MODEL GVF-100 GAS VOLUME FRACTION MONITORING SYSTEM INSTALLATION & STARTUP MANUAL CiDRA Corporation Tel. 203-265-0035 50 Barnes Park North Fax. 203-294-4211 Wallingford, CT 06492 www.cidra.
Table of Contents 1 INTRODUCTION .................................................................................1-1 1.1 Sensor Head Description and Function..............................................1-1 1.2 Transmitter Description and Function ................................................1-1 2 INTELLECTUAL PROPERTY NOTICES.............................................2-1 3 EQUIPMENT SAFETY COMPLIANCE ...............................................3-1 3.1 Safety .......................................
8.4.1 Transmitter Housing Cable Entry .................................................8-3 8.4.2 Transmitter Output, Sensor and Sensor Head Connections ........8-4 8.4.3 Transmitter Electrical Power Cable Installation ..........................8-10 8.4.4 Sensor Calibration Label ............................................................8-12 9 TRANSMITTER FUNCTIONS .............................................................9-1 9.1 Transmitter Layout .......................................................
List of Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 Figure 45 Figure 46 Figure 47 Figure 48 Figure 49 General Warnin
Figure 50 Figure 51 Figure 52 Figure 53 Figure 54 Figure 55 Figure 56 Figure 57 Figure 58 Figure 59 Figure 60 Figure 61 Figure 62 Figure 63 Figure 64 Figure 65 Figure 66 Transmitter Front Panel Keyboard..............................................9-7 GVF Startup Screen....................................................................9-8 Operating Transmitter Display ....................................................9-9 Initialization Mode ...............................................................
1 INTRODUCTION The CIDRA Corporation SONARtracTM Model GVF-100 (Gas Volume Fraction) Monitoring System is a clamp-on process monitoring system used to measure the gas volume fraction (amount of entrained air / gas) contained in a fluid within process pipes on a real-time basis. The SONARtracTM GVF-100 utilizes patented array processing techniques to listen to and interpret the acoustic field generated by machinery, piping and flow present in process flow.
2 INTELLECTUAL PROPERTY NOTICES CiDRA Corporation’s Process Monitoring Products may be covered by one or more of the following granted U.S. Patent(s): 6,354,147, 6,587,798, 6,609,069, 6,435,030, 6,691,584, 6,732,575, 6,782,150, 6,862,920, 6,889,562, 6,732,150. Other patents are pending; see www.cidra.com for the latest listing of patents. This manual is covered by U.S. and international copyright laws.
3 EQUIPMENT SAFETY COMPLIANCE 3.1 Safety This equipment is listed with TÜV Rheinland of North America, Inc., a nationally recognized testing laboratory, and certified for ordinary location use per the following US, Canadian, and European standards: UL 61010A-1, CSA C22.2 No. 1010, and EN 61010-1:2001.
3.4 CE Marking This equipment is CE marked for ordinary location use and complies with the following European Directives: 73/23/EEC Low-Voltage Directive 89/336/EEC EMC Directive Further details are listed in the EC Declaration of Conformity (P/N 20634-01), a copy of which can be found in Appendix B of this Document as well as on our website at http://www.cidra.com.
4 WARRANTY The terms and conditions, including warranty, of the purchase of CiDRA’s Process Monitoring Products is outlined in the document entitled “CiDRA’s Terms and Conditions of Sale”.
5 GENERAL SAFETY GUIDELINES CiDRA Corporation recommends the installer fully read this manual prior to installing and operating the SONARtracTM system. Note: Items that pertain to systems rated for Class I, Division 2, Groups A, B, C, and D operation are highlighted in italic print. 5.1 Introduction This manual is intended to be a general installation guide for the CiDRA SONARtracTM GVF-100 System.
5.3.1 General Warning or Caution Figure 1 General Warning or Caution Symbol The Exclamation Symbol in Figure 1 appears in Warning and Caution tables throughout this document. This symbol designates an area where personal injury or damage to the equipment is possible. 5.3.2 Grounding Figure 2 Grounding Symbol The Grounding Symbol in Figure 2 appears on labels affixed to the SONARtracTM system.
5.3.5 General Warnings Observe these general warnings when operating or servicing this equipment: • Prior to operation of this equipment, personnel should read the • • • • instruction manual thoroughly. For systems installed in Class I, Division 2 areas, Power Entry and Inputs/Outputs must be installed in accordance with Article 501.10(B)(1) of the National Electrical Code ANSI/NFPA 70:2005.
• Prior to servicing, lockout all electrical power sources. • Care should be taken when using the operator keypad to avoid touching any electrical connection or contact points. • Do not wear rings or wristwatches when servicing this equipment. • Use only the specified fuse(s) with the correct type number, voltage and current ratings as referenced in the appropriate locations in the service instructions or on the equipment. 5.3.
6 UNPACKING AND PARTS LIST 6.1 Unpacking The SONARtracTM GVF-100 will typically be packaged in three shipping containers. One box will contain the sensor band and sensor cover assemblies, and installation hardware; the second box will contain the transmitter assembly and installation hardware; and the third box will contain the sensor to transmitter cable assembly. Note: Cidra Corp. recommends the original packing materials be saved in the event that the system is removed or relocated.
6.3 Class I, Division 2 Labels Transmitters and sensor covers rated for use in Class I, Division 2 areas are labeled with the following information (or a subset of it) so they can be identified for use in those areas.
7 SENSOR INSTALLATION 7.1 Class I, Division 2, Groups A, B, C, and D Rated Equipment • Equipment so marked is suitable for use in Class I, Division 2, • • • • 7.2 Groups A, B, C, and D or non-hazardous locations only. WARNING – EXPLOSION HAZARD – Do not disconnect equipment unless power has been removed or the area is known to be non-hazardous. WARNING – EXPLOSION HAZARD –Substitution of components may impair suitability for Class I, Division 2.
7.3 Sensor Installation Guidelines The following are general installation guidelines and recommendations for installing a SONARtracTM sensor. • Where necessary, get a Hot Work Permit prior to installation of • • • • • • 7.4 system. Select locations with well-developed flow profiles. Avoid installation locations directly after piping configurations that cause flow jetting. Install flow sensor upstream of control valves, “T”s, orifice plates, and any other severe source of flow disturbance.
7.4.1 Pipe Preparation Remove pipe insulation if it is present. WARNING Asbestos containing insulation materials may be present. Asbestos fibers have been known to cause health problems. If unsure of the contents of pipe insulation materials contact the plant representative for that area. WARNING Process Heating Tapes may be present. This may present an electrical shock hazard. Follow plant Lock-out / Tag-out requirements. WARNING Process pipes may be hot. A burn hazard may exist.
7.5 Sensor Band Installation It will be helpful to have a second person available to assist with holding the sensor assembly in position during installation. Note: Prior to installing the sensor band, remove and save the plastic bag from the sensor band that contains two sensor calibration factor labels. These will be used as described later in this manual for input to the transmitter. Ensure there is no dirt or other foreign material on the sensor assembly.
Wrap the sensor band around the pipe and slide the alignment pins on the attachment rail through their mating holes on the opposite attachment rail. If the process pipe has a welded seam, align the gap between the sensor attachment rails along the pipe weld seam. Final positioning can be made after the sensor screws have been started. Note: When installing the sensor band keep in mind the requirement for transmitter connector socket assembly orientation as described in Section 7.6.
9 7 5 3 1 2 4 6 8 Sensor band assembly Figure 7 Sensor screw Sensor Band Screw Tightening Sequence Sensor screw spacer (may be integral to screw head) Sensor Belleville washers concave side Sensor Belleville washers convex side Note: 10 Belleville Washers on 2-16” bands Belleville washers and spacer compressed against screw head )()()()()()()( Figure 8 Note: Sensor bands 18” and larger have 14 Belleville washers per screw arranged as shown Sensor Band Screw Assembly Copyright © 2006 CiD
Further tightening of the sensor band screws is made while using the sensor band spacer tool (shown below) furnished with the sensor band. The spacer tool is used to set the compression on the Belleville washers referred to above.
Final sensor band screw tightening is as follows: A. For sensor bands sized for 6” and smaller pipe: 1. Tighten screws #1-7 an additional one-half turn in the numbered sequence given in Figure 7. Do not tighten screw #8 & 9 (screws on either end of the sensor band). B. For sensor bands sized for 8” and larger pipe: 1. Starting at screw #1 in Figure 7, tighten each screw an additional one-half turn in the given numbered sequence. 2.
CAUTION Over-tightening of fasteners may damage threads on the sensor. Under tightening may affect flow meter performance. Always use the sensor fastener spacer tool to ensure proper fit of the sensor assembly. 7.5.1 Sensor Band Short Test Shorting of the sensor band to the process pipe may cause signal interference or electrical faults in the system in some instances. The sensor band must be electrically isolated from the process pipe.
7.6 Sensor Cover Installation The upper sensor cover assembly outside and inside are illustrated in the following figures. Cover sizes up to 16 inch are typically made of fiberglass. Cover sizes 18 inch and above are made from stainless steel. The layout of both styles is essentially the same. The differences in installation will be called out in the following sections.
It is helpful to have a second person available to help when installing the cover assembly. When the sensor head is installed on a horizontal pipe, the sensor cover should be installed such that the transmitter cable connector socket is located within the 105° arcs shown in the following figure. Do not install the cover with the transmitter cable connector socket installed downward. (An electrical pre-amplifier board is mounted on the inside of the cover.
This potential problem is most likely to occur in small size meters (<6inch) due to the length and stiffness of the sensor band cable. The following steps will help minimize this problem: 1. Visually look between the cover halves to ensure the cable is not being pinched. 2. Once the cover halves are bolted in place and during installation of the sensor band cable connector into the pre-amplifier through the access cover, verify the sensor band cable is free and not pinched between the cover halves. 3.
Tighten the alignment bolts 2 – 3 turns alternating between both sides of the cover until the cover bolts protrude through the lower cover assembly. Note: Use of the alignment bolts may not be necessary if the cover bolts and nuts can be made up. Place a washer, lock washer and nut on the end of the sensor cover bolt once it is through both halves of the cover and begin drawing the cover halves together using the cover bolts.
7.6.2 Stainless Steel Cover Installation The stainless steel cover is illustrated in the following figure. Transmitter cable connector socket Sensor cable access panel Cover lifting handles (4 plcs) Upper cover assembly Fender assy (4 plcs) Boot Gasket (upper & lower covers Lower cover assembly Figure 17 Stainless Steel Cover Assembly WARNING The handles on the stainless steel cover are not designed or rated for hoisting the cover.
Apply coating of Joining Compound Figure 18 7.6.2.1 Applying Joining Compound to Gasket Edge Boot Gasket Band Installation The boot gasket band will be shipped cut to length for the cover size with the retaining buckle pre-installed. The boot gasket band should be completely installed on one end of the cover and then repeated on the other end.
Remove the GelTek paper backing from the splice protector plate, lift the band using needle nose pliers or a screwdriver, and slide the plate into position over the flange gasket. Be careful the GelTek stays in position on the plate. Pull the band taut. Tighten the socket head cap screw on the band buckle just enough to keep the band in place but loose enough so it will still slide through the buckle. Repeat on the opposite end of the cover.
Tension the band until the resistance on the tool handle is constant (i.e. the band does not slide easily through the buckle). The boot gasket should be tight against the process pipe under the gasket protector plate. Verify the band buckle and splice protector plates are still in place. Tighten the set screw to lock the band in place. The band will be dimpled by the set screw.
7.6.2.2 Boot Gasket Fender Assembly Installation The stainless steel cover uses four boot gasket fender assemblies (two per end) to protect the boot gaskets. The fender should be installed such that the retaining clasp is next to the cover handles. The completed cover assembly is shown in Figure 17. Figure 25 7.6.3 Boot Gasket Fender Assembly Sensor Assembly Cable Connection Remove the tape (if it was used) that was temporarily installed to retain the sensor connector under the cover access panel.
Re-install the sensor cable access panel on the sensor top cover assembly. Tighten the six panel screws to a recommended torque of 11-lbf-in (1.2-Nm). 7.6.4 Rain Boot Installation A sensor cover rain boot will be installed on the upward facing end of sensor covers when the sensor head is installed in vertical applications. The rain boot serves as a secondary seal against water leakage under the cover (the sensor cover seal is the primary seal). Note: The stainless steel covers do not need a rain boot.
7.6.5 Sensor Calibration Label The sensor band is shipped with two labels enclosed with it. The label lists the sensor part number, serial number, date of manufacture and three calibration factors. This information will be entered into the transmitter during setup (section 11.1.1). Affix one of the labels to the outside of the access panel of the sensor cover as shown below. The second label should be installed on the inside of the transmitter cover.
7.7 Sensor to Transmitter Cable Connections The sensor to transmitter cable is used to transmit sensor signals and information between the transmitter and the sensor, and provides electrical power to the sensor pre-amplifier board mounted in the sensor cover. The sensor to transmitter cable consists of 12 twisted pairs of 20 AWG conductors with an overall cable shield encased in a PVC jacket. The standard cable has an operating range of -4 ºF to 221 ºF (–20 ºC to 105 ºC).
7.8 Installations on Tubing The sensor head will fit on process tubing as well as pipe. This is accomplished through the use of a sensor band specifically sized for tubing and the use of elastomeric strips wrapped around the tube (in order to increase the tube diameter to that of pipe) in the areas of the pipe seal gaskets on the fiberglass cover.
8 TRANSMITTER INSTALLATION 8.1 Transmitter Power Requirements The AC version of the transmitter can accommodate an input voltage of 100 – 240 volts AC, 50/60 Hz, and requires 25 watts of power. The AC powered transmitter input power is fuse protected by two 1 amp, 250 volt, 5mm x 20mm fuses. The DC version of the transmitter can accommodate an input voltage of 18 – 36 volts DC and requires 25 watts of power. The DC powered transmitter input power is fuse protected by two 3.
8.3.1 Bulkhead Mounting The transmitter is attached to the bulkhead or panel with user supplied 1/4-inch fasteners through the four panel mounting feet on the transmitter. The mounting dimensions are illustrated in the following figure. 4X 0.31 (8) slot Panel mount feet (4 places) Note: Dimensions in inches (mm) 11.88 (302) 8.00 (203) Figure 29 8.3.2 14.22 (361) 4X 0.
8.4 Transmitter Cable Connections The following figure illustrates the basic power and signal connections for the SONARtracTM GVF Monitor. These are discussed in further detail in the following sections. Fuses Optional power switch Power connector I/O and sensor connects Figure 31 8.4.1 Power and Signal Interconnects Transmitter Housing Cable Entry Power, sensor signal, and input /output signal cables enter the transmitter housing through cable glands.
WARNING Transmitter cover screws must be securely tightened and NEMA 4X rated cable glands and hole plugs must be used in Class I Division 2 applications. Failure to do so may result in violation of Class I Division 2 certification. 8.4.2 Transmitter Output, Sensor and Sensor Head Connections The following figure shows the layout of the transmitter terminal strip board. This board is divided into three sections. The Section#1 terminal blocks are for transmitter outputs.
8.4.2.1 Transmitter Output Connections (Section #1) The following figure provides a close-up of the transmitter output terminals (Section #1 of the terminal board) with their functions listed in the following table. These outputs can be connected as appropriate to permit communications between the transmitter and other equipment.
8.4.2.2 Transmitter Input Connections (Section #2) In some cases, a pressure or temperature transducer signal is used as an input to the transmitter. These terminals are shown in the following figure. Figure 35 Transmitter Sensor Terminals When used, the setup of the individual sensors is performed as part of the overall transmitter setup detailed in this manual. 8.4.2.
WARNING For Class I, Division 2 applications, Sensor Head Cable must be installed in accordance with Article 501.10(B)(3) of the National Electrical Code ANSI/NFPA 70:2005. The transmitter is shipped standard with a cable gland. Replace as local wiring requirements dictate. 8.4.2.3.1 Non-armored cable installation Remove 10 - 12 inches (25 – 30 cm) of outer jacket from the transmitter end of the cable.
Wire Pair # Transmitter Terminal # Function SENSOR CONNECTOR PIN NUMBER 1 Wht/Blk 1 Sensor #1 Input 1 - Wht 13 - Blk 2 Wht/Blk 2 Sensor #2 Input 2 - Wht 14 - Blk 3 Wht/Blk 3 Sensor #3 Input 3 - Wht 15 - Blk 4 Wht/Blk 4 Sensor #4 Input 4 - Wht 16 - Blk 5 Wht/Blk 5 Sensor #5 Input 5 - Wht 17 - Blk 6 Wht/Blk 6 Sensor #6 Input 6 - Wht 18 - Blk 7 Wht/Blk 7 Sensor #7 Input 7 - Wht 19 - Blk 8 Wht/Blk 8 Sensor #8 Input 8 - Wht 20 - Blk 9 Wht/Blk 9 Spare – unused --- -
Armored cable is shipped with the appropriate connector pre-installed on the cable and with the cable prepared for installation in the transmitter. Armored cable installation is similar to the non-armored installation except for the following. • Cut the cable to desired length (if necessary) using a hacksaw to cut through the armor and remove about 14” (36 cm) of outer jacket from the transmitter end of the cable.
• Install the seal washer on the connector assembly entry component. Insert the cable and entry component into the middle hole in the transmitter box (stiffener plate previously installed.) Secure the connector assembly with the retaining nut. Attach the ground wire from the connector nut to any available SHD terminal on the Section #3 terminal block. Strip and install the individual connectors and shield wire per non-armored cable installation instructions.
Feed electrical power wires through the fitting. Referring to the following figure, attach the ground wire (green) to the Ground ( ) terminal , hot (black - U.S., brown - Eur) to the L (+) terminal, and neutral (white – U.S., blue – Eur) to the N (-) terminal. Line In (+) Ground ( ) Neutral (-) Figure 41 8.4.3.2 Transmitter Power Connection DC-Powered SONARtracTM Any voltage within the range of 18 – 36 VDC can be applied to the DC version of the SONARtracTM.
8.4.4 Sensor Calibration Label The sensor band is shipped with two labels attached to it. The label lists the sensor band part number, serial number, date of manufacture and three calibration factors. This information will be entered into the transmitter during setup. If not done previously, install the Sensor Band Assembly label on the inside of the transmitter cover (the other label goes on the sensor head access panel).
9 TRANSMITTER FUNCTIONS The following section of this manual will present the transmitter layout and menus in the SONARtracTM process monitoring system. 9.1 Transmitter Layout The transmitter layout is depicted below. Here each of the major components is labeled.
9.2 Transmitter Output Definitions The following figure shows a diagram of the output portion of the terminal board. The outputs of the transmitter are connected to communicate between the transmitter and other equipment. Figure 44 Transmitter Output Terminals COMM – This denotes the connection point for serial digital communications. Either RS232 or RS485 communications is supported with baud rates settable between 2400 and 115200 baud (8 bits, no parity, 1 stop bit).
PULSE – An isolated solid-state switch-closure-type output occurs between P+ and P- whenever conditions are met that are determined by the pulse setting within the transmitter. The maximum applied voltage between P+ and local ground and P- and local ground shall be within the range of +30V / -10V. The load current shall be a maximum of 100mA. Typical turn on time is 1 msec. Typical turn off time is 0.1 msec.
CUR1 – These terminals are used for connection to the primary 420mA output from the transmitter. The transmitter can be configured such that an external supply can be used for power (i.e. the 4-20mA loop current is driven externally) or such that the transmitter itself will power the loop. A combination of power wiring and internal software setting will ensure that the 4-20mA output will function properly. The following figures show proper wiring for internal and external power.
Externally Powered 4-20mA Loop Configuration - The hookup for a 4-20mA interface configured as “Externally Powered” is shown below. The maximum value of VEXT should be chosen such that the maximum applied voltage between VEXT and local ground and IOUT and local ground shall be within the range of +30V / -10V and current limited to 100mA. The maximum value of RL is determined by the following equation: RL Max = (VEXT – 8.35) / (0.022) For example, with VEXT = 24VDC: RL Max = (24-8.35) / (0.
9.3 Transmitter Input Definitions Gas Volume Fraction calculations use inputs of pressure and temperature. These inputs can be made through the use of pressure and temperature transducers, or alternatively, an assumed value for pressure and temperature can be input into the transmitter during its setup. Two transmitter terminal blocks (shown below) are provided for pressure and temperature transducers.
9.4 Keypad The keypad controls used to set up and access the user input screens are illustrated in the following figure. Figure 50 Transmitter Front Panel Keyboard The SONARtracTM display has 2 distinct modes: the operational mode where the measured parameters are displayed and the menu mode where various system parameters can be set. In each of these modes the keypad will have different functions. The following table shows the function of each key in the keypad depending on the display mode.
9.5 Transmitter Display The transmitter display functions in two distinct modes: an operational mode and a menu mode. These two modes will be explained in the following sections. 9.5.1 Operational Mode The transmitter screen displays the status of the SONARtracTM system. A few typical screen messages and their interpretation follow. 9.5.1.
9.5.1.2 Operating Transmitter Display In operating mode the display screen is split into three distinct portions. The majority of the screen is devoted to a 2-line measurement display as illustrated below. The bottom portion of the screen will display status and configuration information. G Line 1 2.016 % 351.7 ft/s V F S Line 2 O Status Line S SSSSSSSSSSSSSSSSSSSS Figure 52 9.5.1.2.
• Status Messages - ‘S’: A number of status messages can be displayed in the 20 character status message field. They are as follows: Status Message Description GF INITIALIZE MODE GVF Initialize mode INVALID SOS DATA Invalid SOS data BELOW MIN SS QUALITY SOS quality below configured threshold Table 9 Status Line Messages • Quality Messages ‘Q’: The Quality Field is a diagnostic field that can be used to view certain quality values in the transmitter. The factory default is none.
• Communications (C): Indicates a connection (Ethernet) or activity (Serial). No received serial messages for 10 seconds will clear the Serial indicator. • HART Activity (H): Indicates a recent HART message processed by the transmitter. No received HART messages for 10 seconds will clear this indicator. • Write Protect (W): Indicates configuration changes cannot be made to the transmitter. Write Protect can be turned on and off via the menu or HART. Default is OFF.
G 2.016 % 315.7 ft/s V F S O S SQ .72 GVF Figure 54 9.5.2 / GVF Measurement Screen Menu Mode This mode of operation permits the user to adjust various settings on the SONARtracTM transmitter as well as perform multiple diagnostic tests. The menu system is set up in a tree format, with seven top level categories (illustrated in bold print below) that can each have up to two levels of sub menus. The menu structure is shown in the table on the following page.
BASIC CONFIG SENSOR SERIAL # PIPE SIZE ID/Wall Size/Sch OD/Wall FLUID PROPERTIES Spec Gravity SOS (ft/s) Viscosity (Pa-s) Pressure Temperature Pressure Sel Temperature Sel Altitude SET DATE/TIME OUTPUT CONFIG 4-20mA CH 1 Output Sel Power Sel Low End High End Out Of Range Overrange Rail 4mA Trim 20mA Trim 4-20mA CH 2 MM/DD/YY HH:MM:SS Output Sel Power Sel Low End High End Out Of Range Overrange Rail 4mA Trim 20mA Trim SENSOR #1 INPUT CONFIG Units Scale (per mA) Offset (mA) SENSOR #2 DISPLAY Units S
When the display is in operational mode, any key pressed will enter menu mode. In this mode the keypad is used for traversing the menu tree and for modifying system parameters as previously detailed in Table 12. In menu mode the screen is divided into four lines of information. The following figure shows an example of a typical menu screen. BASIC CONFIG • PIPE SIZE INNER DIAM 8.
The following figure shows an example of the second type of parameter editing. In this case the whole parameter is highlighted and the up and down arrow keys will cycle between the available settings. When editing a parameter the ‘ENTER’ key will accept and save the current value. Alternatively the ‘BACK’ key will revert the current parameter to the value before editing was begun. The ‘EXIT’ key will also revert to the previous value (similar to the ‘BACK’ key) and will exit Menu mode.
Table 13 Level 1 Level 2 Transmitter Menu Tree Software Release 03.03.XX Level 3 Range Description 0000000 Serial number of sensor band ID/Wall ID: 1- 100 in (25.42540mm) Wall 0 – 100 in (0 to 2540 mm) Pipe inner diameter and wall thickness Size/Sched 2 to 36" size; schedule Pipe size & schedule OD/Wall ID: 1- 300 in (25.
Level 1 Level 2 4-20mA Ch1& Ch2 Pulse Output Config Alarm Control Level 3 Range Description Output Sel SOS, GVF, Blank Power Sel Internal, External Low End High End Based on ‘output sel’ Based on ‘output sel’ Out of Range Hold, >20mA, <4mA, 4mA Overrange Rail Enable, Disable 4mA Trim 20mA Trim Multiplier Width (ms) Lowcut Output Sel 2 to 6 18 to 22 0 - 999999 .
Level 1 Level 2 Sensor #1 Level 3 Range Description Units PSIg, None, F, C, Barg, kPag Parameter input Scale 0.0000 e-38 to 9.9999 e+38 per mA Input range divided by mA range Offset 0.0000 e-38 to 9.9999 e+38 per mA Correction due to a nonzero mA minimum output Units PSIg, None, F, C, Barg, kPag Parameter input Scale 0.0000 e-38 to 9.9999 e+38 per mA Input range divided by mA range Offset 0.0000 e-38 to 9.
Level 1 Level 2 Level 3 Range Description Line 1 Blank, GVF, SOS Parameter displayed on line 1 Line 2 Blank, GVF, SOS Parameter displayed on line 2 Contrast 0 to 1024 (default 170) Contrast of display Sensor Setup State On/off Enable / disable each sensor SOS Units Units ft/sec, m/sec Sound speed units Enable, Disable When enabled no other parameters can be changed Display Customize Wr Protect Mode Copyright © 2006 CiDRA Corporation Page 9-19 20639-01 Rev 03
Level 1 Level 2 Level 3 Range Description IP Address 0.0.0.0 to 255.255.255.255 Current IP address Subnet Mask 0.0.0.0 to 255.255.255.255 Current Subnet Mask Baud Rate 2400 to 115200 Serial baud rate Config RS232 or RS485 Serial communications protocol type Preambles 5 - 20 # Preamble chars ahead of MSG Resp. Preambles 5 - 20 # Preambles in response from transmitter. Change to match HART communicator Univ. Cmd. Rev.
Level 1 Level 2 Level 3 Range Description Sensor Check PASS or FAIL. (Indicate which sensors failed test) Performs health check on each sensor 4-20mA Test Test 4-20mA outputs from 4 to 20mA Manual testing of 420mA output #1 and 2 1.0, 4.65, 21.55, 98.65 Provides auto adjustment of preamplifier setting based on the current process operating condition 1.0, 4.65, 21.55, 98.65 Provides for manual checking and setting of pre-amplifier gain.
Level 1 Info Level 2 Level 3 Range Description Revisions Provides a list of installed hardware and software Diagnostic Provides a list of key system temps, volts, status Configuration Summary of the system setup Event Log Log of system events (i.e. errors, sensor over ranges, etc.
Each of the system parameters listed above can be accessed and modified using the front panel keypad. Any changes made to any of these parameters will be saved in non-volatile memory and will not be lost when power is removed from the transmitter. Several of the parameters have direct links to other parameters found in different locations in the menu structure. Therefore, it is possible that by changing the value of one parameter it will automatically change the other linked parameter.
10 TRANSMITTER SETUP 10.1 Transmitter Menus The following pages present the steps necessary to setup and operate the SONARtracTM GVF-100 system. Whenever a transmitter front panel entry is made, the transmitter will re-start and output to the plant control or data logging system will be interrupted. It is recommended that the process control room be alerted prior to accessing the transmitter front panel. CAUTION Loss of transmitter output signal may occur when accessing transmitter front panel keys.
• Pressure This input is an important parameter for accurate GVF measurement. If the process pressure is constant, input the normal process operating pressure into the transmitter in units of PSIg, Barg or kPag. For applications where the process pressure varies, it is recommended that a correction for pressure be performed in the process control system. Alternatively, a pressure transmitter can be input to the SONARtracTM transmitter as described in Pressure Sel below.
• Altitude Used to calculate the atmospheric pressure corrected for elevation. Enter the elevation above or below sea level. The following equation is used within the transmitter to correct for elevation. Patm = 14.696 * [1 – ((Alt * 10-3)/145.45)]5.2561 where: Patm = absolute atmospheric pressure corrected for altitude (psi) Alt = altitude (feet) Note: If an “absolute” scaled pressure transducer is used it is not necessary to enter altitude.
OUTPUT CONFIG - 4-20mA CH1 - LOW END 020.0% 1000.0 ft/s Figure 58 Output Configuration Example Screen The ‘Out of Range‘ menu selection permits the user to specify the 420mA output behavior when the meter cannot measure the current value. The settings allow a less than 4mA output (‘<4mA’), a greater than 20mA output (‘>20mA’), a constant 4mA output (‘4mA’), and a hold last valid reading output (‘Hold’).
output a pulse frequency or a number of pulses for one of the following measurements: - Speed of Sound (SOS): Outputs a frequency corresponding to SOS. - Gas Volume Fraction (GVF): Outputs a frequency corresponding to GVF. Menu options for configuring the output include a multiplier, a pulse width, and a low cut setting (see descriptions below).
‘SOS’ and ‘GVF’ generate a pulse frequency based on the current measurement. The pulse width will vary in order to maintain a 50% duty cycle pulse train. Multiplier = 100 SOS 500 fps / 100 = 5 Hz 300 fps / 100 = 3 Hz 1000 fps / 100 = 10 Hz Pulse Width Varies Time (sec) 4 2 0 Figure 60 6 Speed Of Sound and Gas Volume Fraction Pulse Output The following is an example of Pulse settings applied to Gas Volume Fraction: Pulse Output: GVF Multiplier: 1 Pulse Width: 1 ms Low cutoff: 0.
The following table lists the alarm parameters with their default values. Alarm Parameter Band Temperature RMS Sound Pressure Level Speed Of Sound Quality Event log updated Sensor overload Gas Volume Fraction Sensor Failure Condition User Entry TMP> TMP< SPL> SPL< SSQ< LOG OVL GVF> GVF< FAIL Table 15 Y Y Y Y Y N N Y Y N Warning Default Value Critical Default Value > 80 °C < 0 °C > 200 dB < 50 dB < 0.03 > 90 °C < 0 °C > 200 dB < 80 dB < 0.
• SONARtracTM Filters The SONARtracTM transmitter has 3 modes of signal output filtering. These are ‘Damping’, ‘Noise Reduction’, and ‘Spike Filtering’,. They are applied in that order. The filtering affects both the display on the transmitter and the signal to the current, pulse, alarm and digital outputs. -‘GVF Damping Filter’ is used to reduce the noise of a signal through the use of a first order lag filter with a fixed time constant. The time constant of the filter is set by the user.
same number as described above for the ‘no flow’ condition. When the number of consecutive bad readings is exceeded, the output will blank (-----) and the 4-20mA output will be set to the ‘Out Of Range’ state. The second is for spurious in-range calculations of good quality. These will manifest themselves as a positive or negative spike of a magnitude much greater than the steady state deviations. This filter will monitor the rate of change of the calculated value for a number of consecutive readings.
• Sensor 1 & 2 -‘Units’ allows for setting the sensor units to ‘None’ (not used) ‘F’ (temperature degrees F), ‘C’ (temperature degrees C), ‘Barg’ (pressure in Bars gauge), ‘kPag’ (pressure in kilo Pascals gauge), ‘PSIg’ (pressure in pounds per square inch gauge). Note: If an “absolute” scaled pressure transducer is used select ‘None’ for units. -‘Scale’ allows for setting the range of the input in units of measure (‘Units’) per mA.
10.1.5 Communications Menu • Ethernet Option is used to view and set the IP address and Subnet Mask of the transmitter. • Serial Options Used for setting up the ‘Baud Rate’ and the serial communications to ‘RS232’ or ‘RS485’. • HART Settings are used for configuring the protocol when using HART. Default is for single device addressing. • Reset Comms Used to re-initialize the communications ports without loosing data history (as would happed by re-initializing the transmitter).
In previous figure the sensor band failed the test. Sensor 1 and 2 are either mis-wired between their terminals or reversed (wht to blk). Sensor 7 is disconnected (open circuit). If an error is noted when the sensor test is first run, repeat the test to confirm the fault. If the error occurs at first power up, verify wiring termination at the transmitter terminal block.
• Clear History Will delete transmitter stored Data History and re-start saving of transmitter data. • Param Edit This is a diagnostic feature rarely used and should only be used under the direction of CiDRA personnel. Contact CiDRA Technical Support. • Monitor Displays a set of various ‘System’ or ‘Sensor’ parameters, updated at the display update rate. Used by Factory Technical Support personnel. 10.1.
The following figure lists the potential error codes shown in the log. The codes can be used by service personnel to help identify a problem with the transmitter.
10.3 Resetting to Factory Defaults Note: It is recommended that factory defaults be reset only by factory qualified service personnel. All factors (Basic Config, Output Config, etc.) must be re-entered following a Reset to Factory Defaults. To ‘Reset to Factory Defaults’, press and hold the ‘EXIT’ key while pressing the reset switch on the upper left edge of the connector block board. Alternatively, switch transmitter Power OFF and press and hold the ‘EXIT’ key while turning Power On.
11 TRANSMITTER STARTUP & OPERATION 11.1 Initial Start-up At initial power up the Green LED will light and the transmitter will display startup progress; loading firmware into the system, loading system parameters, and the heartbeat indicator as it begins to collect data from the sensor head. Once startup is complete, the display will clear and begin displaying measurements. The following figure illustrates an initial system startup screen.
• • • • • • • ← and → to change position) to enter the sensor serial number. Once all digits are entered, press the ‘ENTER’ key to save to memory. ‘→Sensor Serial #’ will again be displayed on Line 2. Next, press the ↓ key to scroll to the ‘Pipe Size’ menu on Line 2. Press the ‘ENTER’ key to access the options available under that menu. Note: it is necessary to access only one of the following options. The first choice on the ‘Pipe Size’ menu is ‘→ID / Wall’ shown on Line 3 of the display.
• • • • • • values for water at various temperatures. Once the new value has been entered on Line 4, press ‘ENTER’. If no change is made (or after a change in Specific Gravity has been made) pressing the ↓ key will next display ‘→SOS’ on Line 3 and the current value on Line 4. To change the Line 4 value press ‘ENTER’ and use the arrow keys to enter the new value. Water at 25 ºC (4910.4 ft/s) is the default. Appendix E lists values for water at various temperatures.
the Line 4 value press ‘ENTER’ and use the arrow keys to enter the new value. Note: if an external pressure transducer that reads pressure in ‘absolute’ values (e.g. PSIa, BARa, or KPaa is used an altitude correction is not necessary. • Press the ↓ key to scroll to ‘→Set Date/Time’ on Line 2. Press the ‘ENTER’ key and the current saved date and time will be displayed on Line 4 of the display.
Transmitter Serial Number: ______________ Basic Config As Left Sensor S/N Pipe Size Software Revision: __________ Output Config (continued) 4-20mA Ch2 Output Sel ID / Wall Power Sel Size/Sched Low End OD / Wall High End Out of Range Pipe Material Fluid Properties As Left Specific Bravity Overrange Rail SOS (ft/sec) 4mA Trim 20mA Trim Pressure Pulse Multiplier Temperature Width (ms) Pressure Sel Lowcut Temperature Sel Output Sel Altitude AlarmControl Set Date / Time Warning Criti
Customize Display As Left Line 1 Line 2 Contrast Sensor Setup State SOS Units Units Wr Protect Mode Communications Ethernet As Left IP Address Subnet Mask Serial Options Baud Rate Config HART Preambles Resp Preambles Univ Cmd Rev Polling Address Find Dev Arm Table 16 Transmitter Setup Template Copyright © 2006 CiDRA Corporation Page 11-6 20639-01 Rev 03
12 TRANSMITTER USB PORT The USB port allows the user to interface with the transmitter without the use of a computer. Information is stored on a USB memory stick (a SONARstickTM) and then transferred to a computer for storage or transfer. Note: The USB port cannot be used for communications between the transmitter and a computer; it is for use only with a memory stick.
Level 1 Level 2 Level 3 Range Description Snapshot Automatically creates a file of 5 minutes Raw Data; 1 day of Data History; System Info, current Configuration, Event Log Load Configuration Automatically loads a Configuration File from the memory stick File for Save System Config Save Raw Data Alpha numeric entry Save Config Saves the named file Load Config Alpha numeric named files Allows for retrieving and loading a Configuration File Duration 1, 5, 10, 30, 60, 120, 240 minutes Selects
12.1 USB Port File Naming Convention Files collected from the transmitter using the USB Port are automatically named to readily identify them. They are named in accordance with the following naming convention: ssss_nnnnnnnnYYMMDDhhmmss.ext The following table details the naming convention: Characters Description ssss transmitter serial number, maximum of 4 characters nnnnnnnn name string, optional YY year MM month DD day hh hour mm minute ss second ext file extension (.txt, .ini, .
12.2 Save Snapshot Save Snapshot is a one step download of a pre-determined data set from the transmitter. The data set is comprised of the following. (Download of Snapshot takes about 6 – 7 minutes.) • Raw Data Raw Data is as the name implies, a set of unprocessed data from the sensor head. A raw data file (5 minutes duration) is downloaded during Snapshot. • Data History Data History is a compilation of flow system information that is saved within the transmitter.
12.4 Advanced Functions Advanced Functions provides the user with a menu of options for saving data to and uploading data from the SONARstickTM. It also allows for updating system firmware and managing files on the SONARstickTM, and setting the date and time in the transmitter. These options are discussed below. • System Config System Config function allows naming, saving and loading configuration files. (In Snapshot mode a configuration file is automatically saved.
These files are often opened using a spreadsheet program and analyzed using that tool. • Manage Files Manage Files function allows the user to manage the files that reside on the SONARstickTM. The ‘Delete File’ option allows for deleting single files from the SONARstickTM and ‘Delete All’ removes all files. • Set Date/Time Set Time/Date allows the user to change the time and date that is stored in the transmitter. The format of the date and time code is MM/DD/YY hh:mm:ss.
13 SENSOR REMOVAL PROCEDURE If removal of the sensor is required, the following procedure should be followed. 1. Specific details regarding the removal of the SONARtrac sensor should be discussed with a CiDRA representative prior to removal. 2. Obtain Hot Work Permit if required. 3. Turn off electrical power to the system. Follow lock-out / tag-out procedures as required. 4. Open the transmitter door using a screwdriver and remove the sensor band shorting plug (stored in the transmitter) if there is one.
10. Install a sensor band shorting plug on the sensor band cable. This should be stored in the transmitter enclosure. Note: Sensor bands with an “R” in the Part Number suffix (e.g. Part #: 20686-26-R) do not require a shorting plug. WARNING Potential electrical discharge. Always install a sensor band shorting plug (see item 10 above) on the sensor band connector whenever the sensor band connector is not installed in a mating connector. 10.
Appendix A SONARtracTM GVF-100 SPECIFICATIONS A1 Physical Specifications A1.1 Power Supply AC Voltage Version: 100 to 240 Volts AC, 50/60 Hz, 25 watts DC Voltage Version: 18-36 Volts DC, 25 watts A1.2 Fuse Protection AC Voltage Version: The transmitter input power is fuse protected by two 1 amp, 250 volt, 5mm x 20mm fuses. DC Voltage Version: The transmitter input power is fuse protected by two 3.15 amp, 250 volt, 5mm x 20mm fuses. A1.3 A1.4 A1.
• Sensor to Transmitter Cable The standard sensor to transmitter cable consists of 12 twisted pairs of 20 AWG conductors with an overall shield encased in a PVC jacket. The standard cable has an operating range of -4ºF – +221ºF (–20ºC to +105ºC). The cable is UL Listed (UL Standard 13, Type PLTC) and CSA Certified (CSA C22.2 No. 214, PCC FT4). The outer diameter of the cable is 0.61 inch (15.5 mm) nominal. Optional low temperature and armored cables are also available.
A1.7 Fiberglass Sensor Head Cover Envelope The dimensions of the 2” to 16” fiberglass sensor head are given on the following figure and table. 30in (762mm) 0.3in (9mm) 4.2in (106mm) ‘B’ ‘C’ Fiberglass Sensor Head Envelope Model No Pipe / Tube Nominal Size Outside Dia Dim ‘A’ Dim ‘B’ Dim ‘C’ inch mm inch mm inch mm inch mm inch mm SH-E02-01-01 2 50 2.4 60 9.3 236 5.8 147 2.9 74 SH-T02-01-01 2 50 2.0 51 9.3 236 5.8 147 2.9 74 SH-D02-01-01 2.5 65 2.5 64 9.
A1.8 Stainless Steel Sensor Head Cover Envelope The dimensions of the 18” to 36” stainless steel sensor head monitors are given on the following figure and table. 4.2in (105mm) 0.3in (9mm) 1.7in (43mm) 4 plcs 34.7in (881mm) Stainless Steel Sensor Head Envelope Model No Pipe / Tube Nominal Size Outside Dia Dim ‘A’ Dim ‘B’ Dim ‘C’ inch mm inch mm inch mm inch mm inch mm SH-E18-02-02 18 450 18.0 457 22.9 581 22.4 568 11.2 284 SH-E20-02-02 20 500 20.0 508 24.8 631 24.
A1.9 Sensor Band Compatibility The sensor band assemblies are interchangeable with all sensor head cover assemblies of the same pipe diameters. Meter calibration factors are included for each sensor band assembly. All sensor head assemblies, independent of pipe size, are compatible with all transmitters. A1.10 Humidity Limits Transmitter: 0 – 100% A1.11 Analog Output Adjustment Two separate 4-20mA output signals scalable over stated range of meter. Primary 4-20mA output HART compatible. A1.
A2 GVF-100 PERFORMANCE SPECIFICATIONS A2.1 Turn-on Time 30 minutes to rated accuracy from power up 25 seconds from power interruption A2.2 Start-up Time 25 seconds from zero flow A2.4 Gas Volume Fraction Range SONARtracTM is capable of determining the Gas Volume Fraction in fluids between 0% and 20% entrained air. A2.5 Accuracy Accuracy of +/- 5% of reading within the 0.01% to 20% entrained gas/air range when used with an on-line process pressure reading. A2.6 Repeatability +/- 1% of reading A2.
Appendix B SONARtracTM EC DECLARATION OF CONFORMITY Copyright © 2006 CiDRA Corporation Page B-1 20639-01 Rev 03
Appendix C SYSTEM CONTROL DRAWING SONARtracTM, NON-INCENDIVE The system control drawing for installation in Class I Division 2, Groups A, B, C, and D is found on the following page.
Copyright © 2006 CiDRA Corporation Page C-2 20639-01 Rev 03
Appendix D MATERIAL SAFETY DATA SHEETS P/N 52307-01 PTFE Pipe Sealant MATERIAL SAFETY DATA SHEET IDENTITY: FORMULA-8 (Oxygen Compatible) Chemical name: Aqueous Paste & Filler of PTFE Chemical family: Perfluorocarbon Polymer Formula: (CF) 2n MANUFACTURER: Fluoramics CAS NUMBERS: Inc. ADDRESS: 18 Industrial Avenue Mahwah, N.J. 07430 PHONE: 201-825-8110 DATE PREPARED: January, 2003 PREPARED BY: F.G.
SECTION 3 - FIRE & EXPLOSION HAZARD DATA Flash Point & Method Used: None Flammability Limits in Air % by Volume: Non-combustible Extinguisher Media: Incombustible Special Fire Fighting Procedures: None Unusual fire and Explosion Hazards: In extreme fire situation, protection from hydrogen fluoride fumes should be employed .
SECTION 6 - CONTROL AND PROTECTIVE MEASURES Respiratory Protection (Specify Type): If exposed to high temperature processing fumes, wear self-contained breathing apparatus.
Copyright © 2006 CiDRA Corporation Page D-4 20639-01 Rev 03
Copyright © 2006 CiDRA Corporation Page D-5 20639-01 Rev 03
Appendix E CONVERSION FACTORS Dynamic Viscosity Units Conversion To Convert From: To: Multiply By: Pa-sec 4.788 026 e+01 Pa-sec 6.894 757 e+03 (kgf-sec)/m2 Pa-sec 9.806 650 e+00 Poise Pa-sec 1 e-01 Centipoises Pa-sec 1 e-03 lbf/(ft-sec) Pa-sec 1.488 164 e+00 lbf/(ft-hr) Pa-sec 4.133 789 e-04 (dyne-sec)/cm2 Pa-sec 1.0 e-01 (lbf-sec)/ft 2 (lbf-sec)/in 2 Pipe Modulus Units Conversion To Convert From: To: Multiply By: lbf/in2 kPa 6.
Appendix F PHYSICAL PROPERTIES OF WATER Water at 14.7 psia (sea level) Water at 24.7 psia (10 psig) Temp (degC) Sp Grav SOS (ft/s) Viscosity (Pa*s) Temp (degC) Sp Grav SOS (ft/s) Viscosity (Pa*s) 0 1.000 4601.2 1.7909E-03 0 1.000 4601.5 1.7907E-03 5 1.000 4679.0 1.5181E-03 5 1.000 4679.4 1.5180E-03 10 1.000 4748.3 1.3059E-03 10 1.000 4748.6 1.3058E-03 15 0.999 4809.5 1.1375E-03 15 0.999 4809.9 1.1375E-03 20 0.998 4863.3 1.0016E-03 20 0.998 4863.7 1.
Appendix G END USER LICENSE AGREEMENT Copyright © 2006 CiDRA Corporation Page G-1 20639-01 Rev 03
Copyright © 2006 CiDRA Corporation Page G-2 20639-01 Rev 03
Appendix H SPARE PARTS LIST The following is a list of commonly spared parts for SONARtracTM systems. Contact CiDRA Customer Support for items not found on this list, and for price and availability.
Copyright © 2006 CiDRA Corporation Page H-2 20639-01 Rev 03
Appendix I DIRECTIVE 2002/96/EC ON WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT (WEEE) This symbol pictured here and on the transmitter of your SONARtrac system (if purchased after August 13, 2005), indicates that at its endof-life your SONARtrac system is considered to be Waste Electrical and Electronic Equipment (WEEE) in applicable countries of the European Union.
CiDRA Corporation 50 Barnes Park North Wallingford, CT 06492 (In U.S.): 877-cidra77 Tel: 203-265-0035 Fax: 203-294-4211 Visit CiDRA Online at: www.cidra.com P/N 20639-01, Rev.
