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
Endress+Hauser 3

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
6 Endress+Hauser

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
Endress+Hauser 7

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