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SDM – Slurry Density Meter

6

www.rhosonics.com

INSTALLATION

1.4

Document Issue

Document name (Rhosonics): 3A0-031-C56

Date

Issue

Description

11-11-2015

1

Concept

10-10-2016

A

Manual released

01-11-2016

B

Added chapter 9.3

05-12-2016

C

Compatible with software version V07.01.02.02

24-07-2017

C1

Updated operation for added functionality

2.

Installation

2.1

Introduction

Purpose:
Installation of SDM unit, SDM adapters and cables.
The SDM is a 24 VDC powered standalone sensor with 4-20 mA output and HART protocol

Installation should be performed by skilled installation technicians (mechanical and electrical).

The SDM, which is installed in a specially prepared spool section, wafer section or is used in conjunction
with a pipe adapter (weldolet) has a ceramic sensor face which should be in contact with a representative
portion of the slurry to be measured.

IMPORTANT:
The surface of the ceramic front face must be aligned with the inside pipe diameter. Otherwise the SDM
will fail to measure correctly.

Installation:



In chapter 2.1 and 2.2 there are common instructions for mounting the SDM adapter in a process
line. This chapter is valid for all sensor adapter types.



In chapter 2.3 to chapter 2.5 the different SDM adapters mounting instructions are described. In
“Provided by Rhosonics” a description of the different types of SDM adapters.



In chapter 2.6 the SDM mounting instructions are described.

CAUTION:

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Summary of Contents for SDM Series

Page 1: ...SDM SERIES SLURRY DENSITY METER MANUAL ...

Page 2: ... 13 2 4 WELDOLET INSTALLATION SDM 2 OR SDM 3 14 2 5 INSTALLATION OF THE WAFER SDM 4 OR SDM 5 15 2 5 1 WAFER UHMWPE 16 2 5 2 WAFER METAL I E AISI 316 19 2 6 INSTALLATION OF THE SDM TO THE PROCESS ADAPTOR 19 2 7 ELECTRICAL CONNECTIONS SDM 19 2 7 1 USB PORT 21 2 7 2 CONNECTION 24 VDC POWER AND HART 21 2 7 3 HART INSTALLATION CONFIGURATIONS 23 2 7 4 HART CONNECTING THE SECONDARY MASTER TO THE ANALYZER...

Page 3: ...LCD SCREEN 45 5 1 CALIBRATION MENU 45 5 1 1 SET TEMPERATURE 45 5 1 2 S G X 1000 CALIBRATION 45 5 1 3 FIELD CALIBRATION 47 6 MAINTENANCE 48 6 1 REPLACING MOUNTING A SENSOR 48 7 DIAGNOSTICS SERVICE 51 7 1 DIAGNOSTICS MENU 51 7 1 1 SYSTEM STATUS 51 7 1 2 RESTORE CALIBRATIONS 51 7 1 3 SET CLOCK AND DATE 52 7 1 4 LOGGING AND SETTINGS FOR DIAGNOSTICS EVALUATION 52 7 1 5 COLLECT LOG DATA USING USB 53 7 1...

Page 4: ...HARACTERISTICS 60 9 2 SDM HOUSING 60 9 3 SDM SENSOR 61 9 4 SPOOL WELDOLET WAFER 61 10 APPENDICES 62 10 1 LIST OF SPARE PARTS 62 10 2 OPTIONS 62 10 3 APPENDIX A SOUND SPEED OF WATER AT 0 TO 100 C 62 10 4 APPENDIX B DENSITY OF WATER AT 0 TO 100 C 63 10 5 APPENDIX C FLOW DD HART 64 ...

Page 5: ...al messages This symbol indicates that failure to follow directions in the warning message could result in bodily harm This symbol indicates that failure to follow directions could result in damage to the equipment or loss of information IMPORTANT This word indicates that the text that follows contains clarifying information or specific instructions NOTE This word indicates that the text that foll...

Page 6: ...rical The SDM which is installed in a specially prepared spool section wafer section or is used in conjunction with a pipe adapter weldolet has a ceramic sensor face which should be in contact with a representative portion of the slurry to be measured IMPORTANT The surface of the ceramic front face must be aligned with the inside pipe diameter Otherwise the SDM will fail to measure correctly Insta...

Page 7: ...N In chapter 2 7 the electrical mounting instructions of the SDM are described Must be provided on site Mounting hardware e g bolts nuts washers gasket sealing Power 24 VDC Power cable for 24 VDC HART 4 20mA cable OR Combined cable for Power 24 VDC and HART ...

Page 8: ...ter SDM split version e g 52 mm tip Process entry hardware for SDM This adapter exist in five different types o SDM 1 Spool for 16 mm sensor tip see chapter 2 3 SDM 1 Spool 16 mm tip Mounting flange to weldolet wafer or spool O ring sealing not visible in this drawing SDM housing Cable entry cable gland s or blind stop s Standard M16x1 5 Tip length Triclamp ...

Page 9: ...tip see chapter 2 5 SDM 4 wafer 146 mm tip SDM 5 wafer 200 mm tip 2 2 Selecting the SDM location The following guidelines apply to all SDM Install the SDM with 5xD length of straight pipe length upstream and 3xD of straight pipe length downstream Avoid installation in a pipe section where the SDM tip may wear fast Avoid installation near dosing valves Vertical pipe installation is preferred when t...

Page 10: ...n the correct position and the cable glands pointing downwards to prevent intruding liquids Vertical mounting i e wafer 2 2 2 Horizontal pipe mounting Some considerations need to be taken into account in case of installation in a horizontal pipe The preferred installation in a horizontal pipe is shown below The SDM must be installed either on the left or the right hand side of the pipe 90 Horizont...

Page 11: ... i e wafer 2 2 3 Analyzer head rotation The analyzer head can be rotated in any position 360 Below some examples are shown Please make sure you will be very careful with rotating the housing If not handled properly you can damage the SDM beyond repair especially the spring loaded contacts in the sensor part See also chapter 6 Different housing positions CAUTION ...

Page 12: ...ing metal flanges requires skills knowledge and experience Special requirements may apply depending on the piping system in which the spool is installed When you are not familiar with the necessary procedures please consult the responsible person before installation 2 3 2 Gasket sealing For gasket materials please consult the responsible perosn for the original design of the piping system 2 3 3 Bo...

Page 13: ...nd 100 of final torque flange sequential order crisscross One final time after 24 hours clockwise or counter clockwise sequentially around the flange 2 3 6 12 Bolt Flanges and More First round 20 of final torque flange sequential order crisscross Second round 40 of final torque flange sequential order crisscross Third round 80 of final torque flange sequential order crisscross Fourth round 100 of ...

Page 14: ... other gaskets please contact your gasket supplier 2 4 Weldolet installation SDM 2 or SDM 3 A weldolet is a metal piece which should be welded on an existing pipe Please follow the next procedure to mount a weldolet Drill a hole of Ø36 mm in the process pipe comply with vertical and horizontal installation conditions Make sure no burrs are left inside the pipe Hole Ø36 mm in a vertical pipe Mount ...

Page 15: ...bility There are 2 types of wafers UHMWPE Ultra High Molecular Weight Poly Ethylene wafers also called HDPE High Density Poly Ethylene wafer SDM 4 or SDM 5 Metal i e AISI316 Hastelloy C276 etc wafers SDM 4 or SDM 5 The only difference between UHMWPE wafers and metal wafers is the torque value of the bolts when mounted in a pipe This is the reason that the UHMWPE wafer is mentioned separately The t...

Page 16: ...e mating flange becomes self sealing Using this method the specified seating torque needs to be applied followed by a mandatory re torque applied 4 hours to 24 hours after completion of the initial torque application See following table for the torque to be used Note that this is a torque table for 150 LBS flanges with a UHMWPE wafer Gasket sealing The second method with gasket uses a low gasket s...

Page 17: ...nge faces 4 Lightly lubricate and insert all bolts and washers and loosely apply the nuts 5 Number all bolts for record purposes 6 Make sure the faces of the mating surfaces are flush against gasket if present prior to bolting down the flanges 7 Tighten the nuts by hand until they are snug Establish uniform pressure over the flange faces by tightening the bolts in 7 Nm 5 ft lbs increments up to th...

Page 18: ... 28 28 180 240 270 370 30 28 180 240 270 370 32 28 240 330 360 490 34 32 240 330 360 490 36 32 260 350 390 530 38 32 280 380 420 570 40 36 310 420 465 630 42 36 310 420 465 630 44 40 310 420 465 630 46 40 310 420 465 630 48 44 310 420 465 630 50 44 365 490 550 750 54 44 365 490 550 750 56 48 365 490 550 750 58 48 365 490 550 750 60 52 365 490 550 750 IMPORTANT These estimated values are based on n...

Page 19: ...inspected for surface defects 2 The O rings must be new and free of defects In addition the type of material of the O rings must be identified and verified for compatibility with the chemical and design temperature Do not re use O rings otherwise the proper sealing may be jeopardized 3 The grooves in the SDM in which the O rings are seated must be clean and inspected for surface defects Before ins...

Page 20: ...th 4 20 mA Output data cable and Gland Included Cable gland 3 10 mm cable outer diameter Not included Load resistance 50 to 1000 Ω 250 Ω nominal cable resistance included Minimum conductor size 0 51 mm 24AWG runs less than 1500 m Minimum conductor size 0 81 mm 20AWG for longer distance Maximum cable length 2700m Cap 70 pF m Cable type twisted single pair shielded or multiple pair with overall shie...

Page 21: ...ard M16x1 5 if the entry is not used 2 7 2 Connection 24 VDC power and HART The connection for the power and Hart is located in the inside of the SDM The cable s entering the SDM housing through a cable gland s Inside the housing the cable s are connected to a screw connector Below picture shows how to connect the power and HART NOTE Fuse specification Blow Characteristic Fast Acting Fuse Current ...

Page 22: ...SDM Slurry Density Meter 22 www rhosonics com INSTALLATION Rear view SDM back lit removed including cable gland entries Connection 24 VDC and HART on rear side SDM detail ...

Page 23: ...t of the control loop For service and maintenance it might be necessary to connect with HART while the analyzer is disconnected from the DCS The secondary master is connected across a 250Ω resistor Both analog and digital communication is possible Analyzer connected out of the control loop 2 7 3 2 Multidrop configuration The analyzer can be connected in multidrop mode This has some restrictions si...

Page 24: ...ct DD is in the database of the secondary master YOUR_PATH Library 0060C2 E35D Manufacturer ID Rhosonics 0x60C2 Device Type 0xE35D Device Type Name 9D series Analyzer Polling address 0 Open the DD via e g SDC625 SDC625 Map structure start Procedure for multi drop mode The analyzer is configured for point to point mode When the device has to be put into multi drop mode additional action is necessar...

Page 25: ...er than 15 Do this by changing Poll addr Device setup Detailed setup Output condition HART output Poll addr For multidrop mode it is necessary to disable the current output Device setup Detailed setup Output condition Analog output Loop current mode The analyzer can now be installed according the multi drop mode configuration When reconnecting the secondary master make sure the correct polling add...

Page 26: ...d communication problems it is recommended to put the device into the HART write protect mode This is set via the display on the sensor Navigate to Check Function on the analyzer Access code 1802 necessary Set Check Function to On screen becomes orange Result of Check Function set to On Go to the Device Manager on the PC AT91 is now present at COM port PC Device manager Dutch version Windows Appar...

Page 27: ...urry Density Meter 27 www rhosonics com INSTALLATION Start up Rhosonics_SA _9D_ _ exe COM9 selected Connection is made between sensor and service program Whenever the green light is on and the echo is visible ...

Page 28: ...3 options each with its own user interface Operations on the LCD screen see chapter 3 2 Operations via HART see chapter 3 3 Operations through the USB port see chapter 3 4 The choice for each user interface is dependent on the type of user Setup is as follows Operating overview with type of user interface type of user and access level ...

Page 29: ...s Averaging outputs decay time damping Liquid select Configuring output values type and range Loading of settings from file Loading liquid calibration Setting real time clock Backlight setting Calibration Factory calibrations Local offset and span calibrations mA out calibration Local calibration reset Diagnostic NAMUR state General error code Diagnostic measured values Condensed status map HART R...

Page 30: ...n which is close to the process it is possible to do basic calibrations Since retreiving log data will go by USB stick it is possible to set time and date for time stamp values during log as well as setting the log interval A minor system status displays the most relevant error in case of measurement problems To assure settings can only be changed by authorized personal most menu s are hidden behi...

Page 31: ...ue out of range Device is in maintenance Check function is on Maintenance required FailureFunctions Buttons below screen First button Go right Go up Second button Go down Third button Accept or Main menu Fourth button Back Page level higher see schedule 3 2 1 If the button colors are reversed only first and second button means that this button is used last ...

Page 32: ...a button isn t pressed for a while the screen goes to time out NOTE Indicated variables can differ for your analyzer Active Time Out Unlocked Local access Normal operation Device is operating within specified range Output is valid The backlight color is green Unlocked Local access Normal operation Device is operating within specified range Output is valid The backlight color is green Locked Remote...

Page 33: ...nce Required Maintenance on device necessary Output values still valid Icon in upper right corner and backlight change into blue Maintenance Required Maintenance on device necessary Output values still valid Backlight in blue Icon and measurement values are alternating Function check Device is in maintenance Check Function is on Output values temporarily invalid Icon in upper right corner and back...

Page 34: ...it Analyzer variables And there is a model specific folder which is in this example Configuration of 3A Process variables show the output values All settings and measured values are visible in Analyzer variables 3 4 USB port The USB port is used for Software update Saving settings and log data see chapter 7 1 4 Connecting to the service app on laptop via USB cable 3 4 1 Software update The procedu...

Page 35: ... 35 www rhosonics com OPERATION 3 4 2 Rhosonics service application Rhosonics SA 9D The Rhosonics service application has 4 tabs Main Configuration Calibration and diagnostics The structure of the application is the following ...

Page 36: ...ions possible When the analyzer is started up the first page you will see is the Start Page NOTE Except for the Start Page Measured Value page and Decay Time page you will need a higher Access Code see chapter 4 2 4 4 2 1 Start page Measured Values The Start Page contains only four values These four values are the HART communication values If you want to view all values go to the Measured Values p...

Page 37: ... a better indication of the bulk value of the liquid When fast response is not required we strongly recommend setting the Decay Time between 5 and 20 seconds Since smoothing affects the response time the best setting is a trade off between accuracy and response time A Decay Time of 5 seconds is recommended for most applications 4 2 4 Back light Back light changes with the status of the analyzer Ce...

Page 38: ...s Code 2 Enter Access Code using and buttons After entering the Access Code press the button The Advanced Function page is on the screen now 4 2 6 Advanced Function On the Advanced Function page you can choose between 5 options Calibration Menu see chapter 5 Diagnostics Menu see chapter 7 Liquid Select Check Function Output mA Range 4 2 7 Liquid Select On the Liquid Select page you can choose 2 op...

Page 39: ...ong values Another function is that a COM port is configured for a service PC 4 2 9 Output mA range Setting Output mA range is used to assign which value is corresponding to the 4 and 20mA range of the analog output As a consequence the analyzer and mA out will go into the out of specification status when the measured value will go out of these range Screens below shows the menu and the pages wher...

Page 40: ... the HART communication these are called Dynamic Variables The first one is called the Primary Variable PV this value is assigned to the 4 20mA analogue All 4 dynamic variables PV SV TV and 4V can be obtained digitally by a DCS which support HART There are 8 standard variables you can choose from Device Variable 0 Concentration 1 Device Variable 1 Concentration 2 Device Variable 2 Sound Speed Devi...

Page 41: ...ariable for PV is SV is TV is and QV is 4 3 2 Configure 4 20 mA Output This procedure is to specify the 4 20 mA Output The PV LRV Primary Variable Lower Range Value correspond to 4 mA The PV URV Primary Variable Upper Range Value correspond to 20 mA The PV Alrm typ Primary Variable Alarm Type is the Error reaction mode The Loop current mode has to be Enabled Disabled is Multidrop mode The Loop tes...

Page 42: ... URV i e SGx1000 1800 Low and High value 4 20 mA output Setting Analog output condition Open Map Signal condition Online Device Setup Detailed setup Output condition Analog output Set mode for PV Alrm typ choose from Hi Lo Hold last value or None Set Loop current mode to Enabled Use D A trim to fine tune the 4 mA and 20 mA value digitally After this trim a power down and power up must be done Anal...

Page 43: ...st please create this location Press Load settings When Lamp Settings loaded is green the settings are loaded 2 Read settings For reading settings the file SETTING CSV needs to be on this exact location C Users USERNAME Documents LabVIEW Data In this case the files are necessary to get the description for the settings When this location doesn t exist please create this location Press Read settings...

Page 44: ...location Press Read liquid When the descriptions and values in the analyzer are visible and the file column is grey the liquid calibration is read from the analyzer Configuring minimum and maximum values for the 4 20 mA output Open SETTING csv file in Excel Change the values for PV lower range value and PV upper range value Save the file keep csv extension Press Load settings When Lamp Settings lo...

Page 45: ...erature On the temperature Offset Menu page the current fixed temperature is displayed The temperature should be equal to the average process temperature and can be set by changing the offset The temperature must be 5 C the real process temperature Enter temperature Offset using and buttons After entering the Offset press the button 5 1 2 S G x 1000 calibration On the S G x 1000 page you can calib...

Page 46: ... enter the right density value of the water 1000 We use the off set to adjust this Span factor When pumping slurry you will need to have a reference value to verify the accuracy If the shown density on the density meter is too high i e 1350 instead of 1320 we use the span factor to adjust this Simply change the shown value until it reaches the reference value Correct density values Since Rhosonics...

Page 47: ...ome applications the sensitivity of the SDM is either too high or too low When that is the case the span has to be adjusted The way of configuring the span factor is described in earlier in this chapter It is however not necessary to completely understand that explanation By changing the span you get the expected result of the calibration Enter S G x 1000 Span using and buttons After entering the ...

Page 48: ...ing in black Mounting in blue Please make sure you follow this procedure Deviating dis mounting procedure can damage the SDM beyond repair especially the spring loaded contacts in the sensor part Sensor mounted in wafer spool weldolet Dismounting Untighten 8 M5x16 bolts Mounting tighten bolts with 4 2 Nm CAUTION ...

Page 49: ...cs com MAINTENANCE Dismounting Remove sensor from pipe adapter Mounting place sensor into pipe adapter Dismounting Remove nuts from Tri clamp Mounting Tighten nuts to Tri clamp with 25 Nm Dismounting Remove Tri clamp Mounting Place Tri clamp ...

Page 50: ...or and housing NOTE take care of the tiny spring loaded contacts in the sensor part Mounting Connect sensor and housing NOTE take care of the tiny spring loaded contacts in the sensor part Dismounting Remove the M5x16 bolts and M5 washers Mounting Place the M5x16 bolts and M5 washers ...

Page 51: ...ase Log not visible on picture below 7 1 1 System Status On this page you will find the status of the analyzer When the analyzer is running OK it shows Normal Operation When the analyzer is not running OK anymore it shows the error and information about that error 7 1 2 Restore calibrations Preparations Please read this section carefully before starting On this page you can restore all calibration...

Page 52: ...m to Rhosonics the Distributor 3 Restore factory settings only when Rhosonics tells you to do so A log file is automatically started when the power is turned on For trouble shooting or for your own diagnostics evaluation you can save a Log file When this Log file is stored to the USB stick the settings from the analyzer will be stored as well The settings from the analyzer can then be interpreted ...

Page 53: ... This is followed by saving the echoes and settings and measured values Within 20 seconds this should be finished If failed the display shows so After this the log is retrieved from the logging memory This will take several minutes The flashing of loading data as well as the updating of the progress bar indicates that saving the data is in progress When saving data is finished the message loading ...

Page 54: ...L YYMMDD txt Log C YYMMDD txt Liquid echo availability dependent on model E YYMMDD txt Error Status report I YYMMDD txt Interface echo M YYMMDD txt All measured values at time of Get Log RLS FILE csv Liquid calibration in analyzer Loadable for distributors S YYMMDD txt Settings Not loadable SETTING csv Settings Loadable for distributors 7 1 6 Erase Log The device is permanently logging This has th...

Page 55: ...port only Distributors and Factory The USB port is used for Distributor calibrations using a PC via the service application Loading settings into the SDM Loading Liquids into the SDM Calibrations are model dependent The following calibrations are present for every model mA trimming Temperature These Factory calibrations can also be made by trained distributors Calibration page ...

Page 56: ...ature reading regularly and perform a calibration when the reading error exceeds 5 ºC It is advised to configure the set temperature with a calibrated sensor as other temperature sensors in the same process may lack accuracy or may not be representative for the temperature at the installation location of the probe The SDM doesn t measure the temperature The value for the offset is the temperature ...

Page 57: ...SDM Slurry Density Meter 57 www rhosonics com DISTRIBUTORS CALIBRATION FOR RHOSONICS AND DISTRIBUTORS ONLY Enter the certified temperature followed by pressing OK OK stores the result ...

Page 58: ...8 4 SGx1000 calibration 8 4 1 SGx1000 offset calibration Press SG offset calibration Enter a certified SGx1000 Enter Certified SGx1000 A button Calibrate will appear on the screen Calibrate button Press Calibrate and wait 30 seconds averaging time Lamp Calibrating turns into bright green Calibrating SGx1000 ...

Page 59: ...ation can be performed by 2 methods 1 By entering the certified SGx1000 This should not be performed at the same SGx1000 as the offset calibration 2 By changing the span factor This can be performed at any current reading for SGx1000 The span factor changes the sensitivity for the SGx1000 If necessary it can be calculated by using the formula at the top of the calibration screen In that case it is...

Page 60: ... housing Dimensions SDM housing Ø125x212 mm ØxL Dimensions SDM sensor tip Ø60x65 Ø25x 16 34 52 146 200 mm ØxL Display effective area 65x35 mm WxH IP rating with covers IP 68 IP rating without covers IP 54 Ambient Temperature 5 C to 50 C Relative humidity 95 at 40ºC noncondensing Display resolution and color 240x128 dots WxH 5 colors Control push buttons Pillow embossed metal dome 4 pieces Weight 6...

Page 61: ...N 22 5 3 AFNOR Z3 CrNi 22 05 AZ DIN W Nr 1 4462 ISO 4462 318 03 I BS 318S13 SS 2377 JIS SUS 329J3L 9 4 Spool Weldolet Wafer Specific dimensions Spool Diameters up to 30 NW 750 mm Weldolet o SDM 2 up to wall thickness 17 mm o SDM 3 wall thickness 17 39 mm Wafer Diameters up to 60 NW 1500 mm Please contact Rhosonics for exact dimensions All is depending on the pipe schedule and flange specifications...

Page 62: ...7 1554 991 3 1416 985 28 1504 37 53 1545 601 78 1554 862 4 1421 628 29 1506 784 54 1546 517 79 1554 696 5 1426 162 30 1509 127 55 1547 382 80 1554 492 6 1430 589 31 1511 399 56 1548 199 81 1554 251 7 1434 912 32 1513 603 57 1548 967 82 1553 974 8 1439 132 33 1515 738 58 1549 687 83 1553 66 9 1443 251 34 1517 806 59 1550 36 84 1553 31 10 1447 27 35 1519 81 60 1550 986 85 1552 924 11 1451 191 36 152...

Page 63: ...30013 10 999 69386 35 994 02363 60 983 17346 85 968 65748 11 999 59998 36 993 67438 61 982 65745 86 968 00984 12 999 49325 37 993 31720 62 982 13577 87 967 35721 13 999 37393 38 992 95224 63 981 60845 88 966 69961 14 999 24227 39 992 57962 64 981 07555 89 966 03705 15 999 09854 40 992 19946 65 980 53711 90 965 36954 16 998 94297 41 991 81189 66 979 99318 91 964 69708 17 998 77580 42 991 41702 67 9...

Page 64: ...SDM Slurry Density Meter 64 www rhosonics com APPENDICES 10 5 Appendix C Flow DD HART ...

Page 65: ...s and sensors We believe that we can offer solutions for almost any application We can help you by adapting our solutions to improve your production processes together with our worldwide network of distributors CONTACT US Rhosonics Analytical B V Hoge Eng West 30 3882 TR Putten The Netherlands Phone 31 341 37 00 73 Email info rhosonics nl Website www rhosonics nl ...

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