Hycontrol MINIFLEX LR User manual

Rev 0
MINIFLEX LR PROGRAMMABLE LEVEL CONTROLLER
INSTALLATION AND OPERATION MANUAL
Hycontrol Limited, Larchwood House, Orchard Street,
Redditch, Worcestershire, B98 7DP, UK.
Tel: [phone] Fax: [phone]
Email: [email protected] Web: www.hycontrol.com

MINIFLEX LR USER MANUAL - INDEX
Page Drawings
Introduction 1
SECTION 1 Installation
Transceiver Mounting 2 Fig. 1
Transceiver Wiring 3 - 4 Fig. 2 & 3
Transducer Mounting 5 Fig. 4
Transducer Alternative Mounting 6 Fig. 5
Transducer Mounting Faults 7 Fig. 6
Transducer Stand Pipe 7
Transducer Cable Extensions 8 Fig. 7 & 8
Temperature Sensor 9 Fig. 9
SECTION 2 Easy start for Miniflex LR
Quick Start Guide 10
Principle of Programming 10
Keypad Definitions 10 - 11
To Enter Programme 11
To Enter the Password 11
To Change an Option 12
To Reset 13
Simulation Mode 13
SECTION 3 Programming the instrument
Parameter List 14 - 34
SECTION 4 Miniflex LR Default programs
1. Distance Measurement Mode 35
2. Level Measurement Mode 36
3. Contents, Volume Conversion 37
4. Pump Control 38
5. Open Channel Flow 39 - 40
6. Differential 41 - 42
SECTION 5 Commissioning fault finding 43 - 47
APPENDIX 1 LINEARISATION OF SPECIAL 48 - 52
VESSELS OR FLUMES
APPENDIX 2 SPECIFICATION 53
APPENDIX 3 INSTALLATION INSTRUCTIONS 54 - 55
FOR ATEX TRANSDUCER IN
HAZARDOUS AREA
APPENDIX 4 PARAMETER SETTINGS 56 - 62
APPENDIX 5 PARSHALL FLUMES 63
APPENDIX 6 WIRING DIAGRAM FOR 64
SYNCHRONISATION OF
INSTRUMENTS
APPENDIX 7 MINIFLEX LR PROGRAMMING 65 - 74
CHARTS

SECTION 1
MINIFLEX LR PROGRAMMABLE LEVEL CONTROLLER
USER MANUAL
INTRODUCTION
Miniflex LR is a programmable multi-purpose level measurement and flow control
instrument. It consists of two elements, a wall mounted transceiver, which has a display and
an integral keypad for programming, and a transducer, which must be mounted directly above
the surface to be monitored.
Ultrasonic pulses are transmitted by the transducer to the surface of the material to be
monitored and are reflected back to the transducer. The time period between transmission and
reception of the sound pulses is directly proportional to the distance between the transducer
and the material.
Since speed of sound through air is affected by changes in temperature, a separate or
integrated temperature sensor may be fitted to improve accuracy.
Miniflex LR is capable of the following functions:-
a) Distance Measurement (distance from a datum)
b) Level Measurement (height above datum)
c) Volume Measurement
d) Pump Control
e) Open Channel Flow Measurement (O.C.M.)
f) Differential Level Measurement
WARNING
DO NOT OPEN THE TRANSCEIVER
TERMINAL COVER WHEN THE POWER IS ON TO
THE SUPPLY OR RELAY TERMINALS.
IMPORTANT INSTALLATION REQUIREMENTS
1: A SWITCH OR CIRCUIT BREAKER SHALL BE INCLUDED IN
THE INSTALLATION
2: IT SHALL BE IN CLOSE PROXIMITY TO THE EQUIPMENT AND
WITHIN EASY REACH OF THE OPERATOR
3: IT SHALL BE MARKED AS THE DISCONNECTING DEVICE FOR
THE EQUIPMENT
Ref: MINIFLEX LR MANUAL Rev. 0 1

SECTION 1
INSTALLATION
Transceiver For ATEX hazardous areas refer to Appendix 3.
Enclosure mounting
Secure one of the three fixing screws provided with the instrument 30mm below the centre of
where the top of the instrument is to be located. This fixing screw will need to be left 4mm
proud of the surface allowing the instrument to be hung from this point. The instrument is
then secured in place by 2 more screws using the two mounting slots exposed when the
terminal cover is removed. DO NOT use excessive force when tightening the fixings and
avoid any distortion of the enclosure.
Ensure that the mounting surface is not subject to vibration and is not in close proximity to
high voltage cables, contactors or drive controls. The unit should not be mounted in a
confined space where temperatures may exceed the normal working temperature. If the unit
is mounted outside, it must be protected from direct sunlight or severe weather conditions.
Select appropriate knockouts in the base of the enclosure and fit appropriate cable glands to
maintain the IP65 rating.
(MODIFY)
BACK
INCREASE
DIGIT
OPTION
/ DIGIT
RELAY 1
RELAY 3
ECHO
LEVEL CONTROLLER
M
MINIFLEX LR
ENT
HYCONTROL LTD, ENGLAND
TEL:[phone] Website: www.hycontrol.com
213.0
106.5
185.0
∅ 5.4
10
198.0
31.00
MOUNTING POINT 1
FOUND ON REAR
137.0
MOUNTING POINT 2 & 3
(REMOVE TERMINAL COVER)
KNOCKOUTS FOR 1 HOLE 16mm AND 5 HOLES 20mm ∅∅
NOTE: - All dimensions are shown in mm
Figure 1: Enclosure dimensional & mounting drawing
Ref: MINIFLEX LR MANUAL Rev. 0 2

SECTION 1
Electrical and Transducer Connections
The Miniflex LR has two-part screw terminals; the top part can be removed for ease of connection. It can be
powered from either an AC or DC supply.
Power Supply Remove the terminal cover to expose the terminals shown below.
1 2 3 4 5 6 7 8 9 10111213141516171819202122232425
TB1 TB2 TB3 TB4 TB5 TB6
F4
T250mA
95V 110V 230V
F3
T160mA
Figure 2: Terminals as seen in Miniflex LR.
The wiring instructions are on the inside of the terminal cover as shown below.
+
DC POWER
21.6-30VDC
9W
1
RELAY 1 RELAY 3RELAY 2
TRANSDUCER
SHIELD
EL2 LN
-
SHIELD
+
ISOLATED
ANALOG
OUTPUT
SYNC
-
SHIELD
+
RS485
-
2 3 4 5 6 7 8 9 10111213141516171819202122232425
L1
HOT
AC POWER
95/110/230V AC
+10%/-10%
50/60 HZ 12VA
Figure 3: Wiring diagram label inside MIniflex LR terminal cover
AC Supply The instrument will accept either 95V, 110V or 230VAC ±10%, 50Hz or 60Hz, 12VA.
A time lag fuse T160mA is fitted.
Select the voltage required using the jumper link situated just above terminal TB6.
Pass mains cable through cable gland and -Connect:- Earth to terminal 23
Neutral to terminal 24
Live to terminal 25
DC Supply The instrument will accept 21.6 - 30VDC, 5W. A time lag fuse T250mA is fitted.
- Connect :- Positive +ve to terminal 1
Negative -ve to terminal 2
Relays
3 SPDT Relays - rated at 8A/250VAC 8A/30V DC resistive, are connected at terminals 14 to 22, for activating
external alarms, contactors, pumps etc..
Transducer
Transducer RYV15 & RWV15 - is connected:- Black to terminal 6
Blue to terminal 7
Shield to terminal 9
Ref: MINIFLEX LR MANUAL Rev. 0 3

SECTION 1
Temperature compensated transducer RYT15 & RWT15 - is connected: -
Shield to terminal 6
Blue to terminal 7
Black to terminal 8
Analogue Output
Analogue - is connected : - Shield to terminal 11
Positive +ve to terminal 12
Negative -ve to terminal 13
RS485 Output
RS485 - is connected : - Shield to terminal 3
Negative –ve to terminal 4
Positive +ve to terminal 5
Note: - See Page 8 for transducer extension cables.
Ref: MINIFLEX LR MANUAL Rev. 0 4

SECTION 1
Transducer Mounting
The transducer can be supplied as 'standard' or mounted in a flange. For applications
requiring chemical compatibility the transducer is available fully enclosed in PVDF in a
standard mounting or with flange. Figure 4 shows the dimensions:
Figure 4: Transducer mounting diagram
An isolation kit is provided with each transducer to minimise any ringing transmitted through
the mounting structure.
The transducer must be mounted perpendicular to the monitored surface and, ideally, at least
0.5 metres above it.
The transducer has a 12° inclusive conical beam angle at -3dB and must be mounted with a
clear unobstructed sight of the liquid to be measured over the complete measurement range.
The transducer is provided with integral cable which can be extended up to 300 metres using
a suitable junction box and RG62AU cable. The temperature compensated transducer
requires an additional single core screen extension, or twin-ax cable.
Refer to Page 8 for full details.
Transducer cables and temperature compensation cables can be run together but
should be separated from power cables by at least 150mm and preferably installed in
their own earthed steel conduit.
Isolation Kit
Fit as shown
102
M20 x 1.5
50 dia
M32 x 1.5
62
26
92 dia
10m cable 6.0 dia
20
130
assembled
height
20
Dia to suit flange selected
No. & size of bolts
to suit flange selected
Bolt hole PCD to suit
flange selected
INTEGRAL FLANGE
Ref: MINIFLEX LR MANUAL Rev. 0 5

SECTION 1
FLEXIBLE OR RIGID
CONDUIT. BRACKET.
UNDER FLANGE.
INTEGRAL FLANGE
ISOLATION KIT.
ISOLATION KIT.
OPTIONAL
ISOLATION KIT
Figure 5: Alternative mounting arrangements for transducers
Do not mount transducers incorporating temperature compensation in direct sunlight.
Do not over-tighten the bolts on flange construction transducers.
Flange transducers are not pressure rated and are suitable only for atmospheric pressure.
ATEX approved transducers must be mounted and wired in accordance with the appropriate
National Standards concerning installation in hazardous environments.
For differential applications mount both transducers at the same height above the zero
datum point.
For open channel flow applications the transducer must be mounted upstream of the flume
or weir as detailed in BS3680 (usually 3 or 4 times maximum head).
Ref: MINIFLEX LR MANUAL Rev. 0 6

SECTION 1
KEEP TRANSDUCER
PERPENDICULAR
TO LIQUID.
KEEP TRANSDUCERS AND
TEMPERATURE COMPENSATION
PROBES OUT OF DIRECT
SUNLIGHT
DO NOT AIM THROUGH
HOLES IN THE TANK AVOID ROUGH EDGES
IN STANDPIPES
AVOID INFLOWS OR
OTHER OBSTRUCTIONS
CAUTION: AVOID THE FOLLOWING TRANSDUCER INSTALLATION FAULTS
Figure 6: Transducer installation faults
Standpipe Installations
In many applications access to a vessel must be made via a standpipe. However, it is
necessary to observe some basic rules when fitting transducers into standpipes.
BLANKING: Parameter 4.0 should always be set at least 150mm longer than the
length of the standpipe.
STANDPIPE should be in accordance with the following table
DIMENSIONS: Flange size and minimum Maximum length
bore of Standpipe of Standpipe
3" ( 80mm) 300mm
4" (100mm) 300mm
e.g. Using a 4" flanged transducer would require the standpipe length to be no more than
300mm and Pr.4.0 set at 450mm minimum.
The inside of the pipe and joint with vessel top must be clean and free of any
obstructions, seams or welds.
Ref: MINIFLEX LR MANUAL Rev. 0 7

SECTION 1
Transducer Cable Extensions
Transducer cables may be extended using junction boxes as shown in Figure 7:
Junction
Shield - Term 6
RWV15 / RYV15 Transducer
To Miniflex LR
Core - Term 7
Transducer
Black
Shield
Blue
RG62AU
Temperature Compensation RWT15 / RYT15 Transducer
Blue
Junction To Miniflex LRTransducer
Black
Shield
Copper core Term 8
Shield Term 6
Silver core Term 7
Beldon 9207
or equal
Blue
Junction To Miniflex LRTransducer
Black
Shield
Copper core Term 6
Shield Term 9
Silver core Term 7
Beldon 9207
or equal
RWV15 / RYV15 Transducer- alternative
Figure 7: Transducer lead extension diagram
Junction
Shield - Term 6
RWV15 / RYV15 Transducer
To Miniflex LR
Core - Term 22
Upstream Transducer
Black
Shield
Blue
RG62AU
Junction
Shield - Term 9
To Miniflex LR
Core - Term 20
Downstream Transducer
Black
Shield
Blue
RG62AU
Extend transducer cable if necessary
with RG62AU as shown.
Wire unextended transducers as below
+
DC POWER
21.6-30VDC
9W
1
RELAY 1 RELAY 3RELAY 2
TRANSDUCER
SHIELD
EL2 LN
-
SHIELD
+
ISOLATED
ANALOG
OUTPUT
SYNC
-
SHIELD
+
RS485
-
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
L1
UPSTREAM - BLUE
DOWNSTREAM - BLUE
UP & DOWNSTREAM BLACKS
UP & DOWNSTREAM SHIELDS
HOT
AC POWER
95/110/230V AC
+10%/-10%
50/60 HZ 12VA
Note Link
Figure 8: Transducer Wiring for Differential Mode
Ref: MINIFLEX LR MANUAL Rev. 0 8