Boiler Drum Indicator Controller
Boiler Drum Indicator Controller
Boiler Drum Indicator Controller
Section: R500
Bulletin: R500.E249
Date: 09/30/2013
Supersedes: 09/13/2013
BOILER DRUM
INDICATOR/CONTROLLER
Installation, Operation and Maintenance Instructions
16633 Foltz Parkway
Strongsville, OH 44149 USA
Phone: +1 (440) 572‐1500 • Fax: +1 (440) 238‐8828
www.clark‐reliance.com • sales@clark‐reliance.com
TABLE OF CONTENTS
SECTION SUBJECT PAGE
1.0 Product Overview 4
2.0 Components 4
3.0 Unpacking and Inspection 5
4.0 Hardware Installation 5
4.1 Electrolev Water Column and Junction Box 5
4.2 Main Control Unit 8
4.2.1 Main 12 Channel Motherboard 8
4.2.2 Universal AC Power Supply 10
4.2.3 Probe Modules 12
4.3 LED Level Indicators 14
4.3.1 LED Display Controller 15
4.3.2 Medium LED Level Indicator 17
4.3.3 Small LED Level Indicator 21
5.0 Start Up and Operation 23
6.0 System Options 24
6.1 6 Channel Relay Module 24
6.2 4‐20 mA Transmitter Module 26
6.3 Dual Universal AC Power Supplies 33
6.4 24 Channel Expansion PCB 33
7.0 System Maintenance 35
7.1 Periodic Visual Inspection 35
7.2 Electrolev Column Blowdown 35
8.0 System Specifications 37
9.0 System Troubleshooting 38
10.0 Part Number Information 41
11.0 Model Number Information 41
12.0 Warranty 42
Page 2
WARNING!
IN ALL CASES WHERE THIS MARKING IS PRESENT, CONSULT THE
INSTALLATION MANUAL FOR POTENTIAL HAZARDS AND REQUIRED STEPS TO BE
TAKEN BEFORE SERVICE.
WHERE THIS MARKING IS PRESENT, ISOLATE OR DISCONNECT THE
POWER SUPPLY SOURCE BEFORE SERVICE.
THE EYE‐HYE SMARTLEVEL SYSTEM HAS MAINS VOLTAGES UP TO 230VAC PRESENT WHEN
INSTALLED AND OPERATING FROM A POWER SOURCE. CARE MUST BE TAKEN AT ALL TIMES
WHEN THE ENCLOSURE IS OPEN AND MAINS POWER IS APPLIED.
IF THIS EQUIPMENT IS USED IN A MANNER NOT SPECIFIED BY CLARK‐RELIANCE, THE
PROTECTION PROVIDED BY THE EQUIPMENT MAY BE IMPAIRED.
ONLY REPLACEMENT PARTS MANUFACTURED BY CLARK‐RELIANCE SHOULD BE USED TO
ENSURE SAFETY AND RELIABLE OPERATION. ALL SMARTLEVEL COMPONENTS MUST BE
MOUNTED IN PROTECTIVE EARTH GROUNDED METAL ENCLOSURES.
WARNING: USE OF NON CLARK‐RELIANCE PARTS WILL VOID THE FACTORY WARRANTY AND
ANY AGENCY APPROVALS.
ORDER GENUINE CLARK‐RELIANCE REPLACEMENT PARTS AT:
http://parts.clark‐reliance.com
ALL INSTALLATION AND OPERATING ACTIVITIES SHOULD BE PERFORMED BY A QUALIFIED
TECHNICIAN AND SHOULD BE EXECUTED IN ACCORDANCE WITH ALL APPLICABLE NATIONAL
AND LOCAL CODES.
NOTE: Your site may qualify for SureStart, a no‐cost equipment review and start
up assistance program. Contact your local Clark‐Reliance office to see if you
qualify. This service can also be arranged for a nominal fee if your site does not
qualify.
Page 3
1.0 PRODUCT OVERVIEW
The Eye‐Hye SmartLevel system is a microprocessor based industrial level control system that
allows for the direct measurement of water level in a high temperature and pressurized boiler
drum. Its modular design allows it to be configured to measure level over a User determined
range and resolution and indicate it in a variety of methods, visually and/or electronically to
plant control systems.
2.0 SYSTEM COMPONENTS
The Eye‐Hye SmartLevel system consists of (3) basic parts. The first part is a water column that
is custom manufactured for any boiler drum. It can be supplied with up to (24) separate water
probes about the level of interest, linearly or un‐linearly along the column. Each probe is then
connected by high temperature insulated wire to a junction box that serves to connect the
individual probe electrode circuits and the column ground to the main control unit. A separate
conductor is required for each probe.
The second part of the system is the main control unit and is typically mounted locally near the
boiler drum in its own metallic enclosure. The enclosure mounts the main 12/24 channel
backplane that serves as the base for all of the system modules and to make the connections.
One cable entry should be used for probe wires from the column’s junction box and another
dedicated for the AC mains input. Additional cable entries can be added for electrical signal
outputs that connect to other plant control or indication instrumentation.
The third part of the system is the LED level indicators. Two sizes are available to fit the Users
available mounting space and visual requirements. One LED level indicator can be mounted
locally in the enclosure door or multiple indicators separately in their own enclosure nearby or
up to several thousands of feet away, in a control room. Multiple LED level indicators only
require a 4 wire cable connection as they daisy chain from indicator to indicator.
Page 4
3.0 UNPACKING AND INSPECTION
Always use caution when lifting or moving SmartLevel components. Some components may
require special equipment to safely move or install.
Upon receipt of the Eye‐Hye SmartLevel system, examine all products for any damage. Report
any suspicious conditions as soon as possible to your carrier to avoid acceptance of damaged
goods. Clark‐Reliance will not be responsible for goods damaged in shipping, storage, or
subsequent loss or damage due to improper storage and exposure.
Verify all materials are present as recorded on the packing list provided with each shipment.
Report any discrepancies to Clark‐Reliance immediately. Please have the Clark‐Reliance order
number and shipping waybill available at time of reporting.
4.0 HARDWARE INSTALLATION
4.1 ELECTROLEV WATER COLUMN AND JUNCTION BOX
The Electrolev Column should be installed on the boiler drum or vessel as shown
in Figure 1. The distance between the Electrolev and the boiler drum should be
kept to a minimum. A slope in the steam leg running from the drum or vessel
towards the Electrolev of not less than 1 inch (25mm) of fall for each 50 inches
(1.27m) of linear length is recommended. The water leg can be horizontal or
installed with a downward slope running from the Electrolev to the drum or
vessel. Care should be taken to insure no restriction or ‘trap’ occurs in the
pipework which may lead to an accumulation of sediment, resulting in a
restriction of flow to or from the Electrolev column. Isolation (Shut‐off) valves
should be installed to permit maintenance of the Electrolev while the vessel is
pressurized. The standard vessel connections are 1" (25mm) male pipe
projections. Flanged or female socket weld connections are available options. A
drain valve must be installed at the bottom of the Electrolev, as shown in Figure
1. The standard drain connection on the Electrolev is 1/2"(15mm) female
socket‐weld.
If the steam leg piping should be left exposed to encourage the formation of
condensate flow to the Electrolev column (to promote heat transfer to minimize
density related errors), it is recommended that shields or guards be fitted to
reduce the risk of contact with hot surfaces. It is recommended that the water
leg piping between the boiler drum and the Electrolev be insulated. Insulation
will reduce the effects of cooling and will provide added personnel protection
from hot piping. The Electrolev column may be insulated by field personnel, or
with a custom‐fitted insulation jacket available from Clark‐Reliance.
Page 5
Figure 1‐ Eye‐Hye Components and Typical Installation
Field Wiring from the Electrolev is terminated in the Junction Box with the probe
wire per Figure 2, (note that Figure 2 is for a 10 probe column and that systems
that have more or less probe channels are wired similarly). A separate wire from
the water column’s ground is terminated as the GND (signal ground) conductor.
Figure 2 – Electrolev Column Wiring
Page 6
Electrolev columns rated up to 1000 psi (66 Bar) use 18 GA stranded conductor with Teflon
insulation that is rated at 300 VAC and 200°C / 392°F. Columns rated 1000 to 3000 (66 to 200
Bar) psi use 18 GA. stranded Nickel coated Copper conductor with Teflon‐treated glass braid
insulation rated at 600 VAC and 450°C / 842°F ‐ UL #5107. Both are available from Clark‐
Reliance. See Table 1.
Wiring from the Junction Box to the control units should be made with RG‐174
coax. A separate cable is used for each probe, i.e. the column in Figure 2 would
use 10 separate lengths of coax. It is suggested that each cable be prepared as
shown in Figure 3 with a coax ferrule, spade lug, and ground wire before
terminating it at the Junction Box. All are available from Clark‐Reliance. See
Table 1.
Table 1
Item Order
Description Part No.
Units
1 RG‐174 Coax Cable E‐COAX‐RG174 Ft
2 Spade Lug X174973 Ea
3 RG‐174 Cable Ferrule E‐FER‐RG174 Ea
4 22 AWG Stranded Wire E‐W‐22‐00‐1007 Ft
5 RG‐59/174 Ferrule Crimping Tool E‐TOOL‐RG174 Ea
6 18 AWG Stranded Teflon Insulated Probe Ft
X174861
Wire
7 18 AWG Stranded Glass Braided Probe Wire X174863 Ft
Figure 3 – Junction Box Wiring
Page 7
4.2 MAIN CONTROL UNIT
The Control Unit is the central hub of the SmartLevel system and is available in
metal NEMA 4, 4X, and explosion proof enclosures. It should be mounted within
250 feet (75m) from the Electrolev water column in an area that is accessible for
inspection and is below 140°F (60°C). Refer to the dimensional drawings specific
to the materials ordered for mounting dimensions.
The control unit houses all the main electronic components and allows
interfacing to the Electrolev column, mains input power, LED Indicators, and
other process control equipment. The integrity of the NEMA/IP enclosure must
be maintained before and after the installation of cables, accessories, etc.
4.2.1 Main 12 Channel Motherboard
NOTE: All probe module and peripheral installation and removal MUST
be performed with the mains power OFF or disconnected to avoid any
possible damage. It may also be necessary to pre‐bend in the mounting
rails to completely engage the locking tabs should they get bent outward.
The Main 12 Channel Motherboard is the central hardware configuration
platform for the system. It allows for the mounting and electrical
connections between all its probe modules and I/O peripherals and
allows for mains power and Electrolev probe connections. Probe
modules are installed in slots J1‐J12, for channels 1 through 12, in the
center of the PCB assembly, one for each used Electrolev probe,
numbered from the columns bottom up. To install a probe module,
simply insert its connector’s accessible left or right side, then fully engage
connection by gently seating the entire connector until the locking tabs
on the probe module’s cover seats into the slot on the mounting rail.
Care should be taken to avoid bending pins on the probe module by
forcing the insertion. See Figure 4.
Installation of I/O peripherals install similarly to the probe modules
except that they are installed in slots J13‐J15 and are retained by an
upper and lower mounting rail. Installation is made by carefully guiding
each peripheral back while lining up the connector and it’s upper and
lower locking tabs until the connector is fully seated and both locking
tabs are seated in the mounting rails. User I/O electrical wiring
connections can then be made to the I/O peripherals per their individual
instructions. Note the incorporation of plastic cableways on each side of
the motherboard for cable dressing upon wiring completion.
Page 8
SMARTLEVEL MAIN BACKPLANE CLARK RELIANCE - USA
FRONT
J15
PANEL J19 E PWB J1023
EXPANSION I/O
I/O MODULES CPU PROBE INPUTS
PROBE MODULE
AUX MAIN
12 12
CH 11 GND GND
CH 12
11 11
J16
J11 J12 10 10
GND GND
9 9
I/O1 I/O2 I/O3 CH 9 CH 10 8 8
J13 J14 J15 GND GND
J9 J10
7 7
6 6
CH 7 GND GND
CH 8
5 5
J7 J8 4 4
GND GND
3 3
CH 5 CH 6 2 2
GND GND
J5 J6
1 1
TB4 TB3
CH 3 CH 4 PROBE TEST
SW1 SW2 SW3
1 2 3 4 1 2 3 4 1 2 3 4
J3 J4
OPEN OPEN OPEN
1 11
1 2 34 5 6 78 9 0 12
CH 1 CH 2 RTD INPUTS
J1 J2 TOP BOTTOM
EXT+ EXT+
SIG+ SIG+
SIG+ SIG+
POWER SUPPLY 1 POWER SUPPLY 2
EXT- EXT-
TB5 TB6
AUX F1 M1N/L2 AC
MAIN 1
CLARK RELIANCE SMARTLEVEL CLARK RELIANCE SMARTLEVEL
85-264 VAC POWER SUPPLY 85-264 VAC POWER SUPPLY N/L2
L/L1
TB1
F2 M1L/L1
F3 M2N/L2 AC
P1 MAIN 2
J17 J18 N/L2
L/L1
AC IN DC OUT AC IN DC OUT
TB2
F3 M2L/L1
Figure 4 – 12 Channel Mother Board
The probe connections from the Electrolev are made to the probe
modules through the motherboard and are connected to TB3. Prepare
the RG‐174 coax in the same. Solder tin center core wire before installing
into header plug. Note that a pair of probe channel connections shares a
ground connection and that the connector is removable to allow ease of
wiring. See Figure 5.
NOTE: The ferrule crimp is not a requirement for all connections, but is
highly recommended by Clark‐Reliance to ensure the quality and
integrity of the signal.
Connections to J16, TB5, TB6, and J20 are not supported at this time.
Connector J19 allows for electrical connections to the Expansion PCB that
adds an additional 12 probe module channels, for a 24 channel system,
and 4 more I/O peripheral slots, which is described in Options, section
6.0.
A row of 12 DIP switches on the right middle side of the motherboard
allow the User to test each probe module channel and the rest of the
system for operation by simulating a water condition on each channel.
Simply switch the channel to be tested to the ON/UP position to test.
NOTE: All the switches must be OFF/DOWN for normal water level
indication.
Page 9
SPECIAL FERRULE
AND GND WIRE
MAIN BACKPLANE ATTACHED TO
CE CORP. USA RG-174 COAX
PROBE INPUTS
12 12
PROBE CABLE 12
GND GND
PROBE CABLE 11
11 11
10 10
PROBE CABLE 10
GND GND
PROBE CABLE 9
9 9
8 8
PROBE CABLE 8
GND GND
PROBE CABLE 7
7 7
6 6
PROBE CABLE 6
GND GND
PROBE CABLE 5
5 5
4 4
PROBE CABLE 4
GND GND
PROBE CABLE 3
3 3
2 2
PROBE CABLE 2
GND GND
PROBE CABLE 1
1 1
AUX MAIN
INPUTS INPUTS
PROBE TEST
1 2 3 4 1 2 3 4 1 2 3 4
1 11
12 34 5 678 9 0 12
Figure 5 – Probe Module Wiring
4.2.2 Universal AC Power Supply
The Universal AC Power Supply provides power from an AC Main supply
source to power the system. A single supply is typically installed in slot
J17. The supply is installed and secured by (3) 6‐32 x ½ machine screws.
An additional supply can be installed in slot J18 to be either used as a
backup supply from a separate power source or a redundant, backup
supply from a single AC source. See Figure 6.
Figure 6 – Motherboard Power Supplies
Page 10
Each supply can accept 115/230VAC at 50/60Hz and is self‐switching.
The power supplies are also power factor corrected and incorporate
active load sharing. Each is fused for safety as an entity and fused
additionally on the motherboard for servicing. The AC Mains inputs are
easily connected at AC Main 1 and AC Main 2 on removable connectors
that accept wire sizes from 12 to 20 AWG. See Figure 7.
Figure 7 – AC Mains and Protect Earth Grounds
The fuse blocks, F1/F2 and F3/F4 allow for easy fuse servicing. Note that
fuses F2 and F4 allow for fusing of the line on 115 VAC Americas and 230
VAC European single phase systems and that F1 and F3 allows for dual
line fusing on 230 VAC Americas dual phase systems. Note that a shunt
should be used for any single phase neutral, in F1 and/or F3.
AMERICAS ONLY: Fuses are included for both 115VAC and 230VAC
operation and are in labeled bags. Locate the correct fuses for the
power input, install and discard the other fuses.
Replacement Fuses:
1.) T3.15A 5x20 mm Fuse, (for 120 VAC use),
Clark‐Reliance P/N: E‐F‐DIN‐0315‐T
2.) T1.25A 5x20 mm Fuse, (for 240 VAC use),
Clark‐Reliance P/N: E‐F‐DIN‐0125‐T
3.) 5x20 mm Shunt, (for neutral fusing only),
Clark‐Reliance P/N: E‐F‐DIN‐SHUNT
Replacement fuses can be purchased at:
PARTS.CLARK‐RELIANCE.COM
NOTE: The protective earth ground from the Power Mains should be
connected to the enclosure via the bottom right mounting screw securing
the motherboard. A separate earth ground MUST be connected to the
Page 11
terminal lug on the metal mounting plate and secured with the provided
lock washer. See figure 7.
Individual LED indicators are provided to indicate the supply’s operational
status. An AC IN LED is used to indicate a connection to an AC main and a
DC OUT LED is used to indicate a “good” DC voltage output. Each supply
powers a single 12 VDC power buss that is used to power the entire
system. Each supply is rated for 150 watts and is protected by its own
internal safety fuse.
Local and national electrical codes may require a disconnect device
(switch, circuit breaker, etc). This must be appropriately marked in a
suitable location near the equipment and easily accessible. Do not
position the equipment so that it is difficult to operate the disconnecting
device.
4.2.3 Probe Modules
The Probe Modules are the brains of the water detecting technology
within the SmartLevel system. There is one for each probe in the
Electrolev column and each run independent of the others. Using a pulse
width modulated signal (PWM) and a high impedance input circuit, the
return analog signal from the probe is digitized and compared to a
grounded measurement. This allows it not only to detect the presence of
water, but also allows it to determine the integrity of its reading in
regards to the water quality and condition of the probe. Computed
thresholds within the software indicate the presence of water and its
reliability via a probe attention or BLUE LED, Blow‐down Indicator.
Should the Blow‐down indicator illuminate, a blow‐down needs to be
performed. The Blow‐down indicator will reset automatically when the
reading is back to a normal range. This feature eliminates needless
maintenance and keeps personnel safer as a result of lower exposure
times in potentially hazardous area. See Figure 8.
Figure 8 – Probe Module Front Panel
Page 12
Each probe module has 4 LEDs on it and they are explained as follows
from left to right.
1.) PWR – This is a GREEN LED that when lit indicates the module is
receiving power and ON.
2.) STATUS – This is a RED/GREEN LED. When the module is operating
correctly the LED will be GREEN. Should the module stop running the
LED will turn RED.
3.) ATTN PROBE – This is the Blow‐Down Indicator. It is a BLUE LED that
will only light if the probe on that channel is sufficiently
dirty/defective and is need of a blow‐down or possible replacement.
This indication is also qualified over time to prevent false indication
and is self‐clearing when the condition is remedied.
4.) SENSE – This is a GREEN LED that lights when water is sensed on the
probe. It is OFF in steam or when it doesn’t detect water.
The probe module has been designed as a universal probe module and
has a set of recessed DIP switches that allow the operator to change the
way it behaves. They are explained as follows. Note that they are
numbered 1 to 8, left to right and are OFF in the up position.
1.) SW1 – Impedance. This switch allows the sensitivity to be increased.
OFF/UP is Normal or LOW impedance. HIGH impedance is selected by
setting the switch ON/DOWN. This may be needed for process water
that has been highly de‐ionized and treated making it less conductive.
2.) SW2 – Factory Test. Setting this switch ON/DOWN continuously
invokes the Test Outputs command and consecutively runs other
factory diagnostics. Setting this switch OFF/UP turns it OFF. Note that
this switch only works in the MANUAL Mode, see switch SW7.
3.) SW3 – Program 1 (Future use).
4.) SW4 – Response Delay. Setting this switch ON/DOWN implements a
3 second ascending and descending delay. Setting this switch OFF/UP
turns it OFF. Note that this switch only works in the MANUAL Mode –
see switch SW7.
5.) SW5 – Inverse. Setting this switch ON/DOWN implements inverting
the Sense output. Setting this switch OFF/UP turns it OFF. Note that
this switch only works in the MANUAL Mode – see switch SW7.
6.) SW6 – Sense Output ON. Setting this switch ON/DOWN turns ON the
Water Sense output regardless of the readings. Setting this switch
OFF/UP turns it OFF. Note that this switch only works in the MANUAL
Mode – see switch SW7.
7.) SW7 – MANUAL Mode. Setting this switch in the ON/DOWN position
sets the probe module in the MANUAL Mode and allows the
operation of SW2 through SW6. Setting it in the OFF/UP position
disables their operation and enables the AUTO mode.
8.) SW8 – Hardware Reset – Setting this switch to ON/DOWN holds the
module in a hardware reset state. The unit will not perform any run
tasks and will indicate so by turning the status light red.
NOTE: Switch must be in OFF/UP position for normal operation.
Page 13
4.3 LED LEVEL INDICATORS
The LED Level Indicators allow a visual indication of the water level in the
Electrolev column by bi‐colored RED/GREEN LEDs. LED indicators are designed
for panel mounting. All indicators also include a BLUE LED for probe
service/blow‐down indication and another RED/GREEN LED for SYSTEM STATUS
indication.
The LED Level Indicators should be mounted for ease of viewing by the operator
in accordance with operational considerations and applicable codes. Up to 16
indicators can be added in daisy‐chain fashion for distances up to 1 mile
(1.61km) from the LED Display Controller. Weatherproof enclosures are
available for outdoor installations. Wall mounting brackets are also available
from Clark‐Reliance. Refer to dimensional drawings of specific products for panel
cutouts and mounting dimensions.
Contact the Clark‐Reliance Sales Department at:
Email: sales@clark‐reliance.com
Phone: +1 (440) 572‐1500
Page 14
4.3.1 LED Display Controller
The LED Display Controller is a peripheral assembly shown in Figure 9.
Communications to all the LED indicators, small or large, are wired to it.
An industry standard RS‐485 interface is incorporated for reliable
operation and effective immunity to environmental electrical noise. The
display controller updates the indicators every second. Connections are
easily made from the controller to one or more indicators by daisy
chaining their signal connections as shown in Figure 10.
TM
Figure 9 – LED Display Controller
Page 15
2
W2 SW1
3
4
1
PIN6-PWR/COM GND PIN6-PWR/COM GND PIN1-RS422 XA
2
3
PIN5-12VDC OUT PIN5-12VDC IN PIN2-SHIELD
4
PIN4-ISOGND PIN4-ISOGND PIN3-RS422 XB
PIN3-RS422 XB PIN3-RS422 XB PIN4-ISOGND
PIN2-SHIELD PIN2-SHIELD
PIN1-RS422 XA PIN1-RS422 XA PIN5-12VDC IN
PIN6-PWR/COM GND
REMOTE
REMOTE
LOCAL
LOCAL
1
1
2
2
3
3
4
4
TM
LARGE LED
LED DISPLAY SMALL LED INDICATOR
INDICATOR (REMOTE)
CONTROLLER
(LOCAL)
AC WALL
ADAPTER
Figure 10 – Typical LED Display Controller and LED Indicator Wiring
Both LED Indicator connectors pin outs are as follows. Two twisted pairs
or 4 conductor‐shielded 18‐22 AWG wire is recommend for use.
Note the pin numbering above in Figure 10. Pins are not always
numbered in the same direction.
1.) Pin 1 – RS485 XA signal, twisted pair 1.
2.) Pin 2 – Shield common.
3.) Pin 3 – RS485 XB signal, twisted pair 1.
4.) Pin 4 – ISO Ground (only for special circumstances where ground loops
exist).
5.) Pin 5 – 12 VDC fused at 1A for local use, twisted pair 2.
6.) Pin 6 – Power/Signal common/GND, twisted pair 2.
Page 16
Each Display Controller also contains a set of DIP switches for testing
itself and its connected LED indicators. They are numbered 1 to 8,
bottom to top. Switches are OFF/LEFT.
1.) SW8 – Hardware Reset – Setting this switch to ON/RIGHT holds the
Display Controller in a hardware reset state. The unit will not perform
any run tasks and will indicate so by turning the status LED red.
NOTE: Switch must be in OFF/LEFT position for normal operation.
2.) SW7 – Factory – Setting this switch ON/RIGHT continuously runs the
factory diagnostics.
3.) SW6 – Program 2 (Future use)
4.) SW5 – Program 1 (Future use)
5.) SW4 – Status Test – Setting this switch ON/RIGHT turns the SYSTEM
STATUS indicator RED, BUT the module keeps on working otherwise.
Resetting the switch to the OFF/LEFT position returns it to normal
operation.
6.) SW3 – 24 Channel Sequence Test ‐ Setting this switch ON/RIGHT turns
OFF normal level indication and invokes a channel by channel
sequence test where each channel, 1‐24 is RED for 1 second, while
the others are GREEN. The test repeats continuously. Resetting the
switch to the OFF/LEFT position returns it to normal operation.
7.) SW2 – Lamp Test ‐ Setting this switch ON/RIGHT toggles all the LEDs
RED and then GREEN continuously. Resetting the switch to the
OFF/LEFT position returns it to normal operation.
8.) SW1 – Comm Termination – Setting this switch ON/RIGHT adds a 120
ohm terminal resistor on the control unit side of the RS‐422
communication transmission line. Resetting the switch to the
OFF/LEFT position eliminates the resistor.
NOTE: Keep OFF/LEFT unless excessive cable lengths and/or
communication issues require use, (consult factory).
4.3.2 Medium LED Level Indicator
The Medium LED Level Indicator has a panel size of 3 inches (76.2mm)
wide by 11.75 inches (298.5mm) high. It is best suited panel mounted
remotely in a control room application or located in its own enclosure in
other plant remote areas where boiler drum level is required at a glance,
see Figure 11.
Page 17
INCHES FROM NORMAL
+12 +12
+7 +7
+5 +5
+3 +3
+1 +1
0 0
-2 -2
-5 -5
-9 -9
-14 -14
-20 -20
BLOW
STATUS DOWN
Eye-Hye
SmartLevel
Figure 11 – Medium LED Indicator
Each probe channel is indicated by three RED/GREEN bi‐colored LEDs in a
row where GREEN is used to indicate the presence water. All LEDs
protrude from the front panel enough to allow better than 90 degrees of
viewing angle. A single RED/GREEN bi‐colored LED on the bottom left of
the panel is used to indicate the operational status of the entire system,
illuminated GREEN when everything is working normal and turning RED
when there is a detectable problem. A single BLUE LED on the bottom
right of the panel which is not normally lit. Should it light, it is indicating
that a probe is not reading an optimum measurement and that a blow‐
down or probe replacement may be necessary. The operator can then go
to the main control unit and see which probe channel is initiating the
warning by a visibly lit BLUE LED on the corresponding probe module. The
BLUE LED is self‐clearing when the condition is remedied.
All wiring specifications are the same for any LED indicator and are given
in section 4.3.1 for the LED Display Controller.
On the rear side of the Medium LED Indicator are located 3 sets of four
DIP switches for self‐testing and configuring, see Figure 12 for switch
positions and orientation. Note that all switches are OFF/LEFT and
ON/RIGHT.
Page 18
FACTORY PGM
1 2 3 4
SW3 SW2 SW1
1
2
1 2 3 4
3
4
1
2
3
4
1
2
3
4
OFF ON
1 2 3 4
PIN1-RS422 XA
REMOTE
PIN2-SHIELD
PIN3-RS422 XB
PIN4-ISOGND
PIN5-12VDC IN
PIN6-PWR/COM GND
PIN1-RS422 XA
PIN2-SHIELD
LOCAL
PIN3-RS422 XB
PIN4-ISOGND
PIN5-1A FUSED 12VDC
PIN6-PWR/COM GND
Figure 12 – Medium Indicator DIP Switches
1.) SW1‐1 – Program 1 (Future use).
2.) SW1‐2 – Color Blind Mode – Setting this switch ON enables color blind
mode. In color blind mode only GREEN LEDs are lit for the presence
of water. Not being lit means steam or no water is present. NOTE
that only the level indicating LEDs are affected and that this mode
does NOT affect the SYSTEM STATUS light.
3.) SW1‐3 – Channel Mode D0 – The settings of this switch and SW1‐4
allow the LED indicator to switch from viewing 1‐12 channels to 1
through 10, 8 or 6 channels in 12 Channel Mode or viewing 13‐24
channels to 13 through 20, 16, or 14 in 24 Channel Mode. Channels
displayed in 12 Channel Mode are center justified and those in 24
Channel Mode are bottom justified. LEDs on unused rows are turned
OFF. See Figure 13.
Page 19
Figure 13 – SW1‐3 & SW1‐4 Channel Display Modes
4.) SW1‐4 – Channel Mode D1 – See SW1‐3 and Figure 13.
5.) SW2‐1 – Sequence Test – Setting this switch ON allows for the
channel sequence test. Here each channel is individually activated
bottom to top and top to bottom continuously. Returning it OFF
restores normal operating mode.
6.) SW2‐2 – Program 2 (Future use).
7.) SW2‐3 – Program 3 (Future use).
8.) SW2‐4 – Program 4 (Future use).
9.) SW3‐1 – Hardware Reset – Setting this switch to ON holds the module
in a hardware reset state. The unit will not perform any run tasks and
will indicate so by turning the SYSTEM STATUS LED RED.
NOTE: Switch must be in OFF position for normal operation.
10.) SW3‐2 – 24 Channel Mode – Setting this switch ON assigns the display
as the second bank of channels, 13 – 24 in a system with more than
12 channels. Returning to OFF displays channels 1 through 12. Note
the LED row justifications and channel assignments mentioned for
SW1‐3 and SW1‐4 settings.
11.) SW3‐3 – Lamp Test ‐ Setting this switch ON toggles all the LED RED,
then GREEN, continuously. Resetting the switch to the OFF position
returns it to normal operation.
12.) SW3‐4 – Comm Termination – Setting this switch ON/RIGHT adds a
120 Ohm terminal resistor on the control unit side of the RS‐422
communication transmission line, as a standard Buss termination.
Resetting the switch to the OFF/LEFT position removes the
termination resistor to the transmission default. NOTE: Keep
OFF/LEFT unless excessive cable lengths and/or communication issues
require use, (consult factory).
Page 20
4.3.3 Small LED Level Indicator
The Small LED Level Indicator has a panel size of 1.75 inches (44.5mm)
wide by 5 inches (127mm) high. It is best suited panel mounted remotely
in a control room console or locally in the front door of the main control
unit. See Figure 14 below.
Figure 14 – Small LED Indicator
Each probe channel is indicated by three RED/GREEN bi‐colored LEDs in a
row where GREEN is used to indicate the presence water. All LEDs
protrude from the front panel enough to allow better than 90 degrees of
viewing angle. A single RED/GREEN bi‐colored LED on the bottom left of
the panel is used to indicate the operational status of the entire system,
illuminated GREEN when everything is working normal and turning RED
when there is a detectable problem. A single BLUE LED on the bottom
right of the panel which is not normally lit. Should it light, it is indicating
that a probe is not reading an optimum measurement and that a blow‐
down or probe replacement may be necessary. The operator can then go
to the main control unit and see which probe channel is initiating the
warning by a visibly lit BLUE LED on the corresponding probe module.
The BLUE LED is self‐clearing when the condition is remedied.
All wiring specifications are the same for any LED indicator and are given
in section 4.3.1 for the LED Display Controller. The connector pin outs
are as follows for the Remote connector.
As a convenience, an additional local connector is provided. (the small
white connector numbered top to bottom). When using the Local
Connector, the LED display receives the 12VDC power required from the
LED Controller. Pin out information follows.
Page 21
Pin 1 – RS422 XA, communications.
Pin 2 – Shield, communications.
Pin 3 – RS422 XB, communications.
Pin 4 – ISO Ground, (for special circumstances if ground loops exist).
Pin 5 – 12 VDC output, fused at 1A.
Pin 6 – GND, power/ communications ground.
On the rear side of the small LED indicator are located 3 sets of four DIP
switches for self‐testing and configuring. See Figure 15 for switch
positions and orientation.
FACTORY PGM
PIN6-PWR/COM GND
PIN5-12VDC IN
REMOTE
PIN4-ISOGND
PIN3-RS422 XB
PIN2-SHIELD
PIN1-RS422 XA
PIN6-PWR/COM GND
PIN5-1A FUSED 12VDC
LOCAL
PIN4-ISOGND
PIN3-RS422 XB
PIN2-SHIELD
PIN1-RS422 XA
1
1
2
2
3
3
4
Figure 15 – Small Indicator DIP Switches
The DIP switch setting information is identical to that of the Medium LED
Indicator except for the location and orientation of the DIP switches. See
section 4.3.2 for switch functions. Note that all switches are OFF/LEFT
and ON/RIGHT.
Page 22
5.0 SYSTEM STARTUP & OPERATION
NOTE: If you need assistance with start‐up, your site may qualify for SureStart, a no‐cost
equipment review and start up assistance program. Ask your local Clark‐Reliance office if you
qualify. This service can also be added for a nominal fee if you do not qualify.
Before applying the mains power to the Eye‐Hye SmartLevel unit, verify that all mains wiring,
safety and earth grounds, input wiring from the column and LED level indicator(s) wiring is
correct and per their respective wiring diagrams. This includes wiring to and from any optional
peripherals. Also be sure that all of the probe modules, peripherals, and the power supply(s)
are properly installed, fully seated on their proper connectors, and secured by their mounting
rail or mounting hardware.
Electrolev Commissioning: Initial warm‐up of the Electrolev column should be done gradually.
To do this, keep the water valve closed, open the drain valve widely, and crack open the steam
valve for a few minutes. Then, close the drain valve, and slowly open the steam and water
valves fully. Check for any leakage at the conductivity probes. Hot‐torqueing is recommended
on most installations. After initial warm‐up, the Electrolev column should be isolated and the
drain valve opened. After insuring the column is drained and pressure relieved. Re‐torque T, V,
or Z type probes to 40 Ft Lb., (54 Newton‐Meters) and F type probes to 90 Ft Lb. (122 Newton‐
Meters) After torqueing is complete, close the drain valve and return the Electrolev to service.
Hot‐torqueing of the conductivity probes insures proper sealing and extends the sealing gasket
life. Note: FSB probes do not require hot‐torqueing.
Control Unit, Remote Indicators, and Peripherals: Verify all wiring is in accordance with
drawings for the specific model Electro Eye‐Hye and any installed options purchased. Verify
that the proper fuses are installed for the AC mains voltage and type connected. Verify that
either the Electrolev column has no water in it or unplug the probe inputs, TB3, at the main 12
channel motherboard. All probe modules and needed and peripherals should be installed and
connected. Any connection from any of the SmartLevel peripherals to other electrical
equipment is okay as long as their operational functions are temporarily suspended or
bypassed. Mains power can now be cautiously applied to the system. Look for anything that
might be an abnormality indicating that something is wrong (sparking, smoke, erratic operation,
etc).
Further check the system by checking each probe module individually by using the Probe Test
DIP switches on the right side of the main 12 channel motherboard. Turn ON each DIP switch,
left to right for probe channels 1‐12, by sliding them UP. Verify the following for each Probe
channel tested.
1.) The GREEN SENSE LED on the corresponding probe module lights.
2.) The corresponding LEDs on all LED Indicators turn from RED to GREEN.
3.) All assigned relay channels and their associated GREEN LED turn ON and actuate.
4.) The 4‐20 mA transmitter’s current output responds accordingly.
After all channels are verified, re‐connect the probe inputs on connector TB3 and make sure all
the Probe Test DIP switches on the main 12 channel motherboard are in the DOWN position.
Page 23
6.0 SYSTEM OPTIONS
As mentioned in sections 4.0 and 4.2.1, the SmartLevel system allows Users to configure
additional desired functions. These peripherals allow the SmartLevel system to interface with
other plant electrical systems. This section details the add‐on options that are currently
available.
6.1 6 CHANNEL RELAY
The 6 Channel Relay Module allows the User to access 6 separate form C relay
contacts that are isolated from the system for universal interface with other
plant control systems. Each relay contact is rated for either 10A @ 120 VAC, 7A
@ 240 VAC, 5A @ 277 VAC or 20A @ 14 VDC, 10A @ 28 VDC. Each relay can be
assigned to any probe channel output or logically “OR’d” with any combination.
The logical “AND” function can be implemented by wiring relay contact outputs
in series, allowing the User 2 out of 3 channel voting logic. Since each relay
provides form C contacts, fail‐safe outputs can be wired with normally closed
contact sets. See Figure 16 below.
Figure 16 – 6 Channel Relay Wiring and DIP Switches
1.) SW1 and SW2 = Relay 1
2.) SW3 and SW4 = Relay 2
3.) SW5 and SW6 = Relay 3
4.) SW7 and SW8 = Relay 4
5.) SW9 and SW10 = Relay 5
6.) SW11 and SW12 = Relay 6
Page 24
Table 16 – 6 Assigning Probe Numbers to Specific Channels
As shown above in Table 16, SW13‐1 and SW13‐2 assign probe numbers to
channels. While the example above only shows the (4) configurations for SW1
Page 25
and SW2, this set up is consistent with SW3 and SW4, SW5 and SW6, SW7 and
SW8, SW9 and SW10, and SW11 and SW12. Note that the underlined channels
on SW2, SW4, SW6, SW8, SW10, and SW12 always remain unchanged and
assigned as blow down (5), module error (6), peripheral error (7), and bus power
(8).
In addition to the probe channel outputs, the blowdown, module error, and
peripheral error signals can be switched “OR’d” and/or wired “AND’d.” A power
rail selection is also available for power loss indication. The six relays are divided
into two, 3 relay low or high channel banks. The low channel bank is switch
selectable for channels 1‐6 or 13‐18 and the high channel bank is switch
selectable for channels 7‐12 or 19‐24.
The relay contact outputs are wired as either normally open or normally closed
circuits through the common contact as shown in Figure 16. The GREEN LEDs
light when their respective relays are energized.
6.2 4‐20 MA TRANSMITTER
The 4‐20 mA Transmitter module contains two features:
1) An isolated 4‐20 mA transmitter is available on the 5 position terminal block
and includes an internal selectable isolated 24 VDC loop excitation supply,
allowing it to either source current by itself or can run by sinking current
from an external loop supply. The transmitter is calibrated by entering the
number of probe channels to be linearly configured or separately in manual
mode where each channel output can be adjusted up or down using DIP
switches.
2) A Water‐Over‐Steam, (W/S), error detection is available on an isolated form
C relay output. The relay is rated the same as in section 8.2. The water over
steam output actuates a relay should the level rise discontinuously from the
bottom of the column to warn of a faulty output condition. It can also be
User selected to be inverted for fail‐safe operation and be indicated on the
SYSTEM STATUS LED on all the LED indicators. The 4‐20mA’s GREEN LED
lights when the relay is energized. See Figure 17 on the next page.
The relay contact outputs are available on the GREEN 3 pin connector and are
wired as either normally open or normally closed circuits through the common
contact as shown on the next page in Figure 17.
The transmitter output and wiring connections are on a 5 pin removable
connector, as follows:
Pin 5 – Loop (‐)
Pin 4 – Loop (+)
Pin 3 – Shield
Pin 2 – Excitation (+)
Page 26
Pin 1 – Excitation (‐)
Note that pins are numbered bottom to top.
Figure 17 – 4‐20 mA Transmitter Wiring and DIP Switches
The front panel DIP switches allow the User to modify calibration, excitation, and
relay configurations. DIP Switch functions are turned ON when switches are
switched to the right and turned OFF when switched to the left. Note that there
are two eight‐position DIP switches marked SW1 and SW2, upper and lower
respectfully. See Figure 17 for position and orientation. The functions of the DIP
switches are explained as follows:
NOTE: SW1 – 5 only function in Manual Mode (refer to SW1‐7 for mode
operation).
1.) SW1‐1 – Factory. In Manual Mode, tuning this ON causes the current loop
output to ramp up and down its entire mA range and the W/S relay to cycle
ON/OFF at 1 hertz for test purposes. In Auto mode turning this switch ON
does nothing.
2.) SW1‐2 – Cal. Linear – In Manual mode, toggling this switch ON then OFF
assigns linear calibration data for the numbers of channels set on the data
D1‐D5 data switches. In Auto mode turning this switch ON does nothing.
3.) SW1‐3 – Cal. Down – In Manual mode with the Cal. Output function turned
ON, this switch automatically starts increasing the calibrated output for the
Page 27
channel assigned by the D1‐D5 data switches. If left in this position for over
10 seconds the count will increment at 4X the original speed. It returns to
the original speed when toggled through the OFF position. In Auto mode
turning this switch ON does nothing.
4.) SW1‐4 – Cal. Up – In Manual mode with the Cal. Output function turned ON,
this switch automatically starts decreasing the calibrated output for the
channel assigned by the D1‐D5 data switches. If left in this position for over
10 seconds the count will decrement at 4X the original speed. It returns to
the original speed when toggled through the OFF position. In Auto mode,
turning this switch ON does nothing.
5.) SW1‐5 – Cal. Output – In Manual mode turning this switch ON sets the
transmitters output current to the value assigned by the D1‐D5 data switches
and allows for calibration using the Cal. Up or Cal. Down switch. It can also
be used to verify any calibrated output without changing the value. The D1‐
D5 data switches can be changed while this switch is ON to view other
channel calibration outputs. It also allows for the overall output slope
calibration, see Output Slope Calibration. In Auto mode turning this switch
ON does nothing.
6.) SW1‐6 – Error Output – When turned ON, a detected W/S error is allowed to
be indicated on the SYSTEM STATUS LED on all of the LED level indicators by
turning them from GREEN to RED. The indication, like the relay, is self‐
clearing when the condition itself goes away. Note that the relay inversion
function on SW2‐2 only affects the relay and its associated LED indicator.
7.) SW1‐7 – Mode – Turning this function ON enables the Manual mode. When
in manual mode all the 4‐20 ma Cal. switches are available for activation.
These are switches SW1‐1 through SW1‐5. When in Auto mode or OFF, all of
the 4‐20 mA calibration and Factory switches are disabled.
8.) SW1‐8 ‐ Hardware Reset – Setting this switch to ON holds the module in a
hardware reset state. The unit will not perform any run tasks and will
indicate so by turning the status LED RED. Negating the switch return the
module to its normal RUN mode. All outputs are disabled in Reset.
9.) SW2‐1 – Program 1 (Future use).
10.) SW2‐2 –W/S Relay Invert – Turning this function ON inverts the operation of
the water over steam relay. This allows the relay to function in a Fail‐Safe
mode. The relay will be ON in normal mode and OFF when a W/S error
occurs. Note that this function does NOT change the indication of a W/S
error on the LED indicator’s SYSTEM STATUS LEDs.
11.) SW2‐3 – Excitation Control – The internal 24 VDC loop excitation is ON when
this switch is left in the OFF/LEFT position. Turning it ON/RIGHT, turns OFF
the internal excitation and allows for the use of an external supply.
12.) SW2‐4 – Data D5 – This is the Most Significant Bit (MSB) for making channel
assignments. Data is entered in binary.
13.) SW2‐5 – Data D4 – This is bit D4 for making channel assignments. Data is
entered in binary.
14.) SW2‐6 – Data D3 – This is bit D3 for making channel assignments. Data is
entered in binary.
Page 28
15.) SW2‐7 – Data D2 – This is bit D2 for making channel assignments. Data is
entered in binary.
16.) SW2‐8 – Data D1 – This is the Least Significant Bit (LSB) for making channel
assignments. Data is entered in binary.
Note that when calibrating, it is advised that the loop be broken to add a series
DC mA meter to measure and verify the calibrated loop currents. When
calibration is complete, it should be reviewed a second time to verify that it was
completed successfully. When calibration is complete, the DC mA meter can be
removed and the loop reconnected. The calibration should also be verified by
the DCS, PLC, or any other device reading the loop.
To perform a linear calibration for equally spaced probes, perform the following
steps. Note the linear calibration table in Figure 22 for any given number of
probe channels.
1.) Enter Manual mode by turning ON the Mode switch, SW1‐7.
2.) Set the channel data switches D1‐D5, SW2‐4 through SW2‐8, with the total
number of probe channels in the system. Make sure it’s represented in
binary with the MSB and LSB properly oriented. See Figure 18 for a binary
number channel table.
3.) Initiate the calibration by toggling the SW1‐2 (Linear Cal. Switch) ON and
then OFF.
4.) Return the Mode switch, SW1‐7, to OFF to complete the calibration.
Individual channel outputs can be calibrated separately or non‐linear by
performing the following steps.
1.) Perform the linear calibration in the previous paragraph for the number of
desired probe channels. This sets up all the cal data to perform a quicker
calibration.
2.) Re‐enter Manual mode by turning ON the Mode switch, SW1‐7.
3.) Set the channel data switches D1‐D5, SW2‐4 through SW2‐8, to the exact
probe channel number you want to calibrate. Make sure it is represented in
binary with the proper MSB and LSB orientation. See Figure 18 for a binary
number channel table.
4.) Turn ON the Cal. Output switch, SW1‐5, to enable the channels current value
on the transmitters output.
5.) Using either/both the Cal. Down and Cal. Up switches, SW1‐3 and SW1‐4,
respectfully, adjust the assigned probe channels output to the desired
current. This probes calibration is now complete.
6.) Set the next probe channel to be calibrated on data switches D1‐D5, SW2‐4
through SW2‐8, and repeat step 5.
7.) Repeat steps 5 and 6 until all the desired probe channels are calibrated.
8.) Turn OFF the Cal Output SW1‐5 and return SW1‐7 to Auto mode. This will
return the unit to normal operation with the new calibration data.
Page 29
Optional Accuracy Enhancement
Note that any channel that is still not at the desired calibration set point, can be
individually calibrated by performing a non‐linear calibration, as described
earlier, in lieu of performing an Overall Slope Calibration OR after performing an
Overall Slope Calibration.
Overall Slope Calibration – The overall slope of the calibration data can also be
adjusted. It is recommended that this adjustment, if made, be made after any
Linear calibration and before any discrete channel calibration. The slope is
adjusted by pivoting it from its lowest reading of 3.85mA, with the biggest
changes noticed at the highest reading. The procedure is performed by the
following steps.
1.) Perform a linear calibration first as previous described.
2.) Enter the Manual mode by turning ON switch SW1‐7. Verify the accuracy of
the highest calibrated channel or full scale reading, 20mA or whatever is
desired, by setting DIP switches D1‐D5, SW2‐4 through SW2‐8, appropriately
and turning on DIP switch SW1‐5, Cal Output, ON. See Figure 18 for a binary
number channel table. Note the number of counts that the calibration is out.
3.) Set the channel data switches D1‐D5, SW2‐4 through SW2‐8, all OFF. See
Figure 18 for a binary number channel table. The value of the upper slope
value, which is about 16mA, should be measured on the output.
5.) Using either/both the Cal Down and Cal Up switches, SW1‐3 and SW1‐4,
respectfully, adjust or recalibrate the upper slope value by half the counts
out noted in step 2.
6.) Re‐verify all the calibration points by setting DIP switches D1‐D5, SW2‐4
through SW2‐8, accordingly and measuring each output.
7.) Repeat steps 2 through 6 until the desired calibration is achieved.
8.) Turn OFF the Cal Output SW1‐5 and return SW1‐7 to Auto mode. This will
return the unit to normal operation with the new calibration data.
Page 30
CHANNEL DATA SWITCHES PROBE
D5 D4 D3 D2 D1 CHANNEL
ON ON ON ON ON 0 (FAULT)
ON ON ON ON OFF 1
ON ON ON OFF ON 2
ON ON ON OFF OFF 3
ON ON OFF ON ON 4
ON ON OFF ON OFF 5
ON ON OFF OFF ON 6
ON ON OFF OFF OFF 7
ON OFF ON ON ON 8
ON OFF ON ON OFF 9
ON OFF ON OFF ON 10
ON OFF ON OFF OFF 11
ON OFF OFF ON ON 12
ON OFF OFF ON OFF 13
ON OFF OFF OFF ON 14
ON OFF OFF OFF OFF 15
OFF ON ON ON ON 16
OFF ON ON ON OFF 17
OFF ON ON OFF ON 18
OFF ON ON OFF OFF 19
OFF ON OFF ON ON 20
OFF ON OFF ON OFF 21
OFF ON OFF OFF ON 22
OFF ON OFF OFF OFF 23
OFF OFF ON ON ON 24
CAL
OFF OFF OFF OFF OFF SLOPE
Figure 18 – Binary Channel Assignment Table
Figures 19 and 20 illustrate the loops output circuitry and external wiring for
both modes of applied excitation.
Internal Excitation, DIP switch SW2‐3 OFF/LEFT, provides a 2 wire sourcing
configuration, using the internal fixed 24 VDC excitation supply, and is illustrated
in Figure 19. In this mode, 800 ohms is the maximum loop load.
SW2-3 OFF/LEFT
24 INTERNAL DC EXCITATION
VDC 2-WIRE SOURCING
5 I
4
800
3 R OHMS
2 MAX
C
1
Figure 19 – Internal Excitation Wiring
Page 31
External Excitation, DIP switch SW2‐3 ON/RIGHT, provides a 4 wire sinking
configuration, using an external 15‐35 VDC excitation supply, and is illustrated in
Figure 20. In this mode, 1200 ohms can be driven with a higher excitation
voltage. See the loop compliance graph in Figure 21.
SW2-3 ON/RIGHT
EXTERNAL DC EXCITATION
4-WIRE SINKING
5 I
C
4
1200
3 R OHMS
2 MAX
1
VDC IN
(GRAPH)
Figure 20 – Loop Wiring Diagram
Figure 21 illustrates the recommended output drive performance versus the
loop’s line impedance. Use this compliance data graph to figure the maximum
loop impedance over a range of external VDC loop excitation voltages.
1000
LOAD
R
(OHMS)
0 15 25 35
10 20 30 40
DC EXCITATION VOLTAGE
Figure 21 – Loop Compliance Graph
Page 32
Figure 22 – Linear Current Calibration Table
6.3 DUAL UNIVERSAL AC POWER SUPPLIES
As mentioned in section 4.2.2, the SmartLevel systems allows an additional
Universal AC Power Supply to be added for redundancy against a single supply
failure or to add a means for backup power from a separate AC Mains supply or
backup generator. The AC mains can simply be wired in parallel for redundancy,
connecting both TB1 and TB2 together. For backup, each input is connected to a
separate AC power source. Also, see Figure 7 (page 11).
6.4 24 CHANNEL EXPANSION PCB ASSEMBLY
The 24 Channel Expansion PCB assembly allows an additional 12 channels of
probe modules and 4 additional peripheral modules to be added to the system
to allow for more than 12 probes. It should be noted that this expansion option
must be configured before it is ordered from the factory since it requires a larger
enclosure and inner PCB mounting panel. A single 3 row, right angle, 96 pin DIN
connector pair joins the circuitry of the expansion PCB to the main motherboard.
Additional probe wiring terminals and probe channel test DIP switches are also
included for the additional channels. See Figure 23.
Page 33
SMARTLEVEL EXPANSION BACKPLANE
E PWB J1029
I/O MODULES
CLARK RELIANCE - USA
PROBE MODULES PROBE INPUTS
AUX MAIN
12 12
CH 23 CH 24
GND GND
J11 J12 11 11
10 10
GND GND
I/O4 I/O5 I/O6 I/O7 CH 21 CH 22 9 9
J13 J14 J15 J16 8 8
J9 J10
GND GND
7 7
CH 19 6 6
CH 20
GND GND
J7 J8 5 5
4 4
GND GND
CH 17 CH 18 3 3
2 2
J5 J6
GND GND
1 1
TB2 TB1
CH 15 CH 16
PROBE TEST
J3 J4 SW1 SW2 SW3
1 2 3 4 1 2 3 4 1 2 3 4
CH 13 CH 14 1 11
12 34 5 6 78 9 0 12
J1 J2
MOTHERBOARD I/O
P1
Figure 23 – 24 Channel Expansion PCB
As with the 12 Channel Motherboard, signal and probe modules for channels 13
to 24 are installed and connected here. It also has provisions for 4 additional
peripherals.
Page 34
7.0 SYSTEM MAINTENANCE
7.1 PERIODIC VISUAL INSPECTION
It is highly recommend that the system and its components be visually inspected
periodically. The frequency will be determined by use or policy of a preventative
maintenance plan. In either case, the following should be reviewed.
At the Electrolev water column:
1.) Inspect the Electrolev column for any evidence of leaking.
2.) Inspect each probe connection and make sure each wire lug is making a
proper connection and is tight. This includes the column’s ground wire.
3.) Inspect all wiring from the probes to the junction for loss of insulation, opens
and shorts.
4.) Inspect the junction box and make sure all wire connections are secure and
that its interior is free of water, corrosion, or any other foreign matter.
At the Main Control Unit:
1.) Inspect the main enclosure and make sure all wire connections are secure
and that its interior is free of water, corrosion, or any other foreign matter.
2.) Verify that the system and all its modules have their GREEN power LEDs lit.
3.) Verify that all probe module and peripherals LED status indicating LEDs are
GREEN.
4.) Verify that the level indicated by probe modules that are indicating water
matches the level shown in the gage glass.
5.) Verify that all the BLUE LEDs for PROBE STATUS/BLOWDOWN on all of the
probe modules are OFF or unlit. If they are, go to section 7.2.
On all of the LED Indicators:
1.) Verify that its LED SYSTEM STATUS indicating LED is GREEN.
2.) Verify that it is indicating the correct level per the number of lit probe
modules in the main control unit. All indicators should be indicating the
same level.
7.2 ELECTROLEV COLUMN BLOWDOWN
The BLUE PROBE STATUS/BLOWDOWN LED can be used as an indication that it is
time to blow‐down the column. However, the Electrolev column can also have
blow‐downs performed on a regular maintenance schedule schedule to not only
keep the probes clean, but to also keep the lower water leg of the Electrolev
column clean.. This schedule can be anywhere from every 1 week up to 3
months depending on water quality and running conditions. The following
section describes how to blow‐down the Electrolev column.
Page 35
1.) VERIFY that any action produced by blowing down the column will not trigger
an event sequence that is not desired, such as a boiler/turbine trip or other
such alarm condition, by temporarily bypassing such equipment or
operations. It may also be procedure to inform the control room and
tag/lockout any affiliated equipment or valves.
2.) VERIFY that the drain leg of the Electrolev column is properly connected to a
vented discharge tank or sump or otherwise secured for safety and is clear
and unobstructed.
3.) CLOSE the lower water valve(s) to the Electrolev column.
4.) SLOWLY OPEN the drain valve(s) and let the steam from the top of the
column rush down through the column and out the drain line for a minimum
of 30, but no more than 60 seconds at no more than 50% of the drain valves
flow.
5.) CLOSE the drain valve(s) securely and slowly RE‐OPEN the lower water leg
valve(s).
6.) RETURN the system to normal operation and address any additional action
taken in step 1. Note: This should reset or turn OFF any lit BLUE PROBE
STATUS/BLOWDOWN LEDs. If it does not, the associated probe may be too
worn or damaged and needs replaced.
Also note that performing the above blowdown procedure with the lower water
valve(s) OPEN will allow flushing of any debris that might have accumulated in
the lower water leg of the Electrolev column as mentioned above.
Page 36
8.0 SYSTEM SPECIFICATIONS
8.1 AC MAINS
AC Voltage 115/230 VAC +/‐ 10%
Input Current 3.15/1.25A
Max AC watts 300 W
Max Inrush Current 40A Each Supply at 264 VAC
AC Frequency 50‐60 Hz
Fusing for 115 VAC Nominal 3.15A Slow‐Blow 5x20 mm
Fusing for 230 VAC Nominal 1.25A Slow‐Blow 5x20 mm
Power Factor Correction YES
8.2 6 CHANNEL RELAY
Relay Form C (SPDT)
Relay Contact Ratings 10A at 120 VAC
7A at 240 VAC
5A at 277 VAC
20A at 14 VDC
10A at 28 VDC
Isolation, coil to contact 1500 VAC for 1 minute
Isolation, open contact 750 VAC for 1 minute
8.3 LED INDICATORS
Remote Power Supply Voltage 10 – 14 VDC
Max Power Supply Current 1A
8.4 4‐20 MA TRANSMITTER
W/S Error Relay (Same as in section 8.2)
Output Range 3 to 24 mA DC
4‐20 Transmitter Resolution 212 or 6 uVDC
Unadjusted Output Accuracy ±0.35 %FS max.
Adjusted Output Accuracy ±0.07 %FS max.
Temperature Error Coefficient ±16 ppm FSR/°C
Internal Loop Impedance 220 ohms max.
Isolation, Galvanic 1500 Vac for 1 minute
Internal Excitation Load 24 VDC
External Excitation 15 – 35 VDC
Modes/Load Impedance 2‐wire source, (int. Excitation)
4‐wire sink, (ext. Excitation)
(see Figures 19‐21 in section 6.2)
Page 37
8.5 ENVIRONMENTALS
Operating Temperature ‐40°C to 60°C/‐40°F to 140°F
Humidity 20 to 80% RH, Non‐Condensing
Maximum Altitude 2000 m (1.25 miles)
RoHS YES
CE YES with AC Mains Filter
Indoor Use YES
Outdoor Use YES
Overvoltage Category II
Pollution Degree 2
Ingress Rating IP 66
9.0 SYSTEM TROUBLESHOOTING
9.1 SYSTEM POWER
Symptom Possible Cause
1.) No Power Check that power is connected and applied on
TB1/TB2 on the 12 Channel Motherboard.
Check that fusing is not blown, properly
installed, and the correct fuse.
Check to see if Power Supply(s) are fully seated
and secure.
If all of the above are OK:
Power supply has failed.
12 Channel Motherboard is damaged.
2.) No module power Module is bad.
12 Channel Motherboard is damaged.
3.) Any STATUS LED RED Improper DIP switch setting
Water or Steam Error detected from 420
Transmitter .
Bad module or peripheral.
9.2 WATER DETECTION
1.) No water detection Open, shorted, improper Probe input wiring.
Open or bad column ground wiring.
Improperly set DIP switches.
Bad Probe Module.
Bad or dirty Probe.
12 Channel Motherboard damaged.
Page 38
2.) Improper water detection Bad or dirty Probe.
Open, shorted, improper Probe input wiring.
Open or bad column ground wiring.
Improperly set DIP switches.
Bad Probe Module.
Damaged 12 Channel Motherboard.
Boiler turbulence – try delay on Probe Module
9.3 LEVEL INDICATORS
1.) Nothing Lit No power connected or applied
Input or supply fuse open or blown
Bad/Improper supply source should be 12 VDC
Bad LED Indicator
2.) RED/GREEN Flashing Check wiring from Display Controller
Open or improper comm. wiring
Power OFF on LED Display Controller
Improperly set DIP switches
Bad Display Controller
Bad LED Indicator
3.) Improper Level Displayed Improperly set DIP switches
Bad Display Controller
Bad LED Indicator
Bad Probes
Contact your Local Representative or Clark‐Reliance for other troubleshooting
questions regarding your SmartLevel system.
Page 39
10.0 PARTS
The following replacement parts are available for your SmartLevel Main Controller Unit.
Contact your local representative or Clark‐Reliance.
Item Description CR Part Number
T3.15A 5x20 mm Fuse
*1 E‐F‐DIN‐0315‐T
(for 120 VAC use)
T1.25A 5x20 mm Fuse
*2 E‐F‐DIN‐0125‐T
(for 240 VAC use)
5x20 mm Shunt
*3 E‐F‐DIN‐SHUNT
(for neutral fusing only)
4 12 Channel Motherboard PCB RSLC28
5 Probe Module Assy. RSLC23
6 Universal AC Power Supply Assy. RSLC25
7 LED Display Controller Assy. RSLC29
8 Medium LED Indicator RSLI5
9 Small LED Indicator RSLI7
10 6 Channel Relay Assy. RSLC31
11 4‐20 mA Transmitter Assy. RSLC37
12 24 Channel Expansion PCB RSLC41
13 12VDC Wall Adapter / 10ft wire E‐WPS‐12VR1A
*These parts are available at the Clark‐Reliance parts store for next day delivery at:
http://parts.clark‐reliance.com
Page 40
11.0 MODEL & PART NUMBER
INFORMATION
The main model number for ordering the SmartLevel system is as follows.
RSC##ABCDEFGHJ
Where RSC is the base model prefix and the following are the suffixes
## = 06 ‐24 – Number of Probes/Modules
A = 1 – 16x20 NEMA 4, IP65 Steel Enclosure
2 – 16x20 NEMA 4X SS Enclosure
3 – 16x20 NEMA 4X SS Enclosure with Window
4 – 16x20 NEMA 4 Steel Enclosure with Indicator View
5 – 16x20 NEMA 4X SS Enclosure with Indicator View
*6 – 24x20 NEMA 4, IP65 Steel Enclosure
*7 – 24x20 NEMA 4X SS Enclosure
*8 – 24x20 NEMA 4X SS Enclosure with Window
*9 – 24x20 NEMA 4 Steel Enclosure with Indicator View
*10 – 24x20 NEMA 4X SS Enclosure with Indicator View
11 – 16x20 NEMA 7/4X Explosion‐Proof Enclosure
*12 – 24x20 NEMA 7/4X Explosion‐Proof Enclosure
*Only for systems that require an expansion board
**Systems with more than 12 channels come standard with an expansion board
B = 1 – Single Universal AC Power Supply
2 – Dual Universal AC Power Supply
3 – Single Universal AC Power Supply w/CE Kit
4 – Dual Universal AC Power Supply w/CE Kit
5 – Single DC Power Supply
6 – Dual DC Power Supply
C = *0 – No Additional Modules
1 – One Additional 6 Channel Relay
2 – One 4‐20mA Output
**3 – Two Additional 6 Channel Relays
**4 – Three Additional 6 Channel Relays
**5 – One 4‐20mA Output and One Additional 6 Channel Relay
**6 – One 4‐20mA Output and Two Additional 6 Channel Relays
**7 – One 4‐20mA Output and Three Additional 6 Channel Relays
*All control units come standard with one 6 Channel Relay
**Options 3 thru 7 require expansion board
Page 41
D = (Not used at this time)
E = (Not used at this time)
F = (Not used at this time)
G = 0 – No Medium LED Indicator
1 – One Medium LED Indicator
2 – Two Medium LED Indicators
3 – One Medium LED Indicator in NEMA 4 Enclosure
4 – One Medium LED Indicator in NEMA 4X Enclosure
H = 0 – No Small LED Indicator
1 – One Small LED Indicator
2 – Two Small LED Indicators
3 – One Small LED Indicator in NEMA 4 Enclosure
4 – One Small LED Indicator in NEMA 4X Enclosure
J = 0 – None
S – Special ‐ Defined On Order
12.0 WARRANTY
Seller warrants goods manufactured by it will be free from defects in material and
workmanship for one (1) year following the date of shipment. If any of the Goods are found by
Seller to be defective, such Goods will, at the Seller's option, be replaced or repaired at Seller's
cost. The parties hereto expressly agree that Buyer's sole and exclusive remedy against the
Seller shall be for the repair or replacement of defective Goods as provided herein. The
exclusive remedy shall not be deemed to have failed of its essential purpose so long as the
seller is willing and able to repair or replace defective Goods in the prescribed manner.
Page 42
Notes:
Page 43
16633 Foltz Parkway
Strongsville, OH 44149 USA
Phone: +1 (440) 572‐1500 • Fax: +1 (440) 238‐8828
www.clark‐reliance.com • sales@clark‐reliance.com
Page 44