D-2 Incorporated JF-1A Quick guide

JF
-
1A CONDUCTIVITY SENSOR
A440-010
December, 2005
1
D-2INCORPORATED
JetFuel1AConductivity Sensor
Installation &SafeUse Manual
REVISION 3.0
P/NA440-010
ThismanualcoverstheinstallationanduseaspectsoftheD-2JF-1AConductivity
Sensor.D-2continuouslystrives tomeetthefull expectationsofourcustomersandwe
welcomecommentsonthestructure,contentandtheabilityofthismanualtoanswer
yourquestionsregarding ourproduct.Ifyouhaveany suggestionsorcommentsplease
contact usat [e-mail].
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JF
-
1A CONDUCTIVITY SENSOR
A440-010
December, 2005
2
Read the instructionsinthismanualcarefullybeforeinstalling orstartingthe system.
D-2Incorporated willacceptno liabilityfordamagesdue tonon-observanceof this
manual.
Iftheinstructionsintheoperatingmanual arenotadheredtoorare
inadequatelyadheredto,thereshall benoentitlementtoservices
underthewarrantyandtheCEDeclarationofConformityshall
cease tobevalid.
Information inthismanualissubject tochangewithout noticeand doesnot represent a
commitment on the part of D-2Incorporated.
Nopart ofthismanualmaybe reproduced ortransmitted inanyformorbyanymeans,
electronicormechanical, without the priorwritten permission of D-2Incorporated.
Wheremanualsarewritteninseverallanguages, the text it wascreated inisconsidered
the original.
D-2Incorporated
21ACommerceParkRoad
Pocasset, MAUSA 02559
Phone:[phone]
Telefax:01 508-536-5206
E-Mail: [e-mail]
Internet: http://www.D-2Inc.com
© Copyright2005, D-2Incorporated,Pocasset, MA, USA
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JF
-
1A CONDUCTIVITY SENSOR
A440-010
December, 2005
3
Notes forUser
WARNING!
There is a danger to lifeand limb or a risk of serious injur y if the notes on
safety are disregarded!
CAUTION!
There is a risk of injur y and damage to property if the notes on safety are
disregarded!
ATTENTION!
There is a risk of damage to property if the notes on safety are
disr egarded!
IMPORT
ANT!
Notes on working procedures.
RevisionHistory:
Rev Date Description
- 12/19/05Written AJF
1 12/23/05Add FuelTemperature&PressureLimits
Add SafetyGroundWireConnections2-Wire&4-WireDiagrams&Descriptions
EditorialChanges
AJF
1 01/15/06Changeusepressureto16 Bar AJF
2 02/31/06Add Ground WireLugUseInformation(3Places)
Add RS-232 MaximumVoltages&Currents
UpdatedSystemOperating Temperatureto50C
AJF
3 06/15/06Add WarningonCounterClockwiseRotationInstallation&Removal AJF
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JF
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1A CONDUCTIVITY SENSOR
A440-010
December, 2005
4
TABLEOFCONTENTS
OPERATIONMANUAL
1.0GENERAL&LABELING5
2.0INSTRUCTIONFORSAFEUSE6
3.0SENSORMAJORCOMPONENTIDENTIFICATION8
4.0SENSORINSTALLATION(ASSEMBLING/DISMATLING)9
5.0SENSORREMOVAL20
6.0SPECIFICATIONS&MAXIMUMALLOWABLEVALUES 22
7.0MAINTENANCE24
8.0ADJUSTMENT25
9.0DETAILSTO ALLOWSAFEUSEASINTENDED25
10.0SPECIALCONDITIONSOFUSE25
11.0OPTIONAL4-20 TEMPERATUREOUTPUT26
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1A CONDUCTIVITY SENSOR
A440-010
December, 2005
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1.0GENERAL&LABELING
JF-1A
Applications
The JF-1AConductivitySensor is a 2-Wire4-20 mAElectricalConductivity
Measurement Sensor.
Liquid media The sensoris used for measuring theelectricalconductivityof liquid media:
In hazar dous locations, Zone I of Explosion Gr oup II C corresponding to EN
guidelines
In hazar dous locations Class I, Div .1, Gr oup B, C and D in accordance with FM
and CSA guidelines
ATTENTION! The sensoris not designed to meter gaseous media or solids.
ManufacturerD-2Incorporated
21A Commerce ParkRoad
Pocasset, MA 02559, USA
Type II 2G
Code
EEx d[ia]IICT4
Testing StationKEMA QUALITY, B.V., Utrechtseweg310, 6812 AR Arnhem
Certificate#KEMA05ATEX1252
Ambient TempRange -20 to50 Celcius
Process MaxTemperature 40 Celcius
Ambient MaxPressure 16 Bar(235 PSIG)
MaximumVoltage (Loop) 38 VDC
MaximumCurrent (Loop) 22 mA
Maximum(RS-232 Input) (RXD) Maximum+/-25 VDC+/-5mA
Maximum(RS-232 Output) (TXD) Maximum+/-5VDC+/-30 mA (ShortCircuited)
Test VoltageUm=250 VAC
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1A CONDUCTIVITY SENSOR
A440-010
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2.0INSTRUCTION FORSAFEUSE
TheD-2JF-1AConductivityMeterreadsconductivityinpicosiemens/meter,fuel
temperatureinITS-90 degrees C,andfullycompensatedConductivityinpicosiemens/
meterperASTMD2624,AppendixX2inliquidfuelsandsolvents.Thesensorcanbe
usedina2wire4-20mA industrialcontrollooporinconjunctionwithaserialinput
deviceusingRS-232 IEEE StandardASCII SerialInputData.Optionallya2wire(4-20
mA)temperatureinterfacecanbeaddedtoallow remotemonitoringoffuel
temperature.
WARNING: Immediately switch off the sensorin the case of emergency!
Until thesensorisfully installedin afilledproductlinedo
notenergizesensor.
When using the sensor to measure combustible media,
obser ve the r egulations concerning transport and storage
of combustible liquids .
Observe applicable national r egulations for installation abroad.
Only Exdapprovedcableentry devices(e.g.cablegland)shall
beused, withtheapparatus.
Sensorisintendedforuseinproductlineswheretheabsolute
maximumphysicalconditionsdonotexceedthespecifications
listedin Section6.0.
CAUTION: Sensors must be
accessible at all times to facilitate operation
and maintenance. Do not obstruct or block clear access.
Only specially trainedand authorized persons are permitted to
maintain and repair JF-1A Sensorsandtheir peripheral
equipment.
Always depr essurize the liquid end first befor e carr ying out any
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JF
-
1A CONDUCTIVITY SENSOR
A440-010
December, 2005
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work on the Sensor.
If hazardous or unknownsensormedia are used, dischargeand
flush the liquid end before carr ying out any work on the
sensor.
Observe the safety data sheets of the measured liquids.
Always wear protective clothing (goggles, gloves) when
handling hazardous or unknown liquids! This applies in
particular to working on the liquid end.
Assembly oftheJF-1A Sensorwith parts not tested and
approved by D-2Incorporated is prohibited andcan result in
damage to persons and property, for which no liability will be
accepted.
Caution:Installation andRemovalofthesensorfrom
pressurizedlinescareMUST betaken toensuresensordoesnot
“fly”backtostop.
Caution:Atnotimeshouldthemain sensorbody (electronic
housing)berotatedin acontinuouscounterclockwisedirection
assensorcomponentsmay becomeundoneresultingin liquid
(product)ingression intosensor.
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1A CONDUCTIVITY SENSOR
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3.0SENSORMAJORCOMPONENT IDENTIFICATION
Figure2
MajorSystemComponents
1Ball Valve
2SensorMount Adaptor
3Mounting Nut
4Locking Collar
6ElectronicsHousing
7ElectricalConnectionSide
8Label
9InstallationReferencePlane
1
2
3
4
1
2
4
7
3
6
8
9
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-
1A Conductivity Sensor
A440-010
December, 2005
9
4.0INSTALLATION ASSEMBLING/DISMATLING
4.1 MECHANICALINSTALLATION
WARNING!
PriortoInstallation,localcodes andregulationsregardingthe
installationandoperationofthistypeofdeviceshouldbereviewed
andstrictlyadheredwithto ensure safeandreliableoperationofthe
system.
WARNING!
InstallationinProductLineswithFlowAbove1.5M/sec(5ft/sec)
must observerecommendationsaslistedinSection6.5
WARNING!
WARNING:LocalProcedures toreducethepotentialforelectrostatic
dischargeshouldbeobservedpriortohandlingtheJF-1Sensor.
Ensureservicepersonnelhaveproper groundingequipment.
4.2 PIPECONNECTIONS
D-2recommendsa3”long1”NPTnipplebemountedorthogonal(ataright
angle)tothemainproductline.Ifpossiblethenippleshouldbemounted
verticalfromthesectionofpipe.Themainproductlineshouldbehard
mountedandmechanicallystable,free ofexcessivepumporothervibration
sources.
IMPORTANT: Thesuppliednipplemustmeetsitepipingcodesand
requirements.
4.3 PIPEVALVE
Thenippleshould besupplied witha1”OpenThroat Ball Valve.
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1A Conductivity Sensor
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December, 2005
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IMPORTANT: TheBallValveMUST HaveaClearOpeningof1.0”through
itscentertoallowtheD-2sensortopass unobstructed.
4.4 INSTALLATION
Figure4
INSTALLATION DRAWING
1. Turnlockingmechanismcounterclockwise toloosensleeve.
Pushsleeve downasfar aspossible onshaft.
IMPORTANT:Priorto nutinstallation(step2) onto sensoradaptor
ensurethreadsarecoatedwithagoodquality anti-seize lubricant.
2. Positioninstrumentover fittingonpipe. Tighten2"mounting
nutonto ball-valve adaptor.
3. Note:Only turnmountingnutwithball valve closed.
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1A Conductivity Sensor
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Figure5
INSTALLATION DRAWING
ATTENTION! Prior toperformingthenextstepsensure productline
pressure islessthan150 psia(10.0Bar).
4. Turnballvalve handle 1/4 turnto open.
5. Turn“black”lockingmechanism counter-clockwise to loosen
shaft.
WARNING! Donotrotatethe mainbody(electronicshousing)other than
inaclockwisedirectiontoassistthesensor inslidingit down intothe
productline,counter clockwiserotation couldresult indamagetothe sensor
tip.
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1A Conductivity Sensor
A440-010
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ATTENTION! Pushingthe sensor tofarintothe mainproductlinemay
result indamagetosensor andrequire factoryre-calibration or repair.
Ensure entryintomainproductlineisclearandfree ofobstructions.
6. Pushsensor downintoproductline.
7. Adjust sensorheight(seesection4.5forhighflowconditions)
8. Turn“black”lockingmechanism clockwise totightenshaft.
28"
PIPE
C/L
Figure6
INSTALLATION DRAWING
(Noteforhighflow rateapplicationssee section4.5)
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1A Conductivity Sensor
A440-010
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IMPORTANT! Underhigh flowconditions, flow>1.5M/sec (5ft/sec)
installation depth shouldbemodifiedasoutlinedin section 6.5toprevent
vortexflowseparation insidecriticalsensormeasurementvolumes.
IMPORTANT: TheSensorshouldbemountedwell awayfrompossible
sourcesofelectromagneticnoise, suchaslargepumpmotors,ACpower
Lines, orelectricalcircuitscontaininglargetransientswitchingcurrents.
WARNING: Priortoarcweldinginproximity totheJF-1A sensor(closer
than 10 meters(30 feet)thesensorshouldbeeitherremovedfromthe
productlineorataminimumdisconnectedfromall electricalconnectionsto
thesensor.
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1A Conductivity Sensor
A440-010
December, 2005
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4.5 HighFlowRateInstallation
Toreducetheinstanceof fluidflowseparationinsidethe JF-1Asensor
assemblyan alternateinsertion depthisrequired. D-2defineshighflowproduct
linesaslinesinwhichthe velocityof product exceeds1.5M/sec(5ft/sec).
Velocitycanbe determine bydividingthe crosssectionalarea of yourpipe
((I.D./2)^2*3.14 dived intoyourproduct flowrate(inequivalentunitsof
measure).
Inthe figurebelowthe recommended high flowratedepthisillustrated.
PipeID
28"
Figure7
HighFlow RateInsertionDepthIllustration
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1A Conductivity Sensor
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4.6ELECTRICALINSTALLATION
WARNING: OnlyExdapprovedcableentry devices(e.g.cablegland)
shall beused, with theapparatus.
WARNING: All unused¾”NPT housingopeningsmustbeclosedusing
EN50018approvedplugs.
WARNING: Forthepurposeofintrinsicsafety thehousingmustbetiedto
earth. Safety Groundwiremustbeinstalledunderhousinggroundscrewin
userwiringcompartment. Acablelug shall beusedandtheconductorshall
bemountedsothatitissecuredagainstlooseningandtwisting andthatthe
contactpressure ispermanently maintained. Note:theconnectionstoearth
locatedon theterminalblocks can notbeusedforthisearth connection.
ElectricalconnectiondetailsareshowninfigureA.Thereare2screwterminal
blocks,theterminalblockwith4positionshasthe4-wireinterface,theterminal
blockwith3positionsservicesthe2-WireInterface.These are“snap”out
Molexscrewterminalswhichcanberemovedtoassistinwiring.Cablingused
shouldbeincompliancewiththeJF-1AATEX examinationcertificate.The4-
Wiredefinedas PowerGroundRS-232CTransmitandReceiveData,the2-Wire
interfacedefinedas 4-20 mA currentloopandearthsafetygroundconnections.
Notethe4-Wireinputpowerispolarityprotectedwhilethe2-WireInputPower
inputispolarityinsensitive;eitherterminalcanbeconnectedtothepositive
output ofthepowersource.
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-
1A Conductivity Sensor
A440-010
December, 2005
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Figure8
2-WIRE ELECTRICALCONNECTION DETAIL
12 43
3
2
1
3
2
1
4.7 2-Wire4-20mALOOPCONSIDERATIONS
WARNING: 2-WireLoopMaximumResistance includingwirecannot
exceed500 ohms,orinternalintrinsicovervoltagesafetydevicesintheJF-
1A sensormay beactivated.
The4-20mA Loopsupplyopencircuitvoltagemustbeconsistentwiththe
“OpenCircuitSupply”needsoftheJF-1Aatbothitsminimumandmaximum
indicatingcurrents.TheJF-1Ahasbothinputvoltagelimitingprotectionand
polarityprotection.These protectiondevices affectusersupplyvoltage
requirements.Ifproperloopsupplyvoltageisnotmaintained,errorsin
indicatedconductivitycurrentmayoccur.The4-20 mA loopsupplyvoltage
should complywithspecificationssectionofthemanual.
Themaximumlooppowersupplyvoltage,underallconditions,mustalso
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preventthevoltageacross thesensorloopterminalsfromexceedingthe
maximumvoltagelistedinthespecificationssectionofthemanual.Ifthis
conditionisnot maintained,errorsinthecurrent outputmayoccur.
D-2recommendsthata24 VDCisolatedsupplybeusedtopowerthe
instrumentationloop.Thesupplyshouldhavehighisolation(>500Mohm).
Thecurrentloopshouldbewiredusingshieldedtwistedpairwire.Theshield
should besinglepoint groundedtoasolid earth/safetyground.
ATTENTION: Sensorwiringshouldbeperformedasrequiredbylocal
codesasthey apply.
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4.8 RS-232CONNECTIONS Considerations(4-Wire)
Figure8A
4-WIRE ELECTRICALCONNECTION DETAIL
1243
3
2
1
3
2
1
WARNING: Forthepurposeofintrinsicsafety thehousingmustbetiedto
earth. Safety Groundwiremustbeinstalledunderhousinggroundscrewin
userwiringcompartment. Acablelug shall beusedandtheconductorshall
bemountedsothatitissecuredagainstlooseningandtwisting andthatthe
contactpressure ispermanently maintained. Note:theconnectionstoearth
locatedon theterminalblocks can notbeusedforthisearth connection.
The4TerminalScrewConnectorhas bothPowerInputandRS-232/RS-485
Connectionsas listed inTable1below:
TABLE1
SCREWTERMINALCONNECTION PINDETAIL
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1A Conductivity Sensor
A440-010
December, 2005
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TERMINAL Function
1 Data/PowerGround
2 RS-232 DataIn(RXD)
3 PowerInput+
4 RS-232 DataOut (TXD)
TheRS-232 Interfaceisfullyisolatedfromthesensorelectronicsthroughthe
use ofopticalisolatorslocated intheJF-1A/ATEX sensor.
DatacablefortheRS-232 shouldbelow capacitancedatacable.Lengthsin
excess of20 metersmayresult datadegradationoftheRS-232 signals.
4.9 PowerInput(4-Wire)
WARNING:Powersupplymustbefullyisolatedandmeetall localandsite
codesforitsuse.
Powerinputtothe4-WirepowerconnectionsshouldbecleanfilteredDC
voltageintherangeof7–35 VDC.Currentconsumptionisapproximately10
mA.
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5.0SENSORREMOVAL
WARNING:Powermustbedisconnectedbeforesensorremoval.
5.1 DISCONNECTPOWER
Turnoff systempowertotheunitanddisconnectelectricalconnectionsfrom
theuserinterface.Removeany conduitconnectionsfromtheJF-1ASensor.
Ground thesensortothemainlinepriortoremovalfromtheline.
5.2 PULLSENSORBACK
WARNING:Priortohandlingsensorensureoperatorisproperlygrounded
topreventpossibleelectrostaticdischarge.
WARNING:Ensureproductlinepressureisbelow150 psia(10 Bar)prior
tolooseningblacklockingcollar.DONOTHAVEOPERATOR LOCATEDIN
FRONTOFTHESENSORINTHEEVENTTHESENOR“KICKS”OUTDUETO
HIGHPRODUCTLINEPRESSURE.Theoperatorshouldmaintainaslight
pressuretowardstheproductlineatalltimethatthe“lockingcollar”isbeen
loosetoprevent“blowback”.
WARNING:Atno timeduringremovalofthesensorshouldthemainbody
(electronicshousing)ofthesensorberotatedinacontinuouscounter
clockwisedirection. Any suchrotation mayresultinthelooseningofthe
sensorcomponentsandpossibleliquid(product)ingression intotheJF-1A
Sensor.Small rotationsorrotationsinaclockwisedirection areacceptable
toassistin drawingthesensorbackpastthevalve.
Loosentheblacklockingcollarontheretractablemount.Careshouldbetaken
topreventthesensorfrom“blow back,”althoughtheretractablemounthas an
anti-slidecollartoassistinpreventingblow back.Thesensorreferenceplane
willbe28” fromtheadaptorstep(see Figure8)whenthesensorisfullypulled
backinthemount.Thevalveshouldoperateeasilyandwillnotcomeinto
contactwithsensorwhenitisfullywithdrawn.Productwill reducethe
lubricationofthesensorshaft whichmayincreasethefrictionthat isrequired to
withdrawthesensor.
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