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Thermo Electron Polysonics SX40, User Manual

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Thermo Electron Polysonics SX40 User Manual Download Page 38

 

Thermo Electron Corporation 

Polysonics SX40 User Guide     

6-1

 

Chapter 6

 

 

Troubleshooting & Maintenance 

The instrument has 4 modes of operation: 

●

 

Setup 

●

 

Learn 

●

 

Operating 

●

 

Manual (used by factory trained personnel primarily for application 
troubleshooting) 

Use the following table in conjunction with the learn mode and operating 
mode warning tables. 

Table 6–1.

 Action codes 

Action 

Description 

A 

1. Turn meter off. 

2. Apply more compound. 

3. Tighten the pipe strap. 

4. Restart the meter to see if warning clears. 

B 

1. Reposition transducers. 

2. See if signal strength increases. 

3. See if warning clears. 

4. Restart the meter. 

C 

1. Relocate transducers. 

2. See if signal strength increases. 

3. See if warning clears. 

4. Restart meter. 

D 

1. Turn meter off, and remove the transducers. 

2. Grind the pipe surface if it is rough or coated. 

3. Remount the transducers. 

4. Restart the meter. See if warning clears. 

 

 

 

 

General 

Troubleshooting 

Summary of Contents for Polysonics SX40

Page 1: ...re ControlTM Polysonics SX40 Dedicated Doppler Flowmeter User Guide P N 1 0563 006 Revision G HDS MESSTECHNIK Franz Kissing Straße 7 58706 Menden Tel 02373 1341 Fax 02373 2488 info hds messtechnik de www hds messtechnik de ...

Page 2: ...Polysonics SX40 Dedicated Doppler Flowmeter User Guide P N 1 0563 006 Revision G ...

Page 3: ......

Page 4: ...ation Thermo makes every effort to ensure the accuracy and completeness of this manual However we cannot be responsible for errors omissions or any loss of data as the result of errors or omissions Thermo reserves the right to make changes to the manual or improvements to the product at any time without notice The material in this manual is proprietary and cannot be reproduced in any form without ...

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Page 6: ...iring 2 5 AC Power 2 5 DC Power 2 6 Transducers 2 7 Relays 2 9 4 20 mA Current Loop Rev F or Earlier 2 11 4 20 mA Current Loop Rev G or Later 2 13 Connecting a Switch to Remote Zero Feature 2 14 Operation Configuration 3 1 The Interface 3 1 Screen Contrast 3 1 Configuration 3 2 Auto Mode 3 2 Manual Mode 3 3 HydraScan 3 6 Setup Items 4 1 Reset 4 1 Config 4 1 I O Test 4 1 Relays 4 1 4 20 mA Loop Cal...

Page 7: ... 6 1 General Troubleshooting 6 1 Learn Mode Warnings 6 2 Operating Mode Warnings 6 2 Variable Frequency Drives VFDs 6 3 Checking the FFT 6 3 Signal Quality Strength 6 5 General 6 6 Maintenance 6 6 Replacing the Relays 6 6 Replacing the 4 20 mA Board 6 7 Replacing the Fuse 6 8 Upgrades 6 9 Service Returns 6 9 Warranty 6 10 Hazardous Area Installations A 1 Obtaining Pipe ID B 1 Chapter 5 Chapter 6 A...

Page 8: ...art numbers to order spare parts for your instrument Table 1 1 Part Number Description 22767 0001 Poly CD specification sheet meter installation video CD 1 0563 006 User guide 1 0561 005 HydraScan software manual 01008 0006 RS232 cable standard serial 6 ft female to male DB9 10241 0003 Hazardous area relay 3 A SPDT 10261 0013 Fuse 1 A time delay AC input 10396 0194 Power cord connector CGB for 6 f...

Page 9: ...4 0002 PCB assembly adapter board 22732 0001 Front panel assembly includes keypad and display 22801 0002 PCB assembly 4 20 mA output applicable with firmware v 3 03 22061 0003 Heater assembly suitable for 40 F to 140 F 40 C to 60 C operation 24 Vdc Velocity Range 0 2 18 ft s 0 06 5 5 m s Accuracy 1 of velocity full scale Fluids Liquids containing particulate or entrained gas bubbles Pipe Size 0 5 ...

Page 10: ...T programmable relay maximum of 4 Power Supply DC Power 11 28 Vdc AC Power 90 132 Vac or 190 250 Vac switch selectable 50 60 Hz Keypad 19 key with tactile action Display Backlit 240 x 60 dot high resolution graphics display Data Logger 90000 point data logger Programmable in intervals of 30 s 1 5 15 30 and 60 min Programming Via HydraScan software or integral keypad Serial Interface RS232 Function...

Page 11: ...0 C to 121 C coax cable limited to 176 F 80 C Electronics 20 F to 140 F 29 C to 60 C With integral heater 40 F to 140 F 40 C to 60 C Hazardous Area Certification Optional CSA Class I Div 2 or Class II Div 2 Optional CSA Intrinsically Safe Class I Div 1 Class II Div 1 or Class III Div 1 Optional Intrinsically Safe CENELEC LCIE Approvals ...

Page 12: ...ng widening of the pipe Figure 2 1 Recommended installation locations Conditions at locations A B C D and E can interfere with the transmission of the ultrasonic wave and yield inaccurate or unreliable flow readings A Pipe may not be full B Down flow C Too close to elbow D Air collects at the top of the horizontal pipe E Sediment collects at the bottom of the horizontal pipe Note Selecting the pro...

Page 13: ...plication allows install the transducers at the 3 and 9 o clock locations Ensure the transducers are parallel to each other along the pipe circumference Figure 2 2 Recommended transducer orientations 3 Attach the transducers to the pipe strap a Use a screwdriver to loosen the mounting screw and slide the lock back on each transducer Figure 2 3 ...

Page 14: ...h the tension nut assembly b Pull the strap tightly and clamp the tension nut down to secure the strap to the pipe c Loosen the mounting screw of a transducer and move the transducer to the 3 o clock position on the pipe Tighten the mounting screw to secure the transducer d Loosen the mounting screw of the second transducer and move the transducer to the 9 o clock position Tighten the mounting scr...

Page 15: ...prevent the possibility of electrical shock and or damage to the meter do not mount the enclosure where it can be submerged or partially submerged 1 Locate a sturdy vertical mounting surface 2 Remove the meter access cover and locate the 4 mounting holes 1 in each corner of the cover 3 Attach the enclosure to the wall using the mounting screws 4 Replace the meter access cover Note An optional moun...

Page 16: ...e the meter access cover 2 Locate the AC input voltage selector and turn the switch to 110 or 220 V to match the power line voltage 3 Locate the L1 L2 N and GND connections within power input block 4 Turn the terminal screws on top of the input block counterclockwise to fully open the wire connections 5 Make the following connections a Ground wire to GND CE certification requires less than 1 ohm b...

Page 17: ...nto the instrument Refer to the following instructions and Figure 2 8 1 Remove the meter access cover 2 Locate the power input block and turn the terminal screws on top of the input block counterclockwise to fully open the wire connections 3 Make the following connections a 24VDC to P2 24 b 24 VDC return to either of the P2 GND connections 4 Turn the terminal screws clockwise to close them connect...

Page 18: ... power connections Warning Prevent possible electrical shock and or damage to the meter Disconnect power to the meter PRIOR TO wiring 1 Refer to Figures 2 9 and 2 10 2 Remove the meter access cover 3 Remove the nut from the transducer cable connector and draw the cable through the opening in the meter enclosure 4 Thread the nut onto the cable connector to the inside of the enclosure Transducers ...

Page 19: ...ducer block counterclockwise to fully open the connections 8 Identify the transducer s 2 signal wires and 2 braided ground wires 9 Make the following connections a First signal wire to XMT DN b First braided ground wire to XMT GND c Second signal wire to RCV UP d Second braided ground wire to RCV GND 10 Turn each screw clockwise to close the connections 11 Ensure the wire connections are secure an...

Page 20: ...eter Disconnect power to the meter PRIOR TO wiring Refer to step 10 of Manual Mode in Chapter 2 for instructions on relay configuration 1 Refer to Figures 2 11 and 2 12 2 Remove the meter access cover 3 Locate the 4 relay terminals blocks and select the relay you are going to wire 4 Locate the Normally Closed NC Common C and Normally Open NO relay contacts on the terminal block Relays ...

Page 21: ...en the NC and C terminals and closed between the NO and C terminals 5 Turn the terminal screw on top of each connection counterclockwise to fully open the connections 6 Insert the wires for your control system into the corresponding wire connections 7 Turn the terminal screws clockwise to close the connections 8 Ensure the wire connections are secure and test the relay see I O Test in Chapter 4 9 ...

Page 22: ...er to the meter PRIOR TO wiring Warning Use shielded twisted pair wires for this connection If the meter is installed near VFDs install wiring in grounded metal conduit Note These instructions for instruments with main PCB 22302 0002 Rev F or earlier For instructions on performing a 4 20 mA calibration and or test refer to I O Test in Chapter 3 1 Refer to Figures 2 13 and 2 14 4 20 mA Current Loop...

Page 23: ... mA loop and remove the meter access cover 3 Use jumpers to configure the pins on the 4 20 mA card according to the power option selection 4 Connect the wiring to the module 5 Replace the access cover Figure 2 13 Self powered current loop pin configuration Figure 2 14 Externally powered current loop pin configuration ...

Page 24: ...ing in grounded metal conduit Note These instructions for instruments with main PCB 22302 0002 Rev G or later For instructions on performing a 4 20 mA calibration and or test refer to I O Test in Chapter 3 1 Refer to Figures 2 15 and 2 16 2 Select a power option for the 4 20 mA loop and remove the meter access cover 3 Use jumpers to configure the pins on the 4 20 mA card according to the power opt...

Page 25: ...Figure 2 16 Externally powered current loop Warning Prevent possible electrical shock and or damage to the meter Disconnect power to the meter PRIOR TO wiring Refer to step 9 in Manual Mode Chapter 3 for instructions on enabling the remote zero function 1 Refer to Figure 2 17 Connecting a Switch to Remote Zero Feature ...

Page 26: ...within the same block used for connecting DC power 4 Turn the screws on top of the transducer block counterclockwise to fully open the connections 5 Make the following connections a First switch wire to RLYCOM b Second switch wire to POSZERO 6 Turn the screws clockwise to close the connections 7 Ensure the wire connections are secure and replace the meter access cover ...

Page 27: ...Installation Wiring 2 16 Polysonics SX40 User Guide Thermo Electron Corporation Figure 2 17 Remote zero connections ...

Page 28: ...s once you have made an entry Backspace Deletes the last value entered Numeric keys Use to enter values when configuring the meter Menu selection keys Press to select the corresponding menu item displayed on the LCD 1 Press the key 2 When the Adjust Contrast screen appears press the key again and the software scrolls through the levels of contrast Press the key to stop the scrolling 3 Use the scro...

Page 29: ...r the pipe ID and press Enter b Use the scroll key to select the measurement units inches mm Press Enter to select the unit c Scroll through the available wall material options carbon steel cast iron concrete liner stainless steel copper plastic and press Enter to select 2 Select Next to move to the next screen At the Flow Units screen d Use the scroll key to select the flow units US gallons milli...

Page 30: ... copper plastic and press Enter to select 2 Select Next to move to the next screen At the Flow Units screen a Use the scroll key to select the flow units US gallons million gallons cubic meters oil barrels Imperial gallons cubic feet liters liquid barrels and press Enter b Use the scroll key to select the time base for flow measurement seconds minutes hours days and press Enter 3 Select Next to co...

Page 31: ...ss Enter and scroll to the next parameter When a zero flow condition occurs internal sloshing and other fluid movement can prevent the flowmeter from reading total zero This can result in totalizer errors Minimize these errors by setting a low flow cutoff which drives the flowmeter to zero for flow rates at or below specified value b Enter the Signal Strength Cutoff and press Enter 6 Select Next t...

Page 32: ...l room that is powered by an independent source can indicate when the meter looses power This feature is ideal for applications where flowmeter operation is critical d Reset the power monitor by selecting Yes 10 Select Next The next four screens enable you to configure the relays Determine which relay you want to configure and move to that screen a Determine the maximum allowable flow If you want ...

Page 33: ...uide Thermo Electron Corporation 14 Set the time and date at this screen and press Next to complete the configuration process You can also use the HydraScan software to configure the instrument Refer to the HydraScan user guide P N 1 0563 005 HydraScan ...

Page 34: ...for you to test them Note Exiting this screen returns all relays to the OFF positions Activate the relays according to step 10 of Manual Mode in Chapter 3 At the Relay Test screen scroll to the relay you want to test Simply press Enter to switch the relay on energize and press Enter again to switch the relay off de energize Note You will need a calibrated current meter to perform this procedure If...

Page 35: ...the changes If the meter does not follow the changes repeat the calibration Flow menu items are covered in the following chapter Trend runs at a real time rate of action To view the flow trend select Trend from the Flow menu From the Trend screen select Rate Scroll through the available rate options 0 1 0 5 1 5 15 60 minutes reading Press Enter The meter records the maximum flow date and time of t...

Page 36: ...ves the data in sequenced files 0 to 9 The meter advances to the next file each time the logger is turned on or when a file logs more than 9000 points You can use HydraScan to download save load and erase log files Refer to the HydraScan user manual 1 0563 005 Trend runs at a real time rate of action To view the flow trend select Trend from the Flow menu From the Trend screen select Rate Scroll th...

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Page 38: ... 6 1 Action codes Action Description A 1 Turn meter off 2 Apply more compound 3 Tighten the pipe strap 4 Restart the meter to see if warning clears B 1 Reposition transducers 2 See if signal strength increases 3 See if warning clears 4 Restart the meter C 1 Relocate transducers 2 See if signal strength increases 3 See if warning clears 4 Restart meter D 1 Turn meter off and remove the transducers ...

Page 39: ...5 Contact Thermo Warning Low S Strength 1 Turn meter off 2 Refer to Table 6 1 and complete actions A D checking the meter after performing each action to see if the problem was corrected 3 Contact Thermo Warning Poor S Quality 1 Go into operating mode 2 Check the FFT Table 6 3 Operating mode warnings corrective actions Warning Corrective Action PQ Poor Signal Quality 1 Check the FFT 2 Refer to Tab...

Page 40: ...nstalling the power mains in grounded metal conduit may be required 1 From the Flow screen select FFT 2 Refer to Figures 6 1 through 6 6 to determine the FFT condition 3 Refer to the table below to determine the corrective action 4 Return to the Flow screen Table 6 4 FFT Shape Possible Cause Corrective Action Ideal Doppler N A 1 Restart the meter Broadband noise Poor pipe coupling or multiple nois...

Page 41: ...ing Maintenance 6 4 Polysonics SX40 User Guide Thermo Electron Corporation Figure 6 1 Ideal Doppler shape Figure 6 2 Broadband noise Figure 6 3 Steady noise spike with Doppler Figure 6 4 Fluctuating Doppler profile ...

Page 42: ...rength are indicators of how well suited an application is for a Doppler flowmeter To determine the quality of your application go to the Flow screen Note the SS and SQ numbers in the bottom right corner Refer to the following figure to determine the quality of the application Also refer to Table 6 1 for actions you can take to attempt to improve signal quality and strength Figure 6 7 Signal Quali...

Page 43: ...lly or whenever 1 Compound diminishes 2 Repositioning transducers 3 Relocating meter Flowmeter None Factory service item N A Cable connections Ensure connections are secure Remove any buildup within the connections Complete as part of your facility s routine maintenance Warning Prevent possible electrical shock and or damage to the meter Disconnect power to the meter PRIOR TO wiring 1 Disconnect t...

Page 44: ...orners of the module and lift the module straight out to prevent damage to the connector on the main board 4 Align the pins on the replacement module with the connector on the main board 5 Press the module straight in toward the board 6 Ensure the screw holes in the mounting posts on the main board align exactly with the screw holes in the module and replace the screws 7 Wire and configure referen...

Page 45: ...1 Locate the hole in the meter access cover marked FUSE or remove the access cover and locate the fuse holder shown in Figure 6 8 2 Use a small flat blade screwdriver to depress and turn the fuse holder counterclockwise until the holder pops up 3 Insert a similar fuse of the same rating see Figure 6 9 4 Replace the fuse holder Depress and turn the holder clockwise until it locks in place 5 Replace...

Page 46: ...swer questions and provide application assistance If it becomes necessary to contact technical support directly please have the software revision installed in your system available You can obtain support by contacting any of the following USA Thermo Electron Corporation Process Instruments Division 9303 W Sam Houston Parkway S Houston TX 77099 713 272 0404 phone 713 272 5388 fax Web www thermo com...

Page 47: ... charge products which are found by Thermo to be defective in material or workmanship and which are reported to Thermo within the warranty period as provided above This right to replacement shall be Buyer s exclusive remedy against Thermo Thermo shall not be liable for labor charges or other losses or damages of any kind or description including but not limited to incidental special or consequenti...

Page 48: ...Thermo Electron Corporation Polysonics SX40 User Guide A 1 Appendix A Hazardous Area Installations Figure A 1 Hazardous area installation with barriers ...

Page 49: ...Hazardous Area Installations A 2 Polysonics SX40 User Guide Thermo Electron Corporation Figure A 2 Hazardous area installation without barriers ...

Page 50: ...1 610 2 067 2 469 0 957 1 278 1 500 1 939 2 323 3 3 5 4 5 6 3 500 4 000 4 500 5 563 6 625 3 334 3 834 4 334 5 345 6 407 3 260 3 760 4 260 5 295 6 357 3 068 3 548 4 026 5 047 6 065 2 900 3 364 3 826 4 813 5 761 3 624 4 563 5 501 2 624 3 438 4 313 5 187 3 068 3 548 4 026 5 047 6 065 2 900 3 364 3 826 4 813 5 761 8 10 12 14 16 8 625 10 750 12 750 14 000 16 000 8 407 10 482 12 438 15 670 8 329 10 420 ...

Page 51: ... 17 40 19 50 21 60 12 12 14 16 16 20 18 22 20 26 13 20 15 30 17 40 19 50 21 60 11 96 13 98 16 00 18 00 20 00 13 50 15 65 17 80 19 92 22 06 12 14 14 17 16 20 18 18 20 22 13 50 15 65 17 80 19 92 22 06 12 00 14 01 16 02 18 00 20 00 13 78 15 98 18 16 20 34 22 54 12 14 14 18 16 20 18 20 20 24 13 78 15 98 18 16 20 34 22 54 12 00 14 00 16 00 18 00 20 00 14 08 16 32 18 54 20 78 23 02 12 14 14 18 16 18 18 ...

Page 52: ...6 3 98 6 04 8 15 10 16 12 22 0 125 0 250 14 16 18 20 24 15 30 17 40 19 50 21 60 25 80 14 64 16 72 18 80 20 88 25 04 14 58 16 66 18 74 20 82 24 98 14 52 16 00 18 68 20 76 24 92 14 46 16 54 18 62 20 70 24 86 14 40 16 48 18 56 20 64 24 80 14 34 16 42 18 50 20 58 24 74 14 28 16 36 18 44 20 52 24 68 0 1875 0 375 30 36 42 48 54 32 00 38 30 44 50 50 80 57 10 31 22 37 44 43 56 49 78 55 96 31 14 37 34 43 4...

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