Liquid Level Controller

Transcription

1 Liquid Level ontroller Product Bulletin Type: HBLT-1/HBLT-1-E Purpose: The HBLT-1 provides remote liquid level management f industrial refrigeration systems. It can be used with the HBLT-A1 HBLT-Wire analog level probe other similar -wire sens with a 4-20 ma output signal. separats, inter coolers, economizers and receivers installed with an analog sens provide a current signal proptional to the vertical liquid level. The HBLT-1 controller serves as a stand alone programmable device, which converts the return signal and perfms a 4-20 ma output and three programmable relay functions. HBLT-1: ontroller only HBLT-1-E: HBLT-1 controller with encloser and transfmer ontact Infmation: Parker Hannifin pation Refrigerating Specialties Division 2445 South 25th Avenue Broadview, IL phone (708) fax (708) Product Features: ompatible with HB probes and legacy R/S depth tracker probes Two level alarms (high and low) status indicat Three digit display probe level output Visual valve position feedback with five LEDs Available with without enclosure Enclosure is resistant to atmospheric elements and UV rays Exclusive distributs f the Americas

2 Table of ontents 1.0 Technical Data HBLT-1 ontroller. 2 HBLT-1 ontroller with Enclosure Function and Design Installation Instructions Electrical Instructions ontroller Parameter Setup ON Mode ontroller Level s and Level Setup alibration Manual Override Trouble Shooting Menu Flow hart Technical Data HBLT-1 ontroller Mounting Panel Input Power V A/D±10% Frequency /60 Hz urrent Draw Max 40 ma Inputs Sens Analog Input ma Feedback Analog Input ma Relay Function (max level) Relay Voltage V D Outputs Analog Output ma Load A/24V D Relay A/D x A x 5 A x 5 A Solid State Output ,, 1 A/24V A/D Ambient Temperature to 70 (-4 F to 158 F) Relative Humidity Range % to 80% Approvals /ertificates EM Emission EN EM Emission EN GOST-R No Protection Rating IP65 Measurement (BxHxD) External x 96 x 94 mm (.78" x.78" x.70") ut-out x 92.8 mm (.65" x.65") Weight kg (0.44 lbs) HBLT-1 ontroller with Enclosure Mounting Wall Input Power V A (Mean Well RS-5-24 transfmer) urrent Draw Max 50 ma Protection Rating IP65 Measurement (BxHxD) External x 220 x 140 mm (8.07" x 8.66" x 5.51") Weight kg (.09 lbs) 1 HBLT-1-E 2 HBLT-A1 SRV w/ Manifold 1 2 Liquid Level ontroller Liquid Level Transmitter Electronic Valve LLSS Receiver MVS S4A w/ RSF separat installed with an HBLT-A1 analog sens f continuous level control of the vessel. The sens is connected to the HBLT-1 controller, controls the MVS modulating valve so that a constant level is maintained. Application Example: Low Pressure (LP) Liquid Level ontrol 2

3 2.0 Function and Design The HB liquid level controller (HBLT-1) is designed to continuously monit refrigerant levels in: vessels Separats Inter coolers Economizers Receivers Supplied with a microprocess-based design the controller is always delivered with the newest software. The software version can be viewed in the display by pushing on the [UP] [DOWN] at same time. ontroller Running Green LED Indicat Three-Digit Level Display The controller can be configured f a wide variety of level control applications in a industrial refrigeration system. A three-digit LED display provides level moniting and parameter setup. The setting of parameters is managed by using the simple menu push buttons, which consists of: Push Buttons Five LED Electronic Valve Position Indicat ON Provides access to the control parameters: set point, P-band, LP/ HP mode, ramp function and valve damping. ALARM AL Provides access to alarm level: low level, high level, as well as pump level and hysteresis. Provides access to minimum and maximum calibration. Low Level (red), High Level (red) and (green) LED Indicats ontroller Diagram: omponent Identification TEST MODE Starts the test mode, where all parameters are tested. Used to switch between the alarm parameters. onfirms/saves data and also functions as return/fward/enter to the next function. hanges the parameters in a positive direction with +1 increments f each click, through its scroll function by holding the button down. hanges the parameters in a positive direction with 11 increments f each click, through its scroll function by holding the button down. hange from operation mode to display of valve position in -digit display. Provides manual override f valve position. See manual override instructions later in this bulletin..0 Installation Instructions When installing the HBLT-1 HBLT-1-E avoid direct sunlight, heavy dust, heat. Do not expose the instrument to rain, high humidity, ammonia vap other crosive refrigerants. If installing the HBLT-1 controller, it must be installed on the front panel at eye level. The front is designed with a protection class of IP54 and the rear facing electronics are designed to a protection class of IP45. The HBLT-1 controller can be installed directly into a panel with a cut-out of 92.8 x 92.8 mm (.65" x.65"). Two mounting brackets, one located on each side of the controller, are used to secure the controller to the panel. 98.2mm [.65"] The HBLT-1 controller is equipped with three relay outputs, a 4-20 ma analog output and a 4-20 ma valve position feedback. The three relays monit and control the low level alarm, high level alarm and pump status. F liquid level control a 4-20 ma analog output is used to control the MVS electronic valve. Five yellow LED valve position indicats, located on the front of the controller, provides plug position feed back to the controller. If there are no yellow LEDs lit the valve is in the full closed position, three yellow LEDs the valve is 50% open and if all five yellow LEDs are lit the valve is in the full open position. 94mm [.70"] 96mm [.78"] 98.2mm [.65"] Additional LEDs, on the front of the controller, indicates the status operation the controller is in. A lit red LED indicates the low high level alarm has been tripped, a lit green LED indicates the pump is on, a lit yellow LED, on the push buttons, identifies which operation the controller is currently in and a lit green LED indicates the controller is in auto mode (RUN). 96mm [.78"] Dimensional Diagram: HBLT-1 ontroller Mounting Bracket

4 The controller is also available with a self containing enclosure f an independent setup. The mounting holes are 165 mm (6.50") vertical and 105 mm (4.1") hizontal. The enclosures must be opened to properly mount the enclosure. To open the main housing of the controller swing open the clear blue transparent protection cover, located on the front of the enclosure, and unscrew the four large plastic screws until they are loose. The front half of the encloser will swing open and provide access to the mounting holes and electrical connections. 15mm [5.1"] 4.0 Electrical Instructions All terminals are protected against wrong termination up to a supply voltage of 40 V. If the supply voltage is greater than 40 V, the controller will be damaged. F wiring instruction please reference the three wiring diagrams: HBLT-1 controller, HBLT-1-E controller with enclosure and remote moniting. Remote moniting must be wired in series and is wired in the same man f both the HBLT-1 and HBLT- 1-E. Use 20 AWG jacketed stranded wire. If purchased the controller with enclosure, HBLT-1-E, a V A transfmer is included. Electrical onnections Terminal Description Power In - 24 V A/D Supply voltage to the controller 210mm [8.25"] 165mm [6.50"] Sens Input In Input from the sens, e.g. HBLT-A1 Alar in (5..24 V D) can be used f extra high level alarm (GND from power in) P GND/INT P (no function) 226mm [8.88"] 105mm [4.1"] Dimensional Diagram: HBLT-1-E ontroller with Enclosure i Avoid direct sunlight, heavy dust, heat. Do not expose the instrument to rain strong humidity from ammonia vap other crosive refrigerants. ma Feedback Low Level - Out High Level - Out ontrol Out Solid State Relay Power In V A ma feedback (positioning of valve. GND is connected to control out) Low level alarm in the vessel High level alarm in the vessel Signal to start the pump 4-20 ma analog signal to the electronic valve pump N/A Supply voltage with power supply built in HBLT-A1 Liquid Level Transmitter Probe HBLT-1 ontroller ma Solid State Relay IN Solid State Relay OUT 4-20 ma OUT V OUT GND OUT 24V A/D (50/60 Hz) ma Feedback P GND P INT IN 4-20 ma V GND Power IN - Power IN + Out High Level Out Low Level Out GO G Y M U Z ON DIP MVS Relays Outputs The HBLT-1 controller provides three relay outputs f pump, high level alarm and low level alarm. The relays are available in the nmally open () nmally closed () position. Wiring Diagram: HBLT-1 ontroller 4

5 HBLT-A1 Liquid Level Transmitter Probe ma HBLT-1-E ontroller ma Feedback P GND P INT IN 4-20 ma V GND Power IN - Power IN + Solid State Relay IN Solid State Relay OUT 4-20 ma OUT V OUT GND OUT Out High Level Out Low Level Out GO G Y M U Z ON DIP MVS V A (50/60 Hz) L N GND -V +V (A) Transfmer (RS-5-24) Relays Outputs The HBLT-1 controller provides three relay outputs f pump, high level alarm and low level alarm. The relays are available in the nmally open () nmally closed () position. Wiring Diagram: HBLT-1-E ontroller with Enclosure PL 4-20 ma (POS) 4-20 ma (NEG) i When using remote moniting it must be current moniting only (i.e ma). The same wiring method can be used on the the HBLT-1-E. HBLT-A1 Liquid Level Transmitter Probe HBLT-1 ontroller ma Solid State Relay IN Solid State Relay OUT 4-20 ma OUT V OUT GND OUT 24V A/D (50/60 Hz) ma Feedback P GND P INT IN 4-20 ma V GND Power IN - Power IN + Out High Level Out Low Level Out GO G Y M U Z ON DIP MVS Wiring Diagram: HBLT-1/HBLT-1-E ontroller with Remote Moniting 5

6 Bulletin ontroller Parameter Setup Setting the ontrol Parameters Instructions Steps Operation 1 urrent Setpoint 2 Display Setup Instructions Notes Liquid level at 40% 10.4 ma return signal to the HBLT-1 controller. urrent refrigerant level from probe. Facty set at 040. Press the ON button to set up the HBLT-1 Provides access to the control parameters: setpoint, P-band, ramp function, as well as valve position. setpoint parameters To adjust the refrigerant level use the Setpoint Level range is from 0% to 100%. P-band (band percentage above and below the setpoint value). Equation: Setpoint * P-band Percentage 050 x 0% = 15% Range ± 7.5% To adjust the P-band use the 4 P-band In this example, with the setpoint of 50%, the P-band range is 42.5% to 57.5%. Percentage Range is from 0% to 100%. Facty set at P0. i The sum of the setpoint and the P-band may not exceed 100% To adjust the Ramp use the 5 Ramp When complete push the buttons. Since there can be fluctuations in the process parameters during process start-up, it is possible to establish a ramp function (at start up only). Percentage/second range is from 0% to 100%. Facty set at 005. When set at "000", the function is inactive. Analog Output Mode 6 Valve Damping 7 To change from LP/HP use the Analog output to the electronic valve. To adjust the damping use the LP: 4-20 ma (MVS electronic valve) Depending which valve is installed, it may be necessary to dampen the speed at which the valve opens. This is used especially when the valve react too quickly/ strongly. HP: 20-4 ma Percentage/Second Range is from 0% to 100%. Facty set at 005. When set at "000", the function is inactive. 8 9 New Setpoint Push the Does not apply. Facty set at 006. New refrigerant level setpoint. 120% Valve Opening 0% 100% Valve Safety lose 0% Valve Opening 100% LP Mode HP Mode Valve Opening 100% Valve at 0% closed 80% 50% Setpoint (% Liquid Level) 6 P-band % Liquid Level % ON Mode Both the Setpoint and P-band are set as a percentage (0-100%). If the sum is set so it causes the valve to close at 120% (Setpoint = 80% and P-band at 100%), the valve will close at 100% f safety reasons.

7 Bulletin ontroller Level s and Level Setup Setting the High, Low and Parameters Instructions Steps Operation 1 urrent Setpoint 2 Display Setup Instructions Notes urrent refrigerant level from probe. Liquid level at 50% 12 ma return signal to the HBLT-1 controller. Press the Provides access to the alarm levels: low level, high level, as well as pump level and hysteresis ALARM button to start setting the low level alarm, high level alarm and pump level 4 Low Level Low Level Hysteresis To adjust the low level alarm use the Level range is from 0% to 100%. To adjust the low level alarm hysteresis use the Facty set at 010. The low level alarm, based in this example, will turn on when the liquid level reaches 10%; shown in step. The low level alarm red LED, on the controller, will stay on at levels below 10% and will not turn off until it reaches a level of 15%. If the hysteresis level is increased decreased the range above 10%, from this example, will increase decrease. If the low level alarm hysteresis is changed to L10 (10%), in this example, the alarm would stay on below 10% to 20% level. i The sum of the low level alarm setpoint and the low level alarm hysteresis may not exceed 100%. 5 6 High Level High Level Hysteresis To adjust the high level alarm use the To adjust the high level alarm hysteresis use the Level Range is from 0% to 100%. Facty set at 085. The high level alarm, based in this example, will turn on when the liquid level reaches 85%; shown in step 5. The high level alarm red LED, on the controller, will stay on at levels above 85% and will not turn off until it reaches a level 80% below. If the hysteresis level is increased decreased the range below 85%, from this example, will increase decrease. If the high level alarm hysteresis is changed to H10 (10%) the alarm would stay on above 85% to 75% level. i The sum of the high level alarm setpoint and the high level alarm hysteresis may not exceed 100%. To adjust the pump use the 7 When complete push the Hysteresis Note: F a graphical interpretation see the following page. 7 In this example the pump is set to turn off when the level reaches 0%. Level Range is from 0% to 100%. To adjust the pump hysteresis use the 8 buttons. Facty set at 015. The pump, based in this example, will turn off when the liquid level reaches 25%; shown in step 7. The pump green LED, on the controller, will turn off indicating the pump is off. The pump will not turn back on until it reaches a level of 0% and will remain on at levels above 0%. If the hysteresis level is increased decreased the range below 0%, from this example, will increase decrease. If the pump hysteresis is changed to P10 (10%) the pump will turn off at 20% level. Again the pump will not turn back on until it reaches a level of 0%.

8 High level equipment cutout 85% High level setpoint High level equipment restart 80% High level hysteresis High, Low and Parameters Percentage Description 85 High level setpoint 5 High level hysteresis Level setpoint 50% Level setpoint 50 Level setpoint 0 level setpoint 5 level hysteresis restart cutout 0% 25% level setpoint level hysteresis 15 Low level setpoint 5 Low level hysteresis Low level equipment restart Low level equipment cutout 15% 10% Low level hysteresis Low level setpoint Note: The above valves are base from the controller parameter setup and controller level s and pump level setup examples. Level Parameter Diagram: Graphical interpretation of the alarm and pump parameters 7.0 alibration The calibration mode provides access to two point calibration. a two point calibration can be carried out on two randomly selected points from 0-100%. Based on these two values, the controller itself calculates the sens's full scale and 0-point. The idea is to be able to reposition the probe length if the entire length of the probe is not required. Minimum and Maximum alibration Instructions Steps Operation Setup Instructions Notes Provides access to calibrate the required probe length. 1 alubration Mode Press the AL button f 5 seconds. The 'RUN' LED is shut off and the red LED on the AL button turns on when in calibration mode. 2 Minimum alibration To adjust the minimum level use the buttons. When complete push the Probe range is from 0% to 100%. 0% - Minimum Level Maximum alibration To adjust the Maximum level use the buttons. When complete push the button twice. Probe range is from 0% to 100%. 100% - Maximum Level 8.0 Manual Override Manual Override Instructions Steps Operation Setup Instructions Notes 1 Manual Override Press the MODE button f 10 seconds. Provides manual override to the electronic valve plug position. 2 Adjustment To open close the electronic valve plug use the buttons. Valve range is from 0% to 100%. 0% - Full losed 100% - Full Opened Return to Auto Mode When complete push the Returns the HBLT-1 controller to auto mode. 8

9 9.0 Trouble Shooting Symptom Probable ause How to Detect/Repair Defect No light in the display and no LED lamps No power to the unit the wrong voltage Measure the power on 24 V input terminals. activated There is no change in display The valve the pump do not react to the signal from the controller The display shows too low/high level in relation to the actual level in the vessel High/low alarm occurs frequently The display flickers is unstable 1) Defective cable from sens 2) Defective sens ) Valve Shut 4) Wrong min./max. calibration Defective cable lack of a connection to the pump of the valve 1) The cable is defective there is no connection to the sens 2) alibration is not crect ) alibration is not carried out at the operating temperature 4) Sens not calibrated to the crect refrigerant 1) Turbulence in the liquid 2) set too close to the desired setpoint 1) Loose connection in the power supply the sens 2) EM interference from mobile telephones, frequency converters, other equipment that does not meet the legal requirements f EM 1-2) heck the sens. See err detection in the sens's instruction manual ) Look at the valve's position on the five LED on the front of the controller heck the connection to the sens the valve 1) Measure the signal from the sens 2) alibrate the controller ) alibrate at operational temperature 4) alibrate the sens. Look at the sens's instruction manual 1) heck the system's operational state 2) Set the high alarm at a greater difference in value to the desired setpoint. 1) heck f loose connections 2) Install insulated wire from sens to the controller 9

10 Bulletin Menu Flow hart urrent Setpoint/ Facty Setting ontroller Parameter Setup ontroller Level s and Leve Setup alibration ON ALARM AL Setpoint Low Level Min. alibration Hold f 5 sec. Low Level Hysteresis P-band Max. alibration Ramp Auto Mode High Level Hysteresis Valve Damping Hysteresis New Setpoint Note: Returned to Auto Mode. [RUN] LED on High Level Analog Output Mode Auto Mode Note: [RUN] LED on 10 Note: [RUN] LED on

11 urrent Setpoint/ Facty Setting Manual Override Test MODE Hold f 10 sec. TEST Valve Position Open lose Auto Mode Note: [RUN] LED on Auto Mode Note: [RUN] LED on 11

12 Safe Operation (See Bulletin RSBV) People doing any wk on a refrigeration system must be qualified and completely familiar with the system and the Refrigerating Specialties Division valves involved, all other precautions will be meaningless. This includes reading and understanding pertinent Refrigerating Specialties Division Product Bulletins and Safety Bulletin RSB pri to installation servicing wk. Where cold refrigerant liquid lines are used, it is necessary that certain precautions be taken to avoid damage which could result from liquid expansion. Temperature increase in a piping section full of solid liquid will cause high pressure due to the expanding liquid which can possibly rupture a gasket, pipe valve. All hand valves isolating such sections should be marked, warning against accidental closing, and must not be closed until the liquid is removed. heck valves must never be installed upstream of solenoid valves, regulats with electric shut-off, n should hand valves upstream of solenoid valves downstream of check valves be closed until the liquid has been removed. 201 Parker Hannifin pation It is advisable to properly install relief devices in any section where liquid expansion could take place. Avoid all piping control arrangements which might produce thermal pressure shock. F the protection of people and products, all refrigerant must be removed from the section to be wked on befe a valve, strainer, other device is opened removed. Flanges with ODS connections are not suitable f ammonia service. Warranty All Refrigerating Specialties products are under warranty against defects in wkmanship and materials f a period of one year from date of shipment from facty. This warranty is in fce only when products are properly installed, field assembled, maintained, and operated in use and service as specifically stated in Refrigerating Specialties atalogs Bulletins f nmal refrigeration applications, unless otherwise approved in writing by the Refrigerating Specialties Division. Defective products, parts thereof returned to the facty with transptation charges prepaid and found to be defective by facty inspection, will be replaced repaired at Refrigerating Specialties option, free of charge, F.O.B. facty. Warranty does not cover products which have been altered, repaired in the field, damaged in transit, have suffered accidents, misuse, abuse. Products disabled by dirt other feign substances will not be considered defective. The express warranty set fth above constitutes the only warranty applicable to Refrigerating Specialties products, and is in lieu of all other warranties, expressed implied, written including any warranty of merchantability, fitness f a particular purpose. In no event is Refrigerating Specialties responsible f any consequential damages of any nature whatsoever. No employee, agent, dealer other person is authized to give any warranties on behalf of Refrigerating Specialties, n to assume, f Refrigerating Specialties, any other liability in connection with any of its products. 117 EN: /25/201 ISO 9001 ERTIFIED