ULTRASONIC POINT LEVEL SYSTEM Introduction Compliance with growing government regulations mandates tighter level controls with advanced diagnostics to avoid releases, overspills and costly environmental clean-ups. Using anything but the most reliable and dependable point level switch for high level alarms and spill prevention has become unacceptable. Advancements in acoustical design and materials combined with Sapphire s patented Time-Gate technology have produced the most reliable and technically advanced level switch of its type. Sapphire performs exceptionally well in aerated, attenuative, viscous, corrosive, and even more severe applications. From the originators of the ultrasonic point level Gap switch technology, Sapphire is the industry standard for reliable point level measurements. Thermo took 30 years of level experience and developed Sapphire s unique measurement technique with superior selftesting capabilities. The continuous self-test feature automatically checks system integrity including electronics, sensor, and crystal disbonding, without the need for additional crystals or sensors mounted electronics. Sapphire s dual compartment housing provides quick and easy access to field wiring connections while protecting the electronics from exposure to harsh environments, damage, or leaky connections. During system installaion, electronics do not require removal and are safely protected while pulling wire and making field terminations. Sapphire systems carry Factory Mutual Research Corp. (FMRC) and Canadian Standars Asso. (CSA) approvals including Features & Benefits Single & Dual Point Systems Unmatched Reliability Superior Self-Testing Capabilities Variable System Qualification Time New Manual Loop Test Dual-compartment Housing (Single Point) Lowest Total Installed Cost Broad Range of Sensor Materials Broader Hazardous Location Approvals 3A Sanitary Finish and Fittings Dual Point Switch with completely independent electronics Dual point with up to 10 ft. or more separation Two Year Product Warranty NEMA 4X, intrinsically safe, explosion-proof, nonincendive, and dust/ignition-proof ratings. Installation and life cycle costs are reduced significantly with the use of loop powered intrinsically-safe outputs, elimination of poured seals at the electronics in Division 1 areas and elimination of rigid conduit and poured seals in Division 2 areas.
Time Gate Technology Time Gate Technology starts by activating a transit crystal on one side of the measurement Gap and listening with a receive crystal on the opposite side. Since high frequencies of ultrasound travel readily through fluids but not air, liquid presence is determined by ultrasonic transmission within the measurement Gap. The signals from the receive crystal are analyzed at specific time intervals or windows controlled by the Time Gate. This method raises the system s sensitivity beyond the capabilities of previously available systems. Sapphire s patented Time Gate technology provides two important user benefits: 1. Reliable detection of the broadest possible range of process liquids including aerated, attentuative, viscous, corrosive, and more severe applications. 2. Self-tests are performed continuously and automatically. Sappire systems are available in either Gap or Slot configuration. Gap sensors perform exceptionally well in most applications, including aerated and attenuative liquids. The Slot s higher sensitivity provides reliable operation in even more severe applications. Continuous Self-Test Time Gate technology also incorporates a unique selftest function which it performed continuously and automatically. It verifies the system integrity including electronics, sensor and the crystal bond to the sensor body. Sapphire s self-test design does not involve the use of special self-test crystals or electronics inside the sensor probe. The simpler selftest design and the unique ability to detect disbonded crystals raises the level of Sapphire s dependability and reliability. System Qualification Time The System Qualification Time is the amout of time that process liquid must be continuously present or absent within the measurement Gap (in high-level operation) before the process alarm will be indicated. Sapphire qualifies that the new level condition is continuously present instead of a momentary occurence. This assures that the actual liquid level has reached the measurement Gap, instead of a wave fluctuation due to agitation or turbulence. Manual Loop Test The use of spill prevention devices such as Sapphire for high level alarms is on the rise. There are a number of environmental regulations that govern the overfill protection of above ground storage tanks (e.g., EPA, API, OSHA, etc.). In many cases, these regulations require written testing procedures, automatic verification, and on-demand testing of the complete spill prevention system. The Manual Loop Test is standard to verify field wiring, control integrity and operation of spill prevention systems without the need for filling tanks or costly system removal for testing. Manual Loop Test will change the outputs to the opposite state when the systems is not in the self-test or fault condition. The Manual Loop Test is momentarily activated as long as the supplied magnet is placed over the housing cover at the location marked Loop Test Materials and Mounting Gap sensors are available in a broad range of materials which include 316 stainless steel, Hastelloy C, Monel, Hastelloy B and Carpenter20. Slot sensors are available in 316 stainless steel only. Both the Gap and the Slot sensors can be delivered with a 150 grit (32 micro inch) or better, sanitary 3A finish and 316L stainless steel Tri-Clover (16 AMP) fittings that assemble and disassemble quickly for fast cleaning. Sapphire is the only ultrasonic point level system available with 3A symbol authorization. Sapphire systems are available with either 3/4 NPT mounting, various flange sizes, Tri-Clover fittings, or remotely mounted electronics. Sapphire Relay Operation The Sapphire relay models provide one Process relay for process level indication and a second Auxiliary relay for self-test fault indicationn. Both relays utilize gold plated contacts for reliable switching of lower current and voltage levels eliminating the need for DCS users to install interposing relays. Sapphire systems can be field selected for either high-level or low-level fail-safe operation. When high-level operation is selected, the Process relay is energized when the sensor is dry and de-energized when wet (e.g. in alarm). When low-level operation is selected, the Process relay is energized when the sensor is wet and de-energized when dry (e.g. in alarm). In both cases, the Process relay is always deenergized upon process alarm, self-test fault or power loss. The Auxiliary relay always de-energizes on self-test fault or power loss. The Auxiliary relay can be field selected to mimic the Process relay. When Mimic is selected, the Auxiliary relay will de-energize when a
In addition, the SPST Auxiliary relay output is field selectable for either NC or NO operation. Performance Specifications - Relay Operation Supply Voltage: 15-35 VDC (Electronics Model F) 115 VAC, ±10%, 50/60 Hz (Model G) 230 VAC, ±10%, 50/60 Hz (Model S) Power Consumption: 4 Watts maximum (2 Watts typical) Process Relay: SPDT relay with gold plated contacts. De-energizes on process alarm, self-test or power loss Maximum contact rating: 5 Amps at 115/250 VAC or 5 Amps at 30 VDC Minimum contact rating: 100 ma at 5 VDC or 15 ma at 24 VDC Auxiliary Relay: SPST (field selectable for either NC or NO operation) relay with gold plated contacts. De-energizes on selftest, power loss (and process alarm when mimic operation is field selected). Maximum contact rating: 5 Amps at 115/250 VAC or 5 Amps at 30 VDC Minimum contact rating: 100 ma at 5 VDC or 15 ma at 24 VDC Sapphire Two-Wire Operation The Sapphire two-wire, 4-20 ma DC model provides loop powered intrinsically-safe operation and lower installed costs to users with two-wire instrumentation. Two-wire systems use a fixed milliamp output to indicate process level (wet or dry sensor) and self-test fault. The wet and dry conditions can be indicated with either an 8 or 16 ma DC output. A self-test fault is indicated by an output of either 19 or 5 ma DC, depending on whether field selected for high-level or low-level operation, respectively. Performance Specifications - Two-Wire Operation: Supply Voltage: 12-55 VDC (Model J) Power Consumption: 1.1 Watt maximum Analog Ouput (±1 ma) 5 ma Self-Test Fault (low-level mode) 8 ma Dry, 16 ma Wet (field-selectable) 8 ma Wet, 16 ma Dry (field-selectable) 19 ma Self-Test Fault (high-level mode) Sapphire Relay and Two wire Operating Specifications Self-Test Feature Continuous. Automatically checks operation of electronics and sensor, including crystal bond to sensor body. Manual Loop Test: All output conditions momentarily change to the opposite state (except when in a fault condition) by placing the supplied magnet (XB4353) over the housing covers at the location marked Loop Test. System Qualification Time: 0.3 to 12.0 seconds, field selectable Repeatability: ±0.1 inches Enclosure Dual-compartmetn NEMA 4X (ANSI 250 Type 4X) Enclosure 4 housing. Low copper aluminum; Polyurethane paint; Buna-N O-rings. Electrical Connections: Dual 1/2-inch NPT conduit connections. Wire range is 22 to 12 AWG. Operating Temperature Range: Electronics: -40 to 158 F (-40 to 70 C) Metal Sensors: -40 to 320 F (-40 to 160 C) -310 to 212 F (-190 to 100 C) Humidity: 10-95 RH, non-condensing Weight (with 3/4 NPT, 1.0 inch A dimension): 4 lbs. (1.8 Kg) Current Loop Loads: Rload, max = (V supply-12) x 50 Ohms
SAPPHIRE ENCLOSURE DIMENSIONS 4.25 (108.0) 4.10 (104.1) STAINLESS STEEL CUSTOMER TAG (OPTIONAL) 1/2 NPT (2 PLACES) 0.69 (17.5) Place Loop Test Magnet Here 6.60 (167.6) NOTE 2 CONNECTION SIDE 6.15 (156.2) APPROVAL LABEL (IF APPLICABLE) PRODUCT IDENTIFICATION LABEL Circuit Side NOTES: 1. Dimensions are in inches (millimeters), nominal, and are for reference only. 2. Dimensions increase in 3 inches (76.2 mm) with installation of optional thermal isolator (3/4 NPT fitting only). SAPPHIRE SENSOR DIMENSIONS STANDARD GAP SENSOR STANDARD SLOT SENSOR TRI-CLOVER GAP SENSOR A DIMENSION A DIMENSION A DIMENSION 1.44 (36.6) 2.75 (69.9) 1.44 (36.6) 0.88 (22.4) DIA 0.94 (23.9) 0.88 (22.4) DIA 0.30 (7.6) 0.88 (22.4) DIA 0.94 (23.9) NOTES: 1. Dimensions are in inches (millimeters), nominal, and are for reference only. 2. Dotted lines represent optional fitting & flange types. 3. Total sensor length is equal to the A Dimensions plus the remaining sensor length.
Factory Mutual (FM & Canadian Standards Association (CSA) Approved): Explosion Proof: Class I, Division 1, Groups B (FMRC only ), C, & D Intrinsically Safe (Entity) Class I, Division 1, Groups A, B, C, & D. T4 Temperature cods (135 C) when installed in accordance with I/S wiring diagram of Instruction Manual, section 4, page 4-4. Entity parameters: Vmax = 55V, Imax = 118 ma, Ci = 0.024uF, Li = 0 mh. Dust/Ignition Proof: Class II, Division 2, Groups E, F, & G Class III, Hazardous Locations Sensor Style Gap Non-incendive: Class I, Division 2, Groups A, B, C, & D. T4A Temperature Code (120 C) Suitable for Class II, Groups E & G. Suitable for Class III, Hazardous Locations Remote sensor and field wiring are approved as N/I field wiring when installed in accordance with Class I, Division 2 wiring diagram of Instruction Manual Indoor/Outdoor Use: NEMA 4X (ANSI 250 Type 4X) Enclosure 4 Stainless Steel Tagging Each Sapphire can be labeled with up to 15 characters of user-specified 1/16 text located on the product s identification label. An optional stainless steel tag (part #620-000530), located on top of the electronics housing, can provide four lines of 1/8 text (two lines for remote systems) with a maximum of 24 characters per line. Slot Materials of Construction Carpenter 20 Hastelloy C Monel Hastelloy B 316SS 316 SS Min. Sensor A Dimension 1 inch (25 mm) 4 inches (102mm) Max. Sensor A Dimension Remaining Sensor Length Sensor Operating Temperature 1 Maximum Operating Pressure 2 Proof Pressure 2 120 inches (3,048 mm) 1.44 inches (36.6 mm) -40 to 320 F (-40 to 160 C) -310 to 212 F (-69 to 100 C) -10 to 1,000 psig (-69 to 6,895 KPa) 1,500 psig (10,342 KPa) 120 inches (3,048 mm) 0.30 inches (7.6 mm) -40 to 320 F (-40 to 160 C) -310 to 212 F (-190 to 100 C) -10 to 1,000 psig (-69 to 6,895 KPa) 1,500 psgi (10,342 KPa) NOTES 1. The Thermal Isolator is required for 3/4 NPT unit when process temperatures exceed 275 F (135 C). Flanged and remote mounted units do not require the use of the Thermal Isolator. 2. Pressure ratings are for 3/4 NPT units. NOTES 1. Order in 5/10 inch or 10 millimeter increments, because manufacturing tolerances are ±2/10 inch (±5 mm) for metal sensors. 2. When specifiying sensor lengths, be sure to take into consideration that the total installed sensor length is equal to the A dimension plus the remaining sensor length. 3. Tri-Clover fittings are available with integral mounted Sapphire systems only; Tri-Clover fittings are not available with remote mounted systems. A 1 Tri-Clover is the same size as a 1-1/2 Tri-Clover fitting.
SAPPHIRE INTEGRAL MOUNT PRODUCT NOMENCLATURE SASP Code F C Hazardous Location Approvals Factory Mutual Approved Canadian Standards Association Code Electronics J 12-55 VDC Input, 4-20mA Intrinsically Safe Output F 15-35 VDC Input, Relay Output, NO or NC User-selectable Auxiliary Fault Relay G 115 VAC Input, Relay Output, NO or NC User-selectable Auxiliary Fault Relay S 230 VAC Input, Relay Output, NO or NC User-selectable Auxiliary Fault Relay Code Mounting Configuration O Integral Electronics and Sensor T Thermal Isolator (Required for 3/4" NPT units with process temperatures above 275 F/ 135 C) Code Sensor Type G Gap S Slot (316SS, 316SS Polished & Hastelloy C) Code Sensor Material (Same as Fitting/Flange Material) (See Sapphire Ref Note 1) S V H U B Q 316 Stainless Steel (Gap & Slot) 316 Polished Stainless Steel (Gap & Slot) Hastelloy C (Gap & Slot) Monel (Gap only) Hastelloy B (Gap only) Carpenter 20 (Gap only) Code Measurement Units for "A" Dimensions T M Sapphire Inches Millimeters Code Sensor "A" Dimension (See Sapphire Ref Note 3 & 4) 0##0 Sensors are available in 0.5" increments only 316 SS 0010-1200 for Gap Sensors (Minimum 1") (0010 = 1.0") 316 SS/pol'd 0040-1200 for Slot Sensors (Minimum 4") (1200 = 120.0") Hastelloy C 0##0 Sensors are available in 5mm increments only Monel 0025-3050 for Gap Sensors (Minimum 25mm) (0025 = 25mm) Hastelloy B 0100-3050 for Slot Sensors (Minimum 100mm) (3050 = 3050mm) Carpenter20 Code Fitting/Flange Type (See Sapphire Ref Note 1 & 2) N 3/4" NPT (Material same as sensor) F Flange 150 lb. ANSI Raised Face (Metal) G Flange 300 lb. ANSI Raised Face (Metal) T Tri-Clover (16 AMP) Sanitary Fitting & 150 Grit Polished Code Fitting/Flange Size (See Sapphire Ref Note 2) 00 3/4" NPT 10 1" Flange or Tri-Clover Fitting 15 1-1/2" Flange or Tri-Clover Fitting 20 2" Flange or Tri-Clover Fitting 25 2-1/2" Tri-Clover Fitting Only 30 3" Flange or Tri-Clover Fitting 40 4" Flange or Tri-Clover Fitting 60 6" Flange Only Code Fitting/Flange Material (Same as Sensor) S 316 SS V 316 Polished SS (Tri-Clover 3A & 3/4" NPT Only) H Hastelloy C U Monel B Hastelloy B Q Carpenter 20 Code Accessories (Optional) T Stainless Steel Tag (Cust Reqst) SASP F G O G S T 0060 N 00 S Typical Integral System Part Number 103-100031 10/01 Sugar Land 1410 Gillingham Lane Sugar Land, Texas 77478 713-272-0404 800-437-7979 (v) 713-272-4573 (f) Canada 14 Gormley Industrial Avenue, Unit 14 Gormley, Ontario LOH 1G0 905-888-8808 (v) 905-888-8828 (f) www.thermo.com sales.process@thermo.com Winsford Ion Path, Road Three, Winsford Cheshire UK CW7 3GA +44 (0) 1606 548700 (v) +44 (0) 1606 548711 (f)