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Operating Manual
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Kobold Model Operating Manual

Operating Instructions
for
SMART PRESSURE TRANSMITTER
Model: PAS
PAS
1. Contents
1. Contents ........................................................................................................ 2
2. Introduction ................................................................................................... 4
3. Using This Manual ........................................................................................ 5
3.1 Overview of Transmitter ....................................................................... 6
3.2 Software Compatibility ......................................................................... 6
3.3 Transmitter Components ..................................................................... 7
4. Handling Cautions ......................................................................................... 8
4.1 Unpacking ............................................................................................ 9
4.2 Models and Specifications Check ........................................................ 9
4.3 Storage ................................................................................................ 9
4.4 Selecting Installation Locations .......................................................... 10
4.5 Performing Sensor Zero Trim after Installation .................................. 10
4.6 Pressure Connections ........................................................................ 11
4.7 Waterproofing of Cable Conduit Connections .................................... 11
4.8 Restrictions on Use of Radio Transceivers ........................................ 11
4.9 Insulation Resistance Test and Dielectric Strength Test .................... 12
4.10 Installation of Explosion Protected Type Transmitters ....................... 13
4.11 EMC Conformity Standards ............................................................... 14
5. Transmitter Functions ................................................................................. 14
5.1 Overview ............................................................................................ 14
5.2 Safety Message ................................................................................. 14
5.3 Warning ............................................................................................. 15
5.4 Fail Mode Alarm ................................................................................. 15
5.5 EEProm-Write Enable / Disable Mode Switch ................................... 17
5.6 Configuration of Alarm and Security Jumper Procedures .................. 18
5.7 Configuration of Zero and Span Procedures with Buttons ................. 18
5.8 Wiring Connections for External HHT/ Ammeter ................................ 27
6. Installation ................................................................................................... 28
6.1 Overview ............................................................................................ 28
6.2 Safety Message ................................................................................. 28
6.3 Warning ............................................................................................. 28
6.4 Commissioning on the bench with Hand-Held Terminal .................... 29
6.5 General Considerations ..................................................................... 30
6.6 Electrical Considerations ................................................................... 30
6.7 Wiring ................................................................................................. 31
6.8 Mechanical Considerations ................................................................ 37
6.9 Environmental Considerations ........................................................... 38
7. On-line Operation ........................................................................................ 39
7.1 Overview ............................................................................................ 39
7.2 Safety Message ................................................................................. 39
7.3 Configuration Data Review ................................................................ 39
7.4 Check Output ..................................................................................... 39
7.5 Basic Setup ........................................................................................ 40
7.6 Detailed Setup ................................................................................... 40
7.7 Tag Information set up ....................................................................... 41
PAS
7.8 Diagnostics and Services .................................................................. 42
7.9 Calibration ......................................................................................... 42
7.10 Advance Set Up: ................................................................................ 43
8. Maintenance ............................................................................................... 44
8.1 Overview ............................................................................................ 44
8.2 Safety Message ................................................................................. 44
8.3 Hardware Diagnostics ........................................................................ 45
8.4 Hardware Maintenance ...................................................................... 46
9. Appendix I ................................................................................................... 49
10. Declaration of Conformance ....................................................................... 51
11. ATEX Certificate ......................................................................................... 52
Manufactured and sold by:
Kobold Messring GmbH
Nordring 22-24
D-65719 Hofheim
Tel.: +49(0)6192-2990
Fax: +49(0)6192-23398
E-Mail: info.de@kobold.com
Internet: www.kobold.com
PAS
2. Introduction
The PAS Smart Pressure Transmitter are correctly calibrated at the factory before shipment. To ensure correct and efficient use of the instrument, please read this manual thoroughly and fully understand how to operate the instrument before operating it
1. The contents of this manual are subject to change without prior notice.
2. All rights reserved. No part of this manual may be reproduced in any form without KOBOLD Messring GmbH’s written permission.
3. If any question arises or errors are found, or if any information is missing from this manual, please inform the nearest KOBOLD sales office.
4. The specifications covered by this manual are limited to those for the standard type under the specified model number break-down and do not cover custom­made instrument.
5. Please note that changes in the specifications, construction, or component parts of the instrument may not immediately be reflected in this manual at the time of change, provided that postponement of revisions will not cause difficulty to the user from a functional of performance standpoint.
PAS
3. Using This Manual
The Chapters in this operating manual provide information on installing, operating, and maintaining devices from KOBOLD Model PAS Smart Pressure Transmitter. Chapters within this manual are organised as follows.
Chapter 4 Handling Cautions
Chapter 4 provides instructions on software functions, configuration parameters, and online variables.
Chapter 5 Transmitter Functions
Chapter 5 contains instructions for configuring and commissioning Model PAS Smart Pressure Transmitters.
Chapter 6 Installation
Chapter 6 contains mechanical, environment and electrical installation instructions for Model PAS Smart Pressure Transmitters.
Chapter 7 On-line Operation
Chapter 7 describes the configuration process and how to use basic and advanced Model PAS Smart Pressure Transmitter software functions during configuration. Included in these sections are details on using:-. (1) Sensor or Output Trim (2) Changing range configuration, Output Type, Damping, measurement units
etc.
(3) Change of general data such as Tag No. Date, Message etc.
Chapter 8 Maintenance
Chapter 8 contains hardware diagnostics, troubleshooting and maintenance tasks.
Appendix I : List of Error Codes available on LCD display
PAS
3.1 Overview of Transmitter
Kobold Smart Pressure Transmitters are microprocessor based “smart” pressure transmitters. It uses a piezoelectric/ capacitance pickup optimised & accurately characterised with a patented temperature compensation algorithm for high precision & long term stable gauge and absolute pressure measurements over a wide range of operating conditions. PAS is a two wire loop power transmitter and has a standard 4/20mA output scaled for desired output pressure range. In addition it also offers digital HART® (digital signal superimposed over the analogue output) communication that allows transmitting additional digital parameters/diagnostic information for advanced control systems like DCS, PLC. This transmitter can be configured remotely via HART® communication through a HHT (HART® Hand-Held Terminal using DDL or DOF technology) or any HART® enabled PC configurator. This allows critical variables to be changed, configured and tested remotely by users. Note: For HART® Communication a minimum 250~500 Ohm loop resistance is mandatory between power supply and transmitter.
3.2 Software Compatibility
KOBOLD Smart Pressure Transmitters are shipped from the factory with the most up to date firmware. However as product developments and new features are released a firmware update becomes necessary to incorporate these new changes. As such transmitters with older firmware may restrict certain functions when communicating with an external HHT(Model 275/375HART® Communicator). There may also be some differences on supported functions on the local push button menu based on the installed firmware revision of the transmitter. This manual is based on firmware Revision 6.3. Function deviations as to firmware Revision are same as in table below:
Function Supports
FUNCTION
ZERO/SPAN
ZERO TRIM
ZERO Adj
Units set
Range set
Damping set
LCD Decimal set
LCD Mode
: Supported. : Supported but update required
ZERO / SPAN Button
Version 6.3 or above
PC/UMPC
HART
275/375
PAS
3.3 Transmitter Components
The various components of PAS Series Smart Pressure Transmitter are shown below:
[Figure 3-1 Transmitter Exposed View and Components]
PAS
4. Handling Cautions
This chapter consists of cautions for transmitter handling and storage, selection of installation locations, insulation and explosion structure, etc.
[Quick Reference Manual]
Step Job Job Details Instrument
1 Unpacking
Model and
2
Specifications Check
3 Storage
4 Calibration Bench
Installation
5
Locations
Mechanical
6
Considerations
Electrical
7
Considerations
Mounting and
8
Installation
Calibration on
9
Spot
10 Pressure
11 Operation - Make sure that transmitter operates within specs. Visual or HHT
- Unpack transmitter packing
- Make sure whether the delivered transmitter is same
as options attached on its nameplate
- Places not exposed to water, non-vibration and non-
impact area
- Ambient temperature 25 deg C and relative humidity
65 % RH
- Configuration of Range, Zero/Span, Unit, Tag, Damping Time, Transfer Function, DA Trim and other parameters
- Where ambient temperature is not fluctuated
- Where corrosion happens by chemical materials, etc.
- Where vibration and impact is not severe
- Where non-explosion area is matched on
explosionproof regulations
- Where maintenance is very easy
- Where transmitter can be handled easily
- Be cautious of pressure leaks.
- Connect 24 V
(Power Supply is 11.9 V
- For HART communication, total resistance on
transmitter terminal loop should be 250 – 550 Ohm.
- For mounting transmitter, an appropriate bracket
should be used.
- Transmitter should be fixed firmly to its bracket.
- Sensor Zero Trim is highly recommended during first
installation and start-up. During a Zero trim the zero baseline of transmitter is established.
- Before initiating zero trim make sure that PV value of
transmitter is zero and current output is at 4 mA.
- Do not apply differential and/or full line pressure
suddenly.
- Close equalizing valve of 3/5 valve manifold, then,
open stop valve on high and low side slowly and simultaneously..
DC
– 45 VDC)
DC
Nameplate
- HHT
- Pressure Source
- Galvanometer
(Engineering)
(Engineering)
(Engineering)
(Mounting and Installation)
HHT or Zero/Span button
(Applying pressure)
PAS
4.1 Unpacking
When moving the transmitter to the installation site transfer it in its original packaging. Only unpack the transmitter on site of installation to avoid damage during transit.
4.2 Models and Specifications Check
The model name and specifications are indicated on the top name plate fixed to the transmitters. Please check your specification and model supplied for your installation.
4.3 Storage
The following precautions must be observed when storing the instrument, especially for a long period.
(1) Select a storage area that meets the following conditions:
a) It is not directly exposed to rain, water, snow or sun light. b) It is exposed to minimum vibration and shock. c) If possible, it is advisable to store at normal temperature and humidity
(approx. 25°C, 65% RH).
However, it can also be stored under ambient temperature and relative humidity within the following published ranges. Ambient Temperature: -40 ~ 80 °C (with LCD module)* * General use only. For explosion proof versions follow product certification requirements Relative Humidity: 5 % ~ 98 % RH (at 40 °C)
(2) When storing the transmitter, repack with original (or similar) packaging
that was shipped from the factory.
(3) If storing a transmitter that has already been used, thoroughly clean all
wetted parts including diaphragm seals (if installed), process connections/manifolds in contact with process fluid. In addition, make sure before storing the transmitter that remote seal (if supplied) assemblies are securely mounted.
PAS
4.4 Selecting Installation Locations
The transmitter is designed to withstand severe environmental conditions. However, to ensure stable and accurate operation for many years, the following precautions must be observed when selecting an installation location.
(1) Ambient Temperature
Avoid locations subject to wide temperature variations or a significant temperature gradient. If the location is exposed to radiant heat from plant equipment, provide adequate insulation or ventilation.
(2) Ambient Atmosphere
Avoid installing the transmitter in a corrosive atmosphere. If the transmitter must be installed in a corrosive atmosphere, there must be adequate ventilation as well as measures to prevent intrusion or stagnation of rainwater in conduits. Moreover, there should be appropriate ventilation preventing corrosion by rain gathered on conduit.
(3) Shock and Vibration
Select an installation site suffering minimum shock and vibration (although the transmitter is designed to be relatively resistant to shock and vibration)
(4) Accessibility
Select location that provides easy access for maintenance & calibration.
(5) Installation of Explosion Protected Transmitters.
Explosion – protected transmitters can be installed in hazardous areas according to gas types for which they are certified.
4.5 Performing Sensor Zero Trim after Installation
(1) Sensor Zero Trim should be done immediately after transmitter is installed
because zero point can shift due to mounting status of the sensor pick up.
(2) For Sensor Zero Trim, make input pressure of transmitter zero prior to
initiating zero trim calibration. Any Sensor Trim done in field must be carried out after installation is finalized and with transmitter position fixed. Also if applying external pressure ensure the display is sufficiently stabilized (after approximately 10 to 15 seconds) before initiating any Trim function.
(3) There are two recommendations for making input pressure “zero”. One is to
apply a “zero” pressure source (mandatory for absolute pressure models). The second option is to open equalizing valve of manifolds and venting to atmospheric pressure (allowed only for Gauge type models).
(4) Sensor Zero Trim can be performed using an external HHC (Hand held
calibrator), PC or PDA configurator, and/ or using Zero/ Span local push buttons provided on the transmitter.
(5) When using local push buttons please refer to Chapter 4.7 of this manuals for
detailed instructions. If using an external HHT or HART® PC configurator please refer to the user manuals supplied by the third party supplier.
PAS
4.6 Pressure Connections
Instrument installed in the process is under pressure. Never loosen or tighten
the flange bolts as it may cause dangerous spouting of process fluid.
If the accumulated process fluid may be toxic or otherwise harmful, take
approriate care to avoid contact with the body or inhalation of vapors even after dismounting the instrument from process line for maintenance.
The following precautions must be observed in order to safely operate the transmitter under pressure. (1) Never apply a pressure higher than the maximum working pressure specified
on the nameplate.
(2) Use adequate seals for leak tight process connections and use only quality
and standardized parts.
(3) Regularly inspect for signs of leakage and apply corrective actions when
necessary.
Warning
4.7 Waterproofing of Cable Conduit Connections
Apply a non-hardening sealant (silicone or tape, etc.) to the threads to waterproof the transmitter cable conduit connections.
4.8 Restrictions on Use of Radio Transceivers
Although the transmitter has been designed to resist high frequency electrical
noise, if a radio transceiver is used near the transmitter or its external wiring, the transmitter may be affected by high frequency noise pickup. To test for such effects, bring the transceiver in use slowly from a distance of several meters from the transmitter, and observe the measurement loop for noise effects. Thereafter, always use the transceiver outside the area affected by noise.
Warning
PAS
4.9 Insulation Resistance Test and Dielectric Strength Test
Since the transmitter has undergone insulation resistance and dielectric strength tests at the factory before shipment, normally these tests are not required. However, if required, observe the following precautions in the test procedures.
(1) Do not perform such tests more frequently than is absolutely necessary. Even
test voltages that do not cause visible damage to the insulation may degrade the insulation and reduce safety margins.
(2) Never apply a voltage exceeding 500 VDC (100 VDC with an internal lightening
protector) for the insulation resistance test, nor a voltage exceeding 500V (100V AC with an internal lighting protector) for the dielectric strength test.
(3) Before conducting these tests, disconnect all signal lines from the transmitter
terminals. Perform the tests in the following procedure.
(4) Insulation Resistance test
a) Short-circuit the + and - SUPPLY terminals in the terminal box. b) Turn OFF the insulation tester. Then connect the insulation tester plus (+)
lead wire to the shorted SUPPLY terminals and the minus (-) lead wire to the grounding terminal.
c) Turn ON the insulation tester power and measure the insulation
resistance. The voltage should be applied short as possible to verify that insulation resistance is at least 20M.
d) After completing the test and being very careful not to touch exposed
conductors disconnect the insulation tester and connect a 100kW resister between the grounding terminal and the short-circuiting SUPPLY terminals. Leave this resistor connected at least three second to discharge any static potential. Do not touch the terminal while it is discharging.
(5) Dielectric Strength Test
a) Short-circuit the + and - SUPPLY terminals in the terminal box. b) Turn OFF the dielectric strength tester. Then connect the tester between th
shorted SUPPLY terminal and the grounding terminal. Be sure to connect the grounding lead of the dielectric strength tester to the ground terminal.
c) Set the current limit on the dielectric strength tester to 10mA, then turn ON
the power and gradually increase the tester voltage from '0' to the
specified voltage. d) When the specified voltage is reached, hold it for one minute. e) After completing this test, slowly decrease the voltage to avoid any voltage
surges.
AC
PAS
4.10 Installation of Explosion Protected Type Transmitters
4.10.1 ATEX Certification
ATEX Certification number : KEMA 10ATEX0141 X CE 0158 II 2 G
Note 1. Model PAS for potentially explosive atmosphere
• Ex d IIC T6...T4
• Operating Temperature : -20℃ T
• T6 for process 85°C;
• T5 for process 100°C;
• T4 for process 130°C;
Note 2. Electrical Data
• Supply Voltage : 11.9…42 VDC
• Output Signal : 4 to 20 mA + HART
Note 3. Electrical Connection: see ordering table
Note 4. PAS ATEX Certification is according to the below standards EN 60079-0 : 2006 EN 60079-1 : 2007
Note 5. Installation
• All wiring shall comply with local installation requirement.
• The cable glands and blanking elements shall be of a certified flameproof type,
sutable for the condition of use and correctly installed. Also those devices should be endured at the 130 °C.
• Housing Ground must be followed to “local electrical codes”. The most efficient ground procedure is to connect directly to the earth as least impedance.
• How to Housing Ground:
• * Internal Ground Connection: Internal ground connection screw is located in
terminal in housing, the screw can be identified as ground sign.
• * External Ground Assembly: This is located in the right side of housing and identified as ground sign. (For grounding use a cable lug)
• When use tubing, Stopping boxes must be connected with the wall of housing directly.
• Tubing is installed a minimum of 5 threads.
• Sensor is to be threaded a minimum of 7 threads and prevented from turing by
tightening the housing rotation set screw.
• Do not disassemble flameproof Joints but in an unavoidable case to disassemble it or need the specification of flameproof Joints, contact the manufacturer before doing.
≤ +60°C
amb
PAS
Note 6. Operation
• WARNING-DO NOT OPEN WHEN AN EXPLOSIVE ATMOSPHERE MAY BE PRESENT
• Take care not to generate mechanical spark when access to the instrument and peripheral devices in hazardous location.
Note 7. Maintenance and Repair
• The instrument modification or parts replacement by other than authorized representative of KOBOLD Messring GmbH is prohibited and will void KEMA/ATEX Explosion-proof / Flame-proof.
4.11 EMC Conformity Standards
EMI (Emission): EN55011 EMS (Immunity): EN50082-2
KOBOLD Messring GmbH recommends customer to apply the Metal Conduit Wiring or to use the twisted pair Shield Cable for signal wiring to conform the requirement of EMC Regulation, when customer installs KOBOLD Series Transmitters to the plant.
5. Transmitter Functions
5.1 Overview
This Chapter contains information on operating Model PAS. Tasks that should be performed on the bench priori to installation are explained in this chapter.
5.2 Safety Message
Procedures and instructions in this chapter may require special precautions to ensure the safety of the personnel performing the operations. Information that raises potential safety issues is indicated by warning symbol (). Refer to the following safety messages before performing an operation preceded by this symbol.
PAS
5.3 Warning
Warning
Explosion can result in death or serious injury:
Do not remove the transmitter covers in explosion environments when the
circuit is alive.
Check transmitter to install according to Intrinsically safe regulation before HHT
connect to Transmitter in explosive environment.
Transmitter covers must be fully engaged to meet explosion proof
requirements.
Warning
Electrical can result in death serious injury:
Avoid contact with the leads and terminals. High voltage that may be present on
leads can cause electrical shock.
Warning
Electrical can result in death serious injury:
Only qualified & trained personnel should be allowed to operate these
transmitters
5.4 Fail Mode Alarm
KOBOLD Smart Pressure Transmitter automatically and continuously performs self-diagnostic routines. If the self-diagnostic routines detect a failure, the transmitter drives its output outside of the normal saturation values. The transmitter will drive its output low (down) or high (up) based on the position of the failure mode alarm jumper. See Table 5.1 for Output values.
[Table 5-1 Standard Alarm and Saturation Value]
Fail Mode Selection (Fail High/UP or Low/DOWN) can be configured using the appropriate jumper switch provided on the LCD Module or DIP switches included on the Main CPU Module. For units provided with a LCD module one can select desired fail safe mode directly from the jumper switch included in the front display and this setting overrides the DIP settings on the back-end Main CPU module. However in case of blind units please select your required DIP switch settings from the DIP switch labelled (2) marked on the Main CPU board. Recommended jumper & DIP settings are listed in the table below for ready reference.
Level 4~20 mA Saturation 4~20 mA Alarm
Low/Down 3.9 mA 3.75 mA
High/Up 20.8 mA 21.75 mA
PAS
Select Fail
Mode
Fail Down Down D D
Fail Up
Both LCD Module and CPU Module Only CPU Module CPU Module LCD Module CPU Module
Down U U
Up U or D
< Fail Mode Selection DIP Switch of CPU Module >
UP
DOWN
1. WR_EN (EEPROM Write Enable) DOWN : ENABLE CONFIGURATION CHANGES UP : DISABLE / LOCK CONFIGURATION CHANGES
2. Fail Mode(Alarm) DOWN : LOW UP : HIGH
Figure 5-1 Fail Mode and EEPROM-Write Selection Jumper Switch
Note: DIP Switch (1) shown on Left in Fig 5-1 is for Write Enable/ Disable selection. DIP switch (2) shown on right in Fig 5-1 is for Fail Mode.
< Fail Mode Selection Jumper Switch of LCD Module >
U O O O O O O D O O O D
(If Down) FAIL MODE (If Up)
Figure 5-2 Fail Mode Selection Jumper Switch of LCD Module
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