MODEL VF & GVF-100 FLOW and ENTRAINED GAS MONITORING SYSTEM INSTALLATION & STARTUP MANUAL CiDRA Corporation Tel. 203-265-0035 50 Barnes Park North Fax. 203-294-4211 Wallingford, CT 06492 www.cidra.
Table of Contents 1 INTRODUCTION .................................................................................1-1 1.1 Sensor Head Description and Function..............................................1-1 1.2 Transmitter Description and Function ................................................1-1 2 INTELLECTUAL PROPERTY NOTICES.............................................2-1 3 EQUIPMENT SAFETY COMPLIANCE ...............................................3-1 3.1 Safety .......................................
8.4.1 Transmitter Housing Cable Entry .................................................8-3 8.4.2 Transmitter Output, Sensor and Sensor Head Connections ........8-4 8.4.3 Transmitter Electrical Power Cable Installation ..........................8-10 8.4.4 Sensor Calibration Label ............................................................8-12 9 TRANSMITTER FUNCTIONS .............................................................9-1 9.1 Transmitter Layout .......................................................
List of Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 Figure 45 Figure 46 Figure 47 Figure 48 Figure 49 General Warnin
Figure 50 Figure 51 Figure 52 Figure 53 Figure 54 Figure 55 Figure 56 Figure 57 Figure 58 Figure 59 Figure 60 Figure 61 Figure 62 Figure 63 Figure 64 Figure 65 Figure 66 Figure 67 Figure 68 Figure 69 Transmitter Front Panel Keyboard..............................................9-7 VF & GVF Startup Screen...........................................................9-8 Operating Transmitter Display ....................................................9-9 Initialization Mode .....................................
1 INTRODUCTION The CIDRA Corporation SONARtracTM Model VF & GVF-100 (Volumetric Flow and Gas Volume Fraction) System is a clamp-on process monitoring system used to measure the volumetric flow rate and the amount of entrained air / gas (also referred to as gas volume fraction or GVF) contained in a fluid within process pipes on a realtime basis.
output. The electronic assembly is housed in a rugged NEMA 4X enclosure.
2 INTELLECTUAL PROPERTY NOTICES CiDRA Corporation’s Process Monitoring Products may be covered by one or more of the following granted U.S. Patent(s): 6,354,147, 6,587,798, 6,609,069, 6,435,030, 6,691,584, 6,732,575, 6,782,150, 6,862,920, 6,889,562, 6,732,150. Other patents are pending; see www.cidra.com for the latest listing of patents. This manual is covered by U.S. and international copyright laws.
3 EQUIPMENT SAFETY COMPLIANCE 3.1 Safety This equipment is listed with TÜV Rheinland of North America, Inc., a nationally recognized testing laboratory, and certified for ordinary location use per the following US, Canadian, and European standards: UL 61010A-1, CSA C22.2 No. 1010, and EN 61010-1:2001.
3.4 CE Marking This equipment is CE marked for ordinary location use and complies with the following European Directives: 73/23/EEC Low-Voltage Directive 89/336/EEC EMC Directive Further details are listed in the EC Declaration of Conformity (P/N 20634-01), a copy of which can be found in Appendix B of this Document as well as on our website at http://www.cidra.com.
4 WARRANTY The terms and conditions, including warranty, of the purchase of CiDRA’s Process Monitoring Products is outlined in the document entitled “CiDRA’s Terms and Conditions of Sale”.
5 GENERAL SAFETY GUIDELINES CiDRA Corporation recommends the installer fully read this manual prior to installing and operating the SONARtracTM system. Note: Items that pertain to systems rated for Class I, Division 2, Groups A, B, C, and D operation are highlighted in italic print. 5.1 Introduction This manual is intended to be a general installation guide for the CiDRA SONARtracTM VF & GVF-100 System.
5.3.1 General Warning or Caution Figure 1 General Warning or Caution Symbol The Exclamation Symbol in Figure 1 appears in Warning and Caution tables throughout this document. This symbol designates an area where personal injury or damage to the equipment is possible. 5.3.2 Grounding Figure 2 Grounding Symbol The Grounding Symbol in Figure 2 appears on labels affixed to the SONARtracTM system.
5.3.5 General Warnings Observe these general warnings when operating or servicing this equipment: • Prior to operation of this equipment, personnel should read the • • • • instruction manual thoroughly. For systems installed in Class I, Division 2 areas, Power Entry and Inputs/Outputs must be installed in accordance with Article 501.10(B)(1) of the National Electrical Code ANSI/NFPA 70:2005.
• Ensure all power cords, sensor to transmitter cable and signal • • • • 5.3.6 cables are properly routed to eliminate damage to them. Cable conduit may be desirable to minimize potential damage. Prior to servicing, lockout all electrical power sources. Care should be taken when using the operator keypad to avoid touching any electrical connection or contact points. Do not wear rings or wristwatches when servicing this equipment.
6 UNPACKING AND PARTS LIST 6.1 Unpacking The SONARtracTM VF & GVF-100 will typically be packaged in three shipping containers. One box will contain the sensor band and sensor cover assemblies, and installation hardware; the second box will contain the transmitter assembly and installation hardware; and the third box will contain the sensor to transmitter cable assembly. Note: Cidra Corp. recommends the original packing materials be saved in the event that the system is removed or relocated.
6.3 Class I, Division 2 Labels Transmitters and sensor covers rated for use in Class I, Division 2 areas are labeled with the following information (or a subset of it) so they can be identified for use in those areas.
7 SENSOR INSTALLATION 7.1 Class I, Division 2, Groups A, B, C, and D Rated Equipment • Equipment so marked is suitable for use in Class I, Division 2, • • • • 7.2 Groups A, B, C, and D or non-hazardous locations only. WARNING – EXPLOSION HAZARD – Do not disconnect equipment unless power has been removed or the area is known to be non-hazardous. WARNING – EXPLOSION HAZARD –Substitution of components may impair suitability for Class I, Division 2.
7.3 Sensor Installation Guidelines The following are general installation guidelines and recommendations for installing a SONARtracTM sensor. • Where necessary, get a Hot Work Permit prior to installation of • • • • • • system. Select locations with well-developed flow profiles. Avoid installation locations directly after piping configurations that cause flow jetting. Install flow sensor upstream of control valves, “T”s, orifice plates, and any other severe source of flow disturbance.
WARNING Asbestos containing insulation materials may be present. Asbestos fibers have been known to cause health problems. If unsure of the contents of pipe insulation materials contact the plant representative for that area. WARNING Process Heating Tapes may be present. This may present an electrical shock hazard. Follow plant Lock-out / Tag-out requirements. WARNING Process pipes may be hot. A burn hazard may exist. Use care when working with hot pipes.
7.5 Sensor Band Installation It will be helpful to have a second person available to assist with holding the sensor assembly in position during installation. Note: Prior to installing the sensor band, remove and save the plastic bag from the sensor band that contains two sensor calibration factor labels. These will be used as described later in this manual for input to the transmitter. Ensure there is no dirt or other foreign material on the sensor assembly.
Wrap the sensor band around the pipe and slide the alignment pins on the attachment rail through their mating holes on the opposite attachment rail. If the process pipe has a welded seam, align the gap between the sensor attachment rails along the pipe weld seam. Final positioning can be made after the sensor screws have been started. Note: When installing the sensor band keep in mind the requirement for transmitter connector socket assembly orientation as described in Section 7.6.
Sensor screw Sensor screw spacer (may be integral to screw head) Sensor Belleville washers concave side Sensor Belleville washers convex side Note: 10 Belleville Washers on 2-16” bands Belleville washers and spacer compressed against screw head )()()()()()()( Figure 8 Note: Sensor bands 18” and larger have 14 Belleville washers per screw arranged as shown Sensor Band Screw Assembly Further tightening of the sensor band screws is made while using the sensor band spacer tool (shown below) furnished
Using the sensor band screw tightening sequence shown in Figure 9, insert the sensor band spacer tool over the Belleville washers on the middle sensor screw assembly and tighten it such that it is snug but the spacer tool can still be removed. The following figure illustrates use of the sensor band screw spacer tool.
connector as described later in the manual. If necessary, use a piece of tape to temporarily retain the connector on the band so it will be positioned directly below the sensor cable access panel. The final sensor band assembly is illustrated below. Sensor cable installed in cable retaining clip Sensor screws tightened Sensor cable connector with shorting plug installed Alignment pins Figure 11 Installed Sensor Band CAUTION Over-tightening of fasteners may damage threads on the sensor.
7.6 Sensor Cover Installation The upper sensor cover assembly outside and inside are illustrated in the following figures. Cover sizes up to 16 inch are typically made of fiberglass. Cover sizes 18 inch and above are made from stainless steel. The layout of both styles is essentially the same. The differences in installation will be called out in the following sections.
It is helpful to have a second person available to help when installing the cover assembly. When the sensor head is installed on a horizontal pipe, the sensor cover should be installed such that the transmitter cable connector socket is located within the 105° arcs shown in the following figure. Do not install the cover with the transmitter cable connector socket installed downward. (An electrical pre-amplifier board is mounted on the inside of the cover.
The following steps will help minimize this problem: 1. Visually look between the cover halves to ensure the cable is not being pinched. 2. Once the cover halves are bolted in place and during installation of the sensor band cable connector into the pre-amplifier through the access cover, verify the sensor band cable is free and not pinched between the cover halves. 3.
Tighten the alignment bolts 2 – 3 turns alternating between both sides of the cover until the cover bolts protrude through the lower cover assembly. Note: Use of the alignment bolts may not be necessary if the cover bolts and nuts can be made up. Place a washer, lock washer and nut on the end of the sensor cover bolt once it is through both halves of the cover and begin drawing the cover halves together using the cover bolts.
7.6.2 Stainless Steel Cover Installation The stainless steel cover is illustrated in the following figure. Transmitter cable connector socket Sensor cable access panel Cover lifting handles (4 plcs) Upper cover assembly Fender assy (4 plcs) Boot Gasket (upper & lower covers Lower cover assembly Figure 17 Stainless Steel Cover Assembly WARNING The handles on the stainless steel cover are not designed or rated for hoisting the cover.
Apply coating of Joining Compound Figure 18 7.6.2.1 Applying Joining Compound to Gasket Edge Boot Gasket Band Installation The boot gasket band will be shipped cut to length for the cover size with the retaining buckle pre-installed. The boot gasket band should be completely installed on one end of the cover and then repeated on the other end.
Remove the GelTek paper backing from the splice protector plate, lift the band using needle nose pliers or a screwdriver, and slide the plate into position over the flange gasket. Be careful the GelTek stays in position on the plate. Pull the band taut. Tighten the socket head cap screw on the band buckle just enough to keep the band in place but loose enough so it will still slide through the buckle. Repeat on the opposite end of the cover.
Tension the band until the resistance on the tool handle is constant (i.e. the band does not slide easily through the buckle). The boot gasket should be tight against the process pipe under the gasket protector plate. Verify the band buckle and splice protector plates are still in place. Tighten the setscrew to lock the band in place. The band will be dimpled by the setscrew.
Figure 25 7.6.3 Boot Gasket Fender Assembly Sensor Assembly Cable Connection Remove the tape (if it was used) that was temporarily installed to retain the sensor connector under the cover access panel. Remove the factory installed shorting plug from the sensor cable connector. Place the shorting plug in the holder in the transmitter housing. (It will be used if sensor removal from the pipe is necessary.
Re-install the sensor cable access panel on the sensor top cover assembly. Tighten the six panel screws to a recommended torque of 11-lbf-in (1.2-Nm). 7.6.4 Rain Boot Installation A sensor cover rain boot will be installed on the upward facing end of sensor covers when the sensor head is installed in vertical applications. The rain boot serves as a secondary seal against water leakage under the cover (the sensor cover seal is the primary seal). Note: The stainless steel covers do not need a rain boot.
Figure 27 Sensor Calibration Label Copyright © 2006 CiDRA Corporation Page 7-19 20675-01 Rev 02
7.7 Sensor to Transmitter Cable Connections The sensor to transmitter cable is used to transmit sensor signals and information between the transmitter and the sensor, and provides electrical power to the sensor pre-amplifier board mounted in the sensor cover. The sensor to transmitter cable consists of 12 twisted pairs of 20 AWG conductors with an overall cable shield encased in a PVC jacket. The standard cable has an operating range of -4 ºF to 221 ºF (–20 ºC to 105 ºC).
7.8 Installations on Tubing The sensor head will fit on process tubing as well as pipe. This is accomplished through the use of a sensor band specifically sized for tubing and the use of elastomeric strips wrapped around the tube (in order to increase the tube diameter to that of pipe) in the areas of the pipe seal gaskets on the fiberglass cover.
8 TRANSMITTER INSTALLATION 8.1 Transmitter Power Requirements The AC version of the transmitter can accommodate an input voltage of 100 – 240 volts AC, 50/60 Hz, and requires 25 watts of power. The AC powered transmitter input power is fuse protected by two 1 amp, 250 volt, 5mm x 20mm fuses. The DC version of the transmitter can accommodate an input voltage of 18 – 36 volts DC and requires 25 watts of power. The DC powered transmitter input power is fuse protected by two 3.
8.3.1 Bulkhead Mounting The transmitter is attached to the bulkhead or panel with user supplied 1/4-inch fasteners through the four panel mounting feet on the transmitter. The mounting dimensions are illustrated in the following figure. 4X 0.31 (8) slot Panel mount feet (4 places) Note: Dimensions in inches (mm) 11.88 (302) 8.00 (203) Figure 29 8.3.2 14.22 (361) 4X 0.
8.4 Transmitter Cable Connections The following figure illustrates the basic power and signal connections for the SONARtracTM VF & GVF Monitor. These are discussed in further detail in the following sections. Fuses Optional power switch Power connector I/O and sensor connects Figure 31 8.4.1 Power and Signal Interconnects Transmitter Housing Cable Entry Power, sensor signal, and input /output signal cables enter the transmitter housing through cable glands.
WARNING Transmitter cover screws must be securely tightened and NEMA 4X rated cable glands and hole plugs must be used in Class I Division 2 applications. Failure to do so may result in violation of Class I Division 2 certification. 8.4.2 Transmitter Output, Sensor and Sensor Head Connections The following figure shows the layout of the transmitter terminal strip board. This board is divided into three sections. The Section#1 terminal blocks are for transmitter outputs.
8.4.2.1 Transmitter Output Connections (Section #1) The following figure provides a close-up of the transmitter output terminals (Section #1 of the terminal board) with their functions listed in the following table. These outputs can be connected as appropriate to permit communications between the transmitter and other equipment.
8.4.2.2 Transmitter Input Connections (Section #2) In some cases, a pressure or temperature transducer signal is used as an input to the transmitter. These terminals are shown in the following figure. Figure 35 Transmitter Sensor Terminals When used, the setup of the individual sensors is performed as part of the overall transmitter setup detailed in this manual. 8.4.2.
WARNING For Class I, Division 2 applications, Sensor Head Cable must be installed in accordance with Article 501.10(B)(3) of the National Electrical Code ANSI/NFPA 70:2005. The transmitter is shipped standard with a cable gland. Replace as local wiring requirements dictate. 8.4.2.3.1 Non-armored cable installation Remove 10 - 12 inches (25 – 30 cm) of outer jacket from the transmitter end of the cable.
Wire Pair # Transmitter Terminal # Function SENSOR CONNECTOR PIN NUMBER 1 Wht/Blk 1 Sensor #1 Input 1 - Wht 13 - Blk 2 Wht/Blk 2 Sensor #2 Input 2 - Wht 14 - Blk 3 Wht/Blk 3 Sensor #3 Input 3 - Wht 15 - Blk 4 Wht/Blk 4 Sensor #4 Input 4 - Wht 16 - Blk 5 Wht/Blk 5 Sensor #5 Input 5 - Wht 17 - Blk 6 Wht/Blk 6 Sensor #6 Input 6 - Wht 18 - Blk 7 Wht/Blk 7 Sensor #7 Input 7 - Wht 19 - Blk 8 Wht/Blk 8 Sensor #8 Input 8 - Wht 20 - Blk 9 Wht/Blk 9 Spare – unused --- -
Armored cable is shipped with the appropriate connector pre-installed on the cable and with the cable prepared for installation in the transmitter. Armored cable installation is similar to the non-armored installation except for the following. • Cut the cable to desired length (if necessary) using a hacksaw to cut through the armor and remove about 14” (36 cm) of outer jacket from the transmitter end of the cable.
• Install the seal washer on the connector assembly entry component. Insert the cable and entry component into the middle hole in the transmitter box (stiffener plate previously installed.) Secure the connector assembly with the retaining nut. Attach the ground wire from the connector nut to any available SHD terminal on the Section #3 terminal block. Strip and install the individual connectors and shield wire per non-armored cable installation instructions.
Feed electrical power wires through the fitting. Referring to the following figure, attach the ground wire (green) to the Ground ( ) terminal , hot (black - U.S., brown - Eur) to the L (+) terminal, and neutral (white – U.S., blue – Eur) to the N (-) terminal. Line In (+) Ground ( ) Neutral (-) Figure 41 8.4.3.2 Transmitter Power Connection DC-Powered SONARtracTM Any voltage within the range of 18 – 36 VDC can be applied to the DC version of the SONARtracTM.
8.4.4 Sensor Calibration Label The sensor band is shipped with two labels attached to it. The label lists the sensor band part number, serial number, date of manufacture and three calibration factors. This information will be entered into the transmitter during setup. If not done previously, install the Sensor Band Assembly label on the inside of the transmitter cover (the other label goes on the sensor head access panel).
9 TRANSMITTER FUNCTIONS The following section of this manual will present the transmitter layout and menus in the SONARtracTM process monitoring system. 9.1 Transmitter Layout The transmitter layout is depicted below. Here each of the major components is labeled.
9.2 Transmitter Output Definitions The following figure shows a diagram of the output portion of the terminal board. The outputs of the transmitter are connected to communicate between the transmitter and other equipment. Figure 44 Transmitter Output Terminals COMM – This denotes the connection point for serial digital communications. Either RS232 or RS485 communications is supported with baud rates settable between 2400 and 115200 baud (8 bits, no parity, 1 stop bit).
PULSE – An isolated solid-state switch-closure-type output occurs between P+ and P- whenever conditions are met that are determined by the pulse setting within the transmitter. The maximum applied voltage between P+ and local ground and P- and local ground shall be within the range of +30V / -10V. The load current shall be a maximum of 100mA. Typical turn on time is 1 msec. Typical turn off time is 0.1 msec. Refer to the following figure and example.
CUR1 – These terminals are used for connection to the primary 420mA output from the transmitter. The transmitter can be configured such that an external supply can be used for power (i.e. the 4-20mA loop current is driven externally) or such that the transmitter itself will power the loop. A combination of power wiring and internal software setting will ensure that the 4-20mA output will function properly. The following figures show proper wiring for internal and external power.
Externally Powered 4-20mA Loop Configuration - The hookup for a 4-20mA interface configured as “Externally Powered” is shown below. The maximum value of VEXT should be chosen such that the maximum applied voltage between VEXT and local ground and IOUT and local ground shall be within the range of +30V / -10V and current limited to 100mA. The maximum value of RL is determined by the following equation: RL Max = (VEXT – 8.35) / (0.022) For example, with VEXT = 24VDC: RL Max = (24-8.35) / (0.
9.3 Transmitter Input Definitions Entrained Air calculations use inputs of pressure and temperature. These inputs can be made through the use of pressure and temperature transducers, or alternatively, an assumed value for pressure and temperature can be input into the transmitter during its setup. Two transmitter terminal blocks (shown below) are provided for pressure and temperature transducers.
9.4 Keypad The keypad controls used to set up and access the user input screens are illustrated in the following figure. Figure 50 Transmitter Front Panel Keyboard The SONARtracTM display has 2 distinct modes: the operational mode where the measured parameters are displayed and the menu mode where various system parameters can be set. In each of these modes the keypad will have different functions. The following table shows the function of each key in the keypad depending on the display mode.
9.5 Transmitter Display The transmitter display functions in two distinct modes: an operational mode and a menu mode. These two modes will be explained in the following sections. 9.5.1 Operational Mode The transmitter screen displays the status of the SONARtracTM system. A few typical screen messages and their interpretation follow. 9.5.1.
9.5.1.2 Operating Transmitter Display In operating mode the display screen is split into three distinct portions. The majority of the screen is devoted to a 2-line measurement display as illustrated below. The bottom portion of the screen will display status and configuration information. V Line 1 2281.5 gpm 2.016 % F G Line 2 V Status Line F SSSSSSSSSSSSSSSSSSSS Figure 52 9.5.1.2.
• Status Messages - ‘S’: A number of status messages can be displayed in the 20 character status message field.
• Mode Messages – ‘M’: The four character mode field is used to display the operating mode of the system. Their definitions are as follows: Mode Message Description ‘IDL’ Idle / Stop Mode ‘RAW’ Transferring raw data ‘SNG’ Performing a single measurement ‘GVF’ Running in Gas Volume Fraction / Speed Of Sound mode ‘VF’ Running in VF mode blank Running in VF / GVF / SOS mode Table 12 Mode Message Definitions • Communications (C): Indicates a connection (Ethernet) or activity (Serial).
9.5.1.3 Display Examples The following figure shows the display when the system is collecting data to calculate a measurement. The ‘------‘ indicates the system is unable to make a measurement, or an internal parameter was changed that has caused the system to re-initialize. V F G V F VF INITIALIZE MODE Figure 53 ------ gpm ------- % / Initialization Mode In the following display the system is making a measurement. The flow rate is 2281.6 gpm and the entrained air of GVF reading is 2.016 %.
BASIC CONFIG SENSOR SERIAL # PIPE SIZE ID/Wall Size/Sch OD/Wall PIPE MATERIAL OUTPUT CONFIG 4-20mA CH 1 Output Sel Power Sel Low End High End Out Of Range Overrange Rail 4mA Trim 20mA Trim SENSOR #1 INPUT CONFIG Units Scale (per mA) Offset (mA) SENSOR #2 FLUID PROPERTIES Spec Gravity SOS (ft/s) Viscosity (Pa-s) 4-20mA CH 2 PRESSURE TEMPERATURE PRESSURE SEL TEMP SEL ALTITUDE CALIBRATION C0 C1 C2 FLOW DIRECTION Forward/Reverse OP MODE VF/GVF/VF&GVF SET DATE/TIME PULSE Output Sel Power Sel Low
When the display is in operational mode, any key pressed will enter menu mode. In this mode the keypad is used for traversing the menu tree and for modifying system parameters as previously detailed in Table 13. In menu mode the screen is divided into four lines of information. The following figure shows an example of a typical menu screen. BASIC CONFIG • PIPE SIZE INNER DIAM 8.
The following figure shows an example of the second type of parameter editing. In this case the whole parameter is highlighted and the up and down arrow keys will cycle between the available settings. When editing a parameter the ‘ENTER’ key will accept and save the current value. Alternatively the ‘BACK’ key will revert the current parameter to the value before editing was begun. The ‘EXIT’ key will also revert to the previous value (similar to the ‘BACK’ key) and will exit Menu mode.
Table 14 Level 1 Level 2 Transmitter Menu Tree Software Release 03.03.XX Level 3 Range Description 0000000 Serial number of sensor band ID/Wall ID: 1- 100 in (25.42540mm) Wall 0 – 100 in (0 to 2540 mm) Pipe inner diameter and wall thickness Size/Sched 2 to 36" size; schedule Pipe size & schedule OD/Wall ID: 1- 300 in (25.
Table 14 Transmitter Menu Tree Software Release 03.03.
Table 14 Transmitter Menu Tree Software Release 03.03.
Level 1 Level 2 Flow & GVF Damping Flow & GVF Noise Filter Output Config (cont) Level 3 Range Description State Enable, Disable Enable Damping Time Constant (s) 0-600 seconds; default is 3 Smoothes output due to rapid changes in flow State Enable, Disable Enable noise filtering Magnitude Low, High Amount of damping State Enable, Disable Enable spike filtering Length 2 - 60 readings # of measurements to validate Percent or Delta 0 – 100 % % of full measurement range that will define
Table 14 Transmitter Menu Tree Software Release 03.03.XX (page 5) Level 1 Level 2 Sensor #1 Level 3 Range Description Units PSIg, None, F, C, Barg, kPag Parameter input Scale 0.0000 e-38 to 9.9999 e+38 per mA Input range divided by mA range Offset 0.0000 e-38 to 9.9999 e+38 per mA Correction due to a nonzero mA minimum output Units PSIg, None, F, C, Barg, kPag Parameter input Scale 0.0000 e-38 to 9.9999 e+38 per mA Input range divided by mA range Offset 0.0000 e-38 to 9.
Table 14 Transmitter Menu Tree Software Release 03.03.
Table 14 Transmitter Menu Tree Software Release 03.03.XX (page 7) Level 1 Level 2 Level 3 Range Description IP Address 0.0.0.0 to 255.255.255.255 Current IP address Subnet Mask 0.0.0.0 to 255.255.255.255 Current Subnet Mask Baud Rate 2400 to 115200 Serial baud rate Config RS232 or RS485 Serial communications protocol type Preambles 5 - 20 # Preamble chars ahead of MSG Resp. Preambles 5 - 20 # Preambles in response from transmitter. Change to match HART communicator Univ. Cmd. Rev.
Table 14 Transmitter Menu Tree Software Release 03.03.XX (page 8) Level 1 Level 2 Level 3 Range Description Sensor Check PASS or FAIL. (Indicate which sensors failed test) Performs health check on each sensor 4-20mA Test Test 4-20mA outputs from 4 to 20mA Manual testing of 420mA output #1 and 2 1.0, 4.65, 21.55, 98.65 Provides auto adjustment of preamplifier setting based on the current process operating condition 1.0, 4.65, 21.55, 98.
Table 14 Transmitter Menu Tree Software Release 03.03.XX (page 9) Level 1 Info Level 2 Level 3 Range Description Revisions Provides a list of installed hardware and software Diagnostic Provides a list of key system temps, volts, status Configuration Summary of the system setup Event Log Log of system events (i.e. errors, sensor over ranges, etc.
Each of the system parameters listed above can be accessed and modified using the front panel keypad. Any changes made to any of these parameters will be saved in non-volatile memory and will not be lost when power is removed from the transmitter. Several of the parameters have direct links to other parameters found in different locations in the menu structure. Therefore, it is possible that by changing the value of one parameter it will automatically change the other linked parameter.
10 TRANSMITTER SETUP 10.1 Transmitter Menus The following pages present the steps necessary to setup and operate the SONARtracTM VF & GVF-100 system. Whenever a transmitter front panel entry is made, the transmitter will re-start and output to the plant control or data logging system will be interrupted. It is recommended that the process control room be alerted prior to accessing the transmitter front panel.
‘Viscosity’ - Input is default to water at 25 ºC and 14.7 psia. Refer to Appendix E for unit conversions and Appendix F for other temperatures and pressures. ‘Custom user selectable values can also be set. • Pressure This input is an important parameter for accurate GVF measurement. If the process pressure is constant, input the normal process operating pressure into the transmitter in units of PSIg, Barg or kPag.
transducer, user must configure the sensor inputs in the ‘Input Config’ menu. • Altitude Used to calculate the atmospheric pressure corrected for elevation. Enter the elevation above or below sea level. The following equation is used within the transmitter to correct for elevation. Patm = 14.696 * [1 – ((Alt * 10-3)/145.45)]5.
selection of the ‘GVF’, ‘SOS’, ‘Flow Rate’, or ‘Blank’ for no display as the output parameter. The ‘Power Sel’ selection is used to specify whether ‘Internal’ power or ‘External’ power is used to drive the 4-20mA current output. The ‘Low End’ and ‘High End’ menu selections allow the user to change the upper and lower values that are output on the 4-20mA channel. For SOS reporting this is based on 5,000 ft/sec as the maximum output value.
4-20mA Output vs. Flow Velocity 20 19 18 17 16 15 mA Output 14 13 12 11 10 9 8 7 5.6 6 5 4 0 3 6 9 12 15 18 21 24 27 30 Flow Velocity (fps) Figure 60 4-20mA Output Set to 0 – 30 fps Note: For a 4-20mA setting of 0-100%, the system Low Flow Cut Off of 3.0 fps, from the 4–20 mA output will be 5.6mA. At flows less than 3.0 fps, greater than 30.0 fps, or if the meter is not working, the display will read as configured in the setup of the ‘Out of Range’ (i.e.
‘4mA and 20mA Trim’ – allows user to adjust the transmitter 4-20mA outputs to match the plant standard or loop control. The following message screen will appear when this menu item is selected. Connect reference meter to the 4-20 Loop and enter the meter value below. NOTE: You must first perform 4mA Trim first Press ENTER to Continue Figure 61 4-20mA Trim Message box Press ‘ENTER’ to clear the warning and ‘ENTER’ to input the current value measured on the reference meter.
‘Low Cutoff’ - Setting at which the Pulse output will turn off. Care must be taken to configure the multiplier and pulse width to allow the full range of the pulse output to be: 1. Measurable by the user’s equipment. There may be a limitation on the minimum pulse width the user’s equipment can detect. 2. Less than the maximum pulses per second allowed by the transmitter.
‘Flow Rate’, ‘Flow Rate %’, ‘SOS’, and ‘GVF’ generate a different pulse output than ‘Total Flow’ (‘Totalizer’). Flow Rate, Flow Rate %, SOS, and GVF will output a pulse frequency based on the current measurement. The pulse width will vary in order to maintain a 50% duty cycle pulse train.
The following is an example of Pulse settings applied to Flow Rate: Output: Flow Rate (Default setting, based on 8” schedule 40 pipe) Min Flow: 513.575 gal/m Max Flow: 5135.751 gal/m Pulse Output: Flow Rate Multiplier: 100 Pulse Width: 1 ms Low cutoff: 0% or 513.5 gal/m (no cutoff) Min Pulses: 5.136 Pulses per second Max Pulses: 51.357 Pulses per second In the above example, the Pulse output frequency indicates the flow rate in gallons per minute, divided by 100. The output will therefore vary between 5.
should be discarded and closed loop controls switched to manual during a critical alarm. The alarm can be cancelled either manually or will clear automatically when the alarm condition is no longer present depending on the menu option selected (see below). The following table lists the alarm parameters with their default values.
WARNING For Class I, Division 2 applications, follow established safety procedures prior to opening transmitter door. The ‘Alarm Warn Threshold’ and ‘Alarm Crit Threshold’ menu selections are used to set the flow rate and gas volume fraction alarm set points. All other parameters must be set using the Configure menu options in SONARtrac Basic Program. • SONARtracTM Filters The SONARtracTM transmitter has 3 modes of signal output filtering. These are ‘Damping’ ‘Noise Reduction’, and ‘Spike Filtering’.
particularly useful in applications where spurious signals are detected by the meter and are then reported on the display and the transmitter outputs. Once the meter is running and displaying values, this filter will provide two other forms of spike suppression. The first is for spurious dropouts due to poor quality readings. The filter will hold the last good value until a user programmable number of consecutive bad readings have been accumulated.
10.1.3 Input Config The Input Config menu is used when optional external sensors (for example a pressure or temperature transducer) are powered by and input to the transmitter. The transmitter does not have the capability to display or transmit these sensor values. Note: When these sensor inputs are used the ’Temperature Sel’ and ‘Pressure Sel’ menu options under the ‘Basic Config’ menu must be used to designate which sensor input is used for a particular measurement.
• Flow Units The menu selectable ‘Units’ are ‘gal’ (gallons), ‘l’ (liters), ‘m3‘, (cubic meters), ‘user’ (user defined), ‘iga’ (imperial gallons), ‘ft3‘ (cubic feet), ‘ft’ (feet), ‘m’ (meter). The menu selectable units for ‘Time’ are ‘s’ (second), ‘m’ (minute), ‘h’ (hour), ‘d’ (day), ‘user’ (user defined). In both the ‘Volume’ and ‘Time’ selections custom user labels can be input by the user by selecting ‘user’ from the menu.
10.1.5 Communications Menu • Ethernet Option is used to view and set the IP address and Subnet Mask of the transmitter. • Serial Options Used for setting up the ‘Baud Rate’ and the serial communications to ‘RS232’ or ‘RS485’. • HART Settings are used for configuring the protocol when using HART. Default is for single device addressing. • Reset Comms Used to re-initialize the communications ports without loosing data history (as would happed by re-initializing the transmitter).
In previous figure the sensor band failed the test. Sensor 1 and 2 are either mis-wired between their terminals or reversed (wht to blk). Sensor 7 is disconnected (open circuit). If an error is noted when the sensor test is first run, repeat the test to confirm the fault. If the error occurs at first power up, verify wiring termination at the transmitter terminal block.
• Clear History Will delete transmitter stored Data History and re-start saving of transmitter data. • Param Edit This is a diagnostic feature rarely used and should only be used under the direction of CiDRA personnel. Contact CiDRA Technical Support. • Monitor Displays a set of various ‘System’ or ‘Sensor’ parameters, updated at the display update rate, Used by Factory Technical Support personnel. 10.1.
The following figure lists the potential error codes shown in the log. The codes can be used by service personnel to help identify a problem with the transmitter.
10.3 Resetting to Factory Defaults Note: It is recommended that factory defaults be reset only by factory qualified service personnel. All factors (Basic Config, Output Config, etc.) must be re-entered following a Reset to Factory Defaults. To ‘Reset to Factory Defaults’, press and hold the ‘EXIT’ key while pressing the reset switch on the upper left edge of the connector block board. Alternatively, switch transmitter Power OFF and press and hold the ‘EXIT’ key while turning Power On.
11 TRANSMITTER STARTUP & OPERATION 11.1 Initial Start-up At initial power up the Green LED will light and the transmitter will display startup progress; loading firmware into the system, loading system parameters, and the heartbeat indicator as it begins to collect data from the sensor head. Once startup is complete, the display will clear and begin displaying measurements. The following figure illustrates an initial system startup screen.
• • • • • • • ← and → to change position) to enter the sensor serial number. Once all digits are entered, press the ‘ENTER’ key to save to memory. ‘→Sensor Serial #’ will again be displayed on Line 2. Next, press the ↓ key to scroll to the ‘Pipe Size’ menu on Line 2. Press the ‘ENTER’ key to access the options available under that menu. Note: it is necessary to access only one of the following options. The first choice on the ‘Pipe Size’ menu is ‘→ID / Wall’ shown on Line 3 of the display.
• • • • • • values for water at various temperatures. Once the new value has been entered on Line 4, press ‘ENTER’. If no change is made (or after a change in Specific Gravity has been made) pressing the ↓ key will next display ‘→SOS’ on Line 3 and the current value on Line 4. To change the Line 4 value press ‘ENTER’ and use the arrow keys to enter the new value. Water at 25 ºC (4910.4 ft/s) is the default. Appendix E lists values for water at various temperatures.
• • • • • • temperature sensor will be used to input pressure to the transmitter press ‘ENTER’ and use the ↓ key to select either ‘Sensor #1’ or ‘Sensor #2’. (‘Sensor #1’ or ‘Sensor #2’ refers to the sensor input the temperature transducer is wired to on the terminal block within the transmitter box.) Once the selection is made, press ‘ENTER’. Pressing the ↓ key will next display ‘→Altitude’ on Line 2 and the selected value above (or below) sea level on Line 4.
Entry of inputs to the other Level 1 menus is by the same process as used in ‘Basic Config’. The following table provides a template for recording the transmitter setup for future reference.
Transmitter Serial Number: ______________ Basic Config As Left Sensor S/N Pipe Size Software Revision: __________ Output Config (continued) 4-20mA Ch2 Output Sel ID / Wall Power Sel Size/Sched Low End OD / Wall High End Out of Range Pipe Material Fluid Properties Specific Bravity Overrange Rail SOS (ft/sec) 4mA Trim Viscosity (Pa s) 20mA Trim Pressure Pulse Multiplier Temperature Width (ms) Pressure Sel Lowcut Temperature Sel Output Sel Altitude Alarm Control Calibration As Lef
Input Config Sensor #1 As Left Communications Units Ethernet Scale IP Address Subnet Mask Offset Sensor #2 As Left Serial Options Units Baud Rate Config Scale HART Offset Preambles Resp Preambles Univ Cmd Rev Customize Display Polling Address As Left Line 1 Find Dev Arm Line 2 Contrast Sensor Setup State Flow Units Volume Time User Vol Label User Vol Base User Vol Scale User Time Label User Time Base User Time Scale SOS Units Units Flow Cutoff Low End High End Totalizer Units L
12 TRANSMITTER USB PORT The USB port allows the user to interface with the transmitter without the use of a computer. Information is stored on a USB memory stick (a SONARstickTM) and then transferred to a computer for storage or transfer. Note: The USB port cannot be used for communications between the transmitter and a computer; it is for use only with a memory stick.
Level 1 Level 2 Level 3 Range Description Snapshot Automatically creates a file of 5 minutes Raw Data; 1 day of Data History; System Info, current Configuration, Event Log Load Configuration Automatically loads a Configuration File from the memory stick File for Save System Config Save Raw Data Alpha numeric entry Save Config Saves the named file Load Config Alpha numeric named files Allows for retrieving and loading a Configuration File Duration 1, 5, 10, 30, 60, 120, 240 minutes Selects
12.1 USB Port File Naming Convention Files collected from the transmitter using the USB Port are automatically named to readily identify them. They are named in accordance with the following naming convention: ssss_nnnnnnnnYYMMDDhhmmss.ext The following table details the naming convention: Characters Description ssss transmitter serial number, maximum of 4 characters nnnnnnnn name string, optional YY year MM month DD day hh hour mm minute ss second ext file extension (.txt, .ini, .
12.2 Save Snapshot Save Snapshot is a one step download of a pre-determined data set from the transmitter. The data set is comprised of the following. (Download of Snapshot takes about 6 – 7 minutes.) • Raw Data Raw Data is as the name implies, a set of unprocessed data from the sensor head. A raw data file (5 minutes duration) is downloaded during Snapshot. • Data History Data History is a compilation of flow system information that is saved within the transmitter.
12.4 Advanced Functions Advanced Functions provides the user with a menu of options for saving data to and uploading data from the SONARstickTM. It also allows for updating system firmware and managing files on the SONARstickTM, and setting the date and time in the transmitter. These options are discussed below. • System Config System Config function allows naming, saving and loading configuration files. (In Snapshot mode a configuration file is automatically saved.
These files are often opened using a spreadsheet program and analyzed using that tool. • Manage Files Manage Files function allows the user to manage the files that reside on the SONARstickTM. The ‘Delete File’ option allows for deleting single files from the SONARstickTM and ‘Delete All’ removes all files. • Set Date/Time Set Time/Date allows the user to change the time and date that is stored in the transmitter. The format of the date and time code is MM/DD/YY hh:mm:ss.
13 SENSOR REMOVAL PROCEDURE If removal of the sensor is required, the following procedure should be followed. 1. Specific details regarding the removal of the SONARtrac sensor should be discussed with a CiDRA representative prior to removal. 2. Obtain Hot Work Permit if required. 3. Turn off electrical power to the system. Follow lock-out / tag-out procedures as required. 4. Open the transmitter door using a screwdriver and remove the sensor band shorting plug (stored in the transmitter) if there is one.
10. Install a sensor band shorting plug on the sensor band cable. Note: Sensor bands with an “R” in the Part Number suffix (e.g. Part #: 20686-26-R) do not require a shorting plug. WARNING Potential electrical discharge. Always install a sensor band shorting plug (see item 10 above) on the sensor band connector whenever the sensor band connector is not installed in a mating connector. 11.
Appendix A SONARtracTM VF & GVF-100 SPECIFICATIONS A1 Physical Specifications A1.1 Power Supply AC Voltage Version: 100 to 240 Volts AC, 50/60 Hz, 25 watts DC Voltage Version: 18-36 Volts DC, 25 watts A1.2 Fuse Protection AC Voltage Version: The transmitter input power is fuse protected by two 1 amp, 250 volt, 5mm x 20mm fuses. DC Voltage Version: The transmitter input power is fuse protected by two 3.15 amp, 250 volt, 5mm x 20mm fuses. A1.3 A1.4 A1.
• Sensor to Transmitter Cable The standard sensor to transmitter cable consists of 12 twisted pairs of 20 AWG conductors with an overall shield encased in a PVC jacket. The standard cable has an operating range of -4ºF – +221ºF (–20ºC to +105ºC). The cable is UL Listed (UL Standard 13, Type PLTC) and CSA Certified (CSA C22.2 No. 214, PCC FT4). The outer diameter of the cable is 0.61 inch (15.5 mm) nominal. Optional low temperature and armored cables are also available.
A1.7 Fiberglass Sensor Head Cover Envelope The dimensions of the 2” to 16” fiberglass sensor head are given on the following figure and table. 30in (762mm) 0.3in (9mm) 4.2in (106mm) ‘B’ ‘C’ Fiberglass Sensor Head Envelope Model No Pipe / Tube Nominal Size Outside Dia Dim ‘A’ Dim ‘B’ Dim ‘C’ inch mm inch mm inch mm inch mm inch mm SH-E02-01-01 2 50 2.4 60 9.3 236 5.8 147 2.9 74 SH-T02-01-01 2 50 2.0 51 9.3 236 5.8 147 2.9 74 SH-D02-01-01 2.5 65 2.5 64 9.
A1.8 Stainless Steel Sensor Head Cover Envelope The dimensions of the 18” to 36” stainless steel sensor head monitors are given on the following figure and table. 4.2in (105mm) 0.3in (9mm) 1.7in (43mm) 4 plcs 34.7in (881mm) Stainless Steel Sensor Head Envelope Model No Pipe / Tube Nominal Size Outside Dia Dim ‘A’ Dim ‘B’ Dim ‘C’ inch mm inch mm inch mm inch mm inch mm SH-E18-02-02 18 450 18.0 457 22.9 581 22.4 568 11.2 284 SH-E20-02-02 20 500 20.0 508 24.8 631 24.
A1.9 Sensor Band Compatibility The sensor band assemblies are interchangeable with all sensor head cover assemblies of the same pipe diameters. Meter calibration factors are included for each sensor band assembly. All sensor head assemblies, independent of pipe size, are compatible with all transmitters. A1.10 Humidity Limits Transmitter: 0 – 100% A1.11 Analog Output Adjustment Two separate 4-20mA output signals scalable over stated range of meter. Primary 4-20mA output HART compatible. A1.
A2 VF & GVF-100 PERFORMANCE SPECIFICATIONS A2.1 Turn-on Time 30 minutes to rated accuracy from power up 25 seconds from power interruption A2.2 Start-up Time 25 seconds from zero flow A2.3 Low / High Flow Cutoff Adjustable between 3 and 30 ft/sec. At process flow rates below and above these values, the output will register a ‘max flow’ indication. A2.
Appendix B SONARtracTM EC DECLARATION OF CONFORMITY Copyright © 2006 CiDRA Corporation Page B-1 20675-01 Rev 02
Appendix C SYSTEM CONTROL DRAWING SONARtracTM, NON-INCENDIVE The system control drawing for installation in Class I Division 2, Groups A, B, C, and D is found on the following page.
Copyright © 2006 CiDRA Corporation Page C-2 20675-01 Rev 02
Appendix D MATERIAL SAFETY DATA SHEETS P/N 52307-01 PTFE Pipe Sealant MATERIAL SAFETY DATA SHEET IDENTITY: FORMULA-8 (Oxygen Compatible) Chemical name: Aqueous Paste & Filler of PTFE Chemical family: Perfluorocarbon Polymer Formula: (CF) 2n MANUFACTURER: Fluoramics CAS NUMBERS: Inc. ADDRESS: 18 Industrial Avenue Mahwah, N.J. 07430 PHONE: 201-825-8110 DATE PREPARED: January, 2003 PREPARED BY: F.G.
SECTION 3 - FIRE & EXPLOSION HAZARD DATA Flash Point & Method Used: None Flammability Limits in Air % by Volume: Non-combustible Extinguisher Media: Incombustible Special Fire Fighting Procedures: None Unusual fire and Explosion Hazards: In extreme fire situation, protection from hydrogen fluoride fumes should be employed .
SECTION 6 - CONTROL AND PROTECTIVE MEASURES Respiratory Protection (Specify Type): If exposed to high temperature processing fumes, wear self-contained breathing apparatus.
Copyright © 2006 CiDRA Corporation Page D-4 20675-01 Rev 02
Copyright © 2006 CiDRA Corporation Page D-5 20675-01 Rev 02
Appendix E CONVERSION FACTORS Dynamic Viscosity Units Conversion To Convert From: To: Multiply By: Pa-sec 4.788 026 e+01 Pa-sec 6.894 757 e+03 (kgf-sec)/m2 Pa-sec 9.806 650 e+00 Poise Pa-sec 1 e-01 Centipoises Pa-sec 1 e-03 lbf/(ft-sec) Pa-sec 1.488 164 e+00 lbf/(ft-hr) Pa-sec 4.133 789 e-04 (dyne-sec)/cm2 Pa-sec 1.0 e-01 (lbf-sec)/ft 2 (lbf-sec)/in 2 Pipe Modulus Units Conversion To Convert From: To: Multiply By: lbf/in2 kPa 6.
Appendix F PHYSICAL PROPERTIES OF WATER Temp (degC) Water at 14.7 psia (sea level) Sp Grav SOS (ft/s) Viscosity (Pa*s) Temp (degC) Water at 24.7 psia (10 psig) Sp Grav SOS (ft/s) Viscosity (Pa*s) 0 1.000 4601.2 1.7909E-03 0 1.000 4601.5 5 1.000 4679.0 1.5181E-03 5 1.000 4679.4 1.7907E-03 1.5180E-03 10 15 1.000 0.999 4748.3 4809.5 1.3059E-03 1.1375E-03 10 15 1.000 0.999 4748.6 4809.9 1.3058E-03 1.1375E-03 20 0.998 4863.3 1.0016E-03 20 0.998 4863.7 1.0016E-03 25 0.
Appendix G END USER LICENSE AGREEMENT Copyright © 2006 CiDRA Corporation Page G-1 20675-01 Rev 02
Copyright © 2006 CiDRA Corporation Page G-2 20675-01 Rev 02
Appendix H SPARE PARTS LIST The following is a list of commonly spared parts for SONARtracTM systems. Contact CiDRA Customer Support for items not found on this list, and for price and availability.
Appendix I DIRECTIVE 2002/96/EC ON WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT (WEEE) This symbol pictured here and on the transmitter of your SONARtrac system (if purchased after August 13, 2005), indicates that at its endof-life your SONARtrac system is considered to be Waste Electrical and Electronic Equipment (WEEE) in applicable countries of the European Union.
CiDRA Corporation 50 Barnes Park North Wallingford, CT 06492 (In U.S.): 877-cidra77 Tel: 203-265-0035 Fax: 203-294-4211 Visit CiDRA Online at: www.cidra.com P/N 20675-01, Rev.
