Endress+Hauser ZAD 423 User manual

Controller
ZAD 423
for Silopilot FMM
Operating Instructions
BA 161F/00/en/09.97
Software version 1.0
Part No. 017273-1000
Hauser+Endress
Nothing beats know-how

Quick Guide
Basic calibration
Step Calibration
field H Entry ●+ ●–
❍H
❍S
Example Remarks
Set counting interval
1❍+
❍–
●H8
❍S
Number
corresponding
to counting
step of
connected
Silopilot FMM
0= 1dm
1= 5cm
2= 1cm
3= 1in
4 = 1/10 ft
0 = counting
step
1dm
For counting step
see nameplate
Silopilot FMM
"Zähleinheit" or
"Zählung (unit)"
Empty calibration
2❍+
❍–
●H1
❍S
Height E
from flange to
zero point of
measurement
(empty silo)
in m
for steps of
1cm
5cm
1dm
in in
for steps of
1in
in ft
for steps of
1/10 ft
18.7 (m)
Full calibration
3❍+
❍–
●H2
❍S
Height F
from
zero point of
measurement
(empty silo)
to maximum
height
in m
for step of
1cm
5cm
1dm
in in
for step of
1in
in ft
for step of
1/10 ft
17.2 (m)
For display:
4❍+
❍–
●H0
❍S
LEVEL
40.0
or
##.#
Reset
or
previous
measured value
5❍
❍
❍
●Press Pushbutton S min. 3 s
Silopilot starts
measurement
Wait for Silopilot
sensing weight to descend 12.3 Level is shown
F
100 %
E
0%
Quick guide ZAD 423

Table of Contents
1 Software changes . . . . . . . . 2
2 Notes on Safety . . . . . . . . . 3
2.1 General information . . . . . . . . . 3
2.2 Special notes on safety . . . . . . . 4
3 Introduction . . . . . . . . . . 5
3.1 Application . . . . . . . . . . . . 5
3.2 Measuring system . . . . . . . . . 5
3.3 Operating principle . . . . . . . . . 6
4 Installation . . . . . . . . . . . 7
4.1 Planning . . . . . . . . . . . . . 7
4.2 Mounting . . . . . . . . . . . . . 8
5 Electrical Connection . . . . . . 9
5.1 Connecting the Silopilot FMM to
the ZAD 423 Controller . . . . . . . . 10
5.2 Disabling the start-up line (Stop) . . . . 10
5.3 Analogue output signal, current output . 11
5.4 Test output . . . . . . . . . . . . 11
5.5 Limit signal output . . . . . . . . . 11
5.6 Power supply . . . . . . . . . . . 11
6 Start-Up . . . . . . . . . . . 13
6.1 Initial procedures . . . . . . . . . . 13
6.2 General information on settings . . . . 13
6.3 Basic settings . . . . . . . . . . . 16
6.4 Silopilot design . . . . . . . . . . . 18
6.5 Analogue output signal . . . . . . . . 19
6.6 Limit signals . . . . . . . . . . . . 20
6.7 Time switch (Timer) . . . . . . . . . 23
6.8 Display of the measured value . . . . . 24
7 Maintenance . . . . . . . . . 25
8 Trouble-shooting, repairs . . . . 25
8.1 Trouble-shooting table . . . . . . . . 25
8.2 Spare parts . . . . . . . . . . . . 26
8.3 Replacing parts . . . . . . . . . . 26
8.4 Checking . . . . . . . . . . . . . 28
8.5 Returning for repair . . . . . . . . . 29
8.6 Disposal . . . . . . . . . . . . . 29
9 Technical Data . . . . . . . . 31
10 Index . . . . . . . . . . . . 33
ZAD 423 Table of Contents
Endress+Hauser 1

1 Software changes
Version, Date Revisions Changes
1.0 04.04.1997 new
1 Software changes ZAD 423
2 Endress+Hauser

2 Notes on Safety
2.1 General information
In order to highlight safety-relevant or alternative operating procedures in the manual,
the following conventions have been used, each indicated by a corresponding icon.
Icons for
notes on safety
Explosion protection
Electrical symbols
Icon Significance
Note!
A note highlights actions or procedures which, if not performed correctly,
may indirectly affect operation or may lead to an instrument response
which is not planned.
Caution!
Caution highlights actions or procedures which, if not performed correctly,
may lead to personal injury or incorrect functioning of the instrument.
Warning!
A warning highlights actions or procedures which, if not performed correctly,
will lead to serious personal injury, a safety hazard or destruction of the instrument.
Device certified for use in explosion hazardous area
If the device has this symbol embossed on its nameplate it can be installed in an explosion
hazardous area.
Explosion hazardous area
Symbol used in drawings in these operating instructions to indicate explosion hazardous
areas.
— Devices located in and wiring entering explosion hazardous areas must conform with
the stated type of protection.
Safe area (non-explosion hazardous area)
Symbol used in drawings in these operating instructions to indicate non-explosion
hazardous areas.
— Devices located in safe areas still require a certificate if their outputs run into
explosion hazardous areas.
Direct voltage
A terminal to which or from which a direct current or voltage may be applied or supplied.
Alternating voltage
A terminal to which or from which an alternating (sine-wave) current or voltage may be
applied or supplied.
Grounded terminal
A grounded terminal, which as far as the operator is concerned, is already grounded
by means of an earth grounding system.
Protective grounding
A terminal which must be connected to earth ground prior to making any other connection
to the equipment.
Equipotential connection
A connection must be made to the plant grounding system which may be of type
e.g. equipotential line or neutral star according to national or company practice.
Note!
Caution!
Warning!
E
X
E
X
ZAD 423 2 Notes on Safety
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2.2 Special notes on safety
Approved usage The ZAD 423 controller is used to control the Silopilot FMM level measuring device,
to show level on the digital display, to convert the level into an analogue output signal
and to supply limit signals.
The electrical components are specifically designed for this application.
Installation,
commissioning,
operation
The controller has been designed to operate safely in accordance with current
technical and safety and EU standards. If installed incorrectly or used for applications
for which it is not intended, however, it is possible that application-related dangers
may arise, e.g. product overflow or damage to the Silopilot due to incorrect calibration.
For this reason, the instrument must be installed, connected, commissioned,
operated, maintained and repaired according to the instructions in this manual.
Personnel must be authorised and suitably qualified. Modifications or repairs to the
equipment which are not expressly approved in this manual or by the bodies
responsible for compliance may void the user's authority to operate the equipment.
Explosion hazardous
areas All local standards must be complied with when using the Silopilot in explosion hazardous areas.
•Ensure that all personnel are suitably qualified.
•All technical and safety specifications must be complied with at the measuring point.
2 Notes on Safety ZAD 423
4 Endress+Hauser

3 Introduction
3.1 Application
Controller for level measurement with the Silopilot FMM 760 or FMM 460
electromechanical level sensor:
•Automatic and manual output of start pulses for the Silopilot which can also be
switched off, e.g. during filling
•Digital display of silo level
•Conversion of the digital measured value into a standard analogue output signal
- for remote display of level
or - inverted -
- for remote display of free space between the surface and silo roof
•Output of two limit signals
3.2 Measuring system
The measuring system consists of:
•Silopilot FMM 760 or FMM 460
•Controller ZAD 423 with
- integrated time switch,
- digital display,
- analogue output,
- limit switch
•Connected peripherals, such as
- signalling systems,
- registration units, etc.
Silopilot FMM Power supply
Controller
ZAD 423
Fig.1
Measuring system
ZAD 423 3 Introduction
Endress+Hauser 5

3.3 Operating principle
Start-up The integrated time switch (timer) for automatic start-up of the Silopilot can be
adjusted in ten minute intervals, ranging from every 10 minutes to 24 hours.
The timer can also be switched off, e.g. during filling, to prevent the sensor weight
from being buried.
The Silopilot can also be started manually from the ZAD 423 controller.
Level measurement The controller is set to the units of distance (= counting steps) with which the Silopilot
measures the distance to the surface of the solid (e.g. cm, dm , in, 1/10 ft).
The controller receives a reset pulse from the Silopilot every time measurement begins.
It then counts the number of pulses transmitted by the Silopilot. At the end of the
measurement cycle, the level in the silo is shown on the digital display of the ZAD 423
controller in the units required (e.g. m, in, ft).
Output signal The analogue signal (0/4 ... 20 mA) is derived from the digital measurement signal
at the end of the measurement cycle. It can be inverted and set to indicate either the
level of material or the free space remaining in the silo.
On a fault, the output signal can be selected to
- fall to –10 % (MIN. = –2 mA / +2,4 mA),
- rise to 110 % (MAX. = 22 mA),
- remain unchanged (HOLD).
Limit signals The integrated relay with potential-free changeover contact can be set to energise
when a freely selectable height has been reached and to de-energise at another
(two-point control) or else to switch at a limit point.
The relay switching status is shown by an LED.
The relay de-energises on a fault (power failure, defective cable, breakdown of
Silopilot).
3 Introduction ZAD 423
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4 Installation
4.1 Planning
The ZAD 423 controller must be installed in a control room or else in a protective
housing. (This must be outside the explosion hazardous area if the Silopilot FMM is
used in a dust explosion hazardous area.)
The instrument is in Minipac form for single or row-mounting on a symmetrical rail
to EN 50022-35x7.5 or EN 50022-35x15.
A protective housing with ingress protection IP 55 is available for mounting in the
open; see accessories.
Note the permissible ambient temperature, which is dependent on the type of
mounting.
Avoid aggressive atmospheres and excessive humidity which can cause corrosion
to contacts or condensation on the printed circuit board.
See dimensional sketch for dimensions and minimum intervals.
min. 25 mm
100 mm 111 mm
2 mm 75 mm
113 mm (121 mm)
Standard rail EN 50022-35x7.5 / (35x15)
37.5 mm
Fig.2
Dimensional drawing
and
minimum distance between
two rows of instruments
Dimensions in mm
100 mm = 3.94 in
ZAD 423 4 Installation
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4.2 Mounting
Instrument identification Before installing, check to see if you have the correct instrument.
Information about the product is given on the nameplate.
Compare the product designation with that given in the product structure.
Mounting
on the standard rail See Fig. below For disposing of packaging see Section 8.6 "Disposal".
ZAD 423 Controller
Certificates, Approvals
A Standard - without special certificate
Y Other
Version
0 Minipac housing 100 mm, with terminal strips
9 Other
Power Supply
A 180 V ... 253 V, 50/60 Hz
B 90 V ... 140 V, 50/60 Hz
C 38 V ... 53 V, 50/60 Hz
D 21 V ... 28 V, 50/60 Hz
Y Other
Product designation
ZAD 423-
Fig. 3
Product structure
2.
1.
Fig.4
Mounting
1.place against standard rail
2.tilt front downwards
and clip in at back
4 Installation ZAD 423
8 Endress+Hauser

5 Electrical Connection
Warning!
Some of the connecting cables can carry hazardous contact voltages.
Before connecting up switch off all power to the Silopilot FMM, the ZAD 423 controller
and all peripherals (already or still to be connected).
L1 N PE
11 12 10
7 6 5
(10) (9) (8)
9 8
4 3
ZAD 423
+–+–
Analogue
output signal
(remote
transmission)
mA
Test
output
(on site)
mA
Start-up
enabled
Start-up
disabled
(Stop)
Silopilot
FMM 460
or
Silopilot
FMM 760
Counting
RGZ Start
Start-up
(pulse)
Limit signal
output
Power supply
Fig.5
Electrical diagram
ZAD 423 5 Electrical Connection
Endress+Hauser 9

Note:
•The ZAD 423 controller is to be connected to one Silopilot FMM level sensor.
•The ZAD 423 controller and counters must not be connected in parallel to the same
pulse counting outputs of the Silopilot FMM.
•Only operational low voltages are present at the upper terminal block of the ZAD 423.
Terminals 12 and 15 are connected internally.
•Observe all local guidelines covering installation!
•When using screened cable, the screening must be grounded at both ends.
Observe all local regulations covering explosion protection if the Silopilot FMM
is to be mounted in the explosion hazardous area.
Tools Usual tools for connecting electrical devices.
5.1 Connecting the Silopilot FMM to the ZAD 423 Controller
Start-up line (Terminals 41, 51)
To connect the FMM 460:
The two-wire cable for the start-up line can be unscreened or screened commercial
cable for line voltage.
Cable diameter min. 1.5 mm² /
SWG 17 / AWG 16 , max. 2.5 mm² / SWG 16 / AWG 14 ,
(strands with end sleeves).
Cable length max. 250 m /
750 ft (see FMM 460 operating manual on special
procedures for lengths up to 3000 m /
9000 ft ).
To connect to the FMM 760:
The two-wire cable for the start-up line can be screened or unscreened commercial
cable for low voltages (10 V).
Cable diameter max. 2.5 mm² /
SWG 16 / AWG 14 (strands with end sleeves).
Cable length max. 500 m /
1500 ft .
Pulse counting line (Terminals 7, 8, 9)
The three-wire cable for the pulse counting line can be screened or unscreened
commercial cable for low voltages.
Cable diameter max. 2.5 mm² /
SWG 16 / AWG 14 (strands with end sleeves).
Cable length max. 500 m /
1500 ft .
To prevent mutual interference, the start-up and pulse counting lines should be laid as
separate cables.
5.2 Disabling the start-up line (Stop)
(Terminals 14, 15)
Connecting Terminals 14 and 15 together disables automatic and manual start-up
from the controller. This can be used, e.g. during the filling cycle to prevent the sensor
weight of the Silopilot FMM from being buried.
A suitable control switch or relay contact can be connected using
screened or unscreened commercial cable or multicore instrumentation cable
up to 500 m /
1500 ft .
Contact load: max. 5 V, max. 1 mA.
Note!
5 Electrical Connection ZAD 423
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5.3 Analogue output signal, current output
(Terminals 12, 13)
Standard 0 … 20 mA or 4 … 20 mA signal for 0 … 100 % measuring range or inverted
100 … 0 % as required.
Connection of non-grounded display units, plotters, limit signal transmitters etc. in series
if the total load including the cable resistance is less than 500 Ω.
Screened or unscreened commercial cable or multicore instrumentation cable can
be used.
If the output signal must be galvanically isolated from the rest of the circuit
we recommend the use of a direct current isolator, e.g. HAA 420 TSP.
5.4 Test output
(Terminals 10, 11)
For direct connection of an ammeter on site to monitor the analogue output signal
without interrupting the current output.
5.5 Limit signal output
(Terminals 4, 5, 6)
Note that when connecting other devices to the relay contact, the operation of the limit
switch depends on the setting and the level. See Section 6.6 "Limit Signals".
For contact load see Section 9 "Technical Data, Output, Limit Signal".
5.6 Power supply
(Terminals 1, 2, 3)
Note the voltage stated on the nameplate, as well as the voltage tolerances for the
power supply and consumption (see Technical Data).
An isolating switch for a power supply should be installed near to the instrument.
A fine-wire fuse is built into the ZAD 423 controller so that the connection of another
fine-wire fuse is not required.
Important: The protective earth wire (PE) must be connected to Terminal 3.
•Switching to other voltages
and
•replacing the fine-wire fuse
see Section 8.3 "Replacing parts".
ZAD 423 5 Electrical Connection
Endress+Hauser 11

5 Electrical Connection ZAD 423
12 Endress+Hauser

6 Start-Up
6.1 Initial procedures
For the controller ZAD 423:
•Check for correct wiring
- to the Silopilot FMM
- to the peripherals
Counting step of the Silopilot FMM For the Silopilot FMM on the silo:
•Check for correct wiring
•Note the counting step (1 cm, 5 cm, 1 dm, 1 in or 1/10 ft)
- FMM 460, nameplate: indicated as "Zähleinheit"
- FMM 760, nameplate: indicated as "Zählung" (unit)
•FMM 760: set counting to "descend"
•Start up the Silopilot FMM and check operation according to instructions in the
appropriate operating manual.
6.2 General information on settings
•Switch on the power supply to the ZAD 423 controller.
When switching on for the first time or after a reset, the instrument displays the
following:
Pushbuttons for calibration are behind the front panel.
The functions of the pushbuttons are printed on the reverse side of the front panel.
•Opening the front panel:
H
0
999- 9
H
0
Fig.6
Display after first switching on
or after reset
b
a
Screwdriver
Fig.7
Opening the front panel
ZAD 423 6 Start-Up
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The ZAD 423 controller is set using a row of 10 fields:
*) For fields H 0,H1,H2,H4,H5,H6:
The units are set by the counting step in H 8.
m(meter) with counting step 1 cm, 5 cm, 1 dm
in (inch) with counting step 1 in
ft (foot) with counting step 1/10 ft
The decimal point depends on the counting step used.
**) Adjustable in 10-minute intervals;
hours to the left of the point,
minutes to the right of the point.
3
-
●
●
●
●
+
H
S
–
H
0
62 .
Pushbutton +
to increase value
Pushbutton –
to decrease value
Pushbutton H
to select
calibration field
Red LED
to show relay status
Pushbutton S
for manual start
of Silopilot
Digital
level
display
Fault
indication Level check
indication
Arithmetic
sign "minus"
*)
Calibration field
display
Analogue level
display Display showing
time switch in operation:
Start-up disabled:
*) Arithmetic sign –, if the weight falls below the preset zero point (H 1) of measurement level.
Fig.8
Pushbuttons and display field
behind front panel
Calibration
field H 5H 6H 7H 8H 9
Description Limit signal
Relay
energised
Limit signal
Relay
de-energised
Output
signal on
fault
Counting
step of
Silopilot
Time switch
(Timer)
Calibration
modes Height of limit point
for relay
energised
(Fig. 10)
*)
Height of
limit point
for relay
de-energised
(Fig. 10)
*)
0 = –10 %
1 = 110 %
2 = remains
un-
changed
0= 1dm
1= 5cm
2= 1cm
3= 1in
4 = 1/10 ft
Start-up
cycle
h. min
**)
Factory setting
(Reset) 40.0 5.0 0 0 0.00
Fig.9
The 10 Calibration fields
Calibration
field H 0H 1H 2H 3H 4
Description Measured
value
display
Empty
calibration Full calibration Output signal Distance A (Offset)
Calibration
modes None
*)
Height E
(Fig. 10)
*)
Height F
(Fig. 10)
*)
0 = 4…20 mA
1 = 20…4 mA
2 = 0…20 mA
3 = 20…0 mA
Height A
(Fig. 10)
*)
Factory setting
(Reset) –9999 50.0 45.0 0 0.7
6 Start-Up ZAD 423
14 Endress+Hauser

•Selecting the fields:
Press pushbutton Hso long or so often, until the correct field is shown
under the letter H.
•Entering the values or numbers:
Press pushbutton +or –so long or so often, until the correct number is shown.
•Storing the value:
Press pushbutton Hagain after setting the value.
•Calling up the stored value:
Press pushbutton Hso long or so often, until the correct field is shown
under the letter H.
•Reset
Press pushbuttons Hand +at the same time for a min. 4 s,
then all values in the fields are reset to factory values.
Start with the calibration in Section 6.3 "Basic settings".
0%
0/4 mA
0%
0/4 mA
100 %
20 mA
100 %
20 mA
A= Distance to the support of the sensing weight
O= Upper limit
U= Lower limit
Measured value of height
Measured value of free space
F(full) = Full calibration
E(empty) = Empty calibration
Limit
signal
Fig.10
Calibration variables
ZAD 423 6 Start-Up
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6.3 Basic settings
6.3.1 Setting the counting step
Note:
The counting step is distance per pulse which the Silopilot counts as the sensing
weight is lowered into the silo. The counting step (= "Zählung / Zähleinheit / unit") is
•on the nameplate of the Silopilot FMM
or
•above the order designation (e.g. on the delivery note):
FMM 460(Z)-#1… or FMM 460(Z)-#2… = 1 dm ❏
FMM 460(Z)-#3… or FMM 460(Z)-#4… = 1/10 ft ❏
FMM 760(Z)-A… or FMM 760(Z)-B… or FMM 760(Z)-C… = 1 dm ❏
FMM 760(Z)-D… or FMM 760(Z)-E… or FMM 760(Z)-F… = 5 cm ❏
FMM 760(Z)-G… or FMM 760(Z)-H… or FMM 760(Z)-J…=1in❏
FMM 760(Z)-K… or FMM 760(Z)-L… or FMM 760(Z)-M… = 1/10 ft ❏
FMM 760(Z)-N… = 1 cm ❏
6.3.2 Empty calibration
Note:
When defining the zero point for measurement, take into account
- the discharge funnel formed by the bulk solid
- the mounting point of the Silopilot.
Note!
Note!
Step Calibration
field ●HEntry ●+ ●–Example Remarks
1H
8Number corresponding
to counting
step of
connected
Silopilot FMM
0= 1dm
1= 5cm
2= 1cm
3= 1in
4 = 1/10 ft
0 = step
1dm
2H
9Stores entry
Set counting step
Step Calibration
field ●HEntry ●+ ●–Example Remarks
1H
1Height E from flange to
zero point of
measurement
(empty silo)
in m
for steps of
1cm
5cm
1dm
in in
for steps of
1in
in ft
for steps of
1/10 ft
18.7 (m)
2H
2Stores entry
Procedure for empty calibration
E
0%
counting
step
6 Start-Up ZAD 423
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6.3.3 Full calibration
Note:
When defining the maximum height (100%) for measurement, take into account
- the mounds formed by the bulk solid and
- the mounting point of the Silopilot.
The maximum height must be below the tip of the sensing weight of the Silopilot FMM.
*) If the sign for a fault is shown to the left of the display field, then the Silopilot is incorrectly
connected or is counting when ascending. Check the wiring and settings of the Silopilot.
If the sign –is shown in front of the measured value, then the sensing weight is below the
preset zero point of measurement.
Note!
Step Calibration
field ●HEntry ●+ ●–Example Remarks
1H
2Height F from
zero point of
measurement
(empty silo)
to maximum
height
in m
for steps of
1cm
5cm
1dm
in in
for steps of
1in
in ft
for steps of
1/10 ft
17.2 (m)
2H
0Stores entry
3Press Pushbutton ●Smin. 3 s Silopilot will be
activated
12.3 Height is shown
*)
Procedure for full calibration
F
100 %
ZAD 423 6 Start-Up
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6.4 Silopilot design
The factory settings of the ZAD 423 take into account the dimensions of a Silopilot
FMM 760 with standard wiper rods and sensing weight, i.e. 0.7 m from the flange to
the lower edge of the sensing weight (without spike), if the counting step is set
to 1 dm.
For small silos, a change of the factory setting "Offset" in order to increase
measurement accuracy is only of use for:
- other counting steps
- FMM 760 with extended wiper rods
- FMM 760 with other sensing weight
- FMM 460
See corresponding dimensional sketches on the Silopilot and sensing weight.
*) The factory settings change when switching to other counting steps:
Step 1 dm — Factory setting 0.7 m
Step 1 cm — Factory setting 0.07 m
Step 5 cm — Factory setting 0.35 m
Step 1 in — Factory setting 7 in (0.18 m)
Step 1/10 ft — Factory setting 0.7 ft (0.21 m)
Step Calibration
field ●HEntry ●+ ●–Example Remarks
1H
4
Offset
Distance A
from flange
to the
support of
the sensing
weight
in m
for steps of
1cm
5cm
1dm
in in
for steps of
1in
in ft
for steps of
1/10 ft
1.1 (m)
for Silopilot
with
extended
wiping
rod
2H
5Stores entry
Taking account of the model
A
(Factory-set value 0.7 m *)
6 Start-Up ZAD 423
18 Endress+Hauser