Endress+Hauser gammapilot FTG 671 User manual

gammapilot
FTG 671
Level Limit Detection
Operating Instructions
BA 082F/00/en/12.03
016309-1000
Software 1.3
Hauser + Endress
The Power of Know How

Short Instructions
Operation
Selects vertical matrix position
Selects horizontal matrix position
Select positon V0H0
Selects next digit
Move decimal point
Increases value of digit
Decreases value of digit
Registers entry
Function Matrix Action
Reset transmitter V9H5 ●Enter 671: see above for key functions
Press »E« to register entry
Calibrate V3H0
V3H4
V0H1
V0H2
V0H9
●Enter 5 to select standard calibration with background calibration
Press »E« to register entry
●Enter calibration date: year (3 = 93), week (01…53 )
weekday (1=Monday etc.)
Press »E« to register entry
●With vessel empty (wait 100s)
Press »E« to register entry
●With vessel full (wait 100s)
Press »E« to register entry
●With radiation off and vessel full (wait 100s)
Press »E« to register entry
Integration time V0H4 ●Enter max. permissible integration (relay switching) time in s
Press »E« to register entry (default = 7 s)
Relays (default values) …●Relay 1 is set automatically to maximum fail-safe mode
Switch-off point 38, switch-on point 72
●Relay 2 to maximum fail-safe mode
Switch-off point 72, switch-on point 38
VH
00
1
2
VH
+
E
FTG 671
Measured
value
Matrix
selection
Relay status
red: de-energised
green: energised
Parameter entry
Commulog
sockets
Alarm relay
lit: fault
Matrix position
+
+
See also »Controls«, Chapter 3
The FTG 671 transmitter and DG 57 detector must be powered up for at least 6 hours before configuration
Quick Configuration (for Cs137, DG 57) with background calibration
Gammapilot FTG 671 Short Instructions for Use

Inhaltsverzeichnis
1 Introduction . . . . . . . . . . . . . . 5
1.1 Application . . . . . . . . . . . . . . . . 6
1.2 Measuring system . . . . . . . . . . . . . 7
1.3 Measuring principle . . . . . . . . . . . . 8
1.4 Functional description . . . . . . . . . . . 9
2 Installation . . . . . . . . . . . . . . 11
2.1 Measuring system . . . . . . . . . . . . 11
2.2 Installation hints for source container and detector 12
2.3 Gammapilot installation . . . . . . . . . . 18
2.4 Transmitter wiring . . . . . . . . . . . . 20
2.5 Hardware configuration . . . . . . . . . . 24
2.6 Technical data . . . . . . . . . . . . . 25
3 Controls . . . . . . . . . . . . . . . 27
3.1 Commutec operating matrix . . . . . . . . 27
3.2 Configuration from front panel . . . . . . . 28
3.3 Configuration with Commulog VU 260 Z . . . 29
4 Calibration and Operation . . . . . . . 31
4.1 Commissioning . . . . . . . . . . . . . 31
4.2 Standard calibration with background calibration
(for detector DG57) . . . . . . . . . . . . . 33
4.3 Standard calibration (normal) without background
calibration (for DG 17 and DG 27) . . . . . . . 34
4.4 Auxiliary calibration . . . . . . . . . . . 35
4.5 Limit switches . . . . . . . . . . . . . . 36
4.6 Additional functions . . . . . . . . . . . 37
4.7 Measured value display . . . . . . . . . . 37
4.8 Locking the parameter matrix . . . . . . . 38
5 Limit Switches - Relays . . . . . . . . 39
5.1 Configuration . . . . . . . . . . . . . . 40
5.2 Acknowledgement mode . . . . . . . . . 45
6Maintenance
. . . . . . . . . . . . . 47
7 Trouble-Shooting . . . . . . . . . . . 49
7.1 Trouble-shooting tables . . . . . . . . . . 49
7.2 Fault by Gammagraphy . . . . . . . . . . 51
7.3 Simulated operating mode . . . . . . . . . 52
7.4 Exchanging transmitters and detectors . . . . 53
7.5 Repairs . . . . . . . . . . . . . . . . 54
Gammapilot FTG 671 Table of Contents
1

Gammapilot FTG 671 Table of Contents
2

Notes on Safety
Radioactive sourcesRadioactive isotopes are used as sources for level detection by gamma radiation. The
source is encapsulated in a welded, double-walled container of special steel.
•In practically all countries, the handling and operation of radioactive sources
is governed by strict regulations which are enforced by a national radiation
protection board.
•Authorisation, which usually includes a requirement for personnel specially
trained in radiation protection, must be obtained from this board before the
equipment enters the factory.
•If you are in any doubt as to the regulations in your country, call your E+H sa-
les office or representative - they will be glad to help you further!
Endress+Hauser radiometric systems are designed, manufactured and shipped with
special regard to German and International radiation safety regulations. Original radiometric
systems are normally delivered equipped with double-encapsulated sources of Cs 137 or
exceptionally Co 60, both complying with DIN 24426/ISO 2919 classification 66646. This is
acknowledged as the highest safety classification for industrial source containments.
CertificatesThe Gammapilot FTG 671 is a transmitter for level limit detection which can be used with
a variety of radioactive sources and detectors. It must be installed by qualified personnel
according to the instructions in this manual.
The transmitter and ancillary equipment are available with certificates. The Table below
indicates the combinations available and conditions for installation. Full details can be
taken from the certificates. Please note that where quoted technical data differs from that
listed in Section 2.6, that in the certificate applies.
Certificate Instruments Notes
PTB 99 ATEX 2089 Gammapilot FTG 671 II(2)G / [EEx ib] IIC,
s. Safety instructions XA 054F-C
DIBt Check Report
PA-VI 850.01
Gammapilot FTG 671 Overflow protection according to
WHG
PTB Nr. Ex-94.C.1019
ATEX 1104
DG 57-A…
DG 57-H…
DG 57-M…
EEx d ib IIC T6 / ATEX II 2 G
EEx d IIC T6 / ATEX II 2 G
EEx de IIC T6 / ATEX II 2 G
s. Safety instructions XA 057F-A
DMT 01 ATEX E 093 DG 57-D... ATEX II 2 D IP 65 T 60°C
s. Safety instructions XA 112F-A
PTB Report 6.62-1972/1
PTB Report 6.62-1972/2
PTB Report 6.32-2005
QG 020
QG 100
QG 2000
Report on local dosage
measurement on source container
Gammapilot FTG 671 Notes on Safety
3

Safety conventions
In order to highlight safety-relevant or alternate operation procedures in the manual the
following conventions have been used, each indicated by a corresponding icon in the
margin.
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 indicates actions or procedures which, if not performed correctly, may lead
to personal injury or incorrect functioning of the instrument
Warning!
•A warning indicates actions or procedures which, if not performed correctly, will
lead to personal injury, a safety hazard or destruction of the instrument
Gammapilot FTG 671 Notes on Safety
4

1 Introduction
Short instructionsThe front cover contains short instructions for the standard set-up, level limit detection
with two limit relays, using the FTG 671, DG 57 and Cs 137 source.
In this manualUsers unfamiliar with the Gammapilot FTG 671 must read the operating instructions
which are structured as follows:
•Chapter 1: Introduction;
contains general information including application, measurement
principle and functional description.
•Chapter 2: Installation
contains instructions on the installation of the radioactive source,
Geiger-Müller and scintillation counters, Gammapilot FTG card,
hardware configuration, connection diagrams and technical data
for the plug-in card.
•Chapter 3: Controls;
describes operation with the front panel keys, Commulog VU 260 Z
and ZA 67…gateways.
•Chapter 4: Calibration and Operation;
tells you how to commission and operate the Gammapilot for level
limit detection.
•Chapter 5: Limit Switches;
describes in detail the setting of the relays for fail-safe or
acknowleged operation.
•Chapter 6: Trouble-Shooting;
contains a description of the self-checking system with error
messages, the simulation feature as well as instructions for
configuration on replacement of the transmitter, source or detector.
•Index lists key words to help you find information quickly.
Further documentationIn addition to this manual, the following publications provide information on configuration
of the Gammapilot FTG 671.
•BA 028 Commulog VU 260 Z handheld terminal
•BA 054 ZA 672 Modbus Gateway
•BA 073 ZA 673 Profibus Gateway
•BA 085 ZA 674 FIP Gateway
The installation of the radioactive source and detector is described in the documentation
accompanying these articles as well as briefly in Chapter 2.
•TI 264F Source Container QG 020/100
•TI 346F Source Container QG 2000
•TI 180F Scintillation Detectors DG 57
•TI 197F Geiger-Müller counters DG 17 and DG 27
When installing detectors in explosion hazardous areas the instructions included in the
accompanying certification must also be observed.
Gammapilot FTG 671 Chapter 1: Introduction
5

1.1 Application
The Gammapilot FTG 671 is designed as a
•non-contact, level limit switch
for containers (mixers, reactors, hoppers, silos, tanks) e.g. with inflammable, poisonous
and aggressive bulk material and liquids. It is also suitable for applications in the food
processing industry, e.g. on product filling lines.
Gammapilot transmitters may also be used for applications in explosion hazardous
areas, e.g. in acid tanks, boilers, cement silos, etc., and possess intrinsically-safe sensor
circuits conforming to EEx ib IIC. A list of certificated combinations is to be found in
»Notes on Safety« preceding this chapter.
Min./max.
relays
Gammapilot
FTG 671
transmitter
BA082E01
Source Detector
Alarm relay
Fig. 1.1:
Standard application showing
Gammapilot FTG 671, source
and detector
Maximum
level
detection BA082E02
Minimum
level
detection
Fig. 1.2:
Left:
Conveying limestone
Gamma radiation barriers control
the drying process
Right:
Automatic filling of beer barrels
The level is checked as the
barrels move past the barrier
FTG 671
Vibration
channel
Feed rate
1 barrel/2s Full move forward
Half full are
rejected
BA082E03
FTG 671 Filling
station
Gammapilot FTG 671 Chapter 1: Introduction
6

1.2 Measuring system
A working system for limit level detection comprises:
•Gammapilot FTG 671 transmitter,
•QG 020 or QG 100 source container with Co 60 or Cs 137 gamma source
•DG 17 or DG 27 Geiger-Müller counter or
DG 57 scintillation counter.
The Gammapilot may operate as a stand-alone or system unit. Two relays act as freely
programmable limit switches which can be operated in fail-safe or acknowledgement
mode. An alarm relay monitors the correct functioning of the measurement point and
trips on fault condition.
If controlled remotely with other Commutec transmitters within a process control system,
the Gammapilot is addressed via the Rackbus. In this case, communication is controlled
by a ZA 67…Gateway which converts Rackbus data into the appropriate network
protocol. The Gammapilot can be remotely configured, its measured data and status
scanned and its settings up and downloaded through the Gateway.
BA082E41
Detector and source container
in hazardous area
FTG 671 in safe
area
Fig. 1.3:
Gammapilots FTG 671 row
mounted in Monorack II
housings
BA082E04
Commutec transmitters
Rackbus
Personal
computer or
PC system
Programmable logic
controller with Modbus port
Sensors Actuators
RS-232C interface
Modbus interface
ZA 370
or
ZA 371
ZA 672
Fig. 1.4:
The Gammapilot FTG 671 can
be used as part of a process
control system.
Here it is shown with other
Commutec transmitters and the
ZA 672 Modbus Gateway
Gammapilot FTG 671 Chapter 1: Introduction
7

1.3 Measuring principle
Gamma ray absorption When Gamma radiation penetrates a material, it is absorbed to a degree dependent
upon the density ρ, and thickness d of the material as well as the linear absorption factor
µ, which is also dependent on the material and source. The attenuation Fsis given by:
Fs= e−µ • ρ•d
The radiation also decreases with the square of the distance between source and
detector. For limit switching µ, ρ, and d are constants and the detected radiation level
depends upon the presence or not of material in the beam. The countrate is at a maximum
when the beam is completely free and at a minimum when the all radiation has to travel
through the material. The maximum and minimum countrates Nmax and Nmin are obtained
when the transmitter is calibrated. Their dependency is given by:
Nmin =N
max/Fs= Nmaxe−µ • ρ • d
The FTG 671 output is normalised to produce the end values 0 and 100, relay 1 trips at
38 in minimum and relay 2 at 72 in maximum fail-safe mode (10 and 90 for DG 17/27 (Z)
detectors). The detection band is dependent upon the orientation of the detector, which,
however, is usually mounted horizontally on the vessel.
Statistical assessment The precision of a gamma limit switch is dependent on the statistical variation in
countrate. Since the emission of gamma rays from a radioactive source is a random
phenomenom, several successive countrate measurements taken over a given period
of time will be seen to vary randomly about a mean value. The degree of variation between
measurements depends upon the time interval chosen. The measurement precision
depends on the confidence level - 1σ, 2σor 3σ - which is to be attained. For a countrate
of N pulses per second:
±1σ = ±1√N 68.28% confidence level
±2σ = ±2√N 95.45% confidence level
±3σ = ±3√N 99.74% confidence level
Normally a confidence level of 2σis used. The statistical variation is reduced by
increasing the sampling or integration time τ:
Statistical variation = ±2√N
√τ
Barrier covered
Statistical fluctuation
in countrate Residual and
background radiation
BA082E05
Radiation
progressively
absorbed by product
Barrier free
Nmax
Nmin
Detection band
0
100
Display
Detector
Fig. 1.5:
Operating principle of FTG 671
radiometric level limit switch
Gammapilot FTG 671 Chapter 1: Introduction
8