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Emerson DLC3010 Instruction Manual

1. 0 0 0 100 200 300 400 500 600 700 E0370 TEMPERATURE F Process Temperature The digital level controller can receive the process temperature from a resistance temperature detector RTD connected to the unit or if no RTD is connected to the unit you can enter the process temperature directly The digital level controller uses the process temperature to make specific gravity corrections Follow the prompts on the Field Communicator to view or edit process temperature information e Proc Temp Source Manual or RTD Change Proc Temp Source Select Keep Value Edit Value or Install RTD You must select the number of wires for an RTD either 2 or 3 For a 2 wire RTD you must specify the connecting wire resistance If you know the resistance select Resistance and enter the resistance of the wire 250 feet of 16 AWG wire has a resistance of 1 ohm If you do not know the resistance select Wire Gauge Length and the Field Communicator will prompt you for the length and gauge of the wire and calculate the resistance e Proc Temp Display the process temperature e RTD Wire Resistance Displays the RTD wire resistance Device Information Field Communicator Configure Manual Setup Device Information 2 2 4 Follow the prompts on the Field Communicator display to view or edit information in the following fields e HART Tag The HART tag
2. A Field Communicator Signal loop may be grounded at may be connected at any any point or left ungrounded termination point in the signal loop Signal loop must have between 250 and 1100 ohms load for communication NOTE 1 THIS REPRESENTS THE TOTAL SERIES LOOP RESISTANCE E0363 Power Supply To communicate with the digital level controller you need a 17 75 volt DC minimum power supply The power supplied to the transmitter terminals is determined by the available supply voltage minus the product of the total loop resistance and the loop current The available supply voltage should not drop below the lift off voltage The lift off voltage is the minimum available supply voltage required for a given total loop resistance Refer to figure 2 10 to 20 Instruction Manual Installation D102748X012 October 2014 determine the required lift off voltage If you know your total loop resistance you can determine the lift off voltage If you know the available supply voltage you can determine the maximum allowable loop resistance Figure 2 10 Power Supply Requirements and Load Resistance Maximum Load 43 5 X Available Supply Voltage 12 0 783 Load Ohms Operating Region N Ul e 10 12 15 20 25 30 LIFT OFF SUPPLY VOLTAGE VDC If the power supply voltage drops below the lift off voltage while the transmitter is being configured the transm
3. 80 Lever Assembly 81 Removing the Lever Assembly 81 Replacing the Lever Assembly 82 Packing for Shipment 83 Section 7 Parts 85 Parts Orderin Sh atk eae Ee eRe eke 85 MOURLUTQ RIS 85 eos eb edid pb trs 85 Rart USE 86 DLC3010 Digital Level Controllers 96 Transducer Assembly 87 Terminal Box Assembly 88 Terminal Box Cover Assembly 88 Mounting r RN 89 249 Sensors with Heat Insulator 89 Appendix A Principle of Operation 93 HART Communication 93 Digital Level Controller Operation 94 Appendix B Field Communicator T rcr 99 GIOSSALY 105 Instruction Manual Introduction and Specifications D102748X012 October 2014 Section 1 Introduction and Specifications Scope of Manual This instruction manual includes specifications installation operating and maintenance information for FIELDVUE DLC3010 digital level controllers This instruction manual supports the 475 or 375 Field Communicator with device description revision 3 used with DLC3010 instruments with firmware revision 8 You can obtain information about the process instrument or sensor
4. IDROF MODE MODE 0380 e FAIL HDWR This message indicates the existence of one or more of the following conditions The primary sensor input conversion is out of range The primary sensor drive current is out of range The internal reference voltage for controlling the loop current is out of range Perform the diagnostic procedures detailed later in this section to isolate the specific failure If diagnostics indicate a failure of a particular module replace the indicated module with a new one Otherwise correct the mechanical input condition to clear the message e OFLOW The location of the decimal point as configured in the meter setup is not compatible with the value to be displayed by the meter For example if the meter is measuring a level greater that 99 999 mm and the meter decimal point is set to 3 digit precision the meter will display an OFLOW message because it is only capable of displaying a maximum value of 99 999 when set to 3 digit precision The position of the decimal point may be adjusted by using the Field Communicator From the Online menu select Configure gt Manual Setup gt Instrument Display gt Decimal Places 2 2 5 4 Selecting 0 will put the display in auto scale mode The number of decimal places displayed will be the maximum remaining in the display field for the current value of PV Hardware Diagnostics If you suspect a malfunction d
5. 0 cece ee ee eee 23 Two Wire RTD Connections 23 Three Wire RTD Connections 23 Communication Connections 23 Test lt 23 Multichannel Installations 24 www Fisher com FIELDVUE Instruments Alarm Jumper eeeee IIR 25 Changing Jumper Position 25 LOOP eR PS 26 Installation in Conjunction with a Rosemount 333 HART Tri Loop HART to Analog 5 27 Multidrop Communication 93 Section 3 29 Section 4 Setup and Calibration 33 Initial Sel D cedente Ye 33 Configuration Advice 34 Preliminary Considerations 34 Vite LOC ss ese Eoi St EAE DEAS 34 Level Offset o csi ne Shaws 34 Guided Setup 34 38 Marital SeLUD 39 SENSON 39 VENENIS 4 Process WIG 43 Device Information 46 Instrument 47 Alert 49 Primary Variable 49 TEMPE 2 vues Pub E d PIED Sa rs 51 amp Process Management DLC3010 Dig
6. Active Alerts 1 No Active Alerts Visible if there are no active alerts 1 Refresh Alerts 2 a Visible if an alert is active alert name plus C description will be visible if the associated A alert is active gt amp 3 2 2 Primary Variable Variables if PV is Density Y 1 PV Value 1 PV 2 Range 2 Primary Variable 3 AO 4 Inst Temp 3 2 5 5 Process Temperature Process Temperature 6 Torque Rate 1 Proc Temp Source 2 Proc Temp ai 3 2 2 2 Primary Variable Primary Variable 3 AO 4 Inst Temp ae 5 Process Temperature ose 6 Torque Rate 3 2 5 7 Upper Fluid Density Process Temperature 8 Lower Fluid Density 1 Proc Temp Source 3 2 2 Proc Temp Variables if PV is Level 3 2 2 2 Primary Variable _ Primary Variable 3 AO 1 PV Value 4 Inst Temp 5 Process Temperature 6 Torque Rate 3 2 5 7 Lower Fluid Density Process Temperature 1 Proc Temp Source 2 Proc Temp 2 Two Point Calibration Instruction Manual D102748X012 Glossary Alarm Deadband The amount by which the process variable must return within normal limits for the alarm to clear Alarm Limit An adjustable value that when exceeded activates an alert Algorithm A set of logical steps to solve a problem or accomplish a task A computer program contains one or more algorithms Alphanume
7. Enter the displacer weight from the sensor nameplate 39 Configuration Instruction Manual October 2014 D102748X012 e Driver Rod Length Enter the displacer rod length The displacer rod length depends upon the sensor type For a 249 sensor obtain the displacer rod length from table 4 1 or from the Field Communicator Help Refer to figure 4 2 to physically measure this value Torque Tube Follow the prompts on the Field Communicator to enter torque tube data e Torque Rate Displays the torque rate currently stored in the instrument Change Torque Rate Permits changing the torque rate stored in the instrument e TT Material Displays the torque tube material currently stored in the instrument Note A sensor with an N05500 torque tube may have NiCu on the nameplate as the torque tube material TT Comp Selection Torque Tube Compensation Selection permits changing the torque tube material stored in the instrument e TT Comp Table Torque Tube Compensation Table permits you to load a table with the material temperature coefficients Instrument Mounting Follow the prompts on the Field Communicator display to specify if the instrument is to the right or left of the displacer See figure 2 5 Sensor Damping Follow the prompts on the Field Communicator display to configure the input filter Time constant for the input filter in seconds for the A D measurement The filter is applied before PV processing after the A
8. _ _ _ SStrapwrench Helpful for removing a displey cover thathas been overtightened 3 _ Targe iat Bade screwdriver erime 9 Needenosepies Nendmpmgewadon M _ 1 Needed to remove a flex circuit if date code numbers are requested for warranty information Removing the DLC3010 Digital Level Controller from a 249 Sensor 249 Sensor in Standard Temperature Applications 1 Loosen the set screw key 31 in the terminal box cover assembly key 6 so that the cover can be unscrewed from the terminal box 2 After removing the cover key 6 note the location of field wiring connections and disconnect the field wiring from the wiring terminals 3 As shown in figure 2 4 locate the access handle on the bottom of the transducer housing Using a 2 mm hex key back out the set screw in the depression on the access handle until it is flush with the handle surface Press on the back of the handle as shown in the figure and slide the handle toward the front of the unit the locked position to expose the access hole Be sure the locking handle drops into the detent Note If the access handle will not slide the sensor linkage is most likely in an extreme position When the lever assembly is at a hard stop inside the housing the locking pin on the access door may not be able to engage the mating slot in the lever assembly This condition can occur if the displacer has been removed if the sensor is lying on its side
9. e PV Value Indicates the current process variable level interface or density in engineering units e Range Indicates the current process variable in percent of the span determined by the lower range value and the upper range value Refer to figure 5 1 If the digital level controller is setup for direct action i e the lower range value is less than the upper range value 0 range corresponds to the lower range value LRV and 100 range corresponds to the upper range value URV If the digital level controller is setup for reverse action i e the lower range value is greater than the upper range value 0 range corresponds to the upper range value URV and 100 range corresponds to the lower range value LRV Use the following equation to calculate the range values PV range URV LRV x 100 where PVey process variable in engineering units The LRV always represents the 0 range value and the URV always represents the 100 range value 68 Instruction Manual Service Tools D102748X012 October 2014 Figure 5 1 PV Range Indication for Direct and Reverse Action with a 32 Inch Displacer Ranged for 8 to 24 Inches T T 3 3 5 5 2 2 4 12 20 28 32 12 20 24 28 32 We LRV LEVEL INCHES LEVEL INCHES DIRECT ACTION REVERSE ACTION 0383 AO Indicates the current analog output value of the instrument in milliamperes Inst Temp Indicates the current Instrument Temperature Process Tem
10. Figure A 2 Typical Multidropped Network BELL 202 E0375 The Field Communicator can test configure and format a multidropped DLC3010 digital level controller in the same way as in a standard point to point installation Note DLC3010 digital level controllers are set to address 0 at the factory allowing them to operate in the standard point to point manner with a 4 20 mA output signal To activate multidrop communication the address must be changed to a number between 1 and 15 This change deactivates the 4 20 mA analog output sending it to 4 mA The failure mode current also is disabled Digital Level Controller Operation The DLC3010 digital level controller is a loop powered instrument that measure changes in liquid level level of an interface between two liquids or density of a liquid Changes in the buoyancy of a displacer suspended in a vessel vary the load on a torque tube The displacer and torque tube assembly constitute the primary mechanical sensor The angular deflection of the torque tube is measured by the instrument transducer which consists of a magnet system moving over a Hall effect device A liquid crystal display LCD meter can display the analog output process variable level interface level or density the process temperature if an RTD resistance temperature detector is installed the degrees of torque tube rotation and percent range The instrument uses a microcontroller and associated electronic circu
11. must be between 230 and 1100 ohms The transmitter HART receive impedance is defined as Rx 42K ohms and Cx T4 nF Note that in point to point configuration analog and digital signalling are available The instrument may be queried digitally for information or placed in Burst mode to regularly transmit unsolicited process information digitally In multi drop mode the output current is fixed at 4 mA and only digital communication is available continued Instruction Manual D102748X012 Performance w NPS 3 Performance D Jed 2 249W Using w All Other EE Digital Level Criteria 1 a 14 inch 249 Sensors Controller Displacer Independent 0 25 of 0 8 of 0 5 of Linearity output span outputspan output span Hysteresis lt 0 2 of y output span Repeatability 0 1 of full 0 5 of 0 3 of scale output outputspan output span Dead Band ee input span Hysteresis plus lt 1 0 of lt 1 0 of Deadband output span output span NOTE At full design span reference conditions 1 To lever assembly rotation inputs At effective proportional band PB lt 100 linearity dead band and repeatability are derated by the factor 100 PB Operating Influences Power Supply Effect Output changes lt 0 2 of full scale when supply varies between min and max voltage specifications Transient Voltage Protection The loop terminals are protected by a transient voltage suppressor The specifications
12. using the Field Communicator Contact your Emerson Process Management sales office to obtain the appropriate software Note AMS Suite Intelligent Device Manager can also be used to calibrate and configure the DLC3010 and to obtain information about the process instrument or sensor Do not install operate or maintain a DLC3010 digital level controller without being fully trained and qualified in valve actuator and accessory installation operation and maintenance To avoid personal injury or property damage it is important to carefully read understand and follow all of the contents of this manual including all safety cautions and warnings If you have any questions about these instructions contact your Emerson Process Management sales office Conventions Used in this Manual This manual describes using the Field Communicator to calibrate and configure the digital level controller Procedures that require the use of the Field Communicator have the text path and the sequence of numeric keys required to display the desired Field Communicator menu For example to access the Full Calibration menu Field Communicator Configure gt Calibration gt Primary gt Full Calibration 2 5 1 1 Menu selections are shown in italics e g Calibrate An overview of the Field Communicator menu structure is shown in Appendix B Description DLC3010 Digital Level Controllers DLC3010 digital level controllers figure 1 1 are used with leve
13. 1 800 338 8158 e mail education emerson com http www emersonprocess com education Introduction and Specifications October 2014 Table 1 1 DLC3010 Digital Level Controller Specifications Available Configurations DLC3010 Digital Level Controller Mounts on caged and cageless 249 sensors See tables 1 6 and 1 7 and sensor description Function Transmitter Communications Protocol HART Input Signal Level Interface or Density Rotary motion of torque tube shaft proportional to changes in liquid level interface level or density that change the buoyancy of a displacer Process Temperature Interface for 2 or 3 wire 100 ohm platinum RTD for sensing process temperature or optional user entered target temperature to permit compensating for changes in specific gravity Output Signal Analog 4 20 milliamperes DC Bl direct action increasing level interface or density increases output or W reverse action increasing level interface or density decreases output High saturation 20 5 mA Low saturation 3 8 mA High alarm 22 5 mA Low Alarm 3 7 mA Only one of the above high low alarm definitions is available in a given configuration NAMUR NE 43 compliant when high alarm level is selected Digital HART 1200 Baud FSK frequency shift keyed HART impedance requirements must be met to enable communication Total shunt impedance across the master device connections excluding the master and transmitter impedance
14. 20 mA or Other to manually input a value between 4 and 20 milliamps 5 Check the reference meter to verify that it reads the value you commanded the controller to output If the readings do not match either the controller requires an output trim or the meter is malfunctioning After completing the test procedure the display returns to the loop test screen and allows you to choose another output value or end the test 26 Instruction Manual Installation D102748X012 October 2014 Installation in Conjunction with a Rosemount 333 HART Tri Loop HART to Analog Signal Converter Use the DLC3010 digital level controller in operation with a Rosemount 333 HART Tri Loop HART to Analog Signal Converter to acquire an independent 4 20 mA analog output signal for the process variable range electronics temperature and process temperature The Tri Loop divides the digital signal and outputs any or all of these variables into as many as three separate 4 20 mA analog channels Refer to figure 2 13 for basic installation information Refer to the 333 HART Tri Loop HART to Analog Signal Converter Product Manual for complete installation information Figure 2 13 HART Tri Loop Installation Flowchart START HERE Unpack the Install the HART HART Tri Loop ME Product Manual Configure the HART Tri Loop to receive digital level controller Mount the HART burst commands Tri Loop to the DIN rail Check Wire the digital Pass system troubl
15. A Field Communicator command that transfers configuration data from the Field Communicator s working register to the digital level controller memory SI Units The International System of Units Includes metric units such as ampere A meter m kilogram kg Kelvin K and second s October 2014 Software Microprocessor or computer programs and routines that reside in alterable memory usually RAM as opposed to firmware which consists of programs and routines that are programmed into memory usually ROM when the instrument is manufactured Software can be manipulated during normal operation firmware cannot Span Algebraic difference between the upper and lower range values Temperature Sensor A device within the instrument that measures the instrument s internal temperature Upper Range Value URV Highest value of the process variable that the digital level controller is currently configured to measure in the 4 to 20 mA loop Upper Sensor Limit USL Highest value of the process variable that the digital level controller can be configured to measure Working Register Memory location in a Field Communicator that temporarily stores data as it is being entered 107 Glossary Instruction Manual October 2014 D102748X012 108 Instruction Manual D102748X012 Index A access handle 15 Access Handle Assembly removing and replacing 80 Active Alerts Service Tools 67 Advisory Device Status 29 Ala
16. CL1500 or CL2500 CL125 CL150 CL250 CL300 Mounts on Bon ee For NPS 4 raised face or flat face CL600 CL900 or CL1500 side of vessel AE EN PN 10 to DIN PN 160 WCC LCC or CF8M For NPS 4 buttweld end XXZ CL2500 Mounts on top of WCC or CF8M For NPS 3 raised face CL150 CL300 or CL600 vessel or on customer 249W LCC or CF8M For NPS 4 raised face CL150 CL300 or CL600 supplied cage 1 Standard displacer lengths are 14 32 48 60 72 84 96 108 and 120 inches 2 Not used with side mounted sensors 3 EN flange connections available in EMA Europe Middle East and Africa 4 Not available in EMA 5 249P available in EMA only 6 Wafer Body only applicable to the 249W 11 Introduction and Specifications Instruction Manual October 2014 D102748X012 Figure 1 3 Style Number of Equalizing Connections STYLE 3 UPPER AND LOWER SIDE CONNECTIONS SCREWED S 3 OR FLANGED F 3 STYLE 1 TOP AND BOTTOM CONNECTIONS SCREWED S 1 OR FLANGED F 1 STYLE 2 STYLE 4 TOP AND LOWER SIDE CONNECTIONS UPPER SIDE AND BOTTOM CONNECTIONS SCREWED S 2 OR FLANGED F 2 SCREWED S 4 OR FLANGED F 4 28B5536 1 B1820 2 Instruction Manual Installation D102748X012 October 2014 Section 2 Installation This section contains digital level controller installation information including an installation flowchart figure 2 1 mounting and electrical installation information and a discussion of failure mode jumpers Co
17. D conversion Range is 0 to 16 seconds in 0 1 second increments The default value is 0 0 seconds To disable the filter set the time constant to 0 seconds This filter is provided for extreme input noise situations Use of this filter normally should not be necessary Net instrument response is a combination of analog input filtering and output filtering 40 Instruction Manual Configuration D102748X012 October 2014 Variables Field Communicator Configure gt Manual Setup gt Variables 2 2 2 Primary Variables Follow the prompts on the Field Communicator to view or edit Primary Variable information PV is Display the PV currently stored in the instrument Change PV Follow the prompts to change the PV Select Level Units if the PV is level Interface Units if the PV is Interface or Density Units if the PV is Density PV Units Permits changing the PV units For density measurement g cm grams per cubic centimeter kg m kilograms per cubic meter Ib gal pounds per gallon Ib ft pounds per cubic foot g mL grams per milliliter kg L kilograms per liter g L grams per liter Ib in pounds per cubic inch SGU specific gravity units For level and interface measurement ft feet m meters in inches cm centimeters mm millimeters e Level Offset Displays the current Level Offset stored in the instrument Set Level Offset Adding a level offset permits the process variable engineering un
18. D102748X012 Table 1 1 DLC3010 Digital Level Controller Specifications continued Minimum Differential Specific Gravity continued encapsulated printed wiring boards Neodymium Iron Boron Magnets See 249 sensor specifications for standard displacer 3 volumes and standard wall torque tubes Standard volume for 249C and 249CP sensors is 980 cm 60 100 in3 bottom and one on back of terminal box M20 adapters available Electrical Connections Operating at 5 proportional band will degrade accuracy by a factor of 20 Using a thin wall torque Options tube or doubling the displacer volume will each roughly double the effective proportional band When proportional band of the system drops below 50 changing displacer or torque tube should be considered if high accuracy is a requirement ll Heat insulator See description under Ordering Information Bl Mountings for Masoneilan Yamatake and Foxboro Eckhardt displacers available BI Level Signature Series Test Performance Validation Report available EMA only for instruments factory mounted on 249 sensor li Factory Calibration available for instruments OSION factory mounted 249 sensor when application Digital level controllers can be mounted right or process temperature and density s are supplied left of displacer as shown in figure 2 5 ll Device is compatible with user specified remote indicator Instrument orientation is normal
19. Determining the SG of an Unknown Fluid 65 Accuracy Considerations 65 Effect of Proportional Band 65 Density Variations in Interface Applications 65 Extreme lt 66 Temperature Compensation 66 Section 5 Service Tools 67 Active Alerts 67 Variables 68 MaifitelldlleB sm 70 Instruction Manual D102748X012 Section 6 Maintenance and Troubleshooting 71 Diagnostic Messages 71 Hardware Diagnostics 72 Tes Gp RON 74 Removing the Digital Level Controller from the Sensor 74 Removing the DLC3010 Digital Level Controller from 249 5 75 Standard Temperature Applications 75 High Temperature Applications 76 LCD Meter Assembly 76 Removing the LCD Meter Assembly 77 Replacing the LCD Meter Assembly 7 Electronics Module 78 Removing the Electronics Module 78 Replacing the Electronics Module 78 QTV veter mete vt ENA 79 Removing the Terminal Box 79 Replacing the Terminal 79 Removing Replacing the Inner Guide and Access Handle Assembly
20. Instruction Manual Principle of Operation D102748X012 October 2014 Appendix A Principle of Operation HARI Communication The HART Highway Addressable Remote Transducer protocol gives field devices the capability of communicating instrument and process data digitally This digital communication occurs over the same two wire loop that provides the 4 20 mA process control signal without disrupting the process signal In this way the analog process signal with its faster update rate can be used for control At the same time the HART protocol allows access to digital diagnostic maintenance and additional process data The protocol provides total system integration via a host device The HART protocol uses the frequency shift keying FSK technique based on the Bell 202 communication standard By superimposing a frequency signal over the 4 20 mA current digital communication is attained Two individual frequencies of 1200 and 2200 Hz are superimposed as a sinewave over the 4 20 mA current loop These frequencies represent the digits 1 and 0 see figure A 1 The average value of this sinewave is zero therefore no DC value is added to the 4 20 mA signal Thus true simultaneous communication is achieved without interrupting the process signal Figure A 1 HART Frequency Shift Keying Technique ANALOG SIGNAL 1200 Hz 2200 Hz 1 g AVERAGE CURRENT CHANGE DURING COMMUNICATION 0 A6174 The HART protocol allows the capabilit
21. MODE VARIABLE UNITS MODE E0371 After you have selected the desired meter settings press SEND on the Field Communicator to download the meter settings to the instrument 48 Instruction Manual Configuration D102748X012 October 2014 Alert Setup The following menus are available for configuring Alerts Primary Variable Field Communicator Configure gt Alert Setup gt Primary Variable 2 3 1 Follow the prompts on the Field Communicator display to view or edit the following primary variable alerts Primary Variable Hi HiAlert PV Hi Alert Enable On or Off PV High Alert Enable activates checking the primary variable against the PV High Alert limit The High Alert is set if the primary variable rises above the PV High Alert limit Once the alert is set the primary variable must fall below the PV High Alert limit by the PV Alerts Threshold Deadband before the alert is cleared See figure 4 7 PV Hi Alert Threshold Primary Variable Hi Alert Threshold is the value of the process variable in engineering units which when exceeded sets the Primary Variable High Alert PV Hi Alert Threshold Method to change the PV Hi Alert Threshold e Hi Hi Alert PV Hi Hi Alert Enable On or Off PV High High Alert Enable activates checking the primary variable against the PV High High Alert limit The High High Alert is set if the primary variable rises above the PV High High Alert limit Once the alert is set the primary var
22. NN ETE ttt tt ty ttt TTY PT IAL TAL AA 531600 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 TEMPERATURE F NOTE 1 DUETO THE PERMANENT DRIFT THAT OCCURS NEAR AND ABOVE 260 C 500 F N05500 IS NOT RECOMMENDED FOR TEMPERATURES ABOVE 232 C 450 F Introduction and Specifications October 2014 Table 1 3 249 Sensor Specifications Input Signal Liquid Level or Liquid to Liquid Interface Level From 0 to 100 percent of displacer length Liquid Density From 0 to 100 percent of displacement force change obtained with given displacer volume standard volumes are lil 980 cm 60 inches for 249C and 249CP sensors or lil 1640 cm 100 inches for most other sensors other volumes available depending upon sensor construction Sensor Displacer Lengths See tables 1 6 and 1 7 footnotes Sensor Working Pressures Consistent with applicable ANSI pressure temperature ratings for the specific sensor constructions shown in tables 1 6 and 1 7 Caged Sensor Connection Styles Cages can be furnished in a variety of end connection styles to facilitate mounting on vessels the Table 1 4 Allowable Process Temperatures for Common 249 Sensor Pressure Boundary Materials PROCESS TEMPERATURE Instruction Manual D102748X012 equalizing connection styles are numbered and are shown in figure 1 3 Mounting Positions Most level sensors with cage displacers have a rotatable head Th
23. ONLY IF THE DLC3010 REMAINS POWERED UP 14 Setup specific gravity tables Enter Process Instruction Manual D102748X012 Setup and Calibrate RTD Instruction Manual Installation D102748X012 October 2014 4 f the controller was shipped alone the access handle will be in the locked position All Mounting Coupling and Calibration procedures must be performed The access handle includes a retaining set screw as shown in figures 2 4 and 2 6 The screw is driven in to contact the spring plate in the handle assembly before shipping It secures the handle in the desired position during shipping and operation To set the access handle in the open or closed position this set screw must be backed out so that its top is flush with the handle surface Mounting To avoid personal injury always wear protective gloves clothing and eyewear when performing any installation operations Personal injury or property damage due to sudden release of pressure contact with hazardous fluid fire or explosion can be caused by puncturing heating or repairing a displacer that is retaining process pressure or fluid This danger may not be readily apparent when disassembling the sensor or removing the displacer Before disassembling the sensor or removing the displacer observe the appropriate warnings provided in the sensor instruction manual Check with your process or safety engineer for any additional measures that must be taken to protect aga
24. Section 6 Maintenance amp Troubleshooting The DLC3010 digital level controller features a modular design for easy maintenance If you suspect a malfunction check for an external cause before performing the diagnostics described in this section Sensor parts are subject to normal wear and must be inspected and replaced as necessary For sensor maintenance information refer to the appropriate sensor instruction manual A WARNING To avoid personal injury always wear protective gloves clothing and eyewear when performing any maintenance operations Personal injury or property damage due to sudden release of pressure contact with hazardous fluid fire or explosion can be caused by puncturing heating or repairing a displacer that is retaining process pressure or fluid This danger may not be readily apparent when disassembling the sensor or removing the displacer Before disassembling the sensor or removing the displacer observe the appropriate warnings provided in the sensor instruction manual Check with your process or safety engineer for any additional measures that must be taken to protect against process media CAUTION When replacing components use only components specified by the factory Always use proper component replacement techniques as presented in this manual Improper techniques or component selection may invalidate the approvals and the product specifications as indicated in table 1 1 It may also impair operations an
25. Torque Rate Comm Status 1 7 1 8 2 2 4 2 1 7 2 5 2 2 5 4 1 7 1 9 2 2 4 3 1 7 1 4 1 1 2 2 1 2 ts 17343 82 i Display Mode 2253 B4 Distributor 1712 Enter Constant Density 3 327 B4 Scaled D A Trim 2520 Hardware Revision 1 7 2 4 Sensor Damping 2 2 1 5 1 7 1 1 1 7 1 6 2 2 4 1 2 2 4 8 2 B 4 1 7 2 1 Sensor Unit 2 2 1 1 2 2 1 4 Set Level Offset 2 2 2 1 5 B 4 1 7 1 5 2 2 1 3 1 B 4 2248 A Torque Tube Compensation 2 2 1 3 4 Selection Torque Tube Compensation Table 2 2 1 3 5 Torque Tube Material 2 2 1 3 3 B 4 Upper Density Table 2 2 3 1 1 1 4 2 2 3 1 1 4 Upper Fluid Density 32 iO Date DD Information Decimal Places Descriptor Device ID Device Status Displacer Units pjp pp p wD vvv vvv p P P AININ AINI BPN BIN NM SA I BR BI NTN N N Display Alert Saturation Level www T N RIN HART Tag Sensor Serial Number ras aN HART Universal Revision Instrument Mounting Pipl N AINI N Instrument Serial Number rg aN M9 aN 59 Instrument Temperature Instrument Temperature Alerts 2 3 2 1 LCD Configuration 2 2 5 1 LCD Test 3 3 1 10 Level Offset 2 2 2 1 4 3 3 1 1 3 3 1 20 2 2 3 1 1 1 4 2 2 3 1 1 2 5 2 2 3 1 1 or 3 2 7 4 2 2 3 1 2 or 3 2 8 9 2 2 2 3 2 2 3 1 4 T d ri ine Bra A xin Loop Test 2 2 2 3 1 Lower Density Table Upper Range Value 2 3 1 3 Uppe
26. Upper Range Value and Lower Range Value will be swapped 42 Instruction Manual Configuration D102748X012 October 2014 PV Damping PV Damping changes the response time of the controller to smooth variations in output readings caused by rapid changes in input Determine the appropriate damping setting based on the necessary response time signal stability and other requirements of the loop dynamics of your system The default damping value is 0 2 seconds and can be reset to any value between 0 and 16 seconds in 0 1 second increments When set to 0 the damping function is off Net instrument response is a combination of analog input filtering and output filtering Process Fluid Field Communicator Configure gt Manual Setup gt Process Fluid 2 2 3 Note Process Fluid is only visible if PV is Level or Interface Process Fluid Follow the prompts on the Field Communicator to view or edit process fluid information e Upper Fluid Density Indicates the density of the upper fluid Note Upper Fluid Density is only visible if PV is Interface e Lower Fluid Density Indicates the density of the lower fluid e View Fluid Tables Upper Density Table only visible if PV is Interface Lower Density Table Two specific gravity tables are available in the instrument to provide specific gravity correction for temperature For level measurement applications only the lower specific gravity table is used For interface applications b
27. a Trim Zero operation to align the instrument output with the sight glass reading Configure gt Calibration gt Primary gt Partial Calibration gt Trim Zero 2 5 1 3 3 64 Instruction Manual Configuration D102748X012 October 2014 These steps will provide an approximate PV calibration to get a system operational Further refinements can then be made when it is possible to manipulate and observe the level and instrument output Excessive Mechanical Gain If the displacer torque tube sizing provides more than 4 4 degrees of torque tube rotation for a full span change in process input It may be difficult to obtain a valid calibration with the normal coupling procedure In such a case you can utilize the full mechanical span of the DLC3010 by coupling the instrument to the torque tube at the 50 travel condition instead of at the lowest process condition When coupled at the 50 travel condition the travel limits of the 249 hardware will be the constraining factor If the 249 travel limit is reached before full process input travel is achieved the hardware is either improperly sized for the application improperly assembled or damaged Determining the SG of an Unknown Fluid If the instrument has been calibrated with weights or by using a test fluid with a well known SG it is possible to use the instrument to measure the SG of an unknown fluid or the differential SG between two fluids A procedure called Measure Density is provide
28. control the loop with this rough calibration Note The theoretical torque rate for the installed torque tube is available in the Simulation of Process Conditions for Calibration of Fisher Level Controllers and Transmitters instruction manual supplement D103066X012 Contact your Emerson Process Management sales office for information on obtaining this manual supplement 56 Instruction Manual Configuration D102748X012 October 2014 Observations of the sight glass or other independent measurements may be logged against DLC3010 outputs over time The ratio of the independent observable process changes to the DLC3010 output changes may then be used as a scale factor to modify the theoretical torque rate stored in the instrument After each gain adjustment a new zero trim will be required When a plant maintenance shutdown occurs the instrument may be isolated and calibrated in the normal manner Partial Calibration Field Communicator Configure gt Calibration gt Primary gt Partial Calibration 2 5 1 3 Partial Calibration operations are useful when it would take too long to establish a second data point in a single session There are of two partial calibrations capture and trim The capture zero operation sets the input zero reference angle to the value currently being measured It is therefore valid only at the defined zero process condition Trim operations recompute either gain or zero reference angle with one observation
29. explosion if power is applied to the instrument with the covers removed 1 Disconnect power to the digital level controller 2 Remove the cover from the transducer housing In explosive atmospheres do not remove the instrument cover when the circuit is alive unless in an intrinsically safe installation Remove the LCD meter assembly 3 Loosen the two screws that anchor the Electronics Module to the transducer housing These screws are captive and should not be removed 4 Firmly grasp the Electronics Module and pull it straight out of the housing Replacing the Electronics Module Perform the following procedure to replace the Electronics Module 78 Instruction Manual Maintenance amp Troubleshooting D102748X012 October 2014 1 Carefully insert the Electronics Module to mate the interconnecting pins with the receptacles on the Transducer housing CAUTION To prevent damage to the interconnecting pins when installing the Electronics Module use the guide pins to insert the Electronics Module straight onto the Transducer housing receptacles without twisting or turning 2 Tighten the two mounting screws Replace the LCD meter assembly 3 Replace the cover Tighten 1 3 of a revolution after the cover begins to compress the O ring Both instrument covers must be fully engaged to meet explosion proof requirements Terminal Box The terminal box is located on the transducer housing and contains the terminal strip assembly for
30. field wiring connections Unless indicated otherwise refer to figure 7 3 A WARNING On an explosion proof instrument remove the electrical power before removing the instrument covers in a hazardous area Personal injury or property damage may result from fire and explosion if power is applied to the instrument with the covers removed Removing the Terminal Box 1 Loosen the set screw key 31 in the terminal box cover assembly key 6 so that the cover can be unscrewed from the terminal box 2 After removing the cover key 6 note the location of field wiring connections and disconnect the field wiring from the wiring terminals 3 Remove the screw key 7 and pull out the terminal box assembly CAUTION To avoid damaging the terminal box assembly connector pull the terminal box assembly straight out of the housing without twisting or turning Replacing the Terminal Box Note Inspect all O rings for wear and replace as necessary 79 Maintenance amp Troubleshooting Instruction Manual October 2014 D102748X012 1 Apply sealant to the O ring key 27 and install the O ring over the stem of the terminal box as shown in figure 7 3 2 Orient the terminal box so that the connectors engage properly and carefully insert the terminal box into the transducer housing until the O ring is seated CAUTION To avoid damaging the mating pins in the Transducer housing ensure that the guiding mechanism is engaged properly bef
31. field wiring connections and disconnect the field wiring from the wiring terminals As shown in figure 2 4 locate the access handle on the bottom of the transducer housing Using a 2 mm hex key back out the set screw in the depression on the access handle until it is flush with the handle surface Press on the back of the handle as shown in the figure and slide the handle toward the front of the unit the locked position to expose the access hole Be sure the locking handle drops into the detent NJ UJ Note If the access handle will not slide the sensor linkage is most likely in an extreme position When the lever assembly is at a hard stop inside the housing the locking pin on the access door may not be able to engage the mating slot in the lever assembly This condition can occur if the displacer has been removed if the sensor is lying on its side or if the instrument had been coupled to the sensor while the displacer was not connected To correct this condition manipulate the sensor linkage to bring the lever assembly to within approximately 4 degrees of the neutral position before attempting to slide the handle A probe inserted through the top vent of the 249 head may be required to deflect the driver rod to a position where the lever assembly is free 4 Using a 10 mm deep well socket inserted through the access hole loosen the shaft clamp figure 2 4 5 While supporting the instrument loosen and remove the cap screws key
32. how it should be displayed by selecting Change display mode You can select for display PV Displays the process variable level interface or density in engineering units PV Process Temperature Alternately displays the process variable in engineering units the process temperature in the units selected under Temp Units PV Setup and the degrees of torque tube rotation Range Displays the process variable as a percent of span determined by the LRV and URV PV Range Alternately displays the process variable in engineering units and the process variable in percent of span Decimal Places Selects the number of decimal places to display up to four Setting the value to zero puts the display in auto scale mode It will then display as may decimals places as will fit 47 Instruction Manual D102748X012 Configuration October 2014 If PV Proc Temp or PV Range is selected the display alternates every two seconds between the selected readings The meter also simultaneously displays the analog output signal using a percent of scale bar graph around the perimeter of the display face as shown in figure 4 6 no matter what display type is selected Figure 4 6 LCD Meter Display ANALOG OUTPUT d PROCESS VARIABLE VALUE AE e On 50 SOS WHEN PRESENT gt INDICATES WRITES 4 DISABLED ae D dI ve ILI 7 GO A MULTIDROP 499 PROCESS BURST
33. installations where several instruments depend on one power supply and the loss of all instruments would cause operational problems consider an uninterruptible power supply or a back up battery The diodes shown in figure 2 12 prevent unwanted charging or discharging of the back up battery If several loops are connected in parallel make sure the net loop impedance does not reach levels that would prevent communication Figure 2 12 Multichannel Installations Riead Instrument No 1 DC Power Readout Supply Lead Device No 1 Instrument No 2 Ri ead RLead Readout Device No 2 Between To Additional 230 and 1100 0 Instruments E0364 if no Load Resistor Note that to provide a 4 20 mA analog output signal the DLC3010 must use HART polling address 0 Therefore if a multichannel installation is used with all transmitters in 4 20 mA output mode some means must be provided to isolate an individual transmitter for configuration or diagnostic purposes A multichannel installation is most useful if the instruments are also in multi drop mode and all signaling is done by digital polling 24 Instruction Manual Installation D102748X012 October 2014 Alarm Jumper Each digital level controller continuously monitors its own performance during normal operation This automatic diagnostic routine is a timed series of checks repeated continuously If diagnostics detect a failure in the electronics the instrument drives its output to either belo
34. kHz AM at 80 Enclosure Radiated EM field IEC 61000 4 3 1400 to 2000 MHz 3V m with 1 kHz AM at 80 A 2000 to 2700 MHz 1V m with 1 kHz AM at 80 IEC 61000 4 8 60 A m at 50 Hz A magnetic field I O signal control IEC 61000 4 5 1 kV line to ground only each _ Conducted IEC 61000 4 6 150 kHz to 80 MHz at 3 Vrms Note RTD wiring must be shorter than 3 meters 9 8 feet 1 No degradation during testing Temporary degradation during testing but is self recovering Specification limit 1 of span 2 HART communication was considered as not relevant to the process and is used primarily for configuration calibration and diagnostic purposes Instruction Manual Introduction and Specifications D102748X012 October 2014 Figure 1 2 Theoretical Reversible Temperature Effect on Common Torque Tube Materials TORQUE RATE REDUCTION NORMALIZED MODULUS OF RIGIDITY set LE T LI LL LEM _ et _ LLLA 2 ul ul e N06600 Gnorm N10276 MIS EN EN BE NH NN NR RE LL AY _ LA LI LA ULL 531600 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 TEMPERATURE TORQUE RATE REDUCTION NORMALIZED MODULUS OF RIGIDITY Ree N05500 N06600 Gnorm N10276 NS _ N FI AN HEN _ XE
35. only preliminary data essential for the correct calibration of the torque rate is the length of the driver rod being used for the calibration Weight equivalent to the net displacer weight at two valid process conditions must be available The sensor must have been sized properly for the expected service so that the chosen process conditions are in the free motion linear range of the sensor The coupling point should be marked at what is going to be the zero buoyancy weight or the zero differential buoyancy weight depending on the calibration approach The instrument should normally be physically coupled to the pilot shaft at that condition However if the expected operational travel of the pilot is greater than 5 degrees it is advisable to couple the transmitter to the pilot shaft at the condition representing mid travel instead This will prevent hitting a stop in the transmitter before limiting in the sensor The Capture Zero procedure may be run either before or after the Weight based Cal However the PV output is expected to have a bias error until the Reference Coupling Point is correctly marked Follow the prompts on the Field Communicator to calibrate the sensor 1 For interface level or density measurements enter the specific gravity of the upper fluid and lower fluid as requested 2 Place a weight on the displacer rod that is approximately equal to that indicated on the prompt The suggested weight is equivalent to the effective dis
36. serial number assigned to the instrument Lower Range Value LRV Lowest value of the process variable that the digital level controller is currently configured to measure in the 4 to 20 mA loop Lower Sensor Limit LSL Lowest value of the process variable that the digital level controller can be configured to measure Memory A type of semiconductor used for storing programs or data FIELDVUE instruments use three types of memory Random Access Memory RAM Read Only Memory ROM and Non Volatile Memory NVM See also these listings in this glossary 106 Instruction Manual D102748X012 Menu A list of programs commands or other activities that you select by using the arrow keys to highlight the item then pressing ENTER or by entering the numeric value of the menu item Message Thirty two character field for any additional information the user may want to include Multidropping The connection of several field devices to a single communications transmission line Non Volatile Memory NVM Atype of semiconductor memory that retains its contents even though power is disconnected NVM contents can be changed during configuration unlike ROM which can be changed only at time of instrument manufacture NVM stores configuration data On Line Configuration Configuration of the digital level controller operational parameters using a Field Communicator connected to the instrument Parallel Simultaneous said of data tr
37. starting temperature around 15 6 C 60 F for the steam specific gravity table The example set of tables given are generated by visually laying linear segments over a reference curve and are not guaranteed to provide any particular accuracy They are provided to illustrate the quidelines for developing your own table 1 Establish a table for the fluid s you are using over the expected operating range of process temperature This allows you to make best use of the maximum of ten points to obtain the accuracy you require If your fluid specific gravity is very linear over the operating temperature range two data points may be sufficient The correction algorithm provides linear interpolation between data points and bounds the result at the table end points 2 Pick points closer together in regions of higher slope 3 Pick linear segments that distribute the error equally on each side of the true curve Enter or display the specific gravity or enter values in the specific gravity tables The Field Communicator prompts for either a single value for specific gravity or a table of specific gravity versus temperature To enter a single specific 44 Instruction Manual Configuration D102748X012 October 2014 gravity value select Single Point and enter the specific gravity value To display or enter values in the tables select Table of SG vs T The Field Communicator begins by prompting for the temperature of the first pair in the lower
38. the process applied to a sensor other than that of the Primary Variable is beyond the operating limits of the device This indicates Electronics or Process Temperature has reached or exceeded the associated temperature alert limits e M Analog Output Saturated The Analog Output value reported by the instrument is beyond the limits 3 8 or 20 5 mA and no longer represent the true applied process e M Processor Free Time Depleted There is insufficient free time remaining in the execution period to complete the scheduled tasks e M NVM Write Limit Exceeded When active indicates the total number of writes to one of the three areas of NVM has exceeded the hardcoded limit Try cycling power to the instrument and see if it clears If it does not clear replace the Electronics Module If the Hall Transducer count is zero replace the Transducer Module A Analog Output Fixed The Analog Output is in Fixed Current Mode A Cold Start A power failure or device reset has occurred e A Instrument Temperature Too Low When active indicates that the Instrument Temperature has exceeded the value of the Instrument Temperature Low Alert Threshold e A Instrument Temperature Too High When active indicates that the Instrument Temperature has exceeded the value of the Instrument Temperature High Alert Threshold e A Process Temperature Too Low When active indicates that the Process Temperature has exceeded the value of the Process Tempe
39. transducer board 94 96 transient power surge protection 97 Transient Voltage Protection 6 Tri Loop 27 Configuring DLC3010 for use with 27 Trim Gain Calibration Partial 57 Trim Instrument Temperature Calibration 59 Trim Process Temperature Calibration 59 Trim Zero Calibration Partial 58 Troubleshooting 71 TT Comp Selection torque tube 40 TT Comp Table torque tube 40 TT Material torque tube 40 Turn Cells Off 70 Two Point Calibration 55 Index October 2014 U Upper Density Table 43 Upper Fluid Density process fluid 43 Service Tools Variables 69 Upper Range Value primary variable 42 50 Upper Sensor Limit 42 URV Upper Range Value 54 V Variables alarm default values 36 Burst 28 53 Primary Variables 41 Service Tools 68 View Fluid Tables process fluid 43 View Change AO Action primary variable 42 voltage lift off 20 Volume Units Sensor 39 W Weight DLC3010 8 Weight Calibration 56 Weight Units Sensor 39 Wiring Field 21 Working Pressures Sensor 10 Write Lock 31 34 See also Protection Write Lock Setup 31 Z zero buoyancy 38 115 DLC3010 Digital Level Controller Instruction Manual October 2014 D102748X012 Neither Emerson Emerson Process Management any of their affiliated entities assumes responsibility for the selection use maintenance of any product Responsibility for proper selection use and maintenance of a
40. 12100 12800 Series with heat insulator 1 Small Hardware Spare Parts Kit 19B1643X052 Includes Oty kit e Masoneilan 12200 12300 Series Screw key 7 1 Screw hex socket key 13 6 Screw cap hex socket key 14 1 Masoneilan 12200 12300 Series with heat insulator Set Screw key 20 2 Set Screw key 31 2 Test Terminal key 24 4 e Yamatake Honeywell Type NOP Wire Retainer key 25 8 Nut key 34 4 Alarm Jumper key 35 2 Yamatake Honeywell Type NQP with heat insulator Header Assembly key 38 2 2 Spare O Rings Kit Foxboro Eckardt 134LD and 144LD Includes three each of keys 21 26 and 27 19B1643X022 3 Coupling Hardware Spare Parts Kit 19B1643X042 e Foxboro Eckardt 134LD and 144LD with heat insulator Includes Qty kit Clamp Nut key 76 1 Washer Lock Spring key 77 1 Foxboro Eckardt LP167 Bolt lock coupling block key 82 1 Recommended spare parts 85 Parts October 2014 Instruction Manual D102748X012 Pa rts Li st Key Description Part Number 3 Cover Assy includes O ring key 21 M 4 LCD Meter Ass y includes alarm jumper key 35 Rey SOCSCHDEOH Pee header key 38 and captive screws key 40 and LCD Meter ass y 28B5738X012 5 Terminal Box Ass y 28B5740X022 Note Part numbers are shown for recommended spares only For part 6 Terminal Box Cover includes labels numbers not shown contact your Emerson Process Management sales key 30 and 64 and set screw key 31 office 7 Screw hex so
41. 29 Communications Burst Mode 53 Burst Option 53 Compensation Density parameter 7 manual 7 Transducer 7 Configuration digital level controller 13 109 Index October 2014 configuration data factory 33 Connection Styles Caged Sensor 10 Connections Communication 23 current loop 20 Electrical 20 Power Current Loop 23 RTD 23 Test 23 Construction Materials 249 Sensors 10 DLC3010 8 Coupling 38 protecting 13 D D A Trim 54 Date 30 Device Information 47 DD Information 30 Dead Band 6 Decimal Places Instrument Display 47 Density Process DLC3010 6 Descriptor 30 Device Information 47 Device ID 30 Device Information 30 46 Device Revision 30 Device Status 29 Diagnostic Messages LCD Meter 71 Diagnostics Digital Monitors 7 digital to analog D A output 94 Displacer Length 39 Volume 39 Weight 39 Displacer Data Serial Number 47 Weight 39 Displacer Length 54 Displacer Lengths Sensor 10 110 Instruction Manual D102748X012 Displacer Sensors Caged 11 Cageless 11 displacer serial number 47 Displacer Volume 54 Display Alert Saturation Level 31 Display Mode 47 change 47 Distributor 30 DLC3000 Description 3 Specifications 4 Driver Rod Length 40 54 E Educational Services 5 EEPROM 96 Electrical Classification Hazardous Area ATEX 7 CSA 7 FM 7 IECEx 7 Electrical Connections 8 20 Electrical Ho
42. 3 52 Instruction Manual Configuration D102748X012 October 2014 Communications Configure gt Communications gt Burst Mode 2 4 1 or Burst Option 2 4 2 Burst Mode Enabling burst mode provides continuous communication from the digital level controller Burst mode applies only to the transmission of burst mode data and does not affect the way other data is accessed Depending upon the burst option selected the digital level controller will burst the variables as shown in table 2 1 Table 4 4 Burst Variables Sent by the FIELDVUE DLC3010 1 EU engineering units mA current in milliamperes percent Burst Option 1 Select On in the Burst Mode menu press ENTER to enable Burst Mode 2 Select the desired option from the Burst Option menu and press ENTER 3 Press SEND to download the new configuration information to the digital level controller 53 Configuration Instruction Manual October 2014 D102748X012 Calibration Introduction Calibration of Smart Instruments Analog instruments generally have only one interface that can be calibrated by the user A zero and span output calibration is normally performed at the corresponding two input conditions Zero Span calibration is very simple to use but provides little versatility If the 0 and 100 input conditions are not available to the user a calibration can sometimes be accomplished but the gain and offset adjustments will likely interact requiring consi
43. 63 6 Carefully pull the digital level controller straight off the torque tube shaft extension key 58 CAUTION Tilting the instrument when pulling it off of the sensor torque tube can cause the torque tube shaft to bend To prevent damage to the torque tube shaft ensure that the digital level controller is level when pulling it off of the sensor torque tube 7 Loosen and remove the hex nuts key 34 from the mounting studs key 33 8 Pull the heat insulator key 57 off the mounting studs 9 When re installing the digital level controller follow the appropriate procedure outlined in the Installation section Also setup the digital level controller as described in the Setup and Calibration section LCD Meter Assembly In an explosion proof or flame proof installation remove the electrical power before removing the instrument covers hazardous area Personal injury or property damage may result from fire and explosion if power is applied to the instrument with the covers removed Instruction Manual Maintenance amp Troubleshooting D102748X012 October 2014 The digital level controller is designed with a dual compartment housing one compartment contains the LCD meter and Electronics Module the other contains all wiring terminals and the communication receptacles The LCD meter is located in the compartment opposite the wiring terminals as shown in figure 6 2 Figure 6 2 DLC3010 Digital Level Controller Assembly STUD KE
44. 7 3 Terminal Box Assembly L APPLY LUBRICANT 28B5740 B Key Description Part Number Terminal Box Assembly figure 7 3 24 Test Terminal 18 8 SST 2 req d 2 25 Retainer 18 8 SST 8 req d 2 26 O Ring nitrile 1H8762X0012 27 O Ring nitrileG 10A8218X032 28 Pipe Plug 18 8 SST 65 Lubricant Silicone not furnished with instrument 66 Anti Seize Sealant not furnished with instrument Terminal Box Cover Assembly figure 7 4 30 Label internal plastic 31 Set Screw hex socket 18 8 SST 2 64 Label external 88 Instruction Manual D102748X012 HG Figure 7 4 Terminal Cover Assembly 28B5531 B Recommended spare parts 2 Included in small hardware spare parts kit 3 Included in spare O rings kit Instruction Manual Parts D102748X012 October 2014 Figure 7 5 Mounting Kit for 249 Sensors with Heat Insulator 28B5741 A Mounting Parts Key Description Masoneilan Sensors figures 7 6 and 7 7 These parts are available as a kit as indicated in the Mounting Kits section Contact your Emerson Process 12100 or 12800 without Heat Insulator Management sales office for FS numbers for these mounting options 58 Shaft Extension 31600 59 Shaft Coupling 30300 60 Set Screw hex socket SST 2 req d 61 Screw hex hd 18 8 SST 4 req d m 62 Mounting Adapter A03560 Key Description 63 J Screw hex socket 4 req d 12100 or 12800 wi
45. Compensation Transducer compensation for ambient temperature Density parameter compensation for process temperature requires user supplied tables Manual compensation for torque tube rate at target process temperature is possible Digital Monitors Linked to jumper selected Hi factory default or Lo analog alarm signal Torque tube position transducer Drive monitor and signal reasonableness monitor User configurable alarms Hi Hi and Lo Lo Limit process alarms HART readable only RTD signal reasonableness monitor When RTD installed Processor free time monitor Writes remaining in Non Volatile Memory monitor User configurable alarms Hi and Lo limit process alarms Hi and Lo limit process temperature alarms and Hi and Lo limit electronics temperature alarms Diagnostics Output loop current diagnostic LCD meter diagnostic Spot specific gravity measurement in level mode used to update specific gravity parameter to improve process measurement Digital signal tracing capability by review of troubleshooting variables and Basic trending capability for PV TV and SV continued LCD Meter Indications LCD meter indicates analog output on a percent scale bar graph The meter also can be configured to display Process variable in engineering units only Percent range only Percent range alternating with process variable or Process variable alternating with process temperature and degrees of pilot sh
46. EE TABLE 1 4 2 IF AMBIENT DEW POINT IS ABOVE PROCESS TEMPERATURE ICE FORMATION MIGHT CAUSE INSTRUMENT MALFUNCTION AND REDUCE INSULATOR EFFECTIVENESS 39A4070 B A5494 1 Figure 2 8 Digital Level Controller Mounting on Sensor in High Temperature Applications i INSULATOR iaia A KEY 57 2 SHAFT SET SCREWS EXTENSION E KEY 60 KEY 58 N f S588 i X WASHER SHAFT KEY 78 COUPLING HEX NUTS KEY 59 Installation October 2014 Hm 0 WE CAP SCREWS KEY 63 MOUNTING STUDS KEY 33 S SENSOR l DIGITAL LEVEL CONTROLLER 20A7423 C B2707 1 For mounting a digital level controller on a 249 sensor secure the shaft extension to the sensor torque tube shaft via the shaft coupling and set screws with the coupling centered as shown in figure 2 8 2 Slide the access handle to the locked position to expose the access hole Press on the back of the handle as shown in figure 2 4 then slide the handle toward the front of the unit Be sure the locking handle drops into the detent Remove the hex nuts from the mounting studs Install 4 washers key 78 over the studs Install the four hex nuts and tighten U is the bottom of the digital level controller Secure the digital level controller and insulator to the torque tube arm with four cap screws 8 Tighten the cap screws to 10 Nem 88 5 Ibfein Position the insulator on the
47. IMIT EROR __ _ PROCESS VARIABLE ALERT THRESHOLD DEADBAND PROCESS VARIABLE ALERT IS CLEARED E0372 50 Instruction Manual Configuration D102748X012 October 2014 Temperature Field Communicator Configure gt Alert Setup gt Temperature 2 3 2 Follow the prompts on the Field Communicator display to set the following temperature alerts Instrument Temperature e Hi Alert Inst Temp Hi Alert Enable On or Off Instrument Temperature High Alert Enable activates checking of the instrument temperature against the Instrument Temperature High Alert Threshold Instrument Temperature High Alert is set if the instrument temperature rises above the Instrument Temperature High Alert Threshold Once the alarm is set the instrument must fall below the Instrument Temperature High Alert Threshold by the Temperature Deadband before the alarm is cleared See figure 4 8 Inst Temp Hi Alert Threshold Instrument Temperature High Alert Threshold is the instrument electronics temperature in temperature units which when exceeded will set the Electronics High Alert e Lo Alert Inst Temp Lo Alert Enable On or Off Instrument Temperature Low Alert Enable activates checking of the instrument temperature against the Instrument Temperature Low Alert Threshold Instrument Temperature High Alert is set if the instrument temperature rises above the Instrument Temperature Low Alert Threshold Once the alarm is set the instrument must fall
48. Instruction Manual D102748X012 DLC3010 Digital Level Controller October 2014 Fisher FIELDVUE DLC3010 Digital Level Controller This manual applies to Device Type 3010 Device Revision Hardware Revision Firmware Revision Contents Section 1 Introduction and Specifications 3 Scope 3 Conventions Used in this Manual 3 Brie me RD E 3 Specifications 4 Related Documents 5 Educational Services 5 Section 2 Installation 13 Configuration On the Bench or in the Loop 13 Protecting the Coupling and Flexures 13 MOUNTING bm 15 Hazardous Area Classifications and Special Instructions for Safe Use and Installations in Hazardous Locations 15 Mounting the 249 Sensor 15 Digital Level Controller Orientation 16 Mounting the Digital Level Controller Old 249 SemsOE 18 Mounting the Digital Level Controller for High Temperature Applications 18 Electrical Connections 20 Power Supply 20 usto tu tret E PARDO 21 Grondig 22 Shielded Wire 22 Power Current Loop Connections 23 RTD Connections
49. Instruction Manual Configuration D102748X012 October 2014 Full Calibration Field Communicator Configure gt Calibration gt Primary gt Full Calibration 2 5 1 2 Full Calibration operations compute the sensor gain and offset from two independent observations of process data points They are appropriate for cases where the two input conditions can be established relatively quickly in one session Min Max Calibration The following procedure can be used to calibrate the sensor if the process condition can be changed to the equivalent of a completely dry and completely submerged displacer but the actual precise intermediate values cannot be observed E g no sight glass is available but the cage can be isolated and drained or flooded Correct displacer information and the SG of the test fluid must be entered before performing this procedure Capture Zero can be performed at minimum buoyancy or completely submerged in upper fluid before peforming Min Max Calibration Follow the prompts on the Field Communicator to calibrate the instrument and sensor 1 Set the control loop for manual control 2 Enter the specific gravity for the liquid in the system 3 Adjust the liquid level until the displacer is dry or completely submerged in upper liquid Allow the output to settle then acknowledge establishment of the minimum buoyancy condition to the system 4 Adjust the liquid level until the displacer is completely submerged in the l
50. L A3789 1 A3788 1 Digital Level Controller Orientation Mount the digital level controller with the torque tube shaft clamp access hole see figure 2 4 pointing downward to allow accumulated moisture drainage MOUNTING Figure 2 4 Sensor Connection Compartment Adapter Ring Removed for Clarity STUDS ACCESS A HOLE SHAFT CLAMP SET SCREW PRESSHERETO __ MOVE ACCESS SLIDE ACCESS HANDLE TOWARD FRONT OF UNIT HANDLE TO EXPOSE ACCESS HOLE Instruction Manual Installation D102748X012 October 2014 Note If alternate drainage is provided by the user and a small performance loss is acceptable the instrument could be mounted in 90 degree rotational increments around the pilot shaft axis The LCD meter may be rotated in 90 degree increments to accommodate this The digital level controller and torque tube arm are attached to the sensor either to the left or right of the displacer as shown in figure 2 5 This can be changed in the field on the 249 sensors refer to the appropriate sensor instruction manual Changing the mounting also changes the effective action because the torque tube rotation for increasing level looking at the protruding shaft is clockwise when the unit is mounted to the right of the displacer and counter clockwise when the unit is mounted to the left of the displacer All caged 249 sensors have a rotatable head That is the digital level controller can be positioned at any of
51. PV engineering units 7 You should now be able to go to automatic control If observations over time show the instrument output exhibits for example 1 2 times as much excursion as the sight glass input you could divide the stored torque tube rate by 1 2 and send the new value to the instrument Then run another Trim Zero calibration and observe results for another extended period to see if further iteration is required Entering Theoretical Torque Tube TT Rates The Simulation of Process Conditions for Calibration of Fisher Level Controllers and Transmitters instruction manual supplement D103066X012 provides the theoretical composite torque tube TT rate for 249 sensors with DLC3010 controllers These numbers are nominal values They should be within 10 of the values that the instrument would compute when you perform a sensor calibration They will be less accurate for the long torque tubes 249K L N VS and P especially with thin wall constructions If you are unable to perform a sensor calibration during installation you may enter the values into the instrument at the following menu item in the handheld Configure gt Manual Setup gt Sensor gt Torque Tube gt Change Torque Rate 2 2 1 3 2 Then manually set the LRV and URV to the PV values at which you desire 4 and 20 mA output respectively Configure gt Manual Setup gt Variables gt Primary Variable Range gt Upper or Lower Range Value 2 2 2 3 1 or 2 Next perform
52. QUALIZING CONNECTION TZROUF TUPE E AND TORQUE TUBE ARM PRESSURE RATING ORIENTATION MATERIAL Style Cast iron CL125 or CL250 Flanged Screwed or optional socket weld 1 2 or 2 CL600 CL150 CL300 or 249B 249BF 4 Steel Raised face or optional ring type joint CL600 arm rotatable E equalizing E CL300 or connections 316 stainless steel E en d CL600 aised face flange CL150 CL300 or CL600 249K Steel m T CL900 or CL1500 1 Standard displacer lengths for all styles except 249 are 14 32 48 60 72 84 96 108 and 120 inches The 249 uses a displacer with a length of either 14 or 32 inches 2 EN flange connections available in EMA Europe Middle East and Africa 3 Not available in EMA 4 The 249BF available in EMA only Also available in EN size DN 40 with PN 10 to PN 100 flanges and size DN 50 with PN 10 to PN 63 flanges 5 Top connection is NPS 1 ring type joint flanged for connection styles F1 and F2 Table 1 7 Cageless Displacer 1 Standard Head 2 Wafer Body 6 and Torque Tube Flange Connection Size Pressure Rating 3 Arm Material NPS 4 raised face or optional ring type joint CL150 CL300 or CL600 249BP 4 Steel NPS 6 or 8 raised face CL150 or CL300 249CP 316 Stainless Steel NPS 3 raised face CL150 CL300 or CL600 Mounts on top of vessel NPS 4 raised face or optional ring type joint 250 5 Steel or stainless steel ae eer et ae CL150 CL300 CL600 CL900
53. Y 33 HEX NUT KEY 34 ADAPTER RING KEY 32 TERMINAL BOX KEY 5 TERMINAL BOX COVER KEY 6 ELECTRONICS os MODULE KEY 2 ra LCD METER ASSEMBLY KEY 4 COVER KEY 3 Removing the LCD Meter Perform the following procedure to remove the LCD meter 1 Disconnect power to the digital level controller 2 Remove the cover from the transducer housing In explosive atmospheres do not remove the instrument cover when the circuit is alive unless in an intrinsically safe installation 3 Loosen the two screws that anchor the LCD meter to the Electronics Module These screws are captive and should not be removed 4 Firmly grasp the LCD meter and pull it straight away from the Electronics Module Retain the six pin dual header for later reinstallation Replacing the LCD Meter Perform the following procedure to replace the LCD meter 1 Verify that the interconnection header is in the six pin socket on the face of the Electronics Module The longer set of pins should be inserted in the Electronics Module socket 2 Decide which direction to orient the meter The meter can be rotated in 90 degree increments for easy viewing Position one of the four six pin sockets on the back of the meter to accept the interconnection header and insert 77 Maintenance amp Troubleshooting Instruction Manual October 2014 D102748X012 the long meter screws into the two holes on the meter to coincide with the appro
54. aded once in the NVM table and an RTD connected to measure the process temperature and drive the correction table If temperature is not the driving influence the best that can be done is to calibrate for the widest potential differential SG This will keep the variations as small a percentage of calibrated span as possible Then calculate an alarm threshold that will prevent vessel over or under flow at the worst case error Extreme Process Temperatures For applications that will run at extreme temperatures the effect of process temperature on the torque tube must be taken into account Best results are obtained by running the torque tube calibration at actual process temperature However the decrease in spring rate with temperature can be simulated at room temperature by increasing the load on the torque tube during room temperature calibration This will produce the same deflection that would occur at actual process conditions This compensation is theoretical and not perfect but is still an improvement over ambient calibration with no attempt at compensation Note For additional information refer to the Simulation of Process Conditions for Calibration of Fisher Level Controllers and Transmitters instruction manual supplement D103066X012 available from your Emerson Process Management sales office or at www fisher com Temperature Compensation If the process temperature departs significantly from calibration temperature you will n
55. aft rotation Electrical Classification Hazardous Area CSA Intrinsically Safe Explosion proof Division 2 Dust Ignition proof FM Intrinsically Safe Explosion proof Non incendive Dust Ignition proof ATEX Intrinsically Safe Type n Flameproof IECEx Intrinsically Safe Type n Flameproof Electrical Housing CSA Type 4X ATEX IP66 FM NEMA 4X IECEx IP66 Other Classifications Certifications FSETAN Russian Federal Service of Technological Ecological and Nuclear Inspectorate GOST R Russian GOST R INMETRO National Institute of Metrology Standardization and Industrial Quality Brazil NEPSI National Supervision and Inspection Centre for Explosion Protection and Safety of Instrumentation China PESO CCOE Petroleum and Explosives Safety Organisation Chief Controller of Explosives India TIIS Technology Institution of Industrial Safety Japan Contact your Emerson Process Management sales office for classification certification specific information Minimum Differential Specific Gravity With a nominal 4 4 degrees torque tube shaft rotation for a to 100 percent change in liquid level specific gravity 1 the digital level controller can be adjusted to provide full output for an input range of 526 of nominal input span This equates to a minimum differential specific gravity of 0 05 with standard volume displacers Introduction and Specifications Instruction Manual October 2014
56. align the digital Primary Variable with the user s observation of the process and corrects the stored input zero reference assuming that the calibration gain is accurate Use this procedure when the process cannot be moved to zero for capture but gain is known to be correct only a bias error exists If the computed process variable is biased due to the inability to capture zero point correctly which can happen when the sensor hardware is oversized to provide additional gain for some interface level applications the Trim Zero can be used to trim out that bias Before calibration use the Configure gt Manual Setup gt Sensor menu to verify that all sensor and compensation data match the calibration conditions Note If displacer sizing for a density application results in an overweight displacer it will be necessary to set the system up in Level or Interface measurement mode to calibrate effectively The output of the instrument will only make sense in Range units in such a case since density units are not available in Level or Interface Mode Follow the prompts on the Field Communicator 1 Adjust the process condition or simulation to any valid and observable value 2 Enter the external observation of the measurement in the current PV units Secondary Temperature Calibration Field Communicator Configure gt Calibration gt Secondary gt Temperature Calibration 2 5 2 1 This procedure allows you to display the tempe
57. anagement sales office for the driver rod length For other manufacturers sensors see the installation instructions for that mounting 1 Enter displacer length weight volume units and values and moment arm length in the same units chosen for displacer length when prompted 2 Choose Instrument Mounting left or right of displacer refer to figure 2 5 3 Choose Torque Tube Material 35 Configuration Instruction Manual October 2014 D102748X012 4 Select the measurement application level interface or density Note For interface applications if the 249 is not installed on a vessel or if the cage can be isolated calibrate the instrument with weights water or other standard test fluid in level mode After calibrating in level mode the instrument can be switched to interface mode Then enter the actual process fluid specific gravity s and range values If the 249 sensor is installed and must be calibrated in the actual process fluid s at operating conditions enter the final measurement mode and actual process fluid data now Figure 4 2 Method of Determining Moment Arm from External Measurements ee ae s um ams M uu nee Ss VESSEL P 4 VERTICAL C OF DISPLACER MOMENT ARM LENGTH HORIZONTAL C OF TORQUE TUBE E0283 a If you choose Level or Interface the default process variable units are set to the same units chosen for displacer length You
58. anagement sales office or at www fisher com Calibration with an Overweight Displacer When the sensor hardware is sized for greater mechanical gain as it is in some interface or density measurement applications the dry displacer weight is often greater than the maximum permissible load on the torque tube In this situation it is impossible to capture the zero buoyancy rotation of the torque tube because the linkage is lying on a travel stop at that condition The Capture Zero routine in the Partial Calibration menu group will therefore not function correctly in the target PV modes of Interface or Density when the displacer is overweight The Full Calibration routines Min Max Two Point and Weight will all work correctly at the actual process conditions when in interface or density mode because they back compute the theoretical zero buoyancy angle instead of capturing it If itis necessary to use the Partial Calibration methods when the displacer is overweight the following transformation may be used An interface or density application can be mathematically represented as a level application with a single fluid whose density is equal to the difference between the actual SGs of the fluid covering the displacer at the two process extremes 61 Configuration Instruction Manual October 2014 D102748X012 The calibration process flows as follows e Change the PV mode to Level Set the Level Offset to zero e Setthe Range Valu
59. ansmission on two or more channels at the same time Polling Address Address of the instrument If the digital level controller is used in a point to point configuration set the polling address to O If it is used in a multidrop configuration or split range application set the polling address to a value from 0 to 15 Process Variable PV A physical quality or quantity which is monitored as part of a control strategy The digital level controller can measure level interface level between two liquids of different specific gravity and liquid density Protocol A set of data formats and transmission rules for communication between electronic devices Devices that conform to the same protocol can communicate accurately Instruction Manual Glossary D102748X012 Random Access Memory RAM A type of semiconductor memory that is normally used by the microprocessor during normal operation that permits rapid retrieval and storage of programs and data See also Read Only Memory ROM and Non Volatile Memory NVM Read Only Memory ROM A memory in which information is stored at the time of instrument manufacture You can examine but not change ROM contents Reranging Configuration function that changes the digital level controller 4 to 20 mA settings RTD The abbreviation for resistance temperature detector Temperature is measured by the RTD by correlating the resistance of the RTD element with temperature Send Data
60. are as follows Pulse Waveform Max Vc Clamping Pulse Peak Rise Time Decay to us 50 us Voltage V Current A 10 1000 93 6 16 Lo JL m Note us microsecond Max Ipp Ambient Temperature The combined temperature effect on zero and span without the 249 sensor is less than 0 03 of full scale per degree Kelvin over the operating range 40 to 80 C 40 to 176 F Process Temperature The torque rate is affected by the process temperature see figure 1 2 The process density may also be affected by the process temperature Process Density The sensitivity to error in knowledge of process density is proportional to the differential density of the calibration If the differential specific gravity is 0 2 an error of 0 02 specific gravity units in knowledge of a process fluid density represents 10 of span Instruction Manual D102748X012 Introduction and Specifications October 2014 Table 1 1 DLC3010 Digital Level Controller Specifications continued Electromagnetic Compatibility Meets EN 61326 1 and EN 61326 2 3 Immunity Industrial locations per Table 2 of EN 61326 1 and Table AA 2 of EN 61326 2 3 Performance is shown in table 1 2 below Emissions Class A ISM equipment rating Group 1 Class A Supply Requirements See figure 2 10 12 to 30 volts DC instrument has reverse polarity protection A minimum compliance voltage of 17 75 is required to guarantee HART communication
61. are prompted to key in the level offset Range values will be initialized based on Level Offset and displacer size The default upper range value is set to equal the displacer length and the default lower range value is set to zero when the level offset is 0 b If you choose Density the default process variable units are set to SGU Specific Gravity Units The default upper range value is set to 1 0 and the default lower range value is set to 0 1 5 Selectthe desired output action Direct or Reverse Choosing reverse acting will swap the default values of the upper and lower range values the process variable values at 20 mA and 4 mA In a reverse acting instrument the loop current will decrease as the fluid level increases 6 You are given the opportunity to modify the default value for the process variable engineering units 7 You are then given the opportunity to edit the default values that were entered for the upper range value PV Value at 20 mA and lower range value PV Value at 4 mA 8 The default values of the alarm variables will be set as follows Direct Acting Instrument Reverse Acting Instrument Span Upper Range Value Lower Range Value Span Lower Range Value Upper Range Value Alarm Variable Default Alarm Value Alarm Variable Default Alarm Value Hi Hi Alarm Upper Range Value Hi Hi Alarm Lower Range Value 95 span Lower Range Value 95 span Upper Range Value Lo Alarm 5 span Low
62. as the two points are moved farther apart but if the level can be adjusted up or down a minimum 5 span it is enough to make a calculation Most level processes can accept a small manual adjustment of this nature If your process cannot then the theoretical approach is the only method available 63 Configuration Instruction Manual October 2014 D102748X012 1 Determine all the information you can about the 249 hardware 249 type mounting sense controller to the right or left of displacer torque tube material and wall thickness displacer volume weight length and driver rod length the driver rod length is not the suspension rod length but the horizontal distance between the centerline of the displacer and the centerline of the torque tube Also obtain process information fluid densities process temperature and pressure The pressure is used as a reminder to consider the density of an upper vapor phase which can become significant at higher pressures 2 Run Instrument Setup and enter the various data that is requested as accurately as possible In Manual Setup Set the Range Values LRV URV to the PV values where you will want to see 4 mA and 20 mA output respectively These might be 0 and 14 inches on a 14 inch displacer 3 Mount and couple at the current process condition It is not necessary to run the Capture Zero procedure because it stores the current torque tube angle as the zero buoyancy condition and will therefore no
63. ated Documents Other documents containing information related to the DLC3010 digital level controller and 249 sensors include e Bulletin 11 2 DLC3010 FIELDVUE DLC3010 Digital Level Controller D102727X012 e FIELDVUE DLC3010 Digital Level Controller Quick Start Guide D103214X012 e Using FIELDVUE Instruments with the Smart HART Loop Interface and Monitor HIM D103263X012 e Audio Monitor for HART Communications D103265X012 e Fisher 249 Caged Displacer Sensors Instruction Manual D200099X012 e Fisher 249 Cageless Displacer Sensors Instruction Manual D200100X01 2 e Fisher 249VS Cageless Displacer Sensor Instruction Manual D103288X012 e Fisher 249W Cageless Wafer Style Level Sensor Instruction Manual D102803X012 e Simulation of Process Conditions for Calibration of Fisher Level Controllers and Transmitters D103066X012 e Bolt Torque Information D103220X012 e Technical Monograph 7 The Dynamics of Level and Pressure Control e Technical Monograph 18 Level Trol Density Transmitter e Technical Monograph 26 Guidelines for Selection of Liquid Level Control Equipment These documents are available from your Emerson Process Management sales office Also visit our website at www Fisher com Educational Services For information on available courses for the DLC3010 digital level controller as well as a variety of other products contact Emerson Process Management Educational Services Registration Phone 1 641 754 3771 or
64. ation function Device ID Unique identifier embedded in the instrument at the factory Device Revision Revision number of the interface software that permits communication between the Field Communicator and the instrument Firmware Revision The revision number of the instrument firmware Firmware is a program that is entered into the instrument at time of manufacture and cannot be changed by the user Free Time Percent of time that the microprocessor is idle A typical value is 2525 The actual value depends on the number of functions in the instrument that are enabled and on the amount of communication currently in progress 105 Glossary October 2014 Gain The ratio of output change to input change Hardware Revision Revision number of the Fisher instrument hardware The physical components of the instrument are defined as the hardware HART acronym The acronym HART stands for Highway Addressable Remote Transducer The communications standard that provides simultaneous analog and digital signal transmission between control rooms and field devices HART Tag An eight character field for identifying the digital level controller The HART tag is stored in the instrument and can be changed using a Field Communicator and the device information function HART Universal Revision Revision number of the HART Universal Commands which are the communications protocol for the instrument Instrument Serial Number The
65. ause of cage configuration or other concerns the transmitter is uncoupled from the torque tube by loosening the coupling nut and the access handle will be in the locked position Before placing such a configuration into service perform the Coupling procedure found on page 38 3 Fora cageless system where the displacer is not connected to the torque tube during shipping the torque tube itself stabilizes the coupled lever position by resting against a physical stop in the sensor The access handle will be in the unlocked position Mount the sensor and hang the displacer The coupling should be intact 13 Installation October 2014 Figure 2 1 Installation Flowchart START HERE Check Alarm Jumper Position Wire Digital Level Controller Factory mounted on 249 sensor Power Digital Level Controller High temperature application Install heat insulator assembly Enter Tag Messages Mount and Wire Date and check or set Digital level target application data Controller Power Digital level Controller Yes Density Measurement Set Level Offset to Zero Use Setup Wizard to enter sensor data and calibration condition Using Temperature Correction Set Specific Gravity Calibrate sensor Set Range Values NOTE 1 gt IF USING RTD FOR TEMPERATURE CORRECTION Disable Writes ALSO WIRE RTD TO DIGITAL LEVEL CONTROLLER 2 gt DISABLING WRITES IS EFFECTIVE
66. below the Instrument Temperature Low Alert Threshold by the Temperature Deadband before the alert is cleared See figure 4 8 Inst Temp Lo Alert Threshold Instrument Temperature Low Alert Threshold is the instrument electronics temperature in temperature units which when exceeded will set the Electronics Low Alert e Inst Temp Current Instrument Temperature e Inst Temp Offset Offset to trim instrument temperature output to an independent reference Factory calibration that may be modified by user Process Temperature e Hi Alert Proc Temp Hi Alert Enable On or Off Process Temperature High Alert Enable activates checking of the process variable temperature against the Process Temperature High Alert Threshold The Process Temperature High Alert is set if the process variable temperature rises above the Process Temperature High Alert Threshold Once the alert is set the process variable temperature must fall below the Process Temperature High Alert Threshold by the Temperature Deadband before the alert is cleared See figure 4 8 Proc Temp Hi Alert Threshold Process Temperature High Alert Threshold is the process variable temperature in temperature units which when exceeded will set the Process Temperature High Alert e Lo Alert Proc Temp Lo Alert Enable On or Off Process Temperature Low Alert Enable activates checking of the process variable temperature against the Process Temperature Low Alert Threshold The Proces
67. by the magnets on the lever assembly Use care to keep the screws from falling beneath the coupling shield 3 Remove the coupling shield key 16 by removing the two screws key 13 Take care not to drop the screws into the lever assembly compartment where they will be attracted by the magnets 4 Loosen and remove the two screws key 13 in the handle assembly key 12 Remove the handle assembly and the inner guide key 11 5 Apply thread lock to the internal threads of the replacement inner guide Also apply a thin coat of a light grade of grease to the zero locking pin on the inner guide and on the surface that is opposite the zero locking pin as shown in figure 6 3 this surface contacts the transducer housing when installed 80 Instruction Manual Maintenance amp Troubleshooting D102748X012 October 2014 Figure 6 3 Installing Inner Guide and Access Handle Assembly 6 7 10 11 12 13 SCREWS KEY 13 HANDLE iL ASSEMBLY KEY 12 SS VENT HOLES 3 LUBRICATE p 2 LUBRICATE zem THIS SURFACE THIS SURFACE A i Tr VENT HOLE TRANSDUCER HOUSING INNER GUIDE ZERO LOCKING PIN a KEY 11 ACCESS HOLE Place the inner guide in the slot inside the transducer housing so that the vent holes in the inner guide the milled slots in the inner quide see figure 6 3 face the exterior of the housing and are over the access hole Apply a thin coat of a light
68. cket 2 8 Nameplate 9 Drive Screw 18 8 SST 21 O ring nitrile 1K1810X0012 32 Adaptor Ring A03600 JL 33 Stud SST 4 req d DLC3010 Digital Level Controllers 3 2500500 eo 35 Alarm 2 4 5 Ti q ure E 1 36 Screw captive 18 8 SST 1 Transducer Module For electronics ass y 2 req d 4 2 Electronics Ass y includes alarm jumper key 35 and 38 Header Assembly dual row not shown 4 5 captive screws key 36 header ass y key 38 and 40 Screw captive 18 8 SST encapsulated board For LCD meter 2 req d 5 18B5732X012 For use with transducer module 48B5739X012 66 Anti Seize Sealant not furnished with instrument has obsolete Hall sensor on Flex circuit 18B5529X022 67 Thread locking adhesive medium strength For use with transducer module GE18497X022 not furnished with instrument has new Hall sensor on rigid boards 18B5529X032 70 Lithium grease not furnished with instrument Figure 7 1 DLC3010 Digital Level Controller Assembly NOTES 1 INSTALL ALARM JUMPER KEY 35 ON ELECTRONICS ASSEMBLY KEY2 WHEN LCD METER KEY 4 IS NOT INSTALLED 2 LOCATION OF ALARM JUMPER KEY 35 WHEN LCD METER KEY 4 IS INSTALLED L APPLY LUB THREADLOCK Recommended spare parts 1 These parts are not replaced in the field due to serialization and characterization issues but can be replaced at a qualified service center Contact your Emerson Process Management sales office for additional information 2 Included in smal
69. ct the RTD Connect only one end of the shield Connect the shield to either the internal ground connection in the instrument terminal box or to the RTD thermowell Wire the RTD to the digital level controller as follows refer to figure 2 11 Two Wire RTD Connections 1 Connect a jumper wire between the RS and R1 terminals in the terminal box 2 Connect the RTD to the R1 and R2 terminals Three Wire RTD Connections 1 Connect the 2 wires which are connected to the same end of the RTD to the RS and R1 terminals in the terminal box Usually these wires are the same color Connect the third wire to terminal R2 The resistance measured between this wire and either wire connected to terminal RS or R1 should read an equivalent resistance for the existing ambient temperature Refer to the RTD manufacturer s temperature to resistance conversion table Usually this wire is a different color from the wires connected to the RS and R1 terminals NJ Communication Connections A WARNING Personal injury or property damage caused by fire or explosion may occur if this connection is attempted in an area which contains a potentially explosive atmosphere or has been classified as hazardous Confirm that area classification and atmosphere conditions permit the safe removal of the terminal box cap before proceeding The Field Communicator interfaces with digital level controller from any wiring termination point in the 4 20 mA loop except across the po
70. d in the Manual Setup Process Fluid menu when you are in Level measurement mode The procedure presents the measured value and allows you either to automatically move it into the instrument configuration or to manually record it for later use Accuracy Considerations Effect of Proportional Band If you are operating at low Proportional Band PB 100 times full span torque tube rotation 4 4 degrees you can expect a degradation factor of about 100 PB on the Transmitter accuracy specifications Note This formula is most correct for linearity errors that are relatively steep sided If the linearity error curve shape is simple with relatively gradual slope the net effect of reducing span may be less Instruments such as the DLC3010 that use a compensation technique to reduce the residual mechanical or electrical non linearity will generally have a complex shape for the net error curve If this is too much degradation an improvement of 2 0 can be obtained by using a thin wall torque tube Additional gain can be achieved by increasing the displacer diameter Available clearance inside the cage and the need to keep the net displacer weight at the highest and lowest process conditions within the usable range of the torque tube driver rod combination place practical limits on how much the sizing can be adjusted With an overweight displacer the calibration process becomes more difficult because the zero buoyancy condition will
71. d the highest process temperature condition or with an equivalent condition simulated with the calculated weights If the sizing of the sensor results in a proportional band greater than 100 total expected rotational span greater than 4 4 degrees couple the transmitter to the pilot shaft while at the 5025 process condition to make maximum use of available transmitter travel 6 The Capture Zero procedure is still performed at the zero buoyancy or zero differential buoyancy condition 3 Insert a 10 mm deep well socket through the access hole and onto the torque tube shaft clamp nut Tighten the clamp nut to a maximum torque of 2 1 Nem 18 Ibfein 4 Slide the access handle to the unlocked position Press on the back of the handle as shown in figure 2 4 then slide the handle toward the rear of the unit Be sure the locking handle drops into the detent 38 Instruction Manual Configuration D102748X012 October 2014 Manual Setup The DLC3010 digital level controller has the capability to communicate via the HART protocol This section describes the advanced features that can be accessed with the Field Communicator Note Changing setup parameters may require enabling writing to the instrument with the Field Communicator Overview Device Information gt Alarm Type and Security gt Security gt Write Lock Setup Select Writes Enabled to enable writing setup and calibration data or select Writes Disabled to disable writing
72. d the intended function of the device Diagnostic Messages In addition to the output the LCD meter displays abbreviated diagnostic messages for troubleshooting the digital level controller To accommodate two word messages the display alternates between the first and second word The meter displays messages simultaneously on the Process Variable and Process Variable Unit lines as shown in figure 6 1 Messages on the Process Variable line refer to general device conditions while messages on the Process Variable Unit line refer to specific causes for these conditions A description of each diagnostic message follows e BLANK If the meter does not appear to function and the instrument is otherwise functioning correctly make sure the digital level controller is configured for the LCD meter The meter will not function if the LCD Configuration selection is Not Installed To check this function connect the Field Communicator to the digital level controller and turn it on From the Online menu select Configure gt Manual Setup gt Instrument Display gt LCD Configuration 2 2 5 1 For information on setting up the LCD meter see page 47 A diagnostic test for meter function is also detailed later in this section Maintenance amp Troubleshooting Instruction Manual October 2014 D102748X012 Figure 6 1 LCD Meter Diagnostic Display ANALOG DISPLAY OF OUTPUT PROCESS VARIABLE VALUE DIAGNOSTIC MESSAGE
73. data Note that cycling power will clear the Write Lock condition to Writes Enabled Sensor Field Communicator Configure gt Manual Setup gt Sensor 2 2 1 Sensor Units Follow the prompts on the Field Communicator to enter the desired sensor units Length Units Permits setting the units of measure for the displacer length in feet meters inches or centimeters Volume Units Permits setting the units of measure for the displacer volume in liters cubic inches cubic millimeters or milliliters Weight Units Permits setting the units of measure for the displacer weight in grams kilograms pounds or ounces Torque Rate Units Permits setting the torque rate units in Ibf in per deg pounds force inches per degree rotation newton m per deg newton meters per degree rotation or dyne cm per deg dyne centimeters per degree rotation e Temperature Units Select either degC degrees centigrade or degF degrees Fahrenheit to enter the temperature units Note that when using degF the Temperature Alert Deadband parameter is incorrectly displayed with a 32 bias Sensor Dimensions Follow the prompts on the Field Communicator to enter the sensor dimensions Dimensions can be found on the sensor name plate as shown in figure 4 1 Displacer Length Enter the displacer length from the sensor nameplate Displacer Volume Enter the displacer volume from the sensor nameplate Displacer Weight
74. derable iteration to achieve accuracy In contrast intelligent instruments have many interfaces that can be calibrated or scaled by the user with consequent increased versatility Refer to table 4 5 for a list of relationships in the DLC3010 that can be calibrated or configured by the user Note that not all relationships are listed here Table 4 5 Relationships in the FIELVUE DLC3010 that can be User Calibrated or Configured The scale factor between the internal digital representation of the measured pilot shaft rotation and the physical torque TOPLE TUDE Rat input to the sensor The angle of pilot shaft rotation associated with the zero buoyancy condition The zero reference for the input of the PV Reference dry Coupling Point calculation The scale factor moment arm between a force input to the sensor driver rod and the torque developed as input to the Driver Rod Length torque tube The scale factor relating the density of the process fluid to the maximum force that can be produced as an input to the Displacer Volume driver rod of the sensor The density of the process fluid normalized to the density of water at reference conditions The scale factor that transforms displacer volume and measured buoyancy into a level signal normalized to displacer length Displacer Length The scale factor to convert normalized level to level on the displacer in engineering units The zero reference for the output of the PV calculation re
75. digital level controller sliding the insulator straight over the mounting studs Carefully slide the digital level controller with the attached insulator over the shaft coupling so that the access hole 19 Installation Instruction Manual October 2014 D102748X012 Electrical Connections A WARNING Select wiring and or cable glands that are rated for the environment of use such as hazardous area ingress protection and temperature Failure to use properly rated wiring and or cable glands can result in personal injury or property damage from fire or explosion Wiring connections must be in accordance with local regional and national codes for any given hazardous area approval Failure to follow the local regional and national codes could result in personal injury or property damage from fire or explosion Proper electrical installation is necessary to prevent errors due to electrical noise A resistance between 230 and 1100 ohms must be present in the loop for communication with a Field Communicator Refer to figure 2 9 for current loop connections Figure 2 9 Connecting a Field Communicator to the Digital Level Controller Loop 23090 511002 41 ME N 1 N Reference meter forcalibration POWER or monitoring SUPPLY x operation May be a voltmeter across 250 ohm resistor or a current meter O
76. dress Physical Signaling Code Number of Request Preambles Serial Numbers 2 2 4 Serial Numbers 1 Instrument Serial Number Process Fluid if PV is Density 1 Proc Temp Source 2 Change Proc Temp 3 Minimum Span Primary Variable Range 1 Upper Range Value 2 Lower Range Value 3 Proc Temp 4 RTD Wire Resistance 3 View Change AO Action 2 2 3 Process Fluid if PV is Interface 2 2 3 1 1 Process Fluids Process Fluids 2 Process Temperature 1 Upper Fluid Density 2 Lower Fluid Density 2 2 3 3 View Fluid Tables 2 Sensor Serial Number 3 Final Assembly Number Process Fluid if PV is Level 4 Enter Constant Density 1 Process Fluid 5 Load Steam Tables 2 Process Temperature d View Fluid Tables 1 Upper Density Table 2 Lower Density Table Process Temperature 2 2 3 2 Process Temperature amp 1 Proc Temp Source 2 Change Proc Temp 3 Proc Temp 2 2 3 2 4 RTD Wire Resistance 1 Proc Temp Source 2 Change Proc Temp Process Fluid 3 Proc Temp 4 RTD Wire Resistance 1 Lower Fluid Density 2 View Fluid Tables 3 Enter Constant Density 4 Measure Density View Fluid Tables 1 Lower Density Table 102 Instruction Manual D102748X012 Figure B 5 Configure Alert Setup 2 Configure 1 Guided Setup 2 Manual Setup 3 Alert Setup 2 3 1 4 Communications 5 Calibration Aler
77. e 2 9 Connect the Field Communicator to the instrument and turn it on Go to Configure and review the data under Manual Setup Alert Setup and Communications If your application data has changed since the instrument was factory configured refer to the Manual Setup section for instructions on modifying configuration data For instruments not mounted on a level sensor or when replacing an instrument initial setup consists of entering sensor information The next step is coupling the sensor to the digital level controller When the digital level controller and sensor are coupled the combination may be calibrated Sensor information includes displacer and torque tube information such as Length units meters inches or centimeters Volume units cubic inches cubic millimeters or milliliters Weight units kilograms pounds or ounce Displacer Length Displacer Volume Displacer Weight Displacer Driver Rod Length moment arm see table 4 1 Torque Tube Material Note A sensor with an N05500 torque tube may have NiCu on the nameplate as the torque tube material 33 Configuration Instruction Manual October 2014 D102748X012 e Instrument mounting right or left of displacer e Measurement Application level interface or density Configuration Advice Guided Setup directs you through initialization of configuration data needed for proper operation When the instrument comes out of the box the default dimensions are set for th
78. e electronics modulewithaknowngoodpart part 6 If the electronics module and terminal box work on a known good transducer module replace the old Transducer Module transducer module 7 Check for open circuits Loop Wiring 8 Check for proper polarity at the signal terminals See item 2 above 9 Check resistance between Loop and T terminals of terminal box If greater than 1 1 Ohm the internal sense resistor may be damaged An external jumper may be added for a temporary repair Replace terminal box and avoid applying loop voltage across and Loop for long term solution See item 4 above Electronics Module See item 5 above Transducer Module See item 6 above Connect the Field Communicator and Alarm Condition 10 Select LCD Test 3 3 1 1 to isolate a module failure Fail low setting 11 Check PV against Hi Hi and Lo Lo alarm thresholds and PV alarm deadband setting if these alarms are enabled Output 0 mA Terminal Box Fixed Output 3 7 mA Connect the Field Communicator and Fixed Output 3 8 mA Low Saturation 12 Check the PV against the upper and lower range values Check actual process condition and calibration adjustments Fixed Output 20 5 mA High Samson Sn CE see item 12 above Alarm Condition Connect the Field Communicator and Fixed Output 22 5 mA Fail high setting see items 10 and 11 above Loop Wiring 13 Check for short ci
79. e head may be rotated through 360 degrees to any of eight different positions as shown in figure 2 5 Construction Materials See tables 1 5 1 6 and 1 7 Operative Ambient Temperature See table 1 4 For ambient temperature ranges guidelines and use of optional heat insulator see figure 2 7 Options ll Heat insulator see description under Ordering Information W Gauge glass for pressures to 29 bar at 232 C 420 psig at 450 F and W Reflex gauges for high temperature and pressure applications Table 1 5 Displacer and Torque Tube Materials Pat Standard Material Other Materials 316 Stainless Steel N10276 N04400 Displacer 304 Stainless Steel plastic and Special 29CC20 232 C 50 F ly Stainless Steel 198 C 325 F 427 C 800 F other Austenitic Stainless Steels and Special Alloys Displacer Stem Driver Bearing Displacer Rod 316 Stainless Steel N04400 198 C 325 F 427 C 800 F Graphite and Driver Laminate SST 198 C 325 F 427 C 800 F 1 316 Stainless Steel 1 N05500 is not recommended for spring applications above 232 C 450 F Contact your Emerson Process Management sales office or application engineer if temperatures exceeding this limit are required N04400 PTFE ren 73 C 100 F 204 C 400 F 10 Instruction Manual Introduction and Specifications D102748X012 October 2014 Table 1 6 Caged Displacer Sensors STANDARD CAGE HEAD E
80. e most common Fisher 249 construction so if any data is unknown it is generally safe to accept the defaults The mounting sense instrument left or right of displacer is important for correct interpretation of positive motion The torque tube rotation is clockwise with rising level when the instrument is mounted to the right of the displacer and counter clockwise when mounted to the left of the displacer Use Manual Setup to locate and modify individual parameters when they need to be changed Preliminary Considerations Write Lock Field Communicator Overview gt Device Information gt Alarm Type and Security gt Security gt Write Lock 1 7 3 2 2 To setup and calibrate the instrument write lock must be set to Writes Enabled Write Lock is reset by a power cycle If you have just powered up the instrument Writes will be enabled by default Level Offset Field Communicator Configure gt Manual Setup gt Variables gt Primary Variables gt Set Level Offset 2 2 2 1 5 The Level Offset parameter should be cleared to zero before running Instrument Setup To clear Level Offset enter the value 0 0 and press Enter gt Send Guided Setup Configure gt Guided Setup gt Instrument Setup 2 1 1 Note Place the loop into manual operation before making any changes in setup or calibration Instrument Setup is available to aid initial setup Follow the prompts on the Field Communicator display to enter information for the displacer torqu
81. e tube and digital measurement units Most of the information is available from the sensor nameplate shown in figure 4 1 The moment arm is the effective length of the driver rod and depends upon the sensor type For a 249 sensor refer to table 4 1 to determine driver rod length For a special sensor refer to figure 4 2 Instruction Manual Configuration D102748X012 October 2014 Figure 4 1 Example Sensor Nameplate SENSOR TYPE EN DISPLACER WEIGHT PRESSURE RATING PRESSURE RATING 2 9 semiat 249 __ press uniTs Psi RATING 285 100F 378c RATING FP 1500Psi DISELACER 2 x 32 INCHES ASSY WCB STL ASSEMBLY MATERIAL VOLUME CU IN oer TRIM MONEL DISPLACER 316 SST Q li TRIM MATERIAL DISPLACER VOLUME TORQUE TUBE MATERIAL MATERIAL DISPLACER SIZE DIAMETER X LENGTH 23A1725 E sht 1 E0366 Table 4 1 Moment Arm Driver Rod Length MOMENT ARM o 249P mo TES e 1 Moment arm driver rod length is the perpendicular distance between the vertical centerline of the displacer and the horizontal centerline of the torque tube See figure 4 2 If you cannot determine the driver rod length contact your Emerson Process Management sales office and provide the serial number of the sensor 2 This table applies to sensors with vertical displacers only For sensor types not listed or sensors with horizontal displacers contact your Emerson Process M
82. ead of the test meter to the connection and the negative lead to the T connection inside the terminal box 4 Measure Loop current as Voltage on test meter x 1000 milliamps example Test meter Voltage X 1000 Loop Milliamps 0 004 X1000 4 0 milliamperes 0 020 X 1000 20 0 milliamperes 5 Remove test leads and replace the terminal box cover Removing the Digital Level Controller from the Sensor Because of its modular design most of the service and maintenance to the digital level controller can be done without removing it from the sensor However if necessary to replace sensor to instrument mating parts or parts in the transducer housing or to perform bench maintenance perform the following procedures to remove the digital level controller from the sensor A WARNING On an explosion proof instrument remove the electrical power before removing the instrument covers in a hazardous area Personal injury or property damage may result from fire and explosion if power is applied to the instrument with the covers removed Tools Required Table 6 2 lists the tools required for maintaining the DLC3010 digital level controller 74 Instruction Manual Maintenance amp Troubleshooting D102748X012 October 2014 Table 6 2 Tools Required Wl SSCS GES 31 Hex Ke 2mm Handle y Cover lock set screws 20 __________ _ Electronics module mtg screws 36 screwdriver
83. eed to apply a correction factor Interpolate the correction factor from the material specific tables of theoretical normalized modulus of rigidity versus temperature as described in the Simulation of Process Conditions for Calibration of Fisher Level Controllers and Transmitters instruction manual supplement Multiply the measured torque tube rate editable in the review menu under factory settings by the correction factor and enter the new value When you cannot calibrate at process temperature this approach allows a better approximation of the actual torque tube behavior at process conditions 66 Instruction Manual Service Tools D102748X012 October 2014 Section 5 Service Tools Active Alerts Service Tools gt Active Alerts 3 1 Visible if an alert is not active No Active Alerts Visible if an alert is active Refresh Alerts the following menu methods will be visible only if the associated alert is active F Process Temperature Signal Failed When active indicates the process temperature sensor RTD reading has exceeded the hardcoded limits lt 10 ohms or gt 320 ohms If this status message appears reinstall the process temperature sensor RTD F Sensor Drive Failed The Hall sensor drive current read back is outside of the hard coded limits F Sensor Signal Failed The instrumentation amplifier output for the torque tube position is outside of range e M Non Primary Variable Out of Limits When active indicates
84. eight alternate positions around the cage as indicated by the position numbers 1 through 8 in figure 2 5 To rotate the head remove the head flange bolts and nuts and position the head as desired Figure 2 5 Typical Mounting Positions for the FIELDVUE DLC3010 Digital Level Controller on Fisher 249 Sensor SENSOR LEFT OF DISPLACER RIGHT OF DISPLACER CAGELESS lr wor r ja Lo 7 1 gt NOT AVAILABLE FOR SIZE NPS 2 CL300 AND CL600 249C SENSOR 19B2787 Rev D 19B6600 Rev C B1407 2 Installation Instruction Manual October 2014 D102748X012 Mounting the Digital Level Controller on a 249 Sensor Refer to figure 2 4 unless otherwise indicated 1 If the set screw in the access handle figure 2 6 is driven against the spring plate back it out until the head is flush with the outer surface of the handle using a 2 mm hex key Slide the access handle to the locked position to expose the access hole Press on the back of the handle as shown in figure 2 4 then slide the handle toward the front of the unit Be sure the locking handle drops into the detent Figure 2 6 Close up of Set Screw a SET SCREW f _ 2 Using a 10 mm deep well socket inserted through the access hole loosen the shaft clamp figure 2 4 This clamp will be re tightened in the Coupling portion of the Initial Setup section 3 Remove the hex nuts from the mounting studs Do not remove the adapter ring CAUTION Measureme
85. emoving the Digital Level Controller from the Sensor 2 Loosen and remove the hex nuts key 34 from the studs key 33 and remove the adapter ring key 32 3 Remove the coupling shield key 16 by removing the two screws key 13 Take care not to drop the screws into the lever assembly compartment where they will be attracted by the magnets 4 Inspectthe lever assembly alignment with the housing If it is off center or not co axial with the main housing continue with the removal procedure 5 Loosen and remove the mounting screw key 14 from the lever assembly 6 Loosen the flexure block from its machined pocket in the housing by inserting a smooth tool into the hole for the mounting screw and gently rocking it back and forth in what would be the vertical axis if the transmitter were installed 7 Lift the lever assembly out of the housing Inspect the flexure for damage If the flexure is bent or torn replace the lever assembly Replacing the Lever Assembly Replacing the lever assembly in the field may result in a slight degradation in linearity performance since the factory characterizes the entire transducer module as a unit For most applications this degradation should not be noticeable If guaranteed restoration to factory specification is desired the entire transducer module should be replaced 1 Move the zero pin slide to the locking position 2 Apply athin coat of a light grade of grease to the internal thread
86. er Sensor Serial Number Final Assembly Number Date Descriptor Message Revisions HART Universal Revision Field Device Revision Firmware Revision Hardware Revision DD Information 101 Field Communicator Menu Tree Instruction Manual October 2014 D102748X012 Figure B 4 Configure Manual Setup 2 Configure 1 Guided Setup 2 211 i Sensor Units 2 Manual Setup 1 Length Units 3 Alert Setup 2 2 1 2 Volume Units Sensor 4 Communications 5 Calibration 3 Weight Units 1 Sensor Units 4 Torque Rate Units 2 Sensor Dimensions 5 Temperature Units 3 Torque Tube 2 2 1 3 2 2 1 2 4 Instrument Mounting Torque Tube Sensor Dimensions 1 Sensor 3 sensor Damping 1 Torque Rate 1 Displacer Length 2 Variables 2 Change Torque Rate 2 Displacer Volume 3 Process Fluid 3 TT Material 4 Identification 4 TT Comp Selection 5 Instrument Display 5 TT Comp Table 2 2 2 1 2 2 2 Variables oe bv n 1 Primary Variables 3 B Manual Setup 3 Displacer Weight 4 Driver Rod Length Primary Variables If PV is Level Instrument Display 1 LCD Configuration 2 Display Mode 3 Change Display Mode 4 Decimal Places If PV is Interface If PV is Density 2 Sensor Limits 4 Level Offset 3 Primary Variable Range 22222 5 Set Level Offset Sensor Limits 1 Upper Sensor Limit 2 Lower Sensor Limit Identification 2 2 3 HART Tag Date Descriptor Message Polling Ad
87. er Range Value Lo Alarm 5 span Upper Range Value Lo Lo Alarm Lower Range Value Lo Lo Alarm Upper Range Value Instruction Manual Configuration D102748X012 October 2014 PV alert thresholds are initialized at 100 95 5 and 0 span PV alert deadband is initialized to 0 5 span PV alerts are all disabled Temperature alerts are enabled e f Density mode was chosen setup is complete e f Interface or Density mode was chosen you are prompted to enter the specific gravity of the process fluid if interface mode the specific gravities of the upper and lower process fluids Note If you are using water or weights for calibration enter a specific gravity of 1 0 SGU For other test fluids enter the specific gravity of the fluid used For temperature compensation go to Manual Setup Under Process Fluid select View Fluid Tables Temperature compensation is enabled by entering values into the fluid tables Two data tables are available that may be entered in the instrument to provide specific gravity correction for temperature see tables 4 2 and 4 3 For interface level applications both tables are used For level measurement applications only the lower specific gravity table is used Neither table is used for density applications Both tables may be edited during detailed setup Note The existing tables may need to be edited to reflect the characteristics of the actual process fluid e You can accept the current table s modif
88. erature and an EEPROM to store the coefficients associated with the Hall sensor The terminal board contains the EMI filters the loop connection terminals and the connections for the optional RTD used to measure process temperature A level density or interface level change in the measured fluid causes a change in the displacer position figure A 5 This change is transferred to the torque tube assembly As the measured fluid changes the torque tube assembly rotates up to 4 4 degrees for a 249 sensor varying the digital level controller output between 4 and 20 mA Figure A 5 Typical Sensor Operation TORQUE TUBE DISPLACER 249 SENSOR SIDE VIEW The rotary motion of the torque tube is transferred to the digital level controller lever assembly The rotary motion moves a magnet attached to the lever assembly changing the magnetic field that is sensed by the Hall effect sensor The sensor converts the magnetic field signal to an electronic signal The microcontroller accepts the electronic signal which is ambient temperature compensated and linearized The microcontroller can also actively compensate for changes in liquid specific gravity due to changes in process temperature based on an input via HART protocol or via an optional RTD if itis connected The D A output circuit accepts the microcontroller output and provides a 4 to 20 mA current output signal During normal operation when the input is between the lower and u
89. es to LRV 0 0 URV displacer length e Capture Zero at the lowest process condition that is with the displacer completely submerged in the fluid of the lowest density NOT dry e Set Specific Gravity to the difference between the SGs of the two fluids for example if SG upper 0 87 and SG lower 1 0 enter a specific gravity value of 0 13 e Setup a second process condition more than 525 of span above the minimum process condition and use the Trim Gain procedure at that condition The gain will now be initialized correctly The instrument would work fine in this configuration for an interface application However if you have a density application it won t be possible to report the PV correctly in engineering units if the instrument calibration is concluded at this point Since you now have a valid gain e Change the PV mode to Interface or Density e reconfiqure the fluid SGs or range values to the actual fluid values or extremes and e usethe Trim Zero procedure in the Partial Calibration menu to back compute the theoretical zero buoyancy angle The last step above will align the value of the PV in engineering units to the sight glass observation Note Information on simulating process conditions is available in the Simulation of Process Conditions for Calibration of Fisher Level Controllers and Transmitters instruction manual supplement D103066X01 2 available from your Emerson Process Management sales office or at
90. eshooting level controller to test procedures in HART the HART Tri Loop Tri Loop product manual Review the HART Tri Loop Product Manual Digital leve controller nstalled Install the digital level controller Install Channel 1 wires from HART Tri Loop to the control room Set the digital level controller Burst Option Optional e e digita level controller Install Channel 2 and3 wires from HART Tri Loop to the control room Burst Mode E0365 27 Installation Instruction Manual October 2014 D102748X012 Commissioning the Digital Level Controller for use with the HART Tri Loop To prepare the digital level controller for use with a 333 HART Tri Loop you must configure the digital level controller to burst mode and select the dynamic variables to burst In burst mode the digital level controller provides digital information to the HART Tri Loop HART to Analog Signal Converter The HART Tri Loop converts the digital information to a 4 20 mA analog signal The HART Tri Loop divides the signal into separate 4 20 mA loops for the primary PV secondary SV tertiary TV and quaternary QV variables Depending upon the burst option selected the digital level controller will burst the variables as shown in table 2 1 The DLC3010 status words are available in the HART Burst messages However the Tri Loop cannot be configured to monitor them directly To commission a DLC3010 digital le
91. espite the absence of diagnostic messages on the Field Communicator display follow the procedures described in table 6 1 to verify that the digital level controller hardware and process connections are in good working order Under each of the major symptoms specific suggestions are offered for solving problems Always deal with the most likely and easiest to check conditions first 72 Instruction Manual Maintenance amp Troubleshooting D102748X012 October 2014 Table 6 1 Troubleshooting 1 Check resistance between the power supply and the Field Communicator connection The net resistance in the loop must be between 230 and 1100 Ohms for HART communication 2 Check for adequate voltage to the digital level controller Refer to figure 2 10 for requirements Some models Loop Wiring of battery operated field calibrators do not have sufficient compliance voltage to operate a DLC3010 over the Analog Output is within valid entire output current range range but Instrument does 3 Check for excessive capacitance in the field wiring Isolate the instrument from field wiring and try to communicate locally not communicate with Field Communicator 4 If the terminal box does not have a 4 digit date code sticker inside the lower lip it may have developed a high internal resistance Try a new terminal box Electronics Module 5 5 Swap the electronics modulewithaknowngoodpart the electronics module with a known 5 Swap th
92. est position of the linkage may not be captured correctly Moving the handle to the rear of the transmitter closes the coupling access hole and unlocks the lever It functions as the pre calculation zero for the process measurement algorithm This procedure can be run either before or after most of the gain However the procedure returns a valid result at only one input condition zero buoyancy although in Level mode it is equivalent to zero differential buoyancy Before calibration use the Configure gt Manual Setup gt Sensor menu to verify that all sensor and compensation data match the calibration conditions Trim Gain Trim Gain operations recompute gain with one observation of process data The calibration parameter that is NOT being trimmed is assumed to be correct Trim Gain trims the torque rate value to align the digital Primary Variable with the user s observation This calibration assumes that sensor zero is already accurate and only a gain error exists Actual process condition must be non zero 57 Configuration Instruction Manual October 2014 D102748X012 and able to be measured independently Configuration data must contain density of calibration fluid displacer volume and driver rod length Before calibration use the Configure gt Manual Setup gt Sensor menu to verify that all sensor and compensation data match the calibration conditions Trim Zero Trim Zero computes the value of the input angle required to
93. ever the extra noise in floating systems affects many types of readout devices If the signal appears noisy or erratic grounding the current signal loop at a single point may solve the problem The best place to ground the loop is at the negative terminal of the power supply As an alternative ground either side of the readout device Do not ground the current signal loop at more than one point Shielded Wire Recommended grounding techniques for shielded wire usually call for a single grounding point for the shield You can either connect the shield at the power supply or to the grounding terminals either internal or external at the instrument terminal box shown in figure 2 11 Instruction Manual Installation D102748X012 October 2014 Power Current Loop Connections Use ordinary copper wire of sufficient size to ensure that the voltage across the digital level controller terminals does not go below 12 0 volts DC Connect the current signal leads as shown in figure 2 9 After making connections recheck the polarity and correctness of connections then turn the power on RID Connections An RTD that senses process temperatures may be connected to the digital level controller This permits the instrument to automatically make specific gravity corrections for temperature changes For best results locate the RTD as close to the displacer as practical For optimum EMC performance use shielded wire no longer than 3 meters 9 8 feet to conne
94. ferred to the location of the bottom of the displacer at zero Level Offset buoyancy condition URV Upper Range Value The value of computed process variable at which a 20 mA output 100 Range is desired LRV Lower Range Value The value of computed process variable at which a 4 mA output 0 Range is desired D A Trim The gain and offset of the D A converter which executes the digital commands to generate output Bias to improve the accuracy of the ambient temperature measurement used to provide temperature compensation for Instrument Temperature Offset the mechanical to electronic transducer Bias to improve the accuracy of the RTD temperature measurement used to provide compensation for Proc Temp Offset process temperature related density changes These parameters are factory set to the most common values for the 249 sensors Therefore for the bulk of units sold in simple level applications it is possible to accept the defaults and proceed to Trim Zero If any of the advanced features of the instrument are to be used accurate sensor and test fluid information should generally be entered before beginning the calibration Primary Guided Calibration Configure gt Calibration gt Primary gt Guided Calibration 2 5 1 1 Guided Calibration recommends an appropriate calibration procedures for use in the field or on the bench based on your input Follow the Field Communicator prompts to calibrate the digital level controller
95. figuration the Polling Address is 0 When several devices are connected in the same loop each device must be assigned a unique polling address The Polling Address may be set to a value between 0 and 15 For the Field Communicator to be able to communicate with a device whose polling address is not 0 it must be configured to automatically search for all or specific connected devices Serial Numbers Follow the prompts on the Field Communicator display to enter or view the following serial numbers Instrument Serial Number Use this field to enter or view the serial number on the instrument nameplate up to 12 characters Sensor Serial Number Use this field to enter or view the sensor serial number The sensor serial number is found on the sensor nameplate Final Assembly Number A number that can be used to identify the instrument and sensor combination Instrument Display Field Communicator Configure gt Manual Setup gt Instrument Display 2 2 5 Follow the prompts on the Field Communicator display to view or edit what is visible in the instrument display LCD Configuration Select this parameter to indicate if the meter is installed If the meter is physically installed select Installed The meter must be installed before you can set the display type or the decimal places Display Mode Only visible if the meter is installed Change Display Mode Select the type of information the meter should display and
96. for the target process fluid density For an interface application Change the PV mode to Interface verify or adjust the range values presented by the Change PV mode procedure and then use Enter constant SG to configure the instrument for the SGs of each of the target process fluids For a density application Change the PV mode to Density and establish the desired range values in the Change PV mode procedure If the target application temperature is considerably elevated or depressed from ambient refer to pages 37 and 66 for information on temperature compensation If you are able to adjust both process fluids the Two Point Calibration is recommended If you are unable to carry out Min Max or Two Point Calibration set the lowest process condition or zero buoyancy for DLC3010 and Capture Zero Run Trim Gain at a process level of minimum 5 above the Lower Range Value If you only have a single fluid for calibration run through Instrument Setup and verify all displacer data is correct Set Level Offset to 0 Select Level application with direct action and enter SG 1 0 water or actual SG of test fluid if different than 1 0 Proceed with Min Max or Two Point Calibration Note Information on computing precise simulation of this effect is available in the Simulation of Process Conditions for Calibration of Fisher Level Controllers and Transmitters instruction manual supplement D103066X012 available from your Emerson Process M
97. grade of grease to the surface of the replacement handle assembly see figure 6 3 where it will contact the transducer housing Install the handle assembly key 12 in the slot of the transducer housing over the inner guide key 11 so that the vent holes in the handle assembly are over the access hole Install two screws key 13 to secure the handle assembly key 12 to the inner guide key 11 Tighten the screws to 0 48 Nem 4 2 Ibfein Press down on the handle as shown in figure 2 4 and slide it forward to make sure it works smoothly and that the zero locking pin engages the lever assembly Also check for free travel of the lever assembly when the handle is in the unlocked position Install the coupling shield key 16 and secure with the two screws key 13 Tighten the screws to 0 48 Nem 4 2 Ibfein Refer to figure 7 1 Install the adapter ring key 32 on the studs key 33 and secure with hex nuts key 34 When re installing the digital level controller follow the appropriate procedure outlined in the Installation section Also setup the digital level controller as described in the Setup and Calibration section Lever Assembly Removing the Lever Assembly The lever assembly is located in the transducer housing Unless indicated otherwise refer to figure 7 2 81 Maintenance amp Troubleshooting Instruction Manual October 2014 D102748X012 1 Remove the digital level controller from the sensor as described in R
98. he test connections inside the terminal box see the Test Connections procedure or connect the meter in the loop as shown in figure 2 9 2 Access Loop Test 3 Select OK after you set the control loop to manual The Field Communicator displays the loop test menu 4 Select a discreet milliamp level for the controller to output At the Choose analog output prompt select 4 mA 20 mA or Other to manually input a value between 4 and 20 milliamps 5 Check the reference meter to verify that it reads the value you commanded the controller to output If the readings do not match either the controller requires an output trim or the meter is malfunctioning After completing the test procedure the display returns to the loop test screen and allows you to choose another output value or end the test Reset Restore Service Tools gt Mainentance gt Reset Restore 3 3 2 Restore Factory Defaults e Restore Factory Configuration Follow the prompts on the Field Communicator display to restore the digital level controller to the factory configuration e Restore Factory Compensation Replaces all calibration and compensation data with factory defaults Both Restore Factory Configuration and Restore Factory are drastic procedures which should be used only as a last resort Reset Device Issues a master reset request to the processor in the DLC3010 70 Instruction Manual Maintenance amp Troubleshooting D102748X012 October 2014
99. iable must fall below the PV High High Alert limit by the PV Alerts Threshold Deadband before the alert is cleared See figure 4 7 PV HiHi Alert Threshold Primary Variable HiHi Alert Threshold is the value of the process variable in engineering units which when exceeded sets the Primary Variable High High Alert PV HiHi Alert Threshold Method to change the PV HiHi Alert Threshold Note If the Hi Hi Alert is enabled and set the digital level controller output will go to below 3 75 mA or above 21 0 mA depending on the position of the alarm jumper Primary Variable Lo LoAlert PV Lo Alert Enable On or Off PV Lo Alert Enable activates checking the primary variable against the PV Lo Alert limit The Lo Alert is set if the primary variable rises above the PV Lo Alert limit Once the alert is set the primary variable must fall below the PV Lo Alert limit by the PV Alerts Threshold Deadband before the alert is cleared See figure 4 7 49 Configuration Instruction Manual October 2014 D102748X012 PV Lo Alert Threshold Primary Variable Lo Alert Threshold is the value of the primary variable in engineering units which when exceeded sets the Primary Variable Low Alert PV Lo Alert Threshold Method to change the PV Lo Alert Threshold e Lo Lo Alert PV LoLo Alert Enable On or Off PV Lo Lo Alert Enable activates checking the primary variable against the PV Lo Lo Alert limit The Lo Lo Alert is set if the primary va
100. ical Multidropped Network 93 N NAMUR NE 43 97 NEPSI 7 NVM non volatile memory 58 O OFLOW Diagnostic Message 72 Output Signal DLC3010 6 Overview 29 AO 29 Comm Status 29 Device Information 30 Alarm Type and Security 31 Identification 30 Revisions 30 Device Status 29 Primary Variable 29 Process Temperature 30 PV is 29 P Parts Ordering 85 Parts Kits 85 Parts List 86 Percent Range 29 Percent Range Only Display Mode 47 PESO CCOE 7 Polled 29 polling address 24 94 Device Information 47 Power Supply Load Limits 20 Power Supply Effect 6 Power Current Loop Connections 23 Pressure Boundary Materials allowable process temperatures 10 Index October 2014 Primary Variable 29 Alert Setup 49 Service Tools Variables 68 Primary Variable Hi Alert Setup 49 Primary Variable Lo Alert Setup 49 Primary Variable Range 42 Primary Variables 41 Primary Variable Range 42 PV Damping 43 Sensor Limits 42 Principle of Operation DLC3010 94 HART Communication 93 Multidrop Communication 93 Proc Temp Hi Alert Enable 51 Proc Temp Hi Alert Threshold 51 Proc Temp Lo Alert Enable 51 Proc Temp Lo Alert Threshold 52 Proc Temp Offset 52 54 Proc Temp Source 30 Process Density 6 Process Fluid 43 Process Temperature 30 46 47 52 Alert Setup 51 change source 46 display 46 Manual Entry of 59 Service Tools Variables 69 source 46 Pr
101. ield Communicator commands the instrument to set its output back to the original value Calibration Examples Calibration with Standard Displacer and Torque Tube Run the initial calibration near ambient temperature at design span to take full advantage of the available resolution This is accomplished by using a test fluid with a specific gravity SG close to 1 The value of SG in the instrument memory during the calibration process should match the SG of the test fluid being used in the calibration After the initial calibration the instrument may be set up for a target fluid with a given specific gravity or an interface application by simple configuration data changes 1 Run through Guided Setup and verify that all sensor data is correct Procedure Change the PV mode to Level Set the Level Offset value to 0 00 Set the Specific Gravity value to the SG of the test fluid being used Establish the test fluid level at the desired process zero point Make sure that the DLC3010 lever assembly has been properly coupled to the torque tube see coupling procedure on page 38 To unlock the lever assembly and allow it to freely follow the input close the coupling access door on the instrument It is often possible to watch the instrument display and or the analog output to detect when the fluid hits the displacer because the output will not start moving upward until that point is reached Select the Min Max calibration from the Full Calibration
102. imits 42 Sensor Nameplate example 35 Sensor Units 39 Serial Number Instrument 47 Sensor 47 Serial Numbers Device Information 47 Service Tools 67 Maintenance 0 Variables 68 Set Level Offset 41 SG 54 shaft extension torque tube 18 signal conditioning 94 Special Instructions for Safe Use and Installations in Hazardous Locations 15 specific gravity tables 43 Specific Gravity vs Temperature Table for Saturated Steam example 45 Specifications 249 Sensors 10 DLC3010 4 Supply Requirements DLC3010 7 T Table of SG vs T 45 Temperature Ambient DLC3010 6 Process 6 Temperature Calibration 58 Temperature Compensation 66 Temperature Deadband 51 52 temperature sensor 96 Temperature Units Sensor 39 terminal board 94 Terminal Box 22 maintenance 79 Removing 79 Replacing 79 terminal box cover set screw ATEX approved unit 22 Instruction Manual D102748X012 Test connections 24 Test Terminals 23 74 Tests Maintenance 70 Theoretical Reversible Temperature Effect on Common Torque Tube Materials 9 Theoretical Torque Tube TT Rates 64 TIIS 7 Tools required for maintenance 74 75 Torque Rate change torque tube 40 Service Tools Variables 69 torque tube 40 Torque Rate Units Sensor 39 Torque Tube data 40 Torque Tube Compensation Selection 40 Torque Tube Compensation Table 40 Torque Tube Rate 54 torque tube correction data tables 37
103. inst process media Hazardous Area Classifications and Special Instructions for Safe Use and Installations in Hazardous Locations Refer to the DLC3010 Quick Start Guide D103214X012 that ships with the instrument for Hazardous Area Classifications and Special Instructions for Safe Use and Installations in Hazardous Locations If a copy of this quick start quide is needed contact your Emerson Process Management sales office or visit our website at www Fisher com Mounting the 249 Sensor The 249 sensor is mounted using one of two methods depending on the specific type of sensor If the sensor has a caged displacer it typically mounts on the side of the vessel as shown in figure 2 2 If the sensor has a cageless displacer the sensor mounts on the side or top of the vessel as shown in figure 2 3 The DLC3010 digital level controller is typically shipped attached to the sensor If ordered separately it may be convenient to mount the digital level controller to the sensor and perform the initial setup and calibration before installing the sensor on the vessel Note Caged sensors have a rod and block installed on each end of the displacer to protect the displacer in shipping Remove these parts before installing the sensor to allow the displacer to function properly Installation October 2014 Instruction Manual D102748X012 Figure 2 2 Typical Caged Sensor Mounting Figure 2 3 Typical Cageless Sensor Mounting LIQUID LEVE
104. ion 31600 59 Shaft Retainer 530400 60 Hex Socket Screw SST 62 Mounting Adaptor A96061 63 Hex Socket Screw SST 3 req d 71 Hex Socket Screw SST 3 req d 72 Shaft Adapter 530400 73 Hex Socket Screw SST 2 req d With Heat Insulator 57 Heat Insulator S30400 58 Shaft Extension 31600 59 Shaft Retainer 530300 60 Hex Socket Screw SST 61 Hex Cap Screw SST 4 req d 62 Mounting Adaptor A96061 63 Hex Socket Screw SST 3 req d 71 Hex Socket Screw SST 3 req d 72 Shaft Adapter 530400 73 Hex Socket Screw SST 2 req d 78 Washer plain 4 req d Key Parts October 2014 Description Foxboro Eckardt Sensors 144LD without Heat Insulator 58 59 60 62 74 75 Shaft Extension 531600 Shaft Coupling 30300 Set Screw hex socket SST 2 req d Mounting Adapter A92024 Hex Nut steel 4 req d Hex Cap Screw steel 4 req d 144LD with Heat Insulator 57 58 59 60 61 62 74 75 78 Heat Insulator 530400 Shaft Extension 316 SST Shaft Coupling 30300 Set Screw hex socket SST 2 req d Screw hex hd SST 4 req d Mounting Adapter A92024 Hex Nut steel 4 req d Hex Cap Screw steel 4 req d Washer plain 4 req d LP167 without Heat Insulator 58 59 60 62 63 Shaft Extension 31600 Shaft Coupling 30300 Set Screw hex socket SST 2 req d Mounting Adapter A92024 Screw hex socket 4 req d 91 Parts October 2014 92 Instruction Manual D102748X012
105. iple of Operation October 2014 98 Instruction Manual D102748X012 Instruction Manual D102748X012 Appendix B Fast Key Sequence and Field Communicator Menu Tree Fast key sequences are included for common DLC3010 digital level controller fuctions Also included are Field Communiator menu trees Fast key sequences see table B 1 Hot Key menu see figure B 1 Overview menu see figure B 2 Guided Setup menu see figure B 3 Manual Setup menu see figure B 4 Alert Setup menu see figure B 5 Communications menu see figure B 6 Calibration menu see figure B 7 Service Tools menu see figure B 8 Field Communicator Menu Tree October 2014 99 Field Communicator Menu Tree Instruction Manual October 2014 D102748X012 Table B 1 Fast Key Sequence Fast Key Sequence See Figure Function Fast Key Sequence 22 222 2 2 3 1 4 2 2 4 4 2 2 2 2 3 17 13 B B Active Alerts Alarm Jumper 1 7 3 1 1 1 5 rd Analog Output AIN L Burst Mode Burst Options Calibration Full Calibration Partial Number of Request Preambles 2 2 4 7 Percent R 3223 J 88 2 2311 2 2 5 1 2 2 5 1 3 2 5 2 1 2 2 3 20 2 2 3 2 20 2 2 2 1 2 2 2 1 3 2 Sy T N Calibration Temperature aN Change Process Temperature Change Primary Variable 2313 G Process Temperature Process Temperature Source 1 3 B 2 Change
106. is the easiest way to identify and distinguish between controllers in multi controller environments Use the HART tag to label controllers electronically according to the requirements of your application The tag you define is automatically displayed when a HART based communicator establishes contact with the controller at power up The tag may be up to eight characters long and has no impact on the primary variable readings of the controller 46 Instruction Manual Configuration D102748X012 October 2014 e Date Date is a user defined variable that provides a place to save the date of the last revision of configuration or calibration information It has no impact on the operation of the controller or Field Communicator Enter a date with the format MM DD YY Descriptor The Descriptor provides a longer user defined electronic label to assist with more specific controller identification that is available with the HART tag The descriptor may be up to 16 characters long and has no impact on the operation of the controller or HART based communicator Message Message provides the most specific user defined means for identifying individual controllers in multi controller environments it allows for 32 characters of information and is stored with the other configuration data Message has no impact on the operation of the controller or the Field Communicator Polling Address If the digital level controller is used in a point to point con
107. ital Level Controller October 2014 COMMUNI CALIONS ated So ote men pts 53 Burst MOGG oen RR Eon et dins 53 BUESEO DOM s 22155 dancers OS Ub Og Sad remet 53 CalIDFIEIOI Ner Prae ee aane 54 Introduction Calibration of Smart Instruments 54 FP UPRIMA CPP PCT 54 Guided Calibration 54 FUll Calibration rv NC ERES 55 Min Max Calibration 55 Two Point Calibration 55 Weight Calibration 56 Theoretical Calibration 56 Partial Calibration 57 Capture Zer gavin Scone 5 M reri PIE 5 ClO sea LARES ouod 58 Secondaly ds E E pec p a ee acies 58 Temperature Calibration 58 Trim Instrument Temperature 59 Trim Process Temperature 59 Manual Entry of Process Temperature 59 Analog Output Calibratlon 59 Scaled Trim 59 Calibration Examples 60 Calibration with Standard displacer and Torque Tube 60 Calibration with Overweight Displacer 61 Density Applications with Standard Displacer and Torque Tube 63 Calibration at Process Conditions Hot Cut Over when input cannot be varied 63 Entering Theoretical Torque Tube Rates 64 Excessive Mechanical Gain 65
108. itry to measure the process variable provide a current output drive the LCD meter and provide HART communications capability Figure A 3 shows the digital level controller assembly Figure A 4 is a block diagram of the main components in the instrument electronics the LCD meter the processor module the transducer board and the terminal board The processor module contains the microprocessor the analog to digital A D converters loop interface signal conditioning the digital to analog D A output power supply and interfaces to other boards 94 Instruction Manual Principle of Operation D102748X012 October 2014 Figure A 3 FIELDVUE DLC3010 Digital Level Controller Assembly ADAPTER RING TERMINAL BOX TERMINAL BOX TRANSDUCER LEVER ASSEMBLY HOUSING ELECTRONICS ASSEMBLY LCD METER ASSEMBLY E0377 COVER Figure A 4 FIELDVUE DLC3010 Digital Level Controller Principle of Operation Transducer Module Electronics Temperature Sensor Shaft Position Processor Terminal _ Loop HART Transducer Module Interface Linearization Data resident in NVM Torque Tub Rotation RID __ Process _ Temperature Interface E0378 95 Principle of Operation Instruction Manual October 2014 D102748X012 The transducer board contains the Hall sensor a temperature sensor to monitor the Hall sensor temp
109. its to correspond to the externally measured level or interface see figure 4 3 Follow the prompts on the Field Communicator to enter the offset value If you set the level offset after you have set the range values be sure to verify that the range values are still correct Figure 4 3 Example of the Use of Level Offset 10 FEET DISPLACER LRV 6 FEET LEVEL OFFSET 6 FEET E0368 Y 41 Configuration Instruction Manual October 2014 D102748X012 Sensor Limits Follow the prompts on the Field Communicator to view sensor limit information e Upper Sensor Limit Indicates the maximum usable value for the Upper Range Value e Lower Sensor Limit Indicates the minimum usable value for the Lower Range Value e Minimum Span Difference between the Upper Range Value and the Lower Range Value below which amplification of instrument errors may become a concern This effect should be considered when sizing displacer torque tube Primary Variable Range Follow the prompts on the Field Communicator to view or edit range information e Upper Range Value Defines the operational end point from which the Analog Value and the 100 point of the percent range are derived e Lower Range Value Defines the operational end point from which the Analog Value and the 026 point of the percent range are derived View Change AO Action Follow the prompt and change the output action Direct Reverse For Reverse action the
110. itter may output incorrect information The DC power supply should provide power with less than 2 ripple The total resistance load is the sum of the resistance of the signal leads and the load resistance of any controller indicator or related pieces of equipment in the loop Note that the resistance of intrinsic safety barriers if used must be included Field Wiring Note For intrinsically safe applications refer to the instructions supplied by the barrier manufacturer A WARNING To avoid personal injury or property damage caused by fire or explosion remove power to the instrument before removing the digital level controller cover in an area which contains a potentially explosive atmosphere or has been classified as hazardous All power to the digital level controller is supplied over the signal wiring Signal wiring need not be shielded but use twisted pairs for best results Do not run unshielded signal wiring in conduit or open trays with power wiring or near heavy electrical equipment If the digital controller is in an explosive atmosphere do not remove the digital level controller covers when the circuit is alive unless in an intrinsically safe installation Avoid contact with leads and terminals To power the digital level controller connect the positive power lead to the terminal and the negative power lead to the terminal as shown in figure 2 11 21 Installation October 2014 Figure 2 11 Digital Level Contro
111. l hardware spare parts kit 3 Included in spare O rings kit 4 Included in the Electronics Ass y key 2 86 5 Included in the LCD Meter Ass y key 4 Instruction Manual D102748X012 Key Description Transducer Assembly figure 7 2 11 Inner Guide aluminum 12 Handle Ass y aluminum SST 13 Screw hex socket 18 8 SST 4 req d 14 Screw cap 18 8 SST 15 Lever Assembly aluminum SST NdFeB CS 16 Coupling Shield 18 8 SST 17 Ring align clamp Figure 7 2 DLC3010 Digital Level Controller Transducer Assembly Part Number 38B5509X042 68 67 GE18497 Recommended spare parts 1 These parts are not replaced in the field due to serialization and characterization issues but can be replaced at a qualified service center Contact your Emerson Process Management sales office for additional information 2 Included in small hardware spare parts kit 6 Included in Coupling Hardware Spare Parts Kit Key 19 20 31 67 68 76 77 79 80 81 82 Parts October 2014 Description Machine Screw pan head Set Screw 18 8 SST 2 Set Screw hex socket 18 8 SST 2 Thread Locking adhesive medium strength not furnished with instrument Sealant Clamp Nut 18 8 SST 2 6 Spring Lock Washer 18 8 SST 2 6 Transducer Board Assembly Hall Guard Compound silicone Bolt lock coupling block SST 6 87 Parts October 2014 Figure
112. l sensors to measure liquid level the level of interface between two liquids or liquid specific gravity density Changes in level or specific gravity exert a buoyant force ona Introduction and Specifications Instruction Manual October 2014 D102748X012 displacer which rotates the torque tube shaft This rotary motion is applied to the digital level controller transformed to an electrical signal and digitized The digital signal is compensated and processed per user configuration requirements and converted back to a 4 20 mA analog electrical signal The resulting current output signal is sent to an indicating or final control element Figure 1 1 FIELDVUE DLC3010 Digital Level Controller m 2 FIELDVUE Instruments 7977 1 DLC3010 digital level controllers are communicating microprocessor based level interface or density sensing instruments In addition to the normal function of providing a 4 20 milliampere current signal DLC3010 digital level controllers using the HART communications protocol give easy access to information critical to process operation You can gain information from the process the instrument or the sensor using a Field Communicator with device descriptions DDs compatible with DLC3010 digital level controllers The Field Communicator may be connected at the digital level controller or at a field junction box Using the Field Communicator you can perform several operations with the DLC3010 digital
113. ld Communicator and the following procedure to measure specific gravity 1 Setthe control loop for manual control 2 Adjust the liquid level so that the displacer is partially submerged 3 Enter the externally measured level in engineering units After you press OK on the Field Communicator the instrument begins calculating the specific gravity You can then elect to use this value as the specific gravity for all level measurements If you select No the instrument uses the specific gravity entered under PV Setup or the values from the specific gravity tables 4 When finished measuring specific gravity return the control loop to automatic control e Load Steam Tables Note Load Steam Tables is only visible if PV is Interface Table 4 3 lists example entries for saturated steam Figure 4 5 is the curve that results when these values are plotted Table 4 3 Example Specific Gravity vs Temperature Table for Saturated Steam TEMPERATURE 0 00095 0 00850 0 02760 0 04900 0 07200 0 09800 0 13500 0 16800 0 21000 0 31570 1 2 3 4 5 6 7 8 9 10 45 Configuration Instruction Manual October 2014 D102748X012 Figure 4 5 Example Saturated Steam Curve Plotted from Values in Table 4 3 TEMPERATURE C 18 100 200 300 375 0 35 TH Th mal 0 30 0 2 0 2 0 1 SPECIFIC GRAVITY 0 1 0 0
114. level controller You can interrogate configure calibrate or test the digital level controller Using the HART protocol information from the field can be integrated into control systems or be received on a single loop basis DLC3010 digital level controllers are designed to directly replace standard pneumatic and electro pneumatic level transmitters DLC3010 digital level controllers mount on a wide variety of caged and cageless 249 level sensors They mount on other manufacturers displacer type level sensors through the use of mounting adaptors 249 Caged Sensors see table 1 6 e 249 249B 249BF 249C 249K and 2491 sensors side mount on the vessel with the displacer mounted inside a cage outside the vessel The 249BF caged sensor is available only in Europe Middle East and Africa 249 Cageless Sensors see table 1 7 249BP 249CP and 249P sensors top mount on the vessel with the displacer hanging down into the vessel 249VS sensor side mounts on the vessel with the displacer hanging out into the vessel 249W wafer style sensor mounts on top of a vessel or on a customer supplied cage Specifications Specifications for the DLC3010 digital level controller are shown in table 1 1 Specifications for the 249 sensor are shown in table 1 3 Specifications for the Field Communicator can be found in the Product Manual for the Field Communicator Instruction Manual Introduction and Specifications D102748X012 October 2014 Rel
115. ller Terminal Box 4 20 mA LOOP TEST CONNECTIONS CONNECTIONS RTD CONNECTIONS INTERNAL GROUND 1 2 NPT CONNECTION CONDUIT OIC ION TT FRONT VIEW W8041 Instruction Manual D102748X012 1 2 NPT CONDUIT CONNECTION EXTERNAL GROUND CONNECTION REAR VIEW CAUTION Do not apply loop power across the T and terminals This can destroy the 1 Ohm sense resistor in the terminal box Do not apply loop power across the Rs and terminals This can destroy the 50 Ohm sense resistor in the electronics module When wiring to screw terminals the use of crimped lugs is recommended Tighten the terminal screws to ensure that good contact is made No additional power wiring is required All digital level controller covers must be fully engaged to meet explosion proof requirements For ATEX approved units the terminal box cover set screw must engage one of the recesses in the terminal box beneath the terminal box cover Grounding A WARNING Personal injury or property damage can result from fire or explosion caused by the discharge of static electricity when flammable or hazardous gases are present Connect a 14 AWG 2 1 mm ground strap between the digital level controller and earth ground when flammable or hazardous gases are present Refer to national and local codes and standards for grounding requirements The digital level controller will operate with the current signal loop either floating or grounded How
116. lone instrument to prevent damage to the flexure Use the original shipping carton if possible 83 Maintenance amp Troubleshooting October 2014 84 Instruction Manual D102748X012 Instruction Manual Parts D102748X012 October 2014 Section Parts Parts Ordering Whenever corresponding with your Emerson Process Management sales office about this equipment always mention the controller serial number When ordering replacement parts refer to the 11 character part number of each required part as found in the following parts list Parts that do not show part numbers are not orderable A WARNING Use only genuine Fisher replacement parts Components that are not supplied by Emerson Process Management should not under any circumstances be used in any Fisher instrument The use of components not manufactured by Emerson Process Management may void your warranty might adversely affect the performance of the instrument and could cause personal injury and property damage ou nti ng Kits Foxboro Eckardt LP167 with heat insulator Contact your Emerson Process Management sales office for FS numbers for the following DLC3010 Note mounting options Contact your Emerson Process Management sales office for information on the availability of additional mounting kits Fisher 249 sensors heat insulator for field mounting the DLC3010 Parts Kits Masoneilan 12100 12800 Series Description Part Number Masoneilan
117. ly with the coupling access door at the bottom to provide proper Operating Limits drainage of lever chamber and terminal compartment and to limit gravitational effect on the lever assembly If alternate drainage is provided by user and a small performance loss is acceptable the Age TREE instrument could be mounted 90 degree rotational Limits 1 2 Storage Limits Reference increments around the pilot shaft axis The LCD meter Kenia 40 to 80 C 40 to 85 C 35 C may be rotated in 90 degree increments to Temperature 40 to 176 F 40 to 185 F 77 F accommodate this Ambient 0 to 95 0 to 95 Relative non condensing non condensing Humidity 9 3 Construction Materials Process Temperature See table 1 4 and figure 2 7 Ambient Temperature and Humidity See below Case and Cover Low copper aluminum alloy Weight Internal Plated steel aluminum and stainless steel Less than 2 7 Kg 6 Ibs NOTE Specialized instrument terms are defined in ANSI ISA Standard 51 1 Process Instrument Terminology 1 LCD meter may not be readable below 20 C 4 F 2 Contact your Emerson Process Management sales office or application engineer if temperatures exceeding these limits are required Table 1 2 EMC Summary Results Immunity Phenomenon Basic Standard Test Level Criteria 1 2 ul 4 kV contact Electrostatic discharge ESD IEC 61000 4 2 2 kV air A 80 to 1000 MHz 10V m with 1
118. menu and confirm that you are at the Min condition at the prompt After the Min point has been accepted you will be prompted to establish the Max condition The displacer completely covered condition should be slightly higher than the 10026 level mark to work correctly for example 15 inches above the zero mark would generally be enough for a 14 inch displacer on a 249B because the amount of displacer rise expected for that configuration is about 0 6 inch Accept this as the Max condition Adjust the test fluid level and check the instrument display and current output against external level at several points distributed across the span to verify the level calibration a To correct bias errors Capture Zero at the exact zero level condition b To correct gain errors Trim Gain at a precisely known high level condition If the measured output doesn t come off the low saturation value until the level is considerably above the bottom of the displacer it is possible that the displacer is overweight An overweight displacer will rest on the lower travel stop until sufficient buoyancy has developed to allow the linkage to move In that case use the calibration procedure for overweight displacers found on page 61 60 Instruction Manual Configuration D102748X012 October 2014 After the initial calibration For a level application Go to the Sensor Compensation menu and use the Enter constant SG item to configure the instrument
119. mption that the displacer is free moving at zero buoyancy dry conditions Capture Zero accurately at dry displacer conditions and any of the full sensor calibration methods Weight Min Max and Two Point can be used in density mode The terminology can be confusing because it usually refers to a level as the process condition to set up When using one of these method remember that you are in the density mode and enter observed PV in current units of SGU g L Ib in kg m etc Weight Based The Weight Calibration asks you for the lowest and highest density you want to use for the calibration points and computes weight values for you If you can t come up with the exact values asked for you are allowed to edit the values to tell it what weights you actually used Min Max The Min Max Calibration essentially reverts to level mode during the calibration process It asks for the SG of your test fluid first Then it has you set up first a dry and then a completely submerged displacer condition Two Point The Two Point Calibration requires you to set up two different process conditions with as much difference as possible You could use two standard fluids with well known density and alternately submerge the displacer in one orthe other If you are going to try to simulate a fluid by using a certain amount of water remember that the amount of displacer covered by the water is what counts not the amount in the cage The amount in the cage will alwa
120. municator and 18 Run Loop diagnostic test 3 3 1 1 3 3 1 2 if LCD Configuration is installed Leave instrument in fixed current mode at 12 mA command and observe analog output variation with ambient temperature If driftexceeds specifications replace electronics module Electronics Module Connect the Field Communicator and Configuration Data 19 Check stored Specific Gravity values 2 2 3 1 against independent measurement of process density If process SG has changed from calibration values correct configuration data to match process If output current enters a limit cycle between zero and a value within the 4 20 mA range when level reaches some Erratic Output Loop Wiring arbitrary upper threshold 20 Check for excessive loop resistance or low compliance voltage See items 2 and 4 above mE Loop Wiring see item 20 above Insufficient voltage to operate display d LCD Assy 21 Swap LCD Assy with known good part Electronics Module 22 Connector solder joint failure in electronics module Replace module 73 Maintenance amp Troubleshooting Instruction Manual October 2014 D102748X012 Test Terminals Test connections inside the terminal box can be used to measure loop current These terminals are across an internal 1 ohm resistor that is in series with the loop 1 Remove the terminal box cap 2 Adjust the test meter to measure a range of 0 001 to 0 1 volts 3 Connect the positive l
121. nfiguration On the Bench or in the Loop Configure the digital level controller before or after installation It may be useful to configure the instrument on the bench before installation to ensure proper operation and to familiarize yourself with its functionality Protecting the Coupling and Flexures CAUTION Damage to flexures and other parts can cause measurement errors Observe the following steps before moving the sensor and controller Lever Lock The lever lock is built in to the coupling access handle When the handle is open it positions the lever in the neutral travel position for coupling In some cases this function is used to protect the lever assembly from violent motion during shipment A DLC3010 controller will have one of the following mechanical configurations when received 1 A fully assembled and coupled caged displacer system shipped with the displacer or driver rod blocked within the operating range by mechanical means In this case the access handle figure 2 4 will be in the unlocked position Remove the displacer blocking hardware before calibration See the appropriate sensor instruction manual The coupling should be intact CAUTION When shipping an instrument mounted on a sensor if the lever assembly is coupled to the linkage and the linkage is constrained by the displacer blocks use of the lever lock may result in damage to bellows joints or flexure 2 If the displacer cannot be blocked bec
122. nstrument cover before proceeding Use the following procedure to change the position of the alarm jumper 1 If the digital level controller is installed set the loop to manual 2 Remove the housing cover on the electronics side Do not remove the cover in explosive atmospheres when the circuit is alive 3 Set the jumper to the desired position 4 Replace the cover All covers must be fully engaged to meet explosion proof requirements For ATEX approved units the set screw on the transducer housing must engage one of the recesses in the cover 25 Installation Instruction Manual October 2014 D102748X012 Loop Test Field Communicator Service Tools gt Maintenance gt Tests gt Loop Test 3 3 1 1 or 3 3 1 2 if LCD Configuration is installed Loop test can be used to verify the controller output the integrity of the loop and the operations of any recorders or similar devices installed in the loop To initiate a loop test perform the following procedure 1 Connect a reference meter to the controller To do so either connect the meter to the test connections inside the terminal box see the Test Connections procedure or connect the meter in the loop as shown in figure 2 9 2 Access Loop Test 3 Select OK after you set the control loop to manual The Field Communicator displays the loop test menu 4 Select a discreet milliamp level for the controller to output At the Choose analog output prompt select 4 mA
123. nt errors can occur if the torque tube assembly is bent or misaligned during installation 4 Position the digital level controller so the access hole is on the bottom of the instrument 5 Carefully slide the mounting studs into the sensor mounting holes until the digital level controller is snug against the sensor 6 Reinstall the hex nuts on the mounting studs and tighten the hex nuts to 10 Nem 88 5 Ibfein Mounting the Digital Level Controller for High Temperature Applications Refer to figure 2 8 for parts identification except where otherwise indicated The digital level controller requires an insulator assembly when temperatures exceed the limits shown in figure 2 7 A torque tube shaft extension is required for a 249 sensor when using an insulator assembly CAUTION Measurement errors can occur if the torque tube assembly is bent or misaligned during installation 18 Instruction Manual D102748X012 Figure 2 7 Guidelines for Use of Optional Heat Insulator Assembly AMBIENT TEMPERATURE C 40 30 20 10 0 10 20 30 40 50 60 70 80 425 0 400 HEAT INSULATOR 300 REQUIRED 207 100 NO HEAT INSULATOR NECESSARY 0 100 200 40 20 0 20 40 60 80 100 120 140 160 176 AMBIENT TEMPERATURE F STANDARD TRANSMITTER PROCESS TEMPERATURE C PROCESS TEMPERATURE F NOTES 1 FOR PROCESS TEMPERATURES BELOW 29 C 20 F AND ABOVE 204 C 400 F SENSOR MATERIALS MUST BE APPROPRIATE FOR THE PROCESS S
124. ny product remains solely with the purchaser and end user Fisher FIELDVUE DeltaV and Tri Loop are marks owned by one of the companies in the Emerson Process Management business unit of Emerson Electric Co Emerson Process Management Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co HART is a mark owned by the HART Communication Foundation All other marks are the property of their respective owners The contents of this publication are presented for informational purposes only and while every effort has been made to ensure their accuracy they are not to be construed as warranties or guarantees express or implied regarding the products or services described herein or their use or applicability All sales are governed by our terms and conditions which are available upon request We reserve the right to modify or improve the designs or specifications of such products at any time without notice Emerson Process Management Marshalltown lowa 50158 USA Sorocaba 18087 Brazil Chatham Kent ME4 4QZ UK Dubai United Arab Emirates Singapore 128461 Singapore www Fisher com E M ERSON 2000 2014 Fisher Controls International LLC All rights reserved a A
125. occur with the linkage driven hard into a travel stop In interface measurement mode it becomes impossible to Capture Zero One simple and effective solution is to use Level measurement mode Capture Zero at the lowest process condition instead of zero buoyancy and enter the differential SG SGlowerfluid SGupperfluid The algorithm then computes level correctly Density Variations in Interface Applications A high sensitivity to errors in the knowledge of fluid density can develop in some interface applications For example Suppose the whole input span is represented by an effective change in SG of 0 18 Then a change in the actual SG of the upper fluid from 0 8 to 0 81 could cause a measurement error of 5 625 of span at the lowest interface level The 65 Configuration Instruction Manual October 2014 D102748X012 sensitivity to the knowledge of a fluid density is maximum at the process condition where that fluid covers all of the displacer and zero at the opposite extreme process condition If the fluid density changes are batch related or very gradual it may be practical to keep track of the SG of the fluid and periodically reconfigure the transmitter memory to match the actual process condition Frequent automatic updates to this variable are not advised as the NVM location where it is stored has an expected lifetime of about 10 000 write operations If changes are only a function of temperature the characteristic of the fluid can be lo
126. ocess Temperatures extreme 66 process variable 47 processor module 94 Proportional Band effect of 65 Protection 34 39 PV Display Mode 47 PV alert deadband 37 PV alert thresholds 37 PV Alerts Threshold Deadband 49 50 PV Damping 43 PV Hi Alert Enable 49 PV Hi Alert Threshold 49 method 49 PV Hi Hi Alert Enable 49 113 Index October 2014 PV HiHi Alert Threshold 49 method 49 PV is 29 41 Service Tools Variables 68 PV Lo Alert Enable 49 PV Lo Alert Threshold 50 method 50 PV LoLo Alert Enable 50 PV LoLo Alert Threshold 50 method 50 PV Units 41 PV Value 29 50 PV Range Display Mode 47 PV Process Temperature Display Mode 47 R Reference dry Coupling Point 54 Related Documents 5 remote indicator 8 Repeatability 6 replacement parts 85 Reset Restore Maintenance 70 Restore Factory Compensation 0 Restore Factory Configuration 70 Restore Factory Defaults 70 returned goods information 83 reverse polarity protection 97 Revisions 30 Rosemount 333 HART Tri Loop HART to Analog Signal Converter 27 RTD Connections 23 Three Wire 23 Two Wire 23 Setup 46 RTD Wire Resistance 46 S Saturated Water Specific Gravity vs Temperature Table example 44 Scaled D A Trim Analog Output Calibration 59 114 Instruction Manual D102748X012 Security 31 Sensor Connection Compartment 16 Sensor Damping 40 Sensor Dimensions 39 Sensor L
127. of process data The calibration parameter that is NOT being trimmed is assumed to be correct Capture Zero Capture Zero captures the current value of the torque tube angle as the input zero The displacer must be loading the torque tube and not resting on a travel stop The torque tube must be coupled to the DLC3010 and the coupling access door must be closed In Level mode the captured angle represents zero differential buoyancy on displacer and must be obtained at the actual process zero condition In Interface and Density mode the captured angle represents zero absolute buoyancy on displacer and must be obtained at actual dry condition If the displacer is overweight and it is necessary to use the partial calibration methods select Level mode and enter the differential density before using Capture Zero and Trim Gain After the gain is correct switch back to Density or Interface mode re enter individual densities if Interface then perform a Trim Zero procedure to back compute the required zero buoyancy angle The Capture zero procedure prompts you to verify the instrument is coupled to torque tube coupling access door is closed and verify that the displacer is completely dry Note If the handle on the coupling access door is in the position towards the front of the transmitter the coupling access hole is open and the lever is locked pinned in the neutral travel position In this condition the true at r
128. of the hole for the lever mounting bolt 3 Hold lever assembly by coupling block and quide the flexure block into its aligning slot in the housing without applying any downward force to the sprung parts of the lever assembly CAUTION To prevent damage to the flexure when inserting the flexure block into its aligning slot in the housing apply pressure to the flexure block only A long pin inserted into the bolt hole in the flexure block may be used to pull it against the inside corner of the aligning slot 4 Secure the block by reinstalling the M5x20 socket head cap screw key 14 Torque to 2 8 Nem 25 Ibfein 1026 5 Mark bolt head and block with a movement detecting sealant 6 Install the coupling shield key 16 and secure with the two screws key 13 Tighten the screws to 0 48 Nem 4 2 Ibfein 7 Refer to figure 7 1 Install the adapter ring key 32 on the studs key 33 and secure with hex nuts key 34 When re installing the digital level controller follow the appropriate procedure outlined in the Installation section Set up the digital level controller as described in the Setup and Calibration section 82 Instruction Manual Maintenance amp Troubleshooting D102748X012 October 2014 Packing for Shipment If it becomes necessary to return the unit for repair or diagnosis contact your Emerson Process Management sales office for returned goods information CAUTION Lock the lever assembly when shipping the stand a
129. ollow the prompts on the Field Communicator to trim the D A output Scale the output from 4 to 20 mA If your reference meter is graduated in select Proceed and go to step 5 If the reference reading is presented in some other unit system such as or mm select Change and continue with step 2 NJ Enter the scale low output value 3 Enter the scale high output value 4 Ifthe high and low output values are correct select Proceed and continue to step 5 If they are not correct select Change and return to step 2 Ul Connect a reference meter across the test connections in the terminal box See the Test Connections procedure in the Installation section You can also connect a reference meter in the loop as shown in figure 2 9 6 The Field Communicator commands the instrument to set its output to 4 mA or the low output value Enter the reading from the reference meter 59 Configuration Instruction Manual October 2014 D102748X012 8 If the reference meter reading equals 4 mA or the low output value select Yes and continue to step 9 If not select No and return to step 7 9 The Field Communicator commands the instrument to set its output to 20 mA or the high output value 10 Enter the reading from the reference meter 11 If the reference meter reading equals 20 mA or the high output value select Yes and continue to step 12 If not select No and return to step 10 12 The F
130. or if the instrument had been coupled to the sensor while the displacer was not connected To correct this condition manipulate the sensor linkage to bring the lever assembly to within approximately 4 degrees of the neutral position before attempting to slide the handle A probe inserted through the top vent of the 249 head may be required to deflect the driver rod to a position where the lever assembly is free 4 Using a 10 mm deep well socket inserted through the access hole loosen the shaft clamp figure 2 4 5 Loosen and remove the hex nuts key 34 from the mounting studs key 33 6 Carefully pull the digital level controller straight off the sensor torque tube CAUTION Tilting the instrument when pulling it off of the sensor torque tube can cause the torque tube shaft to bend To prevent damage to the torque tube shaft ensure that the digital level controller is level when pulling it off of the sensor torque tube 75 Maintenance amp Troubleshooting Instruction Manual October 2014 D102748X012 7 When re installing the digital level controller follow the appropriate procedure outlined in the Installation section Also setup the digital level controller as described in the Initial Setup section 249 Sensor in High Temperature Applications 1 Loosen the set screw key 31 in the terminal box cover assembly key 6 so that the cover can be unscrewed from the terminal box After removing the cover key 6 note the location of
131. ore applying force 3 Fasten the terminal box to the transducer housing with the screw key 7 Tighten the screw to 6 Nem 53 lbfein 4 Apply sealant to the O ring key 26 and install the O ring over the cover threads on the terminal box Use a tool to prevent cutting the O ring while installing it over the threads 5 Reconnect the field wiring as noted in step 2 in the Removing the Terminal Box procedure 6 Apply lubricant to the threads on the terminal box to prevent seizing or galling while installing the terminal box cover 7 Screw the terminal box cover assembly key 6 completely onto the terminal box to seat the O ring key 26 Loosen the cover not more than 1 turn until the set screw key 31 aligns with one of the recesses in the terminal box beneath the cover Tighten the set screw to engage the recesses but no more than 0 88 Nem 7 8 lbfein 8 Apply lubricant to the conduit entrance plug key 28 and install it in the unused conduit entrance Removing and Replacing the Inner Guide and Access Handle Assembly The access handle and inner guide are located on the transducer housing Unless indicated otherwise refer to figure 7 2 1 Remove the digital level controller from the sensor as described in Removing the Digital Level Controller from the Sensor 2 Loosen and remove the hex nuts key 34 from the studs key 33 and remove the adapter ring key 32 Note In the next step the screws key 13 will be attracted
132. oth the upper and lower table can be displayed and edited For density applications no specific gravity correction table is presented Example entries for saturated water are given in table 4 2 Figure 4 4 shows the curve that results when these values are plotted 43 Configuration Instruction Manual October 2014 D102748X012 Table 4 2 Example Specific Gravity vs Temperature Table for Saturated Water 26 7 93 3 176 7 248 9 1 2 3 4 5 6 7 8 9 10 Figure 4 4 Example Saturated Water Curve Plotted with Values from Table 4 2 TEMPERATURE C 18 30 100 200 300 380 1 0 0 9 0 8 0 6 0 5 SPECIFIC GRAVITY 0 4 0 7 0 3 a se pte E EE EE 0 100 200 300 400 500 600 700 E0369 TEMPERATURE F You can enter up to 10 temperature and specific gravity pairs in the table The table entry function is terminated by entering zero for the specific gravity Keep this in mind when setting up a table for a upper fluid such as steam whose specific gravity approaches 0 at lower temperatures The resolution of the table entry for specific gravity is 5 decimal places This means the smallest specific gravity value you can enter is 0 00001 which should be sufficient to allow a
133. ower liquid Allow the output to settle then acknowledge establishment of the maximum buoyancy condition of the system The sensor torque rate is calibrated If the Capture Zero procedure was run at the minimum buoyancy or completely submerged in upper liquid condition the zero of the PV calculation will be correct also Verify that the upper and lower range values are correct and return the loop to automatic control Two Point Calibration This procedure is usually the most accurate method for calibrating the sensor It uses independent observations of two valid process conditions together with the hardware dimensional data and SG information to compute the effective torque rate of the sensor The two data points can be separated by any span between a minimum of 5 to 100 as long as they remain on the displacer Within this range the calibration accuracy will generally increase as the data point separation gets larger Accuracy is also improved by running the procedure at process temperature as the temperature effect on torque rate will be captured It is possible to use theoretical data to pre compensate the measured torque rate for a target process condition when the calibration must be run at ambient conditions An external method of measuring the process condition is required This procedure may be run before or after Capture Zero It adjusts the calculation gain only so the change in PV output will track the change in input correctly af
134. perature Proc Temp Source The source of measurement for Process Temperature Proc Temp Indicates the current Process Temperature Torque Rate Torque rate of the torque tube applied in PV measurements Upper Fluid Density Density of Upper Fluid applied in PV measurements Note Upper Fluid Density is only visible if PV is Interface Lower Fluid Density Density of Lower Fluid applied in PV measurements Note Lower Fluid Density is only visible if PV is Level or Interface 69 Service Tools Instruction Manual October 2014 D102748X012 Maintenance Tests Field Communicator Service Tools gt Maintenance gt Tests 3 3 1 1 LCD Test only visible if LCD Configuration is installed The meter activates all seqments immediately after power up during a digital level controller self test or during a master reset sent by a host supporting HART communications You can also test the meter by selecting Turn Cells On to turn on all display segments including the analog output bar graph or select Turn Cells Off to turn off all display segments When finished with the test press OK to return the meter to normal display mode Loop Test used to verify the controller output the integrity of the loop and the operations of any recorders or similar devices installed in the loop To initiate a loop test perform the following procedure 1 Connect a reference meter to the controller To do so either connect the meter to t
135. placer weight when the liquid is at its lowest level or the displacer is suspended in the liquid with the lower specific gravity 3 After allowing the system to stabilize enter the actual value of the weight suspended on the displacer rod 4 Place a weight on the displacer rod that is approximately equal to that indicated on the prompt The suggested weight is equivalent to the effective displacer weight when the liquid is at its highest level or the displacer is suspended in the liquid with the higher specific gravity 5 After allowing the system to stabilize enter the actual value of the weight suspended on the displacer rod The sensor torque rate is calibrated If the Capture Zero procedure was performed at the zero buoyancy or zero differential buoyancy condition the zero of the PV calculation will be correct also Check the range values before putting the loop in service Theoretical Calibration In cases where it is not possible to manipulate the input at all the user may set up a nominal calibration using information available about the hardware and the process The theoretical torque rate for the installed torque tube may be looked up and compensated for process temperatures This value is then manually entered in the instrument configuration The displacer information and fluid SGs are entered The desired range values are entered manually Finally Trim Zero computes PV to the current value of the process It should be possible to
136. pper range values the digital level controller output signal ranges between 4 and 20 mA is proportional to the input See figure A 6 If the input should exceed the lower and upper range values the output will continue to be proportional to the input until the output reaches either 3 8 or 20 5 mA At this time the output is considered saturated and will remain at this value until the input returns to the normal operating range However should an alarm occur the output is driven to either 3 7 or 22 5 mA depending upon the position of the alarm jumper 96 Instruction Manual Principle of Operation D102748X012 October 2014 Figure A 6 Digital Level Controller Analog Output Signal 24 22 mE MEME SN Ms c Output Saturated 20 5 mA jm E E Output during Alarm with i8 Alarm Jumper in Hi Position 22 5 mA 16 14 Normal Operation 5 12 10 8 Output Saturated 3 8 mA Output during Alarm with 6 Alarm Jumper in Lo Position 4 ae _ ee 2 20 0 20 40 60 80 100 120 PV Range E0379 Note The upper alarm value is compliant with NAMUR NE 43 but the lower alarm value is not If using in a system with NAMUR NE 43 compatibility the high alarm value may be an appropriate choice Other circuits in the digital level controller provide reverse polarity protection transient power surge protection and electromagnetic interference EMI protection 97 Princ
137. priate holes on the Electronics Module 3 Attach the meter to the interconnection pins Thread the long meter screws into the holes on the Electronics Module and tighten to secure the meter 4 Note the position of the alarm jumper on the LCD meter removed from the digital level controller Remove the alarm jumper and install it on the replacement meter in the same position 5 Install the six pin dual header on the LCD meter Carefully insert the LCD meter to mate with the interconnecting pins with the receptacles on the Electronics Module CAUTION To prevent damage to the interconnecting pins when installing the LCD Meter use the guide pins to insert the LCD meter straight onto the Electronics Module without twisting or turning 6 Replace the cover Tighten 1 3 of a revolution after the cover begins to compress the O ring Both instrument covers must be fully engaged to meet explosion proof or flame proof requirements Electronics Module Removing the Electronics Module Perform the following procedure to remove the Electronics Module Note The electronics are sealed in a moisture proof plastic enclosure referred to as the Electronics Module The assembly is a non repairable unit if a malfunction occurs the entire unit must be replaced A WARNING On an explosion proof instrument remove the electrical power before removing the instrument covers in a hazardous area Personal injury or property damage may result from fire and
138. r Sensor Limit 2 2 2 2 1 Write Lock 1 7 3 2 1 Write Lock Setup 1 7 3 2 2 Lower Fluid Density B 4 B 8 B 4 B 5 B 4 B 1 B 1 Lower Range Value 99 aN c er ecd T ui SS BA 1 If PV is Density 2 If PV is Level or Interface 3 LCD Configuration is installed 4 If PV is Level 5 If PV is Interface 100 Instruction Manual D102748X012 Figure B 1 Hot Key Hot Key 1 Write Lock 2 Write Lock Setup 3 Change PV 4 Enter Contstant Density Figure B 2 Overview 1 4 Field Communicator Menu Tree October 2014 Primary Variable Device Status 1 PV Value 1 Refresh Alerts 2 Range 2 No Active Alerts 1 Overview Process Temperature 1 Device Status 2 Comm Status 3 PVis 4 Primary Variable 5 AO 6 Process Temperature 7 Device Information 1 7 Device Information 1 Identification 2 Revisions 3 Alarm Type and Security 1 7 3 i Alarm Type and Security 1 7 2 1 esr alam Types 2 3 1 Alarm Type 2 Security 1 Alarm Jumper A 5 2 Display Alert Saturation Level 1 7 3 2 Security 1 Write Lock 2 Write Lock Setup Figure B 3 Configure Guided Setup 2 Configure s 1 Guided Setup ___________ _ Guided Setup 2 Manual Setup 1 Instrument Setup 3 Alert Setup 4 Communications 5 Calibration 1 Proc Temp Source 2 Proc Temp Identification HART Tag Distributor Model Device ID Instrument Serial Numb
139. rature Low Alert Threshold A Process Temperature Too High When active indicates that the Process Temperature has exceeded the value of the Process Temperature High Alert Threshold A PV LoLo Alert When active indicates that the Process Variable has exceeded the value of the Process Variable Low Low Alert Threshold Analog Output set to jumper selected alarm current A PV Lo Alert When active indicates that the Process Variable has exceeded the value of the Process Variable Low Alert Threshold 67 Service Tools Instruction Manual October 2014 D102748X012 e A PV HiHi Alert When active indicates that the Process Variable has exceeded the value of the Process Variable High High Alert Threshold Analog Output set to jumper selected alarm current A PV Hi Alert When active indicates that the Process Variable has exceeded the value of the Process Variable High Alert Threshold A PV Out of Limits Primary Variable value is beyond its operating limit Variables Field Communicator Service Tools Variables 3 2 Follow the prompts on the Field Communicator display to view the following analog output variables PV is Indicates the type of measurement either level interface the interface of two liquids of different specific gravities or density measures the liquid specific gravity The process variable displayed and measured depends on the entry for PV is under PV Setup Primary Variable
140. rature as measured by the instrument You can then trim the temperature reading so that it matches the actual temperature more closely in the region of interest This is an offset adjustment only There is no ability to change the gain This calibration is initially performed at the factory Performing it in the field requires an accurate independent measurement of the instrument housing temperature or process temperature as appropriate The instrument should be at a steady state condition with respect to that temperature when performing the procedure Note The effectiveness of the instrument electronic temperature compensation depends upon the accuracy of the electronics temperature offset stored in the NVM non volatile memory If the electronics temperature is incorrect the temperature curve applied to the magnets and Hall sensor will be misaligned resulting in over or under compensation 58 Instruction Manual Configuration D102748X012 October 2014 Trim Instrument Temperature Follow the prompts on the Field Communicator to trim the instrument temperature Trim Process Temperature Trim Process Temperature is available if the Process Temperature Source is not Manual Follow the prompts on the Field Communicator to trim the process temperature Manual Entry of Process Temperature Field Communicator Configure gt Manual Setup gt Process Fluid gt Process Temperature gt Change Proc Temp 2 2 3 2 2 If a process temperature
141. rcuits 14 Remove terminal box from the instrument and apply 24 Volts between Loop and Loop terminals with a fixe Outputs 22 9 mA series resistance of approximately 1200 Ohms to protect power supply If any current flows replace terminal box Electronics Module See item 5 above Output is within 4 20 mA range but does not track displayed PV value e g a gain error b low saturation occurs at a value higher than 3 8 mA C high saturation occurs at a value lower than 20 5 mA Connect the Field Communicator and 15 Run Loop diagnostic test 3 3 1 1 3 3 1 2 if LCD Configuration is installed If the forced output does not track commands attempt Scaled D A Trim procedure 2 5 2 2 1 If D A calibration cannot be restored replace Electronics Module Electronics Module 16 Checktorque tube spring rate change versus process temperature per figure 1 2 Use appropriate material for Sensor um process temperature Pre compensatethe calibration fortarget process condition Connect the Field Communicator and 17 Check Instrument Temperature 3 2 4 against an independent measurement of DLC3010 temperature Transducer Module a lfinaccurate trim the instrument temperature measurement 2 5 2 1 1 to improve ambient temperature compensation performance Output Drifting while at b If Instrument Temperature value is extreme replace transducer module fixed process input Connect the Field Com
142. re Communications 2 Configure 1 Guided Setup 2 Manual Setup 3 Alert Setup 2 4 4 Communications 3 Communications 5 Calibration 1 Burst Mode 2 Burst Options 103 Field Communicator Menu Tree October 2014 Figure B 7 Configure gt Calibration 2 Configure 1 Guided Setup 2 Manual Setup 3 Alert Setup 4 Communications 5 Calibration Secondary 1 Temperature Calibration t _ Temperature Calibration 2 Analog Output Calibration Analog Output Calibration Calibration Primary Primary 1 2 Secondary Instruction Manual D102748X012 2 5 1 2 Full Calibration 1 Min Max Calibration 2 5 1 3 Weight Calibration 1 Guided Calibration 2 5 1 3 2 Full Calibration x 3 Partial Calibration Partial Calibration 1 Capture Zero 2 Trim Gain 2 5 2 2 5 2 1 3 Trim Zero 1 Trim Instrument Temperature 2 Trim Processs Temperature 2 5 2 2 Visible if Process Temperature is not Manual 1 Scaled D A Trim Figure B 8 Service Tools 3 Service Tools 1 Active Alerts 2 Variables 3 Maintenance 3 3 Maintenance p 1 Tests 2 Reset Restore 3 3 1 Tests 1 LCD Test 2 Loop Test Reset Restore Mee 1 Restore Factory Defaults 2 Reset Device 3 3 2 1 Restore Factory Defaults 1 Restore Factory Configuration 2 Restore Factory Compensation 1 LCD Test is visible if LCD Configuration is installed 104 If PV is Level
143. riable rises above the PV Lo Lo Alert limit Once the alert is set the primary variable must fall below the PV Lo Lo Alert limit by the PV Alerts Threshold Deadband before the alert is cleared See figure 4 7 PV LoLo Alert Threshold Primary Variable LoLo Alert Threshold is the value of the primary variable in engineering units which when exceeded sets the Primary Variable Low Low Alert PV LoLo Alert Threshold Method to change the PV Lo Lo Alert Threshold Note If the Lo Lo Alert is enabled and set the digital level controller output will go to below 3 75 mA or above 21 0 mA depending on the position of the alarm jumper PV Value Current process variable level interface or density in engineering units Upper Range Value Highest value of the primary variable that the digital level controller is currently configured to measure in the 4 to 20 mA loop Lower Range Value Lowest value of the primary variable that the digital level controller is currently configured to measure in the 4 to 20 mA loop PV Alerts Threshold Deadband The Primary Variable Alerts Threshold Deadband is the amount the primary variable in engineering units must change to clear a primary variable alert once it has been set The deadband applies to all the primary variable alarms See figure 4 7 Figure 4 7 Process Variable Alert Threshold Deadband Process Variable High Alert Example ALERT IS SET PROCESS VARIABLE HIGH ALERT L
144. ric Consisting of letters and numbers ANSI acronym The acronym ANSI stands for the American National Standards Institute Burst Burst mode is an extension to HART protocol that provides the continuous transmission of standard HART command response by a field device Byte A unit of binary digits bits A byte consists of eight bits Commissioning Functions performed with a Field Communicator and the digital level controller to test the instrument and loop and verify digital level controller configuration data Configuration Stored instructions and operating parameters for a FIELDVUE Instrument Glossary October 2014 Control Loop An arrangement of physical and electronic components for process control The electronic components of the loop continuously measure one or more aspects of the process then alter those aspects as necessary to achieve a desired process condition A simple control loop measures only one variable More sophisticated control loops measure many variables and maintain specified relationships among those variables Damping Output function that increases the time constant of the digital level controller output to smooth the output when there are rapid input variations Descriptor Sixteen character field for additional identification of the digital level controller its use or location The descriptor is stored in the instrument and can be changed using a Field Communicator and the device inform
145. rm Jumper 25 31 Changing Position 25 Alarm Type 31 alarm variables default values 36 Alert Setup 49 Primary Variable 49 Temperature 51 Ambient Temperature Operative 249 10 AMS Suite Intelligent Device Manager 3 Analog Output Calibration 59 Analog Output Signal Digital Level Controller 97 AO 29 Service Tools Variables 69 Assembly LCD Meter 76 ATEX approved units 22 25 Available Configurations 6 B Bell 202 communication standard 93 BLANK Diagnostic Message 71 Burst 29 Burst Mode Communications 53 Burst Operation 28 Burst Option Communications 53 Burst Variables 28 53 Index October 2014 C Calibration Analog Output 59 Full 55 Guided 54 Min Max 55 Partial 57 Capture Zero 57 Trim Gain 57 Trim Zero 58 Scaled D A Trim 59 Temperature 58 Theoretical 56 Trim Instrument Temperature 59 Trim Process Temperature 59 Two Point 55 Weight 56 Calibration 54 Calibration Examples 60 Density Applications with Standard Displacer and Torque Tube 63 Sensor Calibration at Process Conditions Hot Cut Over when input cannot be varied 63 with an Overweight Displacer 61 with Standard Displacer and Torque Tube 60 Capture Zero Calibration Partial 57 Change Display Mode 47 Change Proc Temp Source process temperature 46 Change PV 41 Classifications Certifications 7 FSETAN 7 GOST R 7 INMETRO 7 NEPSI 7 PESO CCOE 7 TIIS 7 Comm Status
146. rocess variable displayed and measured depends on the entry for PV is under PV Setup Primary Variable PV Value displays the process variable level interface or density in engineering units Range displays the process variable as a percent of span determined by the LRV and AO Indicates the current analog output value of the instrument in milliamperes 29 Overview Instruction Manual October 2014 D102748X012 Process Temperature Proc Temp Source Manual or RTD Proc Temp indicates the process temperature Device Information Identification Follow the prompts on the Field Communicator display to view the following information e HART Tag a unique name up to eight characters that identifies the physical instrument e Distributor identifies the distributor of the instrument e Model identifies the instrument model ie DLC3010 e Device ID each instrument has a unique Device Identifier The Device ID provides additional security to prevent this instrument from accepting commands meant for other instruments e Date user defined variable that provides a place to save the date of the last revision of configuration or calibration information e Descriptor a longer user defined electronic label to assist with more specific controller identification that is available with the HART tag e Message user defined means for identifying individual controllers in multi controller environmen
147. roller ships from the factory mounted on a 249 sensor initial setup and calibration is not necessary The factory enters the sensor data couples the instrument to the sensor and calibrates the instrument and sensor combination Note If you received the digital level controller mounted on the sensor with the displacer blocked or if the displacer is not connected the instrument will be coupled to the sensor and the lever assembly unlocked To place the unit in service if the displacer is blocked remove the rod and block at each end of the displacer and check the instrument calibration If the factory cal option was ordered the instrument will be precompensated to the process conditions provided on the requisition and will not appear to be calibrated if checked against room temperature 0 and 100 water level inputs If the displacer is not connected hang the displacer on the torque tube and re zero the instrument by performing the Capture Zero procedure If you received the digital level controller mounted on the sensor and the displacer is not blocked such as in skid mounted systems the instrument will not be coupled to the sensor and the lever assembly will be locked To place the unit in service couple the instrument to the sensor then unlock the lever assembly You may then perform the Capture Zero procedure To review the configuration data entered by the factory connect the instrument to a 24 VDC power supply as shown in figur
148. s Temperature Low Alert is set if the process variable temperature rises above the Process Temperature Low Alert Threshold Once the alert is set the process variable temperature must fall below the Process Temperature Low Alert Threshold by the Temperature Deadband before the Alert is cleared See figure 4 8 51 Configuration October 2014 Instruction Manual D102748X012 Proc Temp Lo Alert Threshold Process Temperature Low Alert Threshold is the process variable temperature in temperature units which when exceeded will set the Temperature Low Alert e Proc Temp Displays the process temperature stored in the instrument e Proc Temp Offset Bias to improve the accuracy of the RTD temperature measurement used to provide compensation for process temperature related density changes e Temperature Deadband The Temperature Deadband is the amount the temperature in temperature units must change to clear a temperature alert once it has been set The deadband applies to all the temperature alerts See figure 4 8 In firmware revision 8 the Temp Alert Offset is displayed incorrectly when the units are DegF The number displayed is 32 more than the actual deadband Figure 4 8 Process Temperature Alert Threshold Deadband Temperature High Alert Example ALERT IS SET PROCESS TEMPERATURE HIGH ALERM LIMIT EEE ___ PROCESS TEMPERATURE ALERT THRESHOLD DEADBAND TEMPERATURE ALERT IS CLEARED E037
149. sensor RTD is not installed itis possible to manually set the Digital Process Temperature variable to the target process temperature This value will be used by any SG compensation tables that the user has entered If no compensation tables are active the Digital Process Temperature value may be used to document the process temperature at which the instrument was calibrated or the process temperature for which the stored torque rate is pre compensated Follow the prompts on the Field Communicator to edit the Digital Proc Temp Analog Output Calibration Scaled D A Trim Field Communicator Configure gt Calibration gt Secondary gt Analog Output Calibration gt Scaled D A Trim 2 5 2 2 This procedure allows trimming the gain and offset of the Digital to Analog D A converter to adjust the accuracy at which the output follows 4 to 20 mA current commands from the firmware This relationship is initially set in the factory and should not require frequent user adjustment Reasons for using this procedure include e Correction for component aging after the instrument has been in service for an extended period e Adjusting D A calibration to be optimum at the normal operating temperature when that temperature is considerably removed from room temperature conditions The procedure is iterative and will eventually reach a resolution limit where attempts to improve the result will cycle at a few decimal places to either side of the target F
150. t Enable 51 Inst Temp Hi Alert Threshold 51 Inst Temp Lo Alert Enable 51 Inst Temp Lo Alert Threshold 51 Inst Temp Offset 51 Installation 13 249 Sensor 15 DLC3010 on 249 Sensor 18 Electrical 20 Field Wiring 21 Heat Insulator 18 Multichannel 24 Power Current Loop Connections 23 RTD Connections 23 Installation Flowchart 14 Instrument Display Manual Setup 47 Instrument Mounting Specifying 40 Instrument Serial Number 47 Instrument Temperature Alert Setup 51 Service Tools Variables 69 Instrument Temperature Offset 54 Interface Applications Density Variations in 65 interface level applications 37 intrinsic safety and multidrop installations 93 intrinsically safe applications 21 111 Index October 2014 L LCD Configuration Instrument Display 47 LCD meter 17 94 Assembly 76 Diagnostic Messages 1 BLANK 71 FAIL HDWR 72 OFLOW 72 removing 77 Replacing 77 LCD Meter Indications 7 LCD Test Maintenance 70 Length Units Sensor 39 level measurement applications 37 Level Offset 34 41 54 Level Signature Series Test 8 Lever Assembly Removing 81 Replacing 82 Lever Lock 13 lift off voltage 20 Lo Alert 49 Instrument Temperature 51 Process Temperature 51 Lo Lo Alert 50 Load Steam Tables process fluid 45 loop connection terminals 96 loop interface 94 Loop Test 26 Maintenance 70 Lower Density Table 43 Lower Fluid Density process fl
151. t Setup 1 Primary Variable 2 Temperature 2 3 2 Temperature 2 1 Instrument Temperature 2 Process Temperature 2 3 2 2 Process Temperature 1 Hi Alert 2 Lo Alert 3 Proc Temp 4 Proc Temp Offset Lo Alert 1 Proc Temp Lo Alert Enable 2 Proc Temp Lo Alert Threshold Primary Variable Primary Variable Hi 1 Primary Variable Hi 1 Hi Alert 2 3 2 Primary Variable Lo 2 HiHi Alert HiHi Alert 3 Upper Range Value 4 Lower Range Value 5 PV Alerts Threshold Deadband J 2 3 2 1 2 3 2 2 1 Field Communicator Menu Tree October 2014 2 3 1 1 1 Hi Alert 1 PV Hi Alert Enable 2 PV Hi Alert Threshold 3 PVHi Alert Threshold Method 2 3 1 1 2 2 3 1 1 1 PV HiHi Alert Enable 2 PV HiHi Alert Threshold 3 PV HiHi Alert Threshold Method 2 3 1 2 Primary Variable Lo 2 3 1 2 1 1 Lo Alert Lo Alert 2 LoLo Alert 1 PV Lo Alert Enable 2 PV Lo Alert Threshold Instrument Temperature 3 PV Lo Alert Threshold Method 1 Hi Alert 2 Lo Alert 2 3 1 2 2 3 Inst Temp LoLo Alert 4 Inst Temp Offset 1 PV LoLo Alert Enable 2 PV LoLo Alert Threshold 3 PV LoLo Alert Threshold Method Lo Alert 1 Inst Temp Lo Alert Enable 2 3 2 1 1 2 Inst Temp Lo Alert Threshold Hi Alert 1 Inst Temp Hi Alert Enable 2 Inst Temp Hi Alert Threshold Hi Alert 1 Proc Temp Hi Alert Enable 2 Proc Temp Hi Alert Threshold Figure B 6 Field Communicator Menu Tree Configu
152. t be accurate 4 With the torque tube type and material information find a theoretical value for the composite or effective torque tube rate Refer to the Entering Theoretical Torque Tube TT Rates procedure in this section and enter it in the instrument memory The value can be accessed by selecting Configure gt Manual Setup gt Sensor gt Torque Tube gt Change Torque Rate 2 2 1 3 2 5 If the process temperature departs significantly from room temperature use a correction factor interpolated from tables of theoretical normalized modulus of rigidity Multiply the theoretical rate by the correction factor before entering the data You should now have the gain correct to within perhaps 10 at least for the standard wall short length torque tubes For the longer torque tubes 249K L N with thin wall and a heat insulator extension the theoretical values are much less accurate as the mechanical path departs considerably from the linear theory Note Tables containing information on temperature effects on torque tubes can be found in the Simulation of Process Conditions for Calibration of Fisher Level Controllers and Transmitters instruction manual supplement D103066X012 available from your Emerson Process Management sales office or at www fisher com 6 Now using a sight glass or sampling ports obtain an estimate of the current process condition Run the Trim Zero calibration and report the value of the actual process in the
153. table After entering the temperature for the first pair press ENTER Enter the specific gravity for the first pair and press ENTER The Field Communicator then prompts for the temperature for the second pair Enter this temperature and press ENTER The Field Communicator then prompts for the specific gravity for the second pair Continue entering each temperature and specific gravity pair When finished enter zero at the Field Communicator prompt for the next specific gravity value to exit the table For level applications the Field Communicator exits to the Instrument Setup menu For interface applications the Field Communicator prompts for the first temperature and specific gravity pair for the upper table Enter Constant Density Enter the density of the process fluid Measure Density Select OK to measure the differential density between lower and upper phases of the process fluid Note Measure Density is only visible if PV is Level If the instrument and sensor are calibrated you can have the digital level controller measure the liquid specific gravity if itis not known You must be able to manipulate the level and externally measure it to have the instrument measure the specific gravity To work properly this procedure must be in done in Level measurement mode and a valid dry coupling reference must have been obtained at the zero buoyance condition Use as high a test level as possible to improve accuracy Follow the prompts on the Fie
154. ter this procedure However there may be a constant bias in the PV until the Capture Zero procedure has been run Follow the prompts on the Field Communicator to calibrate the sensor 1 Put the control loop in manual control 2 Adjust the process condition to a value near the top or bottom of the valid range 3 Enter this externally measured process condition in the current PV units 4 Adjust the process condition to a value near the bottom or top of the valid range but at a position that is toward the opposite end of the range relative to the condition used in step 2 5 Enter this second externally measured process condition in the current PV units 55 Configuration Instruction Manual October 2014 D102748X012 The sensor torque rate is now calibrated Be sure to verify that there is no bias in the PV calculation and that the upper and lower range values are correct before returning the loop to automatic control Weight Calibration This procedure may be used on the bench or with a calibration jig that is capable of applying a mechanical force to the driver rod to simulate displacer buoyancy changes It allows the instrument and sensor to be calibrated using equivalent weights or force inputs instead of using the actual displacer buoyancy changes If the displacer information has been entered prior to beginning the procedure the instrument will be able to compute reasonable weight value suggestions for the calibration However the
155. th Heat Insulator 249 Sensors with Heat Insulator 57 Heat Insulator S30400 figu re 7 5 58 Shaft Extension 531600 57 Heat Insulator 530400 59 Shaft Coupling 30300 58 Shaft Extension NO5500 60 Set Screw hex socket SST 2 req d 59 Shaft Coupling 30300 61 Screw hex hd SST 4 req d 60 Set Screw hex socket SST 2 req d 62 Mounting Adapter A03560 61 Screw hex hd SST 4 req d 63 Screw hex socket steel 4 req d 78 Washer plain 4 req d 78 Washer plain 4 req d 89 Parts October 2014 Instruction Manual D102748X012 Figure 7 6 Mounting Kit for Masoneilan 12200 and 12300 Sensor without Heat Insulator 29B8444 A Figure 7 7 Mounting Kit for Masoneilan 12200 and 12300 Sensor with Heat Insulator 29B8445 A Key Description 12200 or 12300 without Heat Insulator 58 Shaft Extension N05500 59 Shaft Coupling 30300 60 Hex Socket Screw 2 req d 62 Mounting Adaptor A92024 74 Hex Nut SST 4 req d 75 Hex Cap Screw SST 4 req d 90 Key Description 12200 or 12300 with Heat Insulator 57 58 59 61 60 62 74 75 78 Heat Insulator 530400 Shaft Extension 31600 Shaft Coupling 30300 Hex Cap Screw SST 4 req d Hex Socket Screw 2 req d Mounting Adaptor A92024 Hex Nut SST 4 req d Hex Cap Screw SST 4 req d Washer plain 4 req d not shown Instruction Manual D102748X012 Key Description Yamatake NQP Sensor Without Heat Insulator 58 Shaft Extens
156. ts Revisions Follow the prompts on the Field Communicator display to view revision information e HART Universal Revision the revision number of the HART Universal Commands which are used as the communications protocol for the instrument e Field Device Revision the revision of the protocol for interfacing to the functionality of the instrument e Firmware Revision the revision number of the Fisher software in the instrument e Hardware Revision the revision number of the Fisher instrument hardware e DD Information the revision level of the Device Description used by the Field Communicator while communicating with the instrument 30 Instruction Manual Overview D102748X012 October 2014 Alarm Type and Security Alarm Type e Alarm Jumper displays the position of the hardware alarm jumper either high current or low current e Display Alert Saturation Level Security e Write Lock e Write Lock Setup To setup and calibrate the instrument write lock must be set to Writes Enabled Write Lock is reset by a power cycle If you have just powered up the instrument Writes will be enabled by default In AMS go to Device Information in the Overview page Select the Alarms tab to change the write lock 31 Overview October 2014 32 Instruction Manual D102748X012 Instruction Manual Configuration D102748X012 October 2014 Section 4 Configuration and Calibration Initial Setup If a DLC3010 digital level cont
157. uid 43 Service Tools Variables 69 Lower Range Value primary variable 42 50 Lower Sensor Limit 42 LRV Lower Range Value 54 112 Instruction Manual D102748X012 M Maintenance Device Status 29 removing the DLC3010 from a 249 sensor high temperature application 76 standard temperature application 75 Reset Restore 70 Service Tools 70 Tests 70 LCD 70 Loop 70 Maintenance amp Troubleshooting 71 Manual Setup 39 Device Information 46 Instrument Display 47 Materials 249 10 Process Temperature 10 Displacer and Torque Tube 10 Measure Density 65 process fluid 45 Mechanical Gain excessive 65 Message 30 Device Information 47 microprocessor 94 Min Max Calibration 55 Minimum Differential Specific Gravity DLC3010 7 8 Minimum Span sensor limits 42 Model 30 Model 375 Field Communicator 3 modems Bell 202 93 moment arm 34 Moment Arm Driver Rod Length 35 Mounting 249 Sensor 15 Digital Level Controller Orientation 17 DLC3010 15 On 249 Sensor 18 Typical Caged Sensor 16 Typical Cageless Sensor 16 Mounting Kits 85 Mounting Parts 89 Mounting Positions 249 Series 10 DLC3010 8 typical DLC3010 digital level controller on 249 sensor 17 Multichannel Installations 24 Instruction Manual D102748X012 multidrop communication activating 94 Principle of Operation 93 Multidrop installations intrinsic safety 93 Multidropped Communication Typ
158. using 7 Electromagnetic Compatibility 7 electromagnetic interference EMI protection 97 electronics encapsulated 25 Electronics Module Removing 78 Replacing 78 EMI filters 96 EN 61326 1 7 EN 61326 2 3 7 Enter Constant Density process fluid 45 Equalizing Connections 12 F FAIL HDWR Diagnostic Message 72 Failed Device Status 29 Fast Key Sequence 99 Field Communicator Menu Tree 99 Field Device Revision 30 Instruction Manual D102748X012 Field Wiring 21 Final Assembly Number 47 Firmware Revision 30 Flexures protecting 13 FSETAN 7 Full Calibration 55 G Good Device Status 29 GOST R 7 ground strap 22 Grounding 22 Shielded Wire 22 Guided Calibration 54 Guided Setup 34 H Hall sensor 96 Hardware Diagnostics 72 Hardware Revision 30 HART Communication 7 Principle of Operation 93 HART protocol 93 HART Tag 30 46 Device Information 46 HART Universal Revision 30 Hazardous Area Classifications 15 Heat Insulator Installation 18 Hi Alert 49 Instrument Temperature 51 Process Temperature 51 Hi Hi Alert 49 High High Alarm 49 High Temperature Applications 18 Hysteresis 6 Hysteresis plus Deadband 6 Index October 2014 Immunity Performance 8 Independent Linearity 6 Initial Setup 33 INMETRO 7 Inner Guide and Access Handle Assembly Removing and Replacing 80 Input Signal 249 10 DLC3010 6 Inst Temp 51 Inst Temp Hi Aler
159. vel controller for use with a HART Tri Loop perform the following procedure Table 2 1 Burst Variables Sent by the FIELDVUE DLC3010 1 EU engineering units mA current in milliamperes percent Set the Burst Operation Field Communicator Configure gt Communications gt Burst Option 2 4 2 1 Access Burst Option 2 Select the desired burst option and press ENTER 3 Access Burst Mode and select On to enable burst mode Press ENTER 4 Select SEND to download the new configuration information to the digital level controller 28 Instruction Manual Overview D102748X012 October 2014 Section 3 Overview Overview Overview 1 Device Status Good there are no active alerts and instrument is In Service Failed a failed alert is active Maintenance aconfigured maintenance alert is active and a failed alert is turned on Advisory a configured advisory alert is active and configured failed or a maintenance alert is turned on Comm Status Polled communication with Digital Level Controller is established Burst mode is turned off Burst provides continuous communication from the digital level controller Burst mode applies only to the transmission of burst mode data and does not affect the way other data is accessed PV is Indicates the type of measurement either level interface the interface of two liquids of different specific gravities or density measures the liquid specific gravity The p
160. w 3 70 mA or above 22 5 mA depending on the position HI LO of the alarm jumper An alarm condition occurs when the digital level controller self diagnostics detect an error that would render the process variable measurement inaccurate incorrect or undefined or a user defined threshold is violated At this point the analog output of the unit is driven to a defined level either above or below the nominal 4 20 mA range based on the position of the alarm jumper On encapsulated electronics 14B5483X042 and earlier if the jumper is missing the alarm is indeterminate but usually behaves as a FAIL LOW selection On encapsulated electronics 14B5483X052 and later the behavior will default to FAIL HIGH when the jumper is missing Alarm Jumper Locations Without a meter installed The alarm jumper is located on the front side of the electronics module on the electronics side of the digital level controller housing and is labeled FAIL MODE With a meter installed The alarm jumper is located on the LCD faceplate on the electronics module side of the digital level controller housing and is labeled FAIL MODE Changing Jumper Position A WARNING Personal injury or property damage caused by fire or explosion may occur if the following procedure is attempted in an area which contains a potentially explosive atmosphere or has been classified as hazardous Confirm that area classification and atmosphere conditions permit the safe removal of the i
161. wer supply If you choose to connect the HART communicating device directly to the instrument attach the device to the loop and terminals inside the terminal box to provide local communications with the instrument Test Connections A WARNING Personal injury or property damage caused by fire or explosion may occur if the following procedure is attempted in an area which contains a potentially explosive atmosphere or has been classified as hazardous Confirm that area classification and atmosphere conditions permit the safe removal of the terminal box cap before proceeding Installation Instruction Manual October 2014 D102748X012 Test connections inside the terminal box can be used to measure loop current across an internal 1 ohm resistor 1 Remove the terminal box cap 2 Adjust the test meter to measure a range of 0 001 to 0 1 volts 3 Connect the positive lead of the test meter to the connection and the negative lead to the T connection inside the terminal box 4 Measure Loop current as Voltage on test meter x 1000 milliamps example Test meter Voltage X 1000 Loop Milliamps 0 004 X1000 4 0 milliamperes 0 020 X 1000 20 0 milliamperes 5 Remove test leads and replace the terminal box cover Multichannel Installations You can connect several instruments to a single master power supply as shown in figure 2 12 In this case the system may be grounded only at the negative power supply terminal In multichannel
162. www fisher com Following are some guidelines on the use of the various sensor calibration methods when the application uses an overweight displacer Weight based Use two accurately known weights between minimum and maximum buoyancy conditions The full displacer weight is invalid because it will put the unit on a stop Min Max Min now means submerged in the lightest fluid and Max means submerged in the heaviest fluid Two point Use any two interface levels that actually fall on the displacer Accuracy is better if the levels are farther apart The result should be close if you can move the level even 1026 Theoretical If the level cannot be changed at all you can enter a theoretical value for torque tube rate manually In this case you would not be able to Capture Zero at the 025 interface condition 62 Instruction Manual Configuration D102748X012 October 2014 Density Applications with Standard Displacer and Torque Tube Note When you change PV is from level or interface to density the range values will be initialized to 0 1 and 1 0 SGU You may edit the range values according to the specify gravity unit It is necessary to back out of Manual Setup and re enter the Manual Setup menu to see the changes being refreshed If the displacer is overweight there is no way to get the output numerically correct in density mode because the Level Offset is not available Therefore density calibration normally has to begin with the assu
163. y an individual entry or enter a new table manually For an interface application the user can switch between the upper and lower fluid tables Note In firmware version 07 and 08 the data tables for torque tube correction are simply stored without implementation The information may be used to pre compensate the measured torque tube rate manually 37 Configuration Instruction Manual October 2014 D102748X012 Coupling If the digital level controller is not already coupled to the sensor perform the following procedure to couple the digital level controller to the sensor 1 Slide the access handle to the locked position to expose the access hole Press on the back of the handle as shown in figure 2 4 then slide the handle toward the front of the unit Be sure the locking handle drops into the detent 2 Setthe displacer to the lowest possible process condition i e lowest water level or minimum specific gravity or replace the displacer by the heaviest calibration weight Note Interface or density applications with displacer torque tube sized for a small total change in specific gravity are designed to be operated with the displacer always submerged In these applications the torque rod is sometimes resting on a stop while the displacer is dry The torque tube does not begin to move until a considerable amount of liquid has covered the displacer In this case couple with the displacer submerged in the fluid with the lowest density an
164. y of multidropping networking several devices to a single communications line This process is well suited for monitoring remote applications such as pipelines custody transfer sites and tank farms Multidrop Communication Multidropping refers to the connection of several digital level controllers or transmitters to a single communications transmission line Communication between the host and the field instruments takes place digitally with the analog output of the instruments deactivated With the HART communications protocol up to 15 field instruments can be connected on a single twisted pair of wires or over leased phone lines Multidrop installations are not recommended where intrinsic safety is a requirement The application of a multidrop installation requires consideration of the update rate necessary from each instrument the combination of instrument models and the length of the transmission line Communication with the field instruments can be accomplished with commercially available Bell 202 modems and a host implementing the HART protocol Each instrument is identified by a unique address 1 15 and responds to the commands defined in the HART protocol Figure A 2 shows a typical multidrop network Do not use this figure as an installation diagram Contact your Emerson Process Management sales office with specific requirements for multidrop applications 93 Principle of Operation Instruction Manual October 2014 D102748X012
165. ys need to be slightly more because of the displacer motion Because of this inconvenience and the extra work of draining and flooding with two fluids the two point calibration method is probably the least attractive in density mode Note These calibration methods advise you to trim zero for better accuracy That command is not available in density mode Sensor Calibration at Process Conditions Hot Cut Over when input cannot be varied If the input to the sensor cannot be varied for calibration you can configure the instrument gain using theoretical information and use Trim Zero to trim the output to the current process condition This allows you to make the controller operational and to control a level around a setpoint You can then use comparisons of input changes to output changes over time to refine the gain estimate A new trim zero will be required after each gain adjustment This approach is not recommended for a safety related application where exact knowledge of the level is important to prevent an overflow or dry sump condition However it should be more than adequate for the average level control application that can tolerate large excursions from a midspan set point There are a number of calibration methods available in the DLC3010 Device Description Two Point Calibration allows you to calibrate the torque tube using two input conditions that put the measured interface anywhere on the displacer The accuracy of the method increases

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