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Chapter 0
Explanation of symbols
In the manual
Radiation notice
Introduces information concerning radioactive materials or radiation safety.
Caution
Introduces warnings concerning potential damage to the equipment or bodily
harm.
On the instrument
AC current or voltage
A terminal to which or from which an alternating (sine wave) current or voltage
may be applied or supplied.
DC current or voltage
A terminal to which or from which a direct current voltage may be applied or
supplied.
Potentially hazardous voltages
A terminal on which potentially hazardous voltage exists.
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1
INTRODUCTION
Chapter 1
Note: Most source holder models accept a lock. Call Ohmart/VEGA Field
Service (see Customer Service on page 1-11 for contact information)
immediately for further instructions if:
l The source holder does accept a lock and there is no lock on it.
l The lock is not secured.
l You cannot secure the lock.
l The operating handle does not properly move into the OFF position.
See the Radiation Safety for U.S. General and Specific Licensees, Canadian
and International Users Manual and the Radiation Safety Manual Addendum of
Reference Information that came with the source holder and the appropriate
current regulations for details.
Gauge
Avoid storage at temperatures below freezing. Store the gauge indoors in an area that
has temperature control between +10 °C to +35 °C (+50 °F to +95 °F) and < 50% relative
humidity. Store equipment in dry conditions until installation.
LFXG-H specifications
Table 1.1 LFXG-H specifications
System Accuracy ±1% of span Accuracy depends on specific application parameters
typical
Active Lengths Flexible detector 305 – 7,010 mm (12 – 276") in 305 mm (12")
increments
Typical Sources Cesium-137 0.66 MeV gamma radiation emitter, 30.2 year half
life
Cobalt-60 1.2 and 1.3 MeV gamma radiation emitter, 5.3 year
half life
Power AC 100 – 230 ±10% VAC (90 – 250 VAC, or with
Requirements* internal heater kit: 115 – 230 VAC) at 50 – 60 Hz, at
15 VA maximum power consumption (25 VA ≤ with
heater) CE compliance requires 100 – 230
±10% VAC
DC 20 – 60 VDC (< 100 mV, 1 – 1,000 Hz ripple)
at 15 VA
CE compliance requires 24 VDC ± 10%
Wiring Per local code
Signal Cable Maximum length 1,000 m (3,280')
HART signal 1.02 – 0.643 mm (no. 18 or 20 AWG) 2-conductor
shielded
Typical applications
Ohmart/VEGA’s level gauges accurately indicate the level of liquids or bulk materials in
vessels, reactors, or tanks.
In order to achieve a level indication over the desired length, it may be necessary to use
more than one detector. The way these multiple detectors link together depends upon the
types of detectors used. Specific details on using multiple detectors are available from
Ohmart/Vega Corp.
The accuracy of quality control systems that use Ohmart/VEGA nuclear level gauges is
profitable to a wide range of industry operations. A number of applications that use a level
gauge are:
Pulp and Paper
• Liquors
• Bleach plant chemicals
• Coating chemical storage
• Lime mud
Principle of operation
The gauge receives a shaped or collimated beam of radiation from the source holder
through the process material. The material in the vessel shields part of the detector from
exposure to the radiation field. As the process material level decreases, the detector
senses more radiation, and vice versa.
Calibrating the gauge associates the detector readings (or counts) with the level of the
material in engineering units. The output range of the gauge is a 4 – 20 mA current loop
signal, in proportion to the level of the process.
System overview
The gauge uses Ohmart/VEGA’s GEN2000®, Ohmart/VEGA’s newest compact
electronics that support 4 mA – 20 mA HART® protocol, frequency, or field bus output.
The level measurement system includes:
• Source holder
• FiberFlex flexible detector assembly
PC
System Overview
Source holder
• A cast or welded steel device that houses a radiation-emitting source capsule
• Directs the radiation in a narrow collimated beam through the process vessel
• Shields the radiation elsewhere
• The model chosen for each system depends on the source capsule inside and the
radiation specifications
• Its shutter completely shields the radiation (source off) or lets it pass through the
process (source on) (if applicable)
Detector assembly
• Mounts opposite the source holder.
• Inside the flexible detector is a scintillator material, which produces light in proportion to
the intensity of its exposure to radiation.
• A photomultiplier tube detects the scintillator's light and converts it into voltage pulses.
• The microprocessor receives these voltage pulses after amplification and conditioning
by the photomultiplier tube.
• The microprocessor and associated electronics convert the pulses into an output that
can be calibrated.
Power supply board
CPU board
RS-485 ground
Internal housing (if applicable)
ground
External housing
ground
When you insert the CD, the program installs these programs onto your hard drive.
Note: The HART Communication Server must always be on when using
Ohmview 2000's main program and Ohmview 2000 Logger.
Customer Service
U.S. and Canada
On-site field service is available in many locations. Often, a field service engineer is at your
plant for your gauge’s startup. Field service engineers also provide assistance by phone
during office hours.
For emergencies (example: line shut down because of Ohmart/VEGA equipment), you can
reach us 24 hours a day.
Worldwide
Contact your local Ohmart/VEGA representative for parts, service, and repairs.
2
INSTALLATION
Chapter 2
250 – 800 Ω
load resistor (optional)
Mini clips
H1 HART modem
H2
RS-232 cable
Transmitter
test points
PC running
Ohmart/VEGA software
Note: You may need to reset the time and date if the gauge has not had power
for > 28 days. The Real Time Clock Fail message may appear. You must
enter the correct time and date: the clock is the basis for source decay
calculations.
You can calibrate the current loop output on the bench before mounting the detector on
the process. See page 3-3.
Location considerations
When you ordered the gauge, Ohmart/VEGA sized the source for optimal performance.
Notify Ohmart/VEGA before installing the gauge if its location differs. Satisfactory
operation depends on proper location.
Note: Locate the source holder where process material cannot coat it. This
ensures the continuing proper operation of the source ON/OFF
mechanism (if applicable). Many regulatory bodies (example: the U.S.
NRC) require periodic testing of the ON/OFF mechanism.
See the Radiation Safety for U.S. General and Specific Licensees,
Canadian and International Users Manual and the Radiation Safety
Manual Addendum of Reference Information that came with the source
holder and the appropriate current regulations for details.
Stable temperature
Mount the gauge on a portion of the line where the temperature of the process material is
relatively stable. Process temperature can affect the gauge indication. The amount of the
effect depends on:
• Sensitivity of the gauge
• Temperature coefficient of the process material
Protect insulation
Protect from liquid any insulation between the measuring assembly and the process. The
absorption of a liquid, such as water, can affect the gauge indication because it blocks
some radiation.
This type of mount consists of an adapter with a 2" conduit coupler (part number
240721). It provides an air hose fitting for applications that must cool the gauge. The
pole mount requires a nipple and union.
Note: The detector’s active area (where it is possible to make a level
measurement) is between 1" (25mm) from the bottom of the GEN2000
housing to the end of the flexible conduit. Mount the detector so this
area spans the measurement length.
Note: In some cases, the handle on the source holder operates a rotating
shutter. When installing or removing the assembly from the pipe, you
must turn the handle to the closed (OFF) position and lock the handle
with the combination lock provided.
FiberFlex mounting
Use the drawing notes and the steps that follow to make the input and output connections.
Make the connections at the removable terminal strips mounted on the power board. To
access the power board, remove the explosion-proof housing cap.
Ohmart/VEGA provides an internal and external ground screw to connect the power Earth
ground wire. Remove the top cover; the internal ground screw is located at the front of the
housing. The external ground screw is located next to the conduit entry.
Internal housing
ground CPU board
RS-485 ground
(if applicable)
External
housing
ground
Mounting bracket
AC or DC power input
L1
L2
RY NO Relay:
- normally open
RY C - common
RY NC - normally closed
Common
Auxiliary input frequency signal
Power
The AC power source voltage input is 100 – 230 VAC ± 10% (90 – 250 VAC) at 50-60 Hz,
at 15 W (or 25 W with optional heater) maximum power consumption.
AC power must not be shared with transient-producing loads. Use an individual AC
lighting circuit. Supply a separate earth ground.
The DC power source voltage input is 20 – 60 VDC (< 100 mV, 1 – 1,000 Hz ripple) at
15 VA maximum power consumption. DC power cable can be part of a single cable 4-wire
hookup, or can be separate from output signal cable. (See Output current loop section.)
Use wire for power per local code. Use supply wire suitable for +40 °C above surrounding
ambient temperature. All field wiring must have insulation suitable for 250 volts or higher.
Note: HART signal may not operate with some isolating barriers or other non-
resistive loads.
Relay
Use relay contacts rated at 6 A at 240 VAC, 6 A at 24 VDC, or 1/4 HP at 120 VAC.
Frequency input signal is 0 – 100 kHz ≤, true digital.
RS-485
The maximum cable length is 609 meters (2,000'). Use shielded wire per local code.
Connect positive terminals together. Connect negative terminals together. Connect
ground terminals together.
System architecture
Sensor locations Control room
Relay PC
RS-485
Interface mA
Optional Input to
Cable for power modem DCS
per local codes
Output signal
Power cable
Earth
ground Optional field
Housing ground communicator
ATEX ground
Emerson
375
Communication
The HART hand-held terminal can connect anywhere across the 4 mA – 20 mA wires to
communicate with the gauge. A minimum requirement is a 250 Ω load-resistance on the
current loop. A HART modem may connect across the 4 – 20 mA wires to enable
communication between the gauge and a PC.
Conduit
Conduit runs must be continuous and you must provide protection to prevent conduit
moisture condensation from dripping into any housings or junction boxes. Use sealant in
the conduit, or arrange the runs so they are below the entries to the housings and use
weep holes where permitted.
You must use a conduit seal-off near the housing when located in a hazardous area.
Distance must comply with local code.
If you use only one conduit hub, plug the other one to prevent dirt and moisture from entering.
3
CALIBRATION
Chapter 3
To correlate the 4 mA – 20 mA to the process value, set the span of the current loop
output.
Note: The current loop and process spans are independent and set separately.
The current loop span sets the level indications for the 4 mA and the
20 mA outputs. The process span sets the endpoints of the calibration
curve.
A direct measurement of the current is preferable: hook the meter up in series with the
instrument and the DCS. However, if you know the resistance of the DCS, use a voltage
measurement to calculate the current.
5. Click OK.
6. Click YES if the ammeter reads 4.00 mA or NO for any other reading.
7. Repeat until the meter reads 4.00 mA. The meter approaches the 4.00 mA
successively.
8. Read the ammeter; enter the actual milliamp reading.
9. Click OK.
10. Click OK.
You can check the current loop output calibration at any time by using the test mode to
output a user-specified milliamp setting. See page 4-10.
Calibration methods
For each installation, you must choose a method to calibrate the gauge. In almost all
cases, the standard method is the best.
Theory of calibration
Both calibration methods
Enter the values that define the maximum and minimum levels to measure. These
parameters are Max Level and Min Level, and must be set correctly before any of the
calibration steps.
Collection of data points nearest the maximum (but not higher) and minimum (but not
lower) levels occurs during calibration. See the procedure on page 3-9 to collect these
data points.
The figure illustrates the effect on the final output of using the non-linear table vs. the
linear table for the linearizer. Using the non-linear table linearizer in the standard method
produces a linear output.
Maximum
Level
Standard
Indicated
Level
Simple
Minimum
Level
Minimum Actual Level Maximum
Level Level
Min Level
Max Level
Cal Low Cal High
Level Level
The internal software calculates a linearizer curve based on data points. The curve is the
most accurate between the Cal Low Level and Cal High Level.
Simple
Cal High Counts
So, it is best to take the Cal Low and Cal High samples as close as possible to the Min
Level and Max Level to maximize the accuracy within the span.
The linearizer curve maps on 2 axes so it indicates % Count Range vs. % Span.
100%
Standard
% Count Range
Simple
0%
0% 100%
% Span
To construct the linearizer table, a data point calculates for every 2.5% of the span. View
or edit these points in the Linearizer table screen.
Table - Non-linear
Use this type for a standard method calibration. It takes into account the inherent non-
linearity of a nuclear transmission measurement, so it is more accurate than the linear
table.
The non-linear table can use data from:
• Linearizer lookup table (data points that you collect and enter during the calibration
process)
• Linearizer data from an earlier model Ohmart/VEGA level gauge
Table - Linear
Use this type for a simple method calibration. This type lets you use a linear (straight-line)
set of data for a linearizer lookup table. You do not need to collect linearizer table data
points. The straight-line linearizer calculates from the high and low-level calibration points.
This requires you to:
1. Perform a two point calibration.
2. Calculate the calibration.
It is less accurate because it does not compensate for the non-linearity of a radiation
transmission measurement.
Calibration procedures
Standard method Simple method
Includes these steps (see the following pages): Skips steps 3 and 4.
1. Setting the low level and collecting Cal Low data*
2. Setting the high level and collecting Cal High data*
3. Collecting the linearizer table data*
4. Calculating the linearity
5. Calculating the calibration
* Perform these data collection steps in any sequence, depending on your ability to empty
and fill the vessel.
If using the standard method, it may be helpful to record the sensor counts and levels at
each step:
This step lets you collect data points between the high and the low calibration points so
the gauge calculates a response curve based on your data.
Before collecting the linearizer table data:
; Prepare to set the level and take data for ≤10 levels (including the Cal Low and Cal
High levels).
; Prepare to enter the levels into the gauge.
; You can collect linearizer table data with the data collection for the Cal Low and Cal
High levels.
Note: Include the data for the Cal Low and Cal High with the linearizer data
before you perform Calculate linearity. If you did not perform a linearizer
data collection while the process was at the levels for Cal Low and Cal
High, you can manually add those values to the linearizer data.
To add a data point to the linearizer data, you must know the level in
engineering units and the sensor counts.
After collecting the data for a linearizer table, the transmitter uses the data to calculate a
new calibration linearizer table. The Calc linearity function initiates this calculation.
You must perform this step before the Calculate Calibration step (see the next section).
Before calculating the linearizer:
Standardization reminder
If you enable the standardization due alarm, the gauge produces an alarm when
standardization is due. The standardize interval is programmed in Setup | Cal
Parameters.
4
ADVANCED FUNCTIONS
Chapter 4
Functions not required for normal operation of the gauge are in the Ohmview2000
software under the Diagnostics and Gauge Info tabs. These functions are primarily for use
by Ohmart/VEGA personnel for advanced troubleshooting and repair.
Note: Ohmart/VEGA strongly recommends that you ask our advice before
using any advanced function.
Process chain
The process chain is a description of the gauge software’s calculation of a level
measurement from a radiation reading. In the Process Chain tab, you can view
intermediate values of the calculation to verify proper functionality of the software.
Gauge Information
Process Variables tab
Sensor Coefficients
T0 – T3
Value Description
Sensor Coefficients The algorithm that compensates for variations in measurement
output with changes in temperature uses temperature coefficients.
The factory determines the coefficients through rigorous testing. You
cannot change them through normal operation.
Value Description
Sensor Counts The raw uncompensated counts from the detector
Aux in min/max The auxiliary input counts (if used)
Sensor Temperature The internal temperature of the scintillator sensor in the level gauge
Last reset The date of the last min/max reset
You can reset these values so they record from the time of the reset.
Procedure 4.2: To reset the min/max history
Test modes
In the test modes, the transmitter stops measuring the process material and allows
manual adjustment of critical variables for troubleshooting.
The test modes function independently, but you can use them in combination to test
multiple variable effects.
All test modes time out after one hour if you do not exit.
Caution: While in a test mode, the gauge is not measuring process, so its
current output does not reflect the process value. If your DCS is controlling from
the gauge's current output, remove the system from automatic control before
entering a test mode, as prompted by the software screens.
Test
Sensor Test
This mode simulates the sensor output at a number of raw counts you define. This is
before application of:
• Temperature compensation
4. Click OK.
The transmitter functions in this mode until it times out (1 hour), or you click Exit
and OK.
Relay Test
This mode manually toggles the relay On or Off to test the contacts. This is useful for
verifying whether alarm annunciators are functioning.
Procedure 4.8: To perform a relay test
Temperature Test
This mode manually forces the sensor’s temperature probe output to a specified value.
This is useful for verifying the scintillator sensor temperature compensation.
Procedure 4.9: To perform a temperature test
Type
The GEN2000 density and level gauges look similar and use the same software. If your
level transmitter indicates Density, it was set incorrectly for a level application.
Procedure 4.10: To select the transmitter’s type
Location
The local transmitter refers to a gauge that has its sensor electronics and processing
electronics all contained in the same housing.
Set a gauge to Remote if the sensor electronics and processing electronics are in
separate housings and the process signal connects to the auxiliary input of the processing
electronics.
5
DIAGNOSTICS AND REPAIR
Chapter 5
Software diagnostics
The level transmitter system can alert users to potential problems by:
• Posting messages on the Ohmview 2000 message screen
• Energizing the output relay
• Distinctly changing the current loop output
• Tracking the current status and history in the Gauge status screens
Analog alarm
If the current loop output (analog output) is stable at 2 mA or 22 mA, the analog alarm is
set.
The analog alarm is set when the counts from the detector falls below a set threshold,
indicating that the detector is not outputting enough counts to make a meaningful
measurement. This is known as 0 counts.
If the analog alarm is on, verify:
; Source holder shutter is in the On or Open position to create the required radiation
field.
; Extreme build-up on walls or other material shielding the detector from the radiation
field.
; Damage or disconnection of electrical connections from the sensor assembly to the
CPU board.
Process alarm
This alarm alerts users when the process level is above (high limit) or below a setpoint
(low limit). Enter the choice of low or high limit and the setpoint on the Alarm | Relay
Setup tab.
This alarm works only with the output relay. HART messages, gauge status diagnostics,
and history information are not saved for this alarm.
The gauge acknowledges or resets the process alarm when the process value returns to
the setpoint value. Depending on your usage of the process alarm relay, you may install a
process alarm override switch to manually turn off an annunciator when the gauge relay
energizes.
X-ray alarm
This alarm compensates for falsely indicated process values that occur when the gauge
detects external radiographic sources (example: vessel weld inspections often use
portable radiographic (x-ray) sources). X-rays that the gauge detects can cause a false
low reading and adversely affect any control based on the gauge output.
This alarm can:
• Alter the current loop output to indicate the alarm condition
• Trip the output relay, if it is configured to do so
The level gauge enters the x-ray alarm condition when it detects a radiation field above a
set threshold. The gauge sets the current loop output at its value 10 seconds before the
condition. It periodically dithers the output about the average, cycling until the radiation
field is back to the normal level or until a time-out period of 60 minutes.
The standard x-ray alarm only triggers when the counts are greater than the Cal Low
count value. These counts are found on the process variable menu. If the x-ray source is
configured so the counts increase but do not exceed the Cal Low counts, the x-ray alarm
does not trigger and the gauge reads the x-ray interference as a true process shift.
output 10s
before x-ray
Dither level
time (ms)
Dither time
Cycle period
History information
Diag History
The Diagnostics | Diag History tab displays information about critical events.
Use this information to determine whether a problem recently occurred and was internally
repaired (example: EEPROM corruption).
Troubleshooting
Two circuit boards in the level gauge are field-replaceable.
Caution: A minimum of 10 minutes should be allowed after de-
energizing, before opening the GEN2000 for internal inspection to
permit cooling and full capacitor discharge.
RS-485 ground
(if applicable)
External
housing
ground screw
Mounting
bracket
Test points
Located on the power supply and CPU board.
Jumpers
Jumpers JP1 and JP2 on the power supply board set the current loop source or sink
mode.
Note: Do not change the jumpers from the current setting without calling
Ohmart/VEGA Field Service.
The level gauge does not use jumpers J1 – J4 on the CPU board.
LED indicators
Table 5.7 Power supply LED indicators
Normal
LED Description Condition Error condition Recommendation
+6 V +6 V DC ON OFF – electronics are not Verify +6 V on test points.
voltage receiving +6 V DC voltage Check fuse on power supply
level to required for functioning. board. Check power input
electronics terminals 1, 2.
+24 Analog ON OFF – 24 V not present on 4 Check loop wiring and
V output loop – 20 mA output. jumpers JP1, JP2 on power
voltage 4 – 20 mA output and HART supply board. Replace power
communications are bad. supply board.
Rela Relay ON = relay is None Check against relay output
y condition energized. terminals 3, 4, and 5. If no
indicator OFF = relay is relay output, replace power
de-energized. supply board.
On
Note: If the LED band displays the Memory Corrupt pattern, call
FIELD
FIELD
H A RT
H A RT
M EM
M EM
A UX
A UX
CPU
CPU
HV
HV
Blinking
Ohmart/VEGA Field Service to report this condition. The
gauge does not operate if the FLASH chip is corrupt. Off
Normal LED pattern Memory corrupt pattern
Source Functions
Procedure 5.2: To change the due date of source wipe or shutter check
Spare parts
See page 1-13 for contact information. Ask for parts and repairs.
10. Carefully install the circuit boards in the housing. Try not to damage the sensor
cable on the CPU board.
11. Secure the brackets back to the hold-down plate.
12. Reconnect the terminal wiring connector.
13. Install the plastic electronics cover.
14. Install the housing cover.
15. Apply power to the unit. Connect a HART communicator to the unit (a HART
handheld or the Ohmart/VEGA software program) to verify that the unit is
operational.
Note: If you change the CPU board, a New Hardware Found error message
appears when you connect with the HART communicator. This is normal.
Follow the procedure on page 4-7 for installing new hardware so the
non-volatile memory on the CPU configures properly.