ARJAY ENGINEERING 2852-PCD User manual

MODEL 2852-PCD
Plugged Chute Detector
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.: 5.1
SOFTWARE NO.:
SERIAL NO.:

Model: 2852-PCD User Manual Rev: 2.1
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TABLE OF CONTENTS

1.0INSTRUMENT OVERVIEW ............................................................................................3
1.1Features .............................................................................................................3
1.2Model Number vs. Voltage Input........................................................................3
1.3Specifications .....................................................................................................4
2.0INSTALLATION...............................................................................................................6
2.1Controller Installation .........................................................................................6
2.1.1Permanent Power Connection (AC Powered Models only) ................6
2.2Sensor Installation..............................................................................................7
2.3Electrical Installation ..........................................................................................8
2.3.1Input / Output Terminal Specification ..................................................9
2.4Glossary of Symbols ..........................................................................................10
3.0STARTUP AND CALIBRATION......................................................................................11
3.1Startup................................................................................................................11
3.2Menu Flow Chart Background Information ........................................................11
3.2.1Menu Description.................................................................................11
3.2.2Menu Flow Chart .................................................................................11
3.2.3Data Entry............................................................................................12
3.32852 Controller Calibration ................................................................................12
3.3.1Site Calibration ....................................................................................12
4.0SETUP and ALARMS .....................................................................................................13
4.12852 Controller Setup ........................................................................................13
4.22852 Controller Alarms ......................................................................................13
4.32852 Controller Network ....................................................................................14
4.3.1Modbus Configuration .........................................................................14
4.3.22800 Series Modbus Register Mapping ..............................................15
5.0MAINTENANCE ..............................................................................................................16
6.0TROUBLESHOOTING....................................................................................................17
7.0FLOW CHARTS ..............................................................................................................18
TABLE OF FIGURES
Figure 1 – Electrical Installation Overview ....................................................................................8

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1.0 INSTRUMENT OVERVIEW
The Arjay Plugged Chute Detector provides a means of monitoring product within a chute,
conveyor shaft, or vessel for a plugged or high product condition. The sensor is designed to
mount flush within the chute wall so there is no penetration into the moving product. The sensor
uses an RF Capacitance technology that does not require moving parts.
The complete 2852-PCD system consists of the flush mount sensor, the PMC card mounted at the
sensor, and the 2852 controller.
Chute sensor locations can be awkward and are usually accompanied by high vibration equipment.
The PMC card allows the 2852 controller to be mounted away from the sensor location for safety
and ease of maintenance and set-up. The PMC card at the sensor translates the capacitance
signal from the sensor into a frequency pulse, which can then be transmitted up to one kilometer to
the 2852 controller via 2-wire shielded cable.
The standard sensor facing is constructed of UHMPE (ultra-high molecular weight polyethylene) for
high errosion resistance and has a 304 stainless steel backing. Optional facing materials include
Teflon, Nylon and PVDF.
The model is intended for use in General Purpose non-hazardous areas. For hazardous location
use refer to Arjay Engineering Ltd. For appropriate model.
1.1 Features
Microprocessor based capacitance Controller
Relay and 4/20mA alarm output
Modbus protocol via RS-485 for access by Arjay handheld, Central Access Panel or
compatible system
Local Auto calibration or remote calibration via network
User specified custom features may be added by contacting Arjay Engineering Ltd.
1.2 Model Number vs. Voltage Input
2852-PCD-1 100-240 VAC power input
2852-PCD-3 12 VDC power input
2852-PCD-4 24 VDC power input

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1.3 Specifications
Power Input: 12 VDC +15% /-10% or 24 VDC +15% /-10%, 250mA maximum
100VAC – 240VAC +/- 10%, 50/60 Hz, 150mA maximum
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:
Display & Keypad Two line LCD with Alarm status display, select menu or enter
values by keypad (display is internal to housing and used for
set-up and diagnostics only)
Communication Interface: Modbus (RS485)
Analog /Relay Outputs:
mA Signal Output 4 mA during Normal and 20 mA during an alarm condition, 900
Ohms max OR 450 Ohms max (12VDC Power)
Relay Output
2 SPDT relay, dry, N.O. Contact 5A @ 250 VAC (Resistive) and
N.C. Contact 3A @ 250VAC (Resistive), selectable failsafe or
non-failsafe, selectable high or low acting alarm, programmable
time delay: 0 – 600 seconds
Instrument Performance:
Measuring Range 0 - 5000 pF (most applications are 100pF to 1000pF)
Accuracy 0.2% of setpoint
Resolution 0.05% of setpoint via network display
0.002% of Full Scale capacitance via network display
Calibration Single point: Auto calibration
Environmental:
Operating conditions Continuous
Operating Temperature -20 °C to +55 °C controller
-60 °C to +55 °C PMC
-60 °C to + 55 °C sensor
Relative humidity 0 to 95% (non-condensing)
Altitude ≤2000 m
Installation Category II
Pollution Degree 2
Equipment mobility Fixed

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Mechanical Specification: Refer to Dimensional Drawing
Enclosure Rating Type 4 / IP65 Painted Steel (Blue)
Type 4x / IP66 Polycarbonate (Gray)
Type 4x / IP66 316 Stainless Steel
Options on Enclosure Buzzer
Pilot Light OR Strobe/Beacon
Custom alarms
Approval Standards: UL / IEC 61010-1, 2nd Edition, 2005-07-22 (Electrical
Equipment for Measurement, Control, and Laboratory Use;
Part 1: General Requirements)
UL file number: E343390
CAN/CSA-22.2 No. 61010-1, 2nd Edition, 2004-07,
(Electrical Equipment for Measurement, Control, and
Laboratory Use; Part 1: General Requirements)
CE: UL / IEC 61010-1; IEC / EN 61000-4; ISO 9001:2008

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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 Controller 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).
The 2850 controller may be mounted up to one kilometer from the PMC card using a minimum 18
gauge, 2-wire SHIELDED cable.
Check the polarity of the + and - wiring between the controller and the PMC prior to powering on
the unit; + to + and - to - to avoid damage. Shield of cable should be connected to secondary
ground terminal marked as . Incoming Earth ground should be connected to primary ground
terminal marked on sub plate.
Important Note: The controller is factory 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. Wire
accordingly.
Note: Maximum Conduit size for installation size is ¾” FNPT.
2.1.1 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:
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.
Power OnPower Off

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2.2 Sensor Installation
The controller is tuned to the capacitance field in front of the sensor during normal process
conditions. A plugged condition will displace the air & product mix in front of the sensor with
solid product. This results in an increase in the capacitance reading in picofards (pF) and will
trigger the alarm relays.
Consider a mounting location where the sensor face will see a maximum product change from a
normal condition to a plugged condition. Avoid locations that may incur build-up of sticky
materials or do not physically change during a plugged condition.
The controller tunes itself to the capacitance reading of a normal process condition. Changes to
product type or conditions such as dry vs. wet material may cause nuisance alarms and require
a re-calibration.
NOTE:
To ensure proper operation and electrical safety, make sure the 2852 enclosure and
the PMC junction box are electrically grounded.
If the equipment is used in a manner not specified by the manufacturer, the
protection provided by the equipment may be impaired.

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2.3 Electrical Installation
Figure 1 – Electrical Installation Overview
TB1/TB2 - Relay Output
2 SPDT relay, Dry, N.O. Contact 5A @ 250 VAC (Resistive) and N.C. Contact 3A @
250VAC (Resistive), selectable failsafe or non-failsafe, selectable high or low acting alarm,
programmable time delay: 0 – 600 seconds
TB3 - Power Input
Power input as per Model. Check if ordered AC or DC. . Earth ground is connected to G.
TB4 - Network Output
Connect RS485 + and – to the network D+ and D-.
TB5 - 4/20 mA Output (+ and -)
The 4/20 mA is a sourced output referenced to Ground. It is not loop powered.
4mA = Normal 20mA = Alarm
TB6 - Probe Input
Connect ‘+’ to ‘+’ , ‘-‘ to ‘-‘ between the controller and the PMC card. Check polarity to avoid
damage.
TB7 – Buzzer / Red Pilot Light Output (Optional)
The connection will be factory wired if ordered.

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2.3.1 Input / Output Terminal Specification
Input Terminals – Power Source
Terminal
ID Overvoltage category Rated Voltage (V) Rated Current/power
(A/W/VA)
___ HZ or
DC Specified Mains
fluctuation
TB3 II 100-240V 150mA 50/60Hz
 10%
TB3 II 12 OR 24V 250mA DC
 15%
 10%
Input Terminals – Measuring Circuits
Terminal ID Function Measurement
Category Nominal a.c. or d.c line to
neutral voltage
/ if CAT I, Max.
transient
overvoltage Ut
Nominal
a.c. or d.c
current
Rating of
insulation
required for
external
circuit
TB6 Frequency I 15V,50mA / 0 -- DI * or RI**
TB4 RS485
Communicati
on
I 5V, 5mA / 0 -- DI * or RI**
* Double Insulation
**Reinforced Insulation
Output Terminals
Terminal ID Function Isolation or
protection Rated V, A Max. V, A Load type and nominal
TB1 Load Relay N.O. Contact
5A@250VAC &
N.C. Contact
3A@250VAC
-- --
TB2 Load Relay N.O. Contact
5A@250VAC &
N.C. Contact
3A@250VAC
-- --
TB5 Current Isolator(optional) - 18V,20mA,
900

- 9V, 20mA,
450

50mA@18V --
TB7 Voltage None 24VDC, 30mA -- Buzzer / Pilot
Light

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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)
L
Live
Sous tension
N
Neutral
Neutre
G
Ground
Terre

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3.0 STARTUP AND CALIBRATION
3.1 Startup
Check that the power wiring and PMC wiring are wired in accordance with the electrical
installation drawing.
Power On the unit. Allow a 1 hour warm-up period before calibrating.
The Status LED on the controller circuit board should be green. A red Status LED indicates a
fault condition. If red, check the Troubleshooting section.
The unit is pre-configured and tested at the factory. However, a quick field calibration is
required after power up to tune the sensor to the installation conditions. See section 3.3
to calibrate the 2852-PCD.
3.2 Menu Flow Chart Background Information
The control setup, diagnostics, and calibration are accessed using the display and keypad on
the controller. The Flow Chart in Section 7.0 provides an overview to the various menus and
features. Keep a copy of the flow chart at hand when accessing the internal controller features.
Below is a description of the menu functions.
3.2.1 Menu Description
Since the 2852 controller has a small LCD, some menu descriptions may be in short form. The
following are the menu descriptions:
Diags: Diagnostics
Cal Pts: Calibration points
Auto Cal: Auto calibrate
Man Cal: Manual calibrate
Cal Ok: Calibrate ok
Cal Err: Calibrate err
mA out: mA output
mA Span: mA output span
Sec: Seconds
ALRM CAL: Alarm Calibration
Cal: Calibration point
SENSTVTY: Sensitivity
A1: Alarm relay 1
A2: Alarm relay 2
Alrm: Alarm
Alrm Lvl: Alarm level
Diff Hi: Differential Hi alarm set value
Diff Lo: Differential Lo alarm set value
Alrm Del: Alarm Delay
^SP: Relay Setpoint Hi action
vSP: Relay Setpoint Low action
3.2.2 Menu Flow Chart
The 2852 controller will display Normal in its normal operating condition and Alarm during a
plugged chute condition.
From the main menu, you can select Cal Only, View, and Change.
Cal Only allows a user to calibrate after the equipment is installed. A calibration is required at
site after initial power up or anytime a component or sensor is changed out. A password is
required to enter this and is described in the calibration section.
View allows an operator to view the Calibration setpoints in pF, the Alarms settings such as
low or high action, failsafe or non-failsafe and the 0-600 second delay, the Diagnostics of raw
readings and the Setup values such as mA output and ID address. These can be viewed
without a password and without risk of changing any values. This information may be requested
during technical assistance inquiries.

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Change is password protected and allows an operator to enter or change the configuration set-
up values indicated in the View. Changes can be made to the factory defaulted relay setpoints,
delays, span etc.
3.2.3 Data Entry
3.3 2852 Controller Calibration
Power up the 2852 Controller. The status LED should be green. The LCD will scroll to the
normal operating screen after a series of the following screens (each displays for 2 sec.). It may
read Normal or Alarm until a calibration is performed.
3.3.1 Site Calibration
A factory pre-configuration and set-up has been defaulted into the 2852-PCD. As such, a user
set-up is not required in the field. A basic calibration is only required.
Be sure the sensor is wired and installed into it’s final location before calibrating. The process
must be operating so that the sensor face is looking at normal process conditions. For example,
if solids are normally falling past the sensor, be sure this condition is occurring. This is required
so that controller “Zeroes” out any background affects to the capacitance reading.
As per the Flow Chart, press and hold Menu key for 5 seconds to enter the main menu. The
display will read the first menu item Cal only. Press select key, enter password ¨2000¨. A pF
reading of the sensor will be displayed. Press select to acknowledge and then press select to
accept the new calibration. To abort, press the MENU key.
If the calibration is successful, the display will return to the main operating display.
To verify the sensor and electronics are responsive, force a plugged condition, place product in
front of the sensor or place your hand firmly in front of the sensor for at least 30 seconds. The
high dielectric of your hand simulates a plugged condition. Verify that the control unit alarms.
The Alarm1 and Alarm2 LEDs on the circuit will activate red. Remove your hand and the alarm
will clear.
If the calibration is successful, the display will return to the main operating display and show
normal condition.
THIS COMPLETES THE SETUP AND CALIBRATION PROCEDURE FOR THE
2852-PCD Plugged Chute Detector
Arjay
2800
S XXXXXX
PMC= EXT
SW X.XXX
HW X.X
PCD
Normal
Normal Screen
NET ID: X

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4.0 SETUP AND ALARMS
4.1 2852 Controller Setup
The 2852 controller has the following Setup parameters:
1. Sensitivity
The sensitivity determines the amount of pF change required to cause an alarm. The
factory default setting is 1.0 pF. This is the most sensitive setting. Increasing the pF value
will increase the amount of product required to cause an alarm. Since different products
have different dielectrics, a pF to plugged chute relationship cannot be factory determined.
If this setting is changed in the field, it should be tested to confirm an alarm.
2. Alarm Calibration above or below setpoint
This setting advises the controller if the calibrated pF value is above or below the alarm
setpoint. For the PCD, the calibration pF value is below the setpoint because the unit is
required to alarm at a higher pF value, which indicates a plugged condition. The factory
default is therefore Below Setpoint.
3. Defaults
Factory settings are pre-configured into the unit based on the most typical set-up required
for this application. This provides for a quick and easy calibration at site but can be
changed for special applications. If the setup has been changed, this will change it back to
the factory defaults.
4. Net ID
The ID number is used only for network applications. To communicate on a network, each
controller must have a unique ID number. The factory default ID number is 1.
Important: If multiple units on a network have the same address, network errors will result.
5. Filter
Data filtering is used to smooth data from a sudden change and minimize fluctuating
readings. For example, a 5 second setting means the calculated value of the capacitance
and resulting values of pF will start to respond immediately but will take 5 seconds to reach
their final values. The factory default is 0 to provide an immediate and active response.
4.2 2852 Controller Alarms
The two relays on the 2852 operate together. The follow parameters are available as a common
setting to the two relays:
1. Delay. Minimum time in seconds for an alarm to exist before the relays change to an alarm
state. The relay alarm state depends on the Relay Action and Failsafe settings. The factory
setting is 15 seconds to suppress false alarms due to sudden of intermittent disturbances in
front of the sensor.
2. Action. This determines if the Alarms LEDs should activate when the pF reading rises
above or below the setpoint. The factory default is Above the setpoint because the
application of a plugged chute is an increase in capacitance.
3. Failsafe. Failsafe typically means that the relay is held in an energized state when in a
normal operating condition as opposed to an alarm condition. In an alarm condition, the
relay de-energizes which is identical to when the instrument power is shut off. The rationale
is that the alarm condition should match the Power Fail condition. The factory default is
Yes for Failsafe.

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4.3 2852 Controller Network
The 2852 Controller may be monitored and calibrated via RS-485 protocol compatible digital
communications.
Typical features are:
1. Ease of wiring in multiple level point monitoring:
Up to 255 Model 2852's (or other Arjay 2800 Series level monitors) may be connected together
in a daisy chain (2 wire communication plus power wiring) connection to an Arjay Remote
Access monitor or customer control system which allows viewing data and setup of any of the
transmitters on the network. The relay and analog outputs may still be used if necessary.
2. Setup for the 2852 for network operation:
Each 2852 transmitter must have a unique ID number to connect in a network system.
4.3.1 Modbus Configuration
Parameter settings: 9600 Baud Rate; Even Parity, 8 Data Bits and 1 Stop Bit.
Wiring connection: RS485 (+) connect to D+; RS485 (-) connect to D-

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4.3.2 2800 Series Modbus Register Mapping
REG Zero Based DESCRIPTION TYPE
N
o. of
R
eg
40001 0 Serial Number float 2
40003 2 Hardware Rev / Software Rev byte 1
40004 3 Sensitivity / Mode byte 1
40005 4 Instrument Status int 1
40006 5 Model / Modbus Address byte 1
40007 6 Relay2 Setup / Relay 1 Setup byte 1
40008 7 Password int 1
40009 8 XA "A" cal parameter float 2
40011 10 XK "K" cal parameter float 2
40013 12 XC "C" cal parameter float 2
40015 14 Filter float 2
40017 16 Slope – pF per % level float 2
40019 18 Offset – pF for empty vessel float 2
40021 20 mA output span value float 2
40023 22 mA output Zero value float 2
40025 24 mA output Trim Slope value float 2
40027 26 mA output Trim Offset vlaue float 2
40029 28 Cal1 PV: 1st calibration point level value in % float 2
40031 30 Cal2 PV: 2nd calibration point level value in % float 2
40033 32 Cal1 pF: 1st calibration point capacitance value in pF float 2
40035 34 Cal2 pF: 2nd calibration point capacitance value in pF float 2
40037 36 Relay 1 : Differential High Alarm [% Level]. Only used for
Linear Level type. Not used for Single Point Alarm application float 2
40039 38 Relay 2: Differential High Alarm [% Level]. Only used for
Linear Level type. Not used for Single Point Alarm application float 2
40041 40 Relay 1: Differential Low Alarm [% Level] OR Single Point
Alarm [pF]. Single Point Cal: used as captured pF during cal float 2
40043 42 Relay 2: Differential Low Alarm [%Level]. Only used for Linear
Level type. Not used for Single Point Alarm application float 2
40045 44 Relay 1 On delay [in seconds]. Only used for Linear Level or
Single Point Alarm application int 1
40046 45 Relay 2 On delay [ in seconds]. Only used for Linear Level
type. Not used for Single Point Alarm application int 1
40047 46 mA Analog Output float 2
40049 48 Oscillation Frequency float 2
40051 50 Frequency float 2
40053 52 Capacitance float 2
40055 54 Filtered Capacitance float 2
40057 56 Level float 2

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5.0 MAINTENANCE
There is no routine cleaning required for this controller.

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6.0 TROUBLESHOOTING
CONDITION DO THIS
1. Status LED is OFF and the LCD
display if off
Check the power to the unit. If the unit is a 12VDC or
24VDC model, check the external source and polarity
is correct. If the unit is a 100-240VAC model, then
check the Line, Neutral and Ground wiring is correct.
2. If the status LED is RED This indicates a major error such as memory failure,
no sensor signal etc. Check the following:
Make sure the PMC is installed
Make sure the PMC wiring is correct and there
are no breaks in the wiring. At the controller,
measure across the Probe Input terminals with a
DC meter. Make sure “Common” lead of meter is
on ‘-‘ terminal. It should read (+) 8 to (+)10 VDC
with the PMC connected and approximately 20 to
24 VDC with the PMC terminal disconnected.
Microprocessor may have lost its parameters due
to a surge in the line. Go to Diagnostic Menu (see
Flow Chart) to check the Calibration values,
frequency and capacitance values
Call Arjay Technical Support.
3. No mA output OR incorrect mA
output.
IMPORTANT: THE UNIT SOURCES mA OUT
FROM THE mA OUTPUT TERMINAL. THIS
TERMINAL SHOULD NOT BE CONNECTED TO
+24V. IT IS NOT A 2 WIRE mA TRANSMITTER.
See Figure 4 for Electrical hookup details.
Disconnect external wires from mA output and
measure with mA Meter.
Check the mA output Action (direct or inverse)
and mA output Span are set as desired. See
section 7.0 Flow chart / Change menu.
If the mA output still does not match the level,
then call Arjay Technical Support.
4. False Alarms

Check that material is not building up on sensor
Add some time delay in the unit
Make sure there is no external interference and
electrical noise such as motors, high voltage
interference, splashing, etc
Adjust the sensitivity to the next higher value.
Test after any changes to confirm an alarm
Make sure the product materials and moisture
conditions are the same as when calibrated.
ARJAY ENGINEERING TECHNICAL SUPPORT
[phone]
[phone]
www.arjayeng.com

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7.0 FLOW CHARTS

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