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Milltronics Level Genie, Instruction Manual

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Summary of Contents for Level Genie

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Page 3: ...ION CALIBRATION AS A HI LO ALARM HI HI ALARM LO LO ALARM PUMP CONTROL MISCELLANEOUS MAINTENANCE AND OVERHAUL DRAWINGS OUTLINE AND MOUNTING DIMENSIONS TRANSDUCER INSTALLATION EASILY AVOIDABLE INSTALLATION ERRORS OUTLINE AND CABLE CONNECTION DIAGRAM TRANSCEIVER SCHEMATIC DIGITAL PROCESSING SCHEMATIC PAGES l l 2 1 2 2 3 1 3 2 3 3 3 4 4 1 4 2 4 3 5 1 5 2 5 3 5 4 5 5 6 l 7 l RELAY ACTION ...

Page 4: ...ck This measurement is converted electron ically into distance and then compared with the two independently adjustable set points Depending on the programming module employed this comparison actuates the output relays whose 10 amp 115 VAC contacts indicate material level status Programming modules available in easily changeable plug in form allow the Level Genie to operate as an independent high a...

Page 5: ... D Class II Groups F G 1 5 to 10 0 feet 0 45 to 3 1 meters Two 2 Form C S P D T contacts rated 10A 115VAC non inductive Two 2 independently adjustable throughout the range 0 5 inch per ft of range when in alarm mode 0 5 sec without time delay Selectable 3 or 10 seconds Better than 0 1 l 16 on 5 range or l 8 on 10 range Setpoint varies 0 17 of range C deviation from calibration temperature Electron...

Page 6: ...Weight 1 Pump up down 2 Hi Lo alarm 3 Hi Hi alarm 4 Lo Lo alarm One programming module supplied with unit Additional modules available as options Nema 12 standard Nema 4 optional Transducer 2 lbs Enclosure Electronics 12 lbs 2 2 ...

Page 7: ...ions Firstly it is a tuned amplifier operating in conjunction with the tank circuit formed by the inductance of the primary winding of Tl and C5 Secondly Q3 provides time varying gain to over come transducer ringing which occurs immediately after trans mittinq Just after transmitting when ringing is most severe Q3 is driven by very strong signals These signals cause a buildup of voltage at the emi...

Page 8: ...herefore ignored 3 As a Transmitter Q2 and Q5 control the change over from receiver to trans mitter During transmit time Q2 is turned on dissabling Q3 and Q5 is turned off releasing Q4 to operate in place of Q3 Q4 and Q6 are in a closed positive feedback loop which oscillates at the frequency to which the primary of Tl and C5 are tuned ie at the receiver s operating frequency Two gates of IC 7 for...

Page 9: ...he FAR setpoint and limit Maximum Range Switch SWl the maximum range switch allows the range to extend to either 5 feet or 10 feet 3 Alarm Point Recognition IC 5 1 IC 5 2 IC 6 l and IC 6 2 are C MOS NOR gates Each gate accepts two inputs the processed echo and one of the timing functions The order in which the timing functions are connected to the gate inputs determines the mode of operation of th...

Page 10: ... ignores short duration signals such as line transients and most SCR noise b Echo reception logic accepts only one echo per transmit sequence C Digital windows are established at the NEAR and FAR setpoints and only echoes occurring in these zones are recognized d It requires three valid echoes in three successive transmit sequences in order to trigger an output response 3 4 ...

Page 11: ...od electrical ground Since the Level Genie is designed for continuous operation a power switch has not been provided If one is desired it may be included in the external power circuit 2 Pre Start Up Checks A Unit Synchronization To avoid cross talk between multiple units located in the same panel or with common transducer runs the units must be synchronized They must transmit simultaneously To syn...

Page 12: ... both alarm circuits in less than one second and get the system ready for the next detection This situation may also happen when there is an alarm in a dusty area and suddenly the material level is moved out of the alarm region so fast that it causes the loss of echo The alarm anti latch circuit will again unlatch the alarm ie reset the system when the loss of echo is more than one second Note the...

Page 13: ...enerally mounted at the top of the vessel with its radiating surface aimed directly down at the surface of the material being measured The transducer is pro vided with a 1 NPT nipple for direct attachment See Fig 2 for transducer dimensions and typical mounting a b C Mount the transducer at least eighteen 18 inches above the highest level the material will reach in the vessel directly beneath the ...

Page 14: ...ce of the material to be measured and being re flected back along this same sound path Any object within this sound path that reflects an echo will interfere with the measurement of the material level For practical purposes the transducer should be located one half bin radius from the side wall assuming a center fill bin 1 Position the transducer so that its radiating surface is aimed directly at ...

Page 15: ...e Set the NEAR potentiometer fully counter clockwise Set the FAR potentiometer fully clockwise This Steps b c sets the trip points with NEAR at minimum range and FAR at maximum range refer to FIG 5 SPECIFIC CALIBRATION OF HI LO PROGRAM MODULE OMIT IF OTHER PROGRAM USED With the transducer placed at a distance from a fixed target representative of the low level adjust the FAR potentiometer counter ...

Page 16: ...drops out SPECIFIC CALIBRATION OF LO LO PROGRAM MODULE OMIT IF OTHER PROGRAM USED With the transducer placed at a distance from a fixed target representative of the low level farthest from the transducer adjust the FAR potentiometer counter clockwise until LED 2 extinguishes Relay 2 drops out Set the higher of the two low alarm points as follows Adjust the target to sensor distance to correspond t...

Page 17: ...point should always be set to a higher level than the FAR setpoint USING ONLY ONE OF THE DUAL ALARMS As a precaution to avoid having the NEAR and FAR settings crossed use only the FAR setpoint for single alarm operation Turn the NEAR setpoint fully counter clockwise HYSTERISIS Approximately 0 5 in 1 25cm of hysterisis per foot of range is provided Thus a high alarm 8 feet from the transducer has a...

Page 18: ...s achieved Similarly for pump up operation the level must drop below the far setpoint which sets the relay state energized until the level exceeds the near setpoint Pump Module Calibration It is usually expedient to calibrate the Level Genie before installation thereby avoiding the necessity of changing tank levels to set the trip points After installation a spar transducer serves as an invaluable...

Page 19: ...fully counter clockwise Move the transducer forward to a distance representative of the high level Adjust the NEAR set point slowly clock wise until the LED indicators extinguish relays drops out The high pump limit is now established OTHER SETTINGS Generally pump modules are run with the mode switch in CAL position as there is no advantage and possible disadvantage to using time delay in pumping ...

Page 20: ...e to minimum range or within blanking range Turn near setpoint in direction of arrow Erratic Inability to calibrate NEAR and FAR setpoint controls crossed low set point placed above the high setpoint Alarm settings unstable when mode switch placed in run position Unable to calibrate Low alarm Time Delay excessive enabling the level to enter the blanked zone before alarming Maximum range set to sho...

Page 21: ...formance checks and standard good housekeeping practices A periodic inspection of the transducer is recommended in some applications at which time any build up of material on the transducer face should be removed WARNING TURN POWER OFF BEFORE ATTEMPTING TO CLEAN CHASSIS The chassis is best cleaned with a vacuum cleaner or a clean dry cloth Remove all layers of accumulated dust from printed circuit...

Page 22: ...FIG 1 OUTLINE MOUNTING DIAGRAM ...

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Page 24: ...FIG 3 EASILY AVOIDABLE INSTALLATION ERRORS ...

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Page 30: ...ense motion level flow and for providing closed loop control on grinding mills are just a few of our specially designed devices for the process industries Operating installations around the world and customers who keep coming back to our factory trained applications personnel are our best salesmen Naturally our responsibility doesn t end when your order is shipped Our fully trained field service p...

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