an App board panel, the PMC
cards at the probe and the sensing probes.
Optional Remote alarm panels can also be added that will display and provide audio/visual alarms.
Figure 1 – Instrument System Overview

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Main Panel
The main panel is a wall mounted touch screen monitor to be installed in a general purpose (non-
hazardous) location that is accessible for set-up and observation of the display and alarms.
One relay is available for each probe input. See section 4.2 for instruction to change alarm setup.
A 4-20 mA non-isolated output per probe and Modbus RS-485 are provided. The power input at
the main panel serves the HMI, App Board Panel, PMC and probe requirements.
An optional buzzer and strobe (beacon) are available.
The sensing probe is approved for Class 1 Group C&D hazardous locations and can also be made
Intrinsically Safe for Hazardous Classified locations through the installation of an IS Barrier in the
main panel.
The main panel screen provides additional user interface menus for diagnostics, analog output,
calibration, set-up and general help information. Diagnostic Menus can be accessed for viewing at
any time but a password entry is required to make setup changes.
Remote Panel
Remote panels are available for audio/visual alarms.
App Board Panel
The App panel houses the circuitry and processors that monitor each probe. Calibration, setup
and operation functions are stored here. One App board is required per probe and provides a
Modbus communcation that is used by the Main Control Panel and User Interface to communicate
data from the probes.
Remote PMC and Sensing Probe
An Arjay PMC card is installed in the sensing probe junction box. This converts the capacitance
reading of the sensing probe into a frequency pulse for transmission to the main panel. This
unique approach eliminates any operator interface requirements at the probe. All diagnostics and
calibration is done at the main panel.

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1.1 Features
Touch Screen interface with passcode protection
Microprocessor based Controller
Optional Strobe / Buzzer
Display in % oil emulsion and vessel graphics
Diagnostic, set-up and Help menus on all screens
one alarm relay per probe
One common fault relay
analog outputs and RS-485 communication
Arjay PMC Card input per robe
Arjay 4100-PRO module per probe
1.2 Model Numbers
4100‐PRO‐a‐bc d e fg‐h
Example:
4100‐PRO‐1‐111000‐z
b - Enclosure
0 – No
1 – Type 4/IP65 Steel
2 – Type 4X/IP65 Poly
3 – Type 4X/IP65 SS
9 – Custom
c – Strobe Beacon
0 – No
1 – Yes
d – Buzzer
0 – No
1 – Yes
e – 4-20mA Output
0 – No
1 – Yes
f – RS-485 Modbus
Communication
0 – No
1 – Yes
g – Instrinsic Barrier
0 – No
1 – Yes
h – Custom vs.
Standard
x – Custom**
z – Standard
**Fill in the custom
requirement below.
a - Power Input
1 - 100-240 VAC
2 - n/a
3 - n/a
4 - 24 VDC
x – Custom
Description
100-240 vac
Power Input
Selected
Steel
Enclosure
Selected
Strobe
Selected
Buzzer
Selected
No 4-20mA
Selected
Standard
Configuration
Selected
No RS-485
Selected
No Intrinsic
Barrier
Selected

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1.3 Specifications
Power Input: -100-240 VAC +/- 10%, 50/60 Hz, 1PH (1.95A 0.97A) 2.0 fuse
- 24 vdc, 4 amp MAX (Optional)
User Interface:
Touch Screen Full Colour 6 “ display on Main Panel
Outputs:
Alarm Relay Output DPDT relay, 8 A @ 250 VAC dry contacts
Selectable failsafe or non-failsafe
Programmable time delay: 0 – 60 minutes ON and OFF
One relay for each sensing probe
One relay for system fault alarm
Analog (Optional) 0/4-20 mA non-isolated, 600 ohms
Self powered
Communication (Optional) RS-485 Modbus
Probe Input: Capacitance Probe with PMC input
Accuracy: 0.04% of full scale pF
Resolution: 0.007% (0.07pF at 1000pF)
Environmental:
Ambient Temperature Controller 0 to +55 °C
PMC -60°C to +55 °C
Sensing Probe -60°C to +260 °C
Process Pressure 103 bar / 10342 kPA /1500 psi
Relative humidity 0 to 95% (non-condensing)
Installation Category II
Pollution Degree 2
Mechanical Specification: Refer to dimensional drawing

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2.0 INSTALLATION
NOTE: If any damage to the instrument is found, please notify an Arjay Engineering
representative as soon as possible prior to installation.
2.1 Main and Remote APP Panel Installation
Choose a mounting location in accordance with good instrument practice. Extremes of ambient
temperature and vibration should be avoided (see specifications and installation drawing).
Remote APP panel can be mounted up to 1 km away from the main panel using RS485
communication cable (e.g. Belden 9841).
The PMC and sensing probe can be mounted up to 1 km away from the APP panel using 2 wire
shielded cable (e.g. Belden 8760).
Important Note: The controller can be set in a Failsafe mode. This means that the relays are in
an energized state during normal operation. The N.O. relay contact will be held closed and the
N.C. relay contact will be held open during a normal condition. This will allow the relay to return to
its non-energized (shelf) state during an alarm, fault or power failure condition.
2.2 Probe Installation
The probe length is customer specified based on the tank or pipe dimensions. Teflon coated
probes with 316SS concentric shields are used. Optional materials are available.
Typical probe entry into a tank requires a 3/4” NPT opening (standard probes), 1” NPT opening
(heavy duty probes), or 2”NPT (shielded probes). Flanges and concentric shields are available
as options. The entrance configuration may vary depending on the application requirements.
Use a wrench on only the lower half (tank side) of the probe fitting when installing or removing
the probe from the tank or flange. The probe fittings are compression type with Teflon ferrules
assembled by applying torque between the two fitting sections. The fittings are sealed at the
factory to provide a compression seal capable of withstanding high pressures. Once opened
they cannot be reassembled without new ferrules.
Pipe Mounting: The probe can be mounted parallel or at any angle into a pipe. To mount
parallel, a connection point at an elbow is recommended with the probe tip at downstream
direction.
To mount at 90° or other angle, consider the product viscosity and flow strain against the probe.
Tank Mounting: The probe can be mounted from any angle into the tank. If top mounted, an
inactive sheath is required to blind the probe for liquid level changes and the air space. Inactive
sheaths are also used when the probe mounts horizontal through a spool piece. This is to blind
the probe from contaminant build-up that may occur in the spool piece.
IMPORTANT: The active probe portion (exposed white Teflon sleeve) must be submerged in
liquid all the time. Exposure to air will not damage the probe, but will cause a reduced
capacitance reading, resulting in a false positive oil % reading.
The following points are important when installing the probe:
1. Reference ground: This is important and is typically the metal walls of the tank or
pipe. For non-metallic tanks, a concentrically shielded probe is required which
provides its own Ground. IMPORTANT: For threaded entry and flange entry probes,

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make sure the threads are clean to ensure a good electrical ground connection
between the tank, flange and fitting.
2. The distance between the probe and the ground reference: This only applies to
probes without concentric shields. The closer the distance to the tank or pipe wall,
the greater the sensitivity of measurement; too close and bridging problems may
occur.
3. Temperature change of the material in the tank. The amount of measurement
error depends on the material. If the temperature change is excessive, temperature
correction may be required.
4. Agitators or moving objects in the tank: Moving objects in the tank close to the
probe such as agitator blades, moving baffles etc. appear as moving ground
references to a capacitance probe and can cause measurement errors. In
applications where these objects are present, a concentrically shielded probe should
be used.
Below is an overview of the PMC (Pulse Module Circuit) installed at the probe.
1. Remove probe junction enclosure
cover.
2. If PMC 2800 is not already installed,
mount onto the standoffs in the base
of the probe junction enclosure.
3. Remove the mating connector and
wire it as shown.
4. Make sure junction box is electrical
grounded.
Figure 2 – PMC Installation Overview

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Figure 3 – Typical Water In Oil Application Overview

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2.3 Electrical Installation
Refer to the drawings provided by the contractual engineer for your project and the drawings
included with this manual.
Figure 4 – Electrical Installation Overview
Wiring
The main control panel supplies a 24 VDC power to the APP panel and communicates via RS485
modbus. Each APP module communicates with the PMC2800 puse card mounted in each
individual probe via 2 wire shielded cable.
The PMC card drops a frequency pulse onto the power wiring for a return signal to each APP
module. Required wiring between the PMC and the APP panel is two conductor shielded hook-up
cable. When the PMC’s connected, the voltage is 8-10VAC.
A typical wiring type is 18AWG two conductor shielded (Belden #8760 or equivalent).
*Shielded wire is required on all installations.
Maximum wire length is 1km between Main controller & APP panel and between APP panel &
PMC probe junction box.
Refer to the detailed electrical drawings included at the back of this manual.

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2.4 Glossary of Symbols
Attention, consult accompanying documents
Attention, veuillez consulter les documents ci-joints.
Protective Earth
Terre de protection Fuse Coupe-circuit; fusible
Direct Current (DC)
Courant continu Normally open relay contacts Contacts travail
Normally closed relay contacts
Contacts Repos Power off ArróÕ (mise hors tension)
Power on
Marche (mise sous tension) LLive Sous tension
NNeutral
Neutre GGround Terre

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3.0 POWER UP INTRODUCTION
3.1 Power Up
Check that the power wiring and connections to the main panel, remote APP panel, PMC card at
the probe and interfaced equipment are wired in accordance with the electrical installation
drawings.
Power On the unit.
The main screen will light up and run through initialization. After any power interruption, the
system will run through this same 30 second initialization.
The main panel is set to factory defaults or customer specifications. After the initial
installation, the alarm and output functions must be set by the customer and a process
calibration is required. These entries are retained in the CPU memory and are not required
after any further power disruption.
Confirm the screen reads similar to the following.
Figure 5 – Main Screen View
3.2 Screen Menu Background Information
The main screen provides a graphic display of the profile of the tank emulsions. Each colour
bar represents the reading from it’s corresponding probe. The % oil emulsion, raw capacitance
reading (in pF) and relay status is also displayed. A flashing relay status indicates that the relay
is in time delay mode.

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3.2.1 Keypad Main Menu Entry
Below the touch screen are 4 touch keys.
Home
At any time, you can press the Home Key to return directly to the Home Screen
Help
This provides serial number information and an overview of the system operation and
components. Contact details for technical help are included at the end of the text.
Tools
Access this section to view or configure the screen and control settings, view diagnostics and
perform a calibration
Buzzer Silence
During an alarm condition the audio can be silenced (if ordered). Silencing at any panel will
silence all panels. The audio alarm will automatically re-set when the alarm clears.
3.2.2 Password
This model has a touchscreen display. Tap the icon that you wish to change. A keyboard will
display for your changes. Press the Return Key to complete.
Accessing any screen that allows parameters to be changed will require a password. The
factory password is 2000. Touch within the Password box, a keyboard will display. After the
password is entered, press the Return key to complete. Then press OK in Logon screen.
Menus can then be accessed.
Figure 6 – Password Screen View

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4.0 SETUP AND CALIBRATION (PARAMETER SETTINGS)
This section describes the screen, alarm and interface features accessed through the Main
Panel. See Controller Setting Sheet (Section 6.0) in back of manual for Factory Default values.
Press “ “
Figure 7 – Parameter Settings Screen View
Enter into the following menu items to configure your monitor.
4.1 Configuration Main Screen View
Figure 8 – Configure Main Screen View
The Password 2000 will be required to make changes in this section.
Title: You can personalize the main screen title to your application or tag # (i.e. Separator #6 -
LT-4505). Touch the TITLE block and type in your description. The factory default is Oil /Water
Emulsion Profiler.
Current Modbus address: See section 7.0
Data Filtering
Filtering is used to suppress rapid spikes by adding time delay to the response rate. For
example, a sudden change of 40% could cause a valve to move too quickly and upset the
process conditions. Adding 10 seconds of delay will dampen the display measurement and mA

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output so that it approaches the 40% change over a period of 10 seconds. If the level returns to
a lower point, the mA will follow the new path with the same dampening affect.
4.2 Alarm Setup
The Password 2000 will be required to make changes in this section.
There is one relay per probe input. A system Fault relay is also provided. The Failsafe action of
the fault relay is selected on the Alarm Settings screen by toggling the Failsafe icon. Choose
your failsafe mode for the fault relay now. Typical is to make the icon green and read Failsafe
Relay.
Figure 9 – Alarm Setting Screen Views
Each Relay number corresponds to probe and relay number shown on the main screen. Touch
the Relay icon that you wish to set up. Enter the values for parameters described below. (See
table 1 for Effect of the relay action and failsafe).
Setpoint ON
This will determine the % Oil value at which the alarm relay activates for the oil concentration.
Setpoint Off
This will determine the % value at which the alarm relay will turn off. This differential feature is
used to suppress chattering of alarms if the % value is hovering at the setpoint. It can also be
used to control the differential on/off of a pump or valve.
Time Delay (Maximum 3600 seconds)
Delay ON. This is the time, in seconds, that the relay will delay before activating when the
alarm setpoint has been reached. Delay ON is used to suppress a nuisance alarm that may be
caused by a spurious or momentary alarm condition.
Delay OFF. The time, in seconds, that the relays will stay on after the level has returned to a
normal condition. Delay OFF is used to keep controls activated after the alarm has cleared to
ensure a stable normal condition has been reached.
Alarm Above or Below Setpoint
This function is to guide the controller on how to control the failsafe and LED indications on the
screen.
Select ABOVE if the requirement is for the relay to alarm when the % oil rises above the
setpoint.

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Select BELOW if the requirement is for the relay to alarm if the % oil drops below a setpoint.
The parameters are now set for relay 1. Repeat the above steps for the rest of the relays.
Failsafe
Failsafe will determine if the relays are energized or de-energized during a normal operating
state (no alarm condition).
If green Failsafe Relay is selected, the relay will be energized during a normal operating
condition. An alarm or power failure will de-energize the relay to the alarm state.
If in green Failsafe Relay mode, during a normal condition the N.O. contact is closed and the
N.C. contact is open. WIRE ACCORDINGLY.
TABLE 1: The following table shows the effect of the Relay Action and Failsafe settings.
Under normal conditions, the alarm icon on main screen would show “Green”.
Relay
Action Failsafe Setting Effect
Above No Alarm condition when % water in oil rises above the On Setpoint for at
least the alarm delay period.
Alarm condition remains active until the % water in oil drops below the Off
Setpoint.
No action is taken when the % water in oil is between the On and Off
differential Setpoint.
In the alarm condition, the corresponding alarm turns Red, and the relay
is energized.
Above Yes Alarm condition set and reset as above.
In the alarm condition, the corresponding alarm turns Red, but the relay is
de-energized.
Below No Alarm condition when % water in oil drops below the Off Setpoint for at
least the alarm delay period.
Alarm condition remains active until the % water in oil rises above the On
Setpoint.
No action is taken when the % water in oil is between the On and Off
differential Setpoints.
In the alarm condition, the corresponding alarm turns Red, and the relay
is energized.
Below Yes Alarm condition set and reset as above.
In the alarm condition, the corresponding alarm turns Red, but the relay is
de-energized.

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4.3 Analog Output
Figure 10 – Analog Output Screen View
The Passcode 2000 will be required to make changes in this section.
A mA analog output is available for each probe. Select which probe you wish to set up.
0-20mA vs 4-20mA
Select the mA output range for your application.
0/4 mA = 0 and 20 mA = xx%
The 0 or 4 mA is factory defaulted to 0 % level. The 20 mA may be offset to suit your control
requirements and is entered in %. Typically 20 mA is set to the 100% oil.
Force 20mA
For maintenance purposes to check external equipment and alarms or the analog output, the
mA output can be forced by pressing the “Force a 20mA output”.
4.4 Date and Time
The current date and time is displayed on the main screen. This can be changed here.
4.4.1 Color Setup
The main display has a graphic profile view of the tank and the % oil vs water emulsions.
There are six colours that can be displayed to represent the different % ranges of the
emulsions.
Dark blue represents the highest water concentration phase and dark brown represents the oil
phase range. Enter the desired % range of each shade, starting with water. Once the first
color’s entered then the second color is will automatically start from the end of the last %range.

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4.5 Calibration
A calibration at site is required for each probe. Enter the Calibration menu. This is passcode
protected. Enter the Probe Number you are calibrating. A Pulse Card set up will be required.
Confirm that the current A, K and C values shown on the screen match with the values provided
on the label of the PMC card installed in junction box at the probe. If the values are different,
Press the “Change” button on the screen. Enter the A, K and C values and press “Confirm”. The
screen will indicate “Confirmed” and the new values will show.
Figure 11 – Pulse Card Set-up Screen View
Calibration Reminder
The 4100-PRO has a real-time clock. After calibration, the calibration date is recorded in the
diagnostics. A calibration reminder can be set for up to 999 days. This feature can be enabled
by toggling Yes or No on the “ENABLE CALIBRATION REMINDER” icon. The icon “CAL
REMINDER” will appear on the main screen after the preset number of days is reached. Press
“CAL REMINDER” icon on main screen. If a calibration can be done when the cal reminder time
is reached, Press the “Recalibration” icon.
If a calibration cannot be performed at the time of the reminder, this can be reset to a later date
by entering the number of days until the next reminder is desired. Press “Enter” icon to activate
the Reminder countdown.
Figure 12 – Calibration Reminder Screen View

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This unit allows for three types of calibration.
4.5.1 Full Calibration (2 Point) (Most Typical)
After the setup parameters have been entered for the application, a process calibration is required.
The Full Calibration is most typical.
Two calibration points will need to be entered. The % oil concentration surrounding the probe
will need to be changed, up or down, to cause two different calibration points. The actual % oil
around the probe will need to be determined as accurately as possible.
The greater the change between the two points the better. For example, a 1% error in the
entered level value for a 25% change translates to a 4% error at Full Scale.
Ideally, a 0% oil (100% water condition) and a 100% oil (0% oil) condition can be used for
calibration. Until actual % concentration measurements can be made, it may be useful to
callibrate all of the probes using air as 100% oil for the first point. Then fill the vessel with water
and enter 0% as the second point for all the probes. As emulsions tests are done, the
calibration data can be manually corrected in manual calibration to improve accuracy.
To Calibrate.
Enter 2 point Calibration to Proceed.
Figure 13 – 2 Point Calibration Screen View
Note that a current Probe Number and current capacitance reading in pF is displayed on the
screen in blue. This is a real-time reading of the tank capacitance. If filtering has been used then
the user must wait until capacitance reading has stabilized before capturing. Confirm the current
probe number is correct. If not, change the probe number by pressing “Select probe#”