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.

Copyright Siemens Milltronics Process

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

33

3

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

Technical Specifications

Technical SpecificationsTechnical Specifications

Technical Specifications

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

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

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

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

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

55

5

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

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

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

Electrodes and Process Connections

Electrodes and Process ConnectionsElectrodes and Process Connections

Electrodes and Process Connections

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

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

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

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

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

77

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

21

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

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

MST9500 Transmitter

MST9500 TransmitterMST9500 Transmitter

MST9500 Transmitter

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

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

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

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

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

2424

24

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

Installation

InstallationInstallation

Installation

and Interconnection

and Interconnectionand Interconnection

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

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

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

2525

25

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

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

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

Applications

ApplicationsApplications

Applications

and Grounding

and Groundingand Grounding

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

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

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

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

....... 30

3030

30

Start-up

Start-upStart-up

Start-up

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

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

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

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

......... 35

3535

35

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

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

Maintenance

MaintenanceMaintenance

Maintenance

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

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

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

3939

39

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

Appendix A: HART

Appendix A: HARTAppendix A: HART

Appendix A: HARTTM

TMTM

TM Documentation

DocumentationDocumentation

Documentation

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

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

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

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

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

4141

41

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

54

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

56

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

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

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

Index

IndexIndex

Index

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

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

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

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

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

5959

59

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.

Milltronics Mercap MCP01 S series User manual

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