Sapcon COAT-ENDURE User manual

COAT-ENDURE
Admittance Level Limit Switch
INSTRUCTION MANUAL
Version 2.3

Coat-Endure User Manual & Datasheet V 2.3
Contents
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7 Application Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8.1 Procedure for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8.2 Tank Mounting Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8.3 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
9 Calibration and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9.1 Calibration for Non-Conductive Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9.2 Calibration for Conductive Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9.3 Factory Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
9.4 Cover Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
9.5 Uncover Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
9.6 Sensitivity Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9.7 Failsafe Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10 Error Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
11 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
12 Customer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
13 Product Selection Order Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Coat-Endure User Manual & Datasheet V 2.3
List of Figures
1 Coat-Endure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Description of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Dimensional Layout - Top Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Dimensional Layout - Side Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 Cover Delay Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 Setting Cover Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
9 Saving Cover Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
10 Uncover Delay Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11 Setting Uncover Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
12 Saving Uncover Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
13 Failsafe High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
14 Failsafe Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Coat-Endure User Manual & Datasheet V 2.3
List of Tables
1 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Application Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Switching Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Error Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Coat-Endure User Manual & Datasheet V 2.3
Revision History
Revision Date Author(s) Description
1.0 27 Jan 2014 RND First Version Editing
1.1 10 Aug 2014 MRK Applications Revision
1.2 29 May 2015 RND Features Revision
1.3 19 Nov 2015 RND Specs Revision
1.4 25 Jul 2016 RND Specs Revision
2.0 08 Jan 2017 BRND Revised Format
2.1 17 Oct 2017 BRND Branding Revisions
2.2 05 Feb 2018 MRK Marketing Revisions
2.3 11 Oct 2018 RND Specs Revisions
1
1
•Copyright: All content on this document, such as text, graphics, logos and images is the property of Sapcon Instruments Pvt. Ltd. The selection,
arrangement and presentation of all materials on this document and the overall design of this document is the exclusive property of Sapcon Instruments
Pvt. Ltd.
•The images shown in this manual may differ from the actual instrument / housing in terms of dimensions, color and design. Please refer to GA drawings
for dimensional details.
•Values (of performance) described in this manual were obtained under ideal testing conditions. Hence, they may differ under industrial environment and
settings.
General Instructions
•Instrument shouldn’t block the material filling inlet.
•Secure the cover of housing tightly. Tighten the cable glands. For side mounting, the cable glands should point downwards.
•For side mounting, provide a baffle to prevent the material from falling on the probe.
•When handling forks, do not lift them using their tines. While using them with solids, ensure that material size is less than 10mm.
•Deforming the shape of the tines may interfere with the fork’s operating frequency.
•Make all electrical connections as instructed in the manual. Don’t power on the device before verifying the connections.
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Coat-Endure User Manual & Datasheet V 2.3
1 Introduction
Coat-Endure is a microcontroller based compact coat im-
mune admittance level limit switch. It is a compact level
switch which is suitable for sticky solids, pastes and slur-
ries. The device is specially suited for compact silos and
packaging machines where material has a tendency to stick
on the probe.
Figure 1: Coat-Endure
2 Operating Principle
Coat-Endure is an improvement over traditional principle
of admittance. The ring type probe has an alternating active
and an inactive region, which collectively help the controller
to calculate the extent of coating on the probe. In effect,
the device is able to identify the differential coating between
the sense and the shield by measuring their individual ca-
pacitances. As the coating immunity is controlled by the on-
board microcontroller, the extent of coating immunity can be
set easily.
Figure 2: Description of Parts
3 Features
•Universal power supply of 18 - 55 V DC and 90 - 265
V AC on the same terminal.
•Compact and customizable probe size.
•Passive shielding compensation with adjustable coat-
ing immunity.
•Output options: Relay, PNP and Analog.
•High temperature probe suitable for applications up to
250◦C.
•Self-diagnosis for probe and electronics.
•Popular with a wide range of materials: low-to-high di-
electric conductive materials.
4 Applications
•Food & Beverages
•Foundry
•Material Handling
•Poultry
•Packaging Industry
•Chemicals
•Pharmaceuticals
•Dairy
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Coat-Endure User Manual & Datasheet V 2.3
5 Electrical Specifications
Please refer to Table 1 for Electrical Specifications.
PARAMETER VALUE
Input Power Supply 18 - 55V DC and 90 - 265V AC at 50Hz on same terminal
Output
•Relay SPDT , PNP
•Relay DPDT
Power Consumption
•1.5W (SPDT, PNP) at 24 V
•2.2W (DPDT) at 24 V
Switching Single-point level switching
Switching Indication Bi-color LED:
Red - Alarm
Green - Normal
Fail-safe Field Selectable
•Open - Fail-safe High (For High Level)
•Close - Fail-safe Low (For Low Level)
Time Delay Setting 1 - 25 seconds (For both, Covered and Uncovered Delays)
Relay Rating 6 Amps at 230V AC
Table 1: Electrical Specifications
6 Mechanical Specifications
Please refer to Table 2 for Mechanical Specifications.
PARAMETER VALUE
Housing
•SCUTE: Pressure die-cast aluminium weatherproof
(Rating IP-68)
•FP2C: Cast aluminium, weatherproof & flameproof,
powder coated, suitable for Gas Groups IIA, IIB & IIC
as per IS-2148
Electrical Connector 2 x 1/2” BSP/NPT , PG 13.5
Operating Temperature 0◦C to 60◦C (Electronics)
Process Temperature Up to 250◦C
Operating Pressure Up to 10 bar
Mounting
•Screwed: 1/2",1”,1 1/2", 3/4” BSP / NPT
•Flanged: As per user specification
Probe Length 65 mm and (85 mm to 1500 mm)
Insulation Part PTFE / Full PTFE
Table 2: Mechanical Specifications
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Coat-Endure User Manual & Datasheet V 2.3
7 Application Specifications
Please refer to Table 3 for Application Specifications.
PARAMETER VALUE
Response Time 1 second
Sensitivity Refer Table No. 4
Table 3: Application Specifications
8 Installation Guidelines
8.1 Procedure for Installation
For quick and easy installation, follow the steps in the
order mentioned below:
1. Testing Electrical Connections: Before mounting the
device on the tank, understand and test the connec-
tions outside the tank for at least one piece. For details
on connections, refer to Figure 5 before connecting the
device to outputs and power supply.
2. Mounting the Device: Correct mounting of the in-
strument is critical to the operation of the instrument.
Please refer to Tank Mounting Installation to mount the
instrument in the tank/silo or hopper. Coat-Endure is
designed to work properly in metal-body tanks only,
e.g. MS, SS or Aluminium tanks. Performance in plas-
tic tanks might not be satisfactory.
3. Electrical Connections: Perform the electrical con-
nections as mentioned earlier in Step 1.
4. Calibration and Settings:
•For non-conductive materials, Coat-Endure can
be calibrated in an empty process tank without
the application material.
•If the application material is conductive, Coat-
Endure has to be calibrated with the material.
Time-delay and fail-safe selection should be done af-
ter this stage. Section Calibration and Settings covers
settings in more detail.
5. Trial Run: Perform a trail run of the application pro-
cess with the application material. In case of errors
or unsatisfactory output, refer to Section Error Indica-
tions.
6. Finishing the Installation: Tighten the lid and the ca-
ble entries on the instrument so that no moisture seeps
into the instrument.
8.2 Tank Mounting Installations
•Coat-Endure is designed to work in metal-body tanks
only, e.g. M.S., S.S. or Aluminium tanks. Performance
in plastic tanks might not be satisfactory.
•The Coat-Endure probe can be installed in the ves-
sel in both horizontal (side mounting) and vertical (top
mounting) positions. Please refer to Figures 3 and 4.
•To prevent the ingress of moisture and water seepage
in side mounting position, the cable entries should al-
ways point downwards.
•Weatherproofness of enclosure is guaranteed only if
the cover is in place and glands are adequately tight-
ened. Damage due to accidental entry of water can be
avoided if the instrument is installed in a rain shade.
•If the ambient temperature is high, the instrument
should not be installed to receive direct sunlight. If
such a position of shade is not available, a heat shield
should be fitted above the instrument especially if the
operating temperature lies between 60◦C and 80◦C.
•Grounding part (S.S. material) of the probe should be
exposed atleast 20mm inside the hopper after thread-
ing/nozzle.
Figure 3: Dimensional Layout - Top Mounting
Figure 4: Dimensional Layout - Side Mounting
8.3 Electrical Connections
Electrical connections for the instrument will change with
the models. Please refer to figure 5 and the precautions
mentioned below before connecting the device.
Precautions for connecting Coat-Endure :
•Power Supply Rating
Make sure the power supplied to the instrument is
within the specified range mentioned in Table 1.
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Coat-Endure User Manual & Datasheet V 2.3
•Connect Earth
When supplying AC power, please make sure that the
grounding screw on the housing and the earth terminal
are all connected to the plant’s earth.
•Power Supply Fluctuations & Noise
External noise or fluctuating power supplies could af-
fect performance and shorten the life of the instrument.
Use external line suppressors and fuse wires to con-
tain the risk of damage to the circuit.
OPEN
ENTER
COVER
UNCOVER
CALIBRATE
FAILSAFE
COAT-ENDURE
STATUS
LED
RED
GREEN
L N E Relay-1 PNP
1 2 3 4 5 6 7 8 9
+ +
-
NC C NO OUT
-
AC Supply DC Supply
L (Live)
N (Neutral)
90-265 V AC 18-55 V DC
+
R
L
(Available only in DC Power Supply)
(a) Electronics option SPDT Relay and PNP Output(SPN)
OPEN
ENTER
COVER
UNCOVER
CALIBRATE
FAILSAFE
COAT-ENDURE
STATUS
LED
RED
GREEN
L N E Relay-1
1 2 3 4 5 6 7 8 9
+NC C NO
-
AC Supply DC Supply
L (Live)
N (Neutral)
90-265 V AC 18-55 V DC
+
Relay-2
NC C NO
(b) Electronics option DPDT Relay(D)
Figure 5: Electrical Connections
9 Calibration and Settings
The DIP switches for calibration and settings can be ac-
cessed by opening the top aluminium cover. Procedure for
calibration Coat-Endure depends on the conductivity of the
application material:
•Calibration for Non-Conductive Materials
Calibration should be done without the application ma-
terial. Once calibrated in the empty tank, the device
can be used with a wide range of non-conductive ma-
terials.
•Calibration for Conductive Materials
For applications using conductive materials (water,
acid based pastes etc.), Coat-Endure needs to be cali-
brated with the application material. This will make the
instrument specific to the application material i.e. if the
application material is changed; calibration should be
repeated.
Note:
Calibration in air is specific to the tank, if the tank
changes, the instrument needs to be calibrated
again.
9.1 Calibration for Non-Conductive Materials
Coat-Endure needs to be calibrated inside the empty pro-
cess tank (i.e only air, no material). Calibrating the instru-
ment outside the tank can cause malfunctions. Once cali-
brated inside the empty tank, Coat-Endure can operate with
a wide range of application materials without the need of
changing its default sensitivity settings.
1. Make sure that all DIP switches are in the OPEN posi-
tion.
2. To start with the calibration, set the CALIBRATE switch
to CLOSE position (CLOSE is opposite of OPEN for
DIP switch).
3. Make sure that the status LED is not blinking. A blink-
ing LED here indicates Error.
4. Then press ENTER, the status LED will blink once in
RED color.
5. Now set the CALIBRATE switch back to OPEN posi-
tion.
6. Air calibration for Coat-Endure is now complete.
Now, test the calibration by filling in the material or drain-
ing it out from the tank. Repeat the filling and draining to
confirm proper operation of the device.
Note:
For certain application materials, Coat-Endure might
need an adjustment to its settings. Refer to Section
Sensitivity Adjustment for more details.
9.2 Calibration for Conductive Materials
Fill the tank with the application material such that the
probe is completely covered with the material.
1. Make sure that all DIP switches are in the OPEN posi-
tion.
2. To start with the calibration, set the CALIBRATE and
COVER switches to CLOSE position (CLOSE is oppo-
site of OPEN for DIP switch).
3. Make sure that the status LED is not blinking, a blinking
LED here indicates Error.
4. Then press ENTER, the status LED will blink once in
RED color.
5. Now set the CALIBRATE and COVER switch back to
OPEN position.
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Coat-Endure User Manual & Datasheet V 2.3
6. Calibration for Coat-Endure is now complete.
Now, test the calibration by filling in the material or draining
it out from the tank. Repeat the filling and draining to
confirm proper operation of the device.
Note:
For certain conductive application materials, Coat-
Endure might need an adjustment to its settings. Re-
fer to Section Sensitivity Adjustment for more details.
9.3 Factory Reset
To reset time delays and sensitivity values to default val-
ues, follow the following steps:
1. Set the CALIBRATE, COVER and UNCOVER switches
to CLOSE position
2. PRESS and HOLD the ENTER key until the status LED
blinks.
3. Switch the CALIBRATE, COVER and UNCOVER
switches back to OPEN position.
4. This will set the time delay to 0 and the sensitivity level
to 3.
9.4 Cover Delay
When the application material covers the probe, the
changeover of the output can be delayed by a pre-
determined time. This time is called COVER Delay. For
a different value of Cover Delay, the number of blinks can
be adjusted as per requirement.
Note:
You can set the value of COVER DELAY between 1-
25 secs.
Follow the below procedure for setting Cover Delay
1. Ensure that all DIP switches are in OPEN position as
shown in Figure 6. Make sure that STATUS LED is not
blinking for Error.
OPEN
COVER
UNCOVER
CALIBRATE
FAILSAFE
Figure 6: DIP Switch
2. To set the Cover Delay, set the COVER switch to
CLOSE position as shown in Figure 7.
(CLOSE is the opposite of OPEN for a DIP switch.)
The STATUS RED LED will glow.
3. Press ENTER and keep it pressed as shown in Figure
8. The STATUS RED LED will start blinking. Count the
number of blinks. After setting the value release the
ENTER key.
OPEN
ENTER
COVER
UNCOVER
CALIBRATE
FAILSAFE
COAT-ENDURE
STATUS
LED
RED
GREEN
Figure 7: Cover Delay Switch Position
OPEN
ENTER
COVER
UNCOVER
CALIBRATE
FAILSAFE
COAT-ENDURE
STATUS
LED
RED
GREEN
Figure 8: Setting Cover Delay
4. Delay is entered, but not saved. To save and test the
Cover Delay, set the COVER switch back to OPEN po-
sition as shown in Figure 9. The STATUS LED will
come back to its original position.
OPEN
ENTER
COVER
UNCOVER
CALIBRATE
FAILSAFE
COAT-ENDURE
STATUS
LED
RED
GREEN
Figure 9: Saving Cover Delay
5. To test, dip coat-endure into the application material
until the switching point is reached.
The STATUS LED will start blinking RED if the switch
point is reached. It will blink for the number of seconds for
which the cover delay is set. 1 blink is equal to 1 second
during switching. A maximum of 25 seconds can be set.
9.5 Uncover Delay
When the application material uncovers coat-endure’s
probe, the changeover of the output can be delayed by a
pre-determined time. This time is called UNCOVER Delay.
For a different value of Uncover Delay, the number of blinks
can be adjusted as per requirement.
Note:
You can set the value of UNCOVER DELAY between
1-25 secs.
Follow the below procedure for setting Uncover
Delay
1. Ensure that all DIP switches are in OPEN position as
shown in Figure 6. Make sure that STATUS LED is not
blinking for Error.
2. To set the Uncover Delay, set the UNCOVER switch to
CLOSE position as shown in Figure 10.
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