ARJAY ENGINEERING 4100-HCF2 User manual

MODELS:
4100-HCF2
FLOATING OIL THICKNESS MONITOR
USER MANUAL
(
REV: 3.0
)
ARJAY ENGINEERING
2851 Brighton Road
Oakville (Toronto), Canada
L6H 6C9
TEL: ++1 [phone]
FAX: ++1 [phone]
NORTH AMERICA: 1-800-387-9487
WEBSITE: www.arjayeng.com
EMAIL: [e-mail]

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TABLE OF CONTENT
NOTICE Please read the Installation Notes (4.0) prior to locating and mounting
the instrument.
1.0 SPECIFICATION .................................................................................................... 5
2.0 USE HAZARD INFORMATION............................................................................... 7
3.0 INSTRUMENT OVERVIEW..................................................................................... 8
3.1 Features ............................................................................................................................. 10
3.2 Model Number Table .......................................................................................................... 10
4.0 INSTALLATION.................................................................................................... 11
4.1 Main and Remote Panel Installation ................................................................................... 11
4.2 Sensor Installation .............................................................................................................. 12
5.0 ELECTRICAL INSTALLATION OVERVIEW ........................................................ 14
5.1 Permanent Power Connection (AC Powered Models Only) ............................................... 15
5.2 Glossary Of Symbols .......................................................................................................... 15
6.0 STARTUP ............................................................................................................. 16
6.1 Startup ................................................................................................................................ 16
6.2 Screen Menu Background Information ............................................................................... 16
6.2.1 Keypad Main Menu Entry ................................................................................................... 17
6.2.2 Password ............................................................................................................................ 18
7.0 CONTROLLER NETWORK .................................................................................. 19
7.1 Configure Main Screen View .............................................................................................. 19
7.2 Alarms Setup ...................................................................................................................... 20
7.3 Date and Time .................................................................................................................... 22
7.4 Analog (mA) Output (Optional) ........................................................................................... 23
7.5 mA Output Trim (Optional) ................................................................................................. 2 3
7.6 Buzzer and Strobe Beacon (Optional) ................................................................................ 23
7.7 Level Sensor mA Input (Optional) ...................................................................................... 23
7.8 Calibration .......................................................................................................................... 24
7.8.1 Quick Calibration ................................................................................................................ 25
7.8.2 Full Calibration .................................................................................................................... 26
7.8.3 Manual Calibration .............................................................................................................. 26
7.9 Diagnostic Information ........................................................................................................ 27
8.0 TROUBLESHOOTING.......................................................................................... 29
9.0 CONTROLLER SETTING SHEET ........................................................................ 31
10.0 MODBUS MAP AND DETAIL (OPTIONAL).......................................................... 34
10.1 Modbus Commands Supports ............................................................................................ 34
10.2 Register Map ...................................................................................................................... 34
11.0 DETAIL ELECTRICAL AND DIMENSIONAL DRAWINGS................................... 35

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TABLE OF FIGURES
FIGURE 1 – INSTRUMENT SYSTEM OVERVIEW .................................................................... 8
FIGURE 2 – FLOAT SENSOR INSTALLATION OVERVIEW .................................................. 12
FIGURE 3 – TYPICAL OIL THICKNESS MONITOR APPLICATION OVERVIEW ............... 13
FIGURE 4 – ELECTRICAL INSTALLATION OVERVIEW ........................................................ 14
FIGURE 5 – MAIN SCREEN VIEW ............................................................................................. 16
FIGURE 6 – PASSWORD SCREEN VIEW ................................................................................ 18
FIGURE 7 – PARAMETER SETTINGS SCREEN VIEW .......................................................... 19
FIGURE 8 – CONFIGURE MAIN SCREEN VIEW ..................................................................... 19
FIGURE 9 – ALARM SETTING SCREEN VIEW (DISABLED RELAY 3 & 4) ........................ 20
FIGURE 10 – ALARM SETUP SCREEN VIEW ......................................................................... 21
FIGURE 11 – DATE AND TIME SCREEN VIEW ....................................................................... 22
FIGURE 12 – ANALOG OUTPUT SCREEN VIEW ................................................................... 23
FIGURE 13 – BUZZER & STROBE SETTING SCREEN VIEW .............................................. 24
FIGURE 14 – PULSE CARD SET-UP SCREEN VIEW ............................................................ 24
FIGURE 15 – CALIBRATION REMINDER SCREEN VIEW ..................................................... 25
FIGURE 16 – QUICK CALIBRATION SET-UP SCREEN VIEW .............................................. 25
FIGURE 17 – FULL CALIBRATION SET-UP SCREEN VIEW................................................. 26
FIGURE 18 – MANUAL CALIBRATION SET-UP SCREEN VIEW .......................................... 26
FIGURE 19 – DIAGNOSTIC INFORMATION SCREEN VIEW ................................................ 27

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1.0 SPECIFICATION
Specifications are subject to change without notice
Specification Details
Power Input:
(Specify voltage at time of
Order)
100VAC – 240VAC +/- 10%, 50/60 Hz, (1.22A 0.66A) 1.6A Fuse
24VDC, 2.5A maximum (Optional)
Note: DC input models must be supplied by Limited Energy power source. Limited
Energy means compliance with one of the following requirements:
- Class 2 circuit according to Canadian Electrical Code, Part, I, C22.1;
- Class 2 circuit according to National Electrical Code, NFPA-70;
- Limited Power Supply (LPS) according to IEC 60950-1;
- Limited-energy circuit according to IEC 61010-1.
Connections to mains supply Permanent (for AC/DC model)
User Interface:
Touch Screen Full Colour 7“ display on Main Panel
Monochrome 4” on Remote Panel
Relays / Analog Outputs:
Alarm Relay Outputs
(R1, R2, R3 & R4**)
**Can be selected as pump
relay or Level Alarm)
DPDT relay, 8A @ 250 VAC dry contacts
Selectable failsafe or non-failsafe
Programmable time delay: 0 – 60 minutes ON and OFF
R1 relay for setpoint Oil alarm,
R2 relay for setpoint Air (Dry condition) alarm *,
R3 relay for system fault alarm *
* these relays can be selected for Oil alarm
R4 relay for setpoint Oil alarm**
Option: Pump Relay or Level
Alarm (R4)
DPDT relay, 8 A @ 250 VAC dry contacts Programmable pump
run time OR can be set as a level alarm from external level sensor
mA Signal Output 0/4-20mA non-isolated, 600 ohms Self powered
Communication (Optional) RS-485 Modbus
Float Sensor Input: Capacitance Sensor with PMC input
External Level Sensor Input: 4-20mA input from Level transmitte
r
Instrument Performance:
Accuracy 0.04% of full scale pF
Resolution 0.007% (0.07pF at 1000pF)

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Environmental:
Operating conditions Continuous
Ambient Temperature 0°C to +55 °C controller
0 to +55 °C Float Sensor with potted PMC
(Optional high temperature sensor available. Consult factory
)
Relative humidit
y
0 to 95% (no
n
-condensing
)
Installation Categor
y
I
I
Pollution Degree 2
Equipment mobilit
y
Fixed
Mechanical Specification: Refer to Dimensional Drawin
g

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2.0 USE HAZARD INFORMATION
CAUTION Indicates a potentially hazardous situation that may result in minor or
moderate in
j
ur
y.
WARNING Indicates a potentially or imminently hazardous situation which, if not
avoided, could result in death or serious in
j
ur
y.
DANGER Indicates a potentially or imminently hazardous situation which, if not
avoided, will result in death or serious in
j
ur
y.
NOTICE Indicates a situation which, if not avoided, may cause damage to the
instrument. Information that requires special emphasis
.

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3.0 INSTRUMENT OVERVIEW
The Arjay Model 4100-HCF is a capacitance based interface monitor used for the measurement and
control of separated oil on a water surface.
The main panel receives an input from the Arjay PMC card which is potted within the floating sensor.
Through a site calibration, the unit displays the oil depth on water and provides proportional outputs and
relay controls. As an option there is a display of level from an external level sensor.
The monitoring system is comprised of one main control panel, floating sensor with potted PMC card.
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.
Four relays are available. Relay 1 can be field set to alarm at any depth of oil within the range of the
sensor. Relay 2 is factory set as an Air alarm (Dry condition). Relay 3 is factory set as a system fault
relay. Relay 4 can be set as a (1) general purpose oil alarm (factory default), (2) Pump Run relay with a
timed and auto shut-off feature or (3) level sensor mA input alarm. Relay 2 and 3 can also be selected
to act as Oil Alarm relays. See section 7.2 for instruction to change alarm setup.
A 4-20 mA non-isolated output and Modbus RS-485 are optional. The power input at the main panel
serves the HMI, PLC, and sensor requirements.
An optional Buzzer and strobe (beacon) are available.
The float may 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 passcode entry is required to make setup changes.
Remote Panel
Remote panels are available to mimic the screen and audio/visual alarms of the main panel. All access
to the touch screen menus are password protected on the remote panels.
Sensing float
An Arjay PMC card is potted within the sensor. This converts the capacitance reading of the oil
thickness into a frequency pulse for transmission to the main panel. This unique approach eliminates
any operator interface requirements at the sensor. All diagnostics and calibration is done at the main
panel.
The sensor floats on the surface of the changing water level and is tuned to the capacitance field below
it. When oil separates to the surface, the capacitance reading deceases.
The premise of this stable and reliable technology is that the sensor is continuously floating. In
applications where the well or sump may go dry, the water is displaced with air rather than oil. This will
indicate as an oil condition until the water has lowered enough to initiate the Air alarm. In such
applications, a separate low level switch may be considered to alert operations or lock out an oil alarm
that is caused by air displacing the water rather than oil.
External Level Sensor input
A display of the overall level of the sump or tank is provided as an option. This would require a 4-20mA
input from an external level sensor. Relay 4 can be enabled as a level sensor alarm.

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3.1 Features
x Touch Screen Interface with passcode protection
x Microprocessor based Controller
x Oil Display in % and engineering units
x Diagnostic, set-up and Help menus on all screens
x Four alarm relays
x Optional analog outputs and RS-485 communication
x Optional level display in % and unit of measurement
3.2 Model Number Table
4100-HCF2 - a - b c d e f g - h
Example:
4100-HCF2 - 1 - 1 1 1 0 0 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

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4.0 INSTALLATION
NOTICE If any damage to the instrument is found, please notify an Arjay
Engineering representative as soon as possible prior to installation.
NOTICE Qualified Personnel must undertake all installations.
WARNING If the equipment is used in a manner not specified by the manufacturer,
the protection provided by the equipment may be impaired.
4.1 Main and Remote Panel Installation
Choose the mounting location in accordance with good instrument practice. Extremes of ambient
temperature and vibration should be avoided (see specifications and installation drawing).
Remote mimic panels can be mounted up to 300 meters away from the main panel.
The float sensor with built-in PMC card can be mounted up to 1 km away from the main panel.
NOTICE The controller operates in a Failsafe Mode (factory default).
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. If using the Relay 4 as Pump Run relay then non-failsafe mode is used. Wire
accordingly.
CAUTION
The Internal ground screw provided in this enclosure must be used for
equipment grounding connection.
The External ground screw is provided for use only as a supplemental
connection where required (or, permitted) by local codes or authorities.

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4.2 Sensor Installation
NOTICE Read the following information before installation.
The floating sensor comes with 30meter (100ft) of 3 conductor cable. Any excess cable should be cut
back. The installation must allow enough cable for the float sensor to extend down to the lowest water
level.
When the float sensor (A00765) is floating in water the complete white Teflon probe should be
submerged. There is a 1” diameter wire guide available on the float if the user decides to install a guiding
rod/wire in sump.
When the float sensor (A00761) is floating the bottom of sensing pod should be submerged up to “Water
Line” indication.
As the float rises, the cable will hang into the water. A minimal water level change of less than 2 meters
is recommended to reduce the stress pull on the sensor. The sensor should be placed in an area of calm
or protected water. Any splitter junction box must be mounted above the flood level and sealed from
condensation in the conduit.
In applications of high turbulence and extremes of level change, additional guide restraints may be
required. Consult Arjay Engineering.
NOTICE To ensure proper operation and electrical safety, make sure the
controller is electrically grounded.
Figure 2 – Float Sensor Installation Overview
(Without Intrinsic Safety Barrier)

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Figure 3 – Typical Oil Thickness Monitor Application Overview

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5.0 ELECTRICAL INSTALLATION OVERVIEW
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 signal to the PMC card installed in the floating sensor.
When the sensor float is connected, the voltage is 8 – 13 VDC across the + & - terminals of probe input
of an App Board.
The PMC card drops a frequency pulse onto the sensor wiring for a return signal to the main control unit.
Float sensor comes with 30m (100ft) cable. Any extra length would require a weatherproof splitter box
and 3 conductor shielded hook up cable.
A typical wiring type is 20AWG 3 conductor shielded (Belden #8772 or equivalent).
*Shielded wire is required on all installations.
Maximum wire length is 1km between controllers to sensor float.
Refer to the detailed electrical drawings included at the back of this manual.

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5.1 Permanent Power Connection (AC Powered Models Only)
1) Connection to the building wiring system shall be in accordance with the Canadian Electrical
Code (CEC), Part 1 in Canada, the National Electrical Code, ANSI/NFPA 70 in the USA, or the
local electrical codes of the country where the equipment is being installed.
2) A disconnecting device is required. The disconnecting means shall disconnect all current-
carrying conductors.
3) 15A circuit breaker or equivalent fuse is required.
4) An external switch or breaker shall be in close proximity to the equipment and within easy reach
of the operator. The switch shall be marked as the disconnecting device for the equipment and
include the symbols to its “ON” and “OFF” positions using the following symbols:
Power
Off
Power
On
5) The wiring for AC power should be minimum 18 AWG / 300V or as required by local / country
codes.
6) After field wiring, the primary wires must be secured to the enclosure by tie-wraps to maintain
the separation from the signal wires.
7) Wiring diagram for permanent connection: See drawings at the back of this manual.
8) Use copper conductors only.
5.2 Glossary Of Symbols
Attention, consult accompanying documents
Attention, veuillez consulter les documents ci-joints.
Primary Protective Earth Ground
Primaire de terre de protection
Fuse
Coupe-circuit; fusible
Secondary Earth Ground
Mise à la terre de secondaire
Normally open relay contacts
Contacts travail
Direct Current (DC)
Courant continu
Power off
ArróÕ (mise hors tension)
Normally closed relay contacts
Contacts Repos LLive Sous tension
Power on
Marche (mise sous tension) GGround Terre
NNeutral
Neutre

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6.0 STARTUP
6.1 Startup
Check that the power wiring and connections to the main panel, remote panel, floating sensor 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 and remote panels are 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.
Without Level Sensor Main Screen With Level Sensor Main Screen
Figure 5 – Main Screen View
6.2 Screen Menu Background Information
**Screen saver is available thru Control Panel setup at initial Start-up.
The Trend View logs and provides a graphic display of the oil level readings during the past 10
days. This view can be hidden. (Press “No Trend” icon).
In addition to the standard % display, the screen will display in any engineering units entered. Note
that the engineering units must be directly proportional to the % level for the reading to be accurate.
For example, a volume in liters will be proportional to an oil level in a vertical straight walled sump
but will not be proportional to a level in an open pond. The full scale value of units, such as liters or
mm at the determined 100% maximum oil level will be required to be entered during calibration.
Note: The 100% oil depth is a maximum of 25mm for the A00761 style sensor and 300mm for the
A00765 style sensor.

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6.2.1 Keypad Main Menu Entry
Below the touch screen are 4 touch keys (see below keypad image):
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. Silencing at any panel will silence all panels.
The audio alarm will automatically re-set when the alarm clears.

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6.2.2 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 Login screen. Menus can then
be accessed.
Figure 6 – Password Screen View

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7.0 CONTROLLER NETWORK
This section describes the screen, alarm and interface features accessed through the Main Panel.
See Controller Setting Sheet (Section 9.0) in back of manual for Factory Default values. mA Output
and mA Output Trim is optional function.
Press “ “
Figure 7 – Parameter Settings Screen View
Enter into the following menu items to configure your monitor
7.1 Configure 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 # (ie, Sump #6 - LT-
4505). Touch the TITLE block and type in your description. The factory default is OIL THICKNESS
MONITOR.
Level Unit: This is the engineering unit that will displayed for the level of oil. This is factory
defaulted to millimeters (mm). You can change this to any units of your choice by touching the
Level Unit icon and entering your desired units. Note: Any change in units will require a conversion
to the slope used in calibration.
Data Filter: 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
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.

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7.2 Alarms Setup
The Password 2000 will be required to make changes in this section.
There are four relays available.
Relay 1 (R1) is set as General purpose use for Oil alarm setpoints (factory default), valve control, etc.
Relay 2 (R2) is set as an Air alarm (factory default). An air alarm may occur when the sensor is out
of the water due to maintenance, no water in sump or obstruction of float sensor from floating
properly in the water. To disable the factory default setting for relay 2 to act as Oil Alarm, press
“Enabled Relay 2 as Air Alarm relay”.
Relay 3 (R3) is set as a Fault (factory default). A fault alarm may occur when there is no signal from
sensor to main contoller. To disable the factory default setting for relays 3 as Fault, press “Enabled
Relay 3 as fault relay”.
Relay 4 (R4) is set as Oil Alarm (factory default). Relay 4 can be set as (1) Pump Run relay with a
timed and auto shut-off feature or (2) Level sensor. The pump run relay that initiates a pump at a
prescribed % level of oil and then runs for a determined amount of time. The relay will deactivate
the pump after the run time or when the oil level returns to pump reset level on the sensor,
whichever occurs first. The purpose of the run time feature is to allow a pump to run based on a
desired volume evacuation of oil without running dry or pumping water out. To disable the factory
default setting for relay 4 to act as Pump run or Level sensor, press config button then select which
feature for relay 4.
Relay 4 set as a Pump Run relay option,.
Figure 9 – Alarm Setting Screen View (Disabled Relay 3 & 4)
To set up Relays 1, 2**, 3** and/or 4**, Enter “Config other relays” button. If the icon beside each
Relay indicates Enabled, the relay is functional. Pressing the Enabled icon to display Disabled will
render the relay Disabled and will remove that relay from the main screen display. It will disable the
relay from functioning. If it presently reads Disabled, press the icon to Enable the relay.
**If selected as oil alarm only or level sensor for relay 4.