CCS3000 USER MANUAL - Horizon Infrastructure
Contents
1. CCS3000 USER MANUAL IZON Hor Infrastructure Contents 5 A N tenet 2 PIG UNC Ss Ta ias 3 1 ARNO CUO Was 25505 ca ves aal eda seas eda e a 4 2 Y 511 a S Sae me nee eee ae ean ee en rere ee Moen en eer ae ene ee ee 4 2 1 TAD AGING A A o E ats ceconec sacar aniaeahes sane nad ateeb ase ana cedars aaes aeeacdacucanesedanceaaeesae 4 ZZ PAYSICAIMMS tA ALON Sag arta oie adr ao aac eevee ee case ede areecesee edu ead need 4 29 Electrical COMMECTIONS wisest 32 atch estes a A aed A a es eee 5 S MPC CONMMOURAUON SOM WANS iise coh toh c lak pated ii 7 3 1 a A en en ee 9 3 2 CONQUE de a 10 3 2 1 Measurement Mod s cid hein ewe Seed ek ea de 11 3 2 2 Fieldbus HC Olin AON erence ol perc ers ad tl cds 11 3 2 3 Serial 4 20mA ConfiguratiON ccooccooncoccocccocnconcncoconononnnnnnonnnnnronnnnnronnnrnrnronnnnnncnnnnns 11 3 2 4 Product Code ConfiguratiON occcocconcconcocccononcnnonononconononannnnonnnnanonnncnnanonnnennonanes 12 3 2 5 FP FOGUGE FLEMING PP N e r a ao ni isicees oa ee a ee 13 3 2 6 Ememet Contigua tocata aaa 15 A Gala lO ol ans a a a a dius teadetileniatte 16 4 1 1 Offset Method etc 16 4 1 2 Linear Regresiva diia ds 17 9 instrumen ODIOM erenn ld e ee e dean 18 5 1 Vortex Cooling Panel CONNECtIONS ooccoccncncocnncncncnnonoconcnnnconcnnnnoncnnnnoncnnanonnonnnnrinannncos 21 Figures Figure 1 Gauge Mounted on Optional Stand occoocccccccncocnoo Error Bookmark not defined Figur2. oococccccconcoccoccnccoconcnconconconconnnonnnnnnnnnnnnnnnnonnranrnnrnrrnrnnrnnenos 18 Figure 19 STORE TUDO ti ad et craic as A AA tide AA A as 19 Figure 20 Pnetmate sampler A 19 1 Introduction Thank you for choosing MoistTech com a division of Sensortech Systems Inc as your moisture measurement provider The CCS3000 is the most sophisticated on line FOR sensor available offering unmatched accuracy and reliability at a very affordable cost The CCS3000is a smart sensor with all measurement signal processing and control functions self contained It features multiple standard I O including two isolated 4 20mA outputs and one non isolated self powered 4 20mA output RS232 RS422 RS485 serial communications and Ethernet TCP IP amp UDP Optional communications are provided by plug in module and include DeviceNet Profibus and many more This manual is intended for the first time user providing information on installation and wiring simple configuration and basic calibration For more detailed information please consult the factory or local representative 2 Getting Started This chapter covers the mechanical installation of an CCS3000in its simplest configuration e Single CCS3000FOR moisture sensor FORG e 4 20mA Remote display 2 1 Unpacking The CCS3000is securely packaged in a custom urethane foam lined carton along with all accessories Compare contents with packing list and ensure all items are accounted
3. Configuration Poduct Code Configuration Ethernet Canficuration i 192 168 0 94 192 169 0 198 Address 25E 255 255 0 Subnet M 255 255 255 0 192 168 000 001 B Polling Stopped Figure 13 Ethernet Configuration The CCS3000sensor is equipped with multiple communications capability The most powerful communications feature is the TCP IP Ethernet port This feature is standard on all CCS3000series instruments and provides the highest data speed with the most comprehensive data access If the sensor is connected to a DHCP server based network then the DHCP box may be checked in the Ethernet configuration screen for the gauge and in the network settings for the PC Dynamic Host Configuration Protocol DHCP basically assigns suitable IP addresses to all devices on the network at time of boot up Many factory networks use fixed IP addresses In this case a competent IT professional should assign the addresses to the gauge The configuration screen shown in figure 15 initially reads the LAN related parameters from the gauge These parameters may be modified and then re sent to the gauge MoistTech has a comprehensive diagnostics program to run on the LAN network This program uses UDP User Datagram Protocol which differs from TCP IP in that it largely ignores errors but provides a very rapid transfer of large blocks of data If the diagnostics program is to be run the UDP box should be checked and the appropriate IP addres
4. Gate trip level 4 K coefficients If any parameters are changed remember to send to gauge in order for the changes to take effect A IR3000 Configuration Main Setup Absut Configuratior Calbration Manufacturing Measure Configuration Fieldbus Configuration Serial 4 20m4 Configuraion Foduc Code Configuration Ethernet Configuration GeseralParame erz Product Specific Parametsrs Product Filtering Figure 10 Product Code Configuration General Parameters The Product Specific Parameters screen is shown in figure 13 Each displayed parameter is specific to a product code or product calibration The first parameter is the product name If no name is given then default label is Product Code x where x 1 through 50 Product name is changed in the lower product name box 12 Associated with each product is a set of calibration coefficients a b 4 c For more detailed explanation of coefficients see chapter 4 1 MoistTech com IR3000 Configuration Mairi Setup About Configuratior Calbration Manufacturing Measure Configuration Fieldbus Configuration Serial 4 20m4 Configuration Podue Code Configuration Ethernet Configuration GereralPsrameers Product Specific Parameters Product Filtering Figure 11 Product Specific Parameters Coefficient a is always zero unless a quadratic curve fit is used This is for more advanced users and Is cov
5. any wiring and pneumatic connections that may be necessary in order to implement those options Light Tube This accessory is highly recommended to keep the instrument window clean and dust free The light tube mounts to the bottom of the sensor with 4 M6 screws The screws are provided with the light tube In many cases the light tube will do a good job without any air purge but in extremely dusty environments air purging is recommended The light tube comes with a quick fit pneumatic fitting to accept a Y4 plastic air line If metal piping is used a compression fitting may be used The light tube takes a Y NPT fitting The light tube contains a sintered phosphor bronze lining which uniformly distributes the air within the tube In order to avoid turbulence air pressures Figure 15 Light Tube should not exceed 5psi 0 3Bar Turbulence may cause increased buildup on the window Air should be clean and dry Flange Mount Window Type 316 stainless steel flange with 50mm view port Window materials include quartz and sapphire for maximum abrasion resistance Figure 16 Flush Mo unt View Window 18 Aa eh Y A e ar A inte peg hy E l Figure 17 Sight Tube Figure 18 Pneumatic Sampler 19 Sight Tube Mounts directly to sensor providing angled window in contact with product flow Materials 316 stainless steel and sapphire window Tube mounts to flange with sanitary clamp fitting to al
6. for If any items are missing or damaged please contact factory immediately for further instructions 2 2 Physical Installation The CCS3000includes two 2 removable mounting brackets These brackets may be configured in numerous ways to provide flexible mounting options The most common configuration the one provided from the factory is a vertical mounting with the two mounting clamps positioned on the connector end of the gauge Figure 2 illustrates this mounting configuration Mounting brackets are designed to clamp on a diameter of 1 25 1 3 32mm metal bar Due to the many variables associated with any process environment it may be more convenient to use a horizontal mounting bar In this case the mounting clamps need to be relocated using the four mounting holes on the top of the instrument housing The four holes form a square pattern allowing clamps to be mounted in either of two positions at 90 orientation Figure 3 shows several possible mounting configurations The most important mounting consideration is the distance from product to sensor The sensor Figure 1 Gauge Mounting Configurations may be equipped with an air purge nozzle light tube option approximately 4 100mm long This nozzle is generally recommended to keep gauge window clean even when not using air Although the gauge will operate effectively in many applications at distances of 4 24 100mm 600mm the optimum distance for
7. input enables measurement for a timed interval This interval is set by measurement time 3 2 2 Fieldbus Configuration Configuration of serial ports Consult factory or local representative for more details 3 2 3 Serial 4 20mA Configuration v gt Moistlech com IR3000 Configuration Main Setup About Sonfiguration Calbration Measure Configuration Fieldtus Coafiguration Serial 4 20n4 Configuration oduct Cade Configuraticn Ebiemet Configuration Polling Stopped Figure 9 Serial 4 20mA Configuration Screen 11 The serial 4 20mA configuration screen selects serial I O parameters and allocates measured constituents to specific analog outputs For a single constituent gauge e g Moisture only it is possible to configure all three analog outputs to represent the one moisture measurement If moisture and temperature are being measured it is possible to output moisture to analog outputs 1 amp 2 and temperature to output 3 This would provide a non isolated moisture output to a closely positioned remote display while driving an isolated output to a more distant PLC input 3 2 4 Product Code Configuration The CCS3000sensor stores up to 50 product codes within the on board flash memory Product code configuration is divided into three screens The first screen General Parameters is shown in figure 12 General parameters are those common to all product codes and include 1 Constituent name 2 4 20mA range 3 Auto
8. most applications is 6 10 150mm 250mm or 2 6 from end of light tube Highly reflective products such as glossy paper produce first surface reflections detrimental to measurement Setting the gauge at a slight angle from vertical may easily eliminate these reflections Typically an angle of 15 20 from vertical is recommended If air purge nozzle or cooling panel option is used a good supply of clean dry air is required An air filter and regulator located close to the gauge is recommended Vortex air cooler requires air pressure of 80 100psi at flow rate of 4 8 cfm depending on vortex rating Air purge nozzle requires very low pressure 5psi and flow rate See options chapter for more detailed information 2 3 Electrical Connections 4 20 MA OUTPUT SOCKETS ETHERNET LAN IF INSTALLED RECEPTACLE IF INSTALLED PINS SENSOR CONNECTORS OUTLINE DRAWING Figure 2 Gauge Connections Figure 4 shows the rear connector panel of the moisture gauge For detailed wiring descriptions refer to chapter 6 The power connector in the upper right contains live neutral and safety ground connections The instrument is designed to operate from 85 260vac 50 60Hz Ifa pneumatic sampler option is supplied an additional 3 pin socket is located on the bottom of gauge body This provides switched ac mains to the air purge solenoid in the sampler A 6 foot 2m power cord is supplied with the in
9. offset method This method assumes that the gauge has been previously calibrated and the calibration slope is approximately right After inputting the samples to the calibration table and having performed a laboratory analysis on the corresponding samples the laboratory values may be edited into the table Locating cursor over appropriate lab value highlighting that value and entering new lab value does this When all lab values have been entered into the table press the Recalculate Coefficients button The average instrument and lab values are calculated and the c coefficient is updated according to the average error Nothing is changed in the instrument until the Send Coefficients button is pressed The data may also be saved to a file for future amendment 16 Historic data may be handled by loading a data file containing historic samples amending it with current data and then calculating the error over the entire range of data The upper center of screen displays the calibration algorithm to be used Four calibration methods are featured namely linear quadratic logarithmic and offset Only linear and offset will be dealt with in this chapter More advanced users should consult the technical manual Highlighting the data row and pressing the delete button may delete invalid samples Caution Deleted samples are not recoverable It is recommended to save the raw data to a file prior to editing 4 1 2 Linear R
10. auge 1D desd te Chance ES fT Displayed Float Precision Senseo Get Product Lares Download Firmers Polling Stopped Figure 7 Basic Setup Screen 3 2 Configuration After entering password click on Configuration tab the measurement configuration screen shown in figure 10 will be displayed v Moisifech com IR3000 Configuration E ax Wain Setua About Configuration Calibration Measure Configuiation Fielcbus Configuration Serial 4 20m4 Configuration Poduct Code Configuration Ethemet Confiquration Li F Polling Stopped de Figure 8 Measurement Configuration Screen 10 Measurement Configuration allows the user to select the mode of measurement and to set various parameters associated with this mode 3 2 1 Measurement Modes The CCS3000operates in numerous different modes namely 1 Continuous Gauge measures continuously 2 Signal Gated A true logic input enables measurement A false logic input disables measurement and the last measurement is held 3 Auto Gated Similar to signal gated but gating is enabled by moisture level A threshold is programmed and the auto gate trigger is selectable for less than or greater than threshold 4 Timed Sample This is used when a sampling device is attached to the gauge Programmable functions for this mode include fill time measurement time and purge time 5 Gated Timed In this mode an external logic
11. e 2 Typical APpliCatiON ocoocconconocionconoconnaneancanoncanonncnnnns Error Bookmark not defined Figure 3 Gauge Mounting CONFIQUFAatl0NS oocooccoonconconnconooonononnnnnnonnonnncnnnnnronnnnnronnnnnnnnonnnnnninannnss 5 PIQUIC 4 Gauge CONNCCHONS a e ao 6 Figure 5 Remote Display Driven by Self powered Non isolated LOOP 1 ooooocococccccccccncnconononanos T Figure 6 Remote Display Driven by Externally Powered Isolated Loop 2 ocooccccccocicoccocnnonos T Figure Mall Start Up Screen Lis qa 8 Figure 8 Main Screen After Connecting and Polling cooccoccconcococnnoccoconononconononcnnanonanonnnos 9 Figure 9 Basie Setup SCree i crine naaa ia aa a a ia eia Rai ena Rari 10 Figure 10 Measurement Configuration Screen ccoccocccccnncccoconoccnconcnnncnnnnnconnnnnnonnnnnnonnnnanancnnnnnros 10 Figure 11 Serial 4 20mA Configuration Screen ococccccccccnccccoconoconcnnnnnncnnnnnnnnnonnconnnonnnnnnnanonnnnnnaros 11 Figure 12 Product Code Configuration General Parameters cooccoccccccncccococononcocnnnncncnnanoncnnnos 12 Figure 13 Product Specific Parameters oocooccconcconcocccononnononononnonnnnnnonanonnncnnonnnnnnnnoncnnanenannnns 13 Figure 14 Effects of Damping amp Filter Band oocooccocccoccccncococoncnnnconcnnnconcnnnnoncnnnnoncnnnnnronanoneos 14 Figure ElthermetConigura o a A ia 15 FIQUreTO Calbratioh creci 16 Figure TA EONE TUDO declinado diana 18 Figure 18 Flush Mount View WiNdOW
12. egression Linear regression is a statistical program that establishes the direct correlation between two data series A correlation coefficient indicates the quality of correlation This value is between O and 1 with 1 being a perfect correlation In addition to determining the quality of fit the regression program calculates the slope and intercept of the calibration line These two values are the b and c coefficients respectively LL LL YX YX D E E Y Y O O gt 5 10 15 3 10 15 INSTRUMENT INSTRUMENT Figure 17 Effect of Coefficient Figure 18 Effect of Coefficient c on Slope on offset Sampling is performed using the calibration program exactly as in the offset method Using the drop down menu in the upper center box select linear After pressing Recalculate coefficients notice both b and c will change A linear regression should only be performed on data with an adequate range typically at least a 2 absolute range Running a linear regression on static product samples is often a good way of establishing a slope When the instrument is then placed on line the offset method may be best to bring the results into the correct range 17 5 Instrument Options The basic instrument may be enhanced by the purchase of a variety of options These include software packages special interface protocols and hardware accessories The scope of this chapter is to describe the common options and
13. ered in more depth in the technical manual Coefficient b is the slope of the calibration line A higher b value increases instrument sensitivity to moisture In most cases the instrument will be pre calibrated prior to shipping and a suitable b value will be installed Coefficient c is an offset coefficient and may be positive or negative When the instrument displayed values are compared to laboratory analyses grab samples the c coefficient is used to correct for an average bias in the instrument For example if the average of 10 laboratory samples is 0 7 lower than the average instrument display corresponding to those 10 samples then the c coefficient needs decreasing by 0 7 A calibration program is contained in the configuration software and will be explained in more detail in chapter 6 3 2 5 Product Filtering There are three levels of signal filtering within the gauge Wheel rotation averaging is factory set for a specific application and effectively determines the sample update rate If this needs to be changed consult the factory for instructions Median filtering is another factory set parameter and should only be changed by a factory authorized technician 13 The third filtering technique is Damping and is user programmable Damping performs a running average on the real time data For example if a damping value of 10 is chosen then a software buffer is generated containing the las
14. low adjustable depth of penetration Pneumatic Sampler Typically mounted through wall of vertical chute Gravity fed granular materials are captured in sample cup Fill time Sample time and purge time are all user programmable Requires clean dry air supply of 80psi 5Bar Figure 23 Air Cooling Panel Figure 24 Water Cooling Panel Cooling Panel Significantly reduces internal gauge temperature Both water cooling and Vortex air cooling are available 20 5 1 Vortex Cooling Panel Connections The Vortex cooling panel is supplied with various components and requires some assembly The following photographs show the correct sequence of assembly Photo shows Model 828 cooling panel with included air fittings and Vortex tube Use PTFE sealing tape on all connections Screw 90 elbow fitting into left threaded port on side panel until almost fully tight but with elbow aligned as shown at left Screw Vortex Tube on to other end of elbow and fully tighten with Vortex inlet pointing down as in photo Rotate elbow fitting a further 90 so that Vortex tube is vertical and inlet pipe is on left side Screw muffler into right threaded port on side panel and fully tighten Figure 19 Attaching Vortex Tube and Air Fittings 21
15. onnected MEAS IRE Figure 6 Main Screen After Connecting and Polling Important Note This software is only for gauge configuration It is not intended as an HMI or logging program For continuous monitoring of the gauge s MoistTech provides an operator interface option and also gauge monitoring software for continuous PC monitoring If the gauge has been pre calibrated by MoistTech then at this point it is ready to measure The remaining configuration functions set specific I O parameters product names calibration parameters etc 3 1 Password At startup the main screen shows three tabs in the upper left namely Main Setup About The Setup screen provides limited access to change only the alarm levels and constituent name see figure 9 Further functions are password protected for security The factory default password is engpass From the Setup screen it is possible to create new user passwords but the factory default will always work Entering the appropriate password enables more tabs at the top of screen for access to additional functions namely Configuration and Calibration Moisilech com IR3000 Configuration ir Wain Setuo About Change Constituent Deta Change Engineering Password ati Name Old Password l Constituert 0 Cave Farsmeters To File lo Alarm Leve Low moa Alam Leve High Ano Load Parameters From Tile lo Constituent Number Nepeat New Password F Enter IF Address G
16. s of the receiving PC should be entered in the UDP address box 15 4 Calibration A major feature of the configuration program is the calibration software This provides the capability of grabbing a sample from the process at the same time that the gauge is recording a measurement MoistTech com IR3000 Configuration Main Setup About Configuration Calibration Manufacturing Currelitueri 0 Ors Start Sampling Sample Date Gauge Reading m factor Lab Reading m PO 101420052241 7 8 i i E 1014 2005 2 23 5 6 9 10 14 2005 223 4 6 4 UTA PAULO 233 56 110142005 22232 51 10714 2005 2 23 0 48 Coefficient to Relalculale Cuefficia Ls Coefficient B Send Coefficients Coefficient E Save ToFile Load From File Polling Stopped Figure 14 Calibration Screen The calibration procedure comprises pressing the start sampling button in the upper left of screen taking a sample from the process in close proximity to the gauge and then pressing the stop sampling button Each time this button is pressed it will toggle between start and stop After taking a sample the store sample button will be highlighted and the average instrument reading between start and stop sampling is displayed Pressing this button will store this value in the table to the right Each sample has an associated time and date stamp to facilitate sample matching 4 1 1 Offset Method The simplest calibration is the
17. strument with power plug appropriate to country of operation In some cases only the Bulgin connector is supplied Remote display is connected to self powered non isolated 4 20mA output 1 see figure 5 Any third party 4 20mA display may be used for remote readout Sensortech provides 4 digit LCD and LED optional displays If the led version is chosen typically for low light viewing conditions then separate 5vdc power is required to the display For displays mounted more than 12 feet from gauge an isolated loop is recommended loops 2 or 3 The isolated loops require external power 24vdc recommended CCS3000 Moisture Meter Figure 3 Remote Display Driven by Self powered Non isolated Loop 1 Remote CCS 3000 Display Moisture Meter Figure 4 Remote Display Driven by Externally Powered Isolated Loop 2 3 PC Configuration Software A compact disc is included with the gauge This CD contains various software to facilitate sensor configuration PC configuration software is contained in a folder labeled IR3000 Configuration From this folder run Setup exe and follow installation instructions If any earlier versions of MoistTech software are installed they should be detected during the setup procedure and removed It is recommended to remove any earlier Known versions prior to setup At the completion of software installation an icon will be placed on the desktop Double clicking the icon will start the configura
18. t 10 sample updates The instrument value displayed is the average of the data in the buffer The sample update rate is not affected by the damping value but the displayed value is a running average of the last n samples Damping has a smoothing effect on the instrument response but will slow the response to moisture changes Large step changes in a process are unusual but may happen during transitional periods such as process start ups With heavy damping a step change will normally take time to reach final value The CCS3000contains a programmable filter band where any moisture changes within this band have damping applied Changes exceeding the filter band bypass the damping function In this way small steady state fluctuations are smoothed by damping but major disturbances are immediately displayed Gauge Senzorttechl ProductO Producti 11 27 10 a Raw Signal No Damping Gauge Senzortechl Product0 Product Damping 15 samples Filter Band 10 11 33 50 11 34 40 b Damped Signal Gauge Senzorttechl ProduckO Producti Damping 15 samples Filter Band 1 11 36 20 11 37 10 c Damped Signal With Narrow Filter Band Figure 12 Effects of Damping amp Filter Band 14 3 2 6 Ethernet Configuration The Ethernet configuration screen is shown in figure 15 v Moistlech com IR3000 Configuration Main Setup about Configuration Calibration Mesura Configuration Fieldbus Configuration Serial 4 20
19. tion program and display the screen shown in figure 7 MoistTech com IR3000 Configuration hair Setup About Auto Scale None Y Ase Min oo Y Asis Max 0 0 noo E a o noo 8 ss ri PIN FI CIA A LAS PS j Model Number shoe ech 4 comet Seal Number a A sd Firmware Version M oistTech e com j Hardware Revision s A Find Networked NS ia Gauges 1 second fl E Not Connected 0D Figure 5 Main Start Up Screen All gauges connected to host PC will be displayed in the lower left box To communicate with a specific gauge highlight that gauge by clicking on the name in the lower left box and then pressing Connect At this point the information fields immediately right of the Connect button should be filled with the appropriate data associated with the connected gauge To display moisture and commence time plot press Start Polling At this point the large display will indicate a moisture value and the trend plot in the right screen area will begin to scroll see figure 8 Moistlech com R3000 Configuration Main Sctup About CoretituentO Auto Scale None Y Ass Min p o Y Ans Max E o o Gauge Sersortechl Froduct O Producti IA Diae y Disable v Disable vl ble Ann AN ANA ities LONA se a ue feuue Mule Mundie fix at ach 4 08050702 Soral Humber fioziG 0210 Mozo Firmware Wearsior 0 Producti a MoistTech com rodut E Hardware Revision Mu oe ies f C
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