Milltronics Mercap mcp01 s series User manual

MERCAP MERCAP

MERCAP

Instruction Manual

June 2001

Siemens Automation

Safety Guidelines

Warning notices must be observed to ensure personal safety as well as that of others, and to

protect the product and the connected equipment. These warning notices are accompanied

by a clarification of the level of caution to be observed.

Qualified Personnel

This device/system may only be set up and operated in conjunction with this manual.

Qualified personnel are only authorized to install and operate this equipment in accordance

with established safety practices and standards.

Warning: This product can only functionproperly and safely if it is correctly transported,

stored, installed, set up, operated, and maintained.

Note: Always use product in accordance with specifications.

This document is available in bound version and in

electronic version. We encourage users to

purchase authorized bound manuals, or to view

electronic versions as designed and authored by

Siemens Milltronics Process Instruments Inc.

Siemens Milltronics Process Instruments Inc. will

not be responsible for the contents of partial or

whole reproductions of either bound or electronic

versions.

While we have verified the contents of

this manual for agreement with the

instrumentation described, variations

remain possible. Thus we cannot

guarantee full agreement. The

contents of this manual are regularly

reviewed and corrections are included

in subsequent editions. We welcome

all suggestions for improvement.

Technical data subject to change.

MILLTRONICS®is a registered trademark of Siemens Milltronics Process Instruments Inc.

Contact SMPI TechnicalPublications atthe following address:

Technical Publications

Siemens Milltronics Process Instruments Inc.

1954 Technology Drive, P.O. Box 4225

Peterborough, Ontario, Canada, K9J 7B1

Email: techpubs@milltronics.com

For the library of SMPI instruction manuals, visit our Web site: www.milltronics.com

7ML19981CM01.1 MERCAP – INSTRUCTION MANUAL Page 1

Table of Contents

Introduction

IntroductionIntroduction

Introduction

................................

................................................................

....................................

........

.... 3

Identifications and Abbreviations..............................................................................................3

Technical Specifications

Technical SpecificationsTechnical Specifications

Technical Specifications

................................

................................................................

..............................................

............................

.............. 5

Electrodes.........................................................................................................................................5

Wetted Parts....................................................................................................................................5

Transmitter.......................................................................................................................................5

Electrodes and Process Connections

Electrodes and Process ConnectionsElectrodes and Process Connections

Electrodes and Process Connections

................................

................................................................

........................................................

................................................

........................ 7

Handling of Electrodes..................................................................................................................7

Characteristics ................................................................................................................................7

General Design Principles ...........................................................................................................8

Mercap Configurations.................................................................................................................9

Examples of Mercap Level Instruments ................................................................................10

Interface and Level Version (Mercap MCP 02)....................................................................15

Flanges ............................................................................................................................................17

Flange Standards .........................................................................................................................17

Applications Examples................................................................................................................19

Flow-Through Electrode

Flow-Through ElectrodeFlow-Through Electrode

Flow-Through Electrode ................................

................................................................

..............................................

............................

.............. 21

2121

FTS Series ......................................................................................................................................21

FTF Series.......................................................................................................................................22

MST9500 Transmitter

MST9500 TransmitterMST9500 Transmitter

MST9500 Transmitter

................................

................................................................

..................................................

....................................

.................. 24

2424

Operating Principles ....................................................................................................................24

Installation

InstallationInstallation

Installation

and Interconnection

and Interconnectionand Interconnection

and Interconnection................................

................................................................

................................ 25

2525

Interconnection.............................................................................................................................26

Connection Diagrams..................................................................................................................27

Factory settings ............................................................................................................................29

Applications

ApplicationsApplications

Applications

and Grounding

and Groundingand Grounding

and Grounding ................................

................................................................

.......................................

..............

....... 30

3030

Start-up

Start-upStart-up

Start-up

................................

................................................................

.........................................

..................

......... 35

3535

Push-Button Adjustment............................................................................................................35

Adjustment using HARTTM ..........................................................................................................36

Maintenance

MaintenanceMaintenance

Maintenance

................................

................................................................

................................ 39

3939

Test function ..................................................................................................................................39

Appendix A: HART

Appendix A: HARTAppendix A: HART

Appendix A: HARTTM

TMTM

TM Documentation

DocumentationDocumentation

Documentation

................................

................................................................

........................................................

................................................

........................ 41

4141

HARTTM info.....................................................................................................................................41

HARTTM Conformance and Command Class .........................................................................41

MST9500 DD Menu/Variable Organization ..........................................................................43

HARTTM Response Code information.......................................................................................44

General transmitter information...............................................................................................44

Siemens Automation

Page 2 MERCAP –INSTRUCTION MANUAL 7ML19981CM01.1

Additional universal command specifications .....................................................................45

Additional common-practice command specifications.....................................................45

Transmitter specific commands...............................................................................................47

Appendix B: Tables

Appendix B: TablesAppendix B: Tables

Appendix B: Tables

................................

................................................................

.....................................................

..........................................

..................... 54

5454

Table A Conversion......................................................................................................................54

Table B Total Loop ΩVersus Supply Volts..........................................................................55

Table C Voltage Drop Versus mA For Current Transmitter Operation....................................55

Appendix C: Approvals

Appendix C: ApprovalsAppendix C: Approvals

Appendix C: Approvals................................

................................................................

.................................................

..................................

................. 56

5656

CE Certificate .................................................................................................................................56

Certificates and Approvals ........................................................................................................57

Control Drawing FM/CSA Approval Mercap........................................................................58

Index

IndexIndex

Index

................................

................................................................

..............................................

............................

.............. 59

5959

7ML19981CM01.1 MERCAP –INSTRUCTION MANUAL Page 3

Introduction

The Mercap system is a high performance, level measurement instrument consisting of a

sophisticated, easy-to-adjust, transmitter (MST9500) combined with measurement electrodes

and process seals designed to accommodate numerous configurations. The electrode,

comprised of a measurement section and an active shield section, is the primary sensor of

the system, and it indicates the electrical capacitance value of the measurement section

relative to the environment (tank wall, stilling well, or conductive material). This electrode

then connects to the capacitance detector portion of the two-wire loop powered electronic

transmitter. The measurement section can be set up to measure the level of solids, liquids

and slurries, as well as the interface between two immiscible liquids.

The manual is presented in three sections:

1. The electrode process connections and seals

2. The transmitter

3. Appendix sections providing supplementary information.

Identifications and Abbreviations

Various mnemonics and abbreviations are used in this manual. See below:

Short form Long Form Description Units

CE /FM /CSA ConformitèEuropèene/

Factory Mutual/Canadian

Standards Association

DAC Digital Analog Converter

DCS Distributed Control System Control Room apparatus

Ex Explosion Proof

Exd Flame Proof

FV Full Vacuum

ESD Electrostatic Discharge

HARTTM Highway Addressable

Remote Transducer

LRV Lower Range Value value for 0 % 4 mA

LSL Lower Sensor Limit below which PV is incorrect

pF pico Farads 0.000000000001 Farad

ppm parts per million

PV Primary Variable measured value

Stilling Well grounded metal tube with

openings

SV Secondary Variable equivalent value

SVLRV Sec. Var. Lower Range Value 0 % equivalent value

SVURV Sec. Var. Upper Range Value 100 % equivalent value

µFmicro Farads 0.000001 Farad

URV Upper Range Value value for 100% 20 mA

µSec micro Seconds 0.000001 Seconds

USL Upper Sensor Limit above which PV is incorrect

HARTTM Communication Foundation, Austin, Texas, USA

Siemens Automation

Page 4 MERCAP –INSTRUCTION MANUAL 7ML19981CM01.1

7ML19981CM01.1 MERCAP – INSTRUCTION MANUAL Page 5

Technical Specifications

Electrodes

Process connections

Screw mounting:

Flange mounting:

NPT, BSPT, JIS.

ANSI, DIN

Process material: C 22.8 N, AISI 316 L, Monel 400, Hastelloy C22

Probe diameter (mm/inch): 9/0.35 (cable), 16/0.63 (rod), or 24/0.95 (rod)

Probe length (mm/inch)

Rod version:

Cable version:

5500/216

35000/1378

Probe lining: PFA, Enamel, PTFE

Pressure rating (bar/psi): FV - 200/2920 up to 525/7665 as option

Temperature rating (°C/°F): -200°/-328°to 200°/392°up to 450°/842°as option

Wetted Parts

Liner: PFA/PTFE

Flange: stainless steel or teflon lined

Transmitter

Measurement range (pF): 0 – 3300

Span (pF): minimum 3.3

Supply voltage (Vdc): •maximum 33

•minimum 12 Vdc at 3.6 mA

•minimum 9.5 Vdc at 22 mA

Output current (mA): 3.6 – 22 / 22 - 3.6 (2-wire current loop)

Smart communication: Acc. the HART Communication Foundation (HCF)

Temperature range (°C/°F): -40°/-40°to 85°/185°(ATEX–Explosion Proof: -20°/-4°to

60º/140º)

Siemens Automation

Page 6 MERCAP –INSTRUCTION MANUAL 7ML19981CM01.1

Temperature stability: 0.15 pF (0pF) or <0.25% (typically <0.1%) of actual

measurement value, whichever is greater over the full

temperature range of the product.

Non linearity and

reproducibility:

< 0.1% full scale and actual measurement respectively

Accuracy: <0.1% of actual measurement value

Features: •polarity protection input circuit

•E.S.D. protected (Loop)

•galvanically isolated measurement circuit

•fully potted with epoxy resin

Diagnostics (Includes fault

alarm):

•primary variable (PV) out of limits

•system failure measurement circuit

•deviation between A/D and D/A converter values

•check sum

•watch dog

•measurement current out of range

Measurement current

signalling:

NAMUR NE 43

Function rotary switch1

Position 1:

Position 2:

Position 3:

Position 4:

4 mA measurement value (set)

20 mA measurement value (set)

3.8 up to 20.5 mA range by means of a field service

programmer

functionality test

Approvals: •Cenelec, FM/CSA (IS), FM (Ex-proof), CE, ATEX

1 HART communication in all switch positions

7ML19981CM01.1 MERCAP –INSTRUCTION MANUAL Page 7

Electrodes and Process Connections

This section of the manual is designed to assist in the determination of the best possible

probe configuration for your application. Therefore, we discuss the electrodes and process

connections before the instrumentation and the operation procedures. When configuring the

unit to your application, use the sample configurations below as your criteria.

Mercap electrodes come in a variety of formats to provide the necessary characteristics for

correct mounting, chemical compatibility, temperature and pressure requirements, and

dielectric constant. Most applications use the simple threaded connection, which is directly

mounted in the tank with the mating threaded nipple, or with a flange adapter that includes a

threaded hole.

For applications requiring higher temperature and pressure, or greater integrity, welded and

solid machined flange versions are available with single or double cone seals, and/or a

second seal on the flange plate to avoid any metallic wetted parts.

Handling of Electrodes

WARNING: Do not scratch or gouge the PFA electrode insulation since this could

reduce the integrity of the insulation and the useful life of the electrode.

WARNING: Be careful with an enamel insulated electrode. Normally an enamel lining

is protected by a stilling well, which is part of the design.

WARNING: Do not damage the insulation jacket on the electrode during shipping,

packing, and installation. Most electrodes use PFA insulation, a very dense and reliable

type of Teflonthat prevents leakage and corrosion of the metal electrode and acts as

an insulator when conductive materials are being measured. Any damage to the

electrode can prevent proper performance.

WARNING (ATEX 100): Precautions MUST be taken to avoid ignition due to

hazardous electrostatic charges when an isolated probe is used in a potentially

explosive atmosphere caused by gas, vapor, or a non-conductive liquid, requiring

apparatus group IIC equipment. Or when the probe is used in a potentially explosive

atmosphere caused by dust.

Siemens Automation

Page 8 MERCAP – INSTRUCTION MANUAL 7ML19981CM01.1

Characteristics

The following characteristics apply to all general connection configurations:

•The standard Mercap insulated electrode is designed for use in both

conducting and non-conducting liquid applications.

•All electrodes consist of an active shield portion and a measurement portion,

which combine to form the complete electrode.

•The sum of the active shield length and the measurement length is the total

insertion length.

•The active shield design provides continuous immunity to the known changes

in conditions at the top of many vessels, where levels of vapours, dust, and

condensation are constantly changing.

•All changes in capacitance due to temperature and pressure changes that

could cause small changes in the seal geometry are also isolated from the

measurement signal because they are not included in the starting

capacitance of the electrode by virtue of the action of the active shield.

•Due to the well-controlled diameter of the electrodes and insulation, a linear

output is achieved over a wide range of capacitance values (3.3 to 3300 pF).

•The end seal is formed as an integral part of the electrode lining, giving

smooth and uniform insulation characteristics (tested to 55 kV).

•Standard single cone usage

•Secondary cone usage

General Design Principles

The Mercap capacitance level instrument combines an optimum combination of mechanical

and electrical/electronic principles in its design. Combining a single transmitter with as few

electrode configurations as possible maximizes the number of potential applications while it

minimizes the complexity of the instrument.

In principal, the standard threaded process connection (S-Series) with PFA insulated

electrode, including the active shield, provides good results in all measurement situations that

are within the temperature, pressure, and corrosive capabilities of the materials and seals.

This is true over a wide range of dielectric constants in both non-conducting and conducting

materials.

Applications outside of the standard capabilities of the S-Series would require a different

design configuration. These non-standard applications include:

Non-Standard Application Mercap Configuration

Non-metallic tanks with both conducting

and non-conducting liquids.

Use a stilling well to provide second

electrode reference.

Non-conducting liquids in spherical and

horizontal-cylindrical tanks.

Use a stilling well as linearizer.

Highly corrosive materials requiring no

metallic wetted parts.

Use flange mount with D, DD seal

version.

High pressure and temperature (greater

than 200 bar) with conductive liquid.

Use HP version.

Sanitary/food safe applications. Use Mercap MCP 03.

7ML19981CM01.1 MERCAP –INSTRUCTION MANUAL Page 9

Mercap Configurations

The Mercap is a versatile level measurement instrument that can be designed for your

specific application by taking the following conditions into consideration:

Process Connections

Any standard process connection is available with Mercap, and special versions can be

fabricated to match the mounting and application requirements. Various sizes of threaded

and flanged fittings are available.

Seal Types

The basic internal seal for the Mercap is of a conical-shaped, preloaded pressure/leak

resistant construction. Up to three levels of seal protection are implemented depending on

the integrity requirements of the application. A single or double cone internal seal forms 1 or 2

blocks against leaking, and a third flange face gasket is also available in the D and DD seal

construction. The flange face seal also provides a design with no metal wetted parts if

required.

Pressure and Temperature Considerations

The maximum temperature and pressure of operation for the standard Mercap level probe is

200°C (392°F) and 200 bar (2900 psi). There are, of course, qualifications that must be applied

to these maximums.

Enamel probes are suggested when process temperature exceeds 200 °C, and/or in

combination with very high pressure.

Note:

: Consult Milltronics for chemical applications other than water.

Process Connection and Seal Configuration of Mercap

Process Connection

Process ConnectionProcess Connection

Process Connection Seal Type

Seal TypeSeal Type

Seal Type Seal Description

Seal DescriptionSeal Description

Seal Description

Threaded S Single Cone

Welded Flange S Single Cone

S Single Cone

D Single Cone + Teflon flange seal

DD Double Cone + Teflon flange seal Consult factory*

SD Double Cone (used for stilling well applications)

Solid Machined

Flange

HP Consult factory*

Note: HP (high pressure) is only supplied with enamel insulation and a recommended

stilling well for protection of the enamel. A cone seal plus a secondary redundant seal

is provided between the electrode and the stilling well.

Siemens Automation

Page 10 MERCAP –INSTRUCTION MANUAL 7ML19981CM01.1

Examples of Mercap Level Instruments

The following graphics illustrate the variation in configurations available for the Standard

series, Level and Interface series, and Sanitary series Mercap level instrument.

Note: All measurements are given in millimeters/inches.

Standard Level Version (Mercap MCP01)

This is the most common version of Mercap and is available with the following features:

•Threaded flanges, welded flanges, and solid flanges

•S series, D series, SD series, DD series, and HP series process seals.

•Selections of standard ANSI and DIN flanges are available

•The most common electrode is insulated with PFA, but Enamel (HP seal) is also

available as standard (Enamel is only available on rigid design).

•Various process connection materials are also available

•Rigid and Flexible Cable versions available

MCP01 (Standard) S-Series: Threaded Versions

S-Series: Threaded

Active Shield

Insertion

Length+175

(6.9”)

Insertion

Length

Active

Length

∅16 (0.63”)

or ∅24 (0.94")

∅160

(6.3”)

40 (1.57")

Inactive Tip

7ML19981CM01.1 MERCAP –INSTRUCTION MANUAL Page 11

S-Series Cable Version S-Series Cable Version

(with anchor)

MCP01 S-Series Threaded Features

•single process seal

•suitable for most level, interface, or detection applications

•high temperature and pressure resistance

∅160 (6.3”)

Transmitter

Enclosure

120 (4.72")

Insertion Length

Dimension

Varies

Insertion

Length

Seal Gland

Threaded Process

Connector

See Order

Instructions

PTFE Insulation

∅9 (0.35")

Tensile Weight+/-Varies

Insertion

Length

+175 (6.9")

Inactive

Part

125 (4.9")

55 (2.17")

Siemens Automation

Page 12 MERCAP –INSTRUCTION MANUAL 7ML19981CM01.1

MCP01 (Standard) S-Series: Welded and Machined Flanged

Versions

S-Series Welded Flange S-Series Machined Flange

MCP01 S-Series Flange Features

•single process seal

•suitable for most level, interface, or detection applications

•high temperature and pressure resistant

Active

Length

Active

Length

Insertion

Length

Insertion

Length

Insertion

Length

+185 (7.28")

Insertion

Length

+185 (7.28")

Active Shield

TIG Weld

Inactive Tip

∅16 (0.63”)

or ∅24 (0.94")

40 (1.57")

∅16 (0.63”)

or ∅24 (0.94")

7ML19981CM01.1 MERCAP –INSTRUCTION MANUAL Page 13

MCP01 Standard D-Series: Machined Flanged Versions

D-Series DD-Series

MCP01 Standard D-Series Features

•single process seal

•all wetted parts made of PFA (probe

lining) or PTFE (flange face)

•according to NACE requirements

MCP01 Standard DD-Series Features

•double process seal

•redundant safety (e.g. Phenol,

Phosgene applications, etc.)

•all wetted parts made of PFA (probe

lining) or PTFE (flange face)

•according to NACE requirements

•suitable for turbulent and toxic

chemical applications

∅16 (0.63”) or

∅24 (0.94")

∅16 (0.63”) or

∅24 (0.94")

Inactive Tip Inactive Tip

Probe Probe

Insertion

Length

Insertion

Length

Active

Length

Active

Length

Active

Shield

Active

Shield

65 (2.56")

120 (4.72")

120 (4.72")120 (4.72")

∅160 (6.3") ∅160 (6.3")

Transmitter

Enclosure

Transmitter

Enclosure

Seal GlandSeal Gland

Flange

Process

Connection

Flange

Process

Connection

PTFE Lining

∅

∅D

∅

∅D

holes

40 (1.57") 40 (1.57")

PTFE Lining

Siemens Automation

Page 14 MERCAP –INSTRUCTION MANUAL 7ML19981CM01.1

SD-Series Probe/Thermal Isolator

MCP01 Standard SD-Series Features

•double process seal

•redundant safety (e.g. Phenol,

Phosgene applications, etc.)

•all wetted parts made of PFA/PTFE

•according to NACE requirements

•suitable for turbulent and toxic

chemical applications

MCP01 Probe/Thermal Isolator

Features

•thermal isolator

∅160 (6.3") ∅160 (6.3")

Insertion

Length

Insertion

Length

Active

Length

Active

Length

40 (1.57") 40 (1.57")

∅16 (0.63”) or

∅24 (0.94")

∅16 (0.63”) or

∅24 (0.94")

Transmitter

Enclosure Transmitter

Enclosure

120 (4.72") 120 (4.72")

Flange

Process

Connection

Flange

Process

Connection

120 (4.72")

Seal

Gland

Seal

Gland

Thermal

Isolator

Probe

85 (3.35")

∅

∅D∅D

holes

Inactive Tip Inactive Tip

Active Shield Active Shield

Dependent on

extension length

7ML19981CM01.1 MERCAP –INSTRUCTION MANUAL Page 15

Interface and Level Version (Mercap MCP 02)

This version is designed specifically for interface level where a long distance active shield

portion of the electrode is required (up to 35 meters) before the measurement portion of the

electrode begins. This type of application is common in large storage tanks for oil where the

bottom of the tank invariably has a layer of water below the oil. Often, when measurement

spans as much as 5.5 meters (for the water), up to 35 meters of flexible bellows cable are

used.

MCP02: Interface Version

Process Connection Size

•threaded version: ¾", 1", 1½", 2"

NPT, BSPT, or JIS

•sanitary version: on customer

request

•flange version: on customer

request

Options

•thermal isolator

•stilling well

Aluminum Enclosure

•Nema 4/Type 4/IP65

Conduit Entry:

•½" NPT (2x)

Flexible

Tube

Insertion Length

35m (115ft) max.

100 (3.9")

Inactive Tip

∅16 (0.63”) or

∅24 (0.94")

Active Shield

Active Length

∅16 mm=2m

∅24mm=5.5m

∅160 (6.3")

185 (7.28")

Process

Connection:

flange or

threaded

mounting

Seal

Gland

Probe

Dependent on

extension length

Adjustable

extension

part

Transmitter

Enclosure

Siemens Automation

Page 16 MERCAP –INSTRUCTION MANUAL 7ML19981CM01.1

Sanitary Level Version (Mercap MCP 03)

The hygienic design includes threaded and tri-clamp versions for use in the food and

pharmaceutical industry.

MCP03: Sanitary Versions

Sanitary Thread Coupling Sanitary Tri-Clamp

MCP03 Sanitary Tri-Clamp Features

•maximum active length 5.5m

•minimum active length 50mm

∅16 (0.63”) or

∅24 (0.94")

∅16 (0.63”) or

∅24 (0.94")

40 (1.57") 40 (1.57")

Probe

Active

Length

Active

Length

Inactive Tip

118 (4.65")

Seal Gland

Transmitter

Enclosure

∅160 (6.3")

Active

Shield

Insertion

Length

Insertion

Length +

175 (6.9")

Active

Shield

Tri-clamp

Connection

Seal Gland

Insertion

Length

IDF Nut

7ML19981CM01.1 MERCAP –INSTRUCTION MANUAL Page 17

Flanges

Flange Standards

Note:

•All Sizes: MM

•One (1) inch: ^ 25.4mm

•Details: See drawings, technical data, and measuring probe details

øL

øK (n holes)

øD

Siemens Automation

Page 18 MERCAP –INSTRUCTION MANUAL 7ML19981CM01.1

Temperature Versus Pressure Curve Mercap Level Probe

In this situation, as the temperature reaches 75°C (167°F) the maximum pressure must be

derated. As the temperature reaches 200°C (392°F) the maximum pressure is limited to 50 bar

(725 psi). This curve is typical for water only, for other, more aggressive chemicals the

derating curve will be more severe.

Note: For high temperature and pressure ratings for the Enamel probe, please

contact your Siemens Milltronics representative.

Reference Product: Water

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