Milltronics MCP01 S, MCP01 D, MCP03, MCP01 DD, MCP01 SD Instruction Manual

MERCAP

Instruction Manual

June 2001

Safety Guideline s

Warning notices must be obser v ed to ensure personal safety as w ell as that of others, and to protect the product and the connected equipment. These warning notices are accompanied by a clarification of the level of caution to be observed .

Qualified Personnel

This device/system may only be set up and operated in conjunction with this manual. Qualified personn el ar e only authorized to install and operate this equipment in accordance with established safety practices and standards.

Warning: This product can only function properly and safely if it is correctly transported,

stored, installed, set up , operated, and maintained.

Note: Always use p r od uct in accordance with specifications.

Copyright Siemens Milltronics Process

Disclaimer of Liability

This document is available in bound version and in electronic version. We encourage users to purchase authorized bound manuals, or to view electronic versions as designed and authored by Siemens Milltronics Process Instruments Inc. Siemens Milltronics Process Instruments Inc. will not be responsible for t he contents of partial or whole reproductions of eit her bound or electronic versions.

MILLTRONICS®is a registered trademark of Siemens Milltronics Process Instrume nt s Inc.

Contact SMPI Technical Publications at the following address:

Technical Publicat ions Siemens Milltronics Process Instruments Inc. 1954 Technology Drive, P.O. Box 4225 Peterborough, Ontari o, Canada, K9J 7B1 Email: techpubs@millt ronics.com

While we have verified the contents of this manual for agreement w it h t h e instrumentation described, variations remain possible. Thus we cannot guarantee full agreement. The contents of this manual are regularly reviewed and corrections are included in subsequent editions. We w elcome all suggestions for improvement.

Technical data subject to change.

For the library of SMPI instr uction manuals, visit our Web site: www.milltronics.com

Table of Contents

Introduction

Introduction ................................

IntroductionIntroduction

Technical Specifications

Technical Specifications ................................

Technical SpecificationsTechnical Specifications

Electrodes and Process Connections

Electrodes and Process Connections ................................

Electrodes and Process ConnectionsElectrodes and Process Connections

................................................................

Identifications and Abbreviations ..............................................................................................3

................................................................

Electrodes.........................................................................................................................................5

Wetted Parts....................................................................................................................................5

Transmitter.......................................................................................................................................5

................................................................

Handling of Electrodes..................................................................................................................7

Characteristics ................................................................................................................................7

General Design Principles ...........................................................................................................8

Mercap Configurations.................................................................................................................9

Examples of Mercap Level Instruments ................................................................................10

Interface and Level Version (Mercap MCP 02)....................................................................15

Flanges ............................................................................................................................................17

Flange Standards .........................................................................................................................17

Applications Examples................................................................................................................19

....................................

................................................................

..............................................

................................................................

........................................................

................................................................

........................ 7777

................................................

.... 3333

........

.............. 5555

............................

Flow-Through Electrode

Flow-Through Electrode ................................

Flow-Through ElectrodeFlow-Through Electrode

................................................................

FTS Series ......................................................................................................................................21

FTF Series.......................................................................................................................................22

MST9500 Transmitter

MST9500 Transmitter ................................

MST9500 TransmitterMST9500 Transmitter

................................................................

Operating Principles ....................................................................................................................24

Installation

Installation and Interconnection

InstallationInstallation

and Interconnection................................

and Interconnectionand Interconnection

................................................................

Interconnection.............................................................................................................................26

Connection Diagrams..................................................................................................................27

Factory settings ............................................................................................................................29

Applications

Applications and Grounding

ApplicationsApplications

Start-up

Start-up ................................

Start-upStart-up

Maintenance

Maintenance ................................

MaintenanceMaintenance

and Grounding ................................

and Groundingand Grounding

................................................................

Push-Button Adjustment ............................................................................................................35

Adjustment using HART

................................................................

TM

..........................................................................................................36

................................................................

Test function ..................................................................................................................................39

................................................................

..............................................

................................................................

..................................................

................................................................

................................ 25

................................................................

.......................................

................................................................

.........................................

................................................................

................................ 39

................................................................

.................. 24

....................................

.............. 21

............................

21

2121

24

2424

25

2525

....... 30

30

..............

3030

......... 35

35

..................

3535

39

3939

TM

Appendix A: HART

Appendix A: HARTAppendix A: HART

HART HART

TMTM

Documentation

Documentation ................................

Documentation Documentation

TM

info.....................................................................................................................................41

TM

Conformance and Command Class .........................................................................41

MST9500 DD Menu/Variable Organization ..........................................................................43

TM

HART

Response Code information.......................................................................................44

General transmitter information...............................................................................................44

7ML19981CM01.1 MERCAP – INSTRUCTION MANUAL Page 1

................................................................

........................................................

................................................................

........................ 41

................................................

41

4141

Additional universal command specifications .....................................................................45

Additional common-practice command specifications .....................................................45

Transmitter specific commands...............................................................................................47

Appendix B: Tables

Appendix B: TablesAppendix B: Tables

Table A Conversion......................................................................................................................54

................................

................................................................

.....................................................

................................................................

..................... 54

..........................................

54

5454

Table B Total Loop

Table C Voltage Drop Versus mA For Current Transmitter Operation....................................55

Appendix C: Approvals

Appendix C: Approvals................................

Appendix C: ApprovalsAppendix C: Approvals

CE Certificate .................................................................................................................................56

Certificates and Approvals ........................................................................................................57

Control Drawing FM/CSA Approval Mercap ........................................................................58

Index

Index ................................

IndexIndex

................................................................

Ω Versus Supply Volts..........................................................................55

................................................................

.................................................

................................................................

..............................................

................................................................

................. 56

..................................

.............. 59

............................

56

5656

59

5959

Page 2 MERCAP – INSTRUCTION MANUAL 7ML19981CM01.1

Introduction

The Mercap system is a high performance, level measurement instrument consisting of a sophisticated, easy-to-adjust, transmitter (MST9500) combined with measurement electrodes and process seals designed to accommodate numerous configurations. The electrode, comprised of a measurement section and an active shield section, is the primary sensor of the system, and it indicates the electrical capacitance value of the measurement section relative to the environment (tank wall, stilling well, or conductive material). This electrode then connects to the capacitance detector portion of the two-wire loop powered electronic transmitter. The measurement section can be set up to measure the level of solids, liquids and slurries, as well as the interface between two immiscible liquids.

The manual is presented in three sections:

1. The electrode process connections and seals

2. The transmitter

3. Appendix sections providing supplementary information.

Identifications and Abbreviations

Various mnemonics and abbreviations are used in this manual. See below:

Short form Long Form Description Units

CE /FM /CSA Conformitè Europèene/

Factory Mutual/Canadian

Standards Association DAC Digital Analog Converter DCS Distributed Control System Control Room apparatus Ex Explosion Proof Exd Flame Proof FV Full Vacuum ESD Electrostatic Discharge

TM

HART

LRV Lower Range Value value for 0 % 4 mA LSL Lower Sensor Limit below which PV is incorrect pF pico Farads 0.000000000001 Farad ppm parts per million PV Primary Variable measured value Stilling Well grounded metal tube with

SV Secondary Variable equivalent value SVLRV Sec. Var. Lower Range Value 0 % equivalent value SVURV Sec. Var. Upper Range Value 100 % equivalent value µF URV Upper Range Value value for 100% 20 mA µSec USL Upper Sensor Limit above which PV is incorrect

Highway Addressable

Remote Transducer

openings

micro Farads 0.000001 Farad

micro Seconds 0.000001 Seconds

HARTTM Communication Foundation, Austin, Texas, USA

7ML19981CM01.1 MERCAP – INSTRUCTION MANUAL Page 3

Page 4 MERCAP – INSTRUCTION MANUAL 7ML19981CM01.1

Technical Specifications

Electrodes

Process connections

Screw mounting: Flange mounting:

Process material: C 22.8 N, AISI 316 L, Monel 400, Hastelloy C22

Probe diameter (mm/inch): 9/0.35 (cable), 16/0.63 (rod), or 24/0.95 (rod)

Probe length (mm/inch)

Rod version: Cable version:

Probe lining: PFA, Enamel, PTFE

NPT, BSPT, JIS. ANSI, DIN

5500/216 35000/1378

Pressure rating (bar/psi): FV - 200/2920 up to 525/7665 as option

Temperature rating (°C/°F): -200°/-328° to 200°/392° up to 450°/842° as option

Wetted Parts

Liner: PFA/PTFE

Flange: stainless steel or teflon lined

Transmitter

Measurement range (pF): 0 – 3300

Span (pF): minimum 3.3

Supply voltage (Vdc): • maximum 33

• minimum 12 Vdc at 3.6 mA

• minimum 9.5 Vdc at 22 mA

Output current (mA): 3.6 – 22 / 22 - 3.6 (2-wire current loop)

Smart communication: Acc. the HART Communication Foundation (HCF)

Temperature range (°C/°F): -40°/-40° to 85°/185° (ATEX–Explosion Proof: -20°/-4° to

7ML19981CM01.1 MERCAP – INSTRUCTION MANUAL Page 5

60º/140º)

Temperature stability:

0.15 pF (0pF) or <0.25% (typically <0.1%) of actual measurement value, whichever is greater over the full temperature range of the product.

Non linearity and

< 0.1% full scale and actual measurement respectively

reproducibility:

Accuracy: <0.1% of actual measurement value

Features: • polarity protection input circuit

• E.S.D. protected (Loop)

• galvanically isolated measurement circuit

• fully potted with epoxy resin

Diagnostics (Includes fault alarm):

• primary variable (PV) out of limits

• system failure measurement circuit

• deviation between A/D and D/A converter values

• check sum

• watch dog

• measurement current out of range

Measurement current

NAMUR NE 43

signalling:

Function rotary switch

Position 1: Position 2: Position 3:

1

4 mA measurement value (set) 20 mA measurement value (set)

3.8 up to 20.5 mA range by means of a field service programmer

Position 4:

functionality test

Approvals: • Cenelec, FM/CSA (IS), FM (Ex-proof), CE, ATEX

1

HART communication in all switch positions

Page 6 MERCAP – INSTRUCTION MANUAL 7ML19981CM01.1

Electrodes and Process Connections

This section of the manual is designed to assist in the determination of the best possible probe configuration for your application. Therefore, we discuss the electrodes and process connections before the instrumentation and the operation procedures. When configuring the unit to your application, use the sample configurations below as your criteria.

Mercap electrodes come in a variety of formats to provide the necessary characteristics for correct mounting, chemical compatibility, temperature and pressure requirements, and dielectric constant. Most applications use the simple threaded connection, which is directly mounted in the tank with the mating threaded nipple, or with a flange adapter that includes a threaded hole.

For applications requiring higher temperature and pressure, or greater integrity, welded and solid machined flange versions are available with single or double cone seals, and/or a second seal on the flange plate to avoid any metallic wetted parts.

Handling of Electrodes

WARNING: Do not scratch or gouge the PFA electrode insulation since this could

reduce the integrity of the insulation and the useful life of the electrode.

WARNING: Be careful with an enamel insulated electrode. Normally an enamel lining

is protected by a stilling well, which is part of the design.

WARNING: Do not damage the insulation jacket on the electrode during shipping,

packing, and installation. Most electrodes use PFA insulation, a very dense and reliable type of Teflon that prevents leakage and corrosion of the metal electrode and acts as an insulator when conductive materials are being measured. Any damage to the electrode can prevent proper performance.

WARNING (ATEX 100): Precautions MUST be taken to avoid ignition due to

hazardous electrostatic charges when an isolated probe is used in a potentially explosive atmosphere caused by gas, vapor, or a non-conductive liquid, requiring apparatus group IIC equipment. Or when the probe is used in a potentially explosive atmosphere caused by dust.

7ML19981CM01.1 MERCAP – INSTRUCTION MANUAL Page 7

Characteristics

The following characteristics apply to all general connection configurations:

• The standard Mercap insulated electrode is designed for use in both conducting and non-conducting liquid applications.

• All electrodes consist of an active shield portion and a measurement portion, which combine to form the complete electrode.

• The sum of the active shield length and the measurement length is the total insertion length.

• The active shield design provides continuous immunity to the known changes in conditions at the top of many vessels, where levels of vapours, dust, and condensation are constantly changing.

• All changes in capacitance due to temperature and pressure changes that could cause small changes in the seal geometry are also isolated from the measurement signal because they are not included in the starting capacitance of the electrode by virtue of the action of the active shield.

• Due to the well-controlled diameter of the electrodes and insulation, a linear output is achieved over a wide range of capacitance values (3.3 to 3300 pF).

• The end seal is formed as an integral part of the electrode lining, giving smooth and uniform insulation characteristics (tested to 55 kV).

• Standard single cone usage

• Secondary cone usage

General Design Principles

The Mercap capacitance level instrument combines an optimum combination of mechanical and electrical/electronic principles in its design. Combining a single transmitter with as few electrode configurations as possible maximizes the number of potential applications while it minimizes the complexity of the instrument.

In principal, the standard threaded process connection (S-Series) with PFA insulated electrode, including the active shield, provides good results in all measurement situations that are within the temperature, pressure, and corrosive capabilities of the materials and seals. This is true over a wide range of dielectric constants in both non-conducting and conducting materials.

Applications outside of the standard capabilities of the S-Series would require a different design configuration. These non-standard applications include:

Non-Standard Application Mercap Configuration

Non-metallic tanks with both conducting and non-conducting liquids. Non-conducting liquids in spherical and horizontal-cylindrical tanks. Highly corrosive materials requiring no metallic wetted parts. High pressure and temperature (greater than 200 bar) with conductive liquid. Sanitary/food safe applications. Use Mercap MCP 03.

Use a stilling well to provide second electrode reference. Use a stilling well as linearizer.

Use flange mount with D, DD seal version. Use HP version.

Page 8 MERCAP – INSTRUCTION MANUAL 7ML19981CM01.1

Mercap Configurations

The Mercap is a versatile level measurement instrument that can be designed for your specific application by taking the following conditions into consideration:

Process Connections

Any standard process connection is available with Mercap, and special versions can be fabricated to match the mounting and application requirements. Various sizes of threaded and flanged fittings are available.

Seal Types

The basic internal seal for the Mercap is of a conical-shaped, preloaded pressure/leak resistant construction. Up to three levels of seal protection are implemented depending on the integrity requirements of the application. A single or double cone internal seal forms 1 or 2 blocks against leaking, and a third flange face gasket is also available in the D and DD seal construction. The flange face seal also provides a design with no metal wetted parts if required.

Pressure and Temperature Considerations

The maximum temperature and pressure of operation for the standard Mercap level probe is 200°C (392°F) and 200 bar (2900 psi). There are, of course, qualifications that must be applied

to these maximums.

Enamel probes are suggested when process temperature exceeds 200 °C, and/or in combination with very high pressure.

Note:

: Consult Milltronics for chemical applications other than water.

: :

Process Connection and Seal Configuration of Mercap

Process Connection

Process Connection Seal Type

Process ConnectionProcess Connection

Threaded S Single Cone

Welded Flange S Single Cone

Solid Machined

Flange

Seal Type Seal Description

Seal TypeSeal Type

S Single Cone

D Single Cone + Teflon flange seal DD Double Cone + Teflon flange seal Consult factory* SD Double Cone (used for stilling well applications)

HP Consult factory*

Seal Description

Seal DescriptionSeal Description

Note: HP (high pressure) is only supplied with enamel insulation and a recommended

stilling well for protection of the enamel. A cone seal plus a secondary redundant seal is provided between the electrode and the stilling well.

7ML19981CM01.1 MERCAP – INSTRUCTION MANUAL Page 9

Examples of Mercap Level Instruments

The following graphics illustrate the variation in configurations available for the Standard series, Level and Interface series, and Sanitary series Mercap level instrument.

Note: All measurements are given in millimeters/inches.

Standard Level Version (Mercap MCP01)

This is the most common version of Mercap and is available with the following features:

• Threaded flanges, welded flanges, and solid flanges

• S series, D series, SD series, DD series, and HP series process seals.

• Selections of standard ANSI and DIN flanges are available

• The most common electrode is insulated with PFA, but Enamel (HP seal) is also

available as standard (Enamel is only available on rigid design).

• Various process connection materials are also available

• Rigid and Flexible Cable versions available

MCP01 (Standard) S-Series: Threaded Versions

S-Series: Threaded

∅160 (6.3”)

Active Shield

Insertion

Length+175

(6.9”)

Length

Inactive Tip

Page 10 MERCAP – INSTRUCTION MANUAL 7ML19981CM01.1

Active

Length

40 (1.57")

∅16 (0.63”)

or ∅24 (0.94")

120 (4.72")

S-Series Cable Version S-Series Cable Version

(with anchor)

∅160 (6.3”)

Transmitter Enclosure

55 (2.17")

Insertion Length

Dimension Varies

Seal Gland

Threaded Process Connector

See Order Instructions

PTFE Insulation

∅9 (0.35")

Tensile Weight+/-Varies

Inactive

Part

125 (4.9")

Insertion

Length

+175 (6.9")

Insertion

Length

MCP01 S-Series Threaded Features

• single process seal

• suitable for most level, interface, or detection applications

• high temperature and pressure resistance

7ML19981CM01.1 MERCAP – INSTRUCTION MANUAL Page 11

MCP01 (Standard) S-Series: Welded and Machined Flanged Versions

S-Series Welded Flange S-Series Machined Flange

TIG Weld

Insertion

Length

+185 (7.28")

Insertion

Length

+185 (7.28")

Inactive Tip

∅16 (0.63”)

or ∅24 (0.94")

Active Shield

Insertion

Length

Active

Length

Inactive Tip

40 (1.57")

∅16 (0.63”)

or ∅24 (0.94")

MCP01 S-Series Flange Features

• single process seal

• suitable for most level, interface, or detection applications

• high temperature and pressure resistant

Active Shield

Insertion

Length

Active

Length

40 (1.57")

Page 12 MERCAP – INSTRUCTION MANUAL 7ML19981CM01.1

MCP01 Standard D-Series: Machined Flanged Versions

k

D-Series DD-Series

∅160 (6.3") ∅160 (6.3")

65 (2.56")

Insertion

Length

Transmitter Enclosure

120 (4.72") 120 (4.72")

n

holes

Active Shield

Active Length

40 (1.57") 40 (1.57")

∅ ∅D

Flange Process Connection

PTFE Lining

Probe

Inactive Tip Inactive Tip

120 (4.72")

Insertion

Length

Active

Shield

Active

Length

n

holes

Transmitter Enclosure

Seal GlandSeal Gland

Flange Process Connection

∅ ∅D

PTFE Lining

Probe

∅16 (0.63”) or

∅24 (0.94")

MCP01 Standard D-Series Features

• single process seal

• all wetted parts made of PFA (probe

lining) or PTFE (flange face)

• according to NACE requirements

∅16 (0.63”) or ∅24 (0.94")

MCP01 Standard DD-Series Features

• double process seal

• redundant safety (e.g. Phenol,

Phosgene applications, etc.)

• all wetted parts made of PFA (probe

lining) or PTFE (flange face)

• according to NACE requirements

• suitable for turbulent and toxic

chemical applications

7ML19981CM01.1 MERCAP – INSTRUCTION MANUAL Page 13

SD-Series Probe/Thermal Isolator

k

∅160 (6.3") ∅160 (6.3")

Transmitter Enclosure

120 (4.72") 120 (4.72")

Seal

Dependent on

Gland

extension length

120 (4.72")

Active Shield Active Shield

Insertion

Length

Active

Length

n

holes

∅

40 (1.57") 40 (1.57")

∅16 (0.63”) or ∅24 (0.94")

Flange Process Connection

Probe

Inactive Tip Inactive Tip

85 (3.35")

Insertion

Length

Active

Length

n

holes

Transmitter Enclosure

Thermal Isolator

Seal Gland

Flange Process Connection

∅ ∅D ∅D

Probe

∅16 (0.63”) or ∅24 (0.94")

MCP01 Standard SD-Series Features

• double process seal

• redundant safety (e.g. Phenol,

Phosgene applications, etc.)

• all wetted parts made of PFA/PTFE

• according to NACE requirements

• suitable for turbulent and toxic

chemical applications

MCP01 Probe/Thermal Isolator Features

• thermal isolator

Page 14 MERCAP – INSTRUCTION MANUAL 7ML19981CM01.1

Interface and Level Version (Mercap MCP 02)

This version is designed specifically for interface level where a long distance active shield portion of the electrode is required (up to 35 meters) before the measurement portion of the electrode begins. This type of application is common in large storage tanks for oil where the bottom of the tank invariably has a layer of water below the oil. Often, when measurement spans as much as 5.5 meters (for the water), up to 35 meters of flexible bellows cable are used.

MCP02: Interface Version

∅160 (6.3")

Transmitter Enclosure

Seal Gland

Process Connection: flange or threaded

mounting

185 (7.28")

Dependent on extension length

Adjustable extension

part

Flexible Tube

Probe

∅16 (0.63”) or ∅24 (0.94")

Active Shield

Active Length

∅16 mm=2m ∅24mm=5.5m

100 (3.9")

Inactive Tip

Insertion Length 35m (115ft) max.

Process Connection Size

• threaded version: ¾", 1", 1½", 2"

NPT, BSPT, or JIS

• sanitary version: on customer

request

• flange version: on customer

request

Options

• thermal isolator

• stilling well

Aluminum Enclosure

• Nema 4/Type 4/IP65

Conduit Entry:

• ½" NPT (2x)

7ML19981CM01.1 MERCAP – INSTRUCTION MANUAL Page 15

Sanitary Level Version (Mercap MCP 03)

The hygienic design includes threaded and tri-clamp versions for use in the food and pharmaceutical industry.

MCP03: Sanitary Versions

Sanitary Thread Coupling Sanitary Tri-Clamp

∅160 (6.3")

Transmitter Enclosure

118 (4.65")

Seal Gland

Active Shield

Insertion

Length

Active

Length

40 (1.57")

Probe

Inactive Tip

∅16 (0.63”) or ∅24 (0.94")

MCP03 Sanitary Tri-Clamp Features

• maximum active length 5.5m

• minimum active length 50mm

IDF Nut

Inactive Tip

∅16 (0.63”) or

∅24 (0.94")

Seal Gland Tri-clamp Connection

Active Length

40 (1.57")

Active Shield

Insertion Length + 175 (6.9")

Insertion

Length

Page 16 MERCAP – INSTRUCTION MANUAL 7ML19981CM01.1

Flanges

Flange Standards

øL

b

øK (n holes)

øD

Note:

• All Sizes: MM

• One (1) inch: ^ 25.4mm

• Details: See drawings, technical data, and measuring probe details

7ML19981CM01.1 MERCAP – INSTRUCTION MANUAL Page 17

Milltronics MCP01 S, MCP01 D, MCP03, MCP01 DD, MCP01 SD Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual