Thermo Scientific Mini 11-100 Customer's Manual
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Thermo Scientific Mini 11-100 Customer's Manual

Thermo Scientific Mini 11-100 Customer's Manual

Digital c-level . continuous level indicator
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Customer Manual
Digital C-Level
Model Mini 11-100
Continuous Level Indicator
REC 3866 Rev L, Part No. 046637

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Summary of Contents for Thermo Scientific Mini 11-100

  • Page 1 Customer Manual Digital C-Level Model Mini 11-100 Continuous Level Indicator REC 3866 Rev L, Part No. 046637...
  • Page 2 Revision History Revision Number Date Released ECO Number Release Specifics Revision 4 May 1994 Revision B February 1995 Revision C October 1995 Revision D June 1996 Revision E April 1997 Revision F January 1998 Revision G January 2003 Revision H November 2003 ECO 0076 Revision J...
  • Page 3 2004Thermo Fisher Scientific. All rights reserved. This document is confidential and is the property of Thermo Fisher Scientific (Thermo Scientific). It may not be copied or reproduced in any way without the express written consent of Thermo Scientific. This document also is an unpublished work of Thermo Scientific.

  • Page 4: Limitation Of Remedies

    Thermo Scientific will not be liable for any lost profits, lost savings, any incidental damages, or other economic consequential damages, even if Thermo Scientific, or its authorized supplier, has been advised of the possibility of such damages. Thermo Scientific will not be liable for any damages claimed by you based on any third party claim.
  • Page 5 WORKMANSHIP. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES.” Purchaser agrees to underwrite the cost of any labor required for replacement; including time, travel, and living expenses of a Thermo Scientific Field Service Engineer at the closest factory base. Thermo Fisher Scientific 501 90th Ave. NW...
  • Page 6 Please note that Thermo Scientific reserves the right to change and/or improve the product design and specifications without notice.

  • Page 7: Table Of Contents

    Contents Contents ..................i   Introduction ................1-1   General ....................1-1   Junction Box and Strain Sensor ............1-2   Current Output (Option) ..............1-4   Installation ................2-1   General ....................2-1   Sensor Location................... 2-1   General Mounting Rules ..............2-1  ...
  • Page 8 Strain Sensor Test ................4-6   Replacement Parts ..............5-1   General ....................5-1   Parts Ordering Information ..............5-2   Phone/Fax for Thermo Scientific Offices ..........5-3   Parts List ..................... 5-4   Introduction Thermo Fisher Scientific REC 3866 Rev L...

  • Page 9: Introduction

    Chapter 1 Introduction This instruction manual contains information on the installation, General operation, and maintenance of your Thermo Scientific Model 11-100 Digital Continuous Level Indicator (Digital C-Level) for non-hazardous applications. The Digital C-Level is a micro-processor based, continuous level indicator. It monitors one to eight strain sensor(s), located in the support legs of a bin or storage vessel, and displays the level of material in them.

  • Page 10: Junction Box And Strain Sensor

    Introduction The typical C-Level system consists of up to eight strain sensors (U.S. Junction Box Patent No. 4530245). Each strain sensor comes with an individual foam and Strain polystyrene junction box (see Figure 1-2). Sensor Figure 1–2. Strain Sensor Junction Box, Non-Hazardous Area Introduction Thermo Fisher Scientific REC 3866 Rev L...
  • Page 11 Introduction A strain sensor mounting/installation tool (U.S. Patent No. 4738135) is included with each system. The mounting tool assures correct sensor installation (see Figure 1-3). Figure 1–3. Sensor Installation Tool For Flat For Flat Surfaces Surfaces For Round Surfaces Thermo Fisher Scientific Introduction REC 3866 Rev L...

  • Page 12: Current Output (Option)

    Introduction An optional current output board (0-20mA, 4-20mA) can be installed in the electronic package to provide remote level indication (see Figure Current Output 1–4). (Option) Figure 1–4. Simplified System Diagram Introduction Thermo Fisher Scientific REC 3866 Rev L...
  • Page 13 Field, Surface Mount Construction: Structural foam polystyrene; conforms to IP64, per British Standard S490:1966, IEC 529:1976 and DIN4005D (weather- tight, splash-proof, dust-tight). Finish: Textured surface, Thermo Scientific blue. Size: (Overall) 10.0”H x 8.4”W x 5.6”D Material: UL Listing 94HB Environment: Temperature Range: Control storage –20°...
  • Page 14 Digital C-Level with Tool: 15 lbs. Sensor with Junction Box: 3 lbs. Optional Current Output 2 lbs. Board: Mother Board Mini 11-100-01 Jumpers Layout Figure 1–5. 120/240 VAC Panel Mount Jumper Setting Introduction Thermo Fisher Scientific REC 3866 Rev L...

  • Page 15: Installation

    Chapter 2 Installation This chapter contains information necessary to locate and install the General strain sensor and electronics. Correct location and installation of the strain sensor is important for optimum performance. Sensor The strain sensor must be installed in the correct location for best C- Level performance.
  • Page 16 Installation 3. Multiple Sensor Advantages: Allows for strain averaging. Eliminates uneven loading errors. Eliminates wind loading errors. Reduces thermal gradient effects. Improves overall system accuracy. Figure 2–1. General Mounting Rules Installation Thermo Fisher Scientific REC 3866 Rev L...

  • Page 17: Bin Support Stress Level

    Installation Bin Support The strain sensor must see a pounds per square inch (PSI) stress change, between 0 and 100% bin full, of more than 1500 PSI but less than Stress Level 14,300. The sensor accuracy is limited if 1500 PSI change is not seen. Damage due to overloading can occur on stress levels or more than 14,300 PSI.
  • Page 18 Installation Figure 2–2. Vertical Normal Stress Figure 2–3. Horizontal Shear Stress Installation Thermo Fisher Scientific REC 3866 Rev L...
  • Page 19 Installation 3. Skirt Supported Stress Levels  Stress 12  ( ) ( ) ( ) ( ) d sf Where: P = Total Bin Capacity (lbs.) D = diameter in feet π = 3.14 (Pi) St = skirt thickness (in.) EXAMPLE #1 Find the normal stress in the supports of Figure 2–4 given the bin has a capacity of 100,000 lbs and W6 x 15...
  • Page 20 Installation Figure 2–5. Horizontal Beams Shear Stress EXAMPLE #2: Find the shear stress in the horizontal beam supports of the bin on the left in given the bin has W8 x 67 cross-members and a capacity of 125,000 lbs. This structure has four gusset supports and a capacity of 125,000 lbs. 125 000 ...

  • Page 21: On Vertical Supports

    Installation Figure 2–6. Skirted Silo Vertical structures transfer bin forces through columns to the foundation. On Vertical Mount the sensor in the center of the longest free-standing section of the column. If cross bracing or diagonal members are present, mount the Supports sensor between the bracing connection on the column web (See Figure 2-7 and Figure 2-8).
  • Page 22 Installation Figure 2–8. Typical Sensor Locations – Vertical Always mount the strain sensor in the middle of the column web. Never place the sensor in the column flange (See Figure 2-9) Figure 2–9. Strain Sensor Mounting 4. Using multiple sensors lets the sensor average uneven loads, wind, and improves accuracy (See Figure 2-10) Figure 2–10.

  • Page 23: Location On Horizontal Supports

    Do not install the sensor on multiple vessel structures that share common columns and beams unless the vessel support brackets rest on corner braces. Consult your Thermo Scientific representative regarding horizontal support structure layouts not illustrated in Figure 2-11 and Figure 2-12).

  • Page 24: Sensor Installation

    Installation Figure 2–12. Horizontal Applications and Location Sensor The strain sensor must be installed correctly for best C-Level system performance. Proper installation requires the following steps. Installation 1. Selecting the best column or beam location see On Vertical Supports or Location on Horizontal Supports 2.

  • Page 25: Tools Required

    Installation Several tolls are required to install the strain sensor properly. Special Tools Required tools are included in the installation package and several common hand tools are provided by the customer. 1. Installation Package Tools The following items are included in the single sensor installation tool package.

  • Page 26: Using The Strain Sensor Template

    Installation The strain sensor template is used to mark the location of the installation Using The Strain tool mounting holes correctly. The correct strain sensor mounting Sensor Template location must be selected before sensor installation. Review Sensor Location if needed. The following procedure describes how to locate the template.

  • Page 27: Drilling Sensor Hole

    Installation 1. Center punch through the three holes in the sensor location template (See Figure 2-14). CAUTION: BE CAREFUL TO PUNCH THE HOLES ACCURATELY. Drill the tool mounting holes using the following procedure. 2. Drill three 1/8 inch pilot holes through the column web at the location of the punch marks.
  • Page 28 Installation Make sure that the tool is bolted down tightly. A loose tool will produce holes that are too large for the strain sensor. A precision counterbore is used to drill the sensor hole because the hole must be round and the right size. Drill the sensor hole using the following procedure.

  • Page 29: Sensor Alignment Mark

    Installation Figure 2–15. Mounting Installation Tool Make a strain sensor alignment mark on the beam using a pencil or Sensor scratch awl. The strain sensor must be installed so the strain sensor Alignment Mark dimple is at a right angle with the force change. If the sensor is out of angular alignment, maximum stress cannot be measured.
  • Page 30 Installation Figure 2–16. Sensor Alignment The installation tool is used to press-fit the sensor into the beam web. It Sensor aligns and installs the strain sensor without damaging it (Figure 2-17). Installation Install the sensor using the following procedure. 1. Position the installation tool so the chamfered or notched side is away from the beam web.
  • Page 31 Installation 8. Look at the opposite side of the column web. Align the sensor imprint with alignment mark. Then finger tighten the pushplate bolts until they are snug. Keep the strain sensor imprint within 3 degrees of the Note alignment mark. If the sensor is out of angular alignment, maximum stress levels cannot be measured.
  • Page 32 Installation Figure 2–17. Strain Sensor Mounting 2-18 Installation Thermo Fisher Scientific REC 3866 Rev L...
  • Page 33 Installation Table 2-1. Centering Washers Beam Web Thickness Amount of 1/4” SAE washers .062 required for centering push 1/8 - 5/16” 3/8 - 7/17” 1/2 - 9/16” 5/8 - 11/16” 3/4 - 13/16” 7/8 - 5/16” 1 - 1-1/6” Installation tool can only push 38 inch at a time. More than 6 washers will require two or more centering pushes.
  • Page 34 Installation Figure 2–18. Centering Strain Sensor 2-20 Installation Thermo Fisher Scientific REC 3866 Rev L...

  • Page 35: Junction Box Installation

    Installation Junction Box Installation The junction box is mounted directly to the beam protecting the sensor and wiring connections. Use the following procedure to install the junction box. 1. Clean drill residue from the cable side of the beam web. 2.
  • Page 36 Installation Figure 2–19. Junction Box Installation, Non-Hazardous Area. COLUMNS 2-22 Installation Thermo Fisher Scientific REC 3866 Rev L...

  • Page 37: C-Level Electronics Installation

    Installation C-Level The panel mount version shall be mounted in a vibration free cabinet or Electronics control panel. In a typical bin-weigh application, this may be up to 3000 Installation feet from the strain sensors (using the remote sense lines, 6 conductor shielded cable).

  • Page 38: Field Wiring

    Installation Field Wiring Use the typical field wiring diagram (Figure 2–22 and Figure 2-23) as a guide if you do not have a specific wiring diagram for your system. Follow local electrical codes and regulations for minimum wire size and routing.
  • Page 39 Installation Figure 2–22. Typical Field Wiring - Panel Mount 2-25 Thermo Fisher Scientific Installation REC 3866 Rev L...
  • Page 40 Installation Figure 2–23. Typical Field Wiring - Field Mount 2-26 Installation Thermo Fisher Scientific REC 3866 Rev L...

  • Page 41: Calibration

    Chapter 3 Calibration The 11-100 (DCL-100) must be calibrated correctly for proper system operation. Calibration allows the unit to show the correct value of level. The device always displays the contents of the bin, without an operator action required. See Menu Tree for a layout of the options within each menu.
  • Page 42 Calibration Table 3-1 Front Panel Scrolls DESCRIPTION MINIMUM MAXIMUM VALUE DEFAULT VALUE VALUE SETUP KEY Protection (Active, Not Active) Scale Data Decimal Point 0,0000 Scale Capacity 9999999 100.0% Scale Divisions (1, 2, 5, 10, 20, 50, 100) Measurement Units (Tons, Long Tons, Grams, Kilograms, Q, Percent, Lb) Autozero Track 0.0%...
  • Page 43 Calibration Current Output mA Range (4-20, k 0-20, 20-4, 20-0) 4-20 mA mA Value (Gross, Net, Peak) GROSS mA Zero Level (% of Scale Capacity) 0.0% 100% 0.0% mA 100% Level (% of Scale Capacity) 100.0% 100.0% mA Absolute Value (Yes/No) Alarms (Display) Threshold 1 (Alarm, Not Used) NOT USED...

  • Page 44: Setup

    Calibration Filter 10.0 10 SEC Zero 30,000 2 mV Span 9,999,999 10 mV SETPOINT KEY Set Threshold 1 SCALE CAPACITY Set Threshold 2 SCALE CAPACITY 200.0 Set Threshold 3 SCALE CAPACITY 300.0 Set Threshold 4 SCALE CAPACITY 350.0 Var Threshold 1 (Gross, Net, ABS Net, ABS Gross) GROSS Var Threshold 2 (Gross, Net, ABS Net, ABS Gross) GROSS...
  • Page 45 Calibration After selection of the desired location, pressing ENTER displays the current setting of the instrument at that point. Pressing the ENTER key now advances the display to the next set, the actual manipulation of the setting. This is shown by the flashing of the display. For numeric values, the left most digit flashes.
  • Page 46 Calibration Figure 3–2. Menu Tree SETUP KEY Not Active PROTECTION Active Decimal Point Scale Capacity Scale Division - (1,2,5,10 etc.) SCALE DATA Measurement Units - (lb, Kg,gr,% etc.) Enable Autozero Track *Set Tracking Band *Set Time Before AZT Time Zeroing *Set Maximum Limit AZT Correction...
  • Page 47 Calibration protection set to “Not Active” SETUP KEY Continued Print Not Used Set Tare Input 1 Reset Tare Input 2 Update Total Input 3 Clear Total Hold Weight Clear Peak Clear Alarms *INPUT/OUTPUT Not Used Alarm Instrument Ready Output 1 Weight Stable Output 2 Update Total...
  • Page 48 Calibration SETUP KEY Continued Protocol (PC Master, Siemens 3964R, DF1, Modbus) (OPTION) Baud Rate (1200, 2400, 4800, SERIAL 9600, 19200, 38400) COMMUNICATION Stop Bits (1, 2) Parity (Not Used, None, Odd, Even) World Length (7 bit, 8 bit) Handshake (Yes, No) Address (1 through 16) Set Password (00,000,000 - 99,999,999)
  • Page 49 Calibration * Not Active or Factory Set ** Adjustable with Protection set to “Not Active” CAL KEY Continued Acquire R Cal AUTO SPAN RES Calibration Res Weight Unloaded? FILTER ZERO SPAN SETPOINT KEY SET THRESHOLD (1, 2, 3, AND 4) *VAR THRESHOLD Set Variable of Threshold (Net, (1, 2, 3, AND 4)

  • Page 50: Calibration Procedure

    After the calibration has been completed, the zero and span settings are stored in the permanent memory of the unit. The Mini 11-100 D C- Level does not need to be recalibrated if a power outage occurs.

  • Page 51: Zero Or Low Level Calibration Value Entry

    Calibration 4. To toggle the protection from “Active” to “Not Active” (or vice versa), press the ENTER key once. When “Active” or “Not Active” is displayed, the display reads 0. Press the ENTER key again. The display shows 00000000 with the eight zero flashing. Press the up arrow key twice.

  • Page 52: Relay Output Alarms

    Calibration If ever during the calibration procedure you desire to quit NOTE or start over, press the RUN/SETUP key. The device will be returned to the normal operating mode. This calibration has produced a readout in percent of bin full with a resolution of 0.5 percent. The % sign at the right of the display denotes percentage of full scale.

  • Page 53: Relay Function Setup

    ENTER. Use the up arrow key to select the desired function. Press ENTER to install the desired setting. Optional Setups The Mini 11-100 can be customized to fit your application, such as having the display read in engineering units. The following section outlines the programming instructions for specific applicatioins.

  • Page 54: Setting Divisions (Display Increments)

    Run Mode. The Mini-100 is set at the factory to provide 2-1/2 digits NOTE on the display. Thermo Scientific does not recommend having more than 3 active digits. Excessive active digits cause instability of the display. Available settings for units per division are: 1, 2, 5, 10, 20, 50 and 100.

  • Page 55: Alarm List

    Calibration alarm/setpoint is active. In addition, the display flashes a message that one of the alarms (i.e., THRESHOLD 1) is or has been activated. Alarm List The list of alarms is as follows: THRESHOLD 1 THROUGH 4 These indicate the level at which they were set has been exceeded. The continue to flash even after the level has returned to normal.

  • Page 56: Maintenance

    Chapter 4 Maintenance The Thermo Scientific C-Level Model 11-100 continuous level indicator General is one hundred percent solid-state and should require little, if any, maintenance. To assist you in servicing your C-Level, information in this section includes: A preventative maintenance plan with recommended cleaning and sensor protection schedule.

  • Page 57: Diagnostic Procedures

    Maintenance Diagnostic The C-Level has several built-in diagnostic features to help you in Procedures isolating problems in the electronics. One of the diagnostic features is called Load Cell Fail. This message is displayed if the device detects a failure in the excitation or weight signals. It is always active and does not need operator intervention.

  • Page 58: Troubleshooting

    7. Press the up arrow key to display FORCE VALUE Q. This function is not used Troubleshooting The most common C-Level problems and causes are outlined in this section. Thermo Scientific Technology suggests all field wiring and connections be verified before replacement parts are used. Thermo Fisher Scientific Maintenance...

  • Page 59: Visual Inspection

    Maintenance Visual Inspection Often a quick visual inspection leads to the source of trouble. If a problem does develop, check the following before proceeding to more specific troubleshooting procedures: 1. Check Power: a. Check that the power is ON. b. Check that the fuse is NOT blown. 2.

  • Page 60: System Drifts

    Maintenance System Drifts Symptom: Level indication is unstable when bin level is constant. Probable Cause: 1. Strain sensor(s) are not being stressed under load due to improper loading, location, installation or orientation of the strain sensors (Chapter 2.0). 2. Moisture or loose connections in the wiring systems. TB1-1 (+) and TB1-2 (-) should show a positive increase of more than 0.8 millivolts at 100% level with respect to 0 level.

  • Page 61: Strain Sensor Test

    Maintenance Strain Sensor If calibration or drifting problems still prevail, it will be necessary to check each strain sensor for possible failure. Test Test all strain sensors using the following procedure: 1. Leave power applied to the system. 2. Disconnect the red and white wire in the junction box coming from each strain sensor.
  • Page 62 Meter = 0.50 (20 mA - 4 mA) + 4 mA Meter = 12 mA If the meter does not indicate correctly, the current output board is faulty and must be replaced. Figure 4–1. Mini 11-100 / DCL-100 Jumpers and Pots Configuration Bus Board Function...
  • Page 63 Maintenance Microprocessor Board Function Pot/Jumper Status Description CLOSE Factory configured, do not change Reset circuit OPEN Factory configured, do not change CLOSE 19,200 Baud OPEN Debug serial Port OPEN 38,400 Baud CLOSE Line Power Reset CLOSE Factory configured, do not change Filter Cut Out OPEN 10 Hz...

  • Page 64: Replacement Parts

    The maintenance information in this manual is designed to meet your service needs. If you should encounter a problem that requires technical assistance, you may call Thermo Scientific Product Service at (800) 445- 3503. Thermo Scientific also provides on-site service technicians to assist customers with installation, setup, initial calibration, customer training, maintenance, and repair.

  • Page 65: Parts Ordering Information

    1. Determine the broken or faulty part. 2. Locate the part in the Parts List. 3. Find the part number(s) for the item(s) you need. 4. Before you contact Thermo Scientific for your parts, make sure you have the following information: Machine model and serial number...

  • Page 66: Phone/Fax For Thermo Scientific Offices

    Replacement Parts Australia Spain Phone/Fax for +61 (0) 8 8208-8200 +34 91-484-5965 Thermo +61 (0) 8 8234-3772 fax +34 91-484-3597 fax commercial.pid.esmad@thermofisher.com service.auadl@thermofisher.com Scientific United States & Canada Brazil Offices +1 (800) 445-3503 +55-11-2367-2192 +1 (763) 783-2525 fax +55-11-2367-2192 fax service.bulk.us@thermofisher.com parts.bulk.us@thermofisher.com Canada...

  • Page 67: Parts List

    046636 Control Digital C-Level, Panel Mount, 046633 Model 11-100 without Input/Output Control, Digital C-Level, Panel Mount, 046634 Model Mini 11-100 with Input/Output Current Output Board, Panel Mount 046635 Control, Digital C-Level, Field Mount, 051031 Model 11-100F without Serial Output Control, Digital C-Level, Field Mount...

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