Baker Hughes Masoneilan 12400 Series, Instruction Manual & Safety Manual

Page 1: ...Masoneilan 12400 Series Level Transmitter Controller Instruction Manual Safety Guide Rev B BHGE Data classification Public...

Page 2: ...THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION OPERATION OR MAINTENANCE SHOU...

Page 3: ...ES 749 instead of ES 479 Section 5 4 6 Add of this new section to answer requirements from Kazakhstan Metrology Pattern Approval Section 9 2 2 Add of remark that 12400 head with SIL design cannot be...

Page 4: ...ATION ON SITE WITH PROCESS FLUIDS 31 7 3 4 CALIBRATION WITH MECHANICAL STOPS 32 7 4 CALIBRATION OF SPECIFIC GRAVITY METER 34 7 5 MECHANICAL STOPS SETTING 35 7 6 TORQUE TUBE TEMPERATURE COMPENSATION 37...

Page 5: ...elivery whichever occurs first provided such items are used according to all relevant recommendations and instructions from BHGE BHGE reserves the right to discontinue manufacture of any product or ch...

Page 6: ...on the AO_1 terminal is the level or interface measurement signal with HART communication Transmitter model with two 2 adjustable switches and second 4 20mA analog output The two 4 20 mA analog outpu...

Page 7: ...e with the recommendations contained in the relevant standards concerning potentially explosive atmospheres b Used only in situations which comply with the certification conditions shown in this docum...

Page 8: ...g is in a standard die casting alloy which is predominately aluminum The housing can be stainless steel also Before powering the 12400 1 Verify that the electronic cover screws are tightened This main...

Page 9: ...ion NOT pertaining to FM approval is allowed on the label SERIAL xxx xxx WARNING POTENTIAL DANGER OF ELECTROSTATIC DISCHARGE Protection PERMANENTLY MARK PROTECTION TYPE ONCE MARKED IT CAN NOT BE CHANG...

Page 10: ...d O ring are greased with one of the following acceptable greases Grease Type Manufacturer GRAPHENE 702 ORAPI MOLYKOTE111 COMPOUND MOLYKOTE MULTILUB MOLYKOTE GRIPCOTT NF MOLYDAL It is the user s respo...

Page 11: ...ID LOAD 1 to 5 Volts or 4 20mA LEVEL FEEDBACK to Control System VALVE POSITIONER 3 1 2 4 250 Note 7 Note 4 Note 6 Note 7 Note 7 Note 7 Note 5 Barrier with internal or external sense resistor Barrier w...

Page 12: ...on for example MTL 788 or 788R For controller application an active barrier with 4 20mA retransmit can be used to drive a valve positioner Entity Parameters Vmax 30 VDC Imax 125 mA Ci 2 nF Li 500 H Pm...

Page 13: ...entity parameters Note 9 Use in dust atmosphere Dust tight conduit seal must be used when installed in dust hazard environments Note 10 Multiple protection approvals A device which has previously bee...

Page 14: ...e switches and second 4 20mA analogue output signal AO_1 AO_2 DO_1 DO_2 2 Transmitter AO_1 3 Transmitter with adjustable switches and second 4 20mA analogue output signal AO_1 AO_2 DO_1 DO_2 0 Top and...

Page 15: ...range of 50 C to 80 C unless limitations due to hazardous area approvals see Section 2 Note Do not remove instrument cover until the unit has been installed and is ready for calibration The codes show...

Page 16: ...ach into the end of the protective case and depress the torque arm Bring the displacer hanger up through the hole in the bottom of the case and slip the displacer hanger over the torque arm pin Lower...

Page 17: ...echanical flexure 59 which is part of the beam The mechanism 50 is completely factory assembled and calibrated before being installed into the mechanism compartment The pivot 51 is positioned toward t...

Page 18: ...0 5 V 30 V 5 4 4 MAXIMUM POWER 3 W into 12400 case 5 4 5 OUTPUT SIGNAL AND LOAD RESISTANCE AO_1 and AO_2 Response scan time 60ms Power interruption without causing reset 100ms Power Up time 1s Compli...

Page 19: ...higher than 150 C 302 F or lower than 100 C 150 F an extension is required between the case and the torque tube Specific Gravity Range 0 15 to 1 4 with a standard displacer Lower and higher specific...

Page 20: ...BHGE 2017 Baker Hughes a GE company All rights reserved Figure 11 Case External side view of case Terminals for local HART communication Figure 12 Front view Cross section back view 90 or 90A 90 or 9...

Page 21: ...Glass O ring 60 2 CHC M3 8 screw 109 1 O ring 1 251 1 Glass 62 1 CHC M3 8 screw 110 1 CHC M4 16 screw 252 1 Clamp spring 63 1 Flange lamella 111 1 O ring sensor housing 253 4 CHC M4x0 7x10 screw 270...

Page 22: ...instrument The left button is marked with a star the middle button with the sign and the right one with the sign means enter the function accept or save to memory It may be understood as YES or means...

Page 23: ...ult clear with VIEW ERROR menu Appendix G Clear all faults with CLEAR FAULT function Appendix G Come back to normal operating mode display in sequence of level variable and output current 6 1 4 2 SETU...

Page 24: ...nu Appendix G This menu is available only when the instrument failed and went to FAILSAFE mode Then the output signal is locked in low or high failsafe value see Advanced Setup menu This menu allows t...

Page 25: ...chanism compartments and the plug 190 located at the bottom of the instrument b Required level of liquid for coupling b1 At workshop with weights Coupling between torque tube and mechanism is achieved...

Page 26: ...cial conical ended pin 53 by bending the flexure 59 toward the case front see Figure 15 The value read on the LCD must be between 5 and 5 NOTE Check there is no oscillation of the weight used to simul...

Page 27: ...s it might be of interest to set the instrument in interface mode even for a level measurement In this case low specific gravity is set at 0 Mounting position of the instrument head versus displacer L...

Page 28: ...he BASIC SETUP menu Modify it only if zero and span calibration are performed again for a liquid of different specific gravity See Section 7 3 3 Specific Gravity of Service Specific Gravity of Service...

Page 29: ...r calibration SG CALIB The loop current corresponding to REF L may be set through MA LO mA via VAR SET it is generally 4mA The current corresponding to REF H may be set through MA HI mA via VAR SET it...

Page 30: ...esponds to the displacer fully immersed in the liquid of Higher Specific Gravity used for calibration HSG CALIB The loop current corresponding to REF L may be set through MA LO mA via VAR SET it is ge...

Page 31: ...ate the low level c2 Interface application Attach to the torque arm a set of weights equivalent to the displacer weight completely immersed in the liquid of Lower Specific Gravity used for calibration...

Page 32: ...rsed in the liquid of Higher Specific Gravity used for calibration HSG CALIB using the following formula d3 Enter and validate the SPAN the LEVEL value indicated on the display must equal 100 0 If not...

Page 33: ...aftereachlevelvariation f Low Level ZERO f1 Liquid application Empty the displacer chamber f2 Interface application Fully immerse the displacer in the liquid of Lower Specific Gravity used for calibra...

Page 34: ...gravity of calibration in level application SG CALIB or the low and high specific gravities in interface application LSG CALIB and HSG CALIB f Low Level ZERO f1 Liquid application Move the flexure 59...

Page 35: ...stabilizes g2 Interface application Move the flexure 59 against the adjusting screw shoulder 114 which corresponds to the high level of highest specific gravity fluid of calibration HSG CALIB on disp...

Page 36: ...ue arm equivalent to the true displacer weight i e 1362 g for a standard displacer to simulate the low level or empty the displacer chamber c2 Enter and validate the ZERO the LEVEL value indicated on...

Page 37: ...t slide the flexure left or right along the surface of the screw post Figure 18 c Perform the two adjusting screws 114 setting by reading the specific gravity value indicated by the specific gravity m...

Page 38: ...s the value of process specific gravity SG CALIB f2 Interface application Press the flexure 59 against the adjusting screw shoulder 114 which corresponds to the highest specific gravity HSG CALIB Whil...

Page 39: ...odules that may happen in case of temperature difference between temperature saved during calibration procedure and current temperature impacted by ambient and process temperatures This function is av...

Page 40: ...he Advanced Setup tab click on Database b Click on the arrow of the drop down list located at the right of the Torque Tube Matl c Select the materials related to the torque tube and housing sub assemb...

Page 41: ...signal available on AO_1 terminals is the controller output signal generated by a PID algorithm based on error between the local setpoint and the level process variable HART communication is availabl...

Page 42: ...r CTRL menu and press to enter c Activate or disable the Controller function d Leave the Advanced Setup menu to validate the new setting 7 7 3 PID CONTROLLER STRUCTURE The PID structure used is the pa...

Page 43: ...t is power up Setpoint Unit Use the pulldown to select the unit for use in the program If the setpoint units do not match the level units the Ratio Control Activation automatically activates Setpoint...

Page 44: ...constant of integral control Higher values of I cause slower integral action Common values are 0 to 100 10 seconds A value of zero disables integral action D ms Derivative time or rate time is the ti...

Page 45: ...functionalities View Controller Bargraphs with controller output on the left bargraph and process variable and controller setpoint on the right bargraph Set Controller Setpoint in Normal mode or Contr...

Page 46: ...44 BHGE 2017 Baker Hughes a GE company All rights reserved...

Page 47: ...Average Probability of Failure on Demand Safety Accuracy The measurement error that occurs due to component degradation and failure during the useful life of an instrument SFF Safe Failure Fraction su...

Page 48: ...e HFT for safety related type B subsystems Proportion of non dangerous failures SFF Fault tolerance of the hardware HFT 0 1 2 60 Not permitted SIL 1 SIL 2 60 90 SIL 1 SIL 2 SIL 3 90 99 SIL 2 SIL 3 SIL...

Page 49: ...p calibration and diagnostics purposes not for safety critical operation The application program in the logic solver is constructed in such a way that Fail High and Fail Low failures are detected rega...

Page 50: ...e safety function and take appropriate actions to avoid a false trip and any safe actions against dangerous atmospheres 2 Inspect the instrument for dirty or clogging parts adequate wiring correct mou...

Page 51: ...A 12200 300 400 SERIES TORQUE TUBE a Mount the torque tube 137 on a support The knife pivot at the back of the tube must be oriented toward the top b On the transmission rod 138 mount the bias assembl...

Page 52: ...tighten l Verify again that the beam is free to rotate and that the coupling flexure 71 is not deformed The coupling on the beam 54 is tightened later Note At this point if instrument service conditi...

Page 53: ...s chamber 131 or tank g Be sure that requirements for instruments installed in explosive areas are strictly followed Remove screw 106 from connection compartment and unscrew cover 104 Disconnect suppl...

Page 54: ...the coupling does not match the mounting direction verify that the screw 62 is loose and pin 72 is free to rotate in the coupling end of the beam 54 before hooking the displacer on the torque arm 135...

Page 55: ...g screws per Sections 7 4 and 7 5 Proceed with calibration following Section 7 3 Note The specific gravity meter function and the adjusting screws are features offered by the instrument They enable a...

Page 56: ...al blocks of main analog output connections AO_1 10 4 OUTPUT SIGNAL DIFFERS FROM VALUE DISPLAYED ON LCD Check the load resistance is compliant with Section 5 4 5 and the power supply applied to main a...

Page 57: ...rs menus In such case LOCK message is indicated on LCD display when the user presses a button e Check the wiring capacitance versus length see note Note these data are given in the HART FSK physical l...

Page 58: ...heck you complete level loop LOW LEVEL ALARM 2 Level was below the configured threshold for more than configured time Warning message Low level measure for more than the configured time Check you comp...

Page 59: ...he failure persists replace the device NVM MODULE TEST Non Volatile Memory error of sensor circuit board if write to FRAM failed or if data repairing in FRAM failed Warning message A problem occurred...

Page 60: ...Working time exceeded the configurable threshold Warning message N A Perform maintenance of device CURRENT SIGNAL SENSOR Error of 4 20 mA sensor Failsafe position Fail Low or High user adjustable Fai...

Page 61: ...ition or adjusted position is outside the range of 200 Warning message Bad calibration or mechanical hardware adjustment Check displacer and torque tube S A characteristics Redo calibration SG LEVEL M...

Page 62: ...60 BHGE 2017 Baker Hughes a GE company All rights reserved APPENDICES...

Page 63: ...E AUTOMATIC POWER ON To BAS SETUP Menu To ADV SETUP Menu Annex F Annex B Annex C VIEW DATA To VIEW ERR Menu Annex G RESET Lock Lock Lock To FAILSAFE Menu If any critical default remains Annex G CTRL m...

Page 64: ...etup Menu NORMAL Validate by pressing the to return to Normal Menu In Normal Mode the screen displays in sequence the value of the level and of the output current VIEW DATA Validate by pressing the to...

Page 65: ...2017 Baker Hughes a GE company All rights reserved Masoneilan 12400 Series Transmitter Controller Instruction Manual 63 APPENDIX B BASIC SETUP Menu...

Page 66: ...Validate by pressing the to cancel the parameters saving procedure COUPLING Only necessary on instrument head delivered alone without torque tube Function used to mechanically couple the sensor to th...

Page 67: ...in case it is different from the Specific Gravity of Calibration SPECIFIC GRAVITY of SERVICE Validate by pressing the to set the Specific Gravity of the liquid of service if it is different from the...

Page 68: ...66 BHGE 2017 Baker Hughes a GE company All rights reserved APPENDIX C see following pages...

Page 69: ...ART FLT SG CALIB ZERO SPAN SAVE CANCEL W VAL s DAMPI ON DAMPI OFF W INTG s DZ INTG SAVE BACK FAIL DIR FAIL LOW FAIL HIGH DAMPING s To ENG UNIT Menu Annex D Selection select one option only SAVE CANCEL...

Page 70: ...rally 20 mA must be between the low current signal value MA LOW and 20 5 mA ENGINEERING UNIT Validate by pressing the to enter the sub menu to define the level variable and select the desired engineer...

Page 71: ...eturn to previous menu SPECIFIC GRAVITY METER CALIBRATION Validate by pressing the to calibrate the Specific Gravity Meter Enter the sub menu and proceed as a normal level calibration SPECIFIC GRAVITY...

Page 72: ...70 BHGE 2017 Baker Hughes a GE company All rights reserved APPENDIX D see following pages...

Page 73: ...2017 Baker Hughes a GE company All rights reserved Masoneilan 12400 Series Transmitter Controller Instruction Manual 71 APPENDIX D...

Page 74: ...9 SAVE Validate by pressing the to start the saving procedure of parameters previously entered in the instrument memory BACK Return to previous menu SCREEN DESCRIPTION FOR FILTERING MENU FILTERING Val...

Page 75: ...Baker Hughes a GE company All rights reserved Masoneilan 12400 Series Transmitter Controller Instruction Manual 73 APPENDIX E 4 20mA GENERATION Menu 12420 Model 12410 or 12430 Models AUTOMATIC TUNING...

Page 76: ...TOR Validate by pressing the to enter the sub menu allowing to set the Analog Output 1 loop current to a defined value SIGNAL mA Validate by pressing the to set the AO_1 loop current to a value betwee...

Page 77: ...VIEW DATA Menu To FILTERING menu BA SETUP AD SETUP DIAGNOS SG METER 111 DLT REV BACK READ CTR RESET CTR SENS TEMP MODL TEMP BACK NBR FILL TIME LOW TIME HIGH TIME WORK BACK MA HI mA Z SHIFT R SPAN FILT...

Page 78: ...vel calibrated value TIME HIGH Time number of hours during which the instrument worked within 5 of high level that is between 95 and 105 of calibrated value TIME WORKING Time number of hours during wh...

Page 79: ...hes a GE company All rights reserved Masoneilan 12400 Series Transmitter Controller Instruction Manual 77 APPENDIX G FAILSAFE Menu VIEW ERROR Menu Please consult Section 10 7 to get the full list of e...

Page 80: ...error message s saved in memory SCREEN DESCRIPTION FOR VIEW ERROR MENU NO ERROR Indicates there is no error in memory RESET Validate by pressing the to put the instrument in factory set configuration...

Page 81: ...D ARAB EMIRATES Phone 971 4 8991 777 Fax 971 4 8991 778 UNITED KINGDOM Bracknell Phone 44 1344 460 500 Fax 44 1344 460 537 UNITED STATES Jacksonville Florida Phone 1 904 570 3409 Fax 1 508 427 8971 De...