UWT Nivotec NT 4500 User manual

Level monitoring system
NT 4500
Technical information / Instruction manual
page
Table of contents
Subject to technical change. We assume no liability for typing errors.
Page
Safety notes/ Technical support 2
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Overview 3
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Technical Data 4
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Accessories 4
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Electrical installation 5
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Commissioning 10
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Visualisation - Operation 11
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Safety notes / Technical support
Notes
• Installation, maintenance and commissioning must be carried out only by qualied technical personnel.
• The product must be used only in the manner outlined in this instruction manual.
Special attention must be paid to warnings and notes as follows:
WARNING
Relates to a caution symbol on the product and means, that a failure to observe the necessary
precautions can result in death, serious injury and/ or considerable material damage.
WARNING
Relates to a caution symbol on the product and means, that a failure to observe the necessary
precautions can result in death, serious injury and/ or considerable material damage.
This symbol is used, when there is no corresponding caution symbol on the product.
A failure to observe the necessary precautions can result in considerable material damage.
CAUTION
Safety symbols
In manual and on
product Description
CAUTION: refer to related documents (manual) for details.
Earth (ground) Terminal
Protective Conductor Terminal
Technical support
Please contact your local supplier (see www.uwt.de for address). Otherwise you can contact:
UWT GmbH Tel. [phone]
Westendstr. 5 Fax. [phone]
87488 Betzigau [email protected]
Germany www.uwt.de
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Overview
Level monitoring and visualisation via web server
- Standardized system up to 50 silos
- Visualisation and operation via standard internet browser software
- Software language german, english or dutch
- Password protected
- Worldwide remote enquiry of the level
- Data in percentage, height, volume or weight
- Trend display, data storage, export via csv-le
- Evaluation of the analogue 4-20mA signals of any sensors, as well as Modbus RTU of the UWT-systems
- Different input signals within the same system is possible
- Implementation of full detectors
- Fill control via full alarm signal (buzzer)
- Indication of warnings/ reports
NT4500 Basic unit
The heart of the NT4500 is the web server module, which
the visualisation software uses. All ll level control and
display functions can be operated via the visualisation on
a PC. An Ethernet interface ensures that the visualisation
can be simultaneously operated from all PCs which are
connected to the interface. Access is password protected.
The electromechanical lead system can be started by the
visualisation.
Integration of full detector incl. alarm
- Flashlight-buzzer with reset button (supplied loose,
for outdoor mounting)
- One unit for all connected silos
- Alarm happens, if one of the silos gets full
- Reset of the alarm "Full Level Indicator
- Provided for mounting directly on the silo
Modbus converter
- For connection of 4-20 mA/ 2-wire sensors and full detectors
- On each converter up to 4 sensors and 4 full detectors can
be connected
- Provided for mounting directly on the silo
NT4500
Buzzer Reset
button
Modbus converter
e.g NR3000 Full detector
Modbus RTU
NB3000
Modbus RTU
Modbus RTU
4-20mA
Full detector
Connection of
further Modbus
converters
Connection of
further NB3000
Alarm "Full
Level Indicator"
Ethernet
Basis unit
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Technical Data / Accessories
Technical data
Dimensions NT 4500, Modbus converter: 300 x 300 x 210 mm (W x H x D
Mounting NT 4500, Modbus converter: wall mounting
Material NT 4500, Modbus converter: steel plate
Ingress protection NT 4500, Modbus converter: IP65
Ambient temperature NT 4500: 0 .. +55°C
Modbusumsetzer: -25 .. +70°C
Power supply NT 4500, Modbus converter: 115 V or 230 V 50/ 60 Hz (integrated power converter 24 VDC)
NR 3000: supplied by Modbus converter
NB 3000/ NB 4000: 115 V or 230 V AC, connection is made on site
Full detector: Connection either on NB 3000/ NB 4000 resp. Modbus
converter. In this case the supply voltage must be equal to
NB 3000/ NB 4000 resp. Modbus converter. Alternative
it is possible to connect on site.
Power consumption NT 4500, Modbus converter: 20 VA
Connected level sensors: see documentation of the respective sensors
Signal output full detector Floating contact is required
Terminal box
Intermediate terminals for the wires leading to the silo (mounting e.g. on the silo frame).
Applicable for cables of level (Modbus or 4-20 mA), limit switch, buzzer, reset button
Technical data
Dimensions 200 x 300 x 120 mm (W x H x D), for wall mounting
Material steel plate
Ingress protection IP65
Ambient temperature -25 .. +60°C
Terminal blocks 15 pieces grey, 5 pieces blue, 5 pieces green/ yellow; each terminal implements 3 cable inlets
2.5 mm2, mounted on top hat rail
Cable glands 6 pieces M20 x 1.5 2 pieces M25 x 1.5
Technical data of the used Wago Controllers:
see www.wago.com, search for 750-8202
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Electrical installation
Handling In case of improper handling or handling malpractice, the electric safety of the device cannot be
guaranteed.
Installation regulations The local regulations or VDE 0100 (Regulations of German Electrotechnical Engineers) must be
observed.
Fuse Use a fuse as stated in the connection diagrams.
RCCB protection In case of a fault, the supply voltage must be automatically switched off by a RCCB protection switch
to protect against indirect contact with dangerous voltages.
Power supply switch A voltage disconnection switch must be provided near the device.
Wiring diagram The electrical connections are made in accordance with the wiring diagram.
Supply voltage Compare the supply voltage applied with the specications given on the name plate before switching
the device on.
Cable gland Make sure that the screwed cable gland safely seals the cable and that it is tight (danger of water
intrusion).
Cable glands that are not used have to be sealed with a blanking element.
Field wiring cables All eld wirings must have insulation suitable for at least 250 V AC. The temperature rating must be at
least 80°C (176°F).
Installation in Hazardous
Locations
The NT 4500 and the Mobus converter are not permitted for installation in Hazardous Areas. Observe
the valid regulations for wiring in Hazardous Areas, if the NB 3000/ NB 4000 is installed in Hazardous
Areas.
Safety Instructions
Modbus network
Modbus Master
NT 4500
Other used notations:
D0 = Rx-/Tx- = A
D1 = Rx+/Tx+ = B
Modbus converter or
NB 3000/ NB 4000
Modbus Slaves
General wiring of a Modbus network
Terminals D0 as well as D1 are
internally connected.
Termination Resistor
120 Ohm at the end of the
strand. It is present inside
each Modbus converter and
NB 3000/ NB 4000 and can be
switched in.
Modbus converter or
NB 3000/ NB 4000
Modbus converter or
NB 3000/ NB 4000
Note:
If required it is possible to split the Modbus network into two strands. Both strands are wired in parallel at the Modbus Master.
A termination resistor must be present at the end of each strand.
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Electrical installation
Cable recommendations for Modbus network
Shielded cable
Functionality up to 50m
Manufacturer: Lapp, Type UNITRONIC LiYCY 2x0.34, Art.no: 0034502
Twisted pair cable
Functionality up to 1,000m
Manufacturer: Lapp, Type UNITRONIC BUS CAN 1x2x0.34, Art.no: 2170263
UV-protection hose with threaded hose coupling M20 x 1.5
UV protection for Modbus cable
Manufacturer: Flexa, Type Rohrex PA6, Art.no: 0233.202.012 and Type RQG1-M, Art.no: 5020.055.018
ATEX-protection hose with threaded hose coupling M20 x 1.5
For installation of Modbus cable in ATEX Zone 21
Manufacturer: PMA, Type ESX, Art.no: ESXT-12B.50 and Type END, Art.no: BEND-M202GT
NT4500
Ethernet
(plug in
at X1)
Reset button and buzzer
(Alarm silo full)
Modbus
Fuse: max.10A
0.14 .. 2.5mm2
(AWG 26 .. 14)
115V or
230V
50/ 60Hz
SD-Card
(data-
export)
Note:
- The sliding swith on the controller is set to RUN and must not be changed.
- The csv-le for data-export is written on a SD-card.
The SD-card hast to rest in the controller for continoous recording.
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Electrical installation
NB 3000/ NB 4000
Full detector
Contact must be
closed in case of
full detection
Modbus
Fuse: max. 10 A
0.14 .. 2.5 mm2
(AWG 26 .. 14)
115 V or
230 V
50/ 60Hz
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Setting: Biasing and Termination Resistor
For use of NB 4000 units in a external Modbus network, it is
possible to set Biasing and Termination Resistor on each unit
as required.
Electrical installation
*factory provided
Biasing OFF* OFF ON ON
Termination
Resistor
OFF* ON OFF ON
*factory provided
Biasing OFF* OFF ON
Termination
Resistor
OFF* ON ON
Version with Jumper
Version with DIP switch
Biasing OFF* OFF ON ON
Termination
Resistor
OFF* ON OFF ON
NB 4000
NB 3000
DIP Switch position:
Side viewTop view
DIP Switch position:
Side viewTop view
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Electrical installation
The stated wiring inside the Modbus converter is factory provided.
Termination Resistor needs to be connected at the end of the Modbus strand.
Power
supply
Modbus converter
115V or
230V
50/ 60Hz
Fuse: max. 10 A
Terminals M-7002: 0.14 .. 1.5 mm2(AWG 26 .. 16)
Other terminals: 0.14 .. 2.5 mm2(AWG 26 .. 14)
Max. 4 sensors
4-20 mA/ 2-wire
Sensor Sensor
Sensor
Sensor
Max. 4 full detectors
Detector Detector Detector
Detector
Modbus
Modbus converter
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Commissioning
2. Check the wiring
Make sure that the Modbus network is wired, set the Modbus Termination Resistor (and for NB 3000/ NB 4000 the Biasing), check that
the Ethernet connection is available (see "Electrical installation" from page 5 onwards).
Note: All units are presetted to 19200 Baud. Thus no setting is required.
3. Web server conguration
CAUTION: The conguration should be done by the network administrator only.
The web server is preset to the IP address 192.168.10.70. It must be changed to a company's own IP address as follows:
• Use a PC, which is connected via Ethernet to the Web server. Set in the system control the TCP/ IP to address 192.168.10.xxx,
whereas xxx can be any number between 0 and 255 (the access to the Web server requires the number 192.168.10., the last
numberblock is not relevant).
• An up to date version of Internet browser must be installed.
• Open the Internet browser and type the IP address 192.168.10.70 of the web server in the command bar. The overview page
"Home" of the visualisation opens (see page 11).
• Click the "Login" button and set the user name to "Admin" with the password "admin". The "System Cong" button will appear in the
menu bar.
• Click on this button. The conguration page of the web server will open (see page13ff.).
• Enter the number of silos, language, date and time, your IP address, sub net mask and gateway.
• Then reset to your TCP/ IP address in the system control of your PC.
4. Perform the basic settings of the connected sensors
With the following settings, the connected sensors are addressed via the visualisation and give a real measurement result. For this
settings the above mentioned synoptical table is helpful. On the overview page "Home", click into the desired silo. There you have to edit
the following settings:
• On page "Setup" (see page17f.) the data under "Silo Data", "Modbus RTU" and "Level Limit Sensor".
• On page "Volume Calculation" (see page19) the data under "Silo Shape" and "Silo Data".
5. Perform further user settings
Enter the required user specic settings according to the "Visualisation - Operation" from page 11 onwards.
1. Generation of a synoptical table
Commissioning is facilitated if an overview of the connected sensors is made in advance.
The table shows an example of a project with 11 silos and mixed conguration of Nivobob NB 3000 and NR 3000 radar
as well as implementation of full detectors:
Silo Sensor Modbus
ID
Modbus converter
Channel*
Modbus converter
Terminal of
sensor
Modbus converter
Terminal of full
detector
1NB 3000 3 n/ a n/ a n/ a
2NB 3000 4 n/ a n/ a n/ a
3NB 3000 5 n/ a n/ a n/ a
4NB 3000 6 n/ a n/ a n/ a
5NR 3000 1 0 Vin0+ DI0
6NR 3000 1 1 Vin1+ DI1
7NR 3000 1 2 Vin2+ DI2
8NR 3000 1 3 Vin3+ DI3
9NR 3000 2 0 Vin0+ DI0
10 NR 3000 2 1 Vin1+ DI1
11 NR3000 2 2 Vin2+ DI2
* see page17f. under "Modbus RTU"/ "Full Detector"
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Visualisation - Operation
By entering the IP address in the browser (according to the web server conguration) the visualisation starts.
After sucessful start the overview page "Home" appears.
Start of the Visualisation
Display of level, level limit sensors, information regarding silo and error messages
All user names
The selected number of silos (see page "System Cong" -> Number of silos) is presented. If more than 10 silos are dened, a button
appears for progression to the next page.
Note: If a distorted image on the PC is present, it should not be viewed in full screen mode, thus the window can be drawn in an
undistorted view.
Overview page (Home)
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The following selections appear depending on the setted user name:
Login Logout
Using the Login button, you can change tio other user names with additional privilegs:
User (password: user)
- Page "Silo Single View"
- View of Event List
- Page "System Cong"
- Download of trend data
- Start Nivobob
- Reset of the full signal (buzzer) and of error messages
- Logout
Purchase (password: purchase)
Similar to User, additional:
- On page "Silo Single View": page "Logistics Department"
Admin (password: admin)
Similar to Purchase, additional:
- On page "Silo Single View":
- Page "Setup"
- Page "Volume Calculation"
- On page "System Cong":
- Page "Number of silo - Date - Time - Language - Trend"
- Page "Network"
- Page "E-Mail"
- Release User Settings
The button Logout is used to logout.
Silo Single View (click on a silo)
The single view for the respective silo will open (see page16).
System Cong
See page13ff.
Download Trend
Issue of trend data for all silos as csv-le. The level values are stated in the unit as dened under "Volume Calculation" (see page19).
Start Nivobob
Starts the measurement of all connected Nivobobs. If more than 10 silos are dened, the measurements of the silos not displayed on the
screen are started as well. As long as the measurement is running, a green arrow appears in each silo.
Quit
Reset of the full signal (buzzer) and of error messages.
Visualisation - Operation
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Page "System Conguration"
Display of Softwareinformations, navigation to extended user settings
All user names
Visualisation - Operation
The following selections appears depending on the setted user name:
Number of Silo - Date - Time - Language - Trend
See page14.
Network
See page15.
E-Mail
See page15.
Reset User Settings
The button "Change Password" will be shown for 5 minutes (independent from
logged in user name).
Change Password
A popup to change the password of the actually logged in user name will be
shown.
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Visualisation - Operation
Page "System Cong" Button "Number os Silo - Date - Time - Language - Trend"
Setting of date, time, menu language of software, number of silos, writing interval for trend and reset
of trend .csv le
User name Admin
Number of Silo
The number of silos to be displayed on Overview page (Home) is set here. Per page a maximum of 10 silos will be shown, additional
silos will be shown on a following page. The maximum amount of shown silos is limited to 25 or rather 50 silos, depending on device
conguration.
Tend
The trend on the pages "Silo Single View" and "Logistics Department" consist in total of 200 measurement points per silo. The oldest
measurement point will be deleted, if an actual value is added. By editing the "Interval Writing", the total time of the trend can be
determined. The trend saving takes place in this interval (hours:minutes:seconds). By changing the Iinterval writing, the existing trend
will be deleted, to ensure a linear display of the trend.
Trend CSV File
The trend data is written continuous to a csv-le on SD-card. By using the button "Download Trend", the csv-le can be downloaded
(see page11f.). To avoid large data-les, the csv-le can be reseted manually by using the button "Delete". Hint: When changing the
number of silos, the csv-le will be deleted also.
Event CSV File
The event data are stored continuously to the SD-card for diagnostics. Per quarter and silo, one le is created. There are les for the prior
and for the actual quater up to the actual date available for download. Older les are deleted automatically.
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Visualisation - Operation
Page "Send an E-Mail"
Setting of parameters for the network interface
User name Admin
Setting of receiver for notes per email when full detector, demand detector, empty detector and failure
User name Admin
Hint: If you make a mistake at conguration or loose the settings, the
controller can be addressed on connector X2 (see page6) with IP address
192.168.30.70.
Page "Ethernet Conguration"
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View of details and settings of the sensors for a silo
User name User, Purchase and Admin
Clicking on a silo in the Overview page (Home) opens the Silo Single View.
The level is displayed in the unit as dened under "Volume Calculation" (see page19), in addition as a percentage.
The colored points display the full, demand and empty detection. The color of the lling can be set on page "Setup" (see page17f.) to
the demand of the lling.
The trend stores a total of 200 data points per silo. The oldest point is deleted when a new value is stored.
Events are displayed in a table. The selection "+" opens the list of the last 11 events. In case of a alarm, above the table up to 3
notications will be shown additional.
Page "Silo Single View"
Visualisation - Operation
Nivobob Start
Starts the measurement of the Nivobob for this silo. During the measurement, the button appears gray. When the measurement is
completed, the color changes back to green.
The button appears only if the detected sensor is a Nivobob.
Disposition
Leads to the page "Logistics Department" of this silo (see page20).
Setup
Leads to the page "Setup" of this silo (see page17ff.).
Volume Calculation
Leads to the page "Volume Calculation" of this silo (see page19).
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Detail settings for the respective measurement point
User name Admin
Page "Setup"
View with selection "Hardware - Nivobob":
Visualisation - Operation
The following selections appears under topic Nivobob, if according sensor is connected:
Enable
The measurement start can be blocked by deactivation of this eld, e.g. when a silo si lled up.
Automatic Power Measurement Start
After rebooting the webserver or blackout, the Nivobob will start automatically, if this eld is activated. The lling level is then
immediatelly actual (Nivobob looses measusement values after blackout, until measurement is started).
Interval Start, Interval Time, Starttime Interval
If the eld "Interval Start" is activated, measurement starts of the Nivobob take place automatically. The starts take place daily, rst-time
at "Starttime Interval" (hours-minutes-seconds), then with periodic repeated interval time" (hours-minutes-seconds).
Start Time 1to 4
Additional/ alternative to the Interval Start up to 4 individual Start Times can be set per day (hours-minutes-seconds).
Start Full Detector
If the eld "Start Full Detector" is activated, measurement start of the Nivobob takes plase automatically, if the full detector of the
corresponding silo is actuated. From actuation to measurement start is a delay of 10 minutes.
View if connected sensor is a Novobob:
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Visualisation - Operation
View if connected sensor is connected via Modbus converter:
Silo Daten
The silo shown can be labeled with any text for silo name, content and article number.
Modbus RTU
Setting of the Modbus address of the conected hardware.
If a Modbus converter is connected to the selected address, the Nivotec detects this automatically. A eld to select the channel
number for the 4-20mA sensor and the full detector appears:
Channel 0 is allocated to the terminal Vin0+ and DI0 (see electrical installation on page9)
Channel 1 is allocated to the terminal Vin1+ and DI1
Channel 2 is allocated to the terminal Vin2+ and DI2
Channel 3 is allocated to the terminal Vin3+ and DI3
Hint for dening the Modbus addresses:
The Modbus address of the Nivobob is setted in the Nivibob communication menu (see manual Nivobob). It is reasonable to use the
address 1 for the rst device, then ascending to 2, 3, etc. With mixed use of Modbus converters the rst addresses of the Modbus
converters are already preset (see below), the Nivobob addresses must then be allocated above these. Optional (with selection code
33) the Nivobob devices are delivered with already preset address.
The Modbus converters are factory presetted to address 1 for the rst Modbus converter, then ascending to 2, 3, etc. The settings
can not be changed. A label with the Modbus address is present inside the Modbus converters on the implemented module M-7002.
Grenzstansmelder
If a full detector is connected, it is read with setting to "Modbus".
If "value" is selected, the message for full is activated, when the entered value (in accordance to the unit set on page "Volume
Calculation", see page19) is exceeded by the material level. The message for demand and empty is activated, when the material level is
below the entered values. The demand and empty message can only be acticated via the input "value".
Hint: When changing the unit on page "Volume Calculation", the values for full, demand and empty detector have to be adapted
accordingly.
Silo color
The chromatic illustration of the lling can be adapted to the lling.
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Silo Prole and Silo Data
With the setted data the software calculates the actual content:
Programming of the sensors
For the correct measurement display the connected sensors must be set as follows:
• Nivobob NB 3000/ NB 4000:
The value "Move Distance Nivobob" must equal the silo hight to use the full measurement range down to 0%.
Values can be exchanged with the Nivobob via the buttons "Read from Nivobob" and "Transmint to Nivobob".
• 4-20mA sensors (connected via Modbus converter):
4mA must correspond to the value 0% given above
20mA must correspond to the value 100% given above
Note: All sensors needs to have a linear level signal (relation between the signal output and level in the silo).
The volume-based calculation is performed in the visualisation only.
Unit/ Density
The selected unit is used in the visualisation. When selecting a mass unit (kilograms, tons, US tons), the entered bulk denstiy is used for
calculation of the mass.
Calculated values
Display of the calculated maximum content (according to the entered Silo Prole and Data) and the actual content.
Both values are shown in the above selected unit.
Page "Volume Calculation"
Settings for volume related measurement display and setting of the silo dimensions
User name Admin
Visualisation - Operation
Nivotec®1
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NT4500 gi010218 19

Level monitoring system
NT 4500
Technical information / Instruction manual
page
Visualisation - Operation
Page "Logistics Department"
View and setting of silo content, article number and density, as well as view of maximal content,
current content and current free space
User name Purchase and Admin
Nivotec®
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NT4500
gi010218
20