Thermo Scientific DensityPRO-T User manual

Gamma Density Systems
Installation Guide
PN 1-0702-144
DensityPRO & DensityPRO-T

DensityPRO & DensityPRO-T
Gamma Density Systems
Installation Guide
PN 1-0702-144

© 2014 Thermo Fisher Scientific Inc. All rights reserved.
“Microsoft” and “Windows” are either trademarks or registered trademarks of Microsoft Corporation in the United States
and/or other countries. “HART” is a registered trademark of the HART Communication Foundation.
“FOUNDATION Fieldbus” and “Fieldbus Foundation” are registered trademarks of Fieldbus Foundation.
“National Instruments” is a registered trademark of National Instruments Corporation.
All other trademarks are the property of Thermo Fisher Scientific Inc. and its subsidiaries.
Thermo Fisher Scientific Inc. (Thermo Scientific) makes every effort to ensure the accuracy and completeness of this
manual. However, we cannot be responsible for errors, omissions, or any loss of data as the result of errors or omissions.
Thermo Scientific reserves the right to make changes to the manual or improvements to the product at any time without
notice.
The material in this manual is proprietary and cannot be reproduced in any form without expressed written consent from
Thermo Scientific.

Revision History
Revision Level Date Comments
A 06-2014 Initial Release per ERO 8453
Thermo Scientific DensityPRO Installation Manual v

Thermo Scientific DensityPRO Installation Manual vii
Contents
Safety Information & Guidelines ................................................................................................... ix
Safety Considerations......................................................................................................................ix
Warnings, Cautions & Notes ............................................................................................................x
Introduction ..................................................................................................................................... 1-1
Overview ....................................................................................................................................... 1-1
Configurations.......................................................................................................................... 1-2
The Source ............................................................................................................................... 1-2
The Detector-Transmitter......................................................................................................... 1-2
Functional Description .................................................................................................................. 1-3
Measurement Calculation........................................................................................................ 1-3
Communications & Measurement Display .............................................................................. 1-3
EZ-Cal II Software Configuration ............................................................................................. 1-3
Multiple Readouts.................................................................................................................... 1-4
Totalizers & Batch Control ....................................................................................................... 1-4
Input & Output Signals............................................................................................................. 1-4
Associated Documentation...................................................................................................... 1-4
Handling, Storage & Shipping...................................................................................................... 2-1
ESD Procedures............................................................................................................................. 2-1
Unpacking, Inspection & Storage ................................................................................................. 2-2
Shipping ........................................................................................................................................ 2-2
Installation....................................................................................................................................... 3-1
General.......................................................................................................................................... 3-1
Licensing ....................................................................................................................................... 3-1
Guidelines ..................................................................................................................................... 3-2
General..................................................................................................................................... 3-2
Mounting....................................................................................................................................... 3-2
Mounting Configurations ......................................................................................................... 3-3
Mounting Instructions.............................................................................................................. 3-4
Pipe Saddle (Cradle) Mount ................................................................................................ 3-4
Pipe Spool Mount................................................................................................................ 3-5
Z-Pipe (Axial) Mount ........................................................................................................... 3-5
System PCAs ................................................................................................................................. 3-5
DensityPRO............................................................................................................................... 3-5
DensityPRO-T ........................................................................................................................... 3-8
Remote Detector ................................................................................................................. 3-8
Transmitter........................................................................................................................ 3-10
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Thermo Scientific DensityPRO Installation Manual viii
Wiring............................................................................................................................................... 4-1
Preparation.................................................................................................................................... 4-1
DensityPRO Wiring Procedures..................................................................................................... 4-2
Power Supply Wiring .................................................................................................................... 4-3
Protective Earth Grounding ...................................................................................................... 4-3
Safety Disconnect Mains Requirements ................................................................................. 4-3
DC Power.................................................................................................................................. 4-3
AC Power.................................................................................................................................. 4-4
Serial Communications ................................................................................................................. 4-4
RS232 Wiring ........................................................................................................................... 4-5
RS485 Wiring ........................................................................................................................... 4-6
RS485 Detector to Transmitter Wiring ............................................................................... 4-7
Initial Setup for Party-Line Communications ...................................................................... 4-7
Standard Wiring............................................................................................................................ 4-7
USB........................................................................................................................................... 4-7
Ethernet.................................................................................................................................... 4-7
Voltage Output ......................................................................................................................... 4-8
DensityPRO.......................................................................................................................... 4-8
DensityPRO-T ...................................................................................................................... 4-8
Current Output.......................................................................................................................... 4-9
Voltage Input............................................................................................................................ 4-9
Current Input .......................................................................................................................... 4-10
DensityPRO........................................................................................................................ 4-10
DensityPRO-T .................................................................................................................... 4-10
Relay Outputs......................................................................................................................... 4-10
Contact Closure (Digital) Inputs ............................................................................................. 4-11
Temperature Compensation................................................................................................... 4-11
Wiring the Optional ISIO Boards................................................................................................. 4-12
Current Output........................................................................................................................ 4-12
HART®Communications ........................................................................................................ 4-12
FOUNDATION™ Fieldbus Communications ............................................................................... 4-15
Support ............................................................................................................................................. 5-1
Contact Information ...................................................................................................................... 5-1
Warranty ....................................................................................................................................... 5-2
Ordering Information..................................................................................................................... A-1
Specifications................................................................................................................................ B-1
Drawings..........................................................................................................................................C-1
Risk Assessment............................................................................................................................ D-2
Index ....................................................................................................................................... INDEX-1
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Safety Information & Guidelines
All persons installing, using or maintaining this equipment must read and understand
the information contained in this section.
Safety
Considerations
Failure to follow appropriate safety procedures and/or inappropriate use of the
equipment described in this manual can lead to equipment damage or injury to
personnel.
Any person working with or on the equipment described in this manual is required to
evaluate all functions and operations for potential safety hazards before commencing
work. Appropriate precautions must be taken as necessary to prevent potential damage
to equipment or injury to personnel.
The information in this manual is designed to aid personnel in correctly and safely
installing, operating, and/or maintaining the system described; however, personnel are
still responsible for considering all actions and procedures for potential hazards or
conditions that may not have been anticipated in the written procedures. If a
procedure cannot be performed safely, it must not be performed until appropriate
actions can be taken to ensure the safety of the equipment and personnel. The
procedures in this manual are not designed to replace or supersede required or
common sense safety practices. All safety warnings listed in any documentation
applicable to equipment and parts used in or with the system described in this manual
must be read and understood prior to working on or with any part of the system.
Caution: Using this equipment in a manner not specified by Thermo
Scientific may impair the protective features provided by the product, leading
to equipment damage and/or personnel injury.
Thermo Scientific DensityPRO Installation Manual ix

Safety Information & Guidelines
Warnings, Cautions & Notes
Warnings,
Cautions &
Notes
The following admonitions are used throughout this manual to alert users to potential
hazards or important information. Failure to heed the warnings and cautions in this
manual can lead to injury or equipment damage.
Warning: The triangular icon displayed with a warning advises the user about
the type of hazard covered by the warning. See the table below for the types of
warning symbols used in this manual.
Table 1. Types of Warnings
Symbol Warning TypeDescription
General
Notifies users of procedures, practices, conditions, etc.,
which may result in injury or death if not carefully observed
or followed.
Electrical Safety
Notifies users of procedures, practices, conditions, etc.,
which involve electrical circuitry and may result in injury or
death if not carefully observed or followed.
Ionizing Radiation
Notifies users of procedures, practices, conditions, etc.,
where ionizing radiation may be present and may result in
health issues or death if not carefully observed or followed.
Caution: Cautions notify users of operating procedures, practices, conditions,
etc., which may result in equipment damage if not carefully observed or
followed.
Note: Notes emphasize important or essential information or a statement of
company policy regarding an operating procedure, practice, condition, etc.
xDensityPRO Installation Manual Thermo Scientific

Chapter 1
Introduction
Overview Thermo Scientific designed the family of DensityPRO measurement systems to
provide reliable, accurate process material density measurements for a wide variety of
challenging applications. The density gauge, which attaches to the outside of the
process vessel or pipe, never contacts the process material and can measure the density
of almost any liquid, slurry, emulsion or solution.
Each gauge can convert the basic density measurement into a variety of output values
as appropriate for specific applications, e.g., bulk density or percent-by-weight solids.
Given a temperature input, the gauge can compensate for process temperature swings,
reporting the density measurement corrected to a user-specified reference temperature.
If a flow input is provided, it can calculate material mass flow.
The system consists of up to three basic elements: the source head, which contains the
radioisotope source; the detector, which converts the incident radiation to a useable
electronic signal; and the transmitter, which translates the detector’s signal in to a
density value.
The radioisotope source emits gamma radiation, which passes through the vessel wall
and the process material before arriving at the detector. The detector then measures the
level of arriving radiation to determine the density of the process material. The amount
of radiation that reaches the gauge varies inversely with the density of the process
material.
Note: The gamma radiation used by the gauge cannot make the vessel, process
or structure radioactive.
Figure 1-1. DensityPro Measurement System
Thermo Scientific DensityPRO Installation Manual 1-1

Introduction
Overview
Configurations The Thermo Scientific DensityPRO density gauge consolidates the transmitter
function and the detector to form an integrated system.
The DensityPRO-T provides the user with a separate transmitter unit.
Note: For the purposes of this manual, instructions referring only to the
DensityPRO should be considered applicable to the entire family of
DensityPRO measurement systems. Any installation instructions that apply
exclusively to the DensityPRO will be specifically called out within the text.
The Source A Cesium (Cs-137) radioisotope source is used to provide the gamma radiation field
for most applications. A Cobalt (Co-60) source is available for applications requiring a
higher energy source – typically those with very large or thick-walled vessels. The
source capsule secures the radioisotope inside a glass matrix and then double
encapsulates the glass in a pair of sealed stainless steel capsules, ensuring extreme
resistant to vibration and mechanical shock.
The source head, a lead-filled, welded steel housing, further encloses the source
capsule. A shaped opening in the lead shielding directs the gamma radiation beam
through the process material towards the detector. For most density applications, the
source is designed to produce a very narrow beam of approximately 13° included angle.
Outside of the beam path, the energy emitted from the source head is very low and
well within prescribed limits.
Closing the source shutter blocks the radiation, attenuating the energy in the beam
path and allowing for safe handling, installation or servicing of the gauge. All source
housings meet or exceed the safety requirements of regulatory agencies such as the U.S.
Nuclear Regulatory Commission (NRC), agreement states, the Canadian Nuclear
Safety Commission and local regulatory agencies in other countries selling the device.
Please refer to the Gamma Radiation Safety Guide (p/n 717904) for more radiation
safety information.
The Detector-
Transmitter
The transmitter function in the DensityPRO system is incorporated into the detector
housing to create an integrated system, while in the DensityPRO-T system the
transmitter is a separate enclosure.
The DensityPRO measurement system utilizes two different detection media to detect
the radiation. One detector uses a sodium iodide scintillation detector. The other uses
a PVT (Polyvinyl Toluene) scintillation detector. Both are connected to a
photomultiplier tube. When gamma radiation strikes the scintillation material, small
flashes of light are emitted. As the density of the process material increases, more
gamma radiation is attenuated by the process material, which allows fewer gamma rays
to reach the detector and generates fewer light pulses. The photomultiplier tube and
associated detector electronics convert the light pulses into electrical pulses that are
processed by electronics in the detector of the integrated unit or transmitter to
determine the process material density and related measurement values.
1-2 DensityPRO Installation Manual Thermo Scientific

Introduction
Functional Description
Functional
Description
Measurement
Calculation
After the gauge calculates the process material density, it can convert the measurement
into a number of formats. For slurry, a solid material in a carrier fluid, the gauge can
provide measurements based on the ratio of solids to carrier. Similar measurements can
be made for both emulsions, a mixture of two different fluids, and for solutions,
comprised of a solute material dissolved in a solvent fluid.
Communications &
Measurement
Display
There are various communications options available with the DensityPRO
measurement system.
Using a PC with the Thermo Scientific communication software allows serial data
communication with the gauge via the RS485 or the RS232 serial ports and the USB
port.
The HART® communication protocol is supported over the 4–20 mA current output.
Communication with the gauge takes place through an Emerson Electric Co. field
communicator, Model 275 or newer or any other compatible device containing the
appropriate device descriptors. DensityPRO systems equipped with the HART
communication option are supported on the Emerson Electric Co. Asset Management
System (AMS).
With the FOUNDATION™ Fieldbus communication option, the DensityPRO system
provides users with access to control or program parameters via a host system. The
FOUNDATION Fieldbus communication option is FISCO-qualified.
DensityPRO systems equipped with the Profibus PA communication option provide
users with access to control or program parameters via a host system.
Upon completion of gauge setup, any present density measurement appears on the
external display, if so equipped.
Note: The HART, FOUNDATION Fieldbus, and Profibus PA communication
options are not available on the beta versions of the DensityPRO systems.
EZ-Cal II Software
Configuration
The DensityPRO comes with the Windows-based EZ Cal II configuration software.
This program allows you to construct a gauge configuration file for a specific
application, and either upload it immediately to a connected gauge, or store it on your
Windows-based PC for later implementation. The EZ Cal II software includes a
configuration wizard, significantly simplifying the gauge configuration process.
Alternately, the EZ Cal II program also provides direct access to a wide range of
configuration and troubleshooting tools.
Thermo Scientific DensityPRO Installation Manual 1-3

Introduction
Functional Description
1-4 DensityPRO Installation Manual Thermo Scientific
Multiple Readouts The DensityPRO gauges can provide a local readout of density parameters, either by
adding an optional local display to the DensityPRO or through the LCD display built
into the transmitter of the DensityPRO-T. For those applications where it may be
advantageous to display the density parameters in different units, both types of display
can accommodate up to four values.
Totalizers & Batch
Control
Four independent totalizers may be configured to count elapsed time or cumulative
mass/volume when a flow input signal is provided and a mass/volume-flow
measurement has been defined. Totalizers can be assigned to drive relays, and relays
can be set to open or close at specified “slow” or “stop” counts for batch or sample
control.
Input & Output
Signals
Any process measurement can be assigned to the 4–20 mA current output, or the
measurement values can be read using a Modbus master host. The two contact closure
inputs can be used to activate many system commands based on a user-provided switch
input.
Associated
Documentation
Along with this guide, all persons installing, using or maintaining this equipment must
read and understand the following documents:
–Gamma Radiation Safety Guide, p/n 717904
–DensityPRO Foundation Fieldbus Application Guide, p/n 717917 (for units with
Foundation Fieldbus installed)
–(pending) DensityPRO / DensityPRO-T with HART Protocol Interface
Operation Guide (for units using HART protocol)

Chapter 2
Handling, Storage & Shipping
This chapter addresses procedures for handling electrostatic discharge (ESD) sensitive
equipment, as well as procedures for unpacking, inspecting, and storing of the system.
Caution: This system is an ESD sensitive instrument. Use proper ESD
protective equipment and procedures. Failure to comply with ESD procedures
can result in circuit damage.
ESD Procedures The instrument contains electronic components that can be damaged from discharges
of static electricity. Ordinarily, handling the circuit boards by their edges will not
damage the circuits.
Caution: Do not touch the circuit board components.
Observe the following when installing, setting up, servicing, troubleshooting or
repairing the instrument:
1. Use an antistatic bag. Most instrument subassemblies ship in a special antistatic
bag. When not installed, keep the assembly in the bag as often as possible.
2. Remove ESD-sensitive subassemblies only under the following conditions:
a. When standing at a designated static-free workstation, or when the bag is
grounded at a field site.
b. After the conductive area of the container has been neutralized.
c. After making firm contact with an antistatic mat and/or firmly gripping a
grounded individual.
3. Personnel handling ESD-sensitive devices should be neutralized to a static-free
workstation by means of a grounding wrist strap connected to the station or to a
good grounding point at the field site.
4. Do not allow clothing to make contact with ESD sensitive devices.
5. Avoid touching edge connectors and components.
6. Avoid partially connecting ESD-sensitive devices. Floating leads can damage these
devices, especially the power supply connector.
7. Ground all test equipment.
8. Avoid static charges during troubleshooting.
Thermo Scientific DensityPRO Installation Manual 2-1

Handling, Storage & Shipping
Unpacking, Inspection & Storage
Unpacking,
Inspection &
Storage
All personnel involved in the packing, shipping, or receiving of hazardous material
must be trained in accordance with the United States Department of Transportation
(DOT) and OSHA hazardous materials regulations or in accordance with the
Canadian Nuclear Safety Commission (CNSC) regulations.
Note: Inspection, adjustment, installation, and maintenance of the instrument
must be performed by experienced personnel only.
1. Upon receipt, inspect the instrument for damage that may have occurred while in
transit. If evidence of rough handling or damage exists, file a damage claim with
the transportation company immediately. Notify Thermo Scientific and / or your
sales representative as soon as possible.
2. Carefully inspect the packing material prior to discarding it to ensure the removal
of all equipment and instructional paperwork.
3. Use the original packing material and container for storage if necessary.
4. If storing the instrument, the storage environment should be protected, free from
extremes of temperatures and high humidity, and fall within the environmental
constraints listed in Appendix B.
Shipping In the event it becomes necessary to ship the DensityPRO measurement system, follow
the instructions below.
1. Ensure there are no loose items in the DensityPRO unit.
2. Place the DensityPRO unit on a wooden pallet.
3. Bolt the unit to the pallet to ensure the unit is stable and secure for shipping.
4. Box up the pallet, ensuring there are no loose items in the box.
5. Pack all available space within the box with packing foam to protect the
DensityPRO system from damage during shipment.
Use the photographs in Figure 2-1 for guidance when packaging the DensityPRO
measurement system.
2-2 DensityPRO Installation Manual Thermo Scientific

Handling, Storage & Shipping
Unpacking, Inspection & Storage
Figure 2-1. Packing the DensityPRO for Shipment
Thermo Scientific DensityPRO Installation Manual 2-3