Installation Instructions Spector compact Conductivity Transmitter System LRGT 16-1

Transcription

1 Installation Instructions Spector compact Conductivity Transmitter System LRGT 16-1

2 IMPORTANT NOTES...4 SAFETY NOTES...4 Danger...4 EXPLANATORY NOTES...4 Scope of supply...4 System description...4 Function...5 INSTALLATION...5 Measuring electrode...5 Reduction of length of installation and measuring length (control range)...6 ALIGNING, REMOVING AND MOUNTING OF TERMINAL BOX...8 Align terminal box...8 Remove terminal box...8 Install terminal box...8 WIRING...9 Connecting conductivity transmitter...9 Wiring diagram...10 COMPONENT PARTS...16 COMMISSIONING PROCEDURE...12 Check wiring...12 Set code switch...12 Factory setting...12 Adjust measuring length (control range) and actual value output...12 Check temperature coefficient Tk setting...12 Adjust cell constant...13 Functional test...13 LED display and fault indication

3 TROUBLESHOOTING...15 Fault finding list...15 Changing electronic insert...16 TECHNICAL DATA...16 DIMENSIONS OF LRGT APPLICATION AS CONDUCTIVITY LIMITER AND CONTINUOUS BLOWDOWN CONTROLLER...20 INDUSTRIAL CONTROLLER KS Component parts / front view...20 Designs...20 Wiring...21 Operating structure...22 Configuration level...22 Parameter level...25 Operating level

4 Important Notes Safety Note Use conductivity transmitter system LRGT 16-1 only for monitoring electrical conductivity in liquids. The equipment has to be supplied with 24 V DC from a safety power supply unit (PSU) in accordance with DIN VDE 0106 (safe supply isolation). The PSU must be equipped with an overcurrent protective device according to DIN EN /VDE The transmitter system LRGT 16-1 must only be installed by qualified staff. Qualified staff are those persons who - through adequate training in electrical engineering, the use and application of safety equipment in accordance with regulations concerning electrical safety systems, and first aid & accident prevention have achieved a recognised level of competence appropriate to the installation and commissioning of this critical safety device. Danger When loosening the conductivity transmitter system steam or hot water might escape. This presents the danger of scalding. It is therefore essential not to dismantle the conductivity transmitter system unless the boiler pressure is verified to be zero. Explanatory Notes Scope of Supply LRGT Control electrode with joint ring D 33 x 39 DIN E8P 1 Terminal box with conductivity transmitter 1 Installation manual System Description The LRGT 16-1 is a compact-design conductivity transmitter system consisting of a conductivity electrode, a temperature sensor for detecting the fluid temperature and an integrated conductivity transmitter. The equipment works according to the conductivity measurement two-electrode control principle and provides a conductivity-dependent and temperature compensated measuring current of 4-20 ma. The conductivity transmitter system is designed to measure the electrical conductivity in conductive fluids. If the LRGT 16-1 is connected to the industrial controller type KS 90 the equipment can be used as conductivity limiter and/or continuous blowdown controller in steam boilers, (pressurised) hot-water boilers and condensate systems. Type Approvals TÜV WÜL EG BAF-MUC

5 Function A measuring current of variable frequency flows through the fluid and creates a potential gradient between the measuring electrode and the measuring tube. The potential gradient is evaluated as measuring voltage U U. In order to compensate for polarisation, which would reduce the measuring current, the measuring frequency is adapted accordingly. The resulting measuring current is sensed and transmitted as measuring voltage U I. The electrical conductivity changes as a function of temperature. The resistance thermometer integrated in the electrode measures the fluid temperature and establishes a reference temperature on which the measured values will be based. The electrical conductivity is calculated from the measuring voltages U U and U I and - depending on the adjusted temperature coefficient Tk - is based linearly on the reference temperature 25 C. After converting it into a conductivity-proportional current signal, a current of 4-20 ma is provided for external processing. The cables leading to the measuring electrode, the measuring tube and the resistance thermometer are monitored for interruption and short circuits. In addition, the electronic insert is protected against excessive temperatures in the terminal box. In case of a malfunction the LEDs are permanently illuminated or flashing and the current signal is set to 0 or 0.5 ma. The transmitter is parameterised via code switch. The code switch can also be used for adaptation of the cell constant and triggering a functional test. The electrical conductivity is measured in µs/cm. In some countries use is also made of ppm (parts per million). Conversion: 1 µs/cm = 0.5 ppm. Installation The conductivity transmitter system is designed such that it can be screwed directly into boiler standpipes or suitably tapped flanges. The electrode must be installed such that it is always submerged. The installation in protection tubes is not permitted according to WÜ 100. Ensure a minimum distance of approx. 20 mm between the lower part of the measuring tube and the boiler wall, the smoke tubes, any other metal parts and the low water level (LW). Installation of the Measuring Electrode 1. Check seating surfaces of threads or flange provided on vessel or boiler standpipe. 2. Place ring joint onto the seating surface of the transmitter. Note: Use only ring joint (of stainless steel E8P) D 33 x 39 to DIN 7603 supplied with the electrode. 3. Apply a light smear of silicone grease (e. g. DOW Corning 111 Compound) to electrode thread. 4. Screw conductivity transmitter electrode into threads or flange provided on vessel or boiler standpipe and tighten with a 41 mm open-end spanner. The torque required when cold is 150 Nm. The tapped hole must conform to DIN 3852 part 2, 1" BSP (DIN ISO 228) form X or Y, standard version. The subsequent hole must have a diameter of > 24 mm. 5

6 Reducing length of installation and measuring length (control range) The measuring tube and the electrode can be cut to suit the individual requirements of the installation. Length of installation A [mm] Measuring length L [mm] Possible reduction of length R [mm] 1. Carefully determine the required reduction of length - measured from the bottom end of the measuring tube - and mark this on the measuring tube. 2. Only slacken locking grub screw using a screwdriver size 1.3 for socket-head cap screws. 3. Unscrew measuring tube and cut it to the length marked. 4. Unscrew spacer disc. 5. Mark the reduction of length - measured from the extreme end of the tip - on the electrode tip. 6. Cut electrode tip to length. Cut back mm of the insulation. 7. Screw back the spacer disc onto the electrode tip and fasten fingertight with a 12 mm open end spanner. 8. Screw back measuring tube with a torque of 50 Nm and tighten locking grub screw. Attention! The seating surfaces and threads on the vessel and mounting flanges must be accurately machined.! Do not bend the electrode tip when cutting. Do not subject electrode to physical shocks.! Do not lag the electrode body.! The conductivity transmitter system can be installed horizontally or with a vertical inclination. The measuring surface must be permanently submerged. Tools! 41 mm open-end spanner! 12 mm open-end spanner! Screwdriver size 1.3 for socket-head cap screws! Hacksaw! Flat file, cut 2 6

7 Reducing length of installation and measuring length (control range) 7

8 Aligning, removing and mounting the terminal box Align terminal box 1. Undo cover screws (cross-recess head screws M4) and remove one terminal cover. The arrow on the name plate points towards this cover. 2. Loosen fixing nut using 18 (19) mm open-end spanner and turn terminal box into desired direction (cable outlet). 3. Re-tighten fixing nut with a torque of 30 Nm. 4. Re-install cover, tighten cover screws, ensuring correct seat of the cover gasket. If required you can also remove the terminal box from the electrode and re-install it afterwards. Remove terminal box 1. Loosen cover screws (cross-recess head screws M4) and remove one terminal cover. The arrow on the name plate points towards this cover. 2. Undo fixing screws for cover plate and remove plate. 3. Pull electrode cables from terminal lugs (electronic insert, functional earthing). 4. Loosen fixing nut with 18 (19) mm open-end spanner and remove it. 5. Pull electrode cables through fixing nut. 6. Remove terminal box. Pull all electrode cables through hole for fixing screw. Install terminal box 1. Pull all electrode cables through hole for fixing screw in terminal box. 2. Place terminal box onto electrode and turn it into the desired direction, taking the cable outlet into consideration. Ensure correct seat of the gasket between the electrode and the terminal box. 3. Pull all electrode cables through fixing nut. Screw nut on fixing bolt and tighten with a torque of 30 Nm. 4. Connect electrode cables according to wiring diagram to terminal lugs (electronic insert, functional earthing). 5. Screw back cover plate. Install terminal cover and tighten cover screws, ensuring correct seat of cover gasket. 8

9 Wiring Connect conductivity transmitter The equipment has to be supplied with 24 V DC from a safety power supply unit (PSU) in accordance with DIN VDE 0106 (safe supply isolation). The PSU must be equipped with an overcurrent protective device according to DIN EN /VDE The following steps 1-5 do not apply for equipment fitted with a connector. For wiring use flexible screened control cable, min. conductor size 0.75 mm². 1. Remove terminal strip and pull connecting cable through cable gland. 2. Strip off approx. 40 mm of cable insulation coating and remove approx. 5 mm of conductor end insulation. 3. Carry out wiring in accordance with wiring diagram. 4. Plug in terminal strip. 5. Seal cable entry by tightening cable glands. Use sealing plug to seal off cable glands that are not used. 6. Install terminal cover and tighten cover screws, ensuring correct seat of cover gasket. Tools! Screwdriver size 1 for cross-recess head screws! Screwdriver size 2.5 for slotted screws, completely insulated to VDE 0680! 18 (19) mm open-end spanner 9

10 Wiring diagram Version with terminal strip: Connection of terminal lugs 1-6 (electrode cables) 1, 2 Measuring electrode 3, 4 Measuring tube (mass) 5, 6 Resistance thermometer 10

11 Functional elements Representation without cover plate 11

12 Commissioning Procedure Check wiring 1. Make sure that the conductivity transmitter system is wired in accordance with the wiring diagram. 2. Check that the supply voltage corresponds to the name plate rating. Set code switch The transmitter is parameterised by means of a ten-pole code switch. This code switch can also be used to adjust the cell constant and trigger off the functional test. The individual switch positions can be changed by using e. g. a ball pen. Factory setting S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 ON ON ON OFF ON ON OFF OFF OFF OFF In the following table the factory setting is highlighted in grey: Adjust measuring length (control range) and actual value output Code switch Control range Current output ma = µs/cm [µs/cm at 25 C] 4 ma correspond to 20 ma correspond to OFF OFF OFF ON OFF OFF OFF ON OFF ON ON OFF OFF OFF ON ON OFF ON OFF ON ON ON ON ON During the commissioning procedure (when the supply voltage is applied) the first output will be 4 ma, then the output current increases until it reaches the actual value. Check temperature coefficient Tk setting For a linear compensation of the measured conductivity value based at 25 C the temperature coefficient Tk is set at our works to 2.1 % per C. Once the service temperature is reached you can check this setting by carrying out a comparison measurement - e. g. as part of the commissioning procedure. If there is a deviation between the indicated conductivity and the measured comparison value you can correct the measurement result of the transmitter by adjusting a lower or higher temperature coefficient. Continue modifying the Tk setting until the indicated conductivity value and measured comparison value agree. Code switch Temperature coefficient Tk [%/ C] OFF OFF OFF OFF 0 (no compensation) ON OFF OFF OFF 1.6 OFF ON OFF OFF 1.7 ON ON OFF OFF

13 Code switch Temperature coefficient Tk [%/ C] OFF OFF ON OFF 1.9 ON OFF ON OFF 2.0 OFF ON ON OFF 2.1 ON ON ON OFF 2.2 OFF OFF OFF ON 2.3 ON OFF OFF ON 2.4 OFF ON OFF ON 2.5 ON ON OFF ON 2.6 OFF OFF ON ON 2.7 ON OFF ON ON 2.8 OFF ON ON ON 2.9 ON ON ON ON 3.0 Adaptation of the cell constant The cell constant adjusted at our factory is a characteristic geometric quantity of the equipment and influences the calculation of conductivity. However, during operation this constant can drift, e. g. due to dirt accumulated on the measuring electrode. If the indicated conductivity value deviates from the measured comparative value you can correct the measurement result of the transmitter by re-adjusting the cell constant. Depending on the deviation set code switches 8 or 9 to ON, the cell constant will then change continuously. Observe the conductivity indication and when the indicated value agrees with the comparison measurement set the switch back to OFF. Should an adjustment not be possible remove the transmitter and clean the measuring surface. To restore the factory setting of the cell constant - e. g. after cleaning the measuring surface - set code switches 8 and 9 simultaneously to ON. After approx. 1 sec. switch back to OFF. The factory setting is restored. Code switch Deviation of the indicated 8 9 Function conductivity non OFF OFF No change Indicated value < Measured comparative ON OFF Cell constant increases value Indicated value > Measured comparative OFF ON Cell constant decreases value ON ON Restores factory setting Functional Test Use code switch 10 for performing a functional test. A value is simulated which exceeds the final control range value and a current output of 20 ma is provided. Code switch 10 OFF ON Functional test Normal operation Simulation Final control range value exceeded When the functional test is finished set code switch back to OFF. 13

14 LED Display and Fault Indications A green and a red LED for status and fault indication are provided in the centre of the electronic insert. Normal operation green LED red LED Current output [ma] Conductivity 0 to +10 % of control range lit proportional to measured value Conductivity 90 to 100 % of control range lit proportional to measured value Conductivity 10 to 90 % of control range lit lit proportional to measured value Fault green LED red LED Current output [ma] Value below 0 % setting, flashes 4 ma e. g. electrode exposed Connections to measuring tube/electrode interrupted flashes 0 ma Value above 100 % setting, e. g. control range too small flashes 0 ma Connections to measuring tube/electrode shortcircuited Temperature in terminal box exceeds 85 C flashes 0 ma flashes flashes 0 ma Connection to resistance thermometer interrupted or short-circuited flash alternately 0.5 ma 14

15 Troubleshooting Fault Finding List Equipment does not work Fault: Remedy: Fault: Remedy: Supply voltage failure - no function. Check power supply and all electrical connections. Electronic insert defective. Replace electronic insert. Equipment signals malfunction LED display: Red LED flashing. Current output: 4 ma Fault: Value below 0 % setting, e. g. electrode exposed. Remedy: Check water level and installation. LED display: Red LED flashing. Current output: 0 ma Fault: Connection to measuring tube/electrode interrupted. Remedy: Check electrode cables (electronic insert, terminal lugs 1-4). Replace equipment if necessary. LED display: Green LED flashing. Current output: 0 ma Fault: Value above 100 % setting, e. g. control range too small. Remedy: Adjust larger control range. LED display: Red LED flashing. Current output: 0 ma Fault: Connections to measuring tube/electrode short-circuited. Remedy: Check electrode cables (electronic insert, terminal lugs 1-4). Replace equipment if necessary. LED display: Red and green LEDs flash alternately. Current output: 0 ma Fault: Temperature in terminal box exceeds 85 C. Remedy: Check ambient temperature. Make sure it does not exceed 70 C. LED display: Red and green LEDs flash alternately. Current output: 0.5 ma Fault: Electrical connections to resistance thermometer interrupted or short-circuited or thermometer defective. Remedy: Check thermometer connections (electronic insert, terminal lugs 5 + 6). Replace equipment if necessary. 15

16 Inaccurate readings Fault: Remedy: Indicated conductivity higher than measured comparison value. During commissioning: Reduce temperature coefficient Tk. During operation: Reduce cell constant. Fault: Remedy: Fault: Remedy: Indicated conductivity lower than measured comparison value. During commissioning: Increase temperature coefficient Tk. During operation: Increase cell constant. The measurement result can no longer be adjusted by changing the cell constant. Remove equipment and clean measuring surface. Exchanging electronic insert 1. Undo lid screws and remove both housing lids. 2. Unscrew fixing screws of cover plate and remove the plate. 3. Pull electrode wires from terminal lugs on circuit board. Plug out the lower terminal strip. 4. Undo fixing screws of electronic insert and remove insert. The electronic insert is available as spare part (type LRV 1-40). When ordering please state the version (VS) and material number indicated on the name plate. 5. Install the new electronic insert in reverse order. Tools! Screwdriver size 1 for cross-recess head screws.! Screwdriver size 2.5 for slotted screws, completely insulated to VDE 0680 Technical data Type code Type L R G T Conductivity measurement Closed-loop control Sensor Transmitter Type of measurement (conductimetry = 1) Pressure rating, PN 40 = 6 Design series Service pressure 32 bar at 238 C 16

17 Connection 1" BSP to DIN ISO 228 Materials Screwed housing: Measuring tube/electrode/screw: Electrode rod insulation: PTFE Spacer disc: PEEK Terminal box: aluminium Length of installation / Measuring length / Reduction of length Length of installation A [mm] Measuring length L [mm] Possible reduction of length R [mm] Temperature sensor Resistance thermometer Pt 1000 Cell constant C 0.2 cm -1 Wiring 5pole screw-type terminal strip, removable, conductor size 1.5 mm² or via 5pole connector Cable entry Cable gland with integral cable clamp, 1 x PG 9 (M16), 1 x PG 16 (M20) Protection IP 65 to DIN Max. admissible ambient temperature 70 C Temperature for storage and transport 40 to + 80 C Supply voltage 24 V DC (18-36 V DC) 17

18 Power consumption 3 W Fuse Electronic thermal fuse T max 85 C, hysteresis 2 C Conductivity control range / Actual value output Control range*) [µs/cm at 25 C] 0.5 Current output ma = µs/cm 4 ma corresponds to 20 ma corresponds to Adjustable via code switch. Max. load for actual value output 750 Ω. *) Conversion µs/cm into ppm (parts per million) 1 µs/cm = 0.5 ppm Measurement cycle 1 sec. Accuracy 5 %, referred to measured conductivity without temperature compensation Temperature compensation linear, Tk adjustable via code switch, 0 %/ C, %/ C in steps of 0.1 %/ C Time constant T (measured acc. to DIN 3440) Temperature: 9 sec. Conductivity: 14 sec. 18

19 Dimensions of Conductivity Transmitter System LRGT

20 Application as conductivity transmitter and continuous blowdown controller Use conductivity transmitter system for conductivity limiting (TDS and continuous blowdown control) in steam boilers only in conjunction with industrial controller KS 90. The following describes the configuration and adjustment of the controller KS 90 when used for conductivity (TDS) limiting and continuous boiler blowdown control. Note: The installation manual for the industrial controller KS 90 supplied with the equipment must also be taken into consideration! Industrial Controller KS 90 Functional elements / Front view Yellow LED C lit: Yellow LED H lit: Green LED AL 1 lit: Continuous blowdown valve opens Continuous blowdown valve closes Max. limit exceeded Versions The following versions can be used: Supply voltage 230/115 V AC 24 V AC or

21 Wiring Keep mains cables separate from signal and measuring cables. We recommend twisted and screened measuring cables (screen connected to earth). Connected final elements must be equipped with protective circuits to manufacturer specification. This avoids voltage peaks which can cause trouble to the controller. The instruments must be protected by an individual or common fuse for a max. power consumption of 10 VA per unit (standard fuse ratings, min. 1.0 A). Signal and measurement circuits may carry max. 50 V r.m.s. against ground, mains circuits may carry max. 250 V r.m.s. between terminals. Output 1: Output 2: Output 3: Continuous blowdown valve closes, relay contact closed Continuous blowdown valve opens, relay contact closed Max. limit exceeded, relay contact open 21

22 Operating Structure After switching on mains (1), the controller is initialised (Test, Con1, Con2), then turns into the #OPERATING LEVEL 1 and controls the process. The controller is matched to the control task at the # PARAMETER LEVEL 2 and to the process at the #CONFIGURATION LEVEL 3. The level transfer is done with the key. To exit the operating level, S.I.L. switch LOCK must be open (factory setting). Exit from the parameter level is via timeout (30 s), too. After keying completely through the configuration level, transfer is into operating level (2 configuration not changed) or into initialisation (3 configuration has been changed). Configuration Level Adjustment: Type of input: 4-20 ma, Inl /InH adjustable Controller function: Three-position stepping controller Function of the outputs: Relay 1: valve CLOSED Relay 2: valve OPEN Relay 3: Alarm 1 22

23 Controller Functions Adjustment: Alarm 1: Sensor alarm + limit contact Absolute limit contact Adjustment: Sensor alarm reaction as X < W, i. e. valve closes 23

24 Adjustment:

25 Parameter Level No. Parameter name Symbol Adjustment range 01 Set-point SP 2 Between lower and upper set point limit ( SPL...SPH ) 02 Segment time P t min, adjustment Limit contact 1 low L C L 1 Lower set-point limit SPL Limit contact 1 high L C H Alarm switch. differential for LC 1 S d A , adjustment 1 06 Operation locking L o c 0 07 Lower set-point limit S P L Start of control range ( InL )... Upper set-point limit ( SPH 1 ) 08 Upper set-point limit S P H Lower set-point limit ( SPL + 1 )... End of control range ( InH ) 09 Proportional band P b %, adjustment 10 % 10 Integral time t i 0 11 Derivative time t d 0 12 Actuator response time t t depend. on actuator, e. g. 120 s 13 Min. step time t t p s, adjustment 2.0 s 14 Trigger point separation S H %, adjustment e. g. 10 % 15 Filter time constant t F s, adjustment e. g. 1.0 s 16 Decimal point d P 0 / 1 / 2 (0 = no decimal point) 17 Start of control range I n L ( InH 1 ) 18 End of control range I n H ( InL +1 )

26 The displayed parameter values of SP 2, LCL, LCH, SdA 1, SPL, SPH, InL and InH depend on the decimal point. Specifications in % refer to the span I n L... I n H. First calibrate start and end of the control range (InL, InH) and then the upper and lower set-point limits (SPL, SPH). Conductivity Controller transmitter Control range* [µs/cm at 25 C] I n L S P L I n H S P H If the equipment is used for conductivity limiting purposes set the limit contact low (LCL1) to the predefined max. electrical conductivity value. When this limit is exceeded the green LED for Alarm 1 lights up and relay output 3 opens the burner protection circuit. The adjusted limit value can be retrieved at any time on the parameter level. Relay output 3 does not interlock automatically. The interlocking function must hence be implemented in the follow-up circuit (burner protection circuit), which has to comply with the requirements of DIN VDE Operating Level This level is for process control. Actual (process) value X and set-point W are displayed in manual and automatic modes. Manipulated variable Y is displayed by means of selector key. Manual and automatic modes are switched with Hand/automatic key. 26

27 The set-point in manual mode or set-point and/or manipulated variable in automatic mode can be changed by means of arrow keys. The change is effective after 2 s or by pressing selector key briefly. For manual operation of the continuous blowdown valve first switch to manual operation using the selector key and then switch to manipulated variable Y. Now it is possible to use the arrow keys for manual adjustments. If the measuring current coming from the conductivity transmitter falls below 2 ma or the line has the wrong polarity the following error message will appear: With this error message the continuous blowdown valve will be closed. 27

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