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KENCO ENGINEERING COMPANY

P.O. BOX 470426 TULSA, OK 74147-0426 ● PHONE: (918) 663-4406 FAX: (918) 663-4480

www.kenco-eng.com e-mail: info@kenco-eng.com

SMARTSONIC INTEGRAL ACOUSTIC WAVE LEVEL / OPEN CHANNEL FLOW TRANSMITTER

INSTALLATION / OPERATION INSTRUCTIONS

TABLE OF CONTENTS

1. GENERAL DESCRIPTION ............................................................. 2

2. PRINCIPLE OF OPERATION ......................................................... 2

3. MODEL DESCRIPTION .................................................................. 2

4. INSTALLATION .............................................................................. 2

5. SPECIFICATIONS .......................................................................... 2

6. DIMENSIONS.................................................................................. 3

7. MOUNTING GUIDELINES .............................................................. 3

8. MOUNTING INSTRUCTIONS ......................................................... 4

9. WIRING ........................................................................................... 4

Wiring Connections....................................................................... 5

Loop Resistance Table (Intrinsically Safe).................................. 5

Loop Resistance Table (Non-Intrinsically Safe).......................... 5

10. CALIBRATION................................................................................ 6

Display / Keypad............................................................................ 6

11. INITIAL SET-UP PROGRAM .......................................................... 7

Initial Set-up Program Menu......................................................... 7

Five Initial Programs (Pr.20 thru Pr.24) ....................................... 8

12. STANDARD PROGRAMS .............................................................. 11

Standard Program Menu............................................................... 11

Programs (Pr.01 thru Pr.10).......................................................... 12

13. OPEN CHANNEL FLOW MEASUREMENT ................................... 21

Program Pr.00 (Flow Measurement) ............................................ 21

Flume / Weir Styles and Dimensions ........................................... 22

Flumes / Weirs – U.S. Standard.................................................... 23

Flumes / Weirs – European........................................................... 26

14. TROUBLESHOOTING .................................................................... 29

15. APPENDIX A (Gas Factor Table) .................................................. 30

Summary of content (30 pages)

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KENCO ENGINEERING COMPANY P.O. BOX 470426 TULSA, OK 74147-0426 ● PHONE: (918) 663-4406 FAX: (918) 663-4480 www.kenco-eng.com e-mail: info@kenco-eng.com SMARTSONIC INTEGRAL ACOUSTIC WAVE LEVEL / OPEN CHANNEL FLOW TRANSMITTER INSTALLATION / OPERATION INSTRUCTIONS TABLE OF CONTENTS 1. 2. 3. 4. 5. 6. 7. 8. 9. GENERAL DESCRIPTION ............................................................. PRINCIPLE OF OPERATION ......................................................... MODEL DESCRIPTION .......................
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GENERAL DESCRIPTION The SmartSonic Acoustic Wave Transmitter is designed for high accuracy level measurement of a variety of liquids. The SmartSonic Integral can also be used for Open Channel Flow Measurement. PRINCIPLE OF OPERATION The SmartSonic Transmitters consist of two main components: • The Electronics • The Sensor (Transducer) Acoustic Waves The transducer contains a piezoelectric crystal that converts an electrical signal from the electronics, into acoustic (sound) waves.
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DIMENSIONS 1.46 1.18 4.25 1.00 2.55 3.75 0.40 7.63 35º 2.16 MOUNTING GUIDELINES The transmitter must be mounted in such a way, as to avoid the process fluid level from entering the Dead Zone. While the narrow wave diameter of the Kenco Acoustic Wave Transmitters allows you to mount the sensor closer to the vessel wall, than other Ultrasonic transmitters, it is recommended to mount the sensor at least 1.64 feet away from the wall.
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MOUNTING INSTRUCTIONS Precautions: • Ensure that the transmitter is mounted in an area that meets the stated temperature, pressure and technical specifications. • Ensure that high voltage (ac) sources or cables are at least 1 yard away from the transmitter and its cable. • Installation and Operation of this transmitter must conform to the National Electric Code and any applicable local codes. 1.
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Wiring Connections Before starting installation procedures in hazardous areas, insure that all power sources have been turned off and locked out. “Live” electrical circuits can ignite flammable gasses and dusts. Do not apply more than 28Vdc to the transmitter, as this may damage the instrument. 1.) 2.) 3.) 4.) Remove the (4) retaining screws from the wiring compartment. Connect the conduit (preferably flexible) to the ½” NPT conduit opening.
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CALIBRATION This section explains how to set up and calibrate the SmartSonic for accurate measurement monitoring. SmartSonic is supplied with preprogrammed default settings, making it ready for immediate operation. It is recommended that you check the Initial Set-up Menu, to verify that the transmitter is set for your Application Type and Measurement Range. Also, you should replace the default tank height value with the actual tank height (Pr. 02).
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NOTE: Within some programs, the digits in the display can be individually modified. This is indicated by a flashing digit. In this case the ENT and ESC buttons are used to move between digits. The BACK and NEXT buttons are used to change the value of the flashing digit. INITIAL SET-UP PROGRAM Prior to calibration, you must verify that the SmartSonic is set for your application. There are five settings to consider. These settings can be accessed through the Pr.02 Program. Initial Set-up Program Menu Pr.
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Five Initial Programs While the Pr.02 Program is normally used to set the Tank Height, there is a special code that is used to enter this Initial Set-up Program.
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Initial Set-up Program Pr.23 (Measurement Range) This program allows you to set the transmitter to either Standard or Short Range. The Standard range is 49.22ft., while the Short Range is 16.41ft. If your Tank Height is less than 16.41ft. select the Short Range, as this will give you better accuracy. Press / Action Display Pr.23 Pr.23 S, r or Description Program #23 Cycle between Standard (S), and Short (r). DO NOT select COdE. Accepting the new “Application Type” Value After a brief time Pr.23 Pr.
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Initial Set-up Program Pr.21 (Flow Measurement Units) This program is only available if you selected Flow in Program 24. This is where you select either Gallons per Minute or 3 Cubic Meters per Hour (m ). Press / Action Display Pr.21 Pr.21 6Pnn, nn3 or Description Program #21 Cycle between Gallons per Minute (6Pnn) and Cubic meters per Hour (mm3). Accepting the new “Application Type” Value After a brief time Pr.21 Pr.21 Initial Set-up Program Pr.
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STANDARD PROGRAMS Standard Program Menu Open Channel Flow Flow Measurement Pr.00 Pr.01 Reset Pr.01 Pr.02 Tank Height Pr.02 Pr.03 Interfering Signals Pr.03 Pr.04 4mA Pr.04 Pr.05 20mA Pr.05 Pr.06 Response Speed Pr.06 Pr.07 Working Area Pr.07 Pr.08 Level / Distance Pr.08 Pr.09 Atmosphere Compensation Pr.09 Pr.10 Factory Default Pr.
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Reset Program The Pr.01 program enables you to do a reset, refreshing the SmartSonic measurement reading, while not changing data saved in other programs. After resetting, the actual reading is shown on the LCD, and SmartSonic begins to scan. This program has the same effect as turning the unit off then on. NOTE: During the reset, SmartSonic will display 8.8.8.8 and the output current will be 22mA. Press / Action and Display Description Enter the Program Menu simultaneously Enter Pr.01.
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Press / Action and Display Description Enter the Program Menu simultaneously Cycle to Program #2 One Time Enter Pr.02. This indicated the measurement unit; meters (shown) or feet (H F). For Example: Displays last saved Tank Height or Maximum Range Change the display to read the Tank Height and Accepting the new “Tank Height” Value Wait a brief time Back to the Program Menu For Example: Measurement reading; Normal Mode Special Functions of Pr.
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Function 00.16 (22mA Error Signal) This function allows you to define if “Near Zone” and “Lost Echo” are allowable errors, and if the result is a 22mA output. The default has the display and 22mA turned on for these errors: Near Zone – Whenever the fluid level is within the Dead Zone. The display will show F.F.F.F Lost Echo – Whenever the echo is lost, or the measurement results exceed the tank height, or when a returned echo is not received. The display will show E.E.E.
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Echo Amplitude Interferences Stored in Memory (up to 6) Real Echo Distance Each reading (scan distance) taken using the Pr.03 program is stored as an interfering signal, until a reading is achieved that indicates the real echo. Prior to running this program, you must verify the distance to the bottom of the tank (i.e. stick the tank). If six interfering signals are already stored, any additional interfering signals will not be stored.
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Temporary display while SmartSonic searches for Interfering Signals For Example: After a brief pause Distance to Interfering Signal Saves the Interfering Signal, then searches again and displays the next reading. Continue to press this button to save up to six interference readings. If you get to the real echo, go to the following steps. Real echo reading (confirmed by manually measuring the distance from the sensor to the bottom of the tank).
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For Example: Change the value to represent the desired 4mA Point in either: Level, Distance, or Flow units. and To save the new value, press ENT. when the far right digit (4mA value) is flashing. Returns to Pr.04 OR To return to the main menu without saving, press ESC. when the far left digit (4mA value) is flashing. Returns to Pr.04 NOTES: • The values for 4mA and 20mA must be different; otherwise an Err error message is displayed.
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For Example: Change the value to represent the desired 2mA Point in either: Level, Distance, or Flow units (selected in Pr.04). and To save the new value, press ENT. when the far right digit (20mA value) is flashing. Returns to Pr.05 OR To return to the main menu without saving, press ESC. when the far left digit (20mA value) is flashing. Returns to Pr.05 NOTES: • Type of measurement (level, distance, flow) selected in Pr.04 is also applicable for Pr.05.
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Working Area The Pr.07 program allows you to add a distance range that exceeds the tank’s height, thus enabling accurate readings of complicated tank shapes with conic bottoms. This may be required when the vessel has a conical shape which is causing false echoes and faulty measurements. The minimum value is the Tank Height; the maximum value is 2X Tank Height. However this value cannot exceed the maximum measurement range (16.41 ft. or 49.22 ft depending on the setting of Pr.
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For Example: Displays the current distance/level mode setting Used to cycle between Distance (d000) and Level (L000) and Select the desired response mode. Returns to Pr.08 Atmosphere Compensation The Pr.09 program enables you to compensate for speed of sound changes in different atmospheres, for example, 100% methane instead of air. See Appendix A for a list of Gasses and their compensation factors.
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Restoring the Default Settings The Pr.10 program allows you to clear programs Pr.00, Pr.02 – Pr.09, and reverts to Factory Settings: • Pr.00 – GPM 1U01 or M3/Hr 1E01 • Pr.02 – Sbd 00.00, E000, Tank Height = Default • Pr.03 – Resets all interfering signals • Pr.04 – Level device L000 and 00.00; Flow Device F000 and 00.00 • Pr.05 – Level device Tank Height = Pr.02; Flow device 55500 M3/Hr or 244400 GPM • Pr.06 – SE 0 • Pr.07 – Tank Height = Pr.02 • Pr.08 – d000 • Pr.09 – 01.00 The Pr.
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Press / Action and Display Description Enter the Program Menu simultaneously Cycle to Program #00 One Time For Example: Indicates the flow measurement version (selected in Pr.21). Gallons per Minute (GPM) shown. Displays the last saved flow measurement value. The first digit is flashing. Enter the “Style” (X) number of the desired flume or weir type (see the following section on Flume / Weir Styles and Dimensions) or Last two digits are flashing.
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Flumes / Weirs – U.S. Standard (dimensions are in inches unless otherwise indicated) Type 1 (X) – Rectangular Suppressed Sharp-Crested Weir Code (FF) Crest Length 01 12.00 02 18.00 03 24.00 04 30.00 05 36.00 06 48.00 07 60.00 08 72.00 09 96.00 Code (FF) Crest Length 01 12.00 02 18.00 03 24.00 04 30.00 05 36.00 06 48.00 07 60.00 08 72.00 09 96.00 Code (FF) Crest Length 01 12.00 02 18.00 03 24.00 04 30.00 05 36.00 06 48.00 07 60.00 08 72.00 09 96.
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Type 4 (X) – V-notch (Triangular) Sharp-Crested Weir Code (FF) V-notch Angle 01 90º 02 60º 03 45º 04 30º 05 22.
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Type 7 (X) – H-Flume Code (FF) Flume Size Measurement Point 01 6 1.96 02 9 2.75 03 12 3.54 04 18 5.51 05 24 7.08 06 30 9.05 07 36 11.02 08 54 16.
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Flumes / Weirs – European (dimensions are in centimeters unless otherwise indicated) Type 1 (X) – Rectangular Suppressed Sharp-Crested Weir Code (FF) Crest Length 01 20 02 40 03 60 04 80 05 100 06 150 07 200 08 300 Type 2 (X) – Rectangular Contracted Sharp-Crested Weir Code (FF) Crest Length 01 20 02 30 03 40 04 50 05 60 06 80 07 100 08 150 09 200 10 300 Type 3 (X) – Trapezoidal (Cipolletti) Sharp-Crested Weir Code (FF) Crest Length 01 35 02 45 03 60 04 80 0
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Type 4 (X) – V-notch (Triangular) Sharp-Crested Weir Code (FF) V-notch Angle 01 90º 02 60º 03 53.8º 04 45º 05 30º 06 28.4º 07 22.5º British Standard 08 90º 09 45º 10 22.
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Type 7 (X) – Palmer-Bowlus Flume Code (FF) Conduit Diameter (in) 01 6 02 8 03 10 04 12 05 15 06 18 07 21 08 24 09 27 10 30 Type 8 (X) – H-Flume Code (FF) Flume Size (in) 01 Measurement Point (cm) 6 5 02 9 7 03 12 9 04 18 14 05 24 18 06 30 23 07 36 54 28 08 41 Type 9 (X) – Neyrpic-Venturi Flume / Long Base Weir Code (FF) Flume Type Code (FF) 01 1253AX 06 Flume Type 1253C 02 1253AY 07 1253D 03 1253AZ 08 1253E 04 1253A 09 1253F 05 1253B Code
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TROUBLESHOOTING This section describes how to resolve problems that may occur when calibrating / operating the SmartSonic. If the following information does not lead to a resolution of the problem, contact Kenco for assistance. Error Solution Description Electrical Noise in Area Check the Power Supply. If needed, install a voltage “snubber”. When active, the output will be 22mA Faulty Power Supply Make sure that the Power Supply conforms to the SmartSonic Specifications.
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Appendix A. – Gas Factor Table Atmosphere (Gas) Factor Atmosphere (Gas) Factor Acetic Acid 0.62 Ethane 0.90 Acetone 0.63 Ethanol 0.71 Acetaldehyde 0.74 Ethylene 0.95 Acetyl Chloride 0.54 Helium 2.93 Acetylene 0.99 Hydrogen 3.79 Ammonia 1.26 Hydrogen Sulfide 0.89 Argon 0.92 Isopropyl Alcohol 0.62 Benzene 0.53 Methane 1.29 Bromine 0.41 Methyl Hydrazine 0.71 Bromochlorodifluoromrthane 0.37 Neon 1.30 Butanone 0.56 Nitrogen 1.01 Carbon Dioxide 0.