Installation and Operating Instructions
Contents
1. Electronic unit malfunction Sensor malfunction Sensor not mounted properly Heavy coating build up on sen sor Defect in cable Electronic unit malfunction Sensor malfunction Adjoining pipe not grounded Adjoining pipe not metallic Correct customer wiring to pipe line fluid sensor No power at either customer supplied starter or pipe line fluid sensor Time delay set for too short or too long a period Electronic unit malfunction Loose wiring Ground strap not connected properly Electronic unit malfunction Voids in the process stream are longer than the time delay period Sensor malfunction 26 One or both light bulbs are burnt C See sec 5 2 and 5 3 See Section 5 4 See Section 5 2 and 5 3 See Section 5 5 Mount sensor in vertical run of pipe See Section 3 5 Consult factory See Section 5 4 See Section 5 2 amp 5 3 See Section 5 5 Ground pipe using ground strap on sensor See Section 3 5 Mount sensor only in non lined metal pipe Check wiring See Sec 3 2 Check power wiring See Sec 3 2 Adjust time delay See Sec 4 4 See Sec 5 2 and 5 3 Check wiring See Sec 3 2 See Sec 3 5 See Sec 5 2 and 5 3 Increase the time delay period See Sec 4 4 See Sec 5 5 Troubleshooting 5 7 Factory Assistance O AMETEK Drexelbrook can answer any questi2. Clearline In Line Fluid Detector Installation and Operating Instructions 3 2 Wiring the Electronic Unit Continued All sensing element cable connections to the electronic chassis are made to the individual terminals on the side opposite the relay terminal strips Be sure to match the colors on the terminals to the colors on the cable See Figure 3 4 BLUE RED Figure 3 4 Cable Connections to Electronic Unit 12 Installation 3 3 Wiring the Remote Sensing Element The cable connections to the sensor have been pre wired at the factory If those connections come loose or the cable is being replaced see Figure 3 5 and use the following procedure for proper wiring l 2 EN Remove the condulet cover Loosen the two screws and remove the cover plate labeled remove for field wiring Wire the green black and blue cable leads to the corresponding color coded screws as shown in Figure 3 5 Slip the cover plate back under the two hold down screws Slip the red SH lug under the red screw and tighten both screws Replace the condulet cover Figure 3 5 Cable Connections to Sensing Element 13 Clearline In Line Fluid Detector Installation and Operating Instructions 3 4 Mounting the Remote Electric Unit The remote electronic unit is designed for wall mounting and it should be mounted in a location that is as free as possible from vibration corrosive atmospheres and any possibility of mecha
3. the pipe is empty The electronic units used for sewage applications 406 7001 modif 91 22 are calibrated differently Because the fluids in waste treatment applications are always conductive these units are calibrated specifically for conductive liquids This increases the unit s ability to ignore conductive fluid coatings on the sensor when the pipe is empty Under special circumstances the factory calibration for the water and Waste treatment applications may prove over an extended period of time to be inadequate Occasionally a permanent coating of different character than the bulk material being pumped will develop on the inside of the sensor and pipe This coating may be either greasy or dry and crusty In any case it is not washed away by the fluid flow and tends to build up over time When this permanent coating reaches a critical thickness it will interfere with the unit s ability to ignore a wet coating of the bulk material when the pipe is actually empty This can result ina false full indication when the pipe is empty which could possibly cause pump damage The critical thickness is difficult to specify because it is dependent on the highly variable electrical properties of both the bulk material and the permanent coating If the previously described coating is typical in your application a periodic empty pipe simulation is recommended to ensure the unit is operating properly There are available indication two correct
4. IS CONDITIONED UPON THESE TERMS AND CONDITIONS AND SELLER OBJECTS TO ANY ADDITIONAL OR DIFFERENT TERMS PROPOSED BY BUYER IN ANY DOCUMENT WHICH SHALL NOT BE BINDING UPON SELLER No salesman or other party is authorized to bind the AMETEK DREXELBROOK Division of AMETEK Inc hereinafter Seller by any agreement warranty statement promise or understanding not herein expressed and no modifications shall be binding on Seller unless the same are in writing and signed by an executive officer of Seller or his or her duly authorized representative Verbal orders shall not be executed until written notification has been received and acknowledged by Seller QUOTATIONS Written quotations are valid for thirty 30 days unless otherwise stated Verbal quotations expire the same day they are made PRICES All prices and terms are subject to change without notice Buyer requested changes to its order Orders including those affecting the identity scope and delivery of the goods or services must be documented in writing and are subject to Seller s prior approval and adjustments in price schedule and other affected terms and conditions Orders requiring certified test data in excess of commercial requirements are subject to a special charge ORDER ACCEPTANCE All Orders are subject to final approval and acceptance by Seller at its office located at 205 Keith Valley Road Horsham Pennsylvania 19044 TERMS OF PAYMENT Seller s standard terms
5. Training Group or call direct 215 674 1234 5 10 Return Equipment Any equipment being returned for evaluation or credit must be pre approved by the factory In many applications sensing elements are exposed to hazardous materials OSHA mandates that our employees be informed and protected from hazardous chemicals Material Safety Data Sheets MSDS listing the hazardous materials to which the sensing element has been exposed MUST accompany any repair It is your responsibility to fully disclose all chemicals and decontaminate the sensing element To obtain a return authorization RA contact the Service department at 1 800 527 6297 US and Canada or 215 674 1234 International Please provide the following information Model Number of Return Equipment Serial Number Process Materials to which equipment has been exposed MSDS sheets for any hazardous materials Billing Address Shipping Address Purchase Order No For Replacement evaluation Please include a purchase order even ifthe returned unit is under warranty If repair is covered under warranty you will not be charged Ship equipment freight prepaid to AMETEK Drexelbrook 205 Keith Valley Road Horsham PA 19044 1499 COD shipments will not be accepted 28 Form 440 0001 001 3 1 2006 TERMS AND CONDITIONS OF SALE GENERAL ALL ORDERS ARE SUBJECT TO THE FOLLOWING TERMS AND CONDITIONS ANY ACCEPTANCE OF ANY OFFER OF BUYER FOR ANY GOODS OR SERVICES
6. of payment for Buyers who qualify for credit are net thirty 30 days from date of invoice All invoices must be paid in United States dollars CREDIT Seller reserves the right at any time to revoke any credit extended to Buyer or otherwise modify terms of payment if Buyer fails to pay for any shipments when due or if in Seller s opinion there is a material adverse change in Buyer s financial condition Seller may at its option cancel any accepted Order if Buyer fails to pay any invoices when due DELIVERY Shipments are F O B place of manufacture Shipping Point and the Buyer shall pay all freight transportation shipping duties fees handling insurance storage demurrage or similar charges from Shipping Point Delivery of goods to common carrier shall constitute delivery and passing of title to the Buyer and all risk of loss or damage in transit shall be borne by Buyer Any claims or losses for damage or destruction after such delivery shall be the responsibility of Buyer Seller reserves the right to make delivery in installments which shall be separately invoiced and paid for when due without regard to subsequent deliveries Delay in delivery of any installment shall not relieve Buyer of its obligation to accept remaining deliveries Acknowledged shipping dates are approximate only and based on prompt receipt of all necessary information from Buyer and Buyer s compliance with terms of payment TAXES All sales excise and simi
7. system is still not operating properly please call the factory Service Department 1 Disconnect the measuring cable from the sensor terminals See Figure 5 6 2 Use an ohmmeter to measure the resistance between the sensor terminals See the chart below SENSOR CONDULET Le ia Terminals Resistance Red SH to black SH Near zero short cir ne nd Cuit Blue CW to red SH Infinite open cir ee CUTE Blue CW to black SH Infinite open cir Cuit Blue CW to green gnd Infinite open cir Lu _ cuit Green gnd to either near zero i mounting flange short ANALOG OHMMETER ZE aad i a Red SH to both outer near zero Fig 5 6 rings on the sensor short Checking the Sensor circuit Figure 5 6 Checking the Sensing Element 25 Clearline In Line Fluid Detector Installation and Operating Instructions 5 6 Possible Problems and Solutions Possible Causes Solution 1 Both red and green lights on the A No voltage between Hot and A Check wiring See Sec 3 2 optional Nema 4 housing are out Neutral terminals B Replace defective bulbs on cover door LED on chassis or Green cover light is on even when pipe is known to be empty LED on chassis is out or Red cover light is on even when pipe is known to be full Motor Starter does not respond as intended Instrument operates intermit tently out Electronic unit malfunction Defect in cable
8. the process fluid to drain whenever the flow is interrupted See Figure 3 7 Non metallic or lined pipe will adversely affect the perfor mance of the unit Consult factory 2 Mount the sensor between two 150 or 300 raised or flat faced flanges only For use with other flange types consult factory Use full face gaskets compatible with the process fluid 4 Install the ground strap under the flange bolt nearest the sensor condulet to insure proper electrical contact See Figure 3 7 5 Tighten the flange bolts evenly to insure a proper seal Check to make sure there is slack in the ground strap and repositions the ground washer if necessary A All bolts should be put in place and hand tightened evenly B All bolts should be tightened in 10ft Ib increments using a star pattern C Torque all bolts to 50ft lb max Ww It is important that the sensor be torqued gradually and evenly to prevent cracking Caution Nominal sensor size must be the same or smaller than the diameter of the mating pipe run This should allow the sensor to be full during normal pump operation Figure 3 7 Mounting the Sensor 15 Section 4 Operation Operation Section 4 Operation 4 1 Start Up Before applying power to the instrument be sure that the wiring connections are correct 4 2 Controls The Clearline in line fluid detector is factory cal brated for proper operation No cal bration adjustments are normally needed For specific ap
9. the time delay period the system should switch and indicate an empty pipe To reduce pump wear during the test the relay control can be reset to its shortest period approximately 5 seconds To do this simply turn the adjustment to its full counterclockwise CCW position Do not forget to reset the time delay after the empty pipe test DREXELBROOK SETPOINT TIME ADJUST DELAY NE O ALARM WHEN OUT MIN CBS Figure 7 1 Setpoint Adjustment for Modif 91 22 19 Section 5 Troubleshooting Troubleshooting Section 5 Troubleshooting 5 1 Introduction The Clearline In Line Fluid Detector is designed to give years of unattended service No periodic or scheduled maintenance is required There are no specific spare parts that we recommend be stocked by the user However if the application is critical 1t 1s best to have a spare electronic unit chassis available in the event of a component failure If difficulty should occur when operating your in line fluid detector divide the system into its component parts and test each part individually for proper operation The following troubleshooting procedures should be used in checking out your system If attempts to solve the difficulty fail notify our local representative or call the factory directly and ask for the service department 5 2 Checking the Electronic Unit Before checking the components separately check all wiring connections to both the e
10. 1A and 3 1B Clearline In Line Fluid Detector Installation and Operating Instructions 3 2 Wiring the Electronic Unit Continued 406 7000 SERIES ELECTRONIC UNIT GRN LT RED LT 406 7001 001 BB CHASIS MODEL NO ano na i CONDUIT ame 3 4 NPT T TO SENSOR CUSTOMER POWER IN 115V 50 60Hz 50 6HZ CLOSED CLOSED Figure 3 1B EMPTY FULL Customer connections to NEMA 4 unit MADE IN U S A Figure 3 1A Customer connections to standard unit ONLY FOR SUCTION LIFT GND APPLICATIONS ON CHASSIS 6 7 8 9 F START OH O Figure 3 2A Wiring for customer supplied pump starter Standard unit STOP BUTTON T Le BUTTON STARTER 10 Installation 3 2 Wiring the Electronic Unit Continued 120 VAC St of 0 NEUT HOT ER GND START 21812181218 PANEL A ONLY FOR BE SUCTION LIFT T ooo APPLICATIONS START STOP BUTTON BUTTON a ag dg s a IQ IN Hu STARTER IN LINE FLUID SENSOR 506 7000 i WIRING BY OTHERS Figure 3 2B Wiring for customer supplied pump starter Optional NEMA 4 unit 406 7001 001 CHASIS MODEL NO DREXELBROOK SETPOINT TIME ADJUST DELAY ZN WwW Q ALARM HEN OUT Y CLOSED CLOSED GND EMPTY FULL START 17 KAKARIKI ao DE 50 6HZ CLOSED CLOSED EMPTY FULL MADE IN U S A Figure 3 3 Relay Contact Position for Empty Pipe Fail Safe 11
11. A number must appear on the shipping label and packing slip Buyer shall be responsible for the returned goods until such time as Seller receives the same at its plant and for all charges for packing inspection shipping transportation or insurance associated with returned goods In the event that credit for returned goods is granted it shall be at the lesser of the then current prices or the original purchase price Claims for shortage or incorrect material must be made within five 5 days after receipt of shipment ALL OTHER WARRANTIES FOR ANY OF SELLER S GOODS OR SERVICES WHETHER ORAL WRITTEN EXPRESS IMPLIED STATUTORY OR OTHERWISE INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE ARE EXCLUDED AMETEK DREXELBROOK INTELLECTUAL PROPERTY Seller s sale of goods or provision of related documentation or other materials to Buyer shall not transfer any intellectual property rights to Buyer unless Seller specifically agrees to do so in writing Seller shall retain ownership of all applicable patents trademarks copyrights and other intellectual property rights Buyer shall not use copy or transfer any such items in violation of Seller s intellectual property rights or applicable law or for any purposes other than that for which the items were furnished Seller shall defend any lawsuit brought against the Buyer based on a claim that the design or construction of the goods sold here
12. DREXELBROOK A Leader in Level Measurement Installation and Operating Instructions For the Clearline In Line Fluid Detector Using 406 7000 000 Electronics For Assistance Call 1 800 527 6297 Outside North America 215 674 1234 AMETEK DREXELBROOK AMETEK Drexelbrook makes no warranty of any kind with regard to the material contained in this manual including but not limited to implied warranties or fitness for a particular purpose Drexelbrook shall not be liable for errors contained herein or for incidental or consequential damages in connection with the performance or use of material Copyright AMETEK Drexelbrook EDO 1 15 102 506 7000 000 LM Issue 3 Installation and Operating Instructions For the Clearline In Line Fluid Detector Using 406 7000 000 Electronics For Assistance Call 1 800 527 6297 Outside North America 215 674 1234 205 Keith Valley Road Horsham PA 19044 a ME i ER U S and Canada 1 800 553 9092 24 Hour Service 1 800 527 6297 DREXELBROOK International 1 215 674 1234 i Fax 1 215 674 2731 An ISO 9001 Certified Company E mail drexelbrook info ametek com Website www drexelbrook com Table of Contents o AP EPEEEEEERUEEREEEBESEUREEEEEEREERERRUEEEDEFEUE 1 A IogGUe oliena 1 2 ECO AAA PU o PO PO E E EE EEEE 1 3 system Descriplioli alp 2 Fd 3 5 Models Avallables oct 4 Section 2 Specifications ia 7 Electronics Specifications ri 7 Sensor S
13. S SS See Figure 1 3 Dimensional Drawing Section 2 Specifications Specifications Section 2 Specifications 2 1 Electronics Specifications Power requirement 120 25 Vac 50 60 Hz 1 watt 240 50 Vac 50 60 Hz 1 watt optional 12 30 Vdc 1 watt optional Ambient temperature 40 F to 140 F 40 C to 60 C Level Output DPDT relay Contact Rating 120 Vac 5A non inductive 3 A inductive 230 Vac 5A non inductive 2 A inductive 24 Vdc 5A non inductive Min Rating 100mA 12VDC Time Delay Adjustable 0 120 sec for pump start stop Fail safe Empty pipe fail safe factory set relay will de energize indicating empty pipe upon loss of power RFI Protection built in The operating point for unit in housing is unaffected by 5W field 27 MHz 150 MHz or 450 MHz at a distance of 5 ft from exposed sensor cable or power line 2 2 Sensor Specifications Process Temperature and Pressure 250 F 100 PSI 121 C 7 bar Material Compatibility Process wetted parts 316L SS amp TFE Mounting VERTICAL ONLY Sensor must be mounted in a vertical run of pipe or sloping pipe run to provide material drainage Section 3 Installation Installation Section 3 Installation 3 1 Unpacking Carefully remove the contents of the shipping carton and check each item against the packing list before destroying any packing material If there 1s any shortage or damage report it immediately to the f
14. actory 3 2 Wiring the Electronic Unit All power and relay connections are made to the terminal strips inside the electronic unit housing Due to the low power consumption of the instrument 1 Watt wiring need only follow local electrical codes The power connections on units within the standard housing are made to terminals 1 and 2 and the green GND terminal on the electronic chassis See Figure 3 1A Power requirements are determined by the transmitter model type 406 7000 requires 120Vac 406 7100 requires 12 30Vdc and 406 7300 requires 240Vac The power connections on the optional Nema 4 unit are made to the terminal strip to the left of the electronic unit chassis It has terminals for ground gnd neutral neut hot and start See Figure 3 1B For wiring to customer supplied motor starter see Figures 3 2A and 3 2B The relay connections for both housing types are made to the terminal strips on the front of the electronic unit chassis The relay has double pole double throw contacts DPDT See Figure 3 3 On the unit within the standard housing both sets of contacts are available to the customer See Figure 3 1 A The relay is a dry contact closure and cannot provide sufficient current to activate motors or heavy equipment See specifications On the optional Nema 4 unit relay terminals 3 4 and 5 are pre wired to the alarm lights by the factory For customer relay connections terminals 7 8 and 9 see Figures 3
15. ct the performance of the unit MIT Figure 1 2 Three Terminal Ring Sensor 1 4 Housing The 406 7000 Series electronics come standard in a housing without lights An optional Nema 4 housing with red green indicator lights available Clearline In Line Fluid Detector Installation and Operating Instructions 1 5 Models Available System Electronics and Sensing Element Model Technology CL Clear Line In Line Fluid Detector Voltage 0 115 VAC 1 12 30 VDC 3 230 VAC Integral Remote 0 Integral 1 Remote Housing 1 Powder coated aluminum 2 6x6 NEMA 4 with Lights Sensor Style 0 Wafer Style Sensor Size 2 O A 2 inch schedule 40 pipe size 3 inch schedule 40 pipe size 4 inch schedule 40 pipe size 6 inch schedule 40 pipe size Material B 316 316L SS Mounting 00 None Cable Length 0 None Integral 5 5 feet 10 10 feet 15 15 feet 20 20 feet Options 00 None 01 Sludge mod 406 9100 022 y Introduction 1 5 Models Available Continued Sensing Element Dimensions and Process Connection ee Model ANSI rali Size Temperature Limits Remote Parts a BE i e i a e scosso sw se 230 rms Rem mersiossi rose e om om 20m Hmaasor Rem nersiossi rosa so ss 2 Hmaasor mega nersiossi rose sw se 230 rms mega mersmeser rose e om se ese rss mega mersiossi HE Reference figure XX XX I UL S
16. ed sensor mounts in a vertical pipe run between two standard 150 flat faced or raised pipe flanges The electronic unit includes the measuring circuit customer connection terminals and time delay The sensor and remote electronic unit are connected by four terminal cable See Figure 1 1 The 406 7000 Series electronic unit is a precision radio frequency RF relay output instrument It provides double pole double throw relay contact closure when the process fluid has been absent in the pipe for a preset period of time This In Line Fluid Detector features Cote ShieldTM electronics which enable the instrument to ignore the effects of material coatings or build up on the sensor The ring sensor is mounted in a vertical pipe run at a point where the presence absence detection is desired It consists of three sections a center measuring electrode a ground electrode and a Cote Shield electrode When a coating or build up occurs on the sensing element the Cote Shield electrode inhibits the flow of current from the center electrode to ground The only path to ground available for the current is through the material being measured This prevents a full pipe indication when only a coating is present Figure 1 1 Typical sensing element with condulet 700 4200 Series Introduction 1 3 System Description Continued Note Sensor must be mounted in a grounded metal section of pipe Non metallic or lined metal pipe can adversely affe
17. ervices this agreement or act to bind Seller unless specifically agreed to by Seller in writing NON WAIVER BY SELLER Waiver by Seller of a breach of any of these terms and conditions shall not be construed as a waiver of any other breach SEVERABILITY AND ENTIRE AGREEMENT If any provision of these terms and conditions is unenforceable the remaining terms shall nonetheless continue in full force and effect This writing together with any other terms and conditions Seller specifically agrees to in writing constitutes the entire terms and conditions of sale between Buyer and Seller and supercedes any and all prior discussions and negotiations on its subject matter AMETEK DREXELBROOK An ISO 9001 Certified Company 205 Keith Valley Road Horsham PA 19044 U S and Canada 1 800 553 9092 24 Hour Service 1 800 527 6297 International 1 215 674 1234 Fax 1 215 674 2731 E mail drexelbrook info ametek com Website www drexelbrook com
18. gineering and custom application whether provided on a fixed cost or time and material basis shall be performed in accordance with generally accepted industry practices D Remedies Seller s liability under this section is restricted to replacing repairing or issuing credit at Seller s option for any returned goods and only under the following conditions 1 Seller must be promptly notified in writing as soon as possible after the defects have been noted by the Buyer but not later than 1 year from date of invoice from Seller 2 The defective goods are to be returned to the place of manufacture shipping charges prepaid by the Buyer 3 Seller s inspection shall disclose to its satisfaction that the goods were defective in materials or workmanship at the time of shipment 4 Any warranty service consisting of time travel and expenses related to such services performed other than at Seller s factory shall be at Buyer s expense E Repaired Reconditioned Goods As to out of warranty goods which Seller has repaired or reconditioned Seller warrants for a period of sixty 60 days from date of its invoice only new components replaced in the most recent repair reconditioning F Returns and Adjustments No goods may be returned unless authorized in advance by Seller and then only upon such conditions to which Seller may agree Buyer must obtain an RMA Return Material Authorization number from Seller prior to any return shipment and such RM
19. goods or services whereupon Buyer shall promptly pay Seller its reasonable termination charges upon submission of Seller s invoices thereof LIMITATION OF LIABILITY Seller s liability for any claim of any kind except infringement of intellectual property rights shall not exceed the purchase price of any goods or services which give rise to the claim SELLER SHALL IN NO EVENT BE LIABLE FOR BUYER S MANUFACTURING COSTS LOST PROFITS LOSS OF USE OF THE GOODS OR SERVICES COST OF CAPITAL COST OF SUBSTITUTE GOODS FACILITIES SERVICES OR REPLACEMENT POWER DOWNTIME COSTS CLAIMS OF BUYER S CUSTOMERS FOR DAMAGES OR OTHER SPECIAL PROXIMATE INCIDENTAL INDIRECT EXEMPLARY OR CONSEQUENTIAL DAMAGES Any action against Seller must be brought within eighteen 18 months after the cause of action accrues These disclaimers and limitations of liability shall apply regardless of the form of action whether in contract tort or otherwise and further shall extend to the benefit of Sellers vendors appointed distributors and other authorized resellers as third party beneficiaries PROHIBITION FOR HAZARDOUS USE Goods sold hereunder generally are not intended for application in and shall not be used by Buyer in the construction or operation of a nuclear installation or in connection with the use or handling of nuclear material or for any hazardous activity or critical application where failure of a single component could cause substantial harm to persons or p
20. ive steps when a false full occurs 1 Periodic cleaning of the sensor will help to increase the reliability of the sensor signal When the sensor is clean it will function properly as cali brated 2 It may be necessary to recalibrate the unit 18 Operation 4 6 Recalibration Procedure for Modif 91 22 1 Remove the preset label on the top of the electronic unit for access to the setpoint adjustment assembly this is the hex nut visible inside the chassis after the label has been removed See Figure 7 1 Using the tuning wrench supplied blue plastic tube with a pointer back out the setpoint adjustment nut until it is fully counterclockwise CCW See Figure 7 2 When the sensor is known to be flooded and power is applied to the sys tem slowly advance the setpoint adjustment clockwise CW until the LED on the unit is out or the indicating lights on the Nema 4 housing door trip from green to red Please count and record the number of turns re quired in this step with the use of the pointer on the Blue tuning wrench Back off the setpoint adjustment 1 full turn counterclockwise CCW Remove the tuning wrench and secure it somewhere in the housing The ClearLine In Line Fluid Detector should have its LED or green indicating LED Illuminated corresponding to the flooded full pipe condition Recalibration is complete Note To verify proper system operation the pipe should then be emptied After the passage of
21. lar taxes which Seller may be required to pay or collect with respect to the goods and or services covered by any Order shall be for the account of the Buyer except as otherwise provided by law or unless specifically stated otherwise by Seller in writing TERMINATION AND HOLD ORDERS No Order may be terminated by Buyer except upon written request by Buyer and approval by Seller and if said request is approved by Seller under the following conditions 1 Buyer agrees to accept delivery of all of the units completed by Seller through the workday on which Seller receives the written termination request 2 Buyer agrees to pay to Seller all direct costs and expenses applicable to the portion of the Order that is incomplete WARRANTY A Hardware Seller warrants its goods against defects in materials and workmanship under normal use and service for one 1 year from the date of invoice B Software and Firmware Unless otherwise specified Seller warrants for a period of one 1 year from date of invoice that standard software or firmware when used with Seller specified hardware shall perform in accordance with Seller s published specifications Seller makes no representation or warranty expressed or implied that the operation of the software or firmware shall be uninterrupted or error free or that functions contained therein shall meet or satisfy the Buyer s intended use or requirements C Services Seller warrants that services including en
22. lectronic unit and sensing element Be sure to match the cable wire sleeve colors to the terminal screw colors on the electronic unit 1 Disconnect the sensor cable from the electronic unit Leave the power connected See Figure 5 1 2 Puta capacitor any value from 10 pF to 12 pF across the blue center CW connection and the green ground gnd FAIR FIRE CW SH CW Cw SH CW Figure 5 1 Testing the Electronic Unit 21 Clearline In Line Fluid Detector Installation and Operating Instructions 5 2 Checking the Electronic Unit Continued 3 With the capacitor attached the relay will change state the LED on top of the electronic unit will illuminate and the green light on the housing door will also be lit optional Nema 4 housing only 4 Remove the capacitor and after a delay time of 0 120 seconds the relay will switch the LED on the top of the unit will turn off but the red light on the housing door will be illuminated optional Nema 4 housing only 5 To check the integrity of the push to start function Remove Power detach the wire from the start terminal See Figure 5 2 and add a jumper wire from the hot terminal to the start terminal Ap ply Power 6 Again the relay will switch The LED will illuminate and the green light on the housing door will be lit optional Nema 4 housing only After the preset time delay period has passed the relay will switch again the LED will go out and the red LED
23. ll insulating applications increases This is due to the higher dielectric constant k of the material which causes a bridge imbalance The signal is demodulated rectified amplified and the output is increased There are drawbacks however especially when there is coating of the probe An RF Admittance level transmitter is the next generation Although similar to the capacitance concept the ClearLine In Line Fluid Detector employs a radio frequency signal and adds the Cote Shield circuitry within the Electronics Unit This patented Cote Shield circuitry is designed into the ClearLine and enables the instrument to ignore the effect of buildup or material coating on the sensing element The sensing element is mounted in the vessel and provides a change in RF admittance indicating presence or absence of material The Cote Shield element of the sensing element prevents the transmission of RF current through the coating on the sensing element The only path to ground available for the RF current is through the material being measured The result is an accurate measurement regardless of the amount of coating on the probe making it by far the most versatile technology good for very wide range conditions and works with many types of materials Clearline In Line Fluid Detector Installation and Operating Instructions 1 3 System Description The Drexelbrook ClearLine Series control consists of three major components The ring shap
24. may not be detected by the following test The only sure way 1s to inspect the coax and associated conduit for trapped water OHMMETER OHMMETER 1 Disconnect all wires of the coaxial cable at the electronic unit 2 Disconnect all wires at the sensing element end of the coax 3 Using an ohmmeter measure between the black and green lugs of the coaxial cable Note any reading Repeat for the red and blue lugs All readings should show an open circuit infinite resistance CHECK FOR SHORT CIRCUIT BLACK GREEN ________OHMS RED BLUE OHMS CORRECT READING OPEN CIRCUIT p NO CONNECTION Figure 5 5 Checking the Cable for a Short Circuit 4 Check for continuity of each conductor Short out the black and green lugs of the coaxial cable and measure these two conductors at the other end A reading lt 10ohms indicates a good cable Move the short to the red and blue lugs and repeat CHECK FOR CONTINUITY BLACK GREEN OHMS RED BLUE OHMS SHORTED WIRES SHOULD READ lt 10 OHMS PS N SHORT TWO CONDUCTORS Figure 5 6 Checking the Cable for Continuity 24 Troubleshooting 5 5 Checking the Sensing Element A thorough check of the sensor requires factory service equipment However the following test can be done with only an ohmmeter to help determine the cause of a possible malfunction If this test indicates the sensor is not functioning properly or if none of the checkout procedures indicate a problem but the
25. nical damage Ambient temperatures should be between 40 F and 140 F For convenience at start up it is best to install the instrument in a reasonably accessible location 3 5 Mounting the Sensing Element Sensor dimensions depend on sensor model See Figure 3 6 Sensing Element Nominal Pipe Pressure Integral Process Wetted Model ANSI Flange Size Temperature Limits Remote Parts rms esr oa as voomieasor teme rermess rms ss me ts mear meg eras sa so si ew mear mem rermessi rs a em am es mer mem eras onen esr sa as mear mem eras TE Reference figure XX XX Remote Integral wi J A PH An 5 13 16 gt dl E D 2 314 Figure 3 6 Dimensional Drawing 14 Installation 3 5 Mounting the Sensing Element Continued Before mounting the sensing element do a quick operational check to be sure the system is working properly With the power on the lid removed and the cable connected between the sensor and the electronic unit touch the center element of the sensor The green LED on the top of the unit will light Remove your hand from the sensor and after the set delay time has passed the LED will go out 1 Be sure to mount the sensor in a vertical run of grounded metal pipe This will allow
26. on the housing door will be lit optional Nema 4 housing only Note To disengage the time delay mark the original position of the ad justment then turn to the full counterclockwise CCW position Be sure to reset the time delay to its original position after checking the electronic unit GND_COM_ HOT START JUMPER Figure 5 2 Checking the Start circuit 22 Troubleshooting 5 3 Checking the Relay 1 The relay output circuit consists of double pole double throw DPDT relay contacts brought out to a terminal strip When the relay is operating properly the following conditions will apply A The LED on the top of the electronic unit chassis should be lit when relay contacts 4 and 5 and 8 and 9 are closed B The LED should be out and 7 and 8 are closed 2 Relay operation may be heard as an audible click if the background noise 1s not too high Use one of the methods shown in Figure 5 4 to determine if the relay contacts are switching Relay in Energized Condition Relay in De Energized Condition Figure 5 3 Relay Contact Chart Figure 5 4 Checking the Relay Circuits 23 Clearline In Line Fluid Detector Installation and Operating Instructions 5 4 Troubleshooting Coaxial Cable If there is water or other conductive material in the conduit 1 e x Excessive wire lube it can change the electrical properties of the coax cable and cause the system to perform poorly Moisture in the conduit
27. ons about your level measurement system For Technical Support 1 800 527 6297 All other inquiries Call Customer Service at 1 800 553 9092 US and Canada or 215 674 1234 International If you require assistance and attempts to locate the problem have failed For Technical Assistance call toll free 1 800 527 6297 US and Canada or 215 674 1234 International FAX 215 443 5117 E mail drexelbrook service ametek com Please provide the following information Instrument Model and Serial Numbers Sensing Element Model Number and Length Material being measured Temperature Pressure Agitation Brief description of the problem Checkout procedures performed and results 5 8 Field Service Trained field service engineers are available on a time plus expense basis to assist in start ups diagnosing difficult application problems or in plant training of personnel Contact the service department for further details 27 Clearline In Line Fluid Detector Installation and Operating Instructions 5 9 Customer Training Periodically AMETEK Drexelbrook instrument training seminars for customers are held at the factory These sessions are guided by Drexelbrook engineers and specialists and provide detailed information on all aspects of level measurement including theory and practice of instrument operation For more information about these valuable workshops write to AMETEK Drexelbrook attention Communications
28. pecifications sica rro Ener erneer eenen 7 Section Installation A A 9 IAC UNG iaa 9 Wiring the Electronic Unit en lar 9 Wiring the Remote Sensing Element ciano 13 Mounting the Remote Electric Unit tra sie dais 14 Mounting the Sensing Elenca 14 A 17 SC 00 e A 17 COMTO ee 17 do leda 17 24 Hime Delay aaa 17 4 5 Special Applications ini 18 Recalibrationi Procedure for Modif 91 2 19 Section 5 Iroubleshootiigi ciclina 21 di TOUCH ON E ER I E 21 5 2 Checking the Fece 21 5 3 Checking en 23 5 4 Troubleshooting Coaxial Cable piensas 24 5 5 Checking the Sensing Element 25 5 6 Possible Problems and Solutions el 26 5 7 FatloVASSISIAN OE alinea ara 27 90 Assisi 27 59 Customer Tal ici ais asirio rear 28 5 1 FELL EI N ee a ee 28 Section 1 Introduction Introduction Section 1 Introduction 1 1 Introduction The instructions in this manual are for the Drexelbrook ClearLine In Line Fluid Detector is used to detect the presence or absence of material in a pipe It provides relay operation when the normally full pipe is empty for a preset period of time Calibration is performed through a simple potentiometer adjustment 1 2 Technology In a simple capacitance probe type sensing element when the level rises and material covers the probe the capacitance within the circuit between the probe and the media conductive applications or the probe and the vessel wa
29. plications using modification 91 22 See Section 4 5 4 3 Fall Safe Fail safe describes the relay contact position when power to the unit is lost The 406 7000 Series electronic unit is available only with empty pipe Fail Safe This means the relay will de energize with an empty pipe or upon loss of instrument power 4 4 Time Delay The time delay adjustment is located on top of the electronic unit chassis See Figure 4 1 The standard time delay is adjustable from 0 120 seconds The purpose of the time delay is to allow the pump to prime itself or ignore voids in the process stream for a preset time period Turning the adjustment clockwise CW will increase the time delay and turning it counterclockwise CCW will decrease the time delay See Figure 4 1 The time delay period can be initiated by the momentary introduction of line voltage to the start terminal This allows the pump to prime itself in suction lift installations DREXELBROOK SETPOINT TIME ADJUST DELAY ER a ALARM a WHEN OUT Figure 4 1 Time Delay Control 17 Clearline In Line Fluid Detector Installation and Operating Instructions 4 5 Special Applications The Clear Line In Line Fluid Detector is factory calibrated for proper operation No field calibration adjustments are needed The standard units are calibrated for use in both insulating and conducting fluids with the ability to ignore most residual fluid coatings on the sensor even when
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32. under by Seller infringe any United States or Canadian Patent Copyright or Mask Work Registration provided that Buyer promptly notifies Seller of such claim in writing and further provided that at Seller s expense 1 Buyer gives Seller the sole right to defend or control the defense of the suit or proceeding including settlement and 2 Buyer provides all necessary information and assistance for that defense In the event of a charge of infringement Seller s obligation under the agreement shall be fulfilled if Seller at its option and expense either i settles such claim ii procures for Buyer the right to continue using such goods iii replaces or modifies goods to avoid infringement or iv accepts the return of any infringing goods and refunds their purchase price or iv defends against such claim If Buyer furnishes specifications or designs to Seller the obligations of Seller set forth above shall not apply to goods made by Seller using such specifications or designs and Buyer shall defend indemnify and hold Seller harmless against any third party claims for infringement which arise out of Seller s use of specifications or designs furnished by Buyer SOFTWARE LICENSE If goods purchased hereunder include software Software Buyer may use the Software only as part of the goods Buyer may not use copy or transfer any of the Software except as may be permitted under the applicable License Agreement provided with the good
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