Sitron SC404 Operation & User’s Manual

Models & Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Mounting Note. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Terms & Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Level Sensor The SC404 is a capacitance continuous level transmitter with an integrated electronics module mounted within the housing. This 2 wire loop powered unit provides a 4-20mA output (galvanically isolated). Set up and calibration is achieved with a zero and span adjustment which works best when starting with an empty tank to set the zero and then filling it to set the span. This flexible level measurement device works well in many industrial processes and process media including a variety of liquids, powders and pastes. The SC404 is made with 316SS rigid rods or 316SS cables (coatings are required for conductive mediums) and can also be made with a secondary reference rod or reference sheath built into the process connection. The wide range of applications for RF analog level measurement probes (such as liquids, pastes, solids and granules), requires attention in selecting the correct configuration and installing it in the proper location. To cater to all applications, Sitron's probes are offered with different designs and features. Wide range of applications/industries: i.e. water, oils, corrosives, solids, powders, grains, etc. Accurate and reliable measurement No moving parts - Rugged construction Can operate at high temperatures and pressure Functions on conductive as well as non-conductive medias Galvanic Isolation Features Introduction Sitron-USA - Phone (516) 935-8001 / Fax (800) 516-1656

Threaded SC404 W/ Reference Sheath SC404 W/ Reference Rod SC404 w/ Cable (also w/ reference cable) SC404 Standard Note: Minimal insertion for the SC404 is ½ meter Extended necks for medium temperature (up to 120°C) 3/4” 1 ½” 1 ½” 1 ½” 2 ½” 2 ½” 1” 2” 2” 2” 3” N1- Nylon G1-Aluminum G2 - Aluminum 1” 1,75 Tri-Clamp Flange Housing Types Mounting Options for SC404 Process Connections TC Connection ANSI 150# ANSI 300# Rubber Seal Process Connection NPT BSP FF RF L 20 ½” 1,6 1”NPT 1”NPT ½” ½” L 25 66 1/4” 1 1/2”NPT L 20 50mm 126mm 130mm 130mm 118mm 89mm 76mm 89mm 80mm

0 2 0 2 Span Zero Gain SC404 Sub + _ 1 2 3 1 + _ 2 3 0 2 Gain SC404-G On S Z SC404 with G1 Housing 1- Power Supply (+) 2- Power Supply ( ) 3- Ground 24Vdc / 4...20mA C A D B A- Adjust Sensibility (Gain) B- Adjust Sensibility (Sub gain) C- Adjust Zero (begin scale) D- Adjust Span (end of scale) A B C D 1- Power Supply (+) 2- Power Supply ( ) 3- Ground 24Vdc / 4...20mA A- Adjust Sensibility (Gain) B- Adjust Sensibility (Sub gain) C- Adjust Zero (begin scale) D- Adjust Span (end of scale) Sitron-USA - Phone (516) 935-8001 / Fax (800) 516-1656 0 2 Sub Wiring Diagram 6

A B C Wiring Diagram 1 24Vdc (+-10%) + 4...20mA 2 - 3 D On Gain 0 2 Zero Sub 0 2 Span SC 404 7 1- Power Supply (+) 2- Power Supply ( ) 3- Ground 24Vdc / 4...20mA A- Adjust Sensibility (Gain) B- Adjust Sensibility (Sub gain) C- Adjust Zero (begin scale) D- Adjust Span (end of scale)

Galvanic Isolator - ISO420 1- Probe (+) 2- Probe( ) 11- Power Supply (+) 12- Power Suppy ( ) 6mm 69.8mm DIN 35mm 111mm 83.5mm 35mm 44mm in 24 VDC 4...20mA 4...20mA Zone 0 out ISO 420 11+ -12 1+ -2 L1 in _ 11+ 1 + 2 _ 12 4...20mA 4...20mA Zone 0 out ISO 420 + - + - N Security Barrier ISO 420 PLC 4...20mA Transmitter 4...20mA

Electrical connection using the Galvanic Isolator for a PLC with a passive input card. Connecting directly into the power supply Active PLC input card Passive PLC input card _ + PLC _ + Power Supply 4 ... 20 mA 0 ... 100 % _ _ + + Power Supply PLC + + + - - - Ground Ground Ground Different wiring scenarios for the N1 electronics 0 2 0 2 0 2 0 2 0 2 0 2 Span Span Span Zero Zero Zero Gain Gain Gain SC404 SC404 SC404 Sub Sub Sub 10...30VDC 10...30VDC 10...30VDC 4...20mA 4...20mA 4...20mA + + + _ _ _ 1 1 1 2 2 2 3 3 3 24Vdc 24Vdc (+/- 10%) 24Vdc (+/- 10%)

Active PLC input card Passive PLC input card _ + PLC _ + Power Supply 4 ... 20 mA 0 ... 100 % _ _ + + Power Supply PLC Different wiring scenarios for the G1 electronics 1 + _ 2 3 V=10...30VDC I=4...20mA 0 2 Gain SC404-G On S Z + - Ground 1 1 + + _ _ 2 2 3 3 V=10...30VDC V=10...30VDC I=4...20mA I=4...20mA 0 0 2 2 Gain Gain SC404-G SC404-G On On S S Z Z + + - - Ground Ground 0 2 Sub 0 2 Sub 0 2 Sub 12...30Vdc 24Vdc (+/- 10%) 24Vdc (+/- 10%)

Electrical connection for a PLC with a passive input card. Connecting directly into the power supply Active PLC input card Passive PLC input card _ + Power Supply 4 ... 20 mA 4 ... 20 mA 4 ... 20 mA 0 ... 100 % _ _ _ + + + Power Supply PLC PLC + + + - - - Ground Ground Ground Different wiring scenarios for the G2 electronics The G2 offers a built in galvanic isolator. In this case a separate one is not necessary. 0 0 0 2 2 2 0 0 0 2 2 2 Span Span Span On On On Zero Zero Zero Gain Gain Gain Sub Sub Sub 1 1 1 2 2 2 3 3 3 SC 404 SC 404 SC 404 24Vdc 24Vdc 24Vdc (+-10%) (+-10%) (+-10%) + + + - - - 4...20mA 4...20mA 4...20mA Sitron-USA - Phone (516) 935-8001 / Fax (800) 516-1656 24Vdc (+/- 10%) 24Vdc (+/- 10%) 24Vdc (+/- 10%)

short circuit between a bare stainless steel probe and the tank wall. For that reason we recommend the use of Teflon or other types of insulating coatings on the rod's surface (Fig. 1) Material build-up also affects the accuracy of RF capacitive measurements, and therefore additional adjustment to the probe's sensitivity is recommended in applications where build-up is a concern (Fig. 2) Housings must also be compatible with the requirements for wash-down, wet, and/or dusty environments. Hazardous environments may require the housing to be certified. In addition, the active probe might need to be intrinsically safe or have an intrinsic safety barrier (Fig. 3). The electronic circuitry of the probe performs several functions such as rectifying and filtering the incoming power, generating the radio frequency signal, measuring the changes in current flow, analog signal generators and display meters. The circuitry is provided with potentiometer adjustments for setting sensitivity that is located in the housing of the probe. These adjustments give an added level of fine-tuning which enable our customers to control the probe's sensitivity with greater accuracy (Fig. 3). Variation in current input (power supply) to the probe will affect the output. Therefore, a stable power supply should be available (Fig. 4). Coating (PTFE or Halar) Bare Rod Fig. 1 Fig. 2 Fig. 4 Fig. 3 Steel Tank Conductive Medium Adjust Sensitivity Build up Power Supply Conduit Conduit Cable Wires Wire Shield 0 2 0 2 Span On Zero Gain Sub 1 2 3 SC 404 24Vdc (+-10%) + - 4...20mA

500mm 100mm Fig. 2 Fig. 1 When installing the probe either directly to the tank, or utilizing a connection, the capacitance probe should be mounted on the top of the tank, never on the side or angle, so that the rod stays parallel to the tank wall (Fig. 1 correct Fig. 2 Incorrect). The mounting location of the probe should stay clear away from the point where the medium enters, this will avoid false reading from the sensor while being filled (Fig. 1 correct Fig. 2 Incorrect). The recommended distance of installation of the probe from the internal wall is a minimum of 500mm, and from the tip of the rod to the bottom of the tank is 100mm, this will prevent a false signal and possible build up between the wall and probe (Fig. 1 correct Fig. 2 Incorrect). Installation

vortices throughout use. If this is not possible we highly recommend a stilling well or sheath (Fig. 1 correct, Fig. 2 incorrect). Ensure that mounting position does not interfere with any obstructions wthin the vessel or tank (Fig. 1 correct, Fig. 2 incorrect). Fig. 1 Fig. 2 Level Rod Sheath Installation

Installation When installing the SC404 with cable and reference be sure that they are well connected to the bottom of the tank and that it has no slack. (Fig. 1 correct Fig. 2 Incorrect). The mounting location of the probe should stay clear away from the point where the medium enters, this will avoid false reading from the sensor while being filled (Fig. 1 correct Fig. 2 Incorrect). The recommended distance of installation of the probe from the internal wall is a minimum of 500mm, and from the tip of the pendulum to the bottom of the tank is 100mm, this will prevent a false signal and possible build up between the wall and probe (Fig. 1 correct Fig. 2 Incorrect). If the cable is secure to the bottom of the vessel it must be isolated and the vessel is steel it must be isolated so that it does not create a short circuit. Fig. 1 Fig. 2 500mm 100mm Isolator 15

signal, the main rod of the probe must have a parallel reference either to the tank or to a secondary reference rod or sheath. If the probe is mounted without this parallel reference within a cylindrical tank that is mounted on its side, the output signal will not be linear. Please consult one of our applications engineers if you have further questions (Fig.1 correct Fig. 2 incorrect). L=y L=z L=x Level Level Rod Single Rod Reference Rod 16

Calibration 8) With the 20mA signal adjusted it is best to re- adjust the Zero. Drain the tank back down to the starting level and re-adjust (if necessary) the minimum level to 4mA one more time. After this stage, set-up is complete. Adjustment (4-20mA): It is recommended that an multimeter be connected according to the figure below (fig.5) to monitor the current value during the calibration. 1) Drain the tank to minimum level (Zero% or 4mA). 2) Select the Gain switch 1,2,3 and Sub positions 1,2 or 3. It is recommended to begin with Gain switch 1 and Sub position 1 (Fig. 2). 3) Use the Zero potentiometer to set the current value for the actual level to 4mA. Turn the potentiometer clockwise to increase current. Turn the potentiometer counter-clockwise to decrease current (If the adjustment wasn't possible, alter the Sub and Gain position and try in adjust the minimum value (4mA) through the Zero Potentiometer)(Fig.3) 4) After calibrating the minimum value (4mA), fill up the tank to maximum level (100% - level). 5) The Sub and Gain switches should be in the same position as adjusted to 4mA. 6) Use the Span potentiometer to set the current value for the actual level to 20mA. Turn the potentiometer clockwise to increase current. Turn the potentiometer counter-clockwise to decrease current (Fig.4). 7) If the current is lower than 20mA after fully turning the Span Potentiometer clockwise, it is necessary to increase the sensitivity by selecting the next level of the switch (Sub and Gain). If the current still remains lower than 20mA, continue on to the next level until you achieve 20mA. 0 0 0 0 2 2 2 2 0 0 0 0 2 2 2 2 Span Span Span Span On On On On Zero Zero Zero Zero Gain Gain Gain Gain Sub Sub Sub Sub Fig.2 Fig.3 Fig.4 Fig.5 17

SC 404 24Vdc (+-10%) + - 4...20mA 0 2 0 2 Span Zero Gain SC404 Sub 10...30VDC 4...20mA + _ 1 2 3 1 + _ 2 3 V=10...30VDC I=4...20mA 0 2 Gain SC404-G On S Z 0 2 Gain 0 2 0 2 Zero Gain SC404 Sub + _ 1 2 3 0 2 On Zero Gain Sub 0 2 Calibration The dielectric value varies according to the product, temperature, pressure, rod's length and shape of the tank. Because of these variations, the parameters of the capacitive probe need to be adjusted according to each application as well as each tank. While the SC404 can be tested on a bench, the results of calibrating it will not be the same as calibrating the unit within the actual tank that you plan on installing it in. The SC 404 has 3 stages of sensitivity and that can be adjusted by a selective switch. Each stage has 3 subdivisions (1, 2, 3) for the SC404 and 4 subdivisions (1, 2, 3, 4) for the SC404-G to be combined with the selective switch. Check the values on the chart below according to your application. Capacitive Range for the SC404-G: Gain Sub 1) 1600pF to 5500pF 1 - 3750 to 5500pF 2 - 2500 to 3750pF 3 - 1600 to 2500pF 2) 400pF to 1500pF 1 - 900 to 1500pF 2 - 600 to 900pF 3 - 400 to 600pF 3) 100pF to 330pF 1 - 225 to 330pF 2 -150 to 225pF 3 -100 to 150pF 4) 25pF to 150pF 1 - 150 to 100pF 2 -100 to 70pF 3 - 70 to 25pF 0 2 Sub 0 2 Sub 18

Handling Probes: Care should be taken when handling and installing probes with coated rods to avoid scratching them. Scratching the coating could interfere with the probe performance. Periodic visual inspection of the probe is required to check for corrosion or deposit build-up. If deposits are found, clean the sensor to ensure optimum performance. The probe should not be dropped or suffer any impact or fall that could damage the electronics or the coating of the probe (Fig. 4 and 5). Seal the thread with Teflon tape before installation (Fig. 1). Do not turn or handle by the housing (Fig. 2). When tightening the sensor, use only use the 316S.S. hexagon fitting to achieve a seal, do not twist with the body of the sensor. (Fig. 3) When cleaning the rod use a soft brush or any other similar object. Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 1

SC404 22mA max 24Vdc (+/- 10%) Application Operating Voltage Current Consumption Electrical Connection Ambient / Operating temp. Cable gland - 1/2” NPT conduit entry or M12 connector Output Max Pressure IP 65 (N1) IP66 (G1/G2) Accuracy Enclosure Material Glass filled nylon, Aluminum Wetted Parts 316 Stainless Steel, PTFE Class Protection Process Connection Adjustment Sensitivity Range Frequency Oscillation Zero & Span Potentiometer 4...20mA (2 wires) 100 to 5500pF 400 kHz Continuous Level Measurement for Liquids and Solids 290 PSI (20 Bar) 0.5% 3/4” to 1 1/2” BSP or NPT Flange or Sanitary Connections -10 to 60ºC / -10 to 80°C (120°C extended neck) G2 G1 N1 Galvanic Isolation 3KVdc/60s 100M ohms, 500VDC

Probable short circuit Sensitivity to high Sensitivity to low Reference is incorrect Add a Reference Sheath the rod Coating on the rod is damaged Send back for repair Lack of signal from referance rod Signal Fluctuating No power supply Verify the grounding Verify that the rod is coated for conductive mediums Adjust sensibility again Adjust sensibility again Verify power supply Fault Cause Solution Verify the polarity of the power supply Inadaquate connection Sitron-USA - Phone (516) 935-8001 / Fax (800) 516-1656

RIGID ROD+REFERENCE ROD-1/2”(12.7mm) or 1/4”(6.3mm)-316SS CABLE GLAND W/ 1/2" BSP CABLE GLAND W/ 3/4" BSP CABLE GLAND W/ 1/2" NPT CABLE GLAND W/ 3/4" NPT ELECTRICAL CONNECTION RIGID ROD-1/2”(12.7mm) or 5/8”(16mm)-316SS 1/2" BSP 3/4" BSP 1/2" NPT 3/4" NPT SMALL ALUMINIUM SMALL NYLON 2 4 5 6 7 9 C 1 ROD (½") and SHEATH 316SS INSERTION LENGTH HOUSING FLANGE ANSI 150# CARBON STEEL PAINTED SPECIFY G1 N1 TYPE OF ROD OR CABLE STEEL CABLE-6.0mm PTFE TUBED L HALAR COATED OTHER-SPECIFY FLANGE ANSI 150# 316 SS FLANGE ANSI 150# 304 SS PROCESS CONNECTION TYPE FLANGE ANSI 150# PVC M RR R C NONE OTHER-SPECIFY COATING TRI-CLAMP S H T X BSP NPT OTHER B D E F K N T X 1 1/2” SIZE 3/4” 1” 2” 3” 4” 4 6 5 7 9 Q X SC404 MODEL SC404 OPTIONS Medium Temp - 50mm 316SS Neck (80-120C) MT LARGE ALUMINIUM G2

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