Echotel Model 3P1 Pump Controller and Ultrasonic Level Transmitter

Transcription

1 Echotel Model 3P1 Pump Controller and Ultrasonic Level Transmitter D E S C R I P T I O N The Echotel Model 3P1 Pump Controller is a full-featured non-contact ultrasonic system designed specifically to provide level measurement and complete control of sumps and wet wells. This versatile system utilizes advanced microprocessor-based electronics along with an Echotel non-contact ultrasonic transducer to provide level measurement and pump control that is not affected by changes in specific gravity, viscosity, or conductivity. The Model 3P1 reliably measures liquids up to 33 feet (10 meters) by utilizing the powerful 38 khz Kynar EchoMaster Ultrasonic transducer. Extensive agency approvals allow this transducer to be installed in a wide variety of applications. F E A T U R E S Front panel keypad and display simplifies programming no need to open enclosure after wiring 4-20 ma isolated (1,000 Ω load) output can be used in active or passive mode RS-485 and RS-232 outputs provide two-way communications utilizing Modbus protocol Eight 10 amp SPDT relays allow for simple alarm configurations to complex pump control including lead/lag alternation of pumps Password code prevents unauthorized tampering of configuration parameters Two-line 16-character alphanumeric display of all configuration and operation parameters Temperature compensation integral to all ultrasonic transducers Menu-driven programming for ease of unit configuration Software totalizer and optional non-resettable 7-digit mechanical totalizer Non-incendive Class I, Division 2, and NEMA 4X rating on the electronics enclosure Class I, Division 1, Groups B, C, & D rating on transducer Analog output signal meets NAMUR NE43 recommendations for 4-20 ma signal levels Complete self-diagnostics assures unit is operating properly by continuously checking transducer and electronics functionality

2 T E C H N O L O G Y The Model 3P1 Pump Controller is a versatile system that utilizes non-contact ultrasonic technology to measure liquid levels in a variety of applications. The system consists of three main components: an ultrasonic transducer, a transmitter, and an interconnecting cable package. The transducer contains a piezoelectric crystal that converts electrical signals generated by the transmitter into ultrasonic pulses. These pulses, or sound waves, are directed through the air toward the liquid surface. They are then reflected off the liquid surface as an echo, and returned to the transducer. The piezoelectric crystal then converts the returned echo into an electrical signal which is analyzed by the transmitter. The elapsed time between the generation of the ultrasonic pulse and the return echo is proportional to the distance between the face of the transducer and the liquid surface. C A P A B I L I T I E S RELIABLE LEVEL MEASUREMENT AND ADVANCED CONTROL FEATURES Sumps and lift station wet wells typically have a level measurement instrument, and a separate PLC or controller to perform various alarm and pump control functions. The Model 3P1 combines both of these functions into one unit. The ultrasonic transducer provides reliable level measurement since it is mounted at the top of the well and does not come in contact with the wastewater. The remote mounted electronics performs advanced pump control, provides extensive alarm capabilities, logs run times and cycle counts of all pumps, and totalizes volumetric flow through the vessel. PUMP CONTROL Six of the eight relays can be used to control pumps. Wear on the pumps is reduced by putting them into either a sequential or equalized time alternation group. In the sequential mode the pumps are operated in a user defined lead/lag pattern. In the equalized time mode the run time of each pump is logged, such that the pump with the least amount of run time is always used first. PUMP EFFICIENCY MONITOR This unique feature monitors each pump cycle to determine if maintenance is needed on the pump or in the wet well. A baseline value is established for each pump by determining the average volumetric throughput over a number of pump cycles. When the pump is a user-defined percentage below this baseline value, a diagnostic relay notifies the operator that maintenance is required. ALARM CAPABILITIES Any of the eight relays can be configured for high or low level alarm points. Two of these relays can also be configured as either system fault or maintenance systems. System fault alarms indicate any problems with the operation of the ultrasonic transducer or the Model 3P1 transmitter. The maintenance alarm notifies the operator when a pump efficiency falls below a user-defined percentage. PUMP DATA LOGGER The pump data logger keeps track of several parameters of each relay selected for pump control. The run time and cycles of each pump, total volume pumped, and all pump efficiency data is stored in the data logger. DUAL DAMPING MODES The Model 3P1 offers different damping times for the fill and drain cycles. Typically there is more turbulence when a sump or wet well is filling than when it is draining or being pumped out. The additional turbulence during the fill cycle may require a longer damping time than the drain cycle. Having two damping times provides additional reliability during turbulent fill cycles, and increased response time while the well is being pumped down. VOLUME TOTALIZER When programmed for volume, the system will calculate and totalize the volumetric flow through the sump or wet well. 2

3 T Y P I C A L M O U N T I N G C O N F I G U R A T I O N S The transducer is mounted above the liquid surface. A minimum dead band distance of 18 inches (460 mm) must be allowed between the face of the transducer and the maximum liquid level. The transducer may be mounted with a wall mount bracket, as shown below, or any other method utilizing the NPT connection. Since the maximum liquid level can often be several feet down from the top of the vessel, it is not always necessary to mount the transducer at the top. Rigid conduit can be used to mount the transducer down into the vessel to avoid submerged pumps, ladders, side walls, or other obstructions. Dead Band 18" (460 mm) minimum 31.5 feet (9.6 m) maximum Span Range 33 feet (10 m) maximum Typical Transducer Mounting in Wet Well or Sump U L T R A S O N I C B E A M A N G L E A 12 conical beam of ultrasonic energy is emitted from the face of the transducer. The transducer should be mounted in a location such that the ultrasonic signal does not touch the side walls or any other obstructions in the well. This is typically accomplished by using a bracket or rigid conduit to mount the transducer in a spot where a strong echo can be received off of the liquid surface. The chart below shows the distance the transducer should be located away from side walls and obstructions. The distances are based on a 6 radius beam at different heights above the liquid surface. The transducer should generally be mounted one foot away from the wall for every 10 feet of height. Distance from 12 Beam Minimum Distance from Transducer Face (feet) Diameter (feet) Wall or Obstruction (inches) 3' 0.6' 4" 6' 1.3' 8" 9' 1.9' 11" 12' 2.5' 15" 15' 3.2' 19" 18' 3.8' 23" 21' 4.4' 26" 24' 5.0' 30" 27' 5.7' 34" 30' 6.3' 38" 33' 6.9' 42" 3

4 T R A N S M I T T E R S P E C I F I C A T I O N S Supply voltage 120 VAC +10%/-15%, Hz 240 VAC +10%/-15%, Hz 24 VDC, ±20% Power consumption 12 watts (without heater) Display Two-line, 16 characters per line alphanumeric LCD Keypad Sixteen (16) button integral to front panel Enclosure material Structural foam thermoplastic Ambient temperature without heater & thermostat -4 to +160 F (-20 to +70 C) with heater & thermostat -40 to +160 F (-40 to +70 C) Analog output signal Active mode 4-20 ma isolated (maximum 1000 Ω loop resistance) Passive mode 4-20 ma isolated (loop resistant dependent on power supply Fail-safe Software selectable for 3.5 ma, 22 ma or Hold Digital Output RS-232 or RS-485 with Modbus Relays Eight 10 amp resistive, SPDT Humidity 99% Non-condensing T R A N S D U C E R S P E C I F I C A T I O N S Material Kynar (PVDF) Frequency 38 khz Maximum range 33 feet (10 meters) from transducer face Maximum span 31.5 feet (9.6 meters) Dead band 18 inches (460 mm) minimum Ambient temperature operational* -40 to +163 F (-40 to +73 C) non-operational +250 F (+121 C) maximum Temperature compensation Automatic over range of sensor operating temperature Operating pressure -10 to +50 psig ( to bar) Beam angle 12 conical (6 radius) Cable length 500 feet (152 meters) maximum between transducer and transmitter * Maximum range is reduced at temperature extremes. Refer to the range calculations on pages 6 and 7. P E R F O R M A N C E S P E C I F I C A T I O N S Response time Accuracy 2 seconds typical ± 0.25% of level span 4

5 A G E N C Y A P P R O V A L S AGENCY MODEL APPROVED APPROVAL CATEGORY APPROVAL CLASSES FM 3P1-X844-10X Non-hazardous NEMA 4X, IP65 Non-incendive Class I, Div. 2; Groups A, B, C & D Class II, Div. 2; Groups F & G Class III 384-XKXX-0XX Non-hazardous NEMA 4X, IP65 Explosion proof Class I, Div. 1; Groups B, C & D Class II, Div. 1; Groups E, F & G Class III CSA 3P1-X844-10X Non-hazardous Type 4X Non-incendive Class I, Div. 2; Groups A, B, C & D Class II, Div. 2; Groups F & G Class III 384-XKXX-0XX Non-hazardous Type 4X, IP XK0X-0XX Explosion proof Class I, Div. 1; Groups B, C & D Class II, Div. 1; Groups E, F & G Class III 384-XK1X-0XX Explosion proof Type 4X, IP XKYX-0XX Class I, Div. 1; Groups C & D Class II, Div. 2; Groups E, F & G Class III These units have been tested to EN and EN and are in compliance with the EMC Directive 89/336/EEC. 5

6 M E A S U R E M E N T R A N G E C A L C U L A T I O N S Ultrasonic non-contact devices are typically rated for a maximum range in ideal conditions. Experience has shown that maximum range must be reduced for certain factors. Although the maximum range rating is somewhat conservative, each application must be evaluated for specific conditions in the tank. Temperature Sensor alignment H O W T O C A L C U L A T E To evaluate the performance of a 3P1 in a particular application, use the chart on page 7, and follow the steps below: 1. Select one condition from each of the operating parameters that best describes your application. 2. Enter the corresponding performance multiplier value in the application column. 3. Multiply all of the selected values together. 4. Multiply step 3 by 33' (maximum potential range); this yields a value that is the maximum allowable measurement range for the application. Pressure Beam spread interference Vapors Surface agitation Air movement Beam spread interference Dust Foam E X A M P L E The vessel is a 20 feet deep wet well. Surface agitation Expect slight agitation from fill line. Performance multiplier 0.9 Vapor and steam A little condensation or fog is expected in the winter due to the temperature difference between the liquid and the air space. Performance multiplier 0.9. Beam interference No interference exists. Performance multiplier 1.0. Transducer alignment The transducer will be perpendicular to the liquid surface. Performance multiplier 1.0. Foam A thin layer of froth occasionally exists on the top of liquid surface. Performance multiplier 1.0. Dust None. Performance multiplier 1.0. Air movement None. Performance multiplier 1.0. Ambient temperature -10 to +100 F. Performance multiplier 1.0. Pressure Atmospheric pressure. Performance multiplier 1.0. Will the Model 3P1 Pump Controller work for this application? C A L C U L A T I O N Multiply all values in the application column: 0.9 x 0.9 x 1.0 x 1.0 x 0.8 x 1.0 x 1.0 x 1.0 x 1.0 x 33 feet (maximum) = 21.4 feet The calculation yields 21.4 feet as the new maximum range. Since the wet well is 20 feet deep, this application will give satisfactory results with the Model 3P1. NOTE: The performance multipliers provided are conservative estimates. Since these factors are subjective, the values have been designed to provide very high confidence of system success. Contact the factory if there are any questions concerning the interpretation of any of these performance multipliers. 6

7 M E A S U R E M E N T R A N G E C A L C U L A T I O N S Operating Parameter Condition Performance Multiplier Smooth, glass-like surface 1.0 SURFACE AGITATION: Surface agitation or waves can degrade the performance. Moderate agitation results in only slight degradation Slight agitation, choppiness 0.9 of performance. The worst case is when the surface is a good Heavy agitation 0.8 reflector, but in the wrong direction. (See also transducer alignment.) Slight vortex (6 ) 0.7 VAPORS AND STEAM: Vapors in the air space, above the process, become apparent, and cause problems when the liquid process No condensation 1.0 temperature is well above the temperature of the airspace. The greater the difference, the more expected vapor problems. The problems result from condensation or layering in the sound path, both of which attenuate the sound signal, degrading performance Little condensation 0.9 Application To avoid these problems, ensure that the vessel is insulated so that vapors are less likely to condense. If a vent is used, be sure that the Much condensation/ vent, which is where condensation will form, is well away from the foggy appearance 0.8 transducer. BEAM SPREAD INTERFERENCE: It is strongly recommended that nothing be allowed within the transducer s beam, except the liquid No interference 1.0 which is being monitored. Often, the signal from the liquid will be strong, compared to the signal from other sources, such as ladder Agitator at speed less than 60 RPM 1.0 rungs, filling process material, support struts, etc. For that reason, Consult some applications may provide satisfactory results, even with Agitator at speed greater than 60 RPM Factory interference. Interference from agitator blades is only an intermittent interference that usually has little effect on performance. Interference outside 4, far from It is recommended there be no interference within the 6 half angle of transducer (in bottom third of range) 0.8 the transducer beam. If interference is unavoidable, make the interference as far as possible from the transducer so that the real signal Interference outside 4, near to at the longest distance is stronger than the interference signal. transducer (in top third of range) 0.5 TRANSDUCER ALIGNMENT: Optimum performance is obtained when the transducer is perfectly aligned. If the process is not perpendicular Beam perpendicular to liquid surface 1.0 to the sound beam, the sound will not reflect properly back to the transducer. The effect is significant. Beam 4 off from perpendicular 0.5 FOAM: Even small thicknesses of foam can attenuate the ultra- No foam 1.0 sound and render the system inoperative. If possible, moving the transducer to an area in the tank where there is less foam will improve Light froth, less than 0.25" thick 0.8 the performance. Thick, heavy-density foams can sometimes produce Light foam, less than 0.5" thick 0.5 a reflection from the top of the foam. The multipliers shown at right are general guidelines. For further assistance consult the factory. Light foam, more than 1" thick 0.1 No dust 1.0 DUST: Dust attenuates the sound and results in poor performance. Haze, barely perceptible 0.7 Even barely perceptible haze in the air can cause significant attenuation. Slight dust 0.4 Heavy dust 0.1 AIR MOVEMENT: The movement of air, as possible in an open top No air movement 1.0 vessel, can create a layer from which the sound will reflect. This will be most noticeable in applications where vapors or steam tend to Open vessel, but transducer below rim 0.8 form. Open air movement in sound path 0.7 AMBIENT TEMPERATURE: The ambient temperature can have a -20 to +140 F (-29 to +50 C) 1.0 significant effect on the sound and on the transducer s capability to transmit and receive sound. The most noticeable effect on the -40 to -20 F (-40 to -29 C) 0.9 transducer is at the temperature extremes to +160 F (+50 to +70 C) 0.9 PRESSURE: Sound requires air molecules to be able to travel. Sound will not travel in a vacuum. Likewise, higher pressures will allow the -10 to +50 psig (0.689 to bar) 1.0 sound to continue without decay, which can cause problems with Consult multiple echoes. Pressures outside above rating Factory Multiply all values together in the application column Multiply by maximum potential range for Model 3P1 X 33' Maximum allowable measurement range for this application = 7

8 D I M E N S I O N A L S P E C I F I C A T I O N S I N C H E S ( M M ) ELECTRONICS 9.50 (241) 6.75 (171) 9.50 (241) (330) 6.00 (152) 3P1 Transmitter: Front View and Side View TRANSDUCERS WITH HOUSING 3/4" NPT 4.63 (118) Dia (76) 2" NPT Process Connection 2.75 (70) 2" NPT Process Connection 4.50 (114) Insertion Length (254) 3.00" (76) Insertion Length Insertion Diameter 2.12" (54) Insertion Diameter 2.12 (54) 384 Transducer with 2" NPT with Housing 8

9 D I M E N S I O N A L S P E C I F I C A T I O N S I N C H E S ( M M ) TRANSDUCERS WITHOUT HOUSING 2" NPT Process Connection 1" NPT Process Connection Insertion Length (254) 2" NPT Process Connection 1" NPT Process Connection Insertion Length (254) 3.00" (76) Insertion Length 3.00 (76) Insertion Length Insertion Diameter 2.12 (54) Insertion Diameter 2.12 (54) Insertion Diameter 2.12 (54) Insertion Diameter 2.12 (54) 384 Transducer with 2" NPT without Housing 384 Transducer with 1" NPT without Housing D I M E N S I O N A L S P E C I F I C A T I O N S I N C H E S ( M M ) OPTIONAL MOUNTING BRACKETS 2" Female NPT (P/N ) 3.00 (76) (736) 3.12 (79) 2" Female NPT (P/N ) 2.00 (50) 3.00 (76) 1.50 (38) 2.00 (50) 6.12 (155) 3.12 (79) (520) (571) 1.50 (38) (520) (571) Wall Mount Bracket Floor Mount Bracket 9

10 T R A N S M I T T E R M O D E L N U M B E R Models available for quick shipment, usually within one week after factory receipt of a purchase order, through the Expedite Ship Plan (ESP) BASIC MODEL 3P1 INPUT POWER VAC, 50/60 Hz VAC, 50/60 Hz 2 24 VDC VAC with heater and thermostat VAC with heater and thermostat SPECIAL OPTIONS 0 None 1 Mechanical totalizer 3 P C O N N E C T I N G C A B L E P A R T N U M B E R CABLE LENGTH IN FEET 10 feet (3 m) minimum, 500 feet (152 m) maximum length. Example: 12 foot cable length = Code

11 M O D E L k H z T R A N S D U C E R M O D E L N U M B E R PROCESS CONNECTION 2 1" NPT, not available with transducer housing code 1 or Y 5 2" NPT TRANSDUCER MATERIAL K Kynar (PVDF) TRANSDUCER HOUSING 0 No housing, 35' (10.7 m) of cable potted into transducer 1 Cast aluminum, NEMA 4X/7/9 housing with 3 4" NPT single conduit, connecting cable ordered separately Y 316 stainless steel, NEMA 4X/7/9 housing with 3 4" NPT single conduit connecting cable ordered separately TRANSDUCER MOUNTING BRACKET 0 No mounting bracket 3 Wall mount bracket for 2" NPT process connection only 4 Floor mount bracket for 2" NPT process connection only TRANSDUCER INSERTION LENGTH 003 3" (76 mm) length " (254 mm) length K 11

12 Q U A L I T Y The quality assurance system in place at Magnetrol guarantees the highest level of quality throughout the company. Magnetrol is committed to providing full customer satisfaction both in quality products and quality service. Magnetrol s quality assurance system is registered to ISO 9001 affirming its commitment to known international quality standards providing the strongest assurance of product/service quality available. E S P Expedite Ship Plan Several Echotel Model 3P1 Ultrasonic Transmitters are available for quick shipment, usually within one week after factory receipt of a purchase order, through the Expedite Ship Plan (ESP). Models covered by ESP service are color coded in the model selection charts. To take advantage of ESP, simply match the color coded model number codes (standard dimensions apply). ESP service may not apply to orders of ten units or more. Contact your local representative for lead times on larger volume orders, as well as other products and options. W A R R A N T Y All Magnetrol electronic level and flow controls are warranted free of defects in materials or workmanship for one full year from the date of original factory shipment. If returned within the warranty period; and, upon factory inspection of the control, the cause of the claim is determined to be covered under the warranty; then, Magnetrol will repair or replace the control at no cost to the purchaser (or owner) other than transportation. Magnetrol shall not be liable for misapplication, labor claims, direct or consequential damage or expense arising from the installation or use of equipment. There are no other warranties expressed or implied, except special written warranties covering some Magnetrol products. For additional information, see Instruction Manual Belmont Road Downers Grove, Illinois Fax Jardin Drive, Units 1 & 2 Concord, Ontario Canada L4K 1X Fax Heikenstraat 6 B 9240 Zele, Belgium Telex Fax Regent Business Ctr., Jubilee Rd. Burgess Hill, Sussex RH15 9TL U.K Fax Copyright 2003 Magnetrol International, Incorporated. All rights reserved. Printed in the USA. Magnetrol and Magnetrol logotype are registered trademarks of Magnetrol International. Performance specifications are effective with date of issue and are subject to change without notice. The brand and product names contained within this document are trademarks or registered trademarks of their respective holders. BULLETIN: EFFECTIVE: August 2003 SUPERSEDES: August 2002