Sapphire Ultrasonic Point Level System User Guide P/N 900-000068 Revision C Part of Thermo Fisher Scientific
Sapphire Ultrasonic Point Level System User Guide P/N 900-000068 Revision C
1992 Thermo Fisher Scientific Inc. All rights reserved. Hastelloy is a registered trademark of Haynes International, Inc. MONEL is a registered trademark of Special Metals. Carpenter 20 is a registered trademark of Carpenter Technology Corp. Tri-Clover is a trademark or registered trademark of Alfa Laval Inc. All other trademarks are the property of Thermo Fisher Scientific Inc and its subsidiaries. Thermo Fisher Scientific (Thermo Fisher) makes every effort to ensure the accuracy and completeness of this manual. However, we cannot be responsible for errors, omissions, or any loss of data as the result of errors or omissions. Thermo Fisher reserves the right to make changes to the manual or improvements to the product at any time without notice. The material in the manual is proprietary and cannot be reproduced in any form without expressed written consent from Thermo Fisher.
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Revision History Revision Level Date Comments 8/92 08-92 Initial release 5/93 05-93 Added Canadian Standards Association (CSA) approval, Factory Mutual (FM) non-incendive approval, relay contact ratings, thermal isolator functionality, 4 20 ma setup procedures, and circuit board replacement section. A00 05-94 Modified to reflect incorporation of gold-plated relay contacts, a lower operating temperature range, and new Hastelloy B and Carpenter 20 sensor materials. Added remote mounting, Tri-Clover, and normally open (NO) auxiliary relay capabilities. A00 02-95 Modified to include the consolidated logic printed circuit board number 220-000448. A00 09-95 Added PFA Teflon Center Shaft Gap Sensor. A00 07-96 Modified to reflect addition of intrinsically safe approvals, field-selectable NO or NC auxiliary fault relay, manual loop test, noise self-test, variable system qualification, and 526/527 operating instructions. A00 09-96 Modified to correct typographical errors. A00 07-97 Modified to reflect address and company name changes. 01 04-00 Deleted PFA probes and added new temperature specifications. 02 02-01 Name change. 03 10-01 PROM change and eliminate noise test. 04 08-02 Revised per ECO 7803. 05 01-03 Revised per ECO 7880. A 01-06 Revised per ECO 5099. B 11-06 Revised per ECO 5412. C 03-08 Revised per ECO 6251. Thermo Fisher Scientific Sapphire User Guide v
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Contents Safety Summary... ix Warnings...ix Cautions...ix Notes...xi Chapter 1 Product Overview... 1-1 Introduction... 1-1 Using this Guide... 1-1 Chapter Overviews... 1-1 Personnel... 1-2 Components... 1-2 Dual Compartment Housing... 1-2 Power Supply... 1-3 Filter Board... 1-3 Logic PCB... 1-3 Sensors... 1-3 Sensor Configurations... 1-4 Two-Wire Electronics... 1-5 Chapter 2 Theory of Operation... 2-1 Ultrasonic Principles... 2-1 Time Gate Technology... 2-2 Continuous Self-Test... 2-2 Manual Loop Test... 2-3 System Qualification Time... 2-3 System Threshold Adjustment... 2-3 Relay Output Models... 2-4 Process Relay Alarm Operation... 2-4 Auxiliary Fault Relay Operation... 2-5 Two-Wire Models... 2-6 Process Alarm Indication... 2-6 Self-Test Fault Indication... 2-6 Optional Thermal Isolator... 2-7 Chapter 3 Special Handling Considerations... 3-1 ESD Procedures... 3-1 Unpacking, Inspection, & Storage... 3-2 Hazardous Location Installations... 3-2 Thermo Fisher Scientific Sapphire User Guide vii
Contents Chapter 4 Installation...4-1 Factory Default Settings... 4-1 Field Setup Procedures... 4-2 Threshold Adjustment Verification... 4-4 Relay Output Models... 4-4 Two-Wire Models... 4-5 Self-Test Verification... 4-6 Relay Output Models... 4-6 Two-Wire Models... 4-7 Installation Guidelines... 4-7 Installation Procedures... 4-9 3/4 NPT Mount Integral Systems... 4-9 Flange Mount Sensors Integral Systems... 4-10 Remote Mount Installations... 4-11 3/4 NPT Mount Remote Systems... 4-12 Flange Mount Sensors Remote Systems... 4-14 Chapter 5 Maintenance...5-1 Electronics... 5-1 Sensors... 5-1 Circuit Board Replacement... 5-1 Procedure... 5-2 Field Adjustments... 5-6 System Sensitivity Adjustment... 5-6 System Qualification Time Adjustment... 5-6 Final Inspections... 5-6 Chapter 6 Troubleshooting & Service...6-1 General... 6-1 Service... 6-2 Appendix A Appendix B Ordering Information...A-1 Integral Mount System...A-1 Remote Mount System...A-3 Specifications...B-1 Relay Operation...B-1 Two-Wire Operation...B-2 Appendix C Drawings... C-1 Appendix D Toxic & Hazardous Substances Tables*...D-1 viii Sapphire User Guide Thermo Fisher Scientific
Safety Summary The following warnings, cautions, and notes appear throughout this guide. Warnings Warnings alert users to operating procedures, practices, conditions, etc. that may result in injury or death if not carefully followed or observed. Warning Sapphire systems may be used only in those hazardous locations identified on the product nameplates. (3 2) Warning Installation must be carried out in accordance with local site requirements and regulations. (4 1) Warning Electrical installation must be made in compliance with application area classification codes. Only qualified personnel should perform installation. (4 2) Warning Hazardous voltages can be present on terminals. Voltages can cause injury or death. Proceed with extreme caution. (4 4) Warning The system may be used only in those hazardous locations identified on the product nameplate. These installation and servicing instructions are for use by qualified personnel only. (4 7) Warning When disconnecting power from the instrument, follow proper lockout/tagout procedures to avoid accidental exposure of personnel to high voltage circuits. (5 2) Cautions Cautions alert users to operating procedures, practices, conditions, etc. that may result in damage to equipment if not carefully followed or observed. Caution The manual loop test feature will not activate (reverse outputs) when the system is in a self-test fault or malfunction condition. (2 3) Caution The thermal isolator is an integral part of the sensor assembly. Do not attempt to remove it from the sensor. Removing or loosening the thermal isolator can damage the sensor. (2 7) Thermo Fisher Scientific Sapphire User Guide ix
Safety Summary Cautions Caution These systems are electrostatic discharge (ESD) sensitive. Use proper ESD protective equipment and follow ESD handling procedures when servicing or handling the instrument. Failure to comply with ESD procedures can result in circuit damage. (3 1) Caution These systems are ESD sensitive instruments. Use proper ESD protective equipment and follow ESD handling procedures when servicing or handling the instrument. Failure to comply with ESD procedures can result in circuit damage. (4 2) Caution Sensors are fragile instruments. Handle with care. Do not support or carry systems by the sensors. Sensor breakage may cause fluids to enter electronics housing. The sensor, flange (if applicable), and electronics have been carefully assembled at the factory. Disassembly of the system is not required for installation and may result in damage to the sensor. (4 9) Caution Do not support or carry flange mounted unit by the sensors. Handle these units by the flange to avoid damaging the sensor. (4 10) Caution The sensor assembly is provided with a pre-determined length (per customer order) of sensor cables. Use care to avoid damaging the cable or phono plugs during installation. (4 12) Caution Due to the nature of the piezoelectric crystals used in the probes of Sapphire systems, Thermo Fisher recommends discharging each signal cable by connecting the shield (case) to center conductor (pin) before connecting to the main logic board or remote mounting bracket signal cables. (4 13) Caution The sensor assembly is provided with a pre-determined length (per customer order) of sensor cables. Use care to avoid damaging the cable or phono plugs during installation. (4 18) Caution Due to the nature of the piezoelectric crystals used in the probes of Sapphire systems, Thermo Fisher recommends discharging each signal cable by connecting the shield (case) to center conductor (pin) before connecting to the main logic board or remote mounting bracket signal cables. (4 15) Caution Do not clean with saturated steam greater than 50 psig. Repeated steam cleaning can potentially shorten sensor life. (5 1) x Sapphire User Guide Thermo Fisher Scientific
Safety Summary Notes Caution Sapphire systems are ESD sensitive instruments. Use proper ESD protective equipment and follow ESD procedures when handling the instrument. Failure to comply with ESD procedures can result in circuit damage. (5 2) Caution Replacement boards are sent in sets. Do not reuse the old circuit board. Improper operation or damage can occur. (5 3) Caution Components L1 and R37 of the logic PCB assembly are factory calibrated. Do not adjust these components. Improper operation or damage can occur. (5 4) Caution Due to the nature of the piezoelectric crystals used in the probes of Sapphire systems, Thermo Fisher recommends discharging each signal cable by connecting the shield (case) to the center conductor (pin) before connecting to the main logic PCB or remote mounting bracket signal cables. (5 4) Notes Notes are statements of company policy regarding operating procedures, practices, conditions, etc. Notes are also used to emphasize operating procedures, practices, conditions, etc. Note The factory settings located on the underside of the main logic PCB are configured for sensor types and should not be changed. (1 3) Note Due to the unique signal processing capability of the slot sensor, the threshold adjustment potentiometer (R9) is not required. This function is disabled on slot sensor units. (2 3) Note System relay operation has been designed for fail-safe operation. A self-test failure or power loss will de-energize the process and auxiliary relays regardless of the actual state of the measurement gap. (2 4) Note Inspection, adjustment, installation, and maintenance of this unit must be performed by experienced personnel. Refer to Personnel in Chapter 1. (3 2) Note The connection compartment can be identified by the product label ( Conn ) located on the side of the dual compartment electrical housing. (4 10) Thermo Fisher Scientific Sapphire User Guide xi
Safety Summary Notes Note Install process signal/alarm and power wiring in accordance with applicable electrical codes. (4 10) Note Sapphire system enclosures installed in Class I, Div. 1 Hazardous (Classified) Locations are factory sealed and require a poured conduit seal only if the conduit run leaves said location or if the conduit run enters another enclosure requiring a poured seal. (4 10) Note The connection compartment can be identified by the product label ( Conn ) located on the side of the dual compartment electrical housing. (4 11) Note Install process signal/alarm and power wiring in accordance with applicable electrical codes. (4 11) Note A system enclosure installed in Class I, Div. 1 Hazardous (Classified) Location is factory sealed and requires a poured conduit seal only if the conduit run leaves the installation location or if the conduit run enters another enclosure requiring a poured seal. (4 11) Note Installation must be done in accordance with local electrical codes. (4 12) Note If optional pipe or wall mounting brackets are used, mount the bracket to a solid structure or pipe prior to mounting the electronics to the bracket. (4 13) Note A minimum of five full threads is required between all threaded joints. (4 13) Note The connection compartment can be identified by the product label ( Conn ) located on the side of the dual compartment electrical housing. (4 13) Note Install process signal/alarm and power wiring in accordance with applicable electrical codes. (4 14) xii Sapphire User Guide Thermo Fisher Scientific
Safety Summary Notes Note A system enclosure installed in Class I, Div. 1 Hazardous (Classified) Location) is factory sealed and requires a poured conduit seal only if the conduit run leaves the installation location or if the conduit run enters another enclosure requiring a poured seal. (4 14) Note If optional pipe or wall mounting brackets are used, mount the bracket to a solid structure or pipe prior to mounting the electronics to the bracket. (4 15) Note A minimum of five full threads is required between all threaded joints. (4 15) Note The connection compartment can be identified by the product label ( Conn ) located on the side of the dual compartment electrical housing. (4 15) Note Install process signal/alarm and power wiring in accordance with applicable electrical codes. (4 16) Note A system enclosure installed in Class I, Div. 1 Hazardous (Classified) Location) is factory sealed and requires a poured conduit seal only if the conduit run leaves the installation location or if the conduit run enters another enclosure requiring a poured seal. (4 16) Note When installing a DC relay/power supply PCB (P/N 220-000450), secure the solder lug from the board against the board using the closest standoff. (5 4) Note The interconnect cable is keyed to prevent incorrect orientation. (5 4) Note Due to the unique signal processing capability of the slot sensor, the threshold adjustment potentiometer (R9) is not required. Slot sensor configured units have this function disabled. (5 6) Note This troubleshooting section is a general list of possible conditions that could exist. This listing is not exhaustive and not meant to address all possible problems. Contact Thermo Fisher if a condition occurs that is not covered in this manual. (6 1) Thermo Fisher Scientific Sapphire User Guide xiii
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Chapter 1 Product Overview Introduction Using this Guide The Thermo Scientific Sapphire Ultrasonic Point Level System is the industry standard for reliable point level measurements. Its continuous selftest feature automatically checks system integrity including electronics, sensor, and crystal disbonding without needing additional crystals or sensor mounted electronics. Dual compartment housing provides quick, easy access to field wiring connections while protecting the electronics from exposure to harsh environments, damage, or leaky connections. This section provides an overview of each chapter and descriptions or qualifications of personnel called out in this guide. Chapter Overviews Chapter 1: Provides a physical description of the system components. Chapter 2: Contains discussions regarding the theory of ultrasonic operation, Time Gate technology, manual loop test, system qualification time, and system threshold adjustment. Also describes the operation of the relay output and two-wire output models. Chapter 3: Discusses procedures for handling electrostatic discharge sensitive equipment, as well as procedures for unpacking, inspecting, and storing the system. Also included are physical mounting instructions for hazardous locations. Chapter 4: Contains information on factory configured default settings for field selected parameters. Specific information and installation guidelines are provided to allow the user to customize and verify operating parameters prior to final installation and placing the system into service. Chapter 5: Recommends preventative maintenance measures for system electronics and sensor components. Also contains series of instructions involving the installation of various circuit board replacement kits. Chapter 6: Provides a series of recommended troubleshooting measures to facilitate diagnosis and isolation of system faults. Appendix A: Provides system ordering information. Thermo Fisher Scientific Sapphire User Guide 1-1
Product Overview Components Appendix B: Provides system specifications. Appendix C: Provides system drawings. Appendix D: Provides Toxic and Hazardous Substances tables. Personnel Installation personnel: Should be an electrician or a person with a solid background in electronics instrumentation. The person should be familiar with the National Electrical Code (NEC), proper grounding and safety procedures, and local wiring regulations. Operating personnel: Should have knowledge of the process and should read and understand this guide before attempting any procedure pertaining to the operation of the system. Maintenance personnel: Should have a background in electricity and be able to recognize shock hazards. Should also be familiar with electronic process control instrumentation and have a good understanding of troubleshooting procedures. Components Following are brief descriptions of the main system components. They are illustrated in Figure 1 1. Dual Compartment Housing All Sapphire systems are supplied with dual compartment housing in either integral or remote mounted configurations. This housing provides easy access to field connections without exposing the electronics to unnecessary handling, harsh environments, or physical damage. CSA approvals allow the Type 4 enclosure to be located in environmentally hazardous and corrosive locations. The two housing compartments are called the circuit compartment and the connection compartment. The circuit compartment contains the power supply or filter board and the logic circuit board. The connection compartments houses two terminal strips for power and signal connections. A product label attached to the outside of the housing identifies the two compartments. The compartments are mechanically isolated from each other using sealed electrical feed-throughs to connect the terminal strips with the circuit boards. Located at the top of the housing are two 1/2-inch NPT conduit connection ports for user supplied power and field wiring terminations. 1-2 Sapphire User Guide Thermo Fisher Scientific
Product Overview Components Power Supply The power supply PCB is used with every relay unit and is located at the bottom of the circuit compartment. It is completely hidden from view by the logic PCB. The board is factory configured for the specific power specifications for each system. Field configuration for NO and NC contacts of the FAULT relay are available for customers. The NC contact is the factory default setting. Filter Board The filter or EMC board replaces the power supply board in two-wire units. Logic PCB The logic PCB is located at the top of the circuit compartment. This PCB contains field and factory selectable jumpers and an adjustment potentiometer. All field selectable settings are accessible on the exposed face of the logic PCB for easy access. Factory settings are located on the underside of the logic PCB, along with sensor and power supply connections. The factory settings on the underside of the logic PCB do not require field modification. Note The factory settings located on the underside of the main logic PCB are configured for sensor types and should not be changed. Sensors Table 1 1. Sensor types Sapphire systems are available in standard gap or optional slot sensor configurations. The gap sensor performs exceptionally well in most applications, including aerated and attenuating liquids which can cause problems for other ultrasonic technologies. The slot sensor provides reliable operation in even more severe or viscous applications (see Table 1 1). The gap sensor will handle over 98% of the applications. Sensor Style Gap Type Slot Type Materials of construction 316SS, Hastelloy B and C, MONEL, Carpenter 20 316SS, Hastelloy C Minimum sensor A dimension 1 (25 mm) 4 (102 mm) Maximum sensor A dimension 120 (3048 mm) 120 (3048 mm) Remaining sensor length 1.44 (36.6 mm) 0.30 (7.6 mm) Sensor operating temperature 1-40 F to +320 F (-40 C to +160 C) -310 F to +212 F (-190 C to +100 C) -40 F to +320 F (-40 C to +160 C) -310 F to +212 F (-190 C to 100 C) Maximum operating pressure 2-10 to 1500 psig (-69 to 10342 KPa) -10 to 1500 psig (-69 to 10342 KPa) 1 The thermal isolator is required for 3/4" NPT units when process temperatures exceed 275 F (135 C). Flanged and remote mounted units do not require the thermal isolator. 2 Pressure ratings are for 3/4 NPT units. Thermo Fisher Scientific Sapphire User Guide 1-3
Product Overview Sensor Configurations Figure 1 1. System components Sensor Configurations Gap sensors are available in a broad range of materials, which include 316SS, Hastelloy C, MONEL, Hastelloy B, and Carpenter 20. Slot sensors are available in 316SS and Hastelloy C only. The stainless steel versions of both sensor types can be delivered with a 150 grit (32 μinch) or better, Sanitary 3A finish and 316L stainless steel Tri-Clover (16 AMP) fitting that assembles and disassembles quickly for fast cleaning. Sensor extensions, nipples, and flanges are available in like materials. All systems are available with 3/4-inch NPT mounting, various flange sizes, Tri-Clover fittings, or remotely mounted electronics. Systems may be installed vertically or horizontally. Every system is imprinted with the sensor material type. For gap sensors, this information is located on the nipple flat or flange edge to orient the bridge location. For slot sensors, it is located on the sensor body side (Figure 1 2). Sensor leads are routed into the circuit compartment of the housing and connected to the underside of the logic PCB. 1-4 Sapphire User Guide Thermo Fisher Scientific
Product Overview Sensor Configurations Two-Wire Electronics Sensors for use with two-wire electronics are approved explosion proof and intrinsically safe. They are identical in performance to earlier explosion proof only sensors but have additional components to meet the intrinsically safe requirements. Figure 1 2. Sensor markings Thermo Fisher Scientific Sapphire User Guide 1-5
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Chapter 2 Theory of Operation Sapphire systems are designed using state-of-the-art ultrasonic and electronic technologies. Advancements in acoustical design and materials, a patented Time Gate technology, and continuous self-test have produced the most reliable and technically advanced ultrasonic level sensor of its type. Ultrasonic Principles The system utilizes ultrasonic sound waves to detect the presence or absence of a liquid within a defined measurement gap. The basic principle that sound waves travel easily through a liquid media, while being severely attenuated when traveling though air, is incorporated into the design. Most ultrasonic level switches utilize the continuous feedback technology developed and patented 30 years ago. A piezoelectric crystal positioned on one side of a measurement gap is continuously excited by an electrical signal. This signal causes an ultrasonic sound wave to travel through the measurement gap (see Figure 2 1). If no liquid is present within the measurement gap, the ultrasonic sound wave is attenuated and the second crystal, called the receive crystal, detects only a small percentage of the original ultrasonic sound wave. This causes only a slight excitation of the receive crystal, resulting in a low amplitude output from the receive crystal. If liquid is present within the measurement gap, a much larger percentage of the transmitted ultrasonic sound wave is detected by the receive crystal, resulting in a much higher amplitude output. To measure aerated and attenuating liquids, the feedback gain must be increased to very high levels. The increased gain amplifies the signal received when the gap is filled with air or liquid. Thermo Fisher Scientific Sapphire User Guide 2-1
Theory of Operation Time Gate Technology Time Gate Technology Continuous Self-Test Thermo Fisher s Time Gate technology pulses the transmit crystal, and the signal from the receive crystal is accepted in predictable, narrow time windows or time gates. The ultrasound received when the gap is dry travels along the bridge of the gap and reaches the receive crystal at a different time than the ultrasound that travels through the air or liquid in the gap. This method separates these signals and raises the sensitivity beyond the capabilities of the continuous feedback method. The Time Gate technology incorporates a continuous self-test feature to monitor system integrity. The unit uses the signal that travels along the bridge for its unique self-test. This signal is always present whether the gap is filled with air or liquid. It must always be present or the unit will indicate a fault. The crystals must be operational and properly bonded to the sensor to generate and receive the ultrasound. The continuous self-test is performed automatically and does not require the use of special self-test crystals or electronics in the sensor probe. The simpler self-test design and the unique ability to detect crystal disbonds add to the unit s high level of reliability. Figure 2 1. Ultrasonic point measurement 2-2 Sapphire User Guide Thermo Fisher Scientific
Theory of Operation Manual Loop Test Manual Loop Test Manual loop test is a feature that allows users to check or verify loop integrity, field wiring, and/or the operation of any downstream equipment activated by system outputs. This feature is momentarily activated when the supplied magnet is placed over the proper location on the housing cover marked Loop Test. Manual loop test will change outputs to the opposite state when systems are not in a self-test fault or malfunction condition. Two-wire looppowered units will change the current output to the opposite 8 or 16 ma state. Relay units will change to the opposite relay state. Caution The manual loop test feature will not activate (reverse outputs) when the system is in a self-test fault or malfunction condition. System Qualification Time System Threshold Adjustment This setting determines the amount of time that liquid must be continuously present within the measurement gap (in high level operation) or absent from the gap (in low level operation) before the process level alarm is indicated. At the point of switching from one condition to the next (from dry to wet), the system first "qualifies" that the new condition is continuously present and not a momentary occurrence. The new condition must be continuously present before the changing liquid level condition is indicated. The implementation of a sensor qualification test assures that the actual liquid level has reached the measurement gap instead of a wave fluctuation due to agitation or turbulence. This setting can be field adjusted by the system qualification time potentiometer (R20) in the range of 0.3 to 12 seconds. The threshold adjustment potentiometer (R9) determines the gap sensor's wet/dry switch point. The factory-configured default position for this setting is approximately mid-range and will operate properly for the majority of system applications. Counterclockwise rotation of the threshold potentiometer increases the threshold. Clockwise rotation decreases the threshold. Note Due to the unique signal processing capability of the slot sensor, the threshold adjustment potentiometer (R9) is not required. This function is disabled on slot sensor units. Thermo Fisher Scientific Sapphire User Guide 2-3
Theory of Operation Relay Output Models Relay Output Models The relay output model provides one process relay for level alarm indication and a second auxiliary relay for self-test fault indication. Both relays use gold-plated contacts for reliable switching of lower current and voltage levels, eliminating the need for DCS users to install interposing relays. Process level alarm indication can be field selected for either high level or low level fail-safe operation by configuring the placement of the process level jumper (J4). Operation of the auxiliary fault relay can be field selected for either fault or mimic operation by the appropriate placement of the auxiliary fault jumper (J3). Table 2 1 defines relay alarm states for all possible combinations of process alarms, self-test faults, and power loss conditions. Process Relay Alarm Operation Relay output models indicate process level alarms through SPDT process relays. The SPDT process relay provides a normally closed (NC) and a normally open (NO) set of contacts. During normal operating conditions, the process relay is energized as long as the process level jumper (J4) is in the correct fail-safe position. Relay output models operate in one of two field selectable fail-safe modes: high level or low level operation. The position of the field selectable process level jumper (J4) determines the fail-safe operation of the unit. When systems are field selected for high level operation, the process relay is energized when the measurement gap is dry and de-energized when the measurement gap is wet. When systems are set for low level operation, the process relay is energized when the measurement gap is wet and de-energized when the gap is dry. Note System relay operation has been designed for fail-safe operation. A self-test failure or power loss will de-energize the process and auxiliary relays regardless of the actual state of the measurement gap. This is provided as a safety feature because reliable information regarding the state of the measurement gap cannot be assured during self-test failures. Therefore, interpretation of both the process and auxiliary relay status is necessary to verify actual process conditions. 2-4 Sapphire User Guide Thermo Fisher Scientific
Theory of Operation Relay Output Models Auxiliary Fault Relay Operation Relay output models indicate self-test fault conditions through a SPST auxiliary relay contact. The SPST auxiliary fault relay provides one field selectable NC or NO contact and is always energized during normal operating conditions. Fault or mimic operation is also selectable through the auxiliary fault jumper (J3). When set for fault operation, the auxiliary relay de-energizes upon self-test failure or power loss. When set for mimic operation, a second set of contacts is available which responds in the same manner as the process alarm relay contacts, and the auxiliary fault relay de-energizes on process alarm, self-test failure, or power loss. Table 2 1. Relay output combinations Jumper & Sensor Condition No Power MF MF Dry Dry Dry Dry Wet Wet Wet Wet Level setting (J4): 1&2: Low level (8 wet/16 dry) 2&3: High level (8 dry/16 wet) Malfunction jumper (J11): 1&2: 5 ma fault output 2&3: 19 ma fault output Auxiliary relay (J3)*: 1&2: Fault operation 2&3: Mimic operation Manual loop test (S3): 0 = No manual loop test (de-energized) 1 = Manual loop test activated (energized) X X X 2 3 1 2 2 3 1 2 2 3 1 2 2 3 1 2 X X X X X X X X X X X X X X 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 X X X 0 0 1 1 0 0 1 1 Process alarm relay output 0 0 0 1 0 0 1 0 1 1 0 Auxiliary fault relay output* 0 0 0 1 1 0 0 1 1 0 0 Where: MF = Malfunction or self-test failure WET = System sensor s measurement gap/slot is physically Wet DRY = System sensor s measurement gap/slot is physically Dry X = Jumper position (e.g. state) does not matter 0 = Relay is de-energized or manual loop test is not activated 1 = Relay is energized or manual loop test is activated 1 2 = Jumper pins in position 1 & 2 2 3 = Jumper pins in position 2 & 3 * When auxiliary relay jumper (J3) is selected for mimic operation (pins 2 & 3), the auxiliary fault relay output will mimic the operation of the process alarm relay output. Thermo Fisher Scientific Sapphire User Guide 2-5
Theory of Operation Two-Wire Models Two-Wire Models The two-wire, 4 20 ma DC model provides reliable level detection and lower installation costs for users with two-wire instrumentation. Table 2 2 defines the two-wire output for all possible process alarm, self-test, power loss, and main logic board jumper settings. Process Alarm Indication Two-wire models do not use relays to indicate process level alarm or selftest failures discussed above. Instead, these loop-powered models use a fixed ma output to indicate both process level alarms and self-test faults. A wet measurement condition is always indicated by an output of 16 ma DC or 8 ma DC depending on the position of jumper J4. Likewise, a dry measurement condition is always indicated by an output of 8 ma DC or 16 ma DC depending on the position of jumper J4. Self-Test Fault Indication The position of the auxiliary fault jumper (J3) has no effect on the fixed ma output for these two-wire systems. By setting the malfunction jumper (J11), users can select whether 5 or 19 ma will indicate self-test failures. In addition, self-test faults are only indicated when a self-test fault occurs. Process alarm indications are not mimicked or coupled to self-test failure indications. Table 2 2. Two-wire output combinations Jumper & Sensor Condition No Power MF MF Dry Dry Dry Dry Wet Wet Wet Wet Level setting (J4): 1&2: Low level (8 Wet/16 Dry) 2&3: High level (8 Wet/16 Dry) Malfunction jumper (J11): 1&2: 5 ma fault output 2&3: 19 ma fault output Auxiliary relay (J3): 1&2: Fault operation 2&3: Mimic operation Manual loop test (S3): 0 = No manual loop test (de-energized) 1 = Manual loop test activated (energized) X X X 2 3 1 2 2 3 1 2 2 3 1 2 2 3 1 2 X 1 2 2 3 X X X X X X X X X X X X X X X X X X X X X X 0 0 1 1 0 0 1 1 Two-wire current output (ma) 0 ma 5 19 8 16 16 8 16 8 8 16 Where: MF = Malfunction or self-test failure WET = System sensor s measurement gap/slot is physically Wet DRY = System sensor s measurement gap/slot is physically Dry X = Jumper position (e.g. state) does not matter 0 = Relay is de-energized or manual loop test is not activated 1 = Relay is energized or manual loop test is activated 1 2 = Jumper pins in position 1 & 2 2 3 = Jumper pins in position 2 & 3 2-6 Sapphire User Guide Thermo Fisher Scientific
Theory of Operation Optional Thermal Isolator Table 2 3. Relay terminal combinations Unit Power Process Alarm Self-Test Fault Auxiliary Jumper Process Relay Auxiliary Relay NO NC If NC If NO On No No Fault C O O C On No No Mimic C O O C On Yes No Fault O C O C On Yes No Mimic O C C O On No Yes Fault O C C O On No Yes Mimic O C C O On Yes Yes Fault O C C O On Yes Yes Mimic O C C O Off No No Fault O C C O Off No No Mimic O C C O Off Yes No Fault O C C O Off Yes No Mimic O C C O Off No Yes Fault O C C O Off No Yes Mimic O C C O Off Yes Yes Fault O C C O Off Yes Yes Mimic O C C O Optional Thermal Isolator Systems with 3/4-inch metal NPT sensors can extend the operating temperature range of the sensor when ordered with the optional thermal isolator. The thermal isolator allows sensors with 3/4-inch NPT fittings to be installed in process applications above 275 F/135 C (up to 320 F/160 C). Flanged units have built-in thermal isolation in the flange nipple and remote mounted systems do not require the use of the thermal isolator. The thermal isolator is an integral part of the sensor assembly and can only be supplied with a new sensor. It is not available as an "add-on" option to an existing sensor. Caution The thermal isolator is an integral part of the sensor assembly. Do not attempt to remove it from the sensor. Removing or loosening the thermal isolator can damage the sensor. Thermo Fisher Scientific Sapphire User Guide 2-7
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Chapter 3 Special Handling Considerations Caution These systems are electrostatic discharge (ESD) sensitive. Use proper ESD protective equipment and follow ESD handling procedures when servicing or handling the instrument. Failure to comply with ESD procedures can result in circuit damage. ESD Procedures These systems are ESD sensitive instruments. They contain electronic components that can be damaged from discharges of static electricity. The following procedures should be observed when installing, setting up, servicing, troubleshooting, and repairing the system: 1. Use an antistatic bag. Electronic subassemblies are shipped in special antistatic bags. Keep the assembly in the bag as often as possible whenever the subassembly is not installed. 2. ESD sensitive subassemblies should be removed from their antistatic bags only: a. At a designated static-free workstation or when the bag is grounded at the field site b. After conductive area of container has been neutralized c. After you have made firm contact with an antistatic mat and/or firmly gripped by a grounded individual 3. Personnel handling ESD sensitive devices should be neutralized to a static-free workstation by a grounding wrist strap that is connected to the station or to a good grounding point at the field site. 4. Do not allow clothing to make contact with ESD sensitive devices. 5. Avoid touching connectors and components. Thermo Fisher Scientific Sapphire User Guide 3-1
Special Handling Considerations Unpacking, Inspection, & Storage 6. Avoid partial connection of ESD sensitive devices. These devices can be damaged by floating leads, especially the power supply connector. 7. Ground test equipment. Unpacking, Inspection, & Storage 8. Avoid static charges during troubleshooting. Note Inspection, adjustment, installation, and maintenance of this unit must be performed by experienced personnel. Refer to Personnel in Chapter 1. Upon receipt, examine the instrument for damage that occurred in transit. If damage is found or there is evidence of rough handling, file a damage claim with the carrier and contact your representative. Carefully inspect the packing material before discarding it to make certain that all equipment and instruction paperwork has been removed. Careful handling and installation will ensure satisfactory performance of the system. Use the original packaging material and container for storage if necessary. The storage environment should be protected and free from extremes of temperatures and high humidity and fall within the environmental constraints listed in the performance specification section of this manual. Hazardous Location Installations CSA units are available for installation in environmentally hazardous and corrosive locations. See the Appendix B for specific agency approval classifications. Warning Sapphire systems may be used only in those hazardous locations identified on the product nameplates. 3-2 Sapphire User Guide Thermo Fisher Scientific
Chapter 4 Installation Warning Installation must be carried out in accordance with local site requirements and regulations. Reference the drawing appendix for system drawings. Factory Default Settings Each system is factory-configured and shipped with the following default settings. Refer to Figures 4 1 and 4 2 for locations of the field selectable jumpers and potentiometers. Table 4 1. Default settings Field Selectable Adjustment Factory Default Setting Process level jumper (J4) High level operation (2 & 3) Auxiliary fault jumper (J3) Fault mode operation (1 & 2) System qualification time potentiometer (R20) Minimum time (0.3 seconds) Threshold adjustment potentiometer (R9) Nominal (center position) Malfunction jumper (J11) 19 ma (2 & 3) NO or NC jumper (J6) NO (2 & 3) Figure 4 1. Main logic PCB field selectable adjustments Thermo Fisher Scientific Sapphire User Guide 4-1
Installation Field Setup Procedures Figure 4 2. Power supply board NO/NC field selection Field Setup Procedures Warning Electrical installation must be made in compliance with application area classification codes. Only qualified personnel should perform installation. All field selectable adjustments should be made prior to installing the system in process locations. Bench adjustments are recommended to avoid exposure of sensitive circuit board components to process environments. Thermo Fisher recommends performing the following prior to final system installation in process locations. Caution These systems are ESD sensitive instruments. Use proper ESD protective equipment and follow ESD handling procedures when servicing or handling the instrument. Failure to comply with ESD procedures can result in circuit damage. 1. Remove the housing covers from the circuit and connection sides of the dual compartment housing. 2. Customize the main logic PCB s field selectable adjustments for your specific application as described below: a. Process level setting (J4): Locate jumper J4 on the main logic PCB. For high level operation (default), place the 2-pin jumper on pins 2 and 3. For low level operation, place the jumper on pins 1 and 2. Place J4 across pins 1 and 2 to have 8 ma for wet condition and 16 ma for dry condition. Place J4 across pins 2 and 3 to have 8 ma for dry conditions and 16 ma for wet condition. 4-2 Sapphire User Guide Thermo Fisher Scientific
Installation Field Setup Procedures b. Auxiliary relay (J3): Locate jumper J3. For fault operation (default), place the 2-pin jumper on pins 1 and 2. For mimic operation, place the jumper on pins 2 and 3. c. Malfunction jumper (J11): Locate jumper J11. The position of J11 determines the current output during self-test or malfunction conditions. The malfunction jumper is applicable to only two-wire output systems. For 19 ma output during malfunction conditions (default), place J11 on pins 2 and 3. For 5 ma output during malfunction conditions, place J11 on pins 1 and 2. d. System qualification time (R20): Locate potentiometer R20. Leave the potentiometer fully counterclockwise (0.3 seconds default) unless the process has excessive agitation and splashing. e. NO/NC setting (J6): Remove the main logic PCB and locate jumper J6 on the power supply board. For NO operation (default), place the 2-pin jumper in pins 2 and 3. For NC operation, place jumper J6 in pins 1 and 2. Reinstall the logic board. 3. Connect incoming power to terminals L1 and L2 of the top terminal strip. Refer to Figure 4 3 for location and identification of terminal connections. Do not turn on power at this time. Figure 4 3. Field wiring connections Thermo Fisher Scientific Sapphire User Guide 4-3
Installation Threshold Adjustment Verification Threshold Adjustment Verification Although the threshold adjustment potentiometer (R9) is factory calibrated for nominal conditions and should operate properly for the majority of applications, we recommend testing functionality using actual process liquids to verify the factory calibrated threshold adjustment. Relay Output Models Follow this procedure to verify and adjust the threshold adjustment potentiometer (R9). Warning Hazardous voltages can be present on terminals. Voltages can cause injury or death. Proceed with extreme caution. 1. Connect the test leads of a digital voltmeter (DVM) to the process terminals 2C (process contact common) and 2NC (process contact NC). Set the DVM for continuity measurement. 2. Turn on power to instrument. 3. Check continuity across the process alarm relay contacts. For high level operation, the DVM should read open. For low level operation, the DVM should show continuity. Hold the loop test magnet next to housing at location marked Loop Test. The process alarm and fault relays should switch. 4. Fill a container with at least four inches of representative sample for typical process conditions. 5. Immerse the sensor in the liquid far enough to cover the entire gap or slot. 6. Within the field selected system qualification time (0.3 to 12.0 seconds), the process alarm relay should change state and de-energize. For high level operation, the DVM should show continuity. For low level operation, the DVM should read open. 7. Remove the sensor from liquid. Within the system qualification time, the process alarm relay should change state and energize. 4-4 Sapphire User Guide Thermo Fisher Scientific
Installation Threshold Adjustment Verification 8. If the process alarm relay did not change states as described in steps 6 and 7, adjust the threshold adjustment potentiometer (R9) as follows: a. If the process alarm relay did not change state within the qualification time when immersed in the liquid, decrease the threshold by rotating potentiometer R9 1/8-turn clockwise. Re-test the unit and, if necessary, adjust in 1/8-turn increments until the process alarm changes state within the qualification time. b. If process alarm relay does not change state within the qualification time when removed from the liquid, increase the threshold by rotating potentiometer R9 1/8-turn counterclockwise. Re-test the unit, and if necessary, adjust in 1/8-turn increments until the process alarm relay changes state within the qualification time. Two-Wire Models For two-wire, 4 20 ma units, the same threshold adjustment procedures can be followed as described in above. However, instead of monitoring relay contacts for wet/dry indication, the ma output should be measured for indication of 8 ma, ±1 ma (dry condition) or 16 ma, ±1 ma (wet condition) if jumper J4 is in 1-2 position. 1. Connect a current meter in series with the DC power supply as shown in Figure 4 4. 2. Turn on power to instrument. 3. Check the ma output on the meter for a dry sensor. The output should read 8 ma, ±1 ma. Hold the loop test magnet over the circuit housing cover at the location marked Test. The output should read 16 ma, ±1 ma. 4. Fill a container with at least four inches of a representative sample for typical process conditions. 5. Immerse the sensor in the liquid far enough to cover the entire gap or slot. 6. Within the system qualification time, the output should change to 16 ma, ±1 ma. 7. Remove the sensor from the liquid. Within the system qualification time, the output should switch back to 8 ma, ±1 ma. Thermo Fisher Scientific Sapphire User Guide 4-5
Installation Self-Test Verification 8. If the output did not change state as described in steps 6 and 7, adjust the threshold adjustment potentiometer (R9) as follows: a. If the analog output did not change state within the qualification time when immersed in the liquid, decrease the threshold adjustment by rotating potentiometer R9 1/8-turn clockwise. Test the unit again and, if necessary, adjust in 1/8-turn increments until the analog output changes state within the qualification time. b. If analog output does not change state within the qualification time when removed from the liquid, increase the threshold adjustment by rotating potentiometer R9 1/8-turn counterclockwise. Re-test the unit, and if necessary, adjust in 1/8-turn increments until the analog output changes state within the qualification time. Figure 4 4. 4 20 ma test wiring diagram Self-Test Verification With the sensor configured for your specific application, perform a final check of the auxiliary relay (relay models only) and the self-test function. Relay Output Models 1. With the sensor outside of the liquid, check for continuity across the auxiliary relay terminals 1C and 1NC or 1NO (auxiliary relay common and normally closed or normally open contact depending on position of jumper J6 on the power supply board). 2. Refer to Table 2 1 to check the auxiliary relay contact operation for proper fault/mimic operation. 3. Submerge the sensor in the liquid. Refer to Table 2 1 for proper auxiliary relay contact operation. Verify with the DVM. Monitor the operation of the process relay. Verify that a self-test fault is not indicated. 4-6 Sapphire User Guide Thermo Fisher Scientific
Installation Installation Guidelines Two-Wire Models 1. The two-wire, 4 20 ma unit does not use an auxiliary relay output to indicate a self-test failure. A properly functioning unit (i.e., no self-test failure) will only provide the appropriate ma output corresponding to the state of the measurement gap (either wet or dry) either 8 ma or 16 ma, depending on the position of jumper J4. Refer to Table 2 2 for proper operation. 2. If a self-test failure is present, the output should read either 5 ma or 19 ma, depending on the position of jumper J11. Installation Guidelines 3. Verify that no self-test failure is present. The system is now ready for field installation. Remove power from the unit, disconnect the wiring, and replace the housing covers. Warning The system may be used only in those hazardous locations identified on the product nameplate. These installation and servicing instructions are for use by qualified personnel only. This system has been designed for long, trouble-free service and has been tested at the factory. However, a good installation is the key to good performance. Thermo Fisher recommends setting the configurable adjustments according to your application (see Field Setup Procedures ) and testing prior to final installation. The following installation guidelines should be considered when selecting a mounting location. The unit should be kept out of the direct flow of liquid during filling operations to avoid erroneous indications. If necessary, a baffle may be used to divert the liquid. Avoid installing the sensor in areas of high turbulence or agitation such as pump discharge or suction. This can cause air pockets to be present in the measurement gap which may cause false process alarm indications. Make sure that a clear space exists inside the vessel or pipe for the sensor length. The measurement gap should be clear of the coupling and wall to avoid forming a pocket which can trap liquid or air. For aerated applications, mount the sensor horizontally, paying particular attention to the orientation of the sensor bridge (Figure 4 6). If reducing bushings are used directly in certain smaller pipe sizes, be sure the measurement gap is beyond the bushings. Thermo Fisher Scientific Sapphire User Guide 4-7
Installation Installation Guidelines The unit may be mounted in any position desired. Horizontal mounting is recommended in highly viscous liquids or liquids containing sludge and debris. Proper sensor orientation is important for reliable operation of the instrument. In horizontal mounting applications, the measurement gap must be oriented so that liquid can easily flow through the gap or slot. Proper horizontal orientation of the sensor is indicated in Figure 4 5. For proper alignment of the gap or slot when installing the probe, a bridge alignment mark is stamped on the hex nipple or flange edge at the top of the sensor. This bridge alignment mark indicates the sensor bridge location for the gap sensor and the sensor body side for the slot sensor. Refer to Figure 4 6. Be certain that all wiring, conduit, and electrical fittings conform to local electrical codes for the location selected. Figure 4 5. Horizontal installation 4-8 Sapphire User Guide Thermo Fisher Scientific