Magnetrol ES Modulevel Installation And Operating Manual
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Magnetrol ES Modulevel Installation And Operating Manual

Top hat assembly design, digital ii modulevel with hart communication and analog modulevel electronic liquid level transmitters
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Installation and Operating Manual
ES/EZ Modulevel
Top Hat Assembly Design
Digital ES II Modulevel
with HART
and Analog EZ Modulevel
Electronic Liquid Level
Transmitters
Communication
®
®

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Summary of Contents for Magnetrol ES Modulevel

  • Page 1 ES/EZ Modulevel ® Top Hat Assembly Design Installation and Operating Manual Digital ES II Modulevel with HART Communication ® and Analog EZ Modulevel Electronic Liquid Level Transmitters...
  • Page 2 WARNINGS Magnetrol/STI will repair or replace the control at no cost Warnings identify potentially dangerous situations or to the purchaser (or owner) other than transportation.

  • Page 3: Table Of Contents

    Electronic Modulevel (Top Hat Assembly Design) Displacer Level Transmitter Installation, Operation and Maintenance Manual Table of Contents 1.0 Complete Installation 4.0 Reference Information 1.1 Unpacking.............1 4.1 Description............25 1.2 Electrostatic Discharge (ESD) .......1 4.2 Theory of Operation ...........26 1.3 Before you begin............2 4.2.1 Displacer Buoyancy ........26 1.3.1 Site Preparation ..........2 4.2.2 LVDT............26...

  • Page 4: Unpacking

    Model Number Serial Number Electrostatic Discharge (ESD) Handling Procedure Magnetrol’s electronic instruments are manufactured to the highest quality standards. These instruments use electronic components which may be damaged by static electricity present in most work environments. The following steps are recommended to reduce the risk of component failure due to electrostatic discharge.

  • Page 5: Before You Begin

    • Handle circuit boards only by the edges. Do not touch components or connector pins. • Ensure that all electrical connections are completely made and that none are partial or floating. Ground all equipment to a good, earth ground. Before You Begin 1.3.1 Site Preparation Each Modulevel transmitter is built to match the specific physical specifications of the required installation.

  • Page 6: Operational Considerations

    1.3.3 Operational Considerations The Modulevel transmitter should be located for easy access for service, configuration, and monitoring. There should be sufficient headroom to allow installation and removal of the transmitter head and, in cases of tank top configuration, the displacer. Special precautions should be made to prevent exposure to corrosive atmosphere, exces- sive vibration, shock, or physical damage.

  • Page 7: Installing A Chamber Type Modulevel

    Note: The adjustable hanger assembly is used when the top of the displacer and, therefore, the top of the measure- ment range must be positioned in the vessel more than 5" (127 mm) below the mounting flange in the case of models 600# or less, or more than 9.31" below the mounting flange on models 900# or greater.
  • Page 8 Before installing, ensure that: • There is adequate room for the installation of the Modulevel. • Using a level, the vessel mounting connections are level within 3° of vertical. • The process temperature, pressure and specific gravity are within the unit’s specifications for installation. See Specifications, Section 4.8.

  • Page 9: Analog Ez Modulevel Wiring And Calibration

    Analog EZ Modulevel Wiring and Calibration Caution: The Analog EZ Modulevel Transmitter operates at voltages 12–36 VDC, 120 VAC or 240 VAC. Incorrect voltages will damage the transmitter. All wiring between the power supply and the Modulevel transmitter on 24 VDC units should be made using 18-22 AWG shielded twisted pair instrument cable or on AC, Ground (green) 120 VDC and 240 VAC units should be made using a...

  • Page 10: Remote Transmitter Wiring

    Note: When operated from a 24 VDC source, the maximum allowable loop resistance is 480 ohms for Analog EZ Modulevels. See Figure 9. When operated from a 120 or 240 VAC source, the Analog EZ current can only be monitored from the meter terminals (M+ and M-) using a multimeter with maximum sensitivity of 100 millivolts.
  • Page 11 Loop Resistance vs. Power Supply Voltage 1100 1000 960 ohms @ 36V 480 ohms at 24 VDC (Analog EZ Modulevel) 12 14 16 18 20 22 24 26 28 30 32 34 36 38 Power Supply Voltage (VDC) Figure 9 Analog EZ Maximum Loop Resistance Transmitter Housing...
  • Page 12 REV ISI ON S THIS DRA W I NG IS T H E E X CLUSI V E PROPERT Y OF MAGNETRO L I NTERNAT I ONA L. NO USE W HATSOEVER O F T H E I NFORMAT I ON CON - THI RD ANG LE DESCRI PTI ON BY &...

  • Page 13: Calibrating The Analog Ez Modulevel

    Calibrating the Analog EZ Modulevel The Analog EZ Modulevel must be calibrated for each unique application. It may be calibrated in service or on a bench calibration stand. Bench calibration provides a convenient way to set up the transmitter before going to the tank site to complete the installation.

  • Page 14: Reverse Acting Field Calibration

    3. Locate the Direct/Reverse switch on the PC board. USA. HEIKENSSTRAAT 6, See Figure 14. B 9240 ZELE, BELGIUM. www.magnetrol.com 4. Move the Direct/Reverse switch to “REV.” REFER TO MODULEVEL MANUAL, BULLETIN 48-615, FOR INSTALLATION AND OPERATION 5. Replace and tighten the transmitter housing cover until INSTRUCTIONS.
  • Page 15 To install transmitter head on calibration stand, carefully slide the white teflon spacer and LVDT assembly down over the open topped enclosing tube. Be certain that both the LVDT assembly and the housing base are fully seated on the fixture. See Figure 15 on page 13. To bench calibrate the Analog EZ transmitter: 1.
  • Page 16 C-ring Located Adjustment Rod Here on Process Level Sensors P .2 LVDT Enclosing Tube P.C. Board Enlarged Detail “O” Rings Adjustment Rod LVDT Core Base and Junction Box White Teflon Spacer Must Be Installed Calibration Stand Tube Figure 15 Bench Calibration Stand (part number 31-6107-001) Note: For units with meter, pull meter out to access wiring terminals...

  • Page 17: Digital Es Ii Modulevel Wiring And Calibration

    Digital ES II Modulevel Wiring and Calibration. Caution: The Digital ES II Modulevel Transmitter operates at voltages of 12-36 VDC. Incorrect voltages will Loop Resistance vs. Power Supply Voltage damage the transmitter. 1090 ohms @ 36V 1100 1000 All wiring between the power supply and the Modulevel transmitter should be made using 18-22 AWG shielded twisted pair instrument cable.

  • Page 18: Remote Transmitter Wiring

    DOWN Black Yellow USA. HEIKENSSTRAAT 6, black brown B 9240 ZELE, Junction Box BELGIUM. green white/green ENTER www.magnetrol.com Terminal Board REFER TO MODULEVEL MANUAL, black white/black BULLETIN 48-615, FOR INSTALLATION AND OPERATION INSTRUCTIONS. blue white/red black – Remote Transmitter Housing –...

  • Page 19: Hazardous Location Wiring

    Hazardous Location Wiring See Figure 11 on page 9 for proper installation of Digital ES II for intrinsically safe locations. Proper installation of Digital ES II with intrinsically safe connections and non- incendive wiring is illustrated in Figure 12 on page 9. Digital ES II Push-Button Calibration The Digital ES II Modulevel must be calibrated for each unique application.

  • Page 20: Push-Button Bench Calibration

    In the case that 20 mA (100%) level cannot be established: 11. After setting the zero point, establish the liquid level as close to the 20 mA level as possible (must be more than 50% of the total span). 12. Press ENTER to start 20 mA calibration. The ZERO LED will light.

  • Page 21: Digital Meter Calibration

    To bench calibrate the Digital ES II transmitter: 1. Connect supply voltage and meter, if necessary, to termi- nals in junction box. See Figure 18 on page 14. 2. Slide the electronics head over the open topped enclosing tube of the calibration stand, making sure that the white plastic washer is in place below the electronics head.

  • Page 22: Interface Calibration

    3.4.3 Digital Meter Calibration (cont.) To position the decimal point and choose meter function: 3. Simultaneously press and immediately release the left and right configuration buttons. See Figure 21. 4. To move the decimal point, press the left button until Digital Display decimal point is in desired location.

  • Page 23: Calibration In Process Liquids

    3.4.4 Interface Calibration (cont.) 7. Establish interface level at desired 20 mA (100%) level on the displacer. 8. Press the ENTER key. The ZERO LED will light. Loop will go to 20 mA. 9. Press UP to lock in the 20 mA value. The ZERO LED will go off.

  • Page 24: Lower S.g. Greater Than 1.0

    4. Press ENTER key to start calibration. ZERO LED will light. Loop will go to 22 mA. 5. Press DOWN key to lock in 4 mA value. Zero LED will flash and remain on. Loop will stay at 22 mA. 6.

  • Page 25: Configuration Using Hart

    USA. HEIKENSSTRAAT 6, B 9240 ZELE, 3.5.1 Connections BELGIUM. ENTER www.magnetrol.com REFER TO MODULEVEL MANUAL, BULLETIN 48-615, FOR INSTALLATION AND OPERATION INSTRUCTIONS. A HART communicator can be operated from a remote location by connecting to a remote junction or by con-...

  • Page 26: Hart Menu

    3.5.4 HART Menu 1 Enter Password password set at factory = 1 1 Device Setup 2 Calibration 1 Set Points 2 Damping 2 Level 3 Fault State view level in % select 3.6 mA–down button 3 Current or 22 mA–up button view level in mA 4 Date/Time/Initials enter this info as...

  • Page 27: 48-618 Es/Ez Modulevel Displacer Level Transmitter (Top Hat Assembly Design

    SG value 1 Model 4 Error Codes 2 Manufacturer if value other than 0000, consult factory 3 Set Magnetrol S/N 5 New password enter new password, or enter value “0” 4 Dev id to disable password function 5 Tag...

  • Page 28: Reference Information

    Reference Information This section presents an overview of the operation of the Electronic Modulevel Displacer Level Transmitter, information on troubleshooting common problems, listings of agency approvals, lists of replacement and recommended spare parts, and detailed physical, functional, and performance specifications. Description The Digital ES II and Analog EZ Modulevels are advanced, intrinsically safe or explosion proof two- wire or four-wire instruments utilizing simple buoyancy principles to detect and convert liquid level...

  • Page 29: Theory Of Operation

    Theory of Operation The Electronic Modulevel Displacer Level Transmitter relies on the principles of buoyancy to convert mechanical movement to an electronic output. See Figure 23. 4.2.1 Displacer Buoyancy The buoyancy force acting on an object is equal to the weight of the liquid displaced by the object.
  • Page 30 Symptom Problem Solution No loop current Power supply not turned on. Turn on power. Insufficient source voltage. The ES II requires a minimum of 12 VDC at terminals TB1 and TB2 while the EZ requires a minimum of 12 VDC at terminals P3 and P4 on amplifier board.

  • Page 31: Maintenance Of Analog Ez Modulevel

    3. Remove the two wires from spade connectors P3 and P4 HEIKENSSTRAAT 6, Cable B 9240 ZELE, BELGIUM. and shield wire from the board mounting screw on the Connector www.magnetrol.com Pins (J2) transmitter PC board. REFER TO MODULEVEL MANUAL, BULLETIN 48-615, FOR INSTALLATION AND OPERATION INSTRUCTIONS.

  • Page 32: Replacing Lvdt

    4.4.3 Replacing LVDT 1. Remove power from the unit. 2. Remove the transmitter housing cover. To remove old LVDT: 3. Locate the black wire which runs from the top of the LVDT to the lower right hand corner of the transmitter PC board.

  • Page 33: Replacing Lvdt

    (+) terminal at TB1 HEIKENSSTRAAT 6, B 9240 ZELE, BELGIUM. ENTER www.magnetrol.com and the black wire is attached to the (-) terminal at TB1. REFER TO MODULEVEL MANUAL, BULLETIN 48-615, FOR INSTALLATION AND OPERATION INSTRUCTIONS.

  • Page 34: Agency Approvals

    Agency Approvals 4.6.1 FM (Factory Mutual) Model Approval XEXX-XXXX EZA, B, C, E, F, G, L, N Explosion Proof with transmitter codes: ESA, E, F, G, 7, 9 Class I, Div. 1; Groups A, B, C, D GZH, K, Q, R, S, T, U, V, 2, 3, 5, 6 Class II, Div.

  • Page 35: Csa (Canadian Standards Association)

    4.6.2 CSA (Canadian Standards Association) Model Approval XE5X-XXXX EZA, B, C, E, F, G, L, N Explosion Proof with transmitter codes: ESA, E, F, G, 7, 9 Class I, Div. 1; Groups B, C, D GZH, K, Q, R, S, T, U, V, 2, 3, 5, 6 Class II, Div.

  • Page 36: Parts

    Parts 4.7.1 Replacement P.C. Boards Replacement Electronic Modulevel Boards Serial Number Format (6 digits)-(2 digits)-(3 digits) 6 or 7 digits Digital ES Date of Manufacture 1998 - present 1995 - 1999 P.C. Board Description Potted module ES II board Through hole ES I board Supply Transmitter...

  • Page 37: Transmitter Head Parts

    Parts 4.7.2 Transmitter Head Parts  LVDT Meter Junction Housing Transmitter/ Junction/Meter Assembly Assembly O-rings LVDT Housing Board (not shown) 89-7828-005 89-7827-001 37-3308-001 89-7830-002 89-6562-001 Z30-2194-001 89-7828-006 37-3310-001 89-7828-001 89-7827-001 89-7830-001 89-6562-001 89-7828-002 89-7828-003 89-7827-001 37-3145-002 89-7830-001 89-6562-001 89-7828-004 89-7828-005 89-7827-006 37-3308-001 89-7830-002...

  • Page 38: Mechanical Replacement Parts

    4.7.4 Mechanical Replacement Parts E-tube kit Standard High Temperature CS to 600# 89-5944-001 89-5944-004 SS to 600# 89-5944-002 89-5944-007 CS - 900# 89-5944-002 89-5944-003 E-tube Gasket CS 1500# & up 89-5944-005 89-5944-006 All Pressures 12-1204-001 Flange/Flange Assembly 150# 300# 600# 900# 1500# 2500#...
  • Page 39 Transmitter P.C. Board LVDT Assembly and Bracket Core Stem Housing Base and Cover LVDT Assembly Junction Box Meter Only Housing O-Rings Range Spring Cotter Pins Enclosing Tube Gasket Flange Flange Assembly Displacer Displacer Low Pressure High Pressure 0.5/1.0 14" 89-6125-001 89-6126-001 89-6125-010 32"...

  • Page 40: Upgrade To Esii Electronics

    II Electronics 4.7.5 Upgrade to ES 4.7.5.1 Procedure for Conversion of Smart ES Electronics to Digital ES II Electronics REMOVAL OF THE ES TRANSMITTER BOARD: 1. Remove power from the Smart ES unit. 2. Remove the transmitter housing cover. 3. Remove the two screws that secure the PC board and bracket assembly to the housing base.

  • Page 41: Ez To Es Ii Conversion

    PC board. HEIKENSSTRAAT 6, B 9240 ZELE, BELGIUM. ENTER www.magnetrol.com REFER TO MODULEVEL MANUAL, 7. Remove the white plastic positioner ring at the base of the BULLETIN 48-615, FOR INSTALLATION AND OPERATION INSTRUCTIONS.

  • Page 42: Specifications

    Specifications 4.8.1 Functional Measurement principle Buoyancy – continuous displacement utilizing a precision range spring Input Measured variable Level, determined by LVDT core movement affected by buoyancy force changes on continuous displacer Physical Range Up to 120" (300 cm) based on displacer length Output (Digital ES II) Type...

  • Page 43: Performance

    Chamber Materials Carbon steel 316/316L stainless steel Wetted parts 304/304L and 316/316L (900# and greater) and Inconel (spring) 316/316L (600# and less) and Inconel (spring) Process connections Tank Top: 3", 4", 6" ANSI Flange Chambered: 1 ⁄ ", 2" NPT ⁄...

  • Page 44: Physical

    4.8.3 Physical Dimensional specifications for standard pressure models E61, E62, E63, E64, E65, E66 19.10 (485) 8.62 Range Spring (219) Specific Gravity Rating 14.06 19.06 23.25 .11 to .54 (357) (484) (591) .55 to 1.09 ± .19 (5) 12.12 17.12 21.31 (308) (435)
  • Page 45 Dimensional specifications for high pressure models E51, E53, E55 10.75 10.75 (273) (273) 8.62 1" NPT 8.62 (219) 1" NPT (219) 1" NPT conduit conduit connector " NPT connector 2.00 (51) 3.50 (89) 2.75 (70) ANSI standard flange Up to 75' (23 m) of Connecting Cable, part Level...

  • Page 46: Model Numbers

    Model Numbers 4.9.1 Models for Steam applications (max. 600 lbs.) DESIGN TYPE Standard design EZ Modulevel MOUNTING AND CHAMBER MATERIALS Œ flanged top cage side/bottom cage side/side tank connection steel 316 SS steel 316 SS steel 316 SS chamber material code Œ...
  • Page 47 TRANSMITTER TYPE & MOUNTING Electronic Integral Mount Electronic Remote Mount Electronic High-temp Integral Mount TRANSMITTER OUTPUT 4-20 mA only (Analog) 24 VDC, 120 VAC or 240 VAC Œ 4-20 mA with HART (Digital) 24 VDC only Œ HART communicator sold separately TRANSMITTER CONFIGURATION AND ACCESSORIES Code Display...

  • Page 48: Models For Steam Applications

    4.9.2 Models for Steam applications (900 to 2500 lbs.) DESIGN TYPE Standard design EZ Modulevel MOUNTING AND CHAMBER MATERIALS flanged cage cage Πside/bottom side/side tank connection with steel chamber material code ΠAdjustable 8' hanger cable (p/n 32-3110-001), required when distance from flange face to top of displacer must be greater than 9.31"...
  • Page 49 TRANSMITTER TYPE & MOUNTING Electronic Integral Mount Electronic Remote Mount Electronic High-temp Integral Mount TRANSMITTER OUTPUT 4-20 mA only (Analog) 24 VDC, 120 VAC or 240 VAC Œ 4-20 mA with HART (Digital) 24 VDC only Œ HART communicator sold separately TRANSMITTER CONFIGURATION AND ACCESSORIES Code Display...

  • Page 50: Models For Non-Steam Applications (Max. 600 Lbs.)

    4.9.3 Models for Non-Steam applications (max. 600 lbs.) DESIGN TYPE Standard design EZ Modulevel MOUNTING AND CHAMBER MATERIALS Πflanged top cage side/bottom cage side/side tank connection steel 316 SS steel 316 SS steel 316 SS chamber material code ΠAdjustable 8' hanger cable (p/n 32-3110-001), required when distance from flange face to top of displacer must be greater than 5.00"...
  • Page 51 TRANSMITTER TYPE & MOUNTING Electronic Integral Mount Electronic Remote Mount Electronic High-temp Integral Mount TRANSMITTER OUTPUT 4-20 mA only (Analog) 24 VDC, 120 VAC or 240 VAC Œ 4-20 mA with HART (Digital) 24 VDC only Œ HART communicator sold separately TRANSMITTER CONFIGURATION AND ACCESSORIES Code Display...

  • Page 52: Glossary

    5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4000 • Fax 630-969-9489 • www.magnetrol.com 145 Jardin Drive, Units 1 & 2 • Concord, Ontario Canada L4K 1X7 • 905-738-9600 • Fax 905-738-1306 Heikensstraat 6 •...

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