Voith OnC LevelSens 362 User manual

Operating Instructions
OnC LevelSens 362
4…20 mA/HART two-wire

Contents
1About this document
1.1Function.................................. 4
1.2Target group .............................. 4
1.3Symbolism used............................ 4
2For your safety
2.1Authorised personnel ........................ 5
2.2Appropriate use ............................ 5
2.3Warning about misuse ....................... 5
2.4General safety instructions .................... 5
2.5Safety label on the instrument .................. 6
2.6CE conformity ............................. 6
2.7Fulfillment of NAMUR recommendations .......... 6
2.8Safety instructions for Ex areas ................. 6
3Product description
3.1Configuration .............................. 7
3.2Principle of operation ........................ 8
3.3Operation................................. 8
3.4Packaging,transport and storage ............... 8
4Mounting
4.1General instructions ......................... 10
4.2Mounting instructions ........................ 12
5Connect to power supply
5.1Prepare the connection....................... 18
5.2Connection procedure........................ 19
5.3Wiring plan,single chamber housing ............. 20
5.4Wiring plan,double chamber housing ............ 21
5.5Switch on phase............................ 22
6Set up with the indicating and adjustment module
6.1Short description ........................... 24
6.2Insert indicating and adjustment module........... 24
6.3Adjustment system .......................... 26
6.4Setup procedure............................ 27
6.5Menu plan ultrasonic sensor ................... 33
6.6Saving the parameter adjustment data ............ 35
7Maintenance and fault rectification
7.1Maintenance .............................. 36
7.2Remove interferences ........................ 36
7.3Exchanging the electronics module .............. 37
7.4Instrument repair ........................... 37
8Dismounting
8.1Dismounting steps .......................... 38
2OnC LevelSens 362 •4…20 mA/HARTtwo-wire
Contents
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8.2Disposal . . ............................... 38
9Supplement
9.1Technical data ............................. 39
9.2Dimensions ............................... 44
Supplementary documentation
Information:
Supplementary documents appropriate to the ordered version come
with the delivery.You can find them listed in chapter "Product
description".
Instructions manuals for accessories and replacement parts
Tip:
l33927 -External adjustment unit OnC UniCom 961
OnC LevelSens 362 •4…20 mA/HART two-wire 3
Contents
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1About this document
1.1Function
This operating instructions manual provides all the information you
need for mounting,connection and setup as well as important
instructions for maintenance and fault rectification.Please read this
information before putting the instrument into operation and keep this
manual accessible in the immediate vicinity of the device.
1.2Target group
This operating instructions manual is directed to trained qualified
personnel.The contents of this manual should be made available to
these personnel and put into practice by them.
1.3Symbolism used
Information,tip,note
This symbol indicates helpful additional information.
Caution:If this warning is ignored,faults or malfunctions can
result.
Warning:If this warning is ignored,injury to persons and/or serious
damage to the instrument can result.
Danger:If this warning is ignored,serious injury to persons and/or
destruction of the instrument can result.
Exapplications
This symbol indicates special instructions for Ex applications.
lList
The dot set in front indicates a list with no implied sequence.
àAction
This arrow indicates a single action.
1Sequence
Numbers set in front indicate successive steps in a procedure.
4OnC LevelSens 362 •4…20 mA/HARTtwo-wire
1About this document
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2For your safety
2.1Authorised personnel
All operations described in this operating instructions manual must be
carried out only by trained specialist personnel authorised by the plant
operator.
During work on and with the device the required personal protective
equipment must always be worn.
2.2Appropriate use
OnC LevelSens 362 is a sensor for continuous level measurement.
You can find detailed information on the application range in chapter
"Product description".
Operational reliability is ensured only if the instrument is properly used
according to the specifications in the operating instructions manual as
well as possible supplementary instructions.
For safety and warranty reasons,any invasive work on the device
beyond that described in the operating instructions manual may be
carried out only by personnel authorised by the manufacturer.Arbitrary
conversions or modifications are explicitly forbidden.
2.3Warning about misuse
Inappropriate or incorrect use of the instrument can give rise to
application-specific hazards,e.g.vessel overfill or damage to system
components through incorrect mounting or adjustment.
2.4General safety instructions
This is a high-tech instrument requiring the strict observance of
standard regulations and guidelines.The user must take note of the
safety instructions in this operating instructions manual,the country-
specific installation standards as well as all prevailing safety
regulations and accident prevention rules.
The instrument must only be operated in a technically flawless and
reliable condition.The operator is responsible for trouble-free
operation of the instrument.
During the entire duration of use,the user is obliged to determine the
compliance of the required occupational safety measures with the
current valid rules and regulations and also take note of new
regulations.
OnC LevelSens 362 •4…20 mA/HART two-wire 5
2For your safety
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2.5Safety label on the instrument
The safety approval markings and safety tips on the device must be
observed.
2.6CE conformity
This device fulfills the legal requirements of the applicable EC
guidelines.By attaching the CE mark,we provide confirmation of
successful testing.
2.7Fulfillment of NAMUR recommendations
With regard to compatibility,OnC LevelSens 362 and its indicating and
adjustment components fulfill NAMUR recommendation NE 53.
The parameter adjustment of the basic sensor functions is independ-
ent of the software version.The range of available functions depends
on the respective software version of the individual components.
The software version of OnC LevelSens 362 can be determined as
follows:
lvia the type label of the electronics
lvia the indicating and adjustment module
Please contact us if you have questions concerning the software
history.
2.8Safety instructions for Ex areas
Please note the Ex-specific safety information for installation and
operation in Ex areas.These safety instructions are part of the
operating instructions manual and come with the Ex-approved
instruments.
6OnC LevelSens 362 •4…20 mA/HARTtwo-wire
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3Product description
3.1Configuration
The scope of delivery encompasses:
lOnC LevelSens 362 ultrasonic sensor
lDocumentation
-this operating instructions manual
-Operating instructions manual 33926 "Indicating and adjust-
ment module"(optional)
-Ex-specific"Safety instructions"(with Ex-versions)
OnC LevelSens 362 consists of the following components:
lProcess fitting with transducer
lHousing with electronics
lHousing cover,optionally available with indicating and adjustment
module
The components are available in different versions.
1
2
3
Fig.1:OnC LevelSens 362 -configuration
1Housing cover with integrated indicating and adjustment module (optional)
2Housing with electronics
3Process fitting with transducer
The type label contains the most important data for identification and
use of the instrument:
lSensor type
lArticle and serial number,sensor
lArticle numbers,documentation
lTechnical data:For example approvals,process temperature,
process fitting/material,signal output,power supply,protection
Scope of delivery
Components
Type label
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3Product description
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3.2Principle of operation
OnC LevelSens 362 is an ultrasonic sensor for continuous level
measurement.It is suitable for liquids and solids in virtually all
industries,particularly in the water and waste water industry.
The transducer of the ultrasonic sensor transmits short ultrasonic
pulses to the measured product.These pulses are reflected by
product surface and received back by the transducer as echoes.The
running time of the ultrasonic pulses from emission to reception is
proportional to the distance and hence the level.The determined level
is converted into an appropriate output signal and outputted as
measured value.
Two-wire electronics 4…20 mA/HART for power supply and
measured value transmission over the same cable.
The supply voltage range can differ depending on the instrument
version.The exact range is stated in chapter "Technical data".
The background lighting of the indicating and adjustment module is
powered by the sensor.Acertain level of operating voltage is required
for this.You can find the exact voltage specifications in chapter
"Technical data".
3.3Operation
OnC LevelSens 362 can be adjusted with different adjustment media:
lwith indicating and adjustment module
lWith a HART handheld
The entered parameters are generally saved in OnC LevelSens 362,
optionally also in the indicating/adjustment module.
3.4Packaging,transport and storage
Your instrument was protected by packaging during transport.Its
capacity to handle normal loads during transport is assured by a test
according to DIN EN 24180.
The packaging of standard instruments consists of environment-
friendly,recyclable cardboard.For special versions,PE foam or PE foil
is also used.Dispose of the packaging material via specialised
recycling companies.
Transport must be carried out under consideration of the notes on the
transport packaging.Nonobservance of these instructions can cause
damage to the device.
The delivery must be checked for completeness and possible transit
damage immediately at receipt.Ascertained transit damage or
concealed defects must be appropriately dealt with.
Application area
Functional principle
Power supply
Packaging
Transport
Transport inspection
8OnC LevelSens 362 •4…20 mA/HARTtwo-wire
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Up to the time of installation,the packages must be left closed and
stored according to the orientation and storage markings on the
outside.
Unless otherwise indicated,the packages must be stored only under
the following conditions:
lNot in the open
lDry and dust free
lNot exposed to corrosive media
lProtected against solar radiation
lAvoiding mechanical shock and vibration
lStorage and transport temperature see chapter "Supplement -
Technical data -Ambient conditions"
lRelative humidity 20 …85 %
Storage
Storage and transport
temperature
OnC LevelSens 362 •4…20 mA/HART two-wire 9
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4Mounting
4.1General instructions
Make sure that all parts of the instrument exposed to the process,in
particular the sensor element,process seal and process fitting,are
suitable for the existing process conditions.These include above all
the process pressure,process temperature as well as the chemical
properties of the medium.
You can find the specifications in chapter "Technical data"or on the
type label.
Select an installation position you can easily reach for mounting and
connecting as well as later retrofitting of an indicating and adjustment
module.The housing can be rotated by 330°without the use of any
tools.You can also install the indicating and adjustment module in four
different positions (each displaced by 90°).
Use the recommended cables (see chapter "Connecting to power
supply")and tighten the cable gland.
You can give your OnC LevelSens 362 additional protection against
moisture penetration by leading the connection cable downward in
front of the cable entry.Rain and condensation water can thus drain
off.This applies mainly to outdoor mounting as well as installation in
areas where high humidity is expected (e.g.through cleaning
processes)or on cooled or heated vessels.
Fig.2:Measures against moisture penetration
The reference plane for the measuring range is the lower edge of the
transducer.
Make sure that a minimum distance from the reference plane -the so-
called dead band,in which measurement is not possible -is
maintained.The exact value of the dead band is stated in chapter
"Technical data".
Suitability for process
conditions
Mounting position
Moisture
Measuring range
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1
2
Fig.3:Minimum distance to the max.level
1Dead band
2Reference plane
Information:
If the medium reaches the transducer,buildup can form on it and
cause faulty measurements later on.
1 32
100%
0%
Fig.4:Measuring range (operating range)and max.measuring distance
1full
2empty (max.measuring distance)
3Measuring range
Gauge pressure in the vessel does not influence OnC LevelSens 362.
Low pressure or vacuum does,however,damp the ultrasonic pulses.
This influences the measuring result,particularly if the level is very low.
With pressures under -0.2bar (-20 kPa)you should use a different
measuring principle,e.g.radar or guided microwave.
Pressure/Vacuum
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4.2Mounting instructions
Screw OnC LevelSens 362 into the mounting socket with an
appropriate spanner applied to the hexagon of the process fitting.Max.
torque see chapter "Technical data".
Warning:
The housing must not be used to screw the instrument in!Applying
tightening force can damage internal parts of the housing.
When mounting OnC LevelSens 362,keep a distance of at least
200 mm (7.874 in)to the vessel wall.If the sensor is installed in the
center of dished or round vessel tops,multiple echoes can arise.
These can,however,be suppressed by an appropriate adjustment
(see chapter "Setup").
1
2
> 200 mm
Fig.5:Mounting on round vessel tops
1Reference plane
2Vessel center or symmetry axis
If you cannot keep this distance you should carry out a false echo
storage before setup.This applies mainly if buildup on the vessel wall
is expected.In this case,we recommend repeating a false echo
storage later with existing buildup.
In vessels with conical bottom it can be advantageous to mount the
sensor in the center of the vessel,as measurement is then possible
down to the lowest point of the vessel bottom.
Screwing in
Mounting position
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Fig.6:Vessel with conical bottom
Socket pieces should be dimensioned so that the lower end of the
transducer protrudes at least 10 mm (0.394 in)out of the socket.
ca. 10 mm
Fig.7:Recommended socket mounting
Ifthe reflective properties of the medium are good,you can mount
OnC LevelSens 362 on sockets higher than the transducer length.You
will find recommended values for socket heights in the following
illustration.The socket end should be smooth and burr-free,if possible
also rounded.Carry out a false echo storage.
Socket
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4Mounting
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d
d
h
100 mm/4"
150 mm/6"
200 mm/8"
300 mm/12"
400 mm/16"
500 mm/20"
h
Fig.8:Deviating socket dimensions
Inliquids,align the sensor as vertical as possible to the product
surface to achieve optimum measuring results.
Fig.9:Alignment in liquids
Toreduce the min.distance to the medium,you can also mount OnC
LevelSens 362 with a beam deflector.By doing this,it is possible to fill
the vessel nearly to maximum.Such an arrangement is suitable
primarily for open vessels such as e.g.overflow basins.
~200
~400x400
45°
Fig.10:Beam deflector
Sensor orientation
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The ultrasonic sensor should be installed at a location where no
installations cross the ultrasonic beam.
Vessel installations such as for example,ladders,limit switches,
heating spirals,struts etc.can cause false echoes that interfere with
the useful echo.Make sure when planning your measuring site that the
ultrasonic signals have a "clear view"to the measured product.
In case of existing vessel installations,a false echo storage should be
carried out during setup.
If large vessel installations such as struts or supports cause false
echoes,these can be attenuated through supplementary measures.
Small,inclined sheet metal or plastic baffles above the installations
scatter the ultrasonic signals and avoid direct false echoes.
α
α
α
α
α
α
Fig.11:Cover smooth profiles with deflectors
If there are agitators in the vessel,a false echo storage should be
carried out with the agitators in motion.This ensures that the interfering
reflections from the agitators are saved with the blades in different
positions.
Fig.12:Agitators
Vessel installations
Agitators
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Do not mount the instruments in or above the filling stream.Make sure
that you detect the product surface,not the inflowing product.
Fig.13:Inflowing liquid
Through the action of filling,stirring and other processes in the vessel,
dense foams which considerably damp the emitted signals may form
on the product surface.
If foams are causing measurement errors,the sensor should be used
in a standpipe or,alternatively,the more suitable guided radar sensors
(TDR)should be used.
Guided radar is unaffected by foam generation and is particularly
suitable for such applications.
If there are strong air currents in the vessel,e.g.due to strong winds in
outdoor installations or air turbulence,e.g.by cyclone extraction you
should mount OnC LevelSens 362 in a standpipe or use a different
measuring principle,e.g.radar or guided radar (TDR).
By using a standpipe (surge or bypass tube), the influence of vessel
installations,foam generation and turbulence is excluded.
Standpipes must extend all the way down to the requested min.level,
as measurement is only possible within the tube.
Inflowing medium
Foam
Air turbulences
Standpipe measureme-
net
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max.
min.
1
Fig.14:Standpipe in tank
1Vent hole:ø5…10 mm (0.197 …0.394 in)
OnC LevelSens 362 can be used from tube diameters of 50 mm
(1.969 in).
Avoid large gaps and thick welding joints when connecting the tubes.
Generally carry out a false echo storage.
Measurement in a standpipe is not recommended for very adhesive
products.
OnC LevelSens 362 •4…20 mA/HART two-wire 17
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5Connect to power supply
5.1Prepare the connection
Always keep in mind the following safety instructions:
lConnect only in the complete absence of line voltage
lIf overvoltages are expected,install overvoltage arresters
In hazardous areas you should take note of the appropriate
regulations,conformity and type approval certificates of the sensors
and power supply units.
Power supply and current signal are carried on the same two-wire
cable.The voltage supply range can differ depending on the
instrument version.
The data for power supply are specified in chapter "Technical data".
Provide a reliable separation between the supply circuit and the mains
circuits according to DIN VDE 0106 part 101.
Keep in mind the following additional influences on the operating
voltage:
lOutput voltage of the power supply unit can be lower under
nominal load (with a sensor current of 20.5mAor 22 mAin case of
fault message)
lInfluence of additional instruments in the circuit (see load values in
chapter "Technical data")
The instrument is connected with standard two-wire cable without
screen.If electromagnetic interference is expected which is above the
test values of EN 61326 for industrial areas,screened cable should be
used.
Use cable with round cross-section.Acable outer diameter of 5…9mm
(0.2…0.35 in)ensures the seal effect of the cable gland.If you are
using cable with a different diameter or cross-section,exchange the
seal or use a suitable cable gland.
If screened cable is necessary,connect the cable screen on one or
both ends to ground potential depending on the plant installation.In the
sensor,the screen must be connected directly to the internal ground
terminal.The ground terminal on the outside of the housing must be
connected to the potential equalisation (low impedance).
If potential equalisation currents are expected,the connection on the
processing side must be made via a ceramic capacitor (e.g.1nF,
1500 V). The low frequency potential equalisation currents are thus
suppressed,but the protective effect against high frequency interfer-
ence signals remains.
Note safety instructions
Take note of
safety instruc-
tions for Ex ap-
plications
Select power supply
Selecting connection
cable
Cable screening and
grounding
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5Connect to power supply
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Take note of the corresponding installation regulations for Ex
applications.In particular,make sure that no potential equalisation
currents flow over the cable screen.In case of grounding on both sides
this can be achieved by the use of a capacitor or a separate potential
equalisation.
5.2Connection procedure
Proceed as follows:
1Unscrew the housing cover
2If an indicating and adjustment module is installed,remove it by
turning it slightly to the left.
3Loosen compression nut of the cable entry
4Remove approx.10 cm of the cable mantle,strip approx.1cm
insulation from the individual wires
5Insert the cable through the cable gland into the sensor
6Lift the opening levers of the terminals with a screwdriver (see
following illustration)
7Insert the wire ends into the open terminals according to the wiring
plan
Fig.15:Connection steps 6and 7
8Press down the opening levers of the terminals,you will hear the
terminal spring closing
Select connec-
tion cable for Ex
applications
IP 66/IP 67 version
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5Connect to power supply
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9Check the hold of the wires in the terminals by lightly pulling on
them
10 Connect the screen to the internal ground terminal,connect the
outer ground terminal with potential equalisation
11 Tighten the compression nut of the cable entry.The seal ring must
completely encircle the cable
12 Screw the housing cover on
The electrical connection is finished.
5.3Wiring plan,single chamber housing
The following illustrations apply to the non-Ex as well as to the Ex-ia
version.
5 6 7 81 2
Display
I²C
2
1
4
3
Fig.16:Electronics and connection compartment,single chamber housing
1Spring-loaded terminals for voltage supply
2Ground terminal for connection of the cable screen
3Spring-loaded terminals for connection of the external indication Uni-
Com961
4Plug connector for service interface
Electronics and connec-
tion compartment
20 OnC LevelSens 362 •4…20 mA/HARTtwo-wire
5Connect to power supply
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