624 User Manual - Electro Tech Systems
Contents
1. 5 5 140mm l 7 125 181mm screw Length 1 75 44 5mm Figure 3 1 2 Control Unit mounting template Sensor The sensor is installed using the 14 20 x 1 25mm stud attached to the top of the housing The sensing element is sensitive to excessive vibration and shock A vibration free location should be used If this is not possible then the sensor should be mounted using shock and vibration absorbing devices or material Figure 3 3 shows the sensor mounting configuration The sensor electronics has internal Gain and Zero Adjust potentiometers that are also shown in Figure 3 3 The two 6 32 screws located on the top of the sensor housing allow access to these adjustments The standard sensor is supplied with a 5 pin locking DIN connector However the sensor can be hard wired directly to the control unit via a 1 2 conduit or compression fittings This configuration should be specified at time of order since a T junction housing is incorporated onto the sensor housing to provide a terminal block interface otherwise the sensor must be returned to ETS for retrofit When wiring the terminal block the following cable color code is used 15 Green 415 Red Gnd amp Shield Black amp Shield Signal White and Reset Yellow The calibrated mounting distance of the standard sensor from the surface being measured is 2 0 inches 51mm For the high sensitivity sensors it is 1 0 inch 25 4mm The surface to2. 115VAC outlet The user may elect to hard wire the system to the power source Both the power cord and the 20 foot 6m sensor cable are hard wired to the unit via plug in screw terminal blocks located conveniently located behind the flip up cover located at the bottom of the control unit The system is fused internally with a 5x20mm 2 amp 250 Volt fuse All power and signal connections are made to the terminal blocks as shown in Figure 3 1 1 The use of plug in terminal blocks enables the user to make all wiring connections outside the confines of the enclosure and then simply plug them in to the respective PC mounted connectors Standard connections are through cable strain relief fittings but the enclosure can be modified to allow for direct installation of 12 12mm conduit ANALOG OUT ANALOG OUT TO REMOVE CONNECTOR SCREW IM TOOL i TB 10 mesoo CH t CH 2 Tae PULL UP GENTLY TBS i5Vm_ WEN GND SIG e RESET go 264 VAC JcH 1 i CH 4 POWER ALARM SENSOR ALARM SENSOR ALARM SENSOR ALARM SENSOR GND NEUT e LINE a TR i Figure 3 1 1 Power and signal connections The control unit should be mounted on a flat surface that is at least 12 inches 300mm square Figure 3 1 2 shows the mounting dimensions required to mount the basic control unit using four 4 8 screws with the internal mounting brackets 6 3 2 ed a ee ee an jga rs a ee ee a Sa Nc ig Mh a pe e NR
3. System is designed to operate with minimum operator control To operate turn on the POWER Allow a few minutes for the system to warm up Depress the GND and ALARM RESET buttons With the process to be monitored shut down the LED bargraph on the control unit should read O no LED s lit The polarity LEDs may read either or The x10 range LED and the ALARM LED s should be off If the alarm function is to be used select the desired alarm level LO or HI by holding the LO HI momentary toggle switch to the left for LO and to the right for HI With the Connector Extractor Screwdriver located in the flip up lid of the connector compartment or any small screwdriver set the desired threshold level by rotating the appropriate alarm threshold potentiometer and observing the desired level on the LED bargraph After setting the threshold level release the toggle When an ALARM threshold is exceeded the large Yellow LO or Red Hl ALARM LED on the respective channel in the control unit will light and remain lit and the respective relay will close and remain closed until it is reset by the operator depressing the RESET button The reset function can be brought outside the control unit by removing the RESET switch wire from the connector on the mother board and connecting a 2 wire cable to an external switch The alarm relay can be used to control whatever signal device or countermeasure that has been installed by the user The black SENSOR RESET mome
4. EVEL NONITORING SYSTEM a o 9 ys d e D K K L L o O V V Oo o L L T TT S S Figure 2 1 1 Standard Model 624 2 CH version For Class Il or lll applications where intrinsically safe apparatus has been approved the Model 624 can be made intrinsically safe The standard system is fitted with 1 8 NPT tapped and plugged holes in the sensor as shown in Figure 2 1 2 for those applications that permit an air purge In certain applications where a threaded Teflon insert is permitted in an explosion proof sensor housing then this type of housing can be provided for custom designed systems Figure 2 1 2 Standard Charged Plate Detector Sensor When high sensitivity in a clean environment is required such as electronic assembly operations the Model 624 is available with an open detector sensor shown in Figure 2 1 3 that increases the basic system sensitivity by a factor of 10 or a modified standard system with closer sensor object spacing that also increases the sensitivity by a factor of 10 Figure 2 1 3 High Sensitivity Open Detector Sensor 2 1 1 Control Unit The control unit is housed in an ABS enclosure with a clear gasketed polycarbonate door that provides sealing up to NEMA 12 13 and a hinged lower compartment that provides easy access to the IN OUT terminal blocks Each channel has a separate plug in terminal block for the sensor and alarm signals and a shared terminal block for the recorder outp
5. STATIC LEVEL MONITORING SYSTEM Model 624 Operating Manual 5 09 electro tech systems INC www electrotechsy stems com 3101 Mt Carmel Avenue Glenside PA 19038 Tel 215 887 2196 e Fax 215 887 0131 1 0 INTRODUCTION Electrostatics is the oldest form of electrical phenomena known but probably the least understood and the most difficult to control Static electricity occurs because a material has a surplus or a deficiency of electrons Static electricity is generated by the separation of materials such as pulverized material passing through chutes or pneumatic conveyers power or conveyer belts in motion motion of all sorts that involve changes in the relative position of contacting surfaces usually of dissimilar substances liquid or solid one of which is usually a poor conductor of electricity In general the lower the electrical conductivity of the material and ambient relative humidity the greater the static charge generation The generation of static charge cannot be prevented absolutely because its intrinsic Origins are present at every interface It is often the ignition source for an ignitable mixture in many unexplained explosions or flash fires The problem is particularly acute in size reduction operations such as milling or pulverizing the movement of particles through conveyers and pipes and the high speed processing of sheet and roll material The resultant materials are often highly
6. be monitored must be in free air If it is against a grounded surface the electrostatic field will be suppressed and no significant measurements will be obtained even though the surface may be charged A clear field of view of at least 6 inches is also reduired to maintain system calibration Grounded objects within this area will also distort the electrostatic field resulting in a lower measured signal If a totally clear field of view is not possible then the system should be recalibrated after installation This requires a high voltage power source of at least 1000 Volts such as the ETS Model 208B battery powered Charging Source a 6 inch square metal plate and an insulated surface Figure 3 4 shows a typical calibration set up for a moving web Turn on the system Allow 5 minutes for warm up Depress the GND button for the channel being calibrated The bargraph should read 0 Apply the high voltage to the isolated metal plate Observe the reading on the LED bargraph display Adjust the sensor surface spacing so that the display indicates the applied voltage If this is not possible then some convenient multiple of the scale Depress the GND button and recheck the measurement Readjust if necessary The user is advised against recalibrating the system using the Gain Adjust in the sensor This adjustment should only be used for the system recalibration per specification Figure 3 3 Standard sensor configuration 8 3 3 3 4 Adj
7. box or boxes if applicable of double wall construction with substantial packing around all sides The RMA number description of the problem along with the contact name and telephone number must be included in formal paperwork and enclosed with the instrument Round trip freight and related charges are the owner s responsibility WARNING WOODEN CRATES MUST NOT BE USED PACKAGING OF DELICATE INSTRUMENTS IN WOODEN CRATES SUBSTANTIALLY INCREASES THE CONTENT S SUSCEPTIBILITY TO SHOCK DAMAGE DO NOT PLACE INSTRUMENTS OR ACCESSORIES INSIDE OTHER INSTRUMENTS OR CHAMBERS ELECTRO TECH SYSTEMS INC WILL NOT ASSUME RESPONSIBILITY FOR ADDITIONAL COST OF REPAIR DUE TO DAMAGE INCURRED DURING SHIPMENT BECAUSE OF POOR PACKAGING 13
8. charged and potentially dangerous or disruptive to the manufacturing process The development of electrical charges may in itself not be a potential explosion hazard There must be a discharge or sudden recombination of separated positive and negative charges In order for static electricity to be a source of ignition four conditions must be fulfilled 1 There must be a source of static electric generation 2 There must be a means of accumulating charge and maintaining a sufficient difference of electrical potential 3 There must be a spark discharge of sufficient energy 4 The spark must occur in an ignitable mixture The ignitable mixture could be from fumes emanating from a solvent used in the process or as in many situations from the dust cloud developed from the material itself Operations where the above conditions can exist are hammer mills storage or transporting facilities such as tanks hoppers grain elevators tankers and barges compounding and calendering of plastics chemical and petrochemical plants and fueling facilities The ability of a spark to produce ignition is governed largely by its energy which will be some fraction of the total stored energy The energy in a static discharge is expressed as E CV2 Joules where C is the capacitance in Farads and V is the potential difference in Volts The magnitude of electrostatic voltage encountered in industry can range anywhere from a few volts to several hundr
9. e Relling 6 e r 8vde Infernal Realale S4Oahros Type 3001 07 139 040 10 Wallugw Relin GA te Wide interagi Ras y 4400 hn Type F001 Um V 150 10 alloge Reling IEN o 18V 5 Mr Spe ar mi ja an ial thal Ra sistanes L tDpbeug ef ol M be st Cerrynt a1 doegi DIN phig 2 Gireuil safely Pas according la FM 3610 es i h shea Be iat Wullag Cr 4 Mozardaus chosillie eh Locotlon Allawad antomo copacilance D iF Claus BIIH Dhuwe 1 amp 7 Allowed axternal induclance S Geht Greups UU only ke J snan Dae pmp kpa Fon e Electro Tech i d Fn aM x PT Ssuggeslad Burrler Selection ofan RYT i T for Slalic Sensor with PN 15V inpul e e TR j Powe st gt fion none Stahl Inc Contact Information 45 Northwestern R Salem NH 03079 PH 603 870 9500 Web www rstahl com Figure 3 6 Intrinsic Barrier Data Sheet 10 4 0 3 5 Explosion Proof Enclosures The Model 624 sensor can be mounted in a rated explosion proof housing However the Teflon isolation core may not meet certain explosion proof housing specifications With this type of installation the sensor cable must be run through rated conduit to the sensor Contact ETS for additional information on a custom designed explosion proof system lt is the responsibility of the user to determine if an explosion proof housing meets all the safety reguirements of the specific application OPERATION The Model 624 Static Level Monitoring
10. e appropriate slot Be sure it is seated properly in its connector Do not force it as this may damage the connector Turn on the power and check for proper operation If everything checks out satisfactorily then again turn off the power and reinstall the front panel If a channel is being added to the system the overlay covering the desired channel s must first be removed Special care must be taken to ensure that all switches and LEDs line up with the holes in the front panel overlay Gently move each board using the toggle switch as a grab point until everything lines up Do not try to force the panel in place This may damage the overlay After the panel is properly installed secure with the 4 40 screws 5 09 12 6 0 WARRANTY Electro Tech Systems Inc warrants its equipment accessories and parts of its manufacture to be and remain free from defects in material and workmanship for a period of one 1 year from date of invoice ETS will at it s discretion either replace or repair without charge F O B Glenside similar eguipment or a similar part to replace any equipment or part of its manufacture which within the above stated time is proved to have been defective at the time it was sold All eguipment claimed defective must be returned properly identified to the Seller or presented to one of its agents for inspection This warranty only applies to equipment operated in accordance with Seller s operating instructions seller s warran
11. ed thousand volts The capacitance of an object depends upon its physical dimensions and its proximity to adjacent objects Generally the Capacitance of pieces of machinery is estimated to range trom 100 to more than 1000 2 0 pf The capacitance of the human body generally ranges between 100 to 300 pf Tests NFPA 77 Static Electricity have shown that saturated hydrocarbon gases and vapors require approximately 0 25 milliJoules of stored energy for spark ignition of optimum mixtures with air In normal industrial environments minimum voltages of approximately several thousand 1 5 5kV would be required Many industrial standards limit the maximum voltage to 500 4000 Volts For dust clouds the minimum ignition energy ranges from approximately 10 to over 100 mJ for many common foodstuffs and resins In normal industrial environments voltages ranging from under 5kV to over 20 kV would be required In practically every situation the capacitance of a system is fixed which means that the ignition energy is a function of the voltage generated The voltage levels are a function of several factors but for a given material the lower the humidity the higher the voltage generated In most industrial operations the voltage levels generated by a material cannot be totally controlled However it is possible to monitor the electrostatic voltage level and when dangerous levels are reached an alarm and or a countermeasure can be activated A
12. el 624 is calibrated for O to 500 Volts autoranging to O to 5000 Volts in 50 and 500 Volt increments respectively at a sensor object spacing of 2 inches Additional modifications can increase the sensitivity to 50 and 500 volts with 5 and 50 Volt resolution at closer sensor to object spacing Each channel has dual alarm thresholds that control both front panel LED indicators and Form C relays The alarm function operates over the entire measurement range as selected by individual 10 turn potentiometers When the measured voltage exceeds the LO threshold a Yellow ALARM LED on the front panel lights and when the HI threshold is exceeded the Red ALARM LED lights The alarms remain activated until the RESET button is depressed The RESET button resets all of the alarm circuits simultaneously The black SENSOR RESET push buttons located on each channel board momentarily grounds the isolated charged plate detector on the respective sensor The Form C relays with NO and NC contacts can be used to activate a remote alarm signal or a countermeasure The relay can switch up to 10 Amps at 30 volts DC or 10 Amps at 115 230 VAC Each channel has two recorder output signals available A O to 1 Volt signal corresponding to the full measurement range of the unit i e O 50 kV and a 4 20ma signal corresponding to 50 to 50 kV These signals can be used to with a strip chart recorder or linked to a computer to signify an alarm event Sensor The senso
13. nother critical area affected by static charge build up is in the manufacture of material using high speed machinery such as fabric nonwoven and plastic webs extruding and calendering processes slitting and rewinding operations paper handling printing etc In many of these processes the build up of static charge can be controlled locally by passive electronic or nuclear ionization However when ionizer performance deteriorates dirt build up on the ionizer points or fails costly machine downtime caused by static electricity can occur Finally many electronic devices are highly susceptible to electrostatic discharge Exposure to an ESD event can damage or destroy electronic equipment Many devices today are sensitive to static discharges less than 200 Volts and new technology devices being sensitive to less than 30 Volts Many automatic handling machines will generate static charges in excess of these levels resulting in decreased product reliability The Model 624 Static Level Monitor is specifically designed to monitor the static charge build up and to activate alarm s or countermeasure s when the level exceeds preset thresholds EQUIPMENT DESCRIPTION 2 1 General The Model 624 shown in Figure 2 1 1 is a multi channel static level monitor that consists of a control unit and remote sensors The system can be configured to meet most user applications The standard Model 624 is designed for use in nonhazardous locations STATIC L
14. ntary pushbutton located at the bottom of each channel display provides a means to ground the isolated 1 25mm diameter detector plate installed on the white Teflon insulator It normally should be pressed just prior to starting the machinery or industrial process NOTE Pressing this button while a static charge is present establishes a new zero point which is at the level just prior to the detector plate being grounded The Model 624 provides both 1 0Volt and 4 20ma signals corresponding to full scale 50kV for the standard system for connection to a recorder data logger or computer with the appropriate interface The voltage signal requires a minimum 10kOhm input resistance 11 5 0 MAINTENANCE CALIBRATION AND REPAIR The Model 624 Static Level Monitoring System requires very little attention if it has been installed properly and protected from excessive contamination dust dirt harmful vapors solvents etc The most vulnerable part of the system is the sensor The chopper stabilized sensing element is susceptible to damage when exposed to excessive shock or vibration A sensor failure is usually indicated by the LED bargraph locked onto a reading continuously flashing with no static field present or not responding to a static field at all If the system does respond to a static field signal but the zero has shifted over time by 1 3 digits the Zero adjust control on the sensor can be readjusted To readjust the zero remo
15. r assembly consists of a chopper stabilized electrostatic sensor mounted in a cast aluminum Le NPT electrical conduit elbow fitting A charged plate detection system is used to isolate the sensor from outside contaminants found in most industrial environments The standard detector is a 1 25 4 mm diameter stainless steel disc mounted in a Teflon housing having a capacitance of 16 pf Other detector 5 3 0 configurations are available to adapt the Model 624 sensor to virtually any application A 20 foot 6m 5 conductor shielded PVC jacketed signal cable is used to connect the sensor to the control unit The cable is connected to the control unit through a screw terminal block and connects to the sensor via a 5 pin locking DIN connector Cable lengths up to 100 feet are available as an option The sensor is mounted using a 1 inch 25mm long 14 20 threaded stud and a vibration proof locking nut Custom mounting configurations are also available INSTALLATION The Model 624 Static Level Monitoring System is a precision measuring instrument The sensor should be installed on a vibration free surface and the control unit away from excessive dusty or damp locations If the system must be installed in a harsh environment contact ETS for custom enclosure configurations and pressurized fittings 3 1 Control Unit The standard Monitor comes equipped with a 6 foot 1 8m power cord for connection to a standard North American grounded
16. rmitted the user need only to install the appropriate 1 8 NPT fitting to the connection provided on the sensor 3 4 2 Facility air at approximately 2 psi is sufficient to Keep dust dirt and harmful vapors from building up in the sensor housing In many applications the use of an inert gas such as dry nitrogen may be required Intrinsically Safe Barrier The standard sensor can be used in Class I ll or lll hazardous locations where intrinsically safe apparatus has been approved and the appropriate intrinsically safe barriers have been installed Intrinsically safe barriers limit the maximum current to the sensor so that a worst case scenario shorted power and signal leads will not produce sufficient energy to support ignition of an optimum mixture of the product and air Intrinsically safe barriers from R Stahl Inc are satisfactory for use Each power signal and ground lead requires its own barrier Installation of intrinsically safe barriers are the responsibility of the user Figure 3 6 shows the installation of the recommended barriers and the applicable safety data Hazordous Location Ponhazardous Location Y eegen a e Pwer Lo it ohin Fawir bw Electro Tech A IE ol E systers Stati Control atic Sensor P Unit m oF 1k ahis a Y N t See er 1 i Egrygnen d i 7 o aao Noles al inlvinale solely Burrlwr Speeliiestions Mier A Stal Ty i0101 19815010 Ne spe Wallag
17. ty with respect to those parts of the equipment that are purchased from other manufacturers shall be subject only to that manufacturer s warranty The Seller s liability hereunder is expressly limited to repairing or replacing any parts of the equipment manufactured by the manufacturer and found to have been defective The Seller shall not be liable for damage resulting or claimed to result from any cause whatsoever This warranty becomes null and void should the equipment or any part thereof be abused or modified by the customer of if used in any application other than that for which it was intended This warranty to replace or repair is the only warranty either expressed or implied or provided by law and is in lieu of all other warranties The Seller denies any other promise guarantee or warranty with respect to the equipment or accessories and in particular as to its or their suitability for the purposes of the buyer or its or their performance either quantitatively or qualitatively or as to the products which it may produce The buyer is expected to expressly waive rights to any warranty other than that stated herein ETS must be notified before any equipment is returned for repair ETS will issue an RMA Return Material Authorization number for return of equipment Equipment should be shipped prepaid and insured in the original packaging If the Original packaging is not available the equipment must be packed in a sufficiently large
18. ust Distance d 6 I a ae d 6 x 6 Metal Plate Insulator ei amp Open Space HVPS Figure 3 5 Calibration Set Up for Moving Web Installation Nonhazardous Location Installation The standard Model 624 Monitoring System is designed for use in nonhazardous locations The sensor is sufficiently sealed to protect the internal components from normal dust and dirt The high sensitivity open view sensor utilizes an exposed sensor and therefore must be used in a clean environment If this system must be used in a moderately dirty environment then an air purge may be used A slight positive pressure will prevent suspended contaminants from entering the sensor housing However this will not protect the sensor from blowing dust The control unit is housed in a sealed polycarbonate enclosure If necessary an air purge fitting can be installed onto the enclosure to provide positive pressure Hazardous Location Installation The Model 624 Sensor can be configured for use in hazardous locations Either air purge intrinsically safe barriers or with certain configurations an explosion proof housing can be used depending upon the governing safety requirements The control unit is normally not installed in the hazardous location but air purge or explosion proof housings can be supplied if required All hazardous location installations are the responsibility of the user 3 4 1 Air Purge In those applications where an air purge is pe
19. ut signals The standard system has separate cable entries for input power alarm and recorder signals and a multiple entry fitting for the sensor connections The control unit contains the system power supply signal processing electronics and alarm relays and ALARM RESET button The switching power supply is designed to operate over the voltage range of 90 to 260VAC 50 60Hz without any wiring changes Power to the Model 624 is controlled by an ON OFF rocker switch located on the front panel The power supply converts the line voltage to 5 15 and 15VDC operating voltages Table 1 lists the voltage and current characteristics of the power and signal lines going to the sensor for applications where intrinsically safe barriers are required 5V is used for the LEDs in the control unit only Table 1 Sm GND 0 0 0 Each channel consists of a separate plug in signal processing board with all controls and displays for the respective channel The associated plug in alarm relays are located on the mother board A 10 segment multi color LED bargraph display is used to indicate the magnitude and single point LEDs are used to indicate the polarity and the x10 range multiplier of the measured electrostatic field The standard Model 624 is calibrated for O to 5 kV autoranging to O to 50kV in 500 Volt and 5000 Volt increments respectively at a sensor object spacing of 2 inches 5 1 cm The high sensitivity version of the Mod
20. ve the 6 32 screw covering the potentiometer Depress the GND button on the control unit Insert a very small flat blade screwdriver 1 8 into the hole and carefully rotate the pot until the bargraph reads zero This occurs when the polarity lights switch between and with equal back and forth adjustment At the completion of this procedure replace the 6 32 screw If the system still fails to operate properly the sensor and or the complete system may have to be returned to ETS for service It is strongly recommended that ETS be contacted at 215 887 2196 if improper system operation is suspected Do not return this or any unit to ETS without first obtaining a Return Material Authorization number RMA Call 215 887 2196 The calibration of the system can be checked by following the procedure outlined in section 3 2 If the installation warrants the system can be sent back to ETS for periodic recalibration The individual channel circuit boards can be easily installed or replaced To gain access to the circuit boards it is first necessary to remove the front panel With the system power OFF remove the 4 40 screws from each corner Using the flat portion of the Connector Extractor tool gently lift off the front panel To install an additional channel board first plug in the two alarm relays and lock them in place Install the sensor connections as described in the initial installation section For new or replacement boards plug it into th
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