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Instruction Manual

D102748X012

DLC3010 Digital Level Controller
Maintenance & Troubleshooting

May 2018

79

Section 6 Maintenance & Troubleshooting

6‐6‐

The DLC3010 digital level controller features a modular design for easy maintenance. If you suspect a malfunction,
check for an external cause before performing the diagnostics described in this section.

Sensor parts are subject to normal wear and must be inspected and replaced as necessary. For sensor maintenance
information, refer to the appropriate sensor instruction manual.

WARNING

To avoid personal injury, always wear protective gloves, clothing, and eyewear when performing any maintenance
operations.

Personal injury or property damage due to sudden release of pressure, contact with hazardous fluid, fire, or explosion can
be caused by puncturing, heating, or repairing a displacer that is retaining process pressure or fluid. This danger may not
be readily apparent when disassembling the sensor or removing the displacer. Before disassembling the sensor or
removing the displacer, observe the appropriate warnings provided in the sensor instruction manual.

Check with your process or safety engineer for any additional measures that must be taken to protect against process
media.

CAUTION

When replacing components, use only components specified by the factory. Always use proper component replacement
techniques, as presented in this manual. Improper techniques or component selection may invalidate the approvals and
the product specifications, as indicated in table 1‐1. It may also impair operations and the intended function of the device.

Diagnostic Messages

In addition to the output, the LCD meter displays abbreviated diagnostic messages for troubleshooting the digital
level controller. To accommodate two‐word messages, the display alternates between the first and second word. The
meter displays messages simultaneously on the Process Variable and Process Variable Unit lines as shown in figure 6‐1.
Messages on the Process Variable line refer to general device conditions, while messages on the Process Variable Unit
line refer to specific causes for these conditions. A description of each diagnostic message follows.

D

[BLANK]

— If the meter does not appear to function, and the instrument is otherwise functioning correctly, make

sure the digital level controller is configured for the LCD meter. The meter will not function if the

LCD Configuration

selection is “Not Installed.” To check this function, connect the Field Communicator to the digital level controller
and turn it on. From the Online menu, select:

Configure > Manual Setup > Instrument Display > LCD Configuration (2-2-7-1)

For information on setting up the LCD meter see page 49.

A diagnostic test for meter function is also detailed

later

in this section.

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Summary of Contents for FISHER FIELDVUE DLC3010

Page 1: ... a 249 Sensor 20 Mounting the Digital Level Controller for High Temperature Applications 20 Electrical Connections 22 Power Supply 22 Field Wiring 23 Grounding 24 Shielded Wire 24 Power Current Loop Connections 25 RTD Connections 25 Two Wire RTD Connections 25 Three Wire RTD Connections 25 Communication Connections 25 Test Connections 26 Multichannel Installations 26 W7977 2 Alarm Jumper 27 Changi...

Page 2: ...9 Extreme Temperatures 70 Temperature Compensation 70 Section 5 Service Tools 71 Active Alerts 71 Variables 73 Maintenance 77 Section 6 Maintenance and Troubleshooting 79 Diagnostic Messages 79 Hardware Diagnostics 80 Test Terminals 82 Removing the Digital Level Controller from the Sensor 82 Removing the DLC3010 Digital Level Controller from a 249 Sensor 83 Standard Temperature Applications 83 Hig...

Page 3: ...ctuator and accessory installation operation and maintenance To avoid personal injury or property damage it is important to carefully read understand and follow all of the contents of this manual including all safety cautions and warnings If you have any questions about these instructions contact your Emerson sales office or Local Business Partner Conventions Used in this Manual This manual descri...

Page 4: ...can perform several operations with the DLC3010 digital level controller You can interrogate configure calibrate or test the digital level controller Using the HART protocol information from the field can be integrated into control systems or be received on a single loop basis DLC3010 digital level controllers are designed to directly replace standard pneumatic and electro pneumatic level transmit...

Page 5: ...Sensor Instruction Manual D103288X012 D Fisher 249W Cageless Wafer Style Level Sensor Instruction Manual D102803X012 D Simulation of Process Conditions for Calibration of Fisher Level Controllers and Transmitters D103066X012 D Bolt Torque Information D103220X012 D Technical Monograph 7 The Dynamics of Level and Pressure Control D Technical Monograph 18 Level Trol Density Transmitter D Technical Mo...

Page 6: ...in Burst mode to regularly transmit unsolicited process information digitally In multi drop mode the output current is fixed at 4 mA and only digital communication is available Performance Performance Criteria DLC3010 Digital Level Controller 1 w NPS 3 249W Using a 14 inch Displacer w All Other 249 Sensors Independent Linearity 0 25 of output span 0 8 of output span 0 5 of output span Hysteresis 0...

Page 7: ...of troubleshooting variables and Basic trending capability for PV TV and SV LCD Meter Indications LCD meter indicates analog output on a percent scale bar graph The meter also can be configured to display Process variable in engineering units only Percent range only Percent range alternating with process variable or Process variable alternating with process temperature and degrees of pilot shaft r...

Page 8: ...ot Eckhardt displacers available J Level Signature Series Test Performance Validation Report available EMA only for instruments factory mounted on 249 sensor J Factory Calibration available for instruments factory mounted on 249 sensor when application process temperature and density s are supplied J Device is compatible with user specified remote indicator Operating Limits Process Temperature See...

Page 9: ... 220 240 260 280 300 320 340 360 380 400 420 1 00 0 96 0 92 0 88 0 84 0 82 0 80 0 90 0 86 0 98 0 94 NOTES 1 DUE TO THE PERMANENT DRIFT THAT OCCURS NEAR AND ABOVE 260_C N05500 IS NOT RECOMMENDED FOR TEMPERATURES ABOVE 232_C 2 FOR PROCESS TEMPERATURES BELOW 29_C AND ABOVE 204_C SENSOR MATERIALS MUST BE APPROPRIATE FOR THE PROCESS SEE TABLE 1 4 1 G norm TEMPERATURE _C 1 10 1 08 1 06 1 04 1 02 1 01 1 ...

Page 10: ...1 09 1 07 320 280 240 200 160 120 80 40 0 40 80 TORQUE RATE REDUCTION NORMALIZED MODULUS OF RIGIDITY TEMPERATURE _F N05500 N06600 N10276 S31600 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1 00 0 96 0 92 0 88 0 84 0 82 0 80 0 90 0 86 0 98 0 94 G norm 1 NOTE 1 DUE TO THE PERMANENT DRIFT THAT OCCURS NEAR AND ABOVE 500_F N05500 IS NOT RECOMMENDED FOR TEMPERATURES ABOVE 450_F 2 FOR P...

Page 11: ...ent positions as shown in figure 2 5 Construction Materials See tables 1 5 1 6 and 1 7 Operative Ambient Temperature See table 1 4 For ambient temperature ranges guidelines and use of optional heat insulator see figure 2 7 Options J Heat insulator J Gauge glass for pressures to 29 bar at 232_C 420 psig at 450_F and J Reflex gauges for high temperature and pressure applications Table 1 4 Allowable ...

Page 12: ...to PN 100 flanges and size DN 50 with PN 10 to PN 63 flanges 5 Top connection is NPS 1 ring type joint flanged for connection styles F1 and F2 Table 1 7 Cageless Displacer Sensors 1 Mounting Sensor Standard Head 2 Wafer Body 6 and Torque Tube Arm Material Flange Connection Size Pressure Rating 3 Mounts on top of vessel 249BP 4 Steel NPS 4 raised face or optional ring type joint CL150 CL300 or CL60...

Page 13: ...gure 1 4 Style Number of Equalizing Connections STYLE 1 TOP AND BOTTOM CONNECTIONS SCREWED S 1 OR FLANGED F 1 STYLE 2 TOP AND LOWER SIDE CONNECTIONS SCREWED S 2 OR FLANGED F 2 STYLE 3 UPPER AND LOWER SIDE CONNECTIONS SCREWED S 3 OR FLANGED F 3 STYLE 4 UPPER SIDE AND BOTTOM CONNECTIONS SCREWED S 4 OR FLANGED F 4 ...

Page 14: ...Instruction Manual D102748X012 DLC3010 Digital Level Controller Introduction and Specifications May 2018 14 ...

Page 15: ...wing mechanical configurations when received 1 A fully assembled and coupled caged displacer system shipped with the displacer or driver rod blocked within the operating range by mechanical means In this case the access handle figure 2 4 will be in the unlocked position Remove the displacer blocking hardware before calibration See the appropriate sensor instruction manual The coupling should be in...

Page 16: ...emperature application Yes No Calibrate sensor Wire Digital Level Controller Power Digital Level Controller Enter Tag Messages Date and check or set target application data Density Measurement Set Range Values Using Temperature Correction Set Temperature Units Setup specific gravity tables Set Specific Gravity Yes No Yes No Using RTD Yes Setup and Calibrate RTD Enter Process Temperature No 1 1 DON...

Page 17: ...instruction manual Check with your process or safety engineer for any additional measures that must be taken to protect against process media Hazardous Area Classifications and Special Instructions for Safe Use and Installations in Hazardous Locations Refer to the DLC3010 Quick Start Guide D103214X012 that ships with the instrument for Hazardous Area Classifications and Special Instructions for Sa...

Page 18: ...ntroller Orientation Mount the digital level controller with the torque tube shaft clamp access hole see figure 2 4 pointing downward to allow accumulated moisture drainage Figure 2 4 Sensor Connection Compartment Adapter Ring Removed for Clarity PRESS HERE TO MOVE ACCESS HANDLE SLIDE ACCESS HANDLE TOWARD FRONT OF UNIT TO EXPOSE ACCESS HOLE ACCESS HOLE MOUNTING STUDS SHAFT CLAMP SET SCREW ...

Page 19: ...ounting also changes the effective action because the torque tube rotation for increasing level looking at the protruding shaft is clockwise when the unit is mounted to the right of the displacer and counter clockwise when the unit is mounted to the left of the displacer All caged 249 sensors have a rotatable head That is the digital level controller can be positioned at any of eight alternate pos...

Page 20: ...n of the Initial Setup section 3 Remove the hex nuts from the mounting studs Do not remove the adapter ring CAUTION Measurement errors can occur if the torque tube assembly is bent or misaligned during installation 4 Position the digital level controller so the access hole is on the bottom of the instrument 5 Carefully slide the mounting studs into the sensor mounting holes until the digital level...

Page 21: ...XTENSION KEY 58 SHAFT COUPLING KEY 59 SET SCREWS KEY 60 INSULATOR KEY 57 CAP SCREWS KEY 63 MOUNTING STUDS KEY 33 HEX NUTS KEY 34 WASHER KEY 78 1 For mounting a digital level controller on a 249 sensor secure the shaft extension to the sensor torque tube shaft via the shaft coupling and set screws with the coupling centered as shown in figure 2 8 2 Slide the access handle to the locked position to ...

Page 22: ...gure 2 9 for current loop connections Figure 2 9 Connecting a Field Communicator to the Digital Level Controller Loop 230 RL 600 POWER SUPPLY Signal loop may be grounded at any point or left ungrounded A Field Communicator may be connected at any termination point in the signal loop other than across the power supply Signal loop must have between 230 and 600 ohms load for communication Reference m...

Page 23: ...e that the resistance of intrinsic safety barriers if used must be included Field Wiring Note For intrinsically safe applications refer to the instructions supplied by the barrier manufacturer WARNING To avoid personal injury or property damage caused by fire or explosion remove power to the instrument before removing the digital level controller cover in an area which contains a potentially explo...

Page 24: ...over Grounding WARNING Personal injury or property damage can result from fire or explosion caused by the discharge of static electricity when flammable or hazardous gases are present Connect a 14 AWG 2 1 mm2 ground strap between the digital level controller and earth ground when flammable or hazardous gases are present Refer to national and local codes and standards for grounding requirements The...

Page 25: ...Manual Setup you must specify the connecting wire resistance for a 2 wire RTD 250 feet of 16 AWG wire has a resistance of 1 ohm Three Wire RTD Connections 1 Connect the 2 wires which are connected to the same end of the RTD to the RS and R1 terminals in the terminal box Usually these wires are the same color 2 Connect the third wire to terminal R2 The resistance measured between this wire and eith...

Page 26: ...he negative lead to the T connection inside the terminal box 4 Measure Loop current as Voltage on test meter 1000 milliamps example Test meter Voltage X 1000 Loop Milliamps 0 004 X1000 4 0 milliamperes 0 020 X 1000 20 0 milliamperes 5 Remove test leads and replace the terminal box cover Multichannel Installations You can connect several instruments to a single master power supply as shown in figur...

Page 27: ...ailure in the electronics the instrument drives its output to either below 3 70 mA or above 22 5 mA depending on the position HI LO of the alarm jumper An alarm condition occurs when the digital level controller self diagnostics detect an error that would render the process variable measurement inaccurate incorrect or undefined while a HiHi or LoLo PV monitor is enabled At this point the analog ou...

Page 28: ...r Loop Test Field Communicator Service Tools Maintenance Tests Loop Test 3 4 1 2 Loop test can be used to verify the controller output the integrity of the loop and the operations of any recorders or similar devices installed in the loop To initiate a loop test perform the following procedure 1 Connect a reference meter to the controller To do so either connect the meter to the test connections in...

Page 29: ...ART to Analog Signal Converter Product Manual 00809 0100 4754 for complete installation information Figure 2 13 HART Tri Loop Installation Flowchart START HERE DONE Digital level controller Installed Unpack the HART Tri Loop Review the HART Tri Loop Product Manual Set the digital level controller Burst Option Set the digital level controller Burst Mode No Yes Install the digital level controller I...

Page 30: ...available in the HART Burst messages However the Tri Loop cannot be configured to monitor them directly To commission a DLC3010 digital level controller for use with a HART Tri Loop perform the following procedure Table 2 1 Burst Variables Sent by the FIELDVUE DLC3010 Burst Option Variable Variable Burst 1 Burst Command Read PV Primary Process variable EU 1 Read PV mA and Range Loop Current Proces...

Page 31: ...es not affect the way other data is accessed Liquid Level Interface Level or Liquid Density Indicates the type of measurement either level interface the interface of two liquids of different specific gravities or density measures the liquid specific gravity The process variable displayed and measured depends on the entry for PV is under PV Setup Process Temperature When the process temperature is ...

Page 32: ... and Lower Range Value Action is DIRECT if the Upper Range Value is greater than the lower range value Action is REVERSE if Lower Range Value is greater than Upper Range Value D Level Offset is the Primary Variable value you want the instrument to report when physical level is at the bottom of displacer It is only available in Level or Interface measurement mode D Set Level Offset adding a level o...

Page 33: ...y the instrument and sensor combination D Date is a user defined variable that provides a place to save the date of the last revision of configuration or calibration information D Description is a longer user defined electronic label to assist with more specific controller identification than is available with the HART tag D Message is a user defined means for identifying individual controllers in...

Page 34: ...he network is in Multi Drop alarm annunciation is disabled and the device is not directly driving any effector so jumper setting is not a concern Refresh Jumper allows you read the alarm jumper position Signal Levels displays the signal saturation or alarm conditions via Analog Output D Security To setup and calibrate the instrument Write Protect must be set to Not Write Protected Write protection...

Page 35: ...and the lever assembly will be locked Before placing the unit in service couple the instrument to the sensor then unlock the lever assembly When the sensor is properly connected and coupled to the digital level controller establish the zero process condition and run the appropriate zero calibration procedure under Partial Calibration The Torque Rate should not need to be re calibrated To review th...

Page 36: ...eft of the displacer Use Manual Setup to locate and modify individual parameters when they need to be changed Preliminary Considerations Write Protect Field Communicator Overview Device Information Alarm Type and Security Security Change Protection 1 7 3 2 2 To setup and calibrate the instrument Write Protect must be set to Not Write Protected Write Protect is reset by a power cycle If you have ju...

Page 37: ...ial card See serial card 249VS Std 343 13 5 249W 203 8 01 1 Moment arm driver rod length is the perpendicular distance between the vertical centerline of the displacer and the horizontal centerline of the torque tube See figure 4 2 If you cannot determine the driver rod length contact your Emerson sales office or Local Business Partner and provide the serial number of the sensor 2 This table appli...

Page 38: ... displacer size The default upper range value is set to equal the displacer length and the default lower range value is set to zero when the level offset is 0 b If you choose Liquid Density the default process variable units are set to SGU Specific Gravity Units The default upper range value is set to 1 0 and the default lower range value is set to 0 1 5 Select the desired output action Direct or ...

Page 39: ...t the displacer to the lowest possible process condition i e lowest water level or minimum specific gravity or replace the displacer by the heaviest calibration weight Note Interface or density applications with displacer torque tube sized for a small total change in specific gravity are designed to be operated with the displacer always submerged In these applications the torque rod is sometimes r...

Page 40: ... units of measure for the displacer volume in liters cubic inches cubic millimeters or milliliters D Weight selects the units of measure for the displacer weight in grams kilograms pounds or ounces D Torque Rate selects the torque rate units in lbf in per deg pounds force inches per degree rotation newton m per deg newton meters per degree rotation or dyne cm per deg dyne centimeters per degree ro...

Page 41: ... the selected torque tube material and modify the stored torque rate by that factor The calibration should then be more accurate at the target process temperature with a corresponding degradation at 70_F It is recommended that you document this action by entering appropriate text in the Description and or Message fields of the device configuration to facilitate reversing the compensation later and...

Page 42: ...nits selection in the Sensor Units menu D Damping changes the response time of the controller to smooth variations in output readings caused by rapid changes in input Determine the appropriate damping setting based on the necessary response time signal stability and other requirements of the loop dynamics of your system The default damping value is 0 2 seconds and can be reset to any value between...

Page 43: ... is equal to the Lower Range Value D Change Action allows you to change the analog output action Direct Reverse For Reverse action the Upper Range Value and Lower Range Value will be swapped D Level Offset is the Primary Variable value you want the instrument to report when physical level is at the bottom of displacer Note Level Offset and Set Level Offset are only available in Liquid Level or Int...

Page 44: ... the target process temperature This value will be used by any SG compensation tables that the user has entered If no compensation tables are active the Digital Process Temperature value may be used to document the process temperature at which the instrument was calibrated or the process temperature for which the stored torque rate is pre compensated The Process Temperature value may be edited dir...

Page 45: ...pper process fluid when Primary Variable is Interface Level Lower Fluid Density indicates the density of the lower process fluid when Primary Variable is Interface Level or indicates the difference between densities of lower and upper process fluids when Primary Variable is Liquid Level View Edit SG Tables allows you to review or edit the configuration of density temperature compensation for the u...

Page 46: ...ng your own table 1 Establish a table for the fluid s you are using over the expected operating range of process temperature This allows you to make best use of the maximum of ten points to obtain the accuracy you require If your fluid specific gravity is very linear over the operating temperature range two data points may be sufficient The correction algorithm provides linear interpolation betwee...

Page 47: ...c gravity entered under PV Setup or the values from the specific gravity tables 4 When finished measuring specific gravity return the control loop to automatic control View Edit SG Tables allows you to review or edit the configuration of density temperature compensation Load Steam Tables is only visible if PV is Interface Level Table 4 3 lists example entries for saturated steam Figure 4 5 is the ...

Page 48: ...y be up to 16 characters long and has no impact on the operation of the controller or HART based communicator D Message provides the most specific user defined means for identifying individual controllers in multi controller environments it allows for 32 characters of information and is stored with the other configuration data Message has no impact on the operation of the controller or the Field C...

Page 49: ...isplay Field Communicator Configure Manual Setup Instrument Display 2 2 7 Follow the prompts on the Field Communicator display to view or edit what is visible in the instrument display D LCD Configuration Select this parameter to indicate if the meter is installed If the meter is physically installed select Installed then send the change to the instrument When switching the setting from Not Instal...

Page 50: ...n display as many decimals places as will fit If PV Proc Temp or PV Range is selected the display alternates every two seconds between the selected readings The meter also simultaneously displays the analog output signal using a percent of scale bar graph around the perimeter of the display face as shown in figure 4 6 no matter what display type is selected Figure 4 6 LCD Meter Display WHEN PRESEN...

Page 51: ... is cleared See figure 4 10 D PV HiHi Threshold Primary Variable HiHi Threshold is the value of the process variable in engineering units which when exceeded sets the Primary Variable High High Alert D Manage HiHi Alert Method to coordinate Hi Hi alert configuration with alarm jumper and other alerts D Hi Enable On or Off High Enable activates checking the primary variable against the PV High Thre...

Page 52: ...in figure 4 8 HiHi Alert enabled High Current alarm jumper position Direct action To keep a vessel from overflowing when the control valve is in the inflow pipe you will want to close the valve If the fill valve opens for an increasing current signal you would select Plot B in figure 4 8 HiHi Alert enabled Low Current alarm jumper position Reverse action If the device is driving the input to a con...

Page 53: ...HIHI THRESHOLD 9 m ALARM SETTING LOW OUTPUT ACTION REVERSE RANGE 10 TO 0 m PV HIHI ALERT ENABLED HIHI THRESHOLD 9 m ALARM SETTING LOW OUTPUT ACTION DIRECT RANGE 0 TO 10 m PV HIHI ALERT ENABLED HIHI THRESHOLD 9 m ALARM SETTING HIGH OUTPUT ACTION REVERSE RANGE 10 TO 0 m NAMUR NE 43 HIGH ALARM LEVEL NAMUR NE 43 LOW ALARM LEVEL 24 22 20 18 16 14 12 10 8 6 4 2 2 0 2 4 6 8 10 12 2 0 2 4 6 8 10 12 24 22 ...

Page 54: ...ent with a very low process When Output Action is Reverse these relationships are swapped See figure 4 7 and 4 9 and examples below to clarify the shape of the Analog Output transfer function under various PV alert configurations Note that the Low Alarm Current capability is not NAMUR NE 43 compliant Examples If the device is driving a valve in a series analog loop you would normally want to use a...

Page 55: ...SHOLD 2 m ALARM SETTING LOW OUTPUT ACTION REVERSE RANGE 10 TO 0 m NAMUR NE 43 LOW ALARM LEVEL 24 22 20 18 16 14 12 10 8 6 4 2 2 0 2 4 6 8 10 12 24 22 20 18 16 14 12 10 8 6 4 2 2 0 2 4 6 8 10 12 NAMUR NE 43 HIGH ALARM LEVEL NAMUR NE 43 HIGH ALARM LEVEL PV LOLO ALERT ENABLED LOLO THRESHOLD 2 m ALARM SETTING HIGH OUTPUT ACTION DIRECT RANGE 0 TO 10 m NAMUR NE 43 LOW ALARM LEVEL PLOT A PLOT B PLOT C PL...

Page 56: ...ble On or Off Instrument Temperature High Enable activates checking of the instrument temperature against the Instrument Temperature High Threshold Instrument Temperature High Alert is set if the instrument temperature rises above the Instrument Temperature High Threshold Once the alarm is set the instrument must fall below the Instrument Temperature High Threshold by the Temperature Deadband befo...

Page 57: ...Low Alert is set if the process temperature falls below the Process Temperature Low Threshold Once the alert is set the process temperature must rise above the Process Temperature Low Threshold by the Temperature Deadband before the Alert is cleared See figure 4 11 D Lo Threshold Process Temperature Low Threshold is the process variable temperature in temperature units which when violated will set...

Page 58: ...od of the sensor SG The density of the process fluid normalized to the density of water at reference conditions The scale factor that transforms displacer volume and measured buoyancy into a level signal normalized to displacer length Displacer Length The scale factor to convert normalized level to level on the displacer in engineering units Level Offset The zero reference for the output of the PV...

Page 59: ...o Point Calibration This procedure uses independent observations of two valid process conditions together with the hardware dimensional data and SG information to compute the effective torque rate and zero reference angle for the sensor The two data points can be separated by any span between a minimum of 5 to 100 as long as they remain on the displacer Within this range the calibration accuracy w...

Page 60: ... to that indicated on the next prompt The suggested weight is equivalent to the effective displacer weight when the liquid is at its highest level or the displacer is suspended in the liquid with the higher specific gravity You may use a smaller weight for greater separation between data points so long as you don t hit the upper travel limit 4 After allowing the system to stabilize enter the actua...

Page 61: ... is coupled to torque tube coupling access door is closed and the displacer is completely dry if the PV is set to Interface Level or the process input is at the zero level condition if the PV is set to Liquid Level Note If the handle on the coupling access door is in the position towards the front of the transmitter the coupling access hole is open and the lever is locked pinned in the neutral tra...

Page 62: ...using temperature or process temperature as appropriate The instrument should be at a steady state condition with respect to that temperature when performing the procedure Note The effectiveness of the instrument electronic temperature compensation depends upon the accuracy of the electronics temperature offset stored in the NVM non volatile memory If the electronics temperature is incorrect the t...

Page 63: ...ect Proceed and continue to step 5 If they are not correct select Change and return to step 2 5 Connect a reference meter across the test connections in the terminal box See the Test Connections procedure in the Installation section You can also connect a reference meter in the loop as shown in figure 2 9 6 The Field Communicator commands the instrument to set its output to 4 mA or the low output ...

Page 64: ...nerally be enough for a 14 inch displacer on a 249B because the amount of displacer rise expected for that configuration is about 0 6 inch Accept this as the Max condition Adjust the test fluid level and check the instrument display and current output against external level at several points distributed across the span to verify the level calibration a To correct bias errors Trim Zero at a precise...

Page 65: ...k correctly at the actual process conditions when in interface or density mode because they back compute the theoretical zero buoyancy angle instead of capturing it If it is necessary to use the Partial Calibration methods when the displacer is overweight the following transformation may be used An interface or density application can be mathematically represented as a level application with a sin...

Page 66: ...u can move the level even 10 Theoretical If the level cannot be changed at all you can enter a theoretical value for torque tube rate manually then Trim Zero to adjust the output to the current independent observation of the process condition Gain and bias errors will exist with this approach but it can provide nominal control capability Keep records of subsequent observations of actual process ve...

Page 67: ...cy of the method increases as the two points are moved farther apart but if the level can be adjusted up or down a minimum 5 span it is enough to make a calculation Most level processes can accept a small manual adjustment of this nature If your process cannot then the theoretical approach is the only method available 1 Determine all the information you can about the 249 hardware 249 type mounting...

Page 68: ... calibration They will be less accurate for the long torque tubes 249K L N VS and P especially with thin wall constructions If you are unable to perform a sensor calibration during installation you may enter the values into the instrument at the following menu item in the handheld Configure Manual Setup Sensor Torque Tube Change Torque Rate 2 2 1 3 5 If you select Find default from nameplate data ...

Page 69: ...use the zero buoyancy condition will occur with the linkage driven hard into a travel stop In interface measurement mode it becomes impossible to Capture Zero One simple and effective solution is to use Level measurement mode Capture Zero at the lowest process condition instead of zero buoyancy and enter the differential SG SGlowerfluid SGupperfluid The algorithm then computes level correctly At D...

Page 70: ...ess Conditions for Calibration of Fisher Level Controllers and Transmitters instruction manual supplement D103066X012 available from your Emerson sales office or Local Business Partner or at www fisher com Temperature Compensation If the process temperature departs significantly from calibration temperature you will need to apply a correction factor Interpolate the correction factor from the mater...

Page 71: ...odule 3 If not replace instrument Check warranty status D F Sensor Signal Failed The instrumentation amplifier output for the torque tube position is outside of range If this message appears 1 Check whether instrument lever assembly is being driven to a mechanical stop by the sensor linkage 2 If so correct the coupling configuration 3 Otherwise replace instrument or electronics module as appropria...

Page 72: ...as accidentally left in loop test exit fixed current mode D A Cold Start A power cycle or device reset has occurred If this message appears 1 If event was unexpected check condition of loop wiring and power supply 2 Check the terminal box integrity and instrument function over the range of environmental conditions being experienced D A Instrument Temperature Too Low When active indicates that the ...

Page 73: ... violation of process limits 2 Take remedial action for any process stream quality or overflow incurred 3 Check calibration of instrument 4 Check for appropriate value of Alert Threshold D A PV Hi Alert When active indicates that the Process Variable has exceeded the value of the Process Variable High Alert Threshold If this message appears 1 Correct the out of limits process condition 2 Check cal...

Page 74: ...es PV range PVEU LRV URV LRV 100 where PVEU process variable in engineering units The LRV always represents the 0 range value and the URV always represents the 100 range value Note In the DLC3010 the Range signal that is reported via HART signalling is back calculated from the Analog Output signal instead of the Analog Output being calculated from the Range Therefore the Range value reported in th...

Page 75: ...Level or Liquid Density Note If the driver rod is on the lower travel stop at dry condition use Liquid Level as the PV and the difference between densities of lower and upper process fluids for Lower Fluid Density Driver Rod Length is the recorded driver length in Mechanical Gain is the mechanical gain of the sensor lbf deg CompensatedTorqueRate DriverRod Displacer Weight is the recorded weight lb...

Page 76: ...ment coupled with the displacer is removed or if there is a severely bent or broken flexure If 1230 mV the Hall sensor input circuit is open or shorted to the high side If very erratic at steady process condition the transducer circuit card is bad Hall Sensor Drive is the diagnostic measurement of the Hall sensor bias current usually near 725 uA Processor is the execution cycle diagnostics menu Fr...

Page 77: ...ay mode Loop Test used to verify the controller output the integrity of the loop and the operations of any recorders or similar devices installed in the loop To initiate a loop test perform the following procedure 1 Connect a reference meter to the controller To do so either connect the meter to the test connections inside the terminal box see the Test Connections procedure or connect the meter in...

Page 78: ... input zero reference assuming that the calibration gain is accurate Use this procedure when the process cannot be moved to zero for capture but gain is known to be correct only a bias error exists Secondary Calibration The following contains a brief overview of the Secondary Calibration procedures Refer to the Calibration section starting on page 58 for detailed calibration information Temperatur...

Page 79: ...nents specified by the factory Always use proper component replacement techniques as presented in this manual Improper techniques or component selection may invalidate the approvals and the product specifications as indicated in table 1 1 It may also impair operations and the intended function of the device Diagnostic Messages In addition to the output the LCD meter displays abbreviated diagnostic...

Page 80: ...e to be displayed by the meter For example if the meter is measuring a level greater that 99 999 mm and the meter decimal point is set to 3 digit precision the meter will display an OFLOW message because it is only capable of displaying a maximum value of 99 999 when set to 3 digit precision The position of the decimal point may be adjusted by using the Field Communicator From the Online menu sele...

Page 81: ...er range values Check actual process condition and calibration adjustments Fixed Output 20 5 mA High Saturation Connect the Field Communicator and see item 12 above Fixed Output 22 5 mA Alarm Condition Fail high setting Connect the Field Communicator and see items 10 and 11 above Fixed Output 22 5 mA Loop Wiring 13 Check for short circuits Terminal Box 14 Remove terminal box from the instrument an...

Page 82: ...e loop current These terminals are across an internal 1 ohm resistor that is in series with the loop 1 Remove the terminal box cap 2 Adjust the test meter to measure a range of 0 001 to 0 1 volts 3 Connect the positive lead of the test meter to the connection and the negative lead to the T connection inside the terminal box 4 Measure Loop current as Voltage on test meter 1000 milliamps example Tes...

Page 83: ... on the access handle until it is flush with the handle surface Press on the back of the handle as shown in the figure and slide the handle toward the front of the unit the locked position to expose the access hole Be sure the locking handle drops into the detent Note If the access handle will not slide the sensor linkage is most likely in an extreme position When the lever assembly is at a hard s...

Page 84: ... side or if the instrument had been coupled to the sensor while the displacer was not connected To correct this condition manipulate the sensor linkage to bring the lever assembly to within approximately 4 degrees of the neutral position before attempting to slide the handle A probe inserted through the top vent of the 249 head may be required to deflect the driver rod to a position where the leve...

Page 85: ...transducer housing In explosive atmospheres do not remove the instrument cover when the circuit is alive unless in an intrinsically safe installation 3 Loosen the two screws that anchor the LCD meter to the Electronics Module These screws are captive and should not be removed 4 Firmly grasp the LCD meter and pull it straight away from the Electronics Module Retain the six pin dual header for later...

Page 86: ...cs Module Perform the following procedure to remove the Electronics Module Note The electronics are sealed in a moisture proof plastic enclosure referred to as the Electronics Module The assembly is a non repairable unit if a malfunction occurs the entire unit must be replaced WARNING On an explosion proof instrument remove the electrical power before removing the instrument covers in a hazardous ...

Page 87: ...ions Unless indicated otherwise refer to figure 7 3 WARNING On an explosion proof instrument remove the electrical power before removing the instrument covers in a hazardous area Personal injury or property damage may result from fire and explosion if power is applied to the instrument with the covers removed Removing the Terminal Box 1 Loosen the set screw key 31 in the terminal box cover assembl...

Page 88: ...n 0 88 NSm 7 8 lbfSin 8 Apply lubricant to the conduit entrance plug key 28 and install it in the unused conduit entrance Removing and Replacing the Inner Guide and Access Handle Assembly The access handle and inner guide are located on the transducer housing Unless indicated otherwise refer to figure 7 2 1 Remove the digital level controller from the sensor as described in Removing the Digital Le...

Page 89: ... zero locking pin engages the lever assembly Also check for free travel of the lever assembly when the handle is in the unlocked position 11 Install the coupling shield key 16 and secure with the two screws key 13 Tighten the screws to 0 48 NSm 4 2 lbfSin 12 Refer to figure 7 1 Install the adapter ring key 32 on the studs key 33 and secure with hex nuts key 34 13 When re installing the digital lev...

Page 90: ...e lever mounting bolt 3 Hold lever assembly by coupling block and guide the flexure block into its aligning slot in the housing without applying any downward force to the sprung parts of the lever assembly CAUTION To prevent damage to the flexure when inserting the flexure block into its aligning slot in the housing apply pressure to the flexure block only A long pin inserted into the bolt hole in...

Page 91: ...neilan 12100 12800 Series with heat insulator D Masoneilan 12200 12300 Series D Masoneilan 12200 12300 Series with heat insulator D Yamatake Honeywellt Type NQP D Yamatake Honeywell Type NQP with heat insulator D Foxboro Eckardt 134LD and 144LD D Foxboro Eckardt 134LD and 144LD with heat insulator D Foxboro Eckardt LP167 D Foxboro Eckardt LP167 with heat insulator Note Contact your Emerson sales o...

Page 92: ...ssembly dual row not shown 2 4 5 40 Screw captive For LCD meter 2 req d 5 66 Anti Seize Sealant not furnished with instrument 67 Thread locking adhesive medium strength not furnished with instrument 70 Lithium grease not furnished with instrument NOTES 1 INSTALL ALARM JUMPER KEY 35 ON ELECTRONICS ASSEMBLY KEY2 WHEN LCD METER KEY 4 IS NOT INSTALLED 2 LOCATION OF ALARM JUMPER KEY 35 WHEN LCD METER K...

Page 93: ...ealant 76 Clamp Nut 2 6 77 Spring Lock Washer 2 6 79 Transducer Board Assembly 1 80 Hall Guard 81 Compound silicone 82 Bolt lock coupling block 6 Figure 7 2 DLC3010 Digital Level Controller Transducer Assembly GE18497 31 77 76 82 Recommended spare parts 1 These parts are not replaced in the field due to serialization and characterization issues but can be replaced at a qualified service center or ...

Page 94: ...req d 2 25 Wire Retainer 8 req d 2 26 O Ring 3 27 O Ring 3 28 Pipe Plug 65 Lubricant Silicone not furnished with instrument 66 Anti Seize Sealant not furnished with instrument Terminal Box Cover Assembly figure 7 4 30 Label internal 31 Set Screw hex socket 2 64 Label external Figure 7 4 Terminal Box Cover Assembly 28B5531 C Recommended spare parts 2 Included in small hardware spare parts kit 3 Inc...

Page 95: ... 5 57 Heat Insulator 58 Shaft Extension 59 Shaft Coupling 60 Set Screw hex socket 2 req d 61 Screw hex hd 4 req d 78 Washer plain 4 req d Key Description Masoneilan Sensors figures 7 6 and 7 7 12100 or 12800 without Heat Insulator 58 Shaft Extension 59 Shaft Coupling 60 Set Screw hex socket 2 req d 61 Screw hex hd 4 req d 62 Mounting Adapter 63 Screw hex socket 4 req d 12100 or 12800 with Heat Ins...

Page 96: ...lator 29B8445 A Key Description 12200 or 12300 without Heat Insulator 58 Shaft Extension 59 Shaft Coupling 60 Hex Socket Screw 2 req d 62 Mounting Adaptor 74 Hex Nut 4 req d 75 Hex Cap Screw 4 req d Key Description 12200 or 12300 with Heat Insulator 57 Heat Insulator 58 Shaft Extension 59 Shaft Coupling 61 Hex Cap Screw 4 req d 60 Hex Socket Screw 2 req d 62 Mounting Adaptor 74 Hex Nut 4 req d 75 ...

Page 97: ... req d 71 Hex Socket Screw 3 req d 72 Shaft Adapter 73 Hex Socket Screw 2 req d 78 Washer plain 4 req d Key Description Foxboro Eckardt Sensors 144LD without Heat Insulator 58 Shaft Extension 59 Shaft Coupling 60 Set Screw hex socket 2 req d 62 Mounting Adapter 74 Hex Nut 4 req d 75 Hex Cap Screw steel 4 req d 144LD with Heat Insulator 57 Heat Insulator 58 Shaft Extension 59 Shaft Coupling 60 Set ...

Page 98: ...Instruction Manual D102748X012 DLC3010 Digital Level Controller Parts May 2018 98 ...

Page 99: ...e 0 5 mA 0 5 mA 1200 Hz 1 2200 Hz 0 AVERAGE CURRENT CHANGE DURING COMMUNICATION 0 ANALOG SIGNAL 0 A6174 The HART protocol allows the capability of multidropping networking several devices to a single communications line This process is well suited for monitoring remote applications such as pipelines custody transfer sites and tank farms Multidrop Communication Multidropping refers to the connectio...

Page 100: ...liquid Changes in the buoyancy of a displacer suspended in a vessel vary the load on a torque tube The displacer and torque tube assembly constitute the primary mechanical sensor The angular deflection of the torque tube is measured by the instrument transducer which consists of a magnet system moving over a Hall effect device A liquid crystal display LCD meter can display the analog output proces...

Page 101: ...LY LEVER ASSEMBLY TERMINAL BOX TERMINAL BOX COVER HOUSING COVER ADAPTER RING TRANSDUCER BOARD Figure A 4 FIELDVUE DLC3010 Digital Level Controller Principle of Operation LCD Meter Transducer Module Processor Module Torque Tube Rotation Linearization Data resident in NVM Terminal Box RTD Process Temperature Interface Loop HART Interface Electronics Temperature Shaft Position Transducer Sensor E0378...

Page 102: ... the lever assembly changing the magnetic field that is sensed by the Hall effect sensor The sensor converts the magnetic field signal to an electronic signal The microcontroller accepts the electronic signal which is ambient temperature compensated and linearized The microcontroller can also actively compensate for changes in liquid specific gravity due to changes in process temperature based on ...

Page 103: ... 22 5 mA Output during Alarm with Alarm Jumper in Lo Position 3 7 mA Output Saturated 20 5 mA Normal Operation Output mA PV Range E0379 Note The upper alarm value is compliant with NAMUR NE 43 but the lower alarm value is not If using in a system with NAMUR NE 43 compatibility the high alarm value may be an appropriate choice Other circuits in the digital level controller provide reverse polarity ...

Page 104: ...Instruction Manual D102748X012 DLC3010 Digital Level Controller Principle of Operation May 2018 104 ...

Page 105: ...nces are included for common DLC3010 digital level controller functions Also included are Field Communiator menu trees D Fast key sequences see table B 1 D Hot Key menu see figure B 1 D Overview menu see figure B 2 D Guided Setup menu see figure B 3 D Manual Setup menu see figure B 4 D Alert Setup menu see figure B 5 D Calibration menu see figure B 6 D Service Tools menu see figure B 7 ...

Page 106: ... 3 B 4 Displacer Weight Constants 3 2 1 3 1 4 B 7 Display Mode 2 2 2 7 2 B 4 Function Fast Key Sequence See Figure Distributor 1 7 1 2 B 2 Driver Rod Length 2 2 1 2 4 B 4 Driver Rod Length Constants 3 2 1 3 1 2 B 7 Dry Deflection Constants 3 2 1 3 1 5 B 7 Edit Compensation Torque Tube 2 2 1 3 3 B 4 Enter Contstant SG Hot Key 8 B 1 2 2 4 4 3 5 B 4 2 2 4 4 4 4 B 4 Final Assembly Number 1 7 1 4 4 B 2...

Page 107: ...Temperature Calibration 1 6 2 1 B 2 Function Fast Key Sequence See Figure Temperature Calibration 2 4 2 1 B 6 Temperature Alert Setup 2 3 2 B 5 Temperature Sensor Units 2 2 1 1 5 B 4 Theoretical Calibration Calibration Scenarios 1 6 1 4 2 4 B 2 Third Variable 2 2 2 4 B 4 Torque Rate 2 2 1 3 4 B 4 Torque Rate Sensor Units 2 2 1 1 4 B 4 Transducer NVM 3 2 1 4 3 2 B 7 Trends 3 3 B 7 Trim Gain 1 6 1 3...

Page 108: ... 1 Device ID 2 Instr Serial Num 3 Sensor Serial Num 4 Final Asmbly Num Full Calibration 1 Min Max Calibration 2 Two Point Calibration 3 Weight Calibration Partial Calibration 1 Capture Zero 2 Trim Gain 3 Trim Zero Secondary 1 Temperature Calibration 2 Analog Output Calibration Temperature Calibration 1 Instrument Temperature 2 Instr Tmpr Offset 3 Trim Inst Tmpr 4 Process Temperature 6 5 Proc Tmpr ...

Page 109: ...Change Mode 8 4 Decimal Places 8 2 2 7 Ranging 1 Upper Sensor Limit 2 Lower Sensor Limit 3 Minimum Span 4 Upper Range Value 5 Lower Range Value 6 Analog Output Action 7 Change Action 8 Level Offset 1 9 Set Level Offset 1 2 2 2 2 2 3 2 2 5 2 2 4 Configure 1 Guided Setup 2 Manual Setup 3 Alert Setup 4 Calibration 2 2 2 Edit Compensation 1 TT Compensation 2 Torque Comp Plot 3 Pre compensate Torque Ra...

Page 110: ...oc Tmpr Source 7 Usage High Alerts 1 HiHi Enable 2 PV HiHi Threshold 3 Manage HiHi Alert 4 Hi Enable 5 PV Hi Threshold 6 Edit Hi Threshold 7 PV 8 PV URV 9 PV LRV 2 3 1 2 2 3 2 2 2 4 2 Primary 1 Guided Calibration 2 Full Calibration 3 Partial Calibration 4 Application Notes 4 see menu in figure B 2 Figure B 6 Configure Calibration Calibration 1 Primary 2 Secondary Full Calibration 1 Min Max Calibra...

Page 111: ...in Max Calibration 2 Two Point Calibration 3 Weight Calibration Partial Calibration 1 Capture Zero 2 Trim Gain 3 Trim Zero Analog Output Calibration 1 Analog Output 2 Scaled D A Trim Temperature Calibration 1 Instrument Temperature 2 Instr Tmpr Offset 3 Trim Inst Tmpr 4 Process Temperature 4 5 Proc Tmpr Offset 4 62Trim Proc Tmpr 4 Trends 1 PV 2 SV 3 TV 4 Summary 1 Mapped Variables 2 Compensation 3...

Page 112: ...he loop continuously measure one or more aspects of the process then alter those aspects as necessary to achieve a desired process condition A simple control loop measures only one variable More sophisticated control loops measure many variables and maintain specified relationships among those variables Damping Output function that increases the time constant of the digital level controller output...

Page 113: ... A type of semiconductor used for storing programs or data FIELDVUE instruments use three types of memory Random Access Memory RAM Read Only Memory ROM and Non Volatile Memory NVM See also these listings in this glossary Menu A list of programs commands or other activities that you select by using the arrow keys to highlight the item then pressing ENTER or by entering the numeric value of the menu...

Page 114: ...l System of Units Includes metric units such as ampere A meter m kilogram kg Kelvin K and second s Software Microprocessor or computer programs and routines that reside in alterable memory usually RAM as opposed to firmware which consists of programs and routines that are programmed into memory usually ROM when the instrument is manufactured Software can be manipulated during normal operation firm...

Page 115: ...lert 71 Analog Output Signal Digital Level Controller 103 Apparent SG 76 ATEX approved units 24 28 Available Configurations 6 B Bell 202 communication standard 99 BLANK Diagnostic Message 79 Buffer NVM 72 76 Buoyant Force 76 Burst 31 Burst Mode 48 Burst Operation 30 Burst Option 49 Burst Variables 30 49 C Calibration 31 Analog Output 63 78 Full 59 Guided 58 Min Max 59 66 78 Partial 61 Capture Zero...

Page 116: ...g 39 protecting 15 CUTR Customs Union Technical Regulations Russia Kazakhstan Belarus and Armenia 7 D D A Trim 58 Damping 42 Date 33 48 DD Information 33 Dead Band 6 Decimal Places 50 Density Process Operating influences 6 density applications 39 Description 33 48 Device ID 33 Device Identification 48 Date 48 Description 48 Final Assembly Number 48 Message 48 Sensor Serial Number 48 Tag 48 Device ...

Page 117: ...tronics Module Maintenance 86 Removing 86 Replacing 86 Electronics Monitors 76 Service Tools Variables 76 EMI filters 102 EN 61326 1 2013 Electromagnetic Compatibility 7 EN 61326 2 3 2006 Electromagnetic Compatibility 7 Enter Constant Density 46 Equalizing Connections 13 F FAIL HDWR Diagnostic Message 80 Failed Device Status 31 Fast Key Sequence 105 Field Communicator Menu Tree 105 Field Wiring 23...

Page 118: ...s Temperature 49 Decimal Places 50 Display Mode 49 LCD Configuration 49 Instrument Mounting 41 Instrument Serial Number 33 48 Instrument Setup 36 Instrument Temperature Alert Setup 56 Service Tools Variables 76 Instrument Temperature Offset 58 Instrument Temperature Too High Alert 72 Instrument Temperature Too Low Alert 72 Interface Applications 38 39 Density Variations in 69 Interface Level 31 in...

Page 119: ...hanical Gain 75 excessive 68 Menu Tree Field Communicator 105 Message 33 48 microprocessor 100 Min Max Calibration 59 66 78 Minimum Differential Specific Gravity 7 8 Minimum Span 32 43 Model 33 modems Bell 202 99 moment arm 36 Moment Arm Driver Rod Length 37 Mounting 41 249 Sensor 17 Digital Level Controller Orientation 18 DLC3010 17 On 249 Sensor 20 DLC3010 On 249 Sensor High Temperature Applicat...

Page 120: ...nication 99 Proc Temp Offset 58 Process Conditions 44 Change Source RTD 44 Enter Constant SG 46 Fluid s 45 Load Steam Tables 47 Lower Fluid Density 45 Measure SG 46 Process Temperature Source 44 RTD Data 44 Upper Fluid Density 45 View Edit SG Tables 45 47 Process Density Operating influences 6 Process Temperature 31 44 57 Alert Setup 57 Operating Limits 8 Service Tools Variables 76 Process Tempera...

Page 121: ...8 Sensor Damping 41 Sensor Dimensions 40 Displacer Length 40 Displacer Volume 40 Displacer Weight 40 Driver Rod Length 40 Sensor Drive Failed Alert 71 Sensor information 35 Sensor Nameplate example 37 Sensor Rotation 75 Sensor Serial Number 48 Sensor Signal Failed Alert 71 Sensor Units 40 Length 40 Temperature 40 Torque Rate 40 Volume 40 Weight 40 Serial Number Instrument 33 48 Sensor 33 48 Serial...

Page 122: ...ce 82 Torque Rate 41 Torque Rate Units Sensor 40 Torque Tube 41 Rate 41 Change Torque Rate torque tube 41 Changing Material 41 Edit Compensation 41 Torque Tube TT Rates Theoretical 68 Torque Tube Rate 58 torque tube shaft extension 20 Transducer Assembly Parts 93 transducer board 100 102 Transducer NVM 76 transient power surge protection 103 Transient Voltage Protection Operating influences 6 Tren...

Page 123: ... Limits 8 Weight Calibration 59 66 67 78 Weight Units Sensor 40 Wiring Field 23 Working Pressures Sensor 11 Write Protect 34 36See also Protection Writes Remaining Buffer NVM 76 Configuration NVM 76 Transducer NVM 76 Y Yamatake NQP Sensor Mounting Parts 97 Z zero buoyancy 39 Zero Reference Angle 58 75 ...

Page 124: ... reserve the right to modify or improve the designs or specifications of such products at any time without notice E 2000 2018 Fisher Controls International LLC All rights reserved Fisher FIELDVUE DeltaV and Tri Loop are marks owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co Emerson Automation Solutions Emerson and the Emerson logo are trademark...

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