Doc. No.

: 00-59203 Issued: 30 NOV 96 Revised: 20 SEPT 10 Approved: ECO Number: EC-00265

MODEL 592 CABLE SUSPENDED LEVEL TRANSMITTER

INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS WITH PARTS LIST AND RECOMMENDED SPARES LIST

TYPE NO: SERIAL NO(S):

CUSTOMER:

CUSTOMER PURCHASE ORDER NO: TAG NO(S):

CALIBRATED RANGE:

OTHER:

RECOMMENDED SPARE PARTS

MODEL NUMBERING SYSTEM

BASIC TYPE TYPE NOSE RANGE & HOUSING FEET OF SENSOR - & RATING - CABLE - OPTIONS

MODEL EXAMPLE

592Y

CN

G4Y

4X

40V

SCI

M/N 592Y 592Z

BODY MATERIAL 316 SS OTHER

M/N AA SU RC SCI NONE

DESCRIPTION

4.0 mA ADJUSTABLE UP TO 30% OF RANGE ABOVE SENSOR 20-4 mADC REVERSE CALIBRATION INTEGRAL VENT TUBE ISOLATION BLADDER; PERMANENT, NO REFILLING OR MAINTENANCE CONVENTIONAL REFILLABLE DESSICANT DRYER FOR VENT TUBE, FOR MOUNTING IN ENCLOSURE BY OTHERS DIRECT READING LCD DISPLAY TANK PRESSURE CORRECTOR, SELECT AND PRICE FROM TPC PRICE LIST AND ADD $ SHOWN THERE 4-20 mA LIQUID TEMPERATURE

M/N

DESCRIPTION

DDI

CN CONICAL, BASIC SN PERFORATED, SLUDGE REPLACE N WITH Y FOR 316 SS AND ADD $50.

328 TPC LT

M/N* G1 Y G2 Y G3 Y G4 Y G5 Y G6 Y

FULL SCALE RANGE (H2O) FEET METERS 3.5 1.0 7.0 2.0 17.5 5.0 35.0 10.0 70.0 20.0 125.0 40.0

CCY 316 SS CABLE CLAMP WITH A CONDUIT CONNECTION INSTEAD OF NYLON TOP STRAIN RELIEF PSM 2 PIPE STAND HOUSING MOUNTING BRACKET (ALSO REQUIRED FOR SURFACE MOUNTING 7W & 7T) VBKT CABLE CLAMP SUPPORT ARM FOR VERTICAL WALL, STEEL HBKT DITTO, EXCEPT HORIZONTAL LEDGE KZ KALREZ SEALS ZA OTHER CONFIGURATIONS BASIC HOUSING MATERIAL IS PVC FOR 4X, AND ALUMINUM FOR 7W

G7 Y 250.0 80.0 C/F FOR HIGHER RANGES * Y = 316L SS FACE AND SHELL IS BASIC, G = HASTELLOY C (OPTIONAL)

M/N DESCRIPTION ENVIRONMENT PROOF; 4X; PVC CONSTRUCTION; SS TRIM; 4X INTRINSICALLY SAFE, CLASSES 1 & 2, DIVISION 1 & 2, GROUPS ABCD,EFG EXPLOSION PROOF; CLASSES 1 & 2; DIVISIONS 1 & 2; GROUPS 7W BCD,EFG; 4X; ALUMINUM CONSTRUCTION EXPROOF, SAME AS ABOVE 7T EXCEPT ALL 300 STAINLESS STEEL CONSTRUCTION

M/N DESCRIPTION * V PVC OUTER JACKET * R TEFZEL OUTER JACKET REPLACE * WITH NUMBER OF FEET REQUIRED, 3/4 NPT NYLON SUPPORT PROVIDED. C/F IF LENGTH IS OVER 2500 FEET (750 M).

1 Figure 1 Model 592 Model Numbering System

DELTA CONTROLS CORPORATION

MODEL 592 CABLE SUSPENDED LEVEL TRANSMITTER DESCRIPTION
The Model 592 is a pressure transmitter designed to measure liquid level in tanks, wells, reservoirs, and pump pits. The small diameter sensor is easy to install in well casings or open pit stilling wells (used when agitation is present). Both the submerged sensor and remote electronics module are sealed for rugged industrial field operation. This extra protection results in very high reliability and long life. The sensor is isolated from the fluid by an oil filled diaphragm. The body is electrically isolated for immunity from circulating ground currents and electrical noise. This instrument is equipped with electrical spark and voltage suppressors. The Model 592 is intrinsically safe when used in an intrinsically safe signal loop.

CABLE TRANSITION

BODY

THEORY OF OPERATION

0.85"

A silicon diaphragm is doped to produce a strain gauge bridge. The pressure to be sensed is applied to one side of this silicon diaphragm. NOSE This flexes the diaphragm a minute amount, which causes a resistive unbalance in the bridge. This change, which is linearly proportional to Figure 2 Model 592 Sensor Assembly the amount of pressure applied, is sensed by an electronics network. The network produces a 4.0 - 20.0 mADC signal proportional to the change and therefore, to the applied pressure. Diaphragm thickness determines the basic range of the instrument, while Zero and Span adjustments in the electronics network allow calibration within the basic range.

USING PRESSURE TO MEASURE LIQUID LEVEL

The difference in pressure between the surface of a liquid and a submerged point near the bottom of the liquid is directly proportional to the density and the depth of the liquid. If the density of the liquid remains constant, the pressure at the bottom of a vessel provides an accurate indication of the level of liquid in the vessel. If the density of the liquid increases, and the level remains constant, then the pressure at the bottom of the vessel will increase proportionally to the increase in density of the liquid. The front of the sensor is exposed to the liquid pressure at the bottom of the liquid. The back of the sensor is exposed to atmospheric pressure. If the container is open, then the surface of the liquid is also exposed to atmospheric pressure and the net pressure sensed is due only to the liquid level in the tank. If the tank is pressurized, the gas space pressure will be added to the reference pressure caused by the liquid height. Some vented tanks have a vent trap to prevent release of vapors from the tank. These traps create a varying difference in pressure between the inside of the tank and the atmosphere. This difference is added by the sensor and results in an error (sometimes insignificant) in level measurement. In these cases, the Model 592 should be equipped with the TPC (Tank Pressure Corrector) option. This configuration measures the pressure in the gas space and subtracts it from the total pressure at the bottom of the tank. The remaining pressure is due only to the liquid height.

INSTALLATION
NOTE: Do not drop or bang the transducer about. The sensing element is a single crystal and can be damaged by sudden high "G" shocks. Provide a mounting and hook-up arrangement in accordance with good instrument practice. The Model 592 is installed by lowering it to the bottom of a tank or down a well bore. If sedimentation is occurring, then the sensor should be installed above the level of sedimentation. Note, however, that the 592 will not sense changes in the level of liquid which occur below the sensor face.

If the 592 is to be installed in a well with other equipment, such as a pump or other instrumentation, it is recommended that the sensor be installed in a 1" pipe mounted in the well bore. If this is not done, the cable or sensor can become entangled with wiring, or other downhole hardware. It may then be difficult to remove the 592 from the well. Contact the Delta factory if the well is deep. The 592 should be positioned away from inlet pipes, drains, etc in open pits and tanks. A flow of liquid across the face of the transmitter can change the pressure which is sensed and result in transmitted signal errors. VENT TUBE The Model 592 has a vent tube built into the body of the unit. This tube allows atmospheric pressure to contact the reference side of the sensing diaphragm and to become the reference from which the transmitter operates. Be careful not to block this vent or allow it to become crimped. If the vent tube terminates inside a conduit, the conduit must not be sealed against changes in atmospheric pressure. In below ground well level service (which can be cooler than ambient air), care should be taken that moisture does not condense in the vent tube. This could cause measurement errors. It is extremely difficult to remove the water from a vent tube once it has accumulated. It is usually best to provide some form of protection to prevent water condensation. Condensation protection consists of placing an isolation bladder module, or desiccant dryer (not recommended due to the requirement for periodic maintenance) on the vent tube inlet. These items are available from Delta Controls. ISOLATION BLADDER (Option SCI) The Isolation Blabber uses a thin rubber diaphragm to transmit changes in atmospheric pressure to the back of the pressure sensor while sealing out moisture and dust. The diaphragm moves as required to keep the pressure in the vent reference the same as the atmospheric pressure; yet water vapor is stopped by the rubber barrier. It has the advantage of requiring no periodic maintenance as does a desiccant dryer. The isolation bladder is used by connecting the vent tube from the pressure sensor to one port of the chamber. The other port of the chamber is connected to a tube running to the outside of the enclosure. SEAL TEST TUBE The Model 592 has a seal test tube (0.028") built into the cable (smaller than the vent tube). This tube allows users to verify body seal integrity when performing calibration or field repairs. The seal test tube is normally plugged at the top and only opened during testing of seal integrity. Care should be taken not to block the seal test tube at the body end of the cable, as this will cause false results during the seal test procedure. ELECTRICAL CONNECTIONS This instrument should be served by a 13-35VDC loop power supply which is equipped with electrical over voltage spike protectors, noise filters, lightning arresters and shields so as to limit the supply voltage to less than 35 volts. The Model 592 is internally equipped with voltage spike limiters and filters. Higher voltage spikes such as caused by power surges, inductors, etc. may damage the bridge or electronics and this damage is not covered by warranty. The Model 592 will not withstand a lightning strike and is not warranted against one. Electrical connections should be accomplished in accordance with the National Electrical or other governing code. The 592 is designed for two wire, 4-20 mADC operation. A typical connection is shown in Figure 4. Ensure that the proper polarity of the connections are observed. Because the Model 592 contains reverse polarity protection circuitry, reverse connections will not usually cause damage to the unit, but will prevent proper operation.

Figure 3 Isolation Bladder Installed in Base of Electrical Housing

GROUNDING One point in the output current loop should be grounded. This will reduce electrical noise which can sometimes create errors because of the sensitive electronics inside the 592. The housing for the electronics module must also be connected to a good earth ground. The housing ground is used in conjunction with the transient protection circuitry that is built into the Model 592. Grounding the housing provides considerable protection against voltage spikes due to nearby (not direct) lightning strikes and other power transients.

24V POWER SUPPLY

RECORDER, INDICATOR, CONTROLLER

HOUSING TRANSMITTER ELECTRONICS MODULE OPEN JUMPER WHEN OPTIONAL LCD INDICATOR IS USED

MODULE MOUNTING SCREW GROUND AT ONE PLACE IN LOOP EARTH GROUND

GND

+
LO0P

RED BLUE BLACK YELLOW WHITE GND

SERIES 550 TWO WIRE TRANSMITTER SPAN

DELTA CONTROLS

INDICATOR POSTS

ZERO

BARE SHIELD DRAIN WIRE

DELTA SHIELDED CABLE

MODULE MOUNTING SCREW NOTE: BOTH MOUNTING SCREWS CONNECT TO THE HOUSING

EARTH GROUND

PRESSURE SENSOR CASE NOTE: IF REMOTED ELECTRONICS, TEMPORARILY GROUND HOUSING TO THE ELECTRONICS TO ENSURE A STEADY READING DURING A CALIBRATION PROCEDURE.

NOTE: CONNECTING THE HOUSING TO EARTH GROUND IS REQUIRED. THIS GROUND CONNECTION MUST BE MADE IF THE HIGH VOLTAGE SPIKE AND NOISE PROTECTION CIRCUITS ARE TO OPERATE, OTHERWISE FAILURES MAY OCCUR.

Figure 4 Model 592 Wiring Diagram OPTIONAL LCD INDICATOR The Model 592 has provision for a local LCD indicator (Model 328). The local indicator is a current measuring device that is in series with the current loop. It plugs into two indicator posts on the 592 electronics module. A jumper plug/pins (signal loop connector) protrudes between the indicator posts. This jumper must be in the open position (pins not jumpered) for the indicator to work. Note that unplugging the local indicator, with the jumper in the open position, will open the current loop and cause the Model 592 to stop working. The jumper must be put into the closed position (pins jumpered) to operate the loop with the indicator unplugged. CALIBRATION There are two calibration potentiometers extending up from the electronics module of the 592. These are shown in Figure 4. Primary calibration is accomplished at the factory, however, changes may be required once the unit is in the field. This may be accomplished in one of two fashions; either with a test stand capable of generating the appropriate pressures or with the unit installed and operating in known depths of water.

TEST STAND CALIBRATION Mount the Model 592 in a calibration stand. Connect a power supply and milliamp meter as shown in Figure 4. For proper grounding connect the body of the 592 sensor to the electronics housing, this will insure a steady reading. Apply that pressure which would be sensed when the pressure is at its minimum (usually zero or atmospheric). Adjust the Zero Pot until 4.00 mA is measured in the signal loop. Adjust the pressure to that which would be sensed when the liquid level is at its maximum. Adjust the Span Pot until 20.00 mA flows in the signal loop. If the unit has a 20.0 - 4.0 mA reverse calibration, apply the maximum pressure at the 4.0 mA setting. INSTALLED CALIBRATION Ensure that the proper loop connections are made for power and place a milliamp measuring reference in the loop as shown in Figure 4. Lower the 592 into the liquid until it is covered to the depth at which 4.00 mA is to be produced. Adjust the Zero Pot until 4.00 mA is measured in the signal loop. Now move the 592 to the depth at which 20.00 mA is to be produced. Adjust the Span Pot until 20.00 mA flows in the signal loop.
SPAN ADJUST

OPTIONAL DISPLAY CALIBRATION The optional Model 328 indicator (Figure 5) is calibrated as follows: Set the loop current to 4.00 mA. Adjust the ZERO pot on the 328 until the unit displays the required value for 0% of scale. Set the loop current to 20.00 mA and adjust the SPAN pot on the 328 until it displays the required value for 100% of scale. Set the decimal point selection jumper on the 328 to the desired position.

MODEL 328 DELTA LCD CONTROLS

SHREVEPORT 71107

ZERO
INPUT: 4-20 MADC

ZERO ADJUST

SPAN

DECIMAL POINT SELECTION

MAINTENANCE AND REPAIR

If the vent tube is equipped with a desiccant bottle, it must be checked Figure 5 Optional Model 328 LCD Indicator periodically. When the desiccant becomes saturated with water, it changes color from blue to pink. This can happen rather quickly in moist climates and in other areas. The desiccant must then be replaced with fresh desiccant for vent moisture protection to continue. If not replaced, the vent tube can fill with water and cause significant errors in the measurement output signal. No maintenance, periodic or otherwise, is normally required for the Model 592. However, if the material being sensed has a tendency to harden or set up, cleaning will be necessary. Remove the two set screws near the bottom end of the transmitter and pull off the nose piece. The nose piece can then be cleaned to remove material plugging the holes. Clean the sensor face by gently flushing with water. Do not touch, rub or scrape the sensor face, as it is very thin and will likely be damaged by an object touching it. NOTE: Do not poke your finger or other object into the sensing end of the transducer. The sensing element is sensitive and the force of a finger pushing against the face of the sensor can damage it. NOTE: Do not drop or bang the transducer about. The sensing element can be damaged by sudden high "G" shocks.
BLACK

RED If a problem is suspected in the 592, disconnect the sensor from the electronics module and check the resistances shown in figure 6. The resistances should be between 2200 and 3500 WHITE ohms and should be within 100 ohms of each other. If not, replace the defective sensor and YELLOW recalibrate. If the resistances are correct and the connecting cable is good, then replace the BLUE electronics module and recalibrate. Figure 6 Sensor Schematic REPLACEMENT PARTS

Replacement parts are listed in Figure 8. When ordering spare or replacement parts, reference should always be made to the unit's Serial Number to ensure receipt of proper components. The serial number is engraved on the body tube near its upper end. MODEL 592 FIELD REPAIRS Delta Controls recommends that units be returned to the factory for repairs. The following procedures are provided in case a field repair is to be attempted. It is critical that care be taken to insure that the o-ring seals are clean and free from sand, dirt, grease, or other materials. Failure to do so will cause the unit to leak when it is put in service.

Before attempting to replace the sensor/electronics assembly in a unit that has been in service, it is highly recommended that you obtain a splice kit (P/N 41-121AA) from the factory. This kit includes special lubrication and sealing compound, replacement O-rings, vent tube connector, test tube connection and shrink/seal tubing. TOOLS REQUIRED Wire stripper/cutter, small needle nose pliers, /16" Allen key wrench, heat shrink gun, solder, soldering iron, Loctite #242 Removable Threadlocker, and a small utility razor knife. REPLACING THE SENSOR Wax is used to provide a secondary seal against condensation and moisture. To remove the wax, place the lower two thirds of the body in simmering water (140F to 160F) for 10 minutes. Remove the two setscrews on the cable end of the transmitter, and gently work the cable transition out of the body. DO NOT loosen the nut at the top of the transmitter body. Pour out the liquefied wax. Caution - liquid wax is hot and can burn skin.
CABLE TRANSITION

Clip the wires and the vent tube as shown in Figure 7. Remove the two setscrews from the bottom of the transmitter and remove the nose. From the cable end, push the electronics module out of the body. Carefully clean the interior surface of the body tube at both ends to insure proper O-ring sealing. Remove the O-ring from the cable transition piece. Carefully clean the transition piece and replace the large O-ring with the one provided in the splice kit. Liberally apply the O-ring lubricant supplied in the splice kit to the sensor O-ring.

RED BLACK BLUE YELLOW WHITE VENT TUBE

CLIP HERE

CABLE

TEST TUBE DO NOT LOOSEN THIS NUT 0-RING

Figure 7 Replacing The Sensor

Slide the sensor in the body (Note: DO NOT poke your finger or other object into the sensing end of the transducer. The sensor element is sensitive and the force of a finger pushing against the face can damage it). Use the flat of the nose piece to push the sensor into the body. Apply Loctite to the two setscrews and screw them into place. Trim the new sensor module wires and the vent tube so that no more than 3 inches of wire protrudes from the end of the body tube. Place a piece of shrink/seal tubing over each of the wires and the vent tubing. Insert the metal vent tube splicer in the vent tube and connect both ends together. Solder the wires to their mates, making sure the lengths of all the wires are equal. Use a heat gun to shrink and seal the shrink tubing over the wires and vent tube connections. (Note: The vent tube will melt and collapse if excessive heat is applied to the shrink/seal tubing). Recover the Sensor/PCB subassembly with melted wax and let solidify. Liberally apply O-ring lubricant to the transition piece O-ring. Rotate the body of the sensor to cause the wires to spiral together. Push the transition piece into the body making sure that the wires are not pinched between the body and the transition piece, and that the test tube does not get clogged with wax. Replace the two setscrews and Loctite the setscrews in place. Calibrate the new sensor. (See Calibration)

TESTING TRANSMITTER BODY INTEGRITY

Place the body of the transmitter in a bucket of water. The seal test tube has a 0.028 inch inner diameter. Pressure this tube to 255 PSIG. Let stand for the length of time specified in the table below. Bubbles continually forming on the body of the sensor will indicate a leakage problem. If no bubbling is observed then proceed with reinstallation of the transmitter. CABLE LENGTH 0-100 FEET 100-250 FEET 250-500 FEET 500-1000 FEET 1000-2500 FEET MINUTES 5.0 6.0 10.0 30.0 60.0

SCHEDULE B - NOSE CONICAL 41-110NY SLUDGE 41-182NY

RANGE DESIGNATION G1 G2 G3 G4 G5 G6 G7 G8

SCHEDULE A SENSOR/PCB SUBASSEMBLIES FULL SCALE RANGES SENSOR P/N FEET H2O PSI METERS H2O 41-010 1.0 1.5 3.5 41-011 2.0 3.0 7.0 41-012 5.0 7.5 17.5 41-013 10.0 15.0 35.0 41-014 20.0 30.0 70.0 41-015 40.0 60.0 125.0 41-016 80.0 120.0 250.0 41-017 160.0 250.0 500.0

SENSOR / PCB SUBASSEMBLY 41-156 41-157 41-158 41-159 41-160 41-161 41-162 41-163

15 1 11-453 AA LABEL INTRINSICALLY SAFE 14 5 ml 23-130 AA WAX PARAFIN, 155F MELT 13 1 41-121 AA SENSOR SPLICE KIT 12 AS REQD 41-074 PT CABLE (PVC JACKET) 11 2 31-001 TT SET SCREW (#6-32NC X 1/8 LONG, SHSS) 10 2 31-027 TT SET SCREW (#6-32NC X 3/16 LONG, SHSS) 9 41-039 VT O RING (17mm X 1mm) 8 1 41-119 VT O RING (0.614 X 0.754 X 0.070)) 7 1 41-112 YY CABLE FOLLOWER 6 1 41-109 YY CABLE TRANSITION 5 2 41-116 VT SEAL 4 2 41-114 TT SLIDER 3 1 SEE SCHEDULE A YB SENSOR / PCB SUBASSEMBLY (SEE SCHEDULE A) 2 1 SEE SCHEDULE B NOSE (CONICAL OR SLUDGE SEE SCHEDULE B) 1 1 41-111 YY BODY TUBE ITEM QTY PART NO MATERIAL DESCRIPTION NOTE: O RING (ITEM 9) IS PART OF THE SENSOR / PCB SUBASSEMBLY (ITEM 3), AND IS ONLY LISTED IN CASE REPLACEMENT IS NEEDED.

BASIC SPECIFICATIONS
WETTED MATERIALS: 316 SS, Nylon, PVC, and Fluorocarbon Rubber (FKM) are basic Hastelloy C and Teflon are optional 2 wire, twisted pair 5 wire, shielded cable with drain wire 4 - 20 mADC, Isolated, Intrinsically safe 13 VDC minimum to 35 VDC maximum 550 ohms @ 24 VDC; 1100 ohms @ 35 VDC 0.5% of maximum range 0.02% per F from 30 F to 130 F None, fully referenced to atmosphere None measurable
o o o o o o

LOOP WIRING: SENSOR WIRING: OUTPUT SIGNAL: SUPPLY POWER: MAX LOOP OHMS: ACCURACY: TEMPERATURE EFFECT: BAROMETRIC EFFECT: HYSTERISIS: OPERATING TEMPERATURE: SENSOR ELECTRONICS PROOF PRESSURE: HAZARDOUS AREAS:

-20 F to 220 F (-28 to 105 C) o o o -20 F to 180 F (-28 to 85 C) 2 times range; 35 PSIG minimum without damage This unit is intrinsically safe in areas rated Classes 1 & 2, Divisions 1 & 2, Groups ABCD,EFG When installed in an intrinsically safe loop Rated Environment proof, 4X; PVC, Aluminum, or SS materials Explosion proof; Aluminum or Stainless Steel materials

REMOTED HOUSING:

CALIBRATION ADJUSTMENTS:

Span from 30% to 100% of sensor range; Zero suppression up to 30% of range, basic CSA (Canada) NRTL/C (USA) Intrinsically Safe Explosion Proof Environment Proof ISO 9001 Quality System

APPROVALS:

NOTES:

Engineered Sensors For Difficult Services

585 Fortson Street Shreveport, La. 71107 - USA Ph: +1(318) 424-8471 Fax: +1(318) 425-2421 E-mail: sales@deltacnt.com Web: www.claustemp.com