KPSI™ Level and Pressure Transducers User`s Manual
Contents
1. 1 0 Product Description General Characteristics KPSI Level and Pressure Transducers use isolated diaphragm sensors that are specifically designed for use with hostile fluids and gases These sensors utilize a silicon pressure cell that has been fitted into a stainless steel or titanium package with an integral compliant stainless steel or titanium barrier diaphragm This sensor assembly is housed in a rugged 316 stainless steel or titanium case which provides for a variety of level ranges from 2 3 ft 0 75 m H2O through 4614 ft 1408 m H2O and pressure inputs from 0 1 7 kPa through 0 15000 psi 103 mPa Our devices feature internal signal conditioning Standard outputs are 4 20 mA and VDC All units containing active electronic components have surge and reverse polarity protection For ease of use in the field our transducers are permanently laser engraved with our logo and name wiring information part number P N serial number S N date of manufacture DOM range excitation and output Transducers are offered in diameters of 1 0 25 mm and 0 75 inches 19 mm Care and Handling Our transducers are designed for rugged use However they need protection from over pressure and sharp impact When lowering them into a liquid penetrate the surface slowly and only to the depth necessary Avoid dropping the unit from above the surface Clean all transducers by rinsing them ina mild detergent Direct probing of the diaphragm2. Transducers User s Manual M Appendix C Troubleshooting Techniques Quick Check Procedure The following is a quick field checkout procedure for KPSI Level and Pressure Transducers It will be referred to throughout the troubleshooting section Should a problem be encountered with a transducer or transmitter it is sometimes helpful to test the transducer independently from the rest of the system thereby establishing where to concentrate the troubleshooting effort On the next page is a simple hookup diagram for the most common types of electrical output a 0 5 VDC transducer and a 4 20 mA transmitter In either case the power supply can be a common 12 volt lantern battery or even a 9 volt transistor radio battery although the lifetime of a 9 volt battery will be limited The meter should be a digital type capable of reading at least 2 digits to the right of the decimal point Use 22 gage or heavier hookup wire or clip leads for jumpers If your unit has other than a 0 5 VDC or 4 20 mA output please call Applications Support at 800 328 3665 for assistance Once your transducer is correctly configured per one of the diagrams below orient the transducer in a vertical position with the pressure port down and then read the zero output on your meter For a 0 5 VDC output the zero should be between 0 and 0 10 volts and for a 4 20 mA output between 3 80 and 4 20 mA For Series 300 the values do not change for VDC output
3. anode maintains a high driving potential throughout its 12 month life is self sluffing and always exposes new zinc for the best possible protection For those applications where cable buoyancy is a problem the sacrificial anode can be substituted for hanging weights Sacrificial Anodes provide cathodic protection against galvanic corrosion for our submersible pressure transducers Galvanic corrosion occurs when dissimilar metals are placed in contact with an electrolyte This condition causes a potential difference to exist between the two metals causing electron flow between them Corrosion of the less corrosion resistant metal is increased and attack of the more resistant metal is decreased The 820 Sacrificial Anode is clamped to the exterior of a one inch bore submersible transducer We also offer a 1 diameter pencil anode the 825 that attaches to the nose cap of either a 3 4 or 1 bore submersible transducer Page 4 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual Absolute Sealed Gage Transducer The sealed gage option for submersible transducers eliminates the need for a vent filter The standard output of a sealed gauge transducer is 4 mA at 14 70 psia Before ordering a sealed gauge transducer the customer should determine the altitude above sea level of the installation and inform PSI s Customer Service of this value before order entry During manufacture the output of
4. ki 8 3 0 Installation amp Maintenance Tips rrrnnnnnrnnnnvennnnnvennnnnevnnnnr 9 General Installation Procedures rrrrrrrrrnrrrnnnnnrrvnnrrnnnnnnnre 9 Transducer nein 9 Transducer Submersion rrnnnnnrnrnnnnnvnrnnnnnvrnrnnnnnonnrnnnnnennnnnn 9 SuperDry Vent Filter Desiccant or 815 Aneroid Bellows Installation ccccceccccsseeeeeeceeeeeeseeeesseeeeseeeesaes 9 Gable Protections EE 10 Bending Of Gable Lassa 10 Cable Compression nnnnnnnnsennnnnnennennnnnnennennnrnnnnneennenenee 10 4 20 mA Output Wiring eronnrrrrrrnnnnrrvnrnnnnrrnvrnnnnrvnnrnnnnrrnnnnnn 11 VDC Output Wiring errrrrnnnnrnrorrrrrnnnnnnrrrrnrrnnnnnnnsvnnnnnnnnnsnnee 11 Model Blaa 11 Sealed Gage Transducer Configured for Altitude Aboye cea Level roren N 12 Transducer Position Gensttivifv 12 General Maintenance Te 12 Desiccant Maintenance 12 Clogged Nose Piece or Dirty Diaphragm so0annnen0nnnnn0nn 13 Cleaning Your Transducer 13 4 0 Warranty and Product Return Koelich 15 Restocking PONGCY EE 17 Appendix A Drawings and Diagrams nnrennnnnnnnnnnnnnnnnnnnnnnnnnennnnnne 18 Appendix B Frequently Asked Questions rrrrrnnnnnnnnnnnnvernnnnnnnnnr 22 Appendix C Field Checkout amp Troubleshooting Techniques 26 Appendix D Calibration Calculations cccccsssseessseeeeeeeeeeeees 39 Page 1 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual
5. the transducer will be adjusted to compensate for the altitude difference if applicable Polyurethane amp ETFE Jacketed Cable Most installations of our submersible level transducers connect our polyurethane or ETFE cable to a junction box From this junction box P N 840 users typically run their own cable to the required instrumentation Polyurethane jacketed cable is used for most applications while ETFE material is recommended for more aggressive environments Specifications for our standard polyurethane and ETFE jacketed cable are as follows fi Standard Standard Specifications Submersible Cable Non Submersible Cable Weight 0 05 Ibs ft 0 07 kg m 0 025 Ibs ft 0 035 kg m Min oD 0 28 7 10 mm 0 189 4 8 mm 0 31 7 87 mm 0 19 4 9 mm Insulation Conductors see or ETFE Color coded PVC Outer jacket Aluminum polyester foil 36 gauge spiral tinned facing outward copper wire foil shield with drain wire i Drain wire Vent Tube POSEEN a ID 1 52 7 32 tinned copper Page 5 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual Chemical resistance of polyurethane Potable Water Wastewater Borax Butane Animal Fat Carbonic Acid Citric Acid Cod Liver Oil Corn Oil Glycerin Glycol Mineral Oils Potassium Nitrate Potassium Sulfate Silicone Oils Stoddard Solvent Tannic Acid 10 Tartaric Acid Turbine Oil Chemical resistance of ETFE Aceti
6. to be powered At 25 C the 22 AWG conducting copper wire used in our polyurethane jacketed cable has a resistance of 16 45 ohms per 1000 feet 304 m Using Ohms Law E IR where E voltage l current and R resistance one finds that a 20 mA signal requires 329 volts to drive it along 1000 feet 804 m of 22 AWG copper wire E 16 45 x 020 This drop is seen on both the supply and return wire for a total loop voltage drop of 0 658 volts To find out how much voltage is required to drive our Series 700 submersible level transducer s 4 20 mA signal 10 000 feet just add the minimum power requirement of the 700 9 VDC to Page 28 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual the resistance offered by 10 000 feet 8048 m of our polyurethane jacketed cable 10 000 1000 x 658 6 58 The resulting power requirement is 15 58 VDC 9 6 58 Connect the cable shield drain wire to a good earth ground This will protect the transducer from relatively minor transient voltages The only exception to this rule is if high rates of electrolytic corrosion have been previously experienced with grounded submersible devices In this case it may be better to leave the shield disconnected Please note When using products with the lightning protection option on 4 20 mA products users should take into account the additional series resistance of this option when selecting the loop power supply T
7. to galvanic corrosion Installation of a P N 820 or 825 sacrificial anode will help protect your transducer from galvanic corrosion Our sacrificial anodes are made of a zinc alloy that being nearer the anodic end of the galvanic series than the 316 stainless steel or titanium housing of the transducer will corrode before the transducer The transducer is buried in dirt or silt and the readings seem to be erroneous Use of a piezometer nosepiece in this application would help This nosepiece can be easily installed in the field and features a very fine screen to keep dirt from fouling the diaphragm but allows the diaphragm to sense moisture levels Transducer has an offset error Our submersible transducers perform best when the sensing end is pointing in a downward manner Keep in mind that you can experience offset error due to the position sensitivity or orientation change of the sensor Offset errors are more prominent in low pressure applications with the sensing end of the transducer lying flat or pointing upward I am testing a Series 700 4 20mA sensor for use with our data logger On page A 2 of the KPSI Level and Pressure Transducers User s Manual I see the standard 4 20mA configuration Does the recording channel of my data logger become the mA meter www PressureSystems com Pressure Systems Inc Page 35 Procedure KPSI Level and Pressure Transducers User s Manual Most data loggers cannot me
8. transducer is getting power If all checks OK the problem could be a circuit board or the sensor in your transducer The unit must be returned to the factory for evaluation The most probable cause of this type of failure is damage to the submersible cable jacket allowing water to leak down the cable and into the transducer housing or lightning damage 9 Symptom Formation of marine growth ona submersible transducer Procedure Certain transducer construction materials for example 316 stainless steel attract marine life snails and algae Clean the transducer diaphragm by soaking it in a bucket of warm water with a non aggressive cleaning solution You can also coat the transducer with marine grease This may be the most effective and inexpensive way to protect your transducer 10 Symptom Submersible transducer exhibits corrosion or pitting on body or diaphragm Procedure Dissimilar metals for example your transducer housing and your pump housing in an electrolytic environment fluid in your well can lead to galvanic corrosion of the metal that is nearer the anodic end of the galvanic series Likewise a voltage potential between the ground wire of the transducer and Page 33 www PressureSystems com Pressure Systems Inc 11 Symptom Procedure 12 Symptom Procedure 13 Symptom Page 34 KPSI Level and Pressure Transducers User s Manual the ground of other equipment in the well can lead
9. waterMONITOR for the restocking policy Page 17 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual ees Appendix A Drawings and Diagrams Wiring Diagram VDC mA and Temp Output 18 Cable Anchoring Gchemes 19 Reference Connection SCHEMES rurrnnunnnnrnnrnuvnnnennvnnnenuvennenne 19 Submersible Cable Termmatnon 20 Page 18 www PressureSystems com KPSI Level and Pressure Pressure Systems Inc Transducers User s Manual Wiring Diagram VDC mA and Temp Output EXCITATION EXCITATION POWER SUPPLY VDC Configuration COMMON VOLTAGE METER SIGNAL DRAIN WIRE WHITE INPUT temp GREEN INPUT temp sens RED INPUT pressure DRAIN WIRE 4 20 mA Configuration Temperature output Option Notes 1 These diagrams depict typical installations Refer to your power supply and instrumentation Manufacturer for the specifics of your application Page 19 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual Cable Anchoring Schemes BEE TOP Reference Connection Schemes TRANSDUCER CABLE VENTED VENT FILTER TANKS K OR ANEROID BELLOWS option reich NON VENTED TANKS VENT FILTER TOP OF L TANK Page 20 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual Submersible Cable Ter
10. 6 If the transducers accuracy is reported as being some percentage of its full scale range then the following table could be used in conjunction with the instructional notations to determine whether a more detailed analysis of data quality is required Model Accuracy Accuracy in mADC 700 1 00 FS 0 16 ma 710 0 50 FS 0 08 ma 720 0 25 FS 0 05 ma 730 0 10 FS 0 016 ma 735 0 05 FS 0 008 ma In order to approximately determine how many milliamps a transducer should output at a given depth 1 Determine the depth in feet at which the transducer is sited 2 Divide the depth value from step 1 by the transducer full scale range in feet Record the value 3 Multiply the value calculated in step 2 by 16 the transducer span in milliamps 4 Add 4 to the product of step 3 This is the approximate value in milliamps that should be output by the transducer at its current depth www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual In order to approximately determine the depth of a transducer in feet using a given value of milliamps 1 Divide the full scale range of the transducer in feet by 16 Record this value 2 Subtract 4 from the milliamp output of the transducer Record this value 3 Multiply the result of step one by the result of step 2 This is the approximate depth at which the transducer is sited If the resulting numbers are reasonably clo
11. Esterline Pressure Systems KPSI Level and Pressure Transducers User s Manual 17 Edition April 2009 Leg F Bi RK gr p ge en weng gt a bd eer gt T e Was Sensing the Envir nment ea Visit us on the web www PressureSystems com On line Transducer Store www LEVELandPRESSURE com Our Company Pressure Systems is an 1S09001 2000 certified U S manufacturer of submersible and non submersible above ground pressure transducers for environmental industrial and municipal applications Our KPSI Level and Pressure Transducers have been specified in thousands of projects throughout the United States Canada and Europe by geologists system integrators national engineering firms and a variety of government agencies Typical applications include but are not limited to pump control tank level monitoring sewage lift station operation reservoirs weirs flumes site remediation watershed management storm water well monitoring pump pipeline pressures and compressor pressures Website and E Mail You may visit our website at www PressureSystems com to look at our latest new product releases application notes product certifications and specifications as well as Intrinsic Safety control installation drawings E mail your questions and comments to us sales PressureSystems com E commerce Orders may be placed on line by visiting our e commerce site www LEVELandPRESSURE com or by co
12. HIELD Slope Zero Offset Comgrz ce Factor Catulations Maod 1 Cakulajo pressure in doshod units using Sensors dulput as independant variable PSG 65411 mA 4 0017 0 0000 HMefod Calculate proche samaa output in desired LES Using Pressute os the independent varinb e P e 1 GATE P SIG OO 4 A 0017 Page 39 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual In this case even though the offset or 0 PSIG output was 4 0017 mADC and the full scale point was 20 0219 mADC the unit actually performed better than its specified accuracy of 0 25 of full scale range as indicated in the Error FS column The calculation for pressure is illustrated below PSIG Span Output in mA Offset And to convert to feet of water Feet H2O PSIG 2 3073 Page 40 www PressureSystems com Headquarters Factory European office 34 Research Drive PO Box 3968 Hamtpton VA 23666 Maidenhead USA SL60 1AY Phone 757 865 1243 United Kingdom Toll Free 800 328 3665 Tel 44 0 1628 776300 Fax 757 865 8744 Fax 44 0 1628 200177 E mail sales PressureSystems com email PSleurope Qpressuresystems com
13. Inc KPSI Level and Pressure Transducers User s Manual 4 0 Warranty and Product Return Procedure Any transducer transmitter that is less than 2 years old see DOM which does not meet the product s specifications and exhibits no obvious physical damage to the housing sensor or cable cuts will be replaced under warranty Units 2 3 years old Units that fall within this age group and exhibit no obvious physical damage to the housing sensor or cable cuts may be replaced at a discounted list price Units greater than 3 years old Units that fall within this age group are not replaced under warranty Merchandise Return Procedures Contact the Applications Support Group or the Customer Service Department at Pressure Systems if your transducer is not operating properly Our staff is available for troubleshooting at 757 865 1243 or toll free at 1 800 328 3665 during normal working hours Eastern time If your transducer or accessory needs to be returned to Pressure Systems obtain a Returned Merchandise Authorization RMA from the Customer Service Department prior to shipment Be prepared to supply the following information when requesting the RMA Part number Serial number Complete description of problems symptoms Bill To and Ship To address Purchase order number not required for warranty repairs Customer contact and telephone number Page 15 www PressureSystems com Pressure Systems Inc KPSI Level and Pressu
14. TFE jacketed cables are quite flexible Care needs to be taken to ensure that when bending the cable to suit your installation you do not crimp the vent tube inside the cable Consequently do not bend the cable more than a radius of 1 inch Cable Compression Many users require a compression fitting to secure our ETFE and polyurethane jacketed cable as it enters a junction box www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Page 11 Transducers User s Manual Care needs to be taken that you do not over tighten the fitting so as to damage the cable 4 20 mA Wiring When connecting a 2 wire 4 20 mA transducer to a typical power supply and mA meter verify that the meter has an input impedance of at least 10 Ohms If you are unsure of the input impedance then a 10 Ohm resistor may be placed in series with the meter and transducer Connect the red lead of the transducer to the terminal of the power supply If the 10 Ohm resistor is required connect it to the black lead of the transducer Use a short length of 22 AWG or heavier wire to connect the terminal of the meter to the resistor if it is required or the black wire of the transducer Connect the terminal of the meter to the terminal of the power supply with a length of 22 AWG or heavier wire Connect the drain wire from the transducer to a good earth ground See Appendix page 14 for wiring diagram Please refer to Maximum Ca
15. asure current mA directly When this is the case a load resistor must be used to convert the current mA output into an appropriate voltage If the User s Manual for your particular instrument does not illustrate a preferred method for recording current mA data then you should attach your transducer signal wires to your data logger in the following manner Transducer red wire Data Logger Excitation Terminal The minimum excitation for a Series 700 Transducer is 9VDC Transducer black wire Data Logger signal input terminal Attach a Load resistor between the Data Logger signal input terminal and the Data Logger signal input terminal Attach a separate piece of wire between the Data Logger signal input and analog ground In this configuration you will turn your data logger into a milliammeter The size of your load resistor can be calculated in the following manner D 0 02 R Where Data logger input range D Full scale output of transducer 0 02 A 20 mA Load Resistor Value R www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual Pick an appropriate standard value 250 Ohms results in 1 to 5 VDC at 4 and 20 mADC 125 Ohms results in 0 5 to 2 5 VDC 500 to 2500 mVDC at 4 and 20 mADC At this point the discussion needs to address IR loss voltage drop in series circuits Note that Series 700 transducers need a minimum of 9 VDC to ope
16. be cleaned in accordance with the procedures listed in step 4 below 3 Cleaning your transducer Materials required e Plastic bowls 8 12 inches 200 300 mm in diameter and 4 6 inches 100 150 mm deep e Supply of clean lint free cleaning rags e 32 ounce bottle of The Works Tub and Shower Cleaner a mild detergent manufactured by Lime O Sol Company in Ashley IN 46705 and available locally through Wal Mart K Mart Target and Ace Hardware stores at 2 to 4 per bottle Preparation Prior to cleaning your pressure transducer ensure that all procedures have been followed in the proper cleaning of the cable and transducer to remove any hazardous materials The vent filter or bellows must be properly attached The cable should be coiled to ensure ease of handling and it must be protected against the possibility of accidental abrasion and or penetration of the cable jacket by harp objects A lead length of 1 to 1 1 2 feet 0 3 0 45 m of cable from the transducer should be allowed to facilitate handling during cleaning The protective covering or similar protective device that is shipped with each transducer should be attached to the transducer at all Page 13 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual times It should only be removed prior to installation or cleaning Your work surface needs to be clean and free of clutter and large enough to accomm
17. ble Lengths and Minimum Supply Voltage in Appendix C page 22 to verify minimum loop supply voltage requirements VDC Wiring To connect a 3 wire VDC output transducer to a typical power supply and the voltmeter connect the terminal of the power supply to the input terminal of the meter with a length of 22 AWG or heavier wire Connect the excitation black lead of the transducer to the input terminal of the meter Connect the input terminal of the meter to the signal lead white of the transducer Connect the terminal of the power supply to the lead red of the transducer Connect the drain wire to a good earth ground See Appendix A page 14 The Model 750 comes standard with a field removable diaphragm protector one inch or 25 mm standoff The diaphragm protector can easily be taken off by removing six 6 fasteners located on the bottom of the unit www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual 10 Sealed Gage Transducer Configured For Altitude 11 Above Sea Level Since sealed gauge transducers are normally calibrated at sea level there may be considerable error induced when used at a higher elevation If the transducer was calibrated without taking into consideration the difference in atmospheric pressure at sea level and the higher elevation an offset error will occur In order to eliminate error due to this difference the customer must identi
18. but the values for mA are between 3 80 and 4 20 mA If the output is outside of these limits you may at your option choose to troubleshoot the transducer per the suggested measurements shown below Otherwise contact our Customer Service Department at 800 328 3665 for a Return Material Authorization number RMA Page 26 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual If the zero output is within these limits the problem will more than likely be found elsewhere in your system YOU MUST ADD 0 5 VDC THESE SECH 4 20 mA YsALAWLIOA XAlddN S YAMOd 4O Aal Ivo AlddNS YAMOd YO AYSLIVE YILIN VU LS When an error is observed at a customer s installation it is important to determine if the fault lies in the transducer or the instrument reading the transducer signal ie digital panel meter programmable logic controller etc To do this a second instrument should be used to confirm the observations The second instrument may be a handheld DMM Digital Multi Meter or a dedicated milliammeter capable of reading 4 20 mA of current to a resolution of at least 0 1 mA The diagram above illustrates the attachment of the meter in series with the black negative signal wire of the transducer using a 9 28 VDC power supply for transducer excitation Some suggested power Supplies are e 1 12 VDC automotive battery e 2 6 VDC lantern batterie
19. c Acid Glacial Acetic Anhydride Acetone Aluminum Chloride Anti Freeze Bromine Calcium Chloride Calcium Hydroxide Chlorine Copper Chloride Ferrous Chloride Hydrochloric Acid Ketones Lacquer Thinners Sulfuric Acid The vented cable termination end is specially prepared at the factory to eliminate the potential for moisture migration Where the lead wires emerge from under the jacket there s potting material and a shrink tube boot every effort should be made to leave this feature intact Should the cable be longer than needed for the installation it is recommended that the excess length be accommodated in a service loop and that the potted end of the cable NOT be shortened The cable attached to this instrument is specifically engineered for submersible applications The polyurethane outer jacket provides long term reliability under most conditions The cable should be handled carefully however as the jacket may be subject to cutting should it be raked over extremely sharp edges To guard against water incursion should an inadvertent minor cut occur we have incorporated an exclusive water block feature immediately beneath the jacket The cable is fully shielded with the shield connected to the metal housing at the transducer end and terminated in a drain wire at the termination or user end The shield should always be terminated to a good earth ground unless the transducer is installed in an area where ga
20. e sure the cable shield is connected to an earth ground as near as possible to the transducer We can provide a surge protection kit for both our Page 22 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual submersible and non submersible transducers See page 4 These kits will handle typical spikes that might come in through the power lines as well as surges that travel through the ground due to nearby lightning strikes 4 Question How much impact shock can your submersible transducers withstand Answer Our transducers are not shock tested and the lower pressure ranges can be damaged if dropped from several feet onto an unforgiving surface like concrete We recommend that the protective shipping foam remain in place until the unit is installed 5 Question What is the response time of your transducer Answer From initial power up the transducer output will stabilize within a fraction of a second The frequency response is rather low probably less than 1 kHz but it depends on the application the media plumbing etc Call our factory for application assistance if frequency response Is critical in your application 6 Question How do I attach your vent filter or aneroid bellows to my cable vent tube Answer The vent filter can be mounted anywhere convenient preferably out of the weather It can be mounted in any position and connects to the cable vent tube via the
21. ent Pressure Systems will prepay and add the shipping charges to the repair bill Incoming freight charges are the customer s responsibility The customer is also responsible for shipping charges to and from Pressure Systems for all equipment not under warranty Page 16 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual Once the return is received it typically takes 5 10 working days for the technician to make a fault determination A cable reconnect fee will be charged when the customer requests a different length of cable Restocking Policy Pressure Systems does allow standard products to be returned for credit in the event it is no longer required providing the products are in new and unused condition A restocking fee will be assessed depending on the model type and variety A 25 restocking fee applies to the following models providing they are vented gage reference format and pressure ranges above 3 psig 20 kPa and below 100 psig 690 kPa Display Meters all models A 50 restocking fee applies to the following models This also applies to all other models with sealed gage and absolute pressure formats as well as vented gage reference formats with pressure ranges below 3 psig 20 kPa and above 100 psig 690 kPa NOTE Expedite premiums and shipping charges are non refundable Please consult the individual manuals for the Series 500 and Series 550
22. extension tube with metal connector tube provided The aneroid bellows must be mounted in a way that its movement is not encumbered It is provided with a mounting base Page 23 www PressureSystems com Pressure Systems Inc 10 11 12 Question Answer Question Answer Question Answer Question Answer Question Answer Question Answer Page 24 KPSI Level and Pressure Transducers User s Manual What is the best way to mark my cable Use white vinyl marking tape available from your local hardware or electronic stores These same stores may also sell cable marking kits Any ideas for preventing marine growth on your submersible transducers You might want to try waterproof grease Remove the threaded nose cap to facilitate applying the grease Take care not to damage the diaphragm when applying the grease and not to trap air bubbles against the sensing diaphragm How many measurements can you make before the diaphragm on the sensor fails In normal operation millions of cycles We find that sensor failure is rarely due to diaphragm fatigue What is the turnaround time on repairs Once we receive a unit into our facility it takes less than 10 working days to complete an evaluation What is the longest length of cable you have attached to a submersible transducer Two thousand feet 610 meters Why do you use 316 SS housings and sensors for your standard tra
23. from identifying change in level Removing the transducer from service and cleaning it as described in Item 2 will generally solve the problem To combat marine growth you might try wrapping the transducer with copper wire similar to that found in wire scouring pads for cleaning dishes Marine growth occurs on the copper and eventually erodes the copper and drops off or the copper is manually removed during routine maintenance Alternatively there are various companies that will impregnate coat the 316 stainless steel with anti fouling chemicals of coatings Level transducers temporarily removed from the well or sump should not be stored dry but should be stored ina bucket of fresh water in order to prevent crust formation Readings increase very slowly over time Our cable is shipped coiled and consequently takes time to straighten when installed Attaching a weight to the transducer e g one of our sacrificial anodes will help To prevent cable stretch with lengths greater than 200 feet 60 m secure the Kevlar fibers just under the cable jacket to your junction box or other secure object www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual 8 Symptom No electrical output from your transducer Procedure Check all electrical connections to ensure they are correct and secure Double check your power supply or use a battery as described previously to ensure the
24. fy the elevation where the transducer will be installed The nominal atmospheric pressure at the location is calculated and the transducer will be ranged accordingly Not all KPSI Transducers are available in a sealed pressure format Please refer to the appropriate datasheet for availability Position Sensitivity The transducer should be installed so that the diaphragm located behind the nose cap is oriented in a vertical position otherwise the unit could exhibit an offset General Maintenance Tips for Submersible Transducers 1 Page 12 Desiccant Maintenance If you use a desiccant vent filter you should establish a regular maintenance schedule You should change your vent filter when it is 75 spent pink color Replacement filters are available at a nominal cost from the factory Do not remove the old vent filter until a new one is available Remember that Pressure Systems improved 810 SuperDry Vent Filter are designed to be effective for at least one year before requiring replacement www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual 2 Clogged Nose Piece or Dirty Diaphragm Either of these conditions could result in erroneous readings from your transducer WARNING NEVER attempt to clean your transducer s nose piece or diaphragm with any object This will dent the sensor diaphragm and cause permanent damage to the transducer Your transducer may
25. his option will increase total loop resistance by 88 Ohms Troubleshooting Techniques 1 Symptom Transducer fails to give output of any kind Procedure Isolate the problem to either the transducer or the power supply readout See the Quick Check Procedures above for this check If it can be determined that the transducer is no longer operable remove it from service for further analysis If the transducer output falls within the limits described above the fault lies somewhere else in your system 2 Symptom Transducer has failed and has been removed for analysis Procedure Inspect the cable for physical damage Cuts in the cable jacket can result in liquid incursion into the transducer housing which can cause permanent damage If operational the cable can be repaired by using a splice kit P N 830 supplied by Pressure Systems Page 29 www PressureSystems com Pressure Systems Inc 3 Page 30 Symptom Procedure KPSI Level and Pressure Transducers User s Manual Inspect the transducer housing It should be intact and free of corrosion If the outer surface of the transducer is pitted this could be an indication of galvanic corrosion caused by stray ground currents If this is the case the transducer will probably require replacement If the external case exhibits none of these characteristics carefully unscrew the nosepiece and look into the pressure sensing end of the transducer The concent
26. his option will increase total loop resistance by 88 Ohms Yo Male NPT Conduit Fitting Submersible level transducers can be attached to a rigid conduit and the cable run through the conduit To achieve this all of our submersible transducers can be fitted with an optional Yo NPT male conduit fitting Specify Electrical Connection Option 4 when ordering where the cable exits the transducer This fitting can be mated to a standard rigid conduit Electrical Outputs We offer the industry standard 0 5 VDC and 4 20 mA outputs In addition we also offer a variety of voltage output ranges Page 7 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual Reverse Signal Output For some applications it is important to know how far the water is from the top of the tank or the surface of the ground If specified by the customer our factory can set the transducer so that zero pressure reads full scale electrical output and maximum pressure reads zero electrical output Temperature Output A temperature output option is available for most transducers having 4 20 mA pressure output The temperature sensor requires an excitation of 9 28 VDC and is calibrated for a temperature range of 20 to 60 C with an accuracy of 4 C Cable Hanger We can supply an optional cable hanger P N 12 90 0931 to help end users secure the cable The cable hanger can be positioned anywhere on the cable by
27. le and transducer in a vertical position with vent tube down overnight to allow water to drain from the transducer and vent tube 4 Symptom Transducer suddenly fails during or just after a nearby lightning event Procedure This failure is usually caused by overvoltage due to ground transients resulting from a direct or indirect lightning event These transients can travel distances of a mile or more The transducer may be returned to the factory for repair and optional retrofit of our lightning protection system This system carries a lifetime warranty against transducer damage due to lightning 5 Symptom Transducer response to pressure level input changes becomes sluggish Procedure This is usually a sign that the sensing end of the transducer has become fouled with residue The transducer must be removed from service and the sensing diaphragm cleaned as described in Item 2 warm soapy water If fouling persists the transducer may be replaced with a Series 705 or Series 750 non fouling transducer which is specifically designed for trouble free operation in a high residue environment Page 31 www PressureSystems com Pressure Systems Inc 6 Symptom Procedure 7 Symptom Procedure Page 32 KPSI Level and Pressure Transducers User s Manual Output reading is within limits but freezes at one point In certain environments crust may form over the sensing diaphragm preventing the sensor
28. lvanic corrosion is known to be a serious problem Page 6 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual Lightning Protection Lightning and surge protection for VDC SDI 12 and 4 20 mA output are available This is achieved through the use of 2 protectors one is integral to the transducer housing and one is provided for the outside line located at the surface and grounded to a DIN Rail Please remember this option must be factory installed at the time of order entry or as a factory upgrade This option cannot be installed in the field Lightning protection is also available for unit only Contact customer service for details Featuring quick response and low clamping voltages these devices protect against fast rising voltage transients as well as severe current surges associated with lightning discharges up to 20 000 amperes Following a surge the protector automatically restores the line to normal operation and awaits the next surge without having to reset a breaker or replace a fuse The power supply needs to be limited to 150 mA to avoid lock up of the gas tube after a suppression event Transducers installed with this option have a lifetime warranty against damage due to voltage surge Please note When using the lightning protection option on 4 20 mA products users should take into account the additional series resistance of this option when selecting the loop power supply T
29. mination ANEROID OR VENT FILTER ub f TO TRANSDUGER Page 21 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual M Appendix B Frequently Asked Questions 1 Question What installation ideas do you have to help me get rid of electrical noise interfering with the signal Answer An ounce of prevention goes a long way Either try to eliminate the source of noise or move the transducer as far away from it as possible We strongly encourage you to secure our cable shield to a good earth ground and that you use a 4 20 mA signal output Armed with these precautions and the fact that many of our transducers are CE approved for electromagnetic interference you should have few problems 2 Question The cable on the submersible transducer always seems to get cut and damaged What am I doing wrong Answer This is the most common problem that our users encounter Make sure that all of your colleagues and staff understand the importance of handling the cable with care The cable should not be bent around rough or sharp edges Always use a cable reel during transport Where possible suspend the unit in a perforated 2 50 mm PVC pipe and thread the cable through protective conduit to the nearest junction box 3 Question have an application where the transducer is frequently damaged by voltage spikes What can be done to prevent this Answer At a minimum mak
30. nsducers It offers a good combination of corrosion resistance and reasonable cost As an option we do offer titanium for more aggressive environments www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual 13 Question What wire gauge should limit myself to when connecting to your 22 AWG wire Answer Use 22 AWG or heavier 14 Question Does it make any difference if mount the transducer in a vertical or horizontal position Answer Yes Our units will experience a certain amount of position sensitivity You should mount it in a vertical position throughout the measurement cycle If you lay the transducer down the user must realize than an offset will occur 15 Question What happens when you freeze your transducer in a column of water Answer We have frozen our transducers in a container of water in a home freezer with no resulting damage However depending on the level range of the unit over pressure of the unit is possible In harsh environments where debris is common and ice shifts you might expect damage to both the transducer and cable 16 Question Why would I choose a KPSI Transducer versus a competitor Answer Reliable long lasting products Rapid delivery Lightning protection lifetime warranty Excellent pre amp post sales application support No hassle service Page 25 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure
31. ntacting the factory or local representative Applicable Products This manual provides information applicable to the use of the following KPSI Level and Pressure Transducers Level Transducers Submersible Series 700 710 720 730 735 Series 320 330 335 340 Please note Series 500 and Series 300DS Series 550 waterMONITOR have Series 705 separate manuals Series 750 Pressure Transducers Non submersible Series 27 28 30 This User s Manual is a copyright product of Pressure Systems Inc 2009 Permission is hereby granted to make copies and distribute verbatim copies of this manual provided the copyright notice and this permission notice are preserved on all copies Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual Table of Contents 1 0 Product Description ue eege SEENEN 2 General Characteristics eege EE 2 G re and Harding EE 2 Se EE EE AA 2 Allee AIS RE EEE ads 3 2 0 Product Accessories and Options ss rurerervnnnnnnnnnvevennnnn 3 Klee 3 810 SuperDry Vent Filter or 815 Aneroid Bellows 4 SACKIUIGIAl AMO E 4 Absolute Sealed Gage Transducer 5 Polyurethane amp ETFE Jacketed Cable annnnannnnannnnnanannni 5 te a 119 ale PrOle COM EE 7 Yo Male NPT Conduit Fitting cece ccccccesesseeeeeeeeeeeeeeeees 7 Electrical QUID UNS e a a oes 7 Reverse Signal Output siirryn eene a ae 8 Temperature Quo ul EE 8 Gable Hanger EE 8 Submersible Cable Splicing
32. o be buried in saturated soil without damage to the sensor diaphragm The 1 4 male NPT pressure nose cap is not only useful for calibration purposes but also allows the device to be used as a submersible or above ground pressure transducer WARNING Caution must be exercised when inserting a screw into the nose cap as the maximum insertion length should not exceed 0 175 Page 3 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual 810 SuperDry Vent Filter or 815 Aneroid Bellows All submersible transducers with vented gauge format are supplied with a protective barrier that guards against moisture buildup in the cable vent tube The 810 SuperDry vent filter is installed free of charge and is guaranteed to operate maintenance free for one year We also offer the 815 Aneroid Bellows as a maintenance free option that can be used on submersibles with accuracies of 1 0 5 or 0 25 FSO These barriers ensure reliable operation and long life as they protect sensitive electronic components from mildew and prevent the formation of a liquid column in the vent tube Any such liquid column directly affects calibration of the transducer Sacrificial Anodes Our sacrificial anodes are made from a special zinc alloy formulated to guarantee continued effectiveness over long periods Because the anodes are 95 galvanic they will not corrode unless there is an electrolytic demand The
33. odate all materials required in addition to the transducer and cable Fill one of the bowls with fresh water one with a mild detergent mixed with water and the last with 16 ounces 0 45 kg of The Works Cleaning Step 1 Step 2 Step 3 Step 4 Page 14 Holding the cable 6 inches 150 mm from the transducer immerse the unit in the bowl containing the mild detergent and stir for 20 30 seconds Remove and rinse in the bowl containing the fresh water using the same stirring motion used in the mild detergent Rinse and wipe dry Holding the body of the transducer with one hand so that you are looking at the retaining screen protecting the sensor carefully remove the sensor nose piece by simply unscrewing it from the transducer body Do not touch the sensor diaphragm with your finger or any other object Also do not try to dry the inside portion of the transducer as you risk damaging the pressure sensor Place the transducer in a vertical position with the sensing end facing downward in the bowl containing The Works solution for approximately 15 20 seconds Rinse in the bowl containing clean water and wipe dry the external casing only Place the protective screen in the same solution for 15 20 seconds rinse and wipe dry Holding the transducer in a vertical position so that you can see the face of the sensor screw the protective nose piece back into place www PressureSystems com Pressure Systems
34. or attempts to remove protective screens will damage the sensor voiding the warranty Calibration All transducers are shipped with calibration information unique to each transducer Make sure you keep each calibration report However should you misplace your calibration sheet you can contact the factory and request a duplicate All Page 2 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual KPSI Transducer calibrations are traceable to the National Institute of Standards and Technology NIST Approvals Most of our products have UL CUL and FM certification for intrinsic safety Their respective installation control drawings can be downloaded from our website Several of our product lines also carry ABS approval Most products are CE compliant to EN61000 6 4 2001 and EN 61000 6 2 2001 CE compliant units are labeled accordingly 2 0 Product Accessories and Options Nose Caps There are several different user installable nose caps for the 700 710 720 730 735 submersible level transducers The ported nose cap Delrin with 8 32UNC 2B threaded hole is best used where weights are required and for those installations where users may encounter sharp protruding objects The open face nose cap which allows maximum contact with the liquid media is ideal for wastewater and greasy applications where clogging of the sensor is a concern The piezometer nose cap allows the unit t
35. ost users either suspend our submersible transducers in stilling wells or attach them to rigid conduit This is done to prevent damage to the transducer from shock caused by water turbulence It is not advisable to tie your transducer to a pump or to piping as any problem with the transducer could require that the pump be pulled from the installation This could prove to be very expensive Please refer to the Cable Anchoring Schemes drawing in Appendix A Some applications use our optional bracket P N 49 06 00PC to clamp the transducer to a fixed object i e wall ladder step or require the unit to be suspended without any protective still well or attachment device In all installations care should be taken to ensure no damage occurs to the cable 2 Transducer Submersion Damage to submersible cable is one of the most frequent causes of transducer failure Lower your transducer into the liquid slowly making sure the cable does not drag over sharp edges and only to the depth necessary Avoid dropping the unit from the surface This does not apply to Series 27 28 and 30 transducers 3 SuperDry Vent Filter Desiccant or Aneroid Bellows Installation For submersible transducers vented gage pressure format only Always install a desiccant vent filter or aneroid bellows immediately Page 9 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Page 10 Transducers User s Manual after transducer in
36. pushing the ends together Once positioned the cable hanger expands and provides a snug grip on the cable When mounting the transducer in a well casing the cable hanger can be secured to a hook on the well plate or an eye bolt may be attached to the side of the well casing The cable hanger loop is then secured to the eye bolt by using any number of types of fasteners A similar technique can be used when working in stilling wells for surface water level measurement In this case the loop end of the cable hanger can be attached directly to a screw or bolt bored into the still well shelf Submersible Cable Splicing Kit Our field installable cable splice kit P N 830 allows you to splice polyurethane and ETFE submersible cable It is most commonly used for well applications where the more expensive ETFE cable is required for Suspension in corrosive media where the liquid level is fairly shallow but the well is hundreds of feet in depth It is also used in emergency situations where Page 8 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual cable must be spliced together to get an application up and running 3 0 Installation amp Maintenance Tips General Installation Procedures The following is important installation and preventive maintenance information Our Customer Service or Applications Engineering Support staff can provide additional instruction 1 Transducer Anchors M
37. rate correctly When the transducer is operating correctly it will output a current which when driven through a resistor will generate some amount of voltage drop If the resistor value is 250 Ohms then the voltage measured across that resistor will be 0 004 A 250 Ohms 1 000 VDC and 0 020 A 250 Ohms 5 VDC Notice that if the available voltage from the data logger is12 VDC then 12 VDC 5 VDC 7 VDC which is less than the voltage required by the transducer to operate If this scenario were to occur the transducer would actually stop functioning correctly when its output reached 12 mADC 50 of transducer full scale range In this case the appropriate choice for a load resistor value is 125 Ohms 14 Symptom I havea Series 700 4 20mA transducer rated for 7 5 PSIG attached to a pressure source that is outputting 7 5 PSIG With 20VDC being supplied I am getting 19 94 mA I can t find the upper range allowance for the sensor but this seems low to me Does this mA reading fall into the acceptable range for the transducer with the settings I ve specified Page 36 www PressureSystems com Pressure Systems Inc Page 37 Procedure KPSI Level and Pressure Transducers User s Manual When evaluating a transducer it is sometimes convenient to make some broad generalizations in order to rapidly determine the condition of the unit In general transducers that output a 4 20 mADC signal have a 16 mADC span 4 20 1
38. re Transducers User s Manual The above information including the RMA number must be on the customer s shipping documents that accompany the equipment to be repaired Pressure Systems also requests that the outside of the shipping container be labeled with the RMA number to assist in tracking the repairs All equipment should be sent to the following address ATTN KPSI TRANSDUCER REPAIR DEPARTMENT 7 digit RMA number Pressure Systems Inc 34 Research Drive Hampton Virginia 23666 Prior to returning to Pressure Systems the transducer and cable must be cleaned per instructions provided on the cleaning certificate supplied when the transducer was delivered The certificate can also be found on Pressure Systems website www PressureSystems com cleaning html The completed certificate must accompany the transducer when shipped to Pressure Systems If the transducer has been used in media other than potable water PSI customer service must be notified at the same time an RMA number is requested PSI reserves the right to reject any shipment deemed to be unsanitary or environmentally unsafe to handle If these guidelines are not met the package will be sent back unopened and at the customer s expense Please include the attached vent filter or aneroid bellow with each returned vented gage submersible transducer Pressure Systems will return warranty items prepaid via UPS GROUND If the customer desires another method of return shipm
39. ric rings of the sensing diaphragm should be visible If they are not it could be that residue has accumulated on the diaphragm preventing it from responding properly to pressure changes The transducer can be cleaned by gently swishing the transducer back and forth in a bucket of warm soapy water until the residue softens and washes off See Cleaning Your Transducer page 8 Under no circumstances should any object or tool be used to remove residue from the sensing diaphragm or else permanent damage will be done f cleaning the diaphragm does not solve the problem the transducer should be returned to the factory for repair or replacement Transducer develops a negative offset and gets worse over time actual level exceeds specified level This may be a sign that moisture has entered the reference vent tube in the cable and is inside the transducer housing This is usually the result of not maintaining the desiccant vent filter or of operating the transducer without a desiccant filter or aneroid bellows If www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual caught early enough the transducer can be saved by coiling the cable and transducer in a pan and baking it in an oven at 50 C 122 F for a minimum of 2 hours Be careful that the oven temperature does not exceed 50 C 122 F or both the transducer and the cable can be damaged Alternatively suspend both the cab
40. s connected in series for a total of 12 VDC e 2 9 VDC transistor batteries connected in series for a total of 18 VDC Page 27 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual Batteries are suggested to power the transducer during testing to eliminate the possibility that line noise is passing through an improperly filtered grounded or damaged power supply All measurements should be recorded and sent to Pressure Systems along with the transducer to assist in the evaluation process 0 5 VDC Should read 420mA Should read Excitation white to gt 2 5 Mohms Excitation red to gt 2 5 Mohms Shield drain Shield drain Excitation black to gt 2 5 Mohms Excitation black to gt 2 5 Mohms Shield drain Shield drain Output red to Shield gt 2 5 Mohms Shield drain to lt 2 ohms drain Housing Maximum Cable Lengths and Minimum Supply Voltage The maximum length of cable to be used with our submersible transducers is largely dependent upon the type of electrical output of the transducer For a 0 5 VDC output a maximum cable length of 100 feet 80 m is recommended A voltage output is more susceptible to electrical interference than a 4 20 mA signal A 4 20 mA signal can be transmitted much longer distances depending upon such factors as temperature wire size length of the wire power supply and voltage requirements of any devices
41. se to some verified value for current water depth then the unit is functioning In order to determine the quality of measurement additional steps need to be performed Page 38 www PressureSystems com Pressure Systems Inc KPSI Level and Pressure Transducers User s Manual een Appendix D Calibration Calculations Pressure Systems ships a calibration sheet with every KPSI Transducer This sheet lists the actual values that were output by the transducer when it was being manufactured at several different pressures In addition two coefficients are provided that can be used to calculate the actual depth from any given mA output value These coefficients are derived from a Least Squares Best Fit Straight Line BFSL calibration using the data listed on the datasheet Our accuracy specification is referenced to the line described by the BFSL coefficients and so the transducer may not output exactly 4 mADC at zero pressure and 20 mADC at full scale As an example here is an example of data for a typical transducer Calibration Report Tes Date 022808 Tast Tima 130257 Model Mo S207 14604008 670000 0008 100308 Tast Tames ROOM 25 3 Deg Saia Wo 08002040 Prasauen Fangs 0 00 bo 167 DE Exotatien 9 28 VDC Cutout 450 ma CU Sanal No TAOS Target Tast Prosana 0 00 172 SEKR Aiba rari Stabe Ered 00620 Fao Maima Hon repasiabiity 0 0000 FSO Electrical termination RED SUPPLY Sopa BLACK BUFFLY Zore Osai BLUE S
42. stallation Failure to use one or the other could result in premature failure of the transducer which would not be covered by warranty If you use a desiccant filter you should establish a regular maintenance schedule You should change your vent filter when it is 75 spent pink color Replacement filters are available at a nominal cost from the factory Do not remove the old vent filter until a new one is available The most common failure mode of our transducers is moisture and corrosion damage due to lack of use or maintenance of the vent filter This will allow air into the desiccant filter and allows the transducer to properly vent with changes in barometric pressure To install replace either the aneroid bellows or the vent filter simply unplug the old unit from the vent tube and plug the 0 062 x 1 stainless steel connector tube supplied with each filter or bellows into the vent tube Installation and mounting instructions are supplied with each aneroid bellows and vent filter The diagram on page 16 shows typical vent filter and aneroid bellows hookups Cable Protection An inexpensive way to protect the cable from damage is to order the submersible pressure transducer with a 7 conduit attachment Connect an inexpensive flexible 5 8 garden hose to the 1 2 conduit fitting with an equally inexpensive female PVC NPT x 3 4 NHT swivel fitting available at your local hardware store Bending of Cable Our polyurethane and E
Download Pdf Manuals
Related Search