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Milltronics Mercap MCP01 D series, Instruction Manual

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Page 30

MERCAP – INSTRUCTION MANUAL

7ML19981CM01.1

Applications

 

and Grounding

Several common applications appear in this section. Common applications are separated into
two types: those with System Grounding and those with Safety Grounding.

System Grounding (referencing)

The correct operation of the measuring system depends on the correct method of grounding.
Make sure that there is a reliable connection to the reference electrode (usually a metal
tank). Some common applications involving system grounding include:

•

 

metal tanks

•

 

metal tanks, cathodically protected

•

 

non-conductive tanks

Metal Tanks

Metal tanks can be (and in
most cases are) normally
grounded.

The connection of the
MST9500 can be
accomplished as shown
here. If a stilling well is
used, it is important that its
metal parts are properly
grounded.

Metal

Ground Lug

Summary of Contents for Mercap MCP01 D series

Page 1: ...ERCAP MERCAP MERCAP Instruction Manual June 2001 ...

Page 2: ...on and in electronic version We encourage users to purchase authorized bound manuals or to view electronic versions as designed and authored by Siemens Milltronics Process Instruments Inc Siemens Milltronics Process Instruments Inc will not be responsible for the contents of partial or whole reproductions of either bound or electronic versions While we have verified the contents of this manual for...

Page 3: ...ectrode 21 21 21 21 FTS Series 21 FTF Series 22 MST9500 Transmitter MST9500 Transmitter MST9500 Transmitter MST9500 Transmitter 24 24 24 24 Operating Principles 24 Installation Installation Installation Installation and Interconnection and Interconnection and Interconnection and Interconnection 25 25 25 25 Interconnection 26 Connection Diagrams 27 Factory settings 29 Applications Applications Appl...

Page 4: ... Tables Appendix B Tables Appendix B Tables 54 54 54 54 Table A Conversion 54 Table B Total Loop Ω Versus Supply Volts 55 Table C Voltage Drop Versus mA ForCurrent Transmitter Operation 55 Appendix C Approvals Appendix C Approvals Appendix C Approvals Appendix C Approvals 56 56 56 56 CE Certificate 56 Certificates and Approvals 57 Control Drawing FM CSA Approval Mercap 58 Index Index Index Index 5...

Page 5: ...ctions and seals 2 The transmitter 3 Appendix sections providing supplementary information Identifications and Abbreviations Various mnemonics and abbreviations are used in this manual See below Short form Long Form Description Units CE FM CSA Conformitè Europèene Factory Mutual Canadian Standards Association DAC Digital Analog Converter DCS Distributed Control System Control Room apparatus Ex Exp...

Page 6: ...Page 4 MERCAP INSTRUCTION MANUAL 7ML19981CM01 1 ...

Page 7: ...robe lining PFA Enamel PTFE Pressure rating bar psi FV 200 2920 up to 525 7665 as option Temperature rating C F 200 328 to 200 392 up to 450 842 as option Wetted Parts Liner PFA PTFE Flange stainless steel or teflon lined Transmitter Measurement range pF 0 3300 Span pF minimum 3 3 Supply voltage Vdc maximum 33 minimum 12 Vdc at 3 6 mA minimum 9 5 Vdc at 22 mA Output current mA 3 6 22 22 3 6 2 wire...

Page 8: ... isolated measurement circuit fully potted with epoxy resin Diagnostics Includes fault alarm primary variable PV out of limits system failure measurement circuit deviation between A D and D A converter values check sum watch dog measurement current out of range Measurement current signalling NAMUR NE 43 Function rotary switch 1 Position 1 Position 2 Position 3 Position 4 4 mA measurement value set...

Page 9: ...ilable with single or double cone seals and or a second seal on the flange plate to avoid any metallic wetted parts Handling of Electrodes WARNING Do not scratch or gouge the PFA electrode insulation since this could reduce the integrity of the insulation and the useful life of the electrode WARNING Be careful with an enamel insulated electrode Normally an enamel lining is protected by a stilling ...

Page 10: ... kV Standard single cone usage Secondary cone usage General Design Principles The Mercap capacitance level instrument combines an optimum combination of mechanical and electrical electronic principles in its design Combining a single transmitter with as few electrode configurations as possible maximizes the number of potential applications while it minimizes the complexity of the instrument In pri...

Page 11: ...required Pressure and Temperature Considerations The maximum temperature and pressure of operation for the standard Mercap level probe is 200 C 392 F and 200 bar 2900 psi There are of course qualifications that must be applied to these maximums Enamel probes are suggested when process temperature exceeds 200 C and or in combination with very high pressure Note Consult Milltronics for chemical appl...

Page 12: ...the following features Threaded flanges welded flanges and solid flanges S series D series SD series DD series and HP series process seals Selections of standard ANSI and DIN flanges are available The most common electrode is insulated with PFA but Enamel HP seal is also available as standard Enamel is only available on rigid design Various process connection materials are also available Rigid and...

Page 13: ...seal suitable for most level interface or detection applications high temperature and pressure resistance 160 6 3 Transmitter Enclosure 120 4 72 Insertion Length Dimension Varies Insertion Length Seal Gland Threaded Process Connector See Order Instructions PTFE Insulation 9 0 35 Tensile Weight Varies Insertion Length 175 6 9 Inactive Part 125 4 9 55 2 17 ...

Page 14: ...ies Flange Features single process seal suitable for most level interface or detection applications high temperature and pressure resistant Active Length Active Length Insertion Length Insertion Length Insertion Length 185 7 28 Insertion Length 185 7 28 Active Shield Active Shield TIG Weld Inactive Tip Inactive Tip 16 0 63 or 24 0 94 40 1 57 40 1 57 16 0 63 or 24 0 94 ...

Page 15: ...lications etc all wetted parts made of PFA probe lining or PTFE flange face according to NACE requirements suitable for turbulent and toxic chemical applications 16 0 63 or 24 0 94 16 0 63 or 24 0 94 Inactive Tip Inactive Tip Probe Probe Insertion Length Insertion Length Active Length Active Length Active Shield Active Shield 65 2 56 120 4 72 120 4 72 120 4 72 160 6 3 160 6 3 Transmitter Enclosure...

Page 16: ...ical applications MCP01 Probe Thermal Isolator Features thermal isolator 160 6 3 160 6 3 Insertion Length Insertion Length Active Length Active Length 40 1 57 40 1 57 16 0 63 or 24 0 94 16 0 63 or 24 0 94 Transmitter Enclosure Transmitter Enclosure 120 4 72 120 4 72 Flange Process Connection Flange Process Connection 120 4 72 Seal Gland Seal Gland Thermal Isolator Probe Probe 85 3 35 k k D D n hol...

Page 17: ...surement spans as much as 5 5 meters for the water up to 35 meters of flexible bellows cable are used MCP02 Interface Version Process Connection Size threaded version 1 1 2 NPT BSPT or JIS sanitary version on customer request flange version on customer request Options thermal isolator stilling well Aluminum Enclosure Nema 4 Type 4 IP65 Conduit Entry NPT 2x Flexible Tube Insertion Length 35m 115ft ...

Page 18: ...anitary Thread Coupling Sanitary Tri Clamp MCP03 Sanitary Tri Clamp Features maximum active length 5 5m minimum active length 50mm 16 0 63 or 24 0 94 16 0 63 or 24 0 94 40 1 57 40 1 57 Probe Active Length Active Length Inactive Tip Inactive Tip 118 4 65 Seal Gland Transmitter Enclosure 160 6 3 Active Shield Insertion Length Insertion Length 175 6 9 Active Shield Tri clamp Connection Seal Gland Ins...

Page 19: ...7ML19981CM01 1 MERCAP INSTRUCTION MANUAL Page 17 Flanges Flange Standards Note All Sizes MM One 1 inch 25 4mm Details See drawings technical data and measuring probe details øL b øK n holes øD ...

Page 20: ...pressure must be derated As the temperature reaches 200 C 392 F the maximum pressure is limited to 50 bar 725 psi This curve is typical for water only for other more aggressive chemicals the derating curve will be more severe Note For high temperature and pressure ratings for the Enamel probe please contact your Siemens Milltronics representative Reference Product Water ...

Page 21: ...trode diameter in meters ξr 1 air ξr 2 oil 24 a K constant can be substituted for 7 32 For Vessels Filled with Oil The following equation applies to oil filled vessels matching the dimensions shown above Please note that the probe must be properly mounted and the metal tank is grounded Cincrease for oil ξr _oil ξr _air 24x0 95 pF 12 7pF Log 1 0 016 OR Cincrease for oil ξr _oil ξr _air 7 32x3 12 pF...

Page 22: ...es yields the following Cincrease for oil ξr _oil ξr _air 7 32x4 5 16 6 pF Log 60 0 63 So for this slightly larger tank the capacitance ranges from 16 6 pF to 33 2 pF So on calibration 16 6 pF 0 4 mA or 20 mA 33 2 pF 100 20 mA or 4 mA Mercap 6 0 5ft L 54 4 5ft 60 5 0ft d 0 63 ...

Page 23: ... The capacitance change is measured and transmitted by a 4 20 20 4mA signal and HART protocol Note If the transmitter s ambient temperature exceeds 85 C 185 F 70 C 158 F in Ex zones mount a thermopart between electrode head and transmitter housing FTS Series The FTS series flow through electrode is suitable for relatively high pressure and temperature conditions It is installed using a sandwich co...

Page 24: ...65 NEMA 4 Type 4 acc DIN 40050 FTF Series The FTF series flow through electrode is designed to accommodate the combination of high temperature and high pressure conditions The electrode is installed using a flange mounting and the PTFE sealing ring provides high chemical resistance Note For flange dimensions and pressure ratings refer to the chart on page 25 100mm 3 9 Flange Connection Electrode H...

Page 25: ... 3 6 5 1 9 4 2 3 7 5 3 1 5 2 8 2 3 1 5 7 8 3 2 9 5 7 4 9 0 4 0 6 7 10 0 4 0 7 0 10 8 3 8 7 5 5 10 0 5 1 7 6 12 5 5 1 8 4 13 0 4 8 9 4 8 13 5 8 0 10 9 15 0 8 0 12 0 16 5 7 6 12 5 10 16 0 10 0 13 3 17 5 10 0 14 1 20 0 9 8 15 6 12 19 0 12 0 16 0 20 5 12 0 16 5 22 0 11 8 17 9 Flanges acc DIN Standards mm class PN 16 PN25 PN40 nom size D x y D x y D x y NW 25 115 24 8 71 115 24 8 71 115 24 8 71 NW 50 1...

Page 26: ...cation A significant advantage of the MST9500 is the Active Shielding feature It prevents any capacitance that may occur in the connection cable process connection and non active parts of the probe from interfering with the measurement As a result the capacitance registered by the MST9500 consists only of the measuring capacitor and a more stable and more reliable measurement is provided Due to in...

Page 27: ... such as sun shields are not normally required Metal Housing and Electrode Assembly The MST9500 is mounted in a powder coated aluminium housing The housing provides a separate customer wiring area in line with the cable conduit inlet outlet openings Terminals for Instrument connection 2 wire current loop Ground connection wire with a sufficiently large conductor diameter As the measurement occurs ...

Page 28: ...o 4 mA the supply voltage on the terminals of the MST9500 should be at least 12 Volts Cable The selection of the cable is mainly determined by two criteria 1 The resistance of the copper conductor Ohm 2 The cable capacity pF The copper resistance influences the voltage drop over the cable The cable capacitance influences the HART TM signals and is important for intrinsically safe applications If f...

Page 29: ...P General Purpose IS Intrinsically Safe XP Explosion Proof 4 20 mA loop connection 1 positive wire 2 negative wire Measuring Signal Ground Connector Command Selection Switch Ground 4 20 mA loop connection 1 positive wire 2 negative wire Current check terminal 1 and 3 Measuring Signal Ground Connector Command Selection Switch Ground Push Button Push Button ...

Page 30: ...ion Some overload can be tolerated indefinitely As a result of well designed circuitry the internal capacitance and inductance on the terminals are isolated and do not interfere with safety calculations The MST9500 is equipped with the HART TM communication protocol so that settings and information can be obtained and altered locally or remotely The internal diagnostic functions continuously monit...

Page 31: ...ng Setting Description Description Description Description ID has a unique serial number PV Units pF USL PV 3300 pF LSL PV 1 666 pF URV PV 3300 pF switch position 2 LRV PV 0 00 pF switch position 1 AO1 PV 4 20 mA is 0 100 TAG customer input data via HART DESCRIPTOR customer input data via HART MESSAGE Milltronics DATE customer input data via HART SENSOR SERIAL NUMBER customer input data via HART F...

Page 32: ...stem depends on the correct method of grounding Make sure that there is a reliable connection to the reference electrode usually a metal tank Some common applications involving system grounding include metal tanks metal tanks cathodically protected non conductive tanks Metal Tanks Metal tanks can be and in most cases are normally grounded The connection of the MST9500 can be accomplished as shown ...

Page 33: ...ell is used it is important that the metal parts of it are grounded on the tank grounded on the tank grounded on the tank grounded on the tank which means being connected through an electrical connection Non Conductive Tanks Non metallic tanks always require a stilling well or proper grounded conductive medium The connection of the MST9500 in such a situation can be realised as shown here The meta...

Page 34: ...rcuited In the second case the negative side of the current loop can be grounded Another type of DCS has galvanically separated inputs for each measurement channel so the grounding method can be chosen as required If no specific Ex conditions apply the MST9500 can and is allowed to be directly connected to the control system DCS The supply voltage however should remain within the limits set by the...

Page 35: ...quired Example 3 This barrier is also used in case of XP Cenelec applications The barrier is then placed in the transmitter housing Grounding is not always direct in this case because of a possible installation on cathodically protected tanks as in Example 4 Example 4 In case of Ex applications where the DCS have galvanically separated inputs both types of barriers can be used See Examples 2 and 5...

Page 36: ... 34 MERCAP INSTRUCTION MANUAL 7ML19981CM01 1 Example 5 When Ex applications are using an Ex approved supply unit the barriers are not used and grounding is optional Stahl barrier 9001 01 280 110 10 or equal ...

Page 37: ...switch to position 1 c Press the push button hold for approximately 2 seconds 2 Set value for 100 a Bring the level of the product to be measured to the level which corresponds with 100 b Turn the rotary switch to position 2 c Press the push button hold for approximately 2 seconds 3 The MST9500 transmitter is now set a Turn the rotary switch back to position 4 Position 4 prevents the alteration of...

Page 38: ...ith the GENERIC device descriptor Example 1 In this situation the level of the product can be easily adjusted to 0 and 100 1 Switch on the 275 and request connection with the MST9500 a Select Online b Select Device set up c Select Diag service d Select Calibration e Select Apply values f Select 4 mA 2 Bring the level of the product to the level which corresponds with 4mA a Select Read new value b ...

Page 39: ...pacitance value at various levels These values can be read in with the 275 communicator 1 Switch on the 275 and establish connection with the MST9500 a Select Online b Select PV The measured value can be read continuously even if current loop value is min or max 2 Write down the measured value in pF with the corresponding level Suppose the following results were recorded a at 17 the measured PV va...

Page 40: ... according to Example 2 Example 2 Example 2 Example 2 whereby the URV value is simply copied If the D C S and or the 275 are fitted with the Device Descriptor for the MST9500 more functions can be used The available functions are Number Number Number Number Description Description Description Description 48 Read Additional Transmitter Status 38 Reset Configuration Changed Flag 128 Set Alarm Select...

Page 41: ... the original current was 20 5 mA the difference will be less due to the transmitter saturation at the top end of the normal active range The test cycle lasts for a total of 10 seconds At the end if the test is successful the current will return to the original value If the test fails the current will show the error value The error value remains until the next test is completed successfully or the...

Page 42: ...utton and 15 pole source connector g no dirt or deposits on coax connector h no cable or wires jammed under cover 2 Functional Checks a provides manual test function 0 25 mA current increase during 10 seconds b check for required minimum terminal voltage c does the current go to the alarm position 3 6 or 22 mA if the coax plug is unplugged If so fasten it again d via HART TM Does the PV go to 0 pF...

Page 43: ...mance Class 1 Conformance Class 1 Conformance Class 1 Conformance Class 1 0 Return Unique Identifier 1 Read Primary Variable Universal Conformance Class 1A Conformance Class 1A Conformance Class 1A Conformance Class 1A 0 Return Unique Identifier 2 Read P V Current and Percent of Range Universal Conformance Class 2 Conformance Class 2 Conformance Class 2 Conformance Class 2 11 Read Unique Identifie...

Page 44: ... 5 Conformance Class 5 6 Write Polling Address 17 Write Message 18 Write Tag Descriptor and Date 19 Write Final Assembly Number Universal 44 Write Primary Variable Units 45 Trim Primary Variable Current DAC Zero 46 Trim Primary Variable Current DAC Gain 49 Write Primary Variable Sensor Serial Number 59 Write Number of Response Preambles Common Practice 128 Set Alarm Select 129 Adjust for Product B...

Page 45: ...er revision Software revision Polling address Request preambles High calibration level Low calibration level Applied rerange Keypad rerange Zero correction Measuring elements menu Signal conditioning menu Output conditioning menu Device info menu PV upper sensor limit PV lower sensor limit PV minimum span PV sensor units PV Upper range value PV Lower range value Damping value Upper range value Low...

Page 46: ...ised Use command 48 to get detailed status information Bit 3 Output Current Fixed This bit is set as long as the Primary Variable Analog Output is set to a fixed value Bit 2 Primary Variable Analog Output Saturated Flag is set when the Primary Analog Output saturates below 3 8 mA and above 20 5 mA Bit 0 Primary Variable Out of Limits This flag is set whenever the Transmitter Variable 0 in pF the P...

Page 47: ...t any time with Command 141 The value returned as S V is the result of the following calculation S V P V Range in percent x SVURV SVLRV SVLRV This method provides a means to transfer the P V which is always in pF to an alternative level or contents value Additional universal command specifications Command 3 Read Dynamic Variables and P V Current The Primary Variable returns the Transmitter Variabl...

Page 48: ...48 Read Additional Transmitter Status This command returns the results of the Transmitter Self Test along with other transmitter information Byte 0 Byte 0 Byte 0 Byte 0 Events May be gone but sent at least once Events May be gone but sent at least once Events May be gone but sent at least once Events May be gone but sent at least once Bit 0 EEROM write error Bit 1 Floating point Math error Bit 2 U...

Page 49: ...ct High or Alarm Select Low Request data bytes Data bytes 0 Alarm Select Code Data byte 0 Alarm Select Code 8 bit unsigned integer Selection may be either 0 or 1 Response data bytes Data bytes 0 Alarm Select Code Data byte 0 Alarm Select Code 8 bit unsigned integer Refer to Alarm Selection Codes table VI Command 129 Adjust for Product Build Up on Sensor This command sets the lowest of LRV URV equa...

Page 50: ...er Sensor Limit Value must not be less than zero and not more than the Upper Sensor Limit Value The Upper Sensor Limit Value may not be more than 3300 and no less than the Lower Sensor Limit The minimum distance between Upper and Lower Sensor Limit is forced to be at least 3 3 pF The actual Upper and Lower Sensor Limit Values can be read with command 14 Read Primary Variable Sensor Information Req...

Page 51: ...e IEE754 Command 140 Write S V Units Upper and Lower Range Values This command writes the units and values for the Secondary Variable Range Values The command accepts any Units type and or values It is up to the user to choose input that makes sense for the application Request data bytes Data byte 0 S V Range Units Code 1 S V Upper Range MSB 2 3 4 S V Upper Range LSB 5 S V Lower Range MSB 6 7 8 S ...

Page 52: ...54 Data byte 5 8 S V Lower Range Value IEE754 Command 141 Return S V Units Upper and Lower Range Values This command returns the units and values for the Secondary Variable Range Values Request data bytes None Response data bytes Data byte 0 Range Units Code 1 S V Upper Range MSB 2 3 4 S V Upper Range LSB 5 S V Lower Range MSB 6 7 8 S V Lower Range LSB Data byte 0 S V Units Code 8 bit unsigned int...

Page 53: ...Recorded P V Max Min Values This command returns the recorded maximum and minimum values for PV since the last reset command or the last power cycle Request data bytes None Return data bytes Data byte 0 P V Range Units Code 1 PV Max Recorded Value MSB 2 3 4 PV Max Recorded Value LSB 5 P V Min Recorded Value MSB 6 7 8 P V Min Recorded Value LSB Data byte 0 P V Units Code 8 bit unsigned integer Data...

Page 54: ... Corr Level Setting LSB Data byte 0 3 Span Corr Level Setting IEE754 Command 147 Read Ratio Level for Span This command returns the Span correction level This is an autocal feature Request data bytes Data byte 0 Span Corr Level Setting MSB 1 2 3 Span Corr Level Setting LSB Data byte 0 3 Span Corr Level Setting IEE754 Command 148 Write Ratio Value for Zero This command sets the Zero correction leve...

Page 55: ... Setting LSB Data byte 0 3 Zero Corr Level Setting IEE754 Command 149 Read Ratio Value for Zero This command returns the Zero correction level This is an autocal feature Request data bytes None Return data bytes Data byte 0 Zero Corr Level Setting MSB 1 2 3 Zero Corr Level Setting LSB Data byte 0 3 Zero Corr Level Setting IEE754 ...

Page 56: ...0 100 Current in Current in Current in Current in mA mA mA mA Range 100 0 Range 100 0 Range 100 0 Range 100 0 0 4 0 100 5 4 8 95 10 5 6 90 15 6 4 85 20 7 2 80 25 8 0 75 30 8 8 70 35 9 6 65 40 10 4 60 45 11 2 55 50 12 0 50 55 12 8 45 60 13 6 40 65 14 4 35 70 15 2 30 75 16 0 25 80 16 8 20 85 17 6 15 90 18 4 10 95 19 2 5 100 20 0 0 ...

Page 57: ...ter Operation total resistance Ohm fixed current 4mA lowest current 3 6 mA highest current 22 mA OPERATION AREA supply voltage Vdc V supply mA voltage drop over 250 ohm measuring resistance voltage drop over 280 ohm in barrier voltage drop over blocking diode in barrier margin c q voltage drop over instrument cable operation voltage MST9500 ...

Page 58: ...49 KRQ EMC 01 4232 EN 62326 1998 Product group standard for Electrical equipment for measurement control and laboratory use from which EN 50011 1998 Emission Class B EN 61000 4 2 1995 Electrostatic Discharge ESD Immunity EN 61000 4 3 1996 Radiated Electro Magnetic Field Immunity EN 61000 4 4 1995 Electrostatic Fast Transient EFT Immunity EN 61000 4 5 1995 Surge Transient Immunity EN 61000 4 6 1996...

Page 59: ...tion of the MST9500 conforms to the following NAMUR recommendation NE 43 This recommendation describes rules with which analogue transmitters transfer their information to D C S equipment This information can be divided into the following types measurement information and failure signalling As far as measurement information measurement information measurement information measurement information is...

Page 60: ...Page 58 MERCAP INSTRUCTION MANUAL 7ML19981CM01 1 Control Drawing FM CSA Approval Mercap ...

Page 61: ...ienic Level Version 16 Identifications and Abbreviations list 3 Installation information and details 25 Interconnection supply and cable information 26 INTERFACE LEVEL VERSION 15 Intrinsical 4 Introduction 3 Maintenance information 39 MCP01 Standard S Series Threaded Versions 10 MCP01 Standard S Series Welded and Machined Flanged Versions 12 MCP01 Standard D Series Machined Flanged Versions 13 MCP...

Page 62: ...RTING WITH HARTTM 39 STARTING WITH THE PUSH BUTTON 39 Test Function information 39 thermopart 21 Total Loop 55 Total Loop Ω Versus Supply Volts 55 Transmitter 5 OVERVIEW 24 SPECIFIC COMMANDS 47 Vessels Filled with Oil 19 VoltageDropVersusMA 55 Wetted Parts 5 ...

Page 63: ... 7ML19981CM01 ...

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