canongate vesselcheck st1 and st1a - rototherm canongate tiup sensor can be supplied to compensate...

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Rototherm Canongate Technology, 53-54 IMEX Centre, Dryden Road, Loanhead, Midlothian, EH20 9LZ Tel: 0131 448 0786, Email: [email protected] , Web: www.ct-uk.co.uk

Canongate VesselCheck ST1 and ST1A

Non-Intrusive Level Measurement Transmitter

User Manual

S-342-E

mailto:[email protected]

http://www.ct-uk.co.uk/

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Contents

1 INTRODUCTION ................................................................................... 4

1.1 General Description....................................................................... 4

1.2 Principle of Level Measurement .................................................... 4

1.3 Installation Equipment .................................................................. 5

1.4 Cable Specification ........................................................................ 5

1.5 ST1 Standard System Layout .......................................................... 7

1.6 ST1A ATEX System Layout ............................................................. 7

1.7 Processor Dimensional Details ....................................................... 8

1.8 ATEX Sensor Special Conditions For Safe Use ................................. 8

2 INSTALLATION ..................................................................................... 9

2.1 Equipment Supplied ...................................................................... 9

2.2 Components Parts ......................................................................... 9

2.3 Systems Installation .................................................................... 10

2.4 Board Layout and Connections .................................................... 11

2.5 Sensor Installation ...................................................................... 13

3 COMMISSIONING ............................................................................... 16

3.1 User Interface Program ............................................................... 16

3.2 Systems Preference Configuration ............................................... 18

3.3 Configuration menu .................................................................... 21

4 TECHNICAL SPECIFICATIONS ............................................................... 25

4.1 Signal Processor Unit ................................................................... 25

4.2 Digital Outputs ............................................................................ 25

4.3 Analogue Outputs ....................................................................... 26

4.4 Standard Ultrasonic Sensor ......................................................... 26

4.5 ATEX Ultrasonic Sensor ............................................................... 26

4.6 ATEX Ultrasonic Sensor + Temperature ........................................ 26



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Canongate Support and Service The equipment you have purchased has been built to the highest quality standards, and has been thoroughly tested before leaving our factory. It will give you many years of reliable and accurate service. If you require additional information, or have any queries or problems, our technical staff will be pleased to assist. For advice or information contact our Service Support Team: Telephone UK +44 (0)131 448 0786 Fax UK +44 (0)164 276 2899 Address Rototherm Canongate Technology 53-54 IMEX Centre Dryden Road Midlothian EH20 9LZ UK E -mail [email protected] Internet www.ct-uk.co.uk Rototherm Canongate Technology is a brand name of

The British Rototherm Co. Ltd. Kenfig Industrial Estate Port Talbot SA13 2PW UK Company Registration Number: 2570730




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1 INTRODUCTION

1.1 General Description

This manual has been written to support the VesselCheck ST1 software version V6.07 or above, and ST1Setup program V4.08 or above. The VesselCheck ST1 is a highly versatile and non-invasive liquid level measurement system. The system comprises a signal processor unit and ultrasonic sensor, which provides a measurement of liquid height in a vessel. The unit is powered from a direct current power supply, a jumper selectable option allows the user to select between a nominal 12v or 24vdc supply. Boards connected to an ATEX sensor are be fitted with 250mA Ferraz Shawmut G3084002 fuse. If this fuse is replaced, it must be fitted with the same type. The unit is supplied with a user selectable 4..20mA or 0..5 volt analogue output. A 4 digit LED display can be supplied as an optional extra. The unit is supplied with a RS232 and RS485 serial communications port as standard. Units fitted with a CT612 circuit board have a single serial port; the port operation is selected via jumpers, LK2 for RS485 and LK3 for RS232. Units fitted with the CT622 have dual serial ports and do not require jumper port type selector.

Note

1.2 Principle of Level Measurement

The unique non-intrusive method of level sensing makes the system ideal in situations where there is no access to the inside of the vessel. An ultrasonic transmit-receive sensor, mounted on the underside of the vessel emits a series of ultrasonic pulses. The time taken for an echo to be received from the liquid surface is measured electronically by the signal processing unit. This time is directly proportional to the distance to the liquid surface. The Canongate TIUP sensor can be supplied to compensate for ambient temperature variations, this sensor incorporates a temperature measurement sensor along with the ultrasonic crystal.

The RS232 protocol on the CT622 circuit boards is Modbus ASCII. The protocol on the RS485 port is user selectable ASCII or RTU.



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1.3 Installation Equipment

The following items will be required before you can begin the installation and calibration of the system:

Basic Hand Tools

Structural Adhesive or Coupling Grease

Silicon rubber sealant

Paint remover (where vessels are painted)

Cleaning solvent / degreaser

Abrasive paper

Marker pen

Paper towel roll

PC with Windows 95 or later and a serial port

9 way to 15 way communications cable

ST1Setup Program

Installation of ATEX sensors require special installation equipment or materials to maintain certification requirements, see section 2.5.

1.4 Cable Specification

1.4.1 Standard Sensor Cable

Description 0.5mm² / 1PR BS5308 PT1 Type 1 Collective Screen Black RP15 16 / 02mm²

Conductor Size 0.5mm²

Number of Conductors 1 Pair

Conductor Type Stranded

Material Copper

Screen / Shield Yes, Overall

Construction Overall Foil

Jacket Material PVC

Armour No

Armour Type None

Temperature Rating 65C

1.4.2 Standard TIUP Sensor Cable





Material Copper



Jacket Material PVC

Armour No



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Armour Type None


1.4.3 ATEX Sensor Cable





Material Copper



Jacket Material PVC

Armour Yes

Armour Type Steel Wired Armour


1.4.4 ATEX TIUP Sensor Cable





Material Copper



Jacket Material PVC

Armour Yes

Armour Type Steel Wired Armour


1.4.5 Power and Analogue Output Cable





Material Copper



Jacket Material PVC



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Armour No

Armour Type None


1.5 ST1 Standard System layout

1.6 ST1A ATEX System layout

The Sensor cable must be installed to comply with installation standard IEC 60079-14. Where steel wire armoured cable is not available cables must be mechanically protected by steel conduit.



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1.7 Processor Dimensional Details

1.7.1 ST1 Enclosure

1.7.2 ST1A Enclosure

1.8 ATEX Sensor Special Conditions for Safe Use

The cable must be mechanically protected and terminated in a suitable Ex d or Ex e terminal box.

The supply to the apparatus must be limited by a 250V fuse rated at not more than 250mA and having a breaking capacity of 1500A in accordance with EN60127 or EN60269. This must be suitably protected for the zone of installation.

The transducer must not be subjected to any external source of heating or cooling outside the range of the ambient temperature.



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2 ISTALLATION

2.1 Equipment Supplied

Signal Processor Unit 1 Ultrasonic Sensor 1 Manual 1 2.2 Component Parts

2.2.1 Signal Processor Unit

This Signal Processor Unit houses the microprocessor controlled board which is the heart of the VesselCheck ST1 system. It generates, transmits, receives, amplifies, conditions and measures the ultrasonic signal, and generates a user scaleable analogue output. The processor unit and sensor are supplied as a tuned pair and should not be mixed with other units. 2.2.2 Standard Ultrasonic Sensor

The sensor is connected to the processor electronics by a twinaxial cable. The standard cable length supplied is ten metres. Longer cable lengths or inline connector can be supplied at extra cost if required. Cable length should be kept as short as possible to reduce the possibility of electrical interference. Cable lengths should not exceed 50metres. 2.2.3 Ultrasonic Sensor + Temperature

The sensor is connected to the processor electronics by a three pair cable. The standard cable length supplied is ten metres. Longer cable lengths or inline connector can be supplied at extra cost if required. Cable length should be kept as short as possible to reduce the possibility of electrical interference. Cable lengths should not exceed 50metres. 2.2.4 ATEX Ultrasonic Sensor

The sensor is connected to the processor electronics by a single pair armoured cable. The standard cable length supplied is ten metres. Longer cable lengths or an ATEX approved junction box can be supplied at extra cost if required. Cable length should be kept as short as possible to reduce the possibility of electrical interference. Cable lengths should not exceed 50 metres. 2.2.5 ATEX Ultrasonic Sensor + Temperature

The sensor is connected to the processor electronics by a two pair armoured cable. The standard cable length supplied is ten metres. Longer cable lengths or an ATEX approved junction box can be supplied at extra cost if required. Cable length should be kept as short as possible to reduce the possibility of electrical interference. Cable lengths should not exceed 50 metres.



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2.3 Systems Installation

2.3.1 General

The system should be installed as follows:

Identify the best location for enclosures and sensors

On hazardous area applications the electronics must be located in the safe area

Install enclosures and cables

Terminate cable

Fit sensors

Configure ST1 Processor using ST1Setup Cable Runs: To reduce the risk of interference, routes for running all cables should be kept clear of areas of high frequencies and voltages, such as high voltage mains cables, and sources of RF interference, such as single phase motors and speed controls. 2.3.2 Signal Processor Unit

A suitable location should be found to mount the unit away from sources of electrical interference and excessive vibration. 2.3.3 Electrical Supply

The system requires either a 12 or 24Vdc supply. 2.3.4 ATEX Ultrasonic Sensor for Hazardous Area Applications

The ultrasonic Sensor is supplied in a version which is certified to ATEX Zone1 standards when installed as per IEC 60079-14:1996. The standard cable length supplied is ten metres. Longer cable lengths can be supplied.

All armoured cables run into hazardous area must be earthed at the control unit.



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2.4 Board Layout and Connections

CT612 circuit board

CT622 Circuit Board

CT622 circuit board

RS232 Connector

Program Jumper

TP A

TRIG

TP B

0 volt

Status LED

+ -

Sensor1

+ -

Output

+ - Supply

+ - Sensor2

0v 0v D +5v . Temp

+ - RS485

LOW HIGH

RS232

RS485 CT612

Program Jumper

TP A

TRIG

TP B

0 volt

Status LED

+ - Sensor1

+ -

Output

+ - Supply

+ - Sensor2

0v 0v D +5v . Temp

+ - RS485

LOW HIGH

mA Volt

CT622

RS232

Connector



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Sensor1 + -

Sensor2 + -

Silver

Screen

Copper

Sensor1 + -

Sensor2 + -

Blue

Copper

Drain Wire

2.4.1 Power Connections

The electrical supply to the unit can be either 12 or 24Vdc. It is also recommended that the zero volts is grounded. 2.4.2 Analogue Output Connections

The analogue output is connected via the two terminals marked Output (+) and (-). 2.4.3 Sensor Connections

Silver Core Sensor 1 + Copper Core to Sensor 1 – Screen to Sensor 2 -

2.4.4 Hazardous Area Connections

Blue Core Sensor 1 + Black Core to Sensor 1 – Drain Wires to Sensor 2 -

2.4.5 Standard Cable Connections with TIUP Sensor

2.4.6 Hazardous Area Connections with TIUP Sensor

+ -

Sensor 1

0v 0v D +5v

Temp

+ -

Sensor 2

+ -

Sensor 1

0v 0v D +5v

Temp

+ -

Sensor 2

Connect the White Core Sensor 1 + Connect the Black Cores Sensor 1 – and 0v Connect the Drain Wires Sensor 2 - Connect the Red Wire +5v Connect the Green Wire D

Connect the TX+ Sensor 1 + Connect the TX- Sensor 1 - Connect the Drain Wires Sensor 2 - Connect the +VE Wire +5v Connect the SIG Wire D

Connect the Ground 0v



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2.4.7 Communications Connections

The unit is supplied with a RS232 serial communication port. The port is connected via the high density 15 way D type socket. The RS485 communications is connected via the RS485 (+) and (-) screw terminals. 2.5 Sensor Installation

2.5.1 Sensor Positioning

To ensure optimum performance, it is imperative that the ultrasonic sensor is installed in the best location on the vessel. Carefully study the sensor location diagrams and confirm the positions on the vessel(s). An angle of up to 2° from horizontal is usually satisfactory, however the smaller the angle the better the signal will be. An angle finder or spirit level can be used to find the best position. Avoid placing the sensor over welds or irregularities on the vessel surface. Ensure the sensor is not placed below filling points or where an obstruction may be directly in the line of fire of the sensor. If you wish to test the sensor before bonding it, an ultrasonic gel or water type lubricant must be used. The sensor will NOT work on a Dry coupling, even over the shortest of measuring distances.



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2.5.2 Sensor Mounting

The sensors are bonded to the vessel with either a structural adhesive or high density grease to ensure an effective acoustic coupling that conducts the sensors ultrasonic signal through the vessel wall and into the monitored liquid. Sensors cannot be dry coupled. Where an angled sensor has been supplied, the angle of the sensors face will be approximately double that of the tank angle i.e. if the tank angle is 4˚ a sensor will be supplied with an 8˚ face, see example below.

2.5.2.1 ATEX Sensor Mounting

To maintain certification requirements ATEX sensors must be bonded to the vessel surface with structural adhesive, typically Loctite adhesive 326 and activator N or Permabond F241 / F246 and initiator 5. The Loctite adhesive is available from RS Components, Adhesive: 326 RS Part No 496-114 and Activator: N 7649 RS Part No 108-716.

Sensor Cable



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After bonding, a silicon sealant such as Dow Corning Silastic 732 must be used to form a continuous sealing fillet around the joint between sensor and vessel.

2.5.2.2 Bonding Using a Structural Adhesive

Once the sensor has been bonded to the vessel, it cannot be removed without damaging it. Ensure that the best possible sensor location has been identified. The adhesive will cure best when warm, so when working in a cold environment keep the adhesive warm.

Ensure the tank surfaces are clean and free from paint. Use an abrasive paper to remove paint and corrosion.

Lightly rub the sensor face with a fine grade abrasive paper.

Degrease both the sensor and vessel surfaces with a solvent cleaner. The cleaner must not leave a residue and must be compatible with the adhesive to be used and the sensor surface.

Follow the adhesive manufactures instructions for the best possible bond.

The best bond for conducting the ultrasonic beam is as thin as possible. The joint must be completely filled with adhesive with no bubbles or voids.

Apply the adhesive to the sensor and mating surface. Lightly press the sensor onto the vessel surface and rotate backwards and forwards slightly, 4 or 5 times, increasing the applied pressure on each rotation. Maintain the applied pressure until the sensor is bonded.

ATEX sensors – use silicon sealant to form a continuous sealing fillet around the joint between sensor and vessel.

Paint any exposed metal. 2.5.2.3 Bonding Using High Density Grease

This is only suitable for standard sensors or ATEX sensors in a safe area.

Some vessels may be surfaced with materials that adhesives have difficulty bonding with. Coupling grease, for example Rocol Kilopoise Grease 0868S, permits sensors to be used on these applications. Using a high density coupling grease also allows a sensor to be removed from a vessel without damage.

Where the sensor is bonded using grease, either a clamp or strap is required to permanently secure the sensor. The grease can only be relied on to provide acoustic coupling.



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3 COMMISSIONING 3.1 User Interface Program Install the ST1Setup program onto the PC by running the setup program from the disk supplied.

From the Windows Start Button, select Programs> Canongate> ST1Setup. The screen following should now be visible:

The program uses the address specified to communicate with the unit. The address is selected from a drop down list of available units. If the “Any” option is selected then any unit will reply, this is helpful if the actual unit address is unknown. This selection will only work on an individual unit and not a multi-dropped system. The unit’s actual Id and current version is displayed in the bottom panel.

Modbus Address

Product Speed of Sound in mm/uS

Span of Analogue output in millimetres

Product selected from pre-defined table

Modbus protocol either ASCII

or RTU

Communications Status to Unit

Update Icon

Software Version Number and Modbus ID Serial Port Status



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The program defaults to Serial Communications Port 1. To select another communications port, refer to section 3.3.7.

3.1.1 Volume % or Height %

The system can be configured to give an analogue output in either volume % or Height %. The measurement type to be output is configured in the User Configuration screen. When Volume % is selected, the volume of the tank’s contents will be calculated and represented in a percentage of the tank’s total volume. When Height % is selected, the measured liquid height will be scaled as a percentage of the span. 3.1.2 Height

This is the height, in millimetres, calculated from the ultrasonic time and the liquid speed of sound. 3.1.3 Status

Defines the Status of the Unit:- Signal OK - Ultrasonic signal OK No Signal - No signal received from the sensor Empty - Vessel detected as empty Initial - Booting up and signals as yet undefined.

3.1.4 Output

Displays the value of the analogue output.



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3.1.5 Signal Quality

Is the quality of the received signal, on a tank with no liquid movement, this value should not drop below 50% for any length of time. 3.1.6 Temperature

Indicates the temperature measured by the sensor. This is only displayed as and extra field if temperature compensation is selected. 3.1.7 Speed

This defines the speed of sound of the liquid. The value is edited by clicking on the edit box, entering a value in millimetres per microsecond and pressing the ENTER key. 3.1.8 Span

Defines the value at which the maximum analogue output is set. When the percentage volume is selected the span will be automatically set to 100. Where height is selected the span must be set to the maximum height to be measured in millimetres. The value is edited by clicking on the edit box and pressing the Enter key when complete 3.1.9 Product

The drop down box contains a list of known liquids with their corresponding speed of sound. Selecting the required value from the drop down list will automatically populate the speeds field. 3.1.10 Apply Button

The Apply Button saves the data displayed in the edit box to the ST1 non volatile memory. 3.1.11 Refresh Button

Clicking on the Refresh Button reads the data from the ST1’s non volatile memory and displays in the Edit Boxes. 3.2 System Preference Configuration To alter the program preferences, select File > Preferences from the Menu Bar



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3.2.1 System Preference Screen

3.2.2 Poll Interval

Is the time in tenths of seconds between communications requests. The default is 20 (2 seconds). 3.2.3 Height Adjust

Adds an offset to the Windows box height. This is required on some operating systems where the height of the Windows box is clipped. 3.2.4 Poll Timeout

This defines the timeout on a Modbus Poll in tenths of a second. This value should be extended from its default 20 to 40 if the communications are to be run via a modem.



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3.2.5 Poll Start Address

Defines the first number in the address drop down list. 3.2.6 Poll End Address

Defines the last number in the address drop down list 3.2.7 Speed File Name

Defines the file that will populate the Speed drop down box on the main screen. The default file name is speeds.spd. 3.2.8 Modbus Type

Defines the Modbus protocol used by the ST1Setup program. On the CT622 circuit boards, the protocol is ASCII. On the CT612 circuit boards, the protocol is defined by the RS485 serial port. 3.2.9 Connection

Defines the hardware connection between the PC and unit. Two options are available Serial and TCP/IP. Where TCP/IP is used the IP Address and Port number of the serial to IP device must be defined. An address book facility is available to save and recall the TCP/IP connections. 3.2.10 Logging

In Manual mode, the control of the systems data logger is controlled by the logging option in the configuration menu. In Automatic mode, the logging function will start on the opening of the ST1Setup program 3.2.11 Operator Level

The system has three operator levels, User, Engineer and Production. This manual only covers the User operation level. The Engineer and Production levels are password protected.



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3.3 Configuration Menu

3.3.1 Tank Calibration Data

This screen allows the user to create a contents profile using tank dimensional sizes. The contents indication is in percentage.

To create a contents profile, select the appropriate Tank Type Tab, enter the tank’s dimensions in meters, click on the Calculate Table button and on the Apply button to save. On horizontal tanks an option is available to enter the slope of the tank in degrees. 3.3.2 Digital Alarms

Two solid state volt free contacts rated at 24Vd.c., 50mA are available for High and Low alarms. These are activated on the User Configuration Screen. The high and low alarm values are entered in a percentage format, the Alarm Delay is entered in seconds. The status of the High and Low Alarms can be viewed on the Real Time Data Screen.



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3.3.3 User Configuration

The user Configuration Screen allows the user to configure the ST1 to meet their own requirements. Digital Alarms: Allows the user to enable or disable this function. 4..20mA and 0..5 Volts Analogue Output: Defines the type of analogue output a link detailed in section 2.4 must also be set. Output Measurement: Defines the units to be displayed on the local LED and on the analogue output. Modbus Protocol: Defines the style of Modbus to be used on the RS485 port. Note on the CT612 circuit board the RS232 and 485 ports are common, so changing the protocol type will require the user to change the protocol in the preferences on the St1Setup program. Probe Selection: Defines the type of probe attached to the unit. This is a drop down list of standard probes. Average Limit: Defines the degree of averaging to be applied. A zero is no averaging, 1-99 defines the number of points to average over.



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3.3.4 Real Time Data

Shows detailed ultrasonic data that may be requested by a Canongate Support Engineer and the status of the High and Low Alarm outputs. If temperature compensation is disabled the bottom panel displaying temperature information is not displayed.

3.3.5 Logging

Records the values selected in the Logging Parameter screen to file. The file name is created using the current time and date, the file name and path can be viewed in the bottom of the Logger window.



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The Logging Parameters Screen allows the user to select the parameters to be stored to file. If temperature compensation is enabled the extra parameters Temperature and Tc Count are included in the selection list.

Maximum Number of Log Files: The program will stop logging when this value is reached. If the value is set to zero, the program will continue to log until manually stopped. Length of Log Files: Defines the file length in minutes. Update Time: The interval time between logging a new set of data. Long File Names: When ticked will create a file name in the following standard C:\S1(CurrentDate & CurrentTime).csv. When unticked the format will conform to the eight dot three file name standard. File Options: Raw, saves the data in csv format, Zipped will store it in a compressed format and both will store the data in both formats. Log Directory: Defines the directory the data is to be stored in. 3.3.6 Test Log

This function should be used if you are having difficulties with the system. When run a test log in the form of a zip file is created on your desktop named St1TestLog.zip. This can be used by our technical sales team to assist with diagnoses of any problems with your system.



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The log file will log for the time specified in the logging time. Pressing the Log button starts the log, Finish allows the log to be stopped at any time during the running, and Abort abandons the log, storing no data. 3.3.7 Comms Port Setup

To display the Communication Port Configuration screen, select Configuration > Comms Port Setup.

Note

4 TECHNICAL SPECIFICATIONS

4.1 Signal Processor Unit

RATING IP56

SUPPLY 12 or 24Vdc

POWER CONSUMPTION 100mA

AMBIENT TEMPERATURE RANGE

-10 to 40C

MAXIMUM DISTANCE FROM VESSEL

50m

ACCURACY Application dependant

4.2 Digital Outputs

OPERATION High and Low Alarms

TYPE Solid State Relay

SPECIFICATION 24Vd.c. rated 50mA

Only the Port selection is user configurable, all

other settings must be left as shown



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4.3 Analogue Outputs

TYPE 0..5 volts or 4..20mA

ACCURACY Better than 1% of full scale

OPERATING RANGE 24V 0..5volts or 4..20mA User Scaleable dc rated 50mA

4.4 Standard Ultrasonic Sensor

CONSTRUCTION PZT Crystal in a phenolic resin laminated plastic housing

OPERATING TEMPERATURE RANGE

Up to 100C continuous

DIMENSIONS Application dependant

RANGE 30mm to 2m (Liquid Dependant)

CABLE LENGTH Standard length 3m

4.5 ATEX Ultrasonic Sensor

CONSTRUCTION PZT Crystal in a phenolic resin laminated plastic housing with stainless steel outer sleeve

ATEX CERTIFICATION BASEEFA 03ATEX0087X


Up to 60C continuous (T5)


4.6 ATEX Ultrasonic Sensor + Temperature

CONSTRUCTION PZT Crystal in a phenolic resin laminated plastic housing with stainless steel outer sleeve

ATEX CERTIFICATION BASEEFA 03ATEX0087X


Up to 60C continuous (T5)




canongate vesselcheck st1 and st1a - rototherm canongate tiup sensor can be supplied to compensate...

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