TD80 LEVEL GAUGING & OVERFILL PREVENTION SYSTEM PRODUCT MANUAL SUPPLEMENT. TPM 005 Revision 0.0

Transcription

1 TD80 LEVEL GAUGING & OVERFILL PREVENTION SYSTEM PRODUCT MANUAL SUPPLEMENT TPM 005 Revision 0.0

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3 Table of Contents 1 TD80 Current Loop Option Introduction Components Operation Installation Programming Error Handling Troubleshooting Finch 5332E/PS External Display, Red Terminal Board and 4-20mA Current Loop Wiring Instructions Finch 5332E External Display, Green Terminal Board and 4-20mA Current Loop Wiring Instructions mA Current Loop Wiring Instructions, no Finch Display Shorting Block Installation Checklist Programming Checklist Operator Information Frequently Asked Questions (FAQ) What to Do when the Spill Alarm Becomes Latched (Stuck) Table of Figures Figure 1-1: TD80 System with Current Loop Option Wiring Overview...3 Figure 1-2: Normal Programming Example...4 Figure 1-3: Normal Programming Example...7 Figure 1-4: 4-20mA Offset Programming Example...8 Figure 1-5: Basic System with Current Loop Option Wiring Diagram for Finch 5332E/PS External Display Figure 1-6: Basic System with Current Loop Option Wiring Schematic for Finch 5332E/PS External Display Figure 1-7: Basic System with Current Loop Option Wiring Diagram for Finch 5332E External Display Figure 1-8: Basic System with Current Loop Option Wiring Schematic for Finch 5332E External Display Figure 1-9:Basic System with Current Loop Option Wiring Diagram without Finch External Display Figure 1-10: Basic System with Current Loop Option Wiring Schematic without Finch External Display Figure 2-1: Dual Rod Shorting Block Installation Index of Tables Table 1-1: TD80 Data and Alarm Communication Summary...5 Table 3-1: Installation Checklist Table 4-1: Programming Checklist Table 5-1: System Operator Information Rev. 0.0, March, 26, 2013 Page 1

4 1 TD80 Current Loop Option All installation steps are to be performed in accordance with the TD80 Installation and Operation Manual, TPM 001. See the TD80 Installation and Operation Manual for details. 1.1 Introduction Current loop signaling is a robust and reliable method for data and analog sensor communications. The TD80 uses an industry standard 4-20mA interface to communicate liquid level. Current loops are ideal for long distance communication due to their inherent insensitively to electrical noise. They are also immune to the effects of power supply voltage variations and wiring resistance. The signaling current flows through each component in the loop. This current is the same through each of the components. Each component creates a voltage drop, and the power supply voltage must be greater than the sum of all the voltage drops at the maximum loop current. TD80 transmitters are available with an optional 4-20mA output. This option must be ordered when purchasing the TD80. It is not upgradable after manufacture of the transmitter. Dual rod, model TD80-T12 and coaxial TD80-T17 transmitters are available with the current loop option. These transmitters also include the standard SV Bus data bus for Finch displayed volume, alarms and error codes. 1.2 Components The following four components create the current loop: 1. Current loop power supply mA transmitter (TD80-T12 or T17) mA receiver (Remote Monitoring System) 4. Current loop wiring Page 2 Rev. 0.0, March 26, 2013

5 Figure 1-1: TD80 System with Current Loop Option Wiring Overview Rev. 0.0, March, 26, 2013 Page 3

6 1.3 Operation The liquid level is detected by the TD80 using a dual rod or coaxial probe and transmitter. This level or depth is converted into a signal of between 4mA and 20mA. A current of 4mA represents the lowest value in the measurement range, or 0% full. 20mA represents the highest value in the measurement range, or 100% full. For example, a current output of 12mA indicates that the liquid is at 50% of the probe height. The 4-20mA signal represents depth of the liquid, not volume. Figure 1-2: Normal Programming Example System errors are signaled with a 22mA loop current. The loop current will be 22mA while the Finch display shows an error code E xx, where xx is a code indicating the nature of the failure. Alarms normally displayed by the Finch display along with relay controlled annunciation are not available at the current loop. The Fill/Fall alarm is controlled by the Finch display while the High-High and Spill alarms are communicated by the SV Bus only. The current loop option will not indicate when the liquid level is within the lower dead band of the probe. The Finch display shows 2 LO as an indication that the liquid level is within the lower dead band of 5.5 and is too low to measure accurately. Page 4 Rev. 0.0, March 26, 2013

7 The output current will not rise above the programmed Spill alarm level. The Spill level is considered to be the upper dead band of the probe where liquid level can t be measured accurately and the danger of a spill exists. A current of 0mA is usually caused by an open loop circuit, most likely due to a broken wire. It may also be caused by a defective loop current transmitter, receiver or power supply. Offset calibration of the TD80 does not affect the 4-20mA output. Finch display initiated offset calibration adjusts the volumetric output of the TD80 to compensate for variations from the manufacturer supplied tank depth chart and small differences in mounting height of the probe above the tank top. The 4-20mA current output is linear and reflects the level or depth of the liquid loaded, not volume. The following table summarizes data and alarm states available through the SV bus to a Finch display and information signaled by the 4-20mA output. Data and Alarm States TD80 SV Bus and Finch TD mA Signal Display Level Output Volume, units Depth, 0 to 100% = 4 to 20mA 2 LO (too low) Indication YES NO Fill/Fall Alarm YES NO High-High Alarm YES NO Spill Alarm YES NO Loss of Communication YES NO Indication TD80 Detected Error Error Code, 00 to 77, 80 to 84 22mA failure signal Table 1-1: TD80 Data and Alarm Communication Summary 1.4 Installation See the Installation and Operation Manual, Section 2.1 for mechanical installation details Figure 1-1 shows an overview of a typical TD80 system installation using the 4-20mA output to a remote monitor. Any combination of Finch display, lights, horns, on-board pump or loading rack controlled overfill prevention system may be installed along with the 4-20mA output option. Figure 1-5 through Figure 1-10 provide installation wiring examples. The instructions and diagrams include Finch 5332E/PS (red terminal board), Finch 5332E (green terminal board) and no Finch display installations. See the Installation and Operation Manual, Section 2.6 for alarm accessory wiring such as lights and horns. The current loop may be installed with an isolated or non-isolated loop power supply. Non-isolated loops share at least the power ground and possibly the power supply as well between the loop transmitter and receiver. Rev. 0.0, March, 26, 2013 Page 5

8 The 4-20mA current loop option may be used along with any TD80 configuration. This option does not interfere with the Finch display, lights, horns, MIC 10, the Finch relay module or P2000 installations. A non-isolated power supply is recommended for use with the TD80 for the following reasons. 1. The loop power supply is automatically controlled along with the TD80 and Finch (if installed). 2. 0mA loop current may indicate a loss of TD80 transmitter power along with the loop power supply or wiring mA is signaled during the 10 second TD80 transmitter warm up period, indicating that no valid level information is available. An isolated loop power supply is not recommended for the following reasons. 1. Loss of data by a TD80 transmitter or power supply failure results in an unknown loop current between 0mA and 22mA. 2. The isolated power supply wiring configuration sends a signal of the last known liquid level information after the TD80 is turned off. It does not return to 0mA until the isolated loop power supply is also turned off. An isolated loop power supply is used in cases when the 4-20mA current loop receiver can t share a common power supply ground with the TD80 or other devices. The receiving device provides operating power to the 4-20mA output option only. The TD80 and other devices such as the Finch display must be powered by the normal 8-28VDC power supply. Page 6 Rev. 0.0, March 26, 2013

9 1.5 Programming See the Installation and Operation Manual, Section for details. TD80 transmitters with the 4-20mA current loop option are programmed using Birdfeeder 2 (BF2). Normal programming of the volume and depth, compensation for a riser or sump, High-High alarm volume and Spill alarm height results in a 4-20mA output that is suitable for most applications. SV Bus data transmits volumetric information while the 4-20mA output is limited to a linear 0-100% output. For any depth of liquid, the SV Bus sends the corresponding volume along with alarm states to the Finch display. The 4-20mA output sends the percentage filled only, scaled between 4mA for empty and completely full at 20mA. Figure 1-3: Normal Programming Example The default setting for the 4-20mA output is a 4mA signal for empty or 0% full and 20mA when the compartment is 100% full with the liquid at the very top of the tank. The signal under these conditions will never completely go down to 4mA or up to 20mA. The bottom of a dual rod probe is normally ½ above the bottom of the tank and the shorting block is ¾ to 2 long depending on probe type. The minimum current signal is slightly above 4mA due to these conditions. The signal also stops at the Spill alarm height at 7.5 for a dual rod probe. The Spill alarm for a coaxial probe and transmitter may be as close as 2.5 from the top of the probe. The maximum signalling current is always less than 20mA for the default settings. Rev. 0.0, March, 26, 2013 Page 7

10 Figure 1-4: 4-20mA Offset Programming Example Optional BF2 settings allow compensation for riser or sump mounted probes. It also provides an output that signals 4mA at the minimum usable volume and 20mA at the maximum safe volume. These settings in BF2 raise the 4mA signal above the bottom of the probe and lower the 20mA signal down the probe. For example, the probe is mounted on a tank with a 5.5 sump and a 7.5 riser. The 4mA or 0% indication may be raised from the bottom of the probe while lowering the 20mA or 100% full signal to the programmed Spill alarm level of 7.5. This setting places the full 16mA span of the output signal across the entire depth of the tank. The 4mA and 20mA positions on the probe may be programmed for any distance required by the application. The only requirement is for 4mA to be positioned lower on the probe than the 20mA position. Page 8 Rev. 0.0, March 26, 2013

11 1.6 Error Handling A loop current of 0mA indicates one or more of the following: 1. Open circuit in the loop wiring 2. Defective loop power supply 3. Defective current transmitter 4. Defective current receiver 22mA signaling current indicates a system failure detected and reported by the TD80. An error code is also available at the Finch display (if installed) E xx where xx is a code or Troubleshooting Analyze the Finch displayed indications along with current and voltage measurements of the current loop components. The BF2 Live Connection tool may be used in the place of a Finch display for 4-20mA current loop output only systems. The first step is to ensure a reliably operating TD80 system. Perform a complete system test and resolve any problems before attempting to troubleshoot and repair the current loop output. Most 4-20mA problems are caused by other failures and are only indicated by the output. Ensure that the TD80 system is provided power from a well charged battery or DC power supply, 8VDC to 28VDC. Do not use a battery charger for testing the system. Confirm this voltage using a Digital Multimeter (DMM). The following steps are suggestions for a methodical troubleshooting procedure. Analyze each result and troubleshoot specific components if the test results are abnormal. See the Installation and Operation Manual, Section 3.1 for general troubleshooting suggestions and Section 3.2 for specific TD80 system troubleshooting steps. 1. Test the TD80 system for normal operation. See the Installation and Operation Manual, Section for details. Troubleshoot and repair any problems before continuing. 2. Measure the current loop power supply voltage and determine if it is within acceptable limits. 3. Measure the TD80 power supply voltage and determine if it is within acceptable limits. 4. Measure the 4-20mA loop current and check for the following: a. 0mA indicates a broken wire or defective current loop component b. 3.8mA indicates that the TD80 transmitter is still in the 10 second warm up cycle or did not start normally. c. 22mA indicates a TD80 reported system failure or error. Finch displayed error codes state the nature of the error. d. Erratic current measurements between 4mA and 20mA with corresponding fluctuations of the Finch displayed volume or error codes indicate a TD80 level transmitter or probe problem. e. Erratic current measurements between 4mA and 20mA while the Finch displayed volume is steady indicate a defective TD80 transmitter, current Rev. 0.0, March, 26, 2013 Page 9

12 loop power supply instability or intermittent loop wiring. It may also be caused by a defective current loop receiver. 1.8 Finch 5332E/PS External Display, Red Terminal Board and 4-20mA Current Loop Wiring Instructions Wiring steps for single TD80 and Finch Display. Refer to Figure 1-5 & Figure 1-6 for Finch 5332E/PS (red board) installation. Confirm Finch 5332E/PS (red terminal board) Fuses are installed with Correct Type (Ceramic, Sand Filled, 5x20mm) and Rating (F1, F3-F5: 2A, F2: 5A). 1. Fused Power wire from nose box socket or junction box to Finch POWER IN (25) 2. Ground wire from nose box socket or junction box to Finch GROUND IN (24) 3. At the TD80, ensure that the following wires are connected to the correct terminals: a. Black wire to PWR b. White wire to GND c. Red wire to SVBUS 4. At the TD80, connect the following wires for the 4-20mA option: a. PWR terminal to LOOP+ b. Unused wire in the cable to LOOP-. Note the wire colour for step TD80 Power (black wire) to Finch GAUGE POWER (4) 6. TD80 Ground (white wire) to Finch GAUGE GROUND (5) 7. TD80 SV Bus (red wire) to Finch GAUGE SV (6) 8. Finch Jumpers, see the manual, Figure 2-37 a. J9 and Decimal Point shunt positions i. J9 removed for Fill alarm, installed for Fall alarm (removed when shipped from factory) ii. Decimal point jumper for required Display 9. Optional PTO or brake air switch to Finch DISPLAY ENABLE (PTO) (7) and Electrical Ground OR 10. Optional Gauge Enable toggle switch red wire to Finch DISPLAY ENABLE (PTO) (7) and black wire to Finch GROUND (9) OR wire Finch DISPLAY ENABLE (PTO) (7) to Finch GROUND (9) when not connected to a PTO or brake air switch OR 11. Optional Gauge Enable toggle switch red wire to Finch POWER ENABLE (27) and black wire to Finch GROUND (26) for power control OR wire Finch POWER ENABLE (27) to Finch GROUND (26) 12. Pass the LOOP- wire, colour noted from step 4 above and GROUND (18) to the Remote Monitor. The 4-20mA analog signal terminals may be labeled differently from this example. Refer to the manufacturer s manual for the specific terminal names and location. LOOP- is connected to the monitor 4-20mA + terminal; GROUND is connected to monitor 4-20mA terminal. Page 10 Rev. 0.0, March 26, 2013

13 Figure 1-5: Basic System with Current Loop Option Wiring Diagram for Finch 5332E/PS External Display Rev. 0.0, March, 26, 2013 Page 11

14 Figure 1-6: Basic System with Current Loop Option Wiring Schematic for Finch 5332E/PS External Display Page 12 Rev. 0.0, March 26, 2013

15 1.9 Finch 5332E External Display, Green Terminal Board and 4-20mA Current Loop Wiring Instructions Wiring steps for single TD80 and Finch Display. Refer to Figure 1-7 & Figure 1-8 for Finch 5332E (green board) installation. Confirm Finch 5332E (green terminal board) 3A Blade Fuse is installed in a nonhazardous location. 1. Fused Power wire from the nose box socket or junction box through a 3A fuse to Finch 8-28 VDC POWER. The fuse must be in a non-hazardous location. 2. Ground wire from nose box socket or junction box to Finch GROUND 3. At the TD80, ensure that the following wires are connected to the correct terminals: a. Black wire to PWR b. White wire to GND c. Red wire to SVBUS 4. At the TD80, connect the following wires for the 4-20mA option: a. PWR terminal to LOOP+ b. Unused wire in the cable to LOOP-. Note the wire colour for step TD80 Power (black wire) to Finch GAUGE POWER 6. TD80 Ground (white wire) to Finch GAUGE GND 7. TD80 SV Bus (red wire) to Finch SV BUS 8. Finch Jumpers, see the manual, Figure a. J9 and Decimal Point shunt positions i. J9 removed for Fill alarm, installed for Fall alarm (removed when shipped from factory) ii. Decimal point jumper for required display 9. Optional PTO or brake air switch to Finch GAUGE ENABLE (PTO) and Electrical Ground OR 10. Optional Gauge Enable toggle switch red wire to Finch GAUGE ENABLE (PTO) and black wire to GROUND OR wire Finch GAUGE ENABLE (PTO) to Finch GROUND when not connected to a PTO or brake air switch. 11. Pass the LOOP- wire, colour noted from step 4 above, and GROUND to the Remote Monitor. The 4-20mA analog signal terminals may be labelled differently from this example. Refer to the manufacturer s manual for the specific terminal names and location. LOOP- is connected to the monitor 4-20mA + terminal; GROUND is connected to monitor 4-20mA terminal. Rev. 0.0, March, 26, 2013 Page 13

16 Figure 1-7: Basic System with Current Loop Option Wiring Diagram for Finch 5332E External Display Page 14 Rev. 0.0, March 26, 2013

17 Figure 1-8: Basic System with Current Loop Option Wiring Schematic for Finch 5332E External Display Rev. 0.0, March, 26, 2013 Page 15

18 mA Current Loop Wiring Instructions, no Finch Display Wiring steps for single TD80 and Finch Display. Refer to Figure 1-9 and Figure 1-10 for installation. Confirm the 1A fuse is installed in a non-hazardous location. 1. Fused Power wire from the nose box socket or junction box through a 1A fuse to the junction box, black terminal. The fuse must be in a non-hazardous location. 2. Ground wire from nose box socket or junction box to the junction box white terminal. 3. At the TD80, ensure that the following wires are connected to the correct terminals: a. Black wire to PWR b. White wire to GND c. Red wire to SVBUS 4. At the TD80, connect the following wires for the 4-20mA option: a. PWR terminal to LOOP+ b. Unused wire in the cable to LOOP-. Note the wire colour for step 6 and 7 5. At the junction box, connect the following wires from the TD80: a. TD80 Power (black wire) to the junction box black terminal b. TD80 Ground (white wire) to the junction box white terminal c. TD80 SV Bus (red wire) to the junction box red terminal 6. At the junction box, connect LOOP- wire, colour noted from step 4 above, to the same colour terminal 7. Connect the following current loop wires from the junction box to the Remote Monitor: a. LOOP- wire, now called 4-20mA+ to the Remote Monitor 4-20mA+ input b. A wire at the white terminal (ground) now called 4-20mA- to the Remote Monitor 4-20mA- input. The 4-20mA analog signal terminals may be labeled differently from this example. Refer to the manufacturer s manual for the specific terminal names and location. LOOP- is connected to the monitor 4-20mA + terminal; GROUND is connected to monitor 4-20mA terminal. Page 16 Rev. 0.0, March 26, 2013

19 Figure 1-9:Basic System with Current Loop Option Wiring Diagram without Finch External Display Rev. 0.0, March, 26, 2013 Page 17

20 Figure 1-10: Basic System with Current Loop Option Wiring Schematic without Finch External Display Page 18 Rev. 0.0, March 26, 2013

21 2 Shorting Block Figure 2-1: Dual Rod Shorting Block Installation Rev. 0.0, March, 26, 2013 Page 19

22 3 Installation Checklist Checked Step 1. Program the TD80 2. Install the 1 NPT Top Fitting 3. Install the Anchor Cone 4. Install the Probe 5. Mount the Transmitter 6. Mount the Finch Display 7. Mount the Relay Module (optional) 8. Mount the Alarm Accessories (optional) 9. Inspect the Mechanical Installation 10. Install the Electrical Wiring 11. Set and Verify the Finch Display Jumpers 12. Confirm Fuses Installed with Correct Type and Rating 13. Perform the TD80 Basic Operation Test 14. Verify TD80 Programming Information 15. Set the Fill or Fall Alarm Level Volume 16. Perform the TD80 System Test and Verification 17. Perform the Offset Calibration Table 3-1: Installation Checklist Page 20 Rev. 0.0, March 26, 2013

23 4 Programming Checklist Checked Step 1. Gather all the programming information a. Transmitter and probe type b. Depth chart for the tank or compartment c. Display precision required for the Finch display d. Transmitter riser and sump options e. Spill alarm distance f. Spill alarm reset option g. High-High alarm volume h. Optional 4-20mA offset adjustments 2. Create the programming file, if required a. Confirm all settings with the information above b. Save the file with a meaningful name 3. Program the TD80 a. Verify all programming settings with the information above. b. Program the TD80 4. Test the programming result a. TD80 operates normally b. Volume is displayed according to the depth chart c. Alarms activate at the programmed levels d. Optional Spill alarm reset clears the alarm e. Optional 4-20mA outputs according to programmed offsets Table 4-1: Programming Checklist Rev. 0.0, March, 26, 2013 Page 21

24 5 Operator Information Table 5-1: System Operator Information Page 22 Rev. 0.0, March 26, 2013

25 6 Frequently Asked Questions (FAQ) 6.1 What to Do when the Spill Alarm Becomes Latched (Stuck) The TD80 level transmitter detects the level where a preset Spill alarm activates to indicate a compartment overfill or spill condition. Dual rod transmitters, T11 and T12 are permanently set to a Spill alarm level of 7.5 from the tank top. Coaxial transmitters, T16 and T17 may be programmed for a Spill alarm level of between 2.5 and 15.5 from the tank top. The TD80 SV communication bus broadcasts the Spill alarm message to all the displays. The Spill alarm is annunciated by flashing SPiLL on the Finch display with the corresponding Spill-Fail relay activation for external devices such as lights, horns or a secondary overfill prevention system. Volume information sent from the TD80 transmitter is frozen at the Spill alarm level. This includes the optional 4-20mA transmitter. It will not increase with detected liquid level above this point. Levels above the Spill alarm setting are within the probe top dead band where measurements are inaccurate and unreliable. The Spill alarm is cleared by unloading liquid below the spill alarm level, while the TD80 system is powered on and reporting level through the SV bus and optional 4-20mA transmitter. This is the normal method to silence the Spill alarm. It cannot be cleared by any button press or turning the power off. Unloading from a Spill alarm condition while the power is turned off will not clear the Spill alarm. It remains latched for all dual rod transmitters while with coaxial transmitters this feature is programmable for latched or auto-clear options using Birdfeeder 2. The TD80 transmitter must detect a liquid level between the Spill alarm level and no more than 24 below the tank top to clear the alarm. For example, a dual rod transmitter must detect a liquid level between 7.5 and 24 from the tank top to clear the alarm. OFFSET CALIBRATION METHOD (TYPICAL) A latched Spill alarm may be cleared by starting an Offset Calibration from the Finch display. Do not change the current offset, cycle the system power and the Spill alarm will be cleared. The alarm can only be cleared when the liquid level in the compartment is below the alarm level, 7.5 for dual rod and 2.5 to 15.5 for coaxial transmitters. MANUAL METHOD TD80 systems installed without a Finch display present a problem to clearing a latched Spill alarm. An alternate method may be used with care and attention to all relevant safety precautions. The Spill alarm may be cleared by reaching inside of the empty compartment, bridging the two rods of a dual rod probe with a bare hand or metal tool, then lowering the short across the rods from the top of the tank toward the bottom for about 2. This will clear the spill alarm. Coaxial probes are handled in a similar way, except a small metal rod or tool is inserted into one of the holes of the tube, shorting the center rod between 1 and 2 from the top of the tank. Rev. 0.0, March, 26, 2013 Page 23

26 All relevant safety precautions and company policy must be observed while clearing the Spill alarm by shorting the probe. Most tanks are higher than 6, requiring suitable fall restraint to be used. Another concern is the nature of the product in the tank. Some products may be flammable, toxic or corrosive and appropriate safety precautions must be observed at all times. SUMMARY The compartment must always be unloaded with the TD80 transmitter and Finch display powered on and reporting volume. This prevents a latched or stuck Spill alarm. A latched Spill alarm may be cleared by using one of two methods. The system must be turned on for these methods to clear a latched Spill alarm by simulating the unloading of liquid from the compartment below the Spill alarm level. Method 1: Offset Calibration (Typical). Begin an Offset Calibration at the Finch display, do not change the setting, turn the system power off and then on. The Spill alarm will be cleared if the liquid level is below the Spill alarm level. OR Method 2: Manual. Short the dual rod or coaxial probe between 1 and 2 from the tank top. The Spill alarm will be cleared if the liquid level is below the Spill alarm level. Page 24 Rev. 0.0, March 26, 2013

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28 Manufactured in Canada Manufactured by: Head Office Street Edmonton, Alberta Canada T6E 5P5 P F Saskatchewan Branch Box Cenaiko Street Lampman, Saskatchewan Canada S0C 1N0 P F Kansas Branch 8900 Nieman Road Overland Park, Kansas USA P F Toll Free TSX-V: TLA Sales Department: us at sales@titanlogix.com Service Department: us at service@titanlogix.com Find us online at