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Emerson DLC3010 Quick Start Guide

1. remember that you are in the density mode and enter observed PV in current units of SGU g L Ib in kg m etc Weight Based The Weight Calibration asks you for the lowest and highest density you want to use for the calibration points and computes weight values for you If you can t come up with the exact values asked for you are allowed to edit the values to tell it what weights you actually used Min Max The Min Max Calibration essentially reverts to level mode during the calibration process It asks for the SG of your test fluid first Then it has you set up first a dry and then a completely submerged displacer condition Two Point The Two Point Calibration requires you to set up two different process conditions with as much difference as possible You could use two standard fluids with well known density and alternately submerge the displacer in one orthe other If you are going to try to simulate a fluid by using a certain amount of water remember that the amount of displacer covered by the water is what counts not the amount in the cage The amount in the cage will always need to be slightly more because of the displacer motion Because of this inconvenience and the extra work of draining and flooding with two fluids the two point calibration method is probably the least attractive in density mode Note These calibration methods advise you to trim zero for better accuracy That command is not available in density mode Sensor Calib
2. The Simulation of Process Conditions for Calibration of Fisher Level Controllers and Transmitters instruction manual supplement D103066X012 provides the theoretical composite torque tube TT rate for 249 sensors with DLC3010 controllers These numbers are nominal values They should be within 10 of the values that the instrument would compute when you perform a sensor calibration They will be less accurate for the long torque tubes 249K L N VS and P especially with thin wall constructions If you are unable to perform a sensor calibration during installation manually enter the values into the instrument using the Field Communicator Configure gt Manual Setup gt Sensor gt Torque Tube gt Change Torque Rate Then manually set the LRV and URV to the PV values at which you desire 4 and 20 mA output respectively Configure gt Manual Setup gt Variables gt Primary Variable Range gt Upper or Lower Range Value See the DLC3010 instruction manual D102748X01 2 for information on accuracy considerations and temperature compensation 31 DLC3010 Digital Level Controller Quick Start Guide September 2014 D103214X012 Schematics This section includes loop schematics required for wiring of intrinsically safe installations If you have any questions contact your Emerson Process Management sales office Figure 14 CSA Loop Schematic CSA ENTITY INSTALLATION DRAWING HAZARDOUS LOCATION NON HAZARDOUS LOCATION CLASS 1 GROUPS A B
3. mounting sense controller to the right or left of displacer torque tube material and wall thickness displacer volume weight length and driver rod length the driver rod length is not the suspension rod length but the horizontal distance between the centerline of the displacer and the centerline of the torque tube Also obtain process information fluid densities process temperature and pressure The pressure is used as a reminder to consider the density of an upper vapor phase which can become significant at higher pressures 2 Run Instrument Setup and enter the various data that is requested as accurately as possible Set the Range Values LRV URV to the PV values where you will want to see 4 mA and 20 mA output respectively These might be 0 and 14 inches on a 14 inch displacer 3 Mount and couple at the current process condition It is not necessary to run the Capture Zero procedure because it stores the current torque tube angle as the zero buoyancy condition and will therefore not be accurate 4 With the torque tube type and material information find a theoretical value for the composite or effective torque tube rate refer to the Entering Theoretical Torque Tube TT Rates procedure in this section and enter it in the instrument memory The value can be accessed by selecting Configure gt Manual Setup gt Sensor gt Torque Tube gt Change Torque Rate 5 the process temperature departs significantly from room te
4. terminal RS or R1 should read an equivalent resistance for the existing ambient temperature Refer to the RTD manufacturer s temperature to resistance conversion table Usually this wire is a different color from the wires connected to the RS and R1 terminals Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 Communication Connections A WARNING Personal injury or property damage caused by fire or explosion may occur if this connection is attempted in an area which contains a potentially explosive atmosphere or has been classified as hazardous Confirm that area classification and atmosphere conditions permit the safe removal of the terminal box cap before proceeding The Field Communicator interfaces with the DLC3010 digital level controller from any wiring termination point in the 4 20 mA loop except across the power supply If you choose to connect the HART communicating device directly to the instrument attach the device to the loop and terminals inside the terminal box to provide local communications with the instrument Test Connections A WARNING Personal injury or property damage caused by fire or explosion may occur if the following procedure is attempted in an area which contains a potentially explosive atmosphere or has been classified as hazardous Confirm that area classification and atmosphere conditions permit the safe removal of the terminal box cap before proceeding Test connections ins
5. C D CLASS Il GROUPS E F G CLASS 111 FISHER TYPE DLC3010 CSA CERTIFIED BARRIER M Vmax 30 VDC 226 mA Ci 5 5 nF Li 0 4 mH SEENOTE3 NOTES 1 BARRIERS MUST BE CSA CERTIFIED WITH ENTITY PARAMETERS AND ARE TO BE INSTALLED IN ACCORDANCE WITH THE MANUFACTURERS l S INSTALLATION INSTRUCTIONS 2 EQUIPMENT SHALL BE INSTALLED IN ACCORDANCE WITH THE CANADIAN ELECTRICAL CODE PART 1 3 IF HAND HELD COMMUNICATOR OR MULTIPLEXER IS USED IT MUST BE CSA CERTIFIED AND INSTALLED PER THE MANUFACTURE S CONTROL DRAWING 4 FOR ENTITY INSTALLATION Vmax gt Voc Imax gt Isc Ci Ccable lt Ca Li Lcable lt La 28B5744 B 32 Quick Start Guide D103214X012 Figure 15 FM Loop Schematic HAZARDOUS LOCATION l S CLASS 1 1 1 DIV 1 GROUPS A B C D E F G N I CLASS I DIV 2 GROUPS A B C D FISHER TYPE DLC3010 Vmax 30 VDC Imax 226 mA Ci 5 5 nF Li 0 4 mH Pi 1 4W THE INSTALLATION MUST BE IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE NEC NFPA 70 ARTICLE 504 AND ANSI ISA RP12 6 CLASS 1 DIV 2 APPLICATIONS MUST BE INSTALLED AS SPECIFIED IN NEC ARTICLE 501 4 B EQUIPMENT AND FIELD WIRING IS NON INCENDIVE WHEN CONNECTED TO APPROVED BARRIERS WITH ENTITY PARAMETERS LOOPS MUST BE CONNECTED ACCORDING TO THE BARRIER MANUFACTURERS INSTRUCTIONS MAXIMUM SAFE AREA VOLTAGE SHOULD NOT EXCEED 250 Vrms RESISTANCE BETWEEN BARRIER GROUND A
6. Controllers and Transmitters Supplement to 249 Sensor Instruction Manuals D103066X012 42 Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 e Bolt Toraue Information Supplement to 249 Sensor Instruction Manuals D103220X012 e Technical Monograph 7 The Dynamics of Level and Pressure Control e Technical Monoaraph 18 Level Trol Density Transmitter e Technical Monograph 26 Guidelines for Selection of Liquid Level Control Equipment Educational Services For information on available courses for the DLC3010 digital level controller as well as a variety of other products contact Emerson Process Management Educational Services Registration Phone 1 641 754 3771 or 1 800 338 8158 e mail education emerson com http www emersonprocess com education 43 DLC3010 Digital Level Controller Quick Start Guide September 2014 D103214X012 Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenance of any product remains solely with the purchaser and end user Fisher and FIELDVUE are marks owned by one of the companies in the Emerson Process Management business unit of Emerson Electric Co Emerson Process Management Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co All other marks are the property of their respectiv
7. Displacer and Torque Tube Materials Part O Standard Material Other Materials 316 Stainless Steel N10276 N04400 Plastic and Special Alloys N10276 N04400 Driver Bearing other Austenitic Displacer Rod and Stainless Steels and Driver Special Alloys 316 Stainless Steel 1 M93300 N06600 N10276 1 N05500 is not recommended for spring applications above 232 C 450 F Contact your Emerson Process Management sales office or application engineer if temperatures exceeding this limit are required Displacer 304 Stainless Steel Displacer Stem 316 Stainless Steel Torque Tube Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 Table 11 Caged Displacer Sensors STANDARD CAGE HEAD EQUALIZING CONNECTION AND TORQUE TUBE ARM PRESSURE RATING 2 2490 Cast iron CL125 or CL250 Flanged 2 Screwed or optional socket weld 1 1 20r2 CL600 CL150 CL300 or 4 1 2 249B 249BF 4 Steel Raised face or optional ring type joint cL600 ORIENTATION flanged Torque tube 5 CL150 CL300 or arm rotatable CL600 equalizing CL150 CL300 or SOMME ENON 249C 3 316 stainless steel ka Raised face flanged CL600 1 Standard displacer lengths for all styles except 249 are 14 32 48 60 72 84 96 108 and 120 inches The 249 uses a displacer with a length of either 14 or 32 inches 2 EN flange connections available in EMA Europe Middle East and Africa 3 Not available in EM
8. IECEx IP66 Other Classifications Certifications FSETAN Russian Federal Service of Technological Ecological and Nuclear Inspectorate GOST R Russian GOST R INMETRO National Institute of Metrology Standardization and Industrial Quality Brazil NEPSI National Supervision and Inspection Centre for Explosion Protection and Safety of Instrumentation China PESO CCOE Petroleum and Explosives Safety Organisation Chief Controller of Explosives India TIIS Technology Institution of Industrial Safety Japan Contact your Emerson Process Management sales office for classification certification specific information Quick Start Guide D103214X012 DLC3010 Digital Level Controller September 2014 Table 6 DLC3010 Digital Level Controller Specifications continued Minimum Differential Specific Gravity With a nominal 4 4 degrees torque tube shaft rotation for a 0 to 100 percent change in liquid level specific gravity 1 the digital level controller can be adjusted to provide full output for an input range of 5 of nominal input span This equates to a minimum differential specific gravity of 0 05 with standard volume displacers See 249 sensor specifications for standard displacer volumes and standard wall torque tubes Standard volume for 249C and 249CP is 980 cm 60 in most others have standard volume of 1640 cm 100 in3 Operating at 5 proportional band will degrade accuracy by a factor
9. The default upper range value is set to 1 0 and the default lower range value is set to 0 1 5 Selectthe desired output action Direct or Reverse Choosing reverse acting will swap the default values of the upper and lower range values the process variable values at 20 mA and 4 mA In a reverse acting instrument the loop current will decrease as the fluid level increases 6 You are given the opportunity to modify the default value for the process variable engineering units 7 You are then given the opportunity to edit the default values that were entered for the upper range value PV Value at 20 mA and lower range value PV Value at 4 mA 24 Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 8 The default values of the alarm variables will be set as follows Direct Acting Instrument Reverse Acting Instrument Span Upper Range Value Lower Range Value Span Lower Range Value Upper Range Value Alarm Variable Default Alarm Value Alarm Variable Default Alarm Value Hi Hi Alarm Upper Range Value Hi Hi Alarm Lower Range Value 95 span Lower Range Value 95 span Upper Range Value 5 span Lower Range Value 5 span Upper Range Value Lo Lo Alarm Lower Range Value Lo Lo Alarm Upper Range Value PV alert thresholds are initialized at 100 95 5 and 0 span PV alert deadband is initialized to 0 5 span PV alerts are all disabled Temperature alerts are enabled e f Densit
10. a certified Ex d IIC cable entry DLC3010 Digital Level Controller Quick Start Guide September 2014 D103214X012 Typen This equipment shall be used with a cable entry ensuring an IP66 minimum and being in compliance with the relevant European standards Operating ambient temperature 40 C to 80 C Refer to table 3 for additional approval information Table 3 Hazardous Area Classifications ATEX Certificate Certification Obtained Entity Rating Temperature Code Intrinsically Safe amp ll1 GD Gas Ex ia IIC T5 Ga Dust Ex ia T83 C Da IP66 Flameproof 11280 ExdlIC T5 Gb Dust Ex tb IIIC T83 C Db IP66 Typen amp 13 Ex nA IIC T5 Gc Dust Ex t IIIC T83 C Dc IP66 T5 Tamb lt 80 C T5 Tamb lt 80 C T5 Tamb lt 80 C IECEx Intrinsically Safe The apparatus can only be connected to an intrinsically safe certified equipment and this combination must be compatible as regards the intrinsically safe rules Operating ambient temperature 40 C to 80 C Flameproof Type n No special conditions for safe use Refer to table 4 for approval information Table 4 Hazardous Area Classifications IECEx Certificate Certification Obtained Entity Rating Temperature Code Intrinsically Safe Ui 30 VDC Gas 226 mA Ex ia IIC T5 Ga 1 4W T5 Tamb lt 80 C Dust Ci 7 5 5 nF Ex ia T83 C Da IP66 Li 0 4 mH Flameproof Gas Ex d IIC T5 Gb T5 T
11. of 20 Using a thin wall torque tube or doubling the displacer volume will each roughly double the effective proportional band When proportional band of the system drops below 50 changing displacer or torque tube should be considered if high accuracy is a requirement Mounting Positions Digital level controllers can be mounted right or left of displacer as shown in figure 5 Instrument orientation is normally with the coupling access door at the bottom to provide proper drainage of lever chamber and terminal compartment and to limit gravitational effect on the lever assembly If alternate drainage is provided by user and a small performance loss is acceptable the instrument could be mounted in 90 degree rotational increments around the pilot shaft axis The LCD meter may be rotated in 90 degree increments to accommodate this Construction Materials Case and Cover Low copper aluminum alloy Internal Plated steel aluminum and stainless steel encapsulated printed wiring boards Neodymium Iron Boron Magnets Electrical Connections Two 1 2 14 NPT internal conduit connections one on bottom and one on back of terminal box M20 adapters available Options ll Heat insulator See description under Ordering Information Bl Mountings for Masoneilan Yamatake and Foxboro Eckhardt displacers available BI Level Signature Series Test Performance Validation Report available EMA only for instruments factory moun
12. sensing process temperature or optional user entered target temperature to permit compensating for changes in specific gravity Output Signal Analog 4 to 20 milliamperes DC Bi direct action increasing level interface or density increases output W reverse action increasing level interface or density decreases output High saturation 20 5 mA Low saturation 3 8 mA High alarm 22 5 mA Low Alarm 3 7 mA Only one of the above high low alarm definitions is available in a given configuration NAMUR NE 43 compliant when high alarm level is selected Digital HART 1200 Baud FSK frequency shift keyed HART impedance requirements must be met to enable communication Total shunt impedance across the master device connections excluding the master and transmitter impedance must be between 230 and 1100 ohms The transmitter HART receive impedance is defined as Rx 42K ohms and Cx 14 nF Note that in point to point configuration analog and digital signalling are available The instrument may be queried digitally for information or placed in Burst mode to regularly transmit unsolicited process information digitally In multi drop mode the output current is fixed at 4 mA and only digital communication is available continued DLC3010 Digital Level Controller September 2014 Performance w NPS 3 249W Using a 14 inch Displacer 0 8 of output span DLC3010 Digital Level Controller Performan
13. 012 CAUTION When shipping an instrument mounted on a sensor if the lever assembly is coupled to the linkage and the linkage is constrained by the displacer blocks use of the lever lock may result in damage to bellows joints or flexure 2 If the displacer cannot be blocked because of cage configuration or other concerns the transmitter is uncoupled from the torque tube by loosening the coupling nut and the access handle will be in the locked position Before placing such a configuration into service perform the Coupling procedure 3 Fora cageless system where the displacer is not connected to the torque tube during shipping the torque tube itself stabilizes the coupled lever position by resting against a physical stop in the sensor The access handle will be in the unlocked position Mount the sensor and hang the displacer The coupling should be intact 4 If the controller was shipped alone the access handle will be in the locked position All of the Mounting Coupling and Calibration procedures must be performed The access handle includes a retaining set screw as shown in figures 2 and 6 The screw is driven in to contact the spring plate in the handle assembly before shipping It secures the handle in the desired position during shipping and operation To set the access handle in the open or closed position this set screw must be backed out so that its top is flush with the handle surface Hazardous Area Approvals and Special I
14. 14B5483X042 and earlier if the jumper is missing the alarm is indeterminate but usually behaves as a FAIL LOW selection On encapsulated electronics 14B5484X052 and later the behavior will default to FAIL HIGH when the jumper is missing Alarm Jumper Locations Without a meter installed The alarm jumper is located on the front side of the electronics module on the electronics side of the digital level controller housing and is labeled FAIL MODE With a meter installed The alarm jumper is located on the LCD faceplate on the electronics module side of the digital level controller housing and is labeled FAIL MODE Changing Jumper Position A WARNING Personal injury or property damage caused by fire or explosion may occur if the following procedure is attempted in an area which contains a potentially explosive atmosphere or has been classified as hazardous Confirm that area classification and atmosphere conditions permit the safe removal of the instrument cover before proceeding Use the following procedure to change the position of the alarm jumper 1 If the digital level controller is installed set the loop to manual 2 Remove the housing cover on the electronics side Do not remove the cover in explosive atmospheres when the circuit is alive 3 Set the jumper to the desired position 4 Replace the cover All covers must be fully engaged to meet explosion proof requirements For ATEX approved units the set screw on the t
15. A 4 The 249BF available in EMA only Also available in EN size DN 40 with PN 10 to PN 100 flanges and size DN 50 with PN 10 to PN 63 flanges 5 Top connection is NPS 1 ring type joint flanged for connection styles F1 and F2 Table 12 Cageless Displacer 1 Standard Head 2 Wafer Body 6 and Torque Tube Flange Connection Size Pressure Rating Arm Material NPS 4 raised face or optional ring type joint CL150 CL300 or CL600 249BP 4 Steel NPS 6 or 8 raised face CL150 or CL300 249CP 316 Stainless Steel NPS 3 raised face CL150 CL300 or CL600 Mounts on 5 top of vessel NPS 4 raised face or optional ring type joint BIS or 250 249 Steel or stainless steel NPS 6 or 8 raised face CL150 CL300 CL600 CL900 CL1500 or CL2500 WCC steel LCC steel CL125 CL150 CL250 CL300 Mounts on or CF8M 316 stainless For NPS 4 raised face or flat face CL600 CL900 or CL1500 249V5 steel EN PN 10 to DIN PN 160 WCC LCC or CF8M For NPS 4 buttweld end XXS CL2500 Mounts on top of WCC or CF8M For NPS 3 raised face CL150 CL300 or CL600 vessel or on 249W customer LCC or CF8M For NPS 4 raised face CL150 CL300 or CL600 supplied cage 1 Standard displacer lengths are 14 32 48 60 72 84 96 108 and 120 inches 2 Not used with side mounted sensors 3 EN flange connections available in EMA Europe Middle East and Africa 4 Not available in EMA 5 249P available in EMA only 6 Wafer Bo
16. E F G T6 T6 Tamb x 80 C Class III FM Special Conditions of Safe Use T6 Tamb lt 80 C Intrinsically Safe Explosion proof Non incendive Dust Ignition proof 1 This apparatus enclosure contains aluminum and is considered to constitute a potential risk of ignition by impact or friction Care must be taken into account during installation and use to prevent impact or friction Refer to table 2 for approval information Table 2 Hazardous Area Classifications FM United States Certification Body Certification Obtained Entity Rating Temperature Code Vmax 30 VDC IS Intrinsically Safe Imax 226 mA Class 1 1 Division 1 GP A B C D Ci 5 5nF T5 Tamb lt 80 C E F G T5 per drawing 28B5745 see figure 15 Li 0 4 mH Pi 1 4W XP Explosion proof Class Division 1 GP B C D T5 NI Non incendive Class Division 2 GP A B C D T5 DIP Dust Ignition proof Class II Division 1 GP E F G T5 S Suitable for Use Class Il III Division 2 GP F G T5 Tamb lt 80 C ATEX Special Conditions for Safe Use Intrinsically Safe The apparatus DLC3010 is an intrinsically safe apparatus it can be mounted in a hazardous area The apparatus can only be connected to an intrinsically safe certified equipment and this combination must be compatible as regards the intrinsically safe rules Operating ambient temperature 40 C to 80 C Flameproof Operating ambient temperature 40 C to 80 C The apparatus must be fitted with
17. ND EARTH GROUND MUST BE LESS THAN ONE OHM NORMAL OPERATING CONDITIONS 30 VDC 20 mADC IF HAND HELD COMMUNICATOR OR MULTIPLEXER IS USED IT MUST BEFM APPROVED AND INSTALLED PER THE MANUFACTURE S CONTROL DRAWING FOR ENTITY INSTALLATION 1 5 AND N I Vmax gt Voc or Vt Ci Ccable lt Ca Imax gt Isc or It Li Lcable lt La Pi gt Po or Pt THE APPARATUS ENCLOSURE CONTAINS ALUMINUM AND IS CONSIDERED TO CONSTITUTE A POTENTIAL RISK OF IGNITION BY IMPACT OR FRICTION AVOID IMPACT AND FRICTION DURING INSTALLATION AND USE TO PREVENT RISK OF IGNITION 28B5745 C DLC3010 Digital Level Controller September 2014 NON HAZARDOUS LOCATION FM APPROVED BARRIER 33 DLC3010 Digital Level Controller Quick Start Guide D103214X012 September 2014 Specifications Specifications for DLC3010 digital level controllers are shown in table 6 Specifications for 249 sensors are shown in table 8 34 Quick Start Guide D103214X012 Table 6 DLC3010 Digital Level Controller Specifications Available Configurations Mounts on caged and cageless 249 sensors See tables 11 and 12 and sensor description Function Transmitter Communications Protocol HART Input Signal Level Interface or Density Rotary motion of torque tube shaft proportional to changes in liquid level interface level or density that change the buoyancy of a displacer Process Temperature Interface for 2 or 3 wire 100 ohm platinum RTD for
18. Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 Fisher FIELDVUE DLC3010 Digital Level Controller This A start quide applies to Contents Device Device Type Installation 3 9 77 EE ER Electrical Connections 13 ardware Revision Initial Setup 21 FirmwareRevsion 8 Calibration 27 Schematics 32 Specifications 34 FIELDVUE Instruments W7977 1 Note This quide describes how to install setup and calibrate DLC3010 digital level controllers using a 475 Field Communicator Additional information for installing operating and maintaining the DLC3010 digital level controllers can be found in the related documents listed on page 42 For information on using the Field Communicator see the Product Manual for the Field Communicator available from Emerson Performance Technologies 1 Y r EM ERSON www Fisher com Process Management DLC3010 Digital Level Controller Quick Start Guide September 2014 D103214X012 Installation Check List Mounting Instrument correctly configured and mounted on the sensor See the appropriate mounting procedure or installation instructions provided with the mounting kit Wiring and Electrical Connections Conduit or l S barrier if necessary is properly installed Refer to local and national electri
19. V mode procedure If the target application temperature is considerably elevated or depressed from ambient refer to the DLC3010 instruction manual D102748X01 2 for information on temperature compensation If you are able to adjust both process fluids the Two Point Calibration is recommended If you are unable to carry out Min Max or Two Point Calibration then establish zero buoyancy and capture zero Next establish a minimum 525 span above the Lower Range Value and Trim Gain If you only have a single fluid for calibration run through Instrument Setup and verify all displacer data is correct Set Level Offset to 0 Select Level application with direct action and enter SG 1 0 water or actual SG of test fluid if different than 1 0 Proceed with Min Max or Two Point Calibration Note Information on computing precise simulation of this effect is available in the Simulation of Process Conditions for Calibration of Fisher Level Controllers and Transmitters instruction manual supplement D103066X012 available from your Emerson Process Management sales office or at www fisher com Calibration with an Overweight Displacer When the sensor hardware is sized for greater mechanical gain as it is in some interface or density measurement applications the dry displacer weight is often greater than the maximum permissible load on the torque tube In this situation it is impossible to capture the zero buoyancy rotation of the torque tube beca
20. acer rise expected for that configuration is about 0 6 inch Accept this as the Max condition Adjust the test fluid level and check the instrument display and current output against external level at several points distributed across the span to verify the level calibration a To correct bias errors Capture Zero at the exact zero level condition b To correct gain errors Trim Gain at a precisely known high level condition If the measured output doesn t come off the low saturation value until the level is considerably above the bottom of the displacer it is possible that the displacer is overweight An overweight displacer will rest on the lower travel stop 27 DLC3010 Digital Level Controller Quick Start Guide September 2014 D103214X012 until sufficient buoyancy has developed to allow the linkage to move In that case use the calibration procedure for overweight displacers below After the initial calibration For a level application Go to the Sensor Compensation menu and use Enter constant SG to configure the instrument forthe target process fluid density For an interface application Change the PV mode to Interface verify or adjust the range values presented by the Change PV mode procedure and then use Enter constant SG to configure the instrument for the SGs of each of the target process fluids For a density application Change the PV mode to Density and establish the desired range values in the Change P
21. amb 80 C Dust Ex t IIIC T83 C Db IP66 Typen Gas Ex nA IIC T5 Gc T5 Tamb lt 80 C Dust Ex t IIIC T83 C Dc IP66 Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 Mounting Mounting the 249 Sensor The 249 sensor is mounted using one of two methods depending on the specific type of sensor If the sensor has a caged displacer it typically mounts on the side of the vessel as shown in figure 3 If the sensor has a cageless displacer the sensor mounts on the side or top of the vessel as shown in figure 4 Figure 3 Typical Caged Sensor Mounting Figure 4 Typical Cageless Sensor Mounting LIQUID LEVEL A3788 1 A3789 1 The DLC3010 digital level controller is typically shipped attached to the sensor If ordered separately it may be convenient to mount the digital level controller to the sensor and perform the initial setup and calibration before installing the sensor on the vessel Note Caged sensors have a rod and block installed on each end of the displacer to protect the displacer in shipping Remove these parts before installing the sensor to allow the displacer to function properly DLC3010 Digital Level Controller Quick Start Guide September 2014 D103214X012 DLC3010 Orientation Mount the digital level controller with the torque tube shaft clamp access hole see figure 2 pointing downward to allow accumulated moisture drainage Note If alternate dra
22. cal codes Loop wiring properly connected to the LOOP and terminals in the terminal box Connect loop wiring as described on page 15 HART impedance requirements met Communication established with the instrument Refer to Electrical Connections on page 13 Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 Installation A WARNING To avoid personal injury always wear protective gloves clothing and eyewear when performing any installation operations Personal injury or property damage due to sudden release of pressure contact with hazardous fluid fire or explosion can be caused by puncturing heating or repairing a displacer that is retaining process pressure or fluid This danger may not be readily apparent when disassembling the sensor or removing the displacer Before disassembling the sensor or removing the displacer observe the appropriate warnings provided in the sensor instruction manual Check with your process or safety engineer for any additional measures that must be taken to protect against process media This section contains digital level controller installation information including an installation flowchart figure 1 mounting and electrical installation information and a discussion of failure mode jumpers Do not install operate or maintain a DLC3010 digital level controller without being fully trained and qualified in valve actuator and accessory installation operation and
23. ce Criteria Independent Linearity Repeatability input span Hysteresis plus 1 026 of 1 025 of Deadband outputspan outputspan NOTE At full design span reference conditions 1 To lever assembly rotation inputs At effective proportional band PB lt 100 linearity dead band repeatability power supply effect and ambient temperature influence are potentially derated by the factor 100 PB w All Other 249 Sensors 0 25 of output span lt 0 2 of output span 0 1 of full scale output 0 5 of output span 0 5 of output span 0 3 of Operating Influences Power Supply Effect Output changes lt 0 2 of full scale when supply varies between minimum and maximum voltage specifications Transient Voltage Protection The loop terminals are protected by a transient voltage suppressor The specifications are as follows Pulse Waveform Max Vc Rise Time Clamping us Voltage V 10 93 6 Max Ipp Pulse Peak Current A Decay to 50 us 1000 MEN Note us microsecond Ambient Temperature The combined temperature effect on zero and span without the 249 sensor is less than 0 03 of full scale per degree Kelvin over the operating range 40 to 80 C 40 to 176 F Process Temperature The torque rate is affected by the process temperature see figure 16 The process density may also be affected by the process temperature Process Density The
24. d national codes could result in personal injury or property damage from fire or explosion Proper electrical installation is necessary to prevent errors due to electrical noise A resistance between 230 and 1100 ohms must be present in the loop for communication with a Field Communicator Refer to figure 9 for current loop connections Power Supply To communicate with the digital level controller you need a 17 75 volt DC minimum power supply The power supplied to the transmitter terminals is determined by the available supply voltage minus the product of the total loop resistance and the loop current The available supply voltage should not drop below the lift off voltage The lift off voltage is the minimum available supply voltage required for a given total loop resistance Refer to figure 10 to determine the required lift off voltage If you know your total loop resistance you can determine the lift off voltage If you know the available supply voltage you can determine the maximum allowable loop resistance If the power supply voltage drops below the lift off voltage while the transmitter is being configured the transmitter may output incorrect information The DC power supply should provide power with less than 2 ripple The total resistance load is the sum of the resistance of the signal leads and the load resistance of any controller indicator or related pieces of equipment in the loop Note that the resistance of intrinsic saf
25. dy only applicable to the 249W 41 DLC3010 Digital Level Controller Quick Start Guide September 2014 D103214X012 Figure 17 Style Number of Equalizing Connections STYLE 1 STYLE 3 TOP AND BOTTOM CONNECTIONS UPPER AND LOWER SIDE CONNECTIONS SCREWED S 1 OR FLANGED F 1 SCREWED 5 3 OR FLANGED F 3 STYLE 2 STYLE 4 TOP AND LOWER SIDE CONNECTIONS UPPER SIDE AND BOTTOM CONNECTIONS SCREWED S 2 OR FLANGED F 2 SCREWED S 4 OR FLANGED F 4 28B5536 1 B1820 2 Related Documents Other documents containing information related to DLC3010 digital level controllers and 249 sensors include e Bulletin 11 2 DLC3010 FIELDVUE DLC3010 Digital Level Controller D102727X012 e FIELDVUE DLC3010 Digital Level Controller Instruction Manual D102748X012 e Using FIELDVUE Instruments with the Smart HART Loop Interface and Monitor HIM Supplement to HART Communicating Fisher FIELDVUE Instrument Instruction Manuals D103263X012 e Audio Monitor for HART Communications Supplement to HART Communicating Fisher FIELDVUE Instrument Instruction Manuals D103265X012 e Fisher 249 Caged Displacer Sensors Instruction Manual D200099X012 e Fisher 249 Cageless Displacer Sensors Instruction Manual D200100X012 e Fisher 249VS Cageless Displacer Sensor Instruction Manual D103288X012 e Fisher 249W Cageless Wafer Style Displacer Sensor Instruction Manual D102803X012 e Simulation of Process Conditions for Calibration of Fisher Level
26. e owners The contents of this publication are presented for informational purposes only and while every effort has been made to ensure their accuracy they are not to be construed as warranties or guarantees express or implied regarding the products or services described herein or their use or applicability All sales are governed by our terms and conditions which are available upon request We reserve the right to modify or improve the designs or specifications of such products at any time without notice Emerson Process Management Marshalltown lowa 50158 USA Sorocaba 18087 Brazil Chatham Kent ME4 4QZ UK Dubai United Arab Emirates Singapore 128461 Singapore www Fisher com E M ERSON 2005 2014 Fisher Controls International LLC All rights reserved A t y
27. ent Mounting left or right of displacer refer to figure 5 3 Choose Torque Tube Material 23 DLC3010 Digital Level Controller Quick Start Guide September 2014 D103214X012 Figure 13 Method of Determining Moment Arm from External Measurements VERTICAL C OF DISPLACER MOMENT ARM LENGTH HORIZONTAL C OF TORQUE TUBE 4 Select the measurement application level interface or density Note For interface applications if the 249 is not installed on a vessel or if the cage can be isolated calibrate the instrument with weights water or other standard test fluid in level mode After calibrating in level mode the instrument can be switched to interface mode Then enter the actual process fluid specific gravity s and range values If the 249 sensor is installed and must be calibrated in the actual process fluid s at operating conditions enter the final measurement mode and actual process fluid data now a If you choose Level or Interface the default process variable units are set to the same units chosen for displacer length You are prompted to key in the level offset Range values will be initialized based on Level Offset and displacer size The default upper range value is set to equal the displacer length and the default lower range value is set to zero when the level offset is 0 b If you choose Density the default process variable units are set to SGU Specific Gravity Units
28. eptember 2014 D103214X012 Configuration and Calibration Check List C Initial setup complete Perform the Instrument Setup procedure using Guided Setup on page 22 C Calibration complete Perform the Guided Calibration procedure on page 27 C Transmitter correctly respond to an input change and is stable Refer to the Troubleshooting section of the FIELDVUE DLC3010 Digital Level Controller Instruction Manual D102748X012 Transmitter is ready to be placed on line Accessing Configuration and Calibration Procedures Procedures that require the use of the Field Communicator have the text path and the sequence of numeric keys required to display the desired Field Communicator menu For example to access the Full Calibration menu Field Communicator Configure gt Calibration gt Primary gt Full Calibration 2 5 1 1 20 Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 Configuration and Calibration Initial Setup If a DLC3010 digital level controller ships from the factory mounted on a 249 sensor initial setup and calibration is not necessary The factory enters the sensor data couples the instrument to the sensor and calibrates the instrument and sensor combination Note If you received the digital level controller mounted on the sensor with the displacer blocked or if the displacer is not connected the instrument will be coupled to the sensor and the lever assembly unlocked To p
29. ernal at the instrument terminal box shown in figure 11 Power Current Loop Connections Use ordinary copper wire of sufficient size to ensure that the voltage across the digital level controller terminals does not go below 12 0 volts DC Connect the current signal leads as shown in figure 9 After making connections recheck the polarity and correctness of connections then turn the power on RTD Connections An RTD that senses process temperatures may be connected to the digital level controller This permits the instrument to automatically make specific gravity corrections for temperature changes For best results locate the RTD as close to the displacer as practical For optimum EMC performance use shielded wire no longer than 3 meters 9 8 feet to connect the RTD Connect only one end of the shield Connect the shield to either the internal ground connection in the instrument terminal box or to the RTD thermowell Wire the RTD to the digital level controller as follows refer to figure 11 Two Wire RTD Connections 1 Connect a jumper wire between the RS and R1 terminals in the terminal box 2 Connect the RTD to the R1 and R2 terminals Three Wire RTD Connections 1 Connect the 2 wires which are connected to the same end of the RTD to the RS and R1 terminals in the terminal box Usually these wires are the same color 2 Connect the third wire to terminal R2 The resistance measured between this wire and either wire connected to
30. ety barriers if used must be included DLC3010 Digital Level Controller September 2014 Quick Start Guide Figure 9 Connecting a Field Communicator to the Digital Level Controller Loop NOTE 1 THIS REPRESENTS THE TOTAL SERIES LOOP RESISTANCE E0363 D103214X012 2300 11009 lt 1 m l Reference meter for calibration POWER or monitoring SUPPLY x operation May be a voltmeter across 250 ohm resistor or a current meter _ O A HART based communicator may be connected at any termination point in the signal loop Signal loop must have between 250 and 1100 ohms load for communication Signal loop may be grounded at any point or left ungrounded Figure 10 Power Supply Requirements and Load Resistance Maximum Load 43 5 X Available Supply Voltage 12 0 Load Ohms 10 12 E0284 14 Operating Region 25 30 LIFT OFF SUPPLY VOLTAGE VDC Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 Field Wiring A WARNING To avoid personal injury or property damage caused by fire or explosion remove power to the instrument before removing the digital level controller cover in an area which contains a potentially explosive atmosphere or has bee
31. gital level controller on a 249 sensor secure the shaft extension to the sensor torque tube shaft via the shaft coupling and set screws with the coupling centered as shown in figure 7 2 Slide the access handle to the locked position to expose the access hole Press on the back of the handle as shown in figure 2 then slide the handle toward the front of the unit Be sure the locking handle drops into the detent Remove the hex nuts from the mounting studs Position the insulator on the digital level controller sliding the insulator straight over the mounting studs Re install the four hex nuts on the mounting studs and tighten the nuts A UJ Carefully slide the digital level controller with the attached insulator over the shaft coupling so that the access hole is on the bottom of the digital level controller Secure the digital level controller and insulator to the torque tube arm with four cap screws 8 Tighten the cap screws to 10 Nem 88 5 Ibfein Electrical Connections A WARNING Select wiring and or cable glands that are rated for the environment of use such as hazardous area ingress protection and temperature Failure to use properly rated wiring and or cable glands can result in personal injury or property damage from fire or explosion Wiring connections must be in accordance with local regional and national codes for any given hazardous area approval Failure to follow the local regional an
32. he handle as shown in figure 2 then slide the handle toward the front of the unit Be sure the locking handle drops into the detent 2 Using a 10 mm deep well socket inserted through the access hole loosen the shaft clamp figure 2 This clamp will be re tightened in the Coupling portion of the Initial Setup section 3 Remove the hex nuts from the mounting studs Do not remove the adapter ring CAUTION Measurement errors can occur if the torque tube assembly is bent or misaligned during installation Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 Figure 5 Typical Mounting Positions for FIELDVUE DLC3010 Digital Level Controller on Fisher 249 Sensor SENSOR LEFT OF DISPLACER RIGHT OF DISPLACER CAGELESS ilz 1 NOT AVAILABLE FOR SIZE NPS 2 CL300 AND CL600 249C SENSOR 19B2787 Rev D 19B6600 Rev C B1407 2 Figure 6 Close up of Set Screw La SET SCREW f 4 Position the digital level controller so the access hole is on the bottom of the instrument 5 Carefully slide the mounting studs into the sensor mounting holes until the digital level controller is snug against the sensor 6 Reinstall the hex nuts on the mounting studs and tighten the hex nuts to 10 Nem 88 5 Ibfein DLC3010 Digital Level Controller Quick Start Guide September 2014 D103214X012 Mounting the Digital Level Controller for Extreme Temperature Applications Refer to figure 7 for parts iden
33. ide the terminal box can be used to measure loop current across an internal 1 ohm resistor 1 Remove the terminal box cap Adjust the test meter to measure a range of 0 001 to 0 1 volts Connect the positive lead of the test meter to the connection and the negative lead to the T connection inside the terminal box UJ N 4 Measure Loop current as Voltage on test meter x 1000 milliamps example Test meter Voltage X 1000 Loop Milliamps 0 004 X1000 4 0 milliamperes 0 020 X 1000 20 0 milliamperes 5 Remove test leads and replace the terminal box cover Alarm Jumper Each digital level controller continuously monitors its own performance during normal operation This automatic diagnostic routine is a timed series of checks repeated continuously If diagnostics detect a failure in the electronics 17 DLC3010 Digital Level Controller Quick Start Guide September 2014 D103214X012 the instrument drives its output to either below 3 70 mA or above 22 5 mA depending on the position HI LO of the alarm jumper An alarm condition occurs when the digital level controller self diagnostics detect an error that would render the process variable measurement inaccurate incorrect or undefined or a user defined threshold is violated At this point the analog output of the unit is driven to a defined level either above or below the nominal 4 20 mA range based on the position of the alarm jumper On encapsulated electronics
34. ify individual parameters when they need to be changed Preliminary Considerations Write Lock Field Communicator Overview gt Device Information gt Alarm Type and Security gt Security gt Write Lock 1 7 3 2 1 To setup and calibrate the instrument write lock must be set to Writes Enabled Write Lock is reset by a power cycle If you have just powered up the instrument Writes will be enabled by default Level Offset Field Communicator Configure gt Manual Setup gt Variables gt Primary Variables gt Level Offset 2 2 2 1 4 The Level Offset parameter should be cleared to zero before running Instrument Setup To clear Level Offset enter the value 0 0 and press Enter gt Send Guided Setup Configure gt Guided Setup gt Instrument Setup 2 1 1 Note Place the loop into manual operation before making any changes in setup or calibration Instrument Setup is available to aid initial setup Follow the prompts on the Field Communicator display to enter information for the displacer torque tube and digital measurement units Most of the information is available from the sensor nameplate shown in figure 12 The moment arm is the effective length of the displacer driver rod length and depends upon the sensor type For a 249 sensor refer to table 5 to determine displacer rod length For a special sensor refer to figure 13 Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 Figure 12 Example Sen
35. ile at the 5025 process condition to make maximum use of available transmitter travel 6 The Capture Zero procedure is still performed at the zero buoyancy or zero differential buoyancy condition 3 Insert a 10 mm deep well socket through the access hole and onto the torque tube shaft clamp nut Tighten the clamp nut to a maximum torque of 2 1 Nem 18 Ibfein 4 Slide the access handle to the unlocked position Press on the back of the handle as shown in figure 2 then slide the handle toward the rear of the unit Be sure the locking handle drops into the detent 26 Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 Calibration Guided Calibration Field Communicator Configure gt Calibration gt Primary gt Guided Calibration 2 5 1 1 Guided Calibration recommends an appropriate calibration procedures for use in the field or on the bench based on your input Follow the Field Communicator prompts to calibrate the digital level controller Detailed Calibration Examples PV Sensor Calibration If the advanced capabilities of the transmitter are to be used it is necessary to calibrate the PV sensor Calibration with Standard Displacer and Torque Tube Run the initial calibration near ambient temperature at design span to take full advantage of the available resolution This is accomplished by using a test fluid with a specific gravity SG close to 1 The value of SG in the instrument memo
36. inage is provided by the user and a small performance loss is acceptable the instrument can be mounted in 90 degree rotational increments around the pilot shaft axis The LCD meter may be rotated in 90 degree increments to accommodate this The digital level controller and torque tube arm are attached to the sensor either to the left or right of the displacer as shown in figure 5 This can be changed in the field on a 249 sensor refer to the appropriate sensor instruction manual Changing the mounting also changes the effective action because the torque tube rotation for increasing level looking at the protruding shaft is clockwise when the unit is mounted to the right of the displacer and counter clockwise when the unit is mounted to the left of the displacer All caged 249 sensors have a rotatable head That is the digital level controller can be positioned at any of eight alternate positions around the cage as indicated by the position numbers 1 through 8 in figure 5 To rotate the head remove the head flange bolts and nuts and position the head as desired Mounting the Digital Level Controller on a 249 Sensor Refer to figure 2 unless otherwise indicated 1 If the set screw in the access handle is driven against the spring plate use a 2 mm hex key to back it out until the head is flush with the outer surface of the handle see figure 6 Slide the access handle to the locked position to expose the access hole Press on the back of t
37. ion more than 5 of span above the minimum process condition and use the Trim Gain procedure at that condition The gain will now be initialized correctly The instrument would work fine in this configuration for an interface application However if you have a density application it won t be possible to report the PV correctly in engineering units if the instrument calibration is concluded at this point Since you now have a valid gain Change the PV mode to Interface or Density e reconfigure the fluid SGs or range values to the actual fluid values or extremes and e use the Trim Zero procedure in the Partial Calibration menu to back compute the theoretical zero buoyancy angle The last step above will align the value of the PV in engineering units to the sight glass observation Note Information on simulating process conditions is available in the Simulation of Process Conditions for Calibration of Fisher Level Controllers and Transmitters instruction manual supplement D103066X01 2 available from your Emerson Process Management sales office or at www fisher com Following are some guidelines on the use of the various sensor calibration methods when the application uses an overweight displacer Weight based Use two accurately known weights between minimum and maximum buoyancy conditions The full displacer weight is invalid because it will put the unit on a stop Min Max Min now means submerged in the lightest fluid and Max mea
38. lace the unit in service if the displacer is blocked remove the rod and block at each end of the displacer and check the instrument calibration If the factory cal option was ordered the instrument will be precompensated to the process conditions provided on the requisition and may not appear to be calibrated if checked against room temperature 0 and 100 water level inputs If the displacer is not connected hang the displacer on the torque tube and re zero the instrument by performing the Capture Zero procedure If you received the digital level controller mounted on the sensor and the displacer is not blocked such as in skid mounted systems the instrument will not be coupled to the sensor and the lever assembly will be locked To place the unit in service couple the instrument to the sensor then unlock the lever assembly Then perform the Capture Zero procedure To review the configuration data entered by the factory connect the instrument to a 24 VDC power supply as shown in figure 9 Connect the Field Communicator to the instrument and turn it on Go to Configure and review the data under Manual Setup Alert Setup and Communications If your application data has changed since the instrument was factory configured refer to the Manual Setup section for instructions on modifying configuration data For instruments not mounted on a level sensor or when replacing an instrument initial setup consists of entering sensor information The
39. maintenance To avoid personal injury or property damage it is important to carefully read understand and follow all of the contents of this manual including all safety cautions and warnings If you have any questions regarding these instructions contact your Emerson Process mx Management sales office before proceeding DLC3010 Digital Level Controller September 2014 Figure 1 Installation Flowchart START HERE Check Alarm Jumper Position Wire Digital Level Controller Factory mounted on 249 sensor Power Digital Level Controller High temperature application Install heat insulator assembly Enter Tag Messages Mount and Wire Date and check or set Digital level target application data Controller Power Digital level Controller Yes Density Measurement Set Level Offset to Zero Using Temperature Correction Use Setup Wizard to enter sensor data and calibration condition Set Specific Gravity Calibrate sensor Set Range Values NOTE 1 gt IF USING RTD FOR TEMPERATURE CORRECTION Disable Writes ALSO WIRE RTD TO DIGITAL LEVEL CONTROLLER 2 gt DISABLING WRITES IS EFFECTIVE ONLY IF THE DLC3010 REMAINS POWERED UP Setup specific gravity tables Enter Process Quick Start Guide D103214X012 Setup and Calibrate RTD Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 Configuration On the Be
40. mes available depending upon sensor construction Sensor Displacer Lengths See tables 11 and 12 footnotes Sensor Working Pressures Consistent with applicable ANSI pressure temperature ratings for the specific sensor constructions shown in tables 11 and 12 Caged Sensor Connection Styles Cages can be furnished in a variety of end connection styles to facilitate mounting on vessels the Table 9 Allowable Process Temperatures for Common 249 Sensor Pressure Boundary Materials PROCESS TEMPERATURE MATERIAL Steel 29 C 20 F 427 C 800 F Stainless Steel 198 C 325 F 427 C 800 F N04400 198 C 325 F 427 C 800 F Graphite Laminate SST 198 C 325 F 427 C 800 F Gaskets N04400 PTFE 73 C 100 F 204 C 400 F Gaskets 40 equalizing connection styles are numbered and are shown in figure 17 Mounting Positions Most level sensors with cage displacers have a rotatable head The head may be rotated through 360 degrees to any of eight different positions as shown in figure 5 Construction Materials See tables 10 11 and 12 Operative Ambient Temperature See table 9 For ambient temperature ranges guidelines and use of optional heat insulator see figure 8 Options Heat insulator see description under Ordering Information W Gauge glass for pressures to 29 bar at 232 C 420 psig at 450 F W Reflex gauges for high temperature and pressure applications Table 10
41. mperature use a correction factor interpolated from tables of theoretical normalized modulus of rigidity Multiply the theoretical rate by the correction factor before entering the data You should now have the gain correct to within perhaps 10 at least for the standard wall short length torque tubes For the longer torque tubes 249K L N with thin wall and a heat insulator extension the theoretical values are much less accurate as the mechanical path departs considerably from the linear theory Note Tables containing information on temperature effects on torque tubes can be found in the Simulation of Process Conditions for Calibration of Fisher Level Controllers and Transmitters instruction manual supplement D103066X01 2 available from your Emerson Process Management sales office or at www fisher com 6 Using a sight glass or sampling ports obtain an estimate of the current process condition Run the Trim Zero calibration and report the value of the actual process in the PV engineering units 7 You should now be able to go to automatic control If observations over time show the instrument output exhibits for example 1 2 times as much excursion as the sight glass input you could divide the stored torque tube rate by 1 2 and send the new value to the instrument Then run another Trim Zero calibration and observe results for another extended period to see if further iteration is required Entering Theoretical Torque Tube TT Rates
42. n classified as hazardous Note For intrinsically safe applications refer to the instructions supplied by the barrier manufacturer All power to the digital level controller is supplied over the signal wiring Signal wiring need not be shielded but use twisted pairs for best results Do not run unshielded signal wiring in conduit or open trays with power wiring or near heavy electrical equipment If the digital controller is in an explosive atmosphere do not remove the digital level controller covers when the circuit is alive unless in an intrinsically safe installation Avoid contact with leads and terminals To power the digital level controller connect the positive power lead to the terminal and the negative power lead to the terminal as shown in figure 11 Figure 11 Digital Level Controller Terminal Box 4 20 mA LOOP TEST CONNECTIONS 1 2 NPT CONNECTIONS CONDUIT CONNECTION RTD CONNECTIONS INTERNAL EXTERNAL GROUND GROUND CONNECTION 1 2 NPT CONNECTION CONDUIT CONNECTION FRONT VIENY REAR VIEW W8041 CAUTION Do not apply loop power across the T and terminals This can destroy the 1 Ohm sense resistor in the terminal box Do not apply loop power across the Rs and terminals This can destroy the 50 Ohm sense resistor in the electronics module When wiring to screw terminals the use of crimped lugs is recommended Tighten the terminal screws to ensure that good contact is made No additional power wi
43. nch or in the Loop Configure the digital level controller before or after installation It may be useful to configure the instrument on the bench before installation to ensure proper operation and to familiarize yourself with its functionality Protecting the Coupling and Flexures CAUTION Damage to flexures and other parts can cause measurement errors Observe the following steps before moving the sensor and controller Lever Lock The lever lock is built in to the coupling access handle When the handle is open it positions the lever in the neutral travel position for coupling In some cases this function is used to protect the lever assembly from violent motion during shipment A DLC3010 controller will have one of the following mechanical configurations when received 1 A fully assembled and coupled caged displacer system is shipped with the displacer or driver rod blocked within the operating range by mechanical means In this case the access handle figure 2 will be in the unlocked position Remove the displacer blocking hardware before calibration See the appropriate sensor instruction manual The coupling should be intact Figure 2 Sensor Connection Compartment Adapter Ring Removed for Clarity MOUNTING STUDS ACCESS HOLE SET SCREW PRESS HERE TO MOVE ACCESS SLIDE ACCESS HANDLE HANDLE TOWARD FRONT OF UNIT TO EXPOSE ACCESS HOLE DLC3010 Digital Level Controller Quick Start Guide September 2014 D103214X
44. next step is coupling the sensor to the digital level controller When the digital level controller and sensor are coupled the combination may be calibrated Sensor information includes displacer and torque tube information such as Length units meters inches or centimeters Volume units cubic inches cubic millimeters or milliliters Weight units kilograms pounds or ounce Displacer Length Displacer Volume Displacer Weight Displacer Driver Rod Length moment arm see table 5 Torque Tube Material Note A sensor with an N05500 torque tube may have NiCu on the nameplate as the torque tube material 21 DLC3010 Digital Level Controller Quick Start Guide September 2014 D103214X012 e Instrument mounting right or left of displacer e Measurement Application level interface or density Configuration Advice Guided Setup directs you through initialization of configuration data needed for proper operation When the instrument comes out of the box the default dimensions are set for the most common Fisher 249 construction so if any data is unknown it is generally safe to accept the defaults The mounting sense instrument left or right of displacer is important for correct interpretation of positive motion The torque tube rotation is clockwise with rising level when the instrument is mounted to the right of the displacer and counterclockwise when mounted to the left of the displacer Use Manual Setup to locate and mod
45. ns submerged in the heaviest fluid Two point Use any two interface levels that actually fall on the displacer Accuracy is better if the levels are farther apart The result should be close if you can move the level even 1026 Theoretical If the level cannot be changed at all you can enter a theoretical value for torque tube rate manually In this case you would not be able to Capture Zero at the 025 interface condition 29 DLC3010 Digital Level Controller Quick Start Guide September 2014 D103214X012 Density Applications with Standard Displacer and Torque Tube Note When you change PV is from level or interface to density the range values will be initialized to 0 1 and 1 0 SGU You may edit the range values according to the specify gravity unit It is necessary to back out of Manual Setup and re enter the Manual Setup menu to see the changes being refreshed If the displacer is overweight there is no way to get the output numerically correct in density mode because the Level Offset is not available Therefore density calibration normally has to begin with the assumption that the displacer is free moving at zero buoyancy dry conditions Capture Zero accurately at dry displacer conditions and any of the full sensor calibration methods Weight Min Max and Two Point can be used in density mode The terminology can be confusing because it usually refers to a level as the process condition to set up When using one of these method
46. nstructions for Safe Use and Installations in Hazardous Locations Certain nameplates may carry more than one approval and each approval may have unique installation wiring requirements and or conditions of safe use These special instructions for safe use are in addition to and may override the standard installation procedures Special instructions are listed by approval type Note This information supplements the nameplate markings affixed to the product Always refer to the nameplate itself to identify the appropriate certification Contact your Emerson Process Management sales office for approval certification information not listed here A WARNING Failure to follow these conditions of safe use could result in personal injury or property damage from fire or explosion or area re classification CSA Intrinsically Safe Explosion proof Division 2 Dust Ignition proof No special conditions for safe use Refer to table 1 for approval information Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 Table 1 Hazardous Area Classifications CSA Canada Certification Body Certification Obtained Entity Rating Temperature Code Vmax 30 VDC Ex ia Intrinsically Safe Imax 226 mA Class Division 1 GP A B C D E F G T6 per drawing 2885744 see figure 14 Pu P er Explosion proof o Class 1 Division 1 GP B C D T6 ToS ONE Class Division 2 GP A B C D T6 Class II Division 1 2 GP
47. ransducer housing must engage one of the recesses in the cover Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 Loop Test optional Field Communicator Service Tools gt Maintenance gt Tests gt Loop Test 3 3 1 1 or 3 3 1 2 if LCD Configuration is installed Loop test can be used to verify the controller output the integrity of the loop and the operations of any recorders or similar devices installed in the loop To initiate a loop test perform the following procedure 1 Connect a reference meter to the controller To do so either connect the meter to the test connections inside the terminal box see the Test Connections procedure or connect the meter in the loop as shown in figure 9 2 Access Loop Test 3 Select OK after you set the control loop to manual The Field Communicator displays the loop test menu 4 Selecta discreet milliamp level for the controller to output At the Choose analog output prompt select 4 mA 20 mA or Other to manually input a value between 4 and 20 milliamps 5 Checkthe reference meter to verify that it reads the value you commanded the controller to output If the readings do not match either the controller requires an output trim or the meter is malfunctioning After completing the test procedure the display returns to the loop test screen and allows you to choose another output value or end the test DLC3010 Digital Level Controller Quick Start Guide S
48. ration at Process Conditions Hot Cut Over when input cannot be varied If the input to the sensor cannot be varied for calibration you can configure the instrument gain using theoretical information and use Trim Zero to trim the output to the current process condition This allows you to make the controller operational and to control a level around a setpoint You can then use comparisons of input changes to output changes over time to refine the gain estimate A new trim zero will be required after each gain adjustment This approach is not recommended for a safety related application where exact knowledge of the level is important to prevent an overflow or dry sump condition However it should be more than adequate for the average level control application that can tolerate large excursions from a midspan set point Two Point Calibration allows you to calibrate the torque tube using two input conditions that put the measured interface anywhere on the displacer The accuracy of the method increases as the two points are moved farther apart but if the level can be adjusted up or down a minimum 5 span it is enough to make a calculation Most level processes can accept a small manual adjustment of this nature If your process cannot then the theoretical approach is the only method available 30 Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 1 Determine all the information you can about the 249 hardware 249 type
49. ring is required All digital level controller covers must be fully engaged to meet explosion proof requirements For ATEX approved units the terminal box cover set screw must engage one of the recesses in the terminal box beneath the terminal box cover DLC3010 Digital Level Controller Quick Start Guide September 2014 D103214X012 Grounding A WARNING Personal injury or property damage can result from fire or explosion caused by the discharge of static electricity when flammable or hazardous gases are present Connect a 14 AWG 2 1 mm ground strap between the digital level controller and earth ground when flammable or hazardous gases are present Refer to national and local codes and standards for grounding requirements The digital level controller will operate with the current signal loop either floating or grounded However the extra noise in floating systems affects many types of readout devices If the signal appears noisy or erratic grounding the current signal loop at a single point may solve the problem The best place to ground the loop is at the negative terminal of the power supply As an alternative ground either side of the readout device Do not ground the current signal loop at more than one point Shielded Wire Recommended grounding techniques for shielded wire usually call for a single grounding point for the shield You can either connect the shield at the power supply or to the grounding terminals either internal or ext
50. ry during the calibration process should match the SG of the test fluid being used in the calibration After the initial calibration the instrument may be set up for a target fluid with a given specific gravity or an interface application by simple configuration data changes 1 Run through Guided Setup and verify that all sensor data is correct Procedure Change the PV mode to Level Set the Level Offset value to 0 00 Set the Specific Gravity value to the SG of the test fluid being used Establish the test fluid level at the desired process zero point Make sure that the DLC3010 lever assembly has been properly coupled to the torque tube see coupling procedure on page 26 To unlock the lever assembly and allow it to freely follow the input close the coupling access door on the instrument It is often possible to watch the instrument display and or the analog output to detect when the fluid hits the displacer because the output will not start moving upward until that point is reached Select the Min Max calibration from the Full Calibration menu and confirm that you are at the Min condition at the prompt After the Min point has been accepted you will be prompted to establish the Max condition The displacer completely covered condition should be slightly higher than the 10025 level mark to work correctly For example 15 inches above the zero mark would generally be enough for a 14 inch displacer on a 249B because the amount of displ
51. sensitivity to error in knowledge of process density is proportional to the differential density of the calibration If the differential specific gravity is 0 2 an error of 0 02 specific gravity units in knowledge of a process fluid density represents 10 of span 35 DLC3010 Digital Level Controller September 2014 Quick Start Guide D103214X012 Table 6 DLC3010 Digital Level Controller Specifications continued Electromagnetic Compatibility Meets EN 61326 1 and EN 61326 2 3 Immunity Industrial locations per Table 2 of EN 61326 1 and Table AA 2 of EN 61326 2 3 Performance is shown in table 7 below Emissions Class A ISM equipment rating Group 1 Class A Supply Requirements See figure 10 12 to 30 volts DC instrument has reverse polarity protection A minimum compliance voltage of 17 75 is required to guarantee HART communication Compensation Transducer compensation for ambient temperature Density parameter compensation for process temperature requires user supplied tables Manual compensation for torque tube rate at target process temperature is possible Digital Monitors Linked to jumper selected Hi factory default or Lo analog alarm signal Torque tube position transducer Drive monitor and signal reasonableness monitor User configurable alarms Hi Hi and Lo Lo Limit process alarms HART readable only RTD signal reasonableness monitor When RTD installed Processor free time monitor Wri
52. sor Nameplate SENSOR TYPE DISPLACER PSSEMBLY DISPLACER PRESSURE RATING PRESSURE RATING 223 076543210 sid 12498 _ press units Psi RATING 285 100F RATING FP 1500 51 DISELACER 2 x 32 INCHES ASSY WCB STL ASSEMBLY MATERIAL VOLUME 103 CU IN eur Ik TRIM MONEL PiSPLACER 316ssT TORQUE k MONEL STD O DISBPACER TRIM MATERIAL DISPLACER VOLUME TORQUE TUBE MATERIAL MATERIAL DISPLACER SIZE DIAMETER X LENGTH 23A1725 E sht 1 E0366 Table 5 Moment Arm Driver Rod Length MOMENT ARM 8 01 249P CL125 CL600 249P CL900 CL2500 249V5 d 2490 1 Moment arm driver rod length is the perpendicular distance between the vertical centerline of the displacer and the horizontal centerline of the torque tube See figure 13 If you cannot determine the driver rod length contact your Emerson Process Management sales office and provide the serial number of the sensor 2 This table applies to sensors with vertical displacers only For sensor types not listed or sensors with horizontal displacers contact your Emerson Process Management sales office for the driver rod length For other manufacturers sensors see the installation instructions for that mounting 1 Enter displacer length weight and volume units and values and for moment arm length in the same units chosen for displacer length when prompted 2 Choose Instrum
53. st be shorter than 3 meters 9 8 feet 1 A No degradation during testing B Temporary degradation during testing but is self recovering Specification limit 1 of span 2 HART communication was considered as not relevant to the process and is used primarily for configuration calibration and diagnostic purposes 38 Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 Figure 16 Theoretical Reversible Temperature Effect on Common Torque Tube Materials TORQUE RATE REDUCTION NORMALIZED MODULUS OF RIGIDITY E 52 550 14 LIZH TEMPERATURE C TORQUE RATE REDUCTION NORMALIZED MODULUS OF RIGIDITY E M N lt NE i ES nas LC ah Ew NN NN EE 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 TEMPERATURE 1 DUETO THE PERMANENT DRIFT THAT OCCURS NEAR AND ABOVE 260 C 500 F N05500 IS NOT RECOMMENDED FOR TEMPERATURES ABOVE 232 C 450 F DLC3010 Digital Level Controller September 2014 Table 8 249 Sensor Specifications Quick Start Guide D103214X012 Input Signal Liquid Level or Liquid to Liquid Interface Level From 0 to 100 percent of displacer length Liquid Density From 0 to 100 percent of displacement force change obtained with given displacer volume standard volumes are W 980 cm 60 inches for 249C and 249CP sensors or Bl 1640 cm 100 inches for most other sensors other volu
54. ted on 249 sensor li Factory Calibration available for instruments factory mounted on 249 sensor when application process temperature and density s are supplied ll Device is compatible with user specified remote indicator Operating Limits Process Temperature See table 9 and figure 8 Ambient Temperature and Humidity See below Conditions Normal Transport and Nominal Limits 1 2 Storagelimits Reference Ambient 40 to 80 C 40 to 85 C 25 C Temperature 40 to 176 F 40 to 185 F 77 F Ambient 0 to 95 0 to 95 9 Relative non condensing non condensing id Humidity Weight Less than 2 7 Kg 6 Ibs NOTE Specialized instrument terms are defined in ANSI ISA Standard 51 1 Process Instrument Terminology 1 LCD meter may not be readable below 20 C 4 F 2 Contact your Emerson Process Management sales office or application engineer if temperatures exceeding these limits are required 37 DLC3010 Digital Level Controller Quick Start Guide September 2014 D103214X012 Table 7 EMC Summary Results Immunity Phenomenon Basic Standard Test Level Perform uen Criteria 1 2 Electrostatic discharge ESD IEC 61000 4 2 8 kV air A 80 to 1000 MHz 10V m with 1 kHz AM at 80 Enclosure Radiated EM field IEC 61000 4 3 1400 to 2000 MHz 3V m with 1 kHz AM at 80 2000 to 2700 MHz 1V m with 1 kHz AM at 80 O signalfcontro T ine to ground oniy each 8 Note RTD wiring mu
55. tes remaining in Non Volatile Memory monitor User configurable alarms Hi and Lo limit process alarms Hi and Lo limit process temperature alarms and Hi and Lo limit electronics temperature alarms Diagnostics Output loop current diagnostic LCD meter diagnostic Spot specific gravity measurement in level mode used to update specific gravity parameter to improve process measurement Digital signal tracing capability by review of troubleshooting variables and Basic trending capability for PV TV and SV 36 continued LCD Meter Indications LCD meter indicates analog output on a percent scale bar graph The meter also can be configured to display Process variable in engineering units only Percent range only Percent range alternating with process variable or Process variable alternating with process temperature and degrees of pilot shaft rotation Electrical Classification Hazardous Area CSA Intrinsically Safe Explosion proof Division 2 Dust Ignition proof FM Intrinsically Safe Explosion proof Non incendive Dust Ignition proof ATEX Intrinsically Safe Type n Flameproof IECEx Intrinsically Safe Type n Flameproof Refer to Hazardous Area Approvals and Special Instructions for Safe Use and Installations in Hazardous Locations in the Installation section starting on page 6 for additional approvals information Electrical Housing CSA Type 4X FM NEMA 4X ATEX IP66
56. the measured torque tube rate manually 25 DLC3010 Digital Level Controller Quick Start Guide September 2014 D103214X012 Coupling If the digital level controller is not already coupled to the sensor perform the following procedure to couple the digital level controller to the sensor 1 Slide the access handle to the locked position to expose the access hole Press on the back of the handle as shown in figure 2 then slide the handle toward the front of the unit Be sure the locking handle drops into the detent 2 Setthe displacer to the lowest possible process condition i e lowest water level or minimum specific gravity or replace the displacer by the heaviest calibration weight Note Interface or density applications with displacer torque tube sized for a small total change in specific gravity are designed to be operated with the displacer always submerged In these applications the torque rod is sometimes resting on a stop while the displacer is dry The torque tube does not begin to move until a considerable amount of liquid has covered the displacer In this case couple with the displacer submerged in the fluid with the lowest density and the highest process temperature condition or with an equivalent condition simulated with the calculated weights If the sizing of the sensor results in a proportional band greater than 100 total expected rotational span greater than 4 4 degrees couple the transmitter to the pilot shaft wh
57. tification except where otherwise indicated The digital level controller requires an insulator assembly when temperatures exceed the limits shown in figure 8 A torque tube shaft extension is required for a 249 sensor when using an insulator assembly Figure 7 Digital Level Controller Mounting on Sensor in High Temperature Applications INSULATOR KEY 57 SHAFT SET SCREWS EXTENSION 60 58 ON L WASHER SHAFT KEY 78 COUPLING HEX NUTS KEY 59 4 KEY 34 CAP SCREWS MOUNTING STUDS ne Res 82707 SENSOR DIGITAL LEVEL CONTROLLER Figure 8 Guidelines for Use of Optional Heat Insulator Assembly AMBIENT TEMPERATURE C 40 30 20 10 10 20 30 40 50 60 70 80 00 HEAT INSULATOR REQUIRED PROCESS TEMPERATURE F PROCESS TEMPERATURE C 40 20 0 20 40 60 80 100 120 140 160 176 AMBIENT TEMPERATURE F STANDARD TRANSMITTER NOTES 1 FOR PROCESS TEMPERATURES BELOW 29 C 20 F AND ABOVE 204 C 400 F SENSOR MATERIALS MUST BE APPROPRIATE FOR THE PROCESS SEE TABLE 9 2 IF AMBIENT DEW POINT IS ABOVE PROCESS TEMPERATURE ICE FORMATION MIGHT CAUSE INSTRUMENT MALFUNCTION AND REDUCE INSULATOR EFFECTIVENESS 39A4070 B A5494 1 CAUTION Measurement errors can occur if the torque tube assembly is bent or misaligned during installation 12 Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 1 For mounting a di
58. use the linkage is lying on a travel stop at that condition The Capture Zero routine in the Partial Calibration menu group will therefore not function correctly in the target PV modes of interface or density when the displacer is overweight The Full Calibration routines Min Max Two Point and Weight will all work correctly at the actual process conditions when in interface or density mode because they back compute the theoretical zero buoyancy angle instead of capturing it If itis necessary to use the Partial Calibration methods when the displacer is overweight the following transformation may be used An interface or density application can be mathematically represented as a level application with a single fluid whose density is equal to the difference between the actual SGs of the fluid covering the displacer at the two process extremes 28 Quick Start Guide DLC3010 Digital Level Controller D103214X012 September 2014 The calibration process flows as follows e Change the PV mode to Level e Set the Level Offset to zero Set the Range Values to LRV 0 0 URV displacer length e Capture Zero at the lowest process condition that is with the displacer completely submerged in the fluid of the lowest density NOT dry e Set Specific Gravity to the difference between the SGs of the two fluids for example if SG_upper 0 87 and SG_lower 1 0 enter a specific gravity value of 0 13 e Set up a second process condit
59. y mode was chosen setup is complete e f Interface or Density mode was chosen you are prompted to enter the specific gravity of the process fluid if interface mode the specific gravities of the upper and lower process fluids Note If you are using water or weights for calibration enter a specific gravity of 1 0 SGU For other test fluids enter the specific gravity of the fluid used For temperature compensation go to Manual Setup Under Process Fluid select View Fluid Tables Temperature compensation is enabled by entering values into the fluid tables Two data specific gravity tables are available that may be entered in the instrument to provide specific gravity correction for temperature refer to the Manual Setup section of the instruction manual For interface level applications both tables are used For level measurement applications only the lower specific gravity table is used Neither table is used for density applications Both tables may be edited during manual setup Note The existing tables may need to be edited to reflect the characteristics of the actual process fluid You can accept the current table s modify an individual entry or enter a new table manually For an interface application you can switch between the upper and lower fluid tables Note In firmware version 07 and 08 the data tables for torque tube correction are simply stored without implementation You may use the information to pre compensate

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