CAPTROL MODEL 500 MANUAL # 44493 R.F. Capacitance Point Level Switch 1
was started in 1976 to offer new and innovative electronic designs in tank gauging. L&J s new products always used the latest electronics and therefore the company quickly grew. Ten years later L&J bought GPE. Along with GPE, L&J bought, a GPE affiliate that manufactures fittings and valves for the same type of tanks that used the gauging equipment. A short time later, all 3 companies were reorganized under one corporate entity called. In 1994, a brand new, state-of-the-art manufacturing facility was built to bring all of the L&J Technologies manufacturing efforts under one roof. In 1996, L&J bought, a manufacturer of liquid level controls and Hi/Low level switches for the boiler, process, and liquid storage industries. On February 28, 2000, L&J purchased Durlam Associates, (now Durlam Inc.). is located in Houston, Texas and is the leading manufacturer of fiberglass reinforced plastic (FRP) Derakane 470 conservation vents and fittings. On March 31, 2000, L&J purchased Delavan Process Instrumentation in Naugatuck, CT. is a well-established name in ultrasonic, capacitance and microwave point level and continuous level measurement for liquids and solids. Delavan was relocated to L&J Technologies corporate headquarters in Hillside, Illinois. Today, the L&J family of companies is the world s largest manufacturer specializing in the monitoring, management, and control of bulk liquids. L&J provides quality products for the Petroleum, Petrochemical, Chemical, Food, Pharmaceutical, Pipeline, Steel, Water Treatment and Biogas ( ) Industries. Visit L&J Technologies on the internet at www.ljtechnologies.com 2
TABLE OF CONTENTS Page(s) 1.0 Introduction 1.1 Description... 4 1.2 Principle Of Operation... 4 1.3 Ordering Information... 5 2.0 Product Specifications 2.1 Dimensions... 5 2.2 Third Party Approvals... 5 2.3 Electrical Specifications... 6 3.0 Installation 3.1 Unpacking... 6 3.2 Mounting Location... 6 3.3 Mounting Instructions... 6 3.3.1 Installation Procedure... 6 3.4 Wiring Procedure... 7 3.4.1 Relay Wiring Truth Tables... 7 4.0 Adjustment Controls 4.1 Component Description... 7-8 5.0 Calibration 5.1 Board Layout... 8 5.2 Equipment/Requirements... 8 5.3 Calibration Procedure... 8-9 6.0 Troubleshooting 6.1 Introduction... 9 6.2 Electronics Test... 9 6.3 Green LED Flashes... 9 6.4 Self Test... 9-10 6.5 Probe Test... 10 6.6 Calibration Application Test... 10-11 7.0 Spare Parts... 11 8.0 Return Goods Policy... 11 9.0 Repairs... 11 10.0 Product Warranty... 11. 3
1.0 INTRODUCTION The contents in this instruction manual are designed for Delavan's model CAPTROL 500 R. F. Capacitance point level switch. Please review the information contained in this instruction manual carefully to ensure proper operation. 1.1 Description Delavan's CAPTROL model 500 is a microcontroller based on/off R.F. Capacitance single point level switch. It may be used in both powder bulk solids and liquid applications. 1.2 Principle of Operation The CAPTROL model 500 microcontroller based level switch consists of solid state electronics mounted in a cast aluminum explosion proof enclosure and a sensing probe. The CAPTROL 500 responds to a change in the low energy electrical field present on the Active sensing element of the probe, the on-board relay transfers to a field selectable energized or de-energized state. This change is created by the process material level having a greater ground potential as it covers the probe. In electronic terms this is described as capacitance, impedance, or admittance change. ACCUMULATED BUILD-UP on the probe is ignored via Delavan's unique drive guard (shown below). The driven guard produces a force field over the build-up; the ground potential of the build-up is removed leaving only the process level to be detected. The Guard Element should protrude at least one inch into the process beyond the mounting nozzle. Product Build-Up Active Guard Typically, ground referencing the process material is accomplished by threading the probe to a metallic tank. Hence the tank becomes the ground reference for the process material. Non-metallic tanks require a ground reference near the probe for optimum performance. A grounded pipe or plate can serve this purpose. Feel free to review this with Delavan if a vessels ground is in question. The amount of capacitance generated in a given application is dependent upon the dielectric constant of the process material, the distance from the sensing probe to the earth ground, or a ground reference, and by the size (surface area) of the sensing probe. Assuming that the dielectric constant of the process material is consistent, and that the sensing elements mounting location in the vessel is fixed, the amount of capacitance generated is based upon the sensing elements overall size or area. When the process material fluctuates in the vessel, the amount of capacitance generated between the sensing element and the vessel wall or ground also fluctuates. C = Ke x A D CAPACITANCE PLATE DISTANCE CAPACITANCE PLATE Size (area) = in Capacitance Distance = in Capacitance Dielectric = in Capacitance C = Capacitance Ke = Dielectric A = Area D = Distance Force Field Product Build-Up 4
1.3 Ordering Information 2.0 PRODUCT SPECIFICATIONS CAPTROL 500 - - - - 2.1 Dimensions STANDARD GT-0918 18 (457.2mm) 9 (228.6mm) 8.25 (209.5mm) Special Features H = High Temperature 12 Lagging Extension (GT, GC, GTH) 90 = 90 Downward Bend on Probe Active Section S = Sensitivity sleeve, 2 or 5 00 = None 3/4 NPT Wrench on these flats only 3/4 NPT Conduit Access both ends 4.5 R Swing (114.3mm) Process Mounting All Flanges Available 00 =None Sensing Probe Type (Specify insertion length) GIMF = Guarded Injection Molded Fortron, 316 GIMN = Guarded Injection Molded Noryl, 316 Stainless Steel, 14 Length GT = Guarded Teflon, 1/4 Center Rod 316 Stainless Steel, 18 Length GT1/2 = Guarded Teflon, 1/2 Center Rod, 316 Stainless Steel, 6 Length GC GFC GTH GTT GAR THD = Guarded Ceramic, High Temp., (750 F max) = GIMN with 316 Stainless Steel Flexible Cable, (25 ft. max) = Guarded Teflon, 1/4 Center Rod, Hastelloy, 36 or Less = Guarded Teflon, Teflon Sealed Active, 18 Length = Guarded Abrasion Resistant Stainless Steel with Durable Plastic Insulator = Non-guarded, Teflon Sealed Active, (Available Bare) 4.5R SWING (114.3 mm) 3/4 Connduit Green Ground Wire w/ring terminals must bond the two enclosures 6.75 (171.5 mm) 3/4 Conduit Access both ends Probe Connection Diestion Length 3/4 NPT Remote Mount Earth Ground 1 150# RF Flange w/1 NPT Thread Electronic Control Options I = Integrated R = Remote Mounted Electronics with 5ft.Cable (50-ft.max) R10 = Includes: 10-ft. cable 1 Mounting Flange, Enclosure 2.2 Third Party Approvals Model 500 R.F. Capacitance Point Level Switch Third Party Agency Approvals CSA Only for probes THD and KHD Class I, Groups C & D Class II, Groups E, F & G, Division 1 & 2 5
2.3 Electrical Specifications Electrical Specifications Supply Voltage 115, 230 VAC @ 60 Hz 24 VDC Power Consumption < 3 VA Sensitivity Adjustable: 0.5 pf to 10 pf Bulk Solids - 8 Ib./cu.ft. & > Liq. -1.5 dielectric constant &> Output Relay, Form C DPDT 5 amp @ 115 VAC Non Ind. 5 amp @ 230 VAC Non Ind. 3 amp @ 26 VDC Non Ind. Time Delay Adjustable:.1 to 30 seconds Fail-safe Switch selectable - High level or Low level Temperature Range Electronics: (-40 to +71 C) (-40 to +160 C) Enclosure Rating Die Cast Aluminum with fused Polyester paint finish 3.0 INSTALLATION 3.1 Unpacking Remove the CAPTROL 500 carefully from the shipping carton. Check to make certain that no damage has occurred to the electronics or to the sensing probe. If the equipment has been damaged, notify the shipping carrier immediately. 3.2 Mounting Location Meets NEMA 4,5,7,9 & 12 NEC Class I Division II NEC Class II Division II Delavan's CAPTROL model 500 should be installed and mounted in an environment where temperatures are no less than -40 F (-40 C) and no greater than +165 F (+73 C). Normally, when installed in metallic vessels, the vessel wall serves as the ground reference. It is important to the overall operation of the system that a good connection be made between the sensing probe and the vessel. If in doubt, connect a separate ground strapping wire between the CAPTROL 500's housing and the metal vessel. When installed in vessels containing conductive liquids, the location of the probe in relationship to the vessel wall is not critical. When the CAPTROL 500 is used to monitor materials that have low dielectric values (nonconductive materials or materials with a dielectric value < 20) special provisions should be made to locate the sensing probe within 10 inches of the vessel wall. If this cannot be accomplished an artificial ground reference (metal pipe or rod) should be considered. This will enhance the units sensitivity and operation. For applications where the CAPTROL 500 is being used in non-metallic vessels i.e. plastic, fiberglass, or concrete, an artificial ground reference that runs parallel to the sensing probe must be used. Typically, this can be accomplished by mounting a steel plate or steel pipe parallel to the probe. A permanent wire connection from the ground reference to the CAPTROL 500 completes the ground reference. Avoid mounting the ground reference where process material can remain bridged between the active probe element and the ground reference. 3.3 Mounting Instructions Delavan's CAPTROL 500 can be used with both rigid sensing probes and flexible cable style sensing probes. Rigid sensing probes up to 20 inches in length are shipped from the factory pre-assembled to the electronic control unit. Sensing probes over 20 inches in length, as well as, flexible cable style sensing probes, must be assembled in the field. 3.3.1 Installation Procedure The probe equipped with your CAPTROL 500 is a sealed gland. Do not separate the probe bushing during installation or removal. 1. Insert the entire probe assembly into the vessel and torque using a wrench on the smaller hex bushing. Max. torque: 120 ft/lb. Pipe dope or Teflon tape is recommended. 2. Conduit requirements are 3/4" N.P.T. To prevent accumulation of moisture in the CAPTROL 500 housing, conduits should enter from a lower point of elevation. Note: Avoid mounting in the fill stream. Note: Mount at least 24 inches from other Radio Frequency (R.F) probes that are in the same plane. 6
3.4 Wiring Procedure WARNING! DO NOT ATTEMPT TO WIRE THE UNIT WITH LIVE POWER. REMOVE POWER UNTIL CONNECTIONS ARE COMPLETE. Power and relay wiring should comply with NEC (National Electrical Code) standards and specifications. When selecting wire for power and relay connections use a light gauge, 14 to 22 AWG insulated wire. The CAPTROL 500 has a removable "Plug-In" terminal block for wiring convenience. Power Wiring 1. Make certain power is disconnected. 2. Run power wires through conduit. 3. Connect the hot wire to the appropriate terminal, 115 VAC to #2, 230 VAC to #1, or 24 VDC to #4. Connect the common wire to terminal #3 when using 115 or 230 VAC. When using 24 VDC connect the common to #5. Connect an earth ground wire to the housing ground screw. (See wiring terminal below) When a ground reference is required (as described in 3.2), the ground wire can be connected to terminal #5 or to the ground screw in the housing. Wiring Terminal Relay Wiring The relay contacts are form C Dry Contacts. Power must be supplied to the relay contacts, typically, by using a jumper between the power terminal and the common terminal of the relay. 3.4.1 Relay Wiring Truth Tables Fail-safe relay connections can be determined by the following truth tables. RELAY FUNCTION SWITCH LOW FAIL-SAFE POSITION LEVEL LEVEL IS FAULT COVERS BELOW CONDITION PROBE PROBE GRN LED ON ON FLASHING RED LED ON OFF OFF RELAY ENERGIZED DE-ENERG DE-ENERG RELAY N.C. OPEN CLOSED CLOSED RELAY N.O. CLOSED OPEN OPEN RELAY FUNCTION SWITCH HIGH FAIL-SAFE POSITION LEVEL LEVEL IS FAULT COVERS BELOW CONDITION PROBE PROBE GRN LED ON ON FLASHING RED LED OFF ON OFF RELAY DE-ENERG ENERGIZED DE-ENERG RELAY N.C. CLOSED OPEN CLOSED RELAY N.O. OPEN CLOSED OPEN 4.0 ADJUSTMENT CONTROLS 220V 110V Housing Ground #10-32 Screw Isolated Form C Relay Contacts 1 2 3 4 5 6 7 8 9 10 11 220VAC 110VAC NEUT. Low Vol TS 24VOC N.C. C. N.O. N.C. C. N.O. Normally Closed Common Normally Open Normally Closed Common Normally Open 4.1 Component Description Refer to 5.1 for the location of the components. Relay Status: Red LED: Illuminates when the relay is energized. System Status: Green LED: This LED stays illuminated through entire detection process. Flashing Green LED indicates a fault. (See trouble shooting). Note: Relay remains de-energized during fault detection. 7
Cal Button: This push button initializes calibration. When the button is depressed for 2 sec., the probe conditions are stored in memory. This should be performed when the process level is at least 6 inches below the probe. Sensitivity: This single turn potentiometer will adjust the trip point of the electronics for detection of the process material. 0-setting is the highest sensitivity for process materials with a very low ground potential (see calibration). 100- setting is low sensitivity. 5.1 Board Layout CAPTROL 500 ELECTRONICS ASSY INSTRUCTION MANUAL TP1 TP2 RELAY STATUS SYSTEM STATUS 44000 44004 TIME-DELAY SENSITIVITY CAL HIGH FAIL SAFE 220VAC 110VAC NEUT LOW VOLTS 24VOC N.C. C. N.O. N.C. C. N.O. 1 2 3 4 5 6 7 8 9 10 11 HOUSING GROUND RELAY FUNCTION LOW FAIL SAFE 5.2 Equipment/Requirements Fail-Safe/Relay Function: Fail-safe high or fail-safe low does not indicate the physical location of the sensor installed in the vessel. The fail-safe switch is a two position switch that determines if the relay is de-energized when the product is above or below the operation point. Time Delay: This single turn potentiometer will delay the relay up to 30 seconds after detection occurs. Delay acts on both presence and absence of the process level. TP1, TP2 Test Points: Test Points TP1 and TP2 can be used in the Calibration - Application Test to diagnose the process variable (High level - Low level). TP1 will read the active measurement signal produced by the probe and the process material. TP2 will read the sensitivity voltage at which the sensitivity pot is set. See section 6.6 for the Calibration - Application Test Procedure 5.0 CALIBRATION Note: For optimum operation and performance this unit requires calibration after installation. Note: Calibrate when the process level is below the probe at least 6 inches. 5.3 Calibration Procedure Determine the fail-safe mode required for your application. The fail-safe switch position determines if the relay is energized when the product is above or below the operating point. Fail-safe High Level probe Low Level probe Relay De-energized When material covers the When material is below the The calibration is initiated by holding the "CAL" button down for at least two seconds. The Green LED will flash rapidly until programming is complete, (approximately 10 seconds). The Green LED should remain illuminated through the entire "No Fault" operation. Sensitivity can be adjusted or re-adjusted at any time. Use the following examples to determine sensitivity for your application. HIGH SENSITIVITY Dry bulk powders from 8 to 15 lb./cu.ft. Non conductive liquids that have a dielectric value of 5 or less. Set sensitivity potentiometer to 0. MEDIUM SENSITIVITY (Typical applications) Dry bulk powders from 15 to 40 lb./cu.ft. Liquids that have a dielectric value greater than 5 and less than 30. Set sensitivity potentiometer to 20-30. 8
LOW SENSITIVITY Bulk solids with a moisture content of 10% or greater and that have a bulk density of at least 40 lb./cu.ft. Conductive liquids with dielectric values greater than 30. Set sensitivity potentiometer to 50 or greater. Verify operation. Red LED and relay should transfer at the desired detection point. Red LED illuminated = relay energized. If erratic relay operation exists, adjust the time delay potentiometer for appropriate response time. CALIBRATION COMPLETE 6.0 TROUBLESHOOTING ATTENTION: The following procedures will affect the output control circuit. To avoid unintentional machine operations, notify department authorities. CAUTION: Ignition spark hazard. This equipment is not intrinsically safe. If hazardous conditions exist, perform trouble shooting in repair shop or nonhazardous area. 6.1 Introduction The CAPTROL 500 is comprised of two major components: 1. Electronics 2. Probe This section covers three areas: 1. Defective Electronics 2. Defective Probe 3. Calibration - Application Verify the operational truth tables shown in this section: Acknowledge position of the Relay Function switch (High or Low Fail-safe?) Use the appropriate table. RELAY FUNCTION SWITCH LOW FAIL-SAFE POSITION LEVEL LEVEL IS FAULT COVERS BELOW CONDITION PROBE PROBE GRN LED ON ON FLASHING RED LED ON OFF OFF RELAY ENERGIZED DE-ENERG DE-ENERG RELAY N.C. OPEN CLOSED CLOSED RELAY N.O. CLOSED OPEN OPEN RELAY FUNCTION SWITCH HIGH FAIL-SAFE POSITION LEVEL LEVEL IS FAULT COVERS BELOW CONDITION PROBE PROBE GRN LED ON ON FLASHING RED LED OFF ON OFF RELAY DE-ENERG ENERGIZED DE-ENERG RELAY N.C. CLOSED OPEN CLOSED RELAY N.O. OPEN CLOSED OPEN 6.2 Electronics Test: Self diagnostic of the CAPTROL 500 can be observed via system status LED (Green). If the Green LED is illuminated, the output control circuit can be checked by turning the time delay to "0" and sliding the Relay Function Switch back and forth. 6.3 Green LED Flashes: One second flashes indicate: 1. System has lost volatile memory, or 2. System needs calibration. Recalibrate per section 5.3. Two second flashes indicate: 1. Brown out - supply voltage has dropped below operating limits. See specifications in section 2.3. Recalibrate 6.4 Self Test: This test exercises the on-board microcontroller relay and associated latching circuitry. Step 1. Remove power. 9
Step 2. Locate points P4 and P5 on the outer edge of the bottom circuit board. (See the Illustration on page 9) Step 3. Insert a jumper across points P4 and P5. Step 4. Set Relay Function switch to the Low Failsafe position. Step 4. Check resistance between the Guard and the Ground. (A reading greater than 10 meg Ohms indicates the probe is operating properly.) ACTIVE CONNECTION GUARD CONNECTION Step 5. Apply power. The relay and Red LED should cycle every five seconds (5 sec. ON, 5 sec. OFF) Step 6. If the electronics do not respond as described, repair or replacement of electronics is required. Step 7. To return to normal operation, remove power, return jumper to P5 only. Return Relay Function switch to the Fail-safe position for your application. The system is now ready for Power and Calibration. 6.5 Probe Test: SELF TEST COMPLETE The probe equipped with the CAPTROL 500 has three steel elements. Each element is insulated from the other. 1. Ground is the bushing which provides the process connection. 2. Guard is the shorter probe element connected to the electronics by a quick disconnect lug. 3. Active is the center rod, longest element connected to the electronics by a banana connector. Step 1. Remove Power Step 2. Unplug the quick disconnect from the guard and the banana plug from the Active probe element. Step 3. Connect an Ohm meter to the Guard and the Active elements of the probe. Polarity does not matter. A non-covered, or a probe in non-conductive material should have a resistance reading greater than 10 meg Ohms. PROBE TEST COMPLETE 6.6 Calibration - Application Test TP1, TP2 Test Points: To diagnose the process variable (High level - Low level). Connect a DC Voltmeter to Terminal #5 (-) and (+) to the appropriate test point. A positive 0 to 5 VDC signal should be present. TP1 will read the active measurement signal produced by the probe and the process material. The voltage will increase in the positive direction as the process level covers the probe. The voltage will stabilize once the probe is fully covered. This voltage change is referred to as "differential". The illustration on page 10 is an example of an ideal calibration. TP2 will read the sensitivity voltage at which the sensitivity pot is set. TP2 voltage should be 50% of the differential voltage (mid-point) for ideal sensitivity setting. Step 1. To check calibration connect a DC voltmeter(0 to 5V) positive to TP1 and negative to terminal #5. Step 2. Record the voltage when the process level is below the probe. (XXX Volts) Step 3. Push the CAL button. Hold down until the Green LED flashes. 10
Step 4. When flashing stops TP1 voltage should be 0 volts. Record voltage (TP1 CAL XXX Volts). Step 5. Read TP1 when the process level covers the probe. Record (TP1 MAX XXX Volts). Step 6. Move positive lead to TP2. The ideal voltage should be in the center of the TP1 CAL and TP1 MAX or (TP1 MAX - TP1 CAL) 2 = TP2. Step 7. To correct TP2 voltage adjust sensitivity potentiometer accordingly to achieve ideal TP2. Step 8. This should render a dependable detection. TEST POINT VOLTAGES (EXAMPLE) 8.0 RETURN GOODS PROGRAM When returning equipment to Delavan, it is necessary to first obtain a return goods authorization (RG) number. In order for Delavan to provide the most efficient service regarding any equipment being returned, the following information is necessary: 1) Billing & shipping addresses 2) Contact name & phone number 3) Reason for return 4) Purchase order number (for repairs) 5) Brief, but detailed, description of problem or reason for return Authorization may be obtained by contacting either Delavan or your local Delavan representative. 9.0 REPAIRS PROCESS LEVEL BELOW PROBE PROCESS LEVEL COVERS PROBE 0V 1 2 3 4 5V TP1 min. TP1 max............. DIFFERENTIAL VOLTAGE TP2 ALARM POINT ADJUST SENSITIVITY POT TO ACHIEVE 50% OF DIFFERENTIAL VOLTAGE AT TP2 CALIBRATION APPLICATION TEST COMPLETE 7.0 SPARE PARTS DESCRIPTION PART NUMBER 500 Final Assembly 44001 500 Electronic Assembly 44000 500 Enclosure 44208 500 Enclosure Lid 44032-2 500 Enclosure Base 43285-4 500 GIMN Probe 44216-1 500 GIMF Probe 44216-2 500 GT Probe 43399 500 Instruction Manual 44004 Delavan equipment returned for repairs will be repaired or replaced at Delavan's discretion to provide optimum performance. The repair item warranty will be the remainder of the original warranty or 90 days, which ever is greater. A flat rate charge applies to repairs out of warranty. This flat rate repair charge also applies to non-warranty items receiving evaluation only. Items with a list price equal to or less than the flat rate repair charge will be replaced and charged accordingly. The customer will be directed to buy a new or re-manufactured replacement for items that cannot be repaired. 10.0 PRODUCT WARRANTY Delavan level control products will be replaced, put in good operating condition, or the purchase price refunded, at the option of Delavan, free of charges except transportation, if defective in their manufacture, labeling, packaging, or shipping, and if notice of said defect is received by Delavan within one year from the date of shipment. The cost of such replacement repair or refund or purchase price shall be the exclusive remedy for any breach of any warranty, and Delavan shall not be liable to any person for consequential damages for injury or commercial loss resulting from any breach of any warranty, of fitness for a particular purpose, and makes no other warranty, express or implied, including implied warranty arising from course of dealing or usage or trade. 11
REACHING NEW LEVELS IN PROCESS MEASUREMENT 5911 Butterfield Rd. Hillside, IL 60162 PH: (708) 236-6000 FAX: (708) 236-6006 E-MAIL: sales@ljtechnologies.com 12