Corr Velox - Alabama Specialty Products, Inc.
Contents
1. moos Soi 4 LCHKDIREV LI 21 5 30Vdc OVdc CN1 RS 485 TERMINAL AND CN2 PROBE CONNECTOR COMBINED CI 68 uF 0 Co 32 uF Lo 1 2 mH EEW CERTIFIED RS485 ISOLATING REPEATER Uo 3 7Vdc lo 225mA Po 0 206W ER Probe Simple Device MS2700E MS2800E Sold Separately 2 RS 485 SIGNAL INTERFACE PC PLC DCSJ NOTE 1 PROBE DIELECTRIC RATING 500V R M S DO NOT EXCEED 2 THE MAXIMUM EXTERNAL CAPACITANCE C O THAT CAN BE CONNECTED BETWEEN RS 485 TERMINALS CN1 AND PROBE TERMINALS CN2 IS 2 d NOTE PRE APPROVED POWER SUPPLY UNIT OR APPROVED EQUIPMENT WITH 3 THE MAXIMUM EXTERNAL INDUCTANCE L O THAT CAN BE THE FOLLOWING MAXIMUM INPUT PARAMETERS SHOULD BE USED CONNECTED BETWEEN RS 485 TERMINALS CN1 AND PROBE TERMINALS CN2 IS 0 14mH MODIFIED ENTITY PARAMETERS POWER SUPPLY CONNECTIONS amp ENTITY PARAMETERS MODIFIED DESCRIPTION BY ICHkbD REV DATE DESCRIPTION 0 J2 TERMINALS U 23 6Vdc l 352 8mA AND P 2 3W CN1 A amp B 03 20 15 Me ties ae e J9 TERMINALS 3 7Vdo I 225mA AND P 0 206W CN1 D amp E DATE 01 13 15 x MUNFORD AL 36268 Control Drawing PHONE2. Whenever an electrically driven sensor or measuring device is used in a potentially explosive environment the measuring system must be installed in such a way that electrical energy is either effectively isolated from the explosive environment via explosive proof containers cable conduits etc or the amount of electrical energy produced in the hazardous area must be limited to an intrinsically safe level Limiting electrical energy is the most practical method of protecting the Corr VzZZX transmitter when it is installed in a hazardous area In the Conn VzZZX transmitter electrical energy limits are maintained by the use of appropriate safety barriers installed in the power and data wiring The safety barriers must be located in the safe area near the boundary between the safe and hazardous areas The safety barrier will repeat the signal current generated by the transmitter and will relay the signal to the data receiving station Caution When a safety barrier is used with the Corr VzZZX transmitter the transmitter wiring connections must be connected to the safety barrier s hazardous area terminals All other connections must be made to the barrier s safe area terminals The type of repeater safety barriers used with the Corr VzZZX transmitter depends on the specific classification of the hazardous environment in question However the entity parameters must match those of the Corr VzZZX transmitter CAUTION For hazardous area installatio
3. CORR Ultra Resolution ER RS 485 Transmitter Model MS2800E Operator s Manual Metal Samples Company A Division of Alabama Specialty Products Inc 152 Metal Samples Rd Munford AL 36268 Phone 256 358 4202 Fax 256 358 4515 E mail msc alspi com Internet www metalsamples com Table of Contents LP EE 1 A General Des eriptien usu A ASS Naa MS Sai AA MA S Sui 1 B Principles of Operation 1 C Technical Specifications 3 II Installation and Operation 4 A Receiving the CORR VzZZX transmitter I n 4 CITAR 4 1 Physical Mounting and Probe Connection 4 a Direct Probe MOUNTING th soos EET RSEN EAR 4 aa PERSE EE Nn ee Eas 5 2 Power and Data Connections 5 a Making Connections in retten ier iem EE aE yuya 5 A E
4. in the element s resistance The probe also contains an internal Reference Element which is used to compensate for the influences of temperature on the Exposed Element The Conn VzZZX transmitter is designed to work with any standard ER probe but it is recommended that Cylindrical and Large Flush type probes be used to ensure optimum performance Their physical design places the Reference Element in closer proximity to the Exposed Element compared to other probe types providing more effective temperature compensation and thus reducing the effects of thermal noise Because they are designed to corrode ER probes are sacrificial in nature Each ER probe will have a finite life that is based on the element thickness ER probes are available in a number of geometries and thicknesses designed to suit a wide variety of applications Table 1 lists the common ER element options available from Metal Samples and the effective life of each 1 Tubular Loop Compatible Wire Loop Compatible Compatible Table 1 Standard ER Probe Elements The Conn VzZZX transmitter measures an ER probe utilizing a high resolution 20 bit measurement This allows the unit to detect much smaller amounts of metal loss thus responding faster to corrosion events and upsets At 20 bit resolution the CoRR VzZZX transmitter can measure metal loss amounts as small as 0 000196 of the probe life For highly sensitive probes such as the 5 mil large flush shown above that result
5. 256 355 422 MS2700E MS2800E ER RS 485 ALABAMA SPECIALTY PRODUCTS INC 2001 THIS DOCUMENT INCLUDING THE INFORMATION HEREIN IS THE PROPERTY OF ALABAMA SPECIALTY PRODUCTS INC ASPI IT CONTAINS PROPRIETARY INFORMATION AND MAY NOT BE REPRODUCED OR COPIED IN WHOLE OR IN PART NOR MAY IT BE FURNISHED OTHERS WITHOUT EXPRESS WRITTEN CONSENT FROM ASPI NOR MAY IT BE USED IN ANY WAY THAT IS OR MAY BE HARMFUL TO ASPI THIS PRINT WILL BE RETURNED UPON REQUEST TO ASPI MAXIMUM OF 32 UNITS CAN BE CONNECTED TO THE NETWORK FAX 256 358 4515 Transmitter Multi Drop A DIVISION OF ALABAMA SPECIALTY PRODUCTS INC 7 EXWDB 000092 MS2700E HIGH RESOLU TION ER RS 485 TRANSMITTER MS2800E ULTRA RESOLUTION ER RS 485 TRANSMITTER O lt lt i lt lt slelssiele ur ER Probe Simple Device Sold Separately ga O Ne vo Probe Cable Assembly Sold Separately ER Probe Simple Device Sold Separately MS2700E MS2800E 2 MS2700E MS2800E 432 O ALABAMA SPECIALTY PRODUCTS INC 2001 THIS DOCUMENT INCLUDING THE INFORMATION HEREIN IS THE PROPERTY OF ALABAMA SPECIALTY PRODUCTS INC ASPI IT CONTAINS PROPRIETARY I
6. Conn VzZZX Transmitter Check the Corr VzZZX Transmitter for any shipping damage when it is first received When the unit is unpacked verify that the following items are included e Transmitter e Wiring Harness e Meter Prover e User s Manual e Probe Cable optional for remote mount only e Mounting Hardware optional for remote mount only In the event of shipping damage quantity shortage or missing items it is recommended that the event is documented immediately and that digital photographs are taken Any shortages or missing items should be reported to Metal Samples immediately In the event of shipping damage a claim should be opened with the responsible carrier B Installation CAUTION Using this product in any way other than that specified within this manual may impair the intrinsic safety protection Installation of the Conn VzZZX transmitter involves the following steps 1 Physical Mounting 2 Electrical Connection 3 Setup and Programming 1 Physical Mounting and Probe Connection When selecting a location to mount the ConR VzZZX transmitter it is important to consider the surrounding environment To ensure proper operation e Donot mount the transmitter in a location that exceeds its operating temperature e Avoid mounting the transmitter near sources of strong electrical noise e Ensure that there is sufficient clearance for installation and to open the transmitter cover afterwards a Direct Probe Moun
7. Service and Warranty Information s eanna nets nsns 17 A Warra tyY EC P X M 17 B Obtaining Service and Returning the Instrument for Repair 17 C Instrument eerie ei eee ee eere eve eicit detinent ua eese onere Eve Eee 18 Appendix A e terree tbe t eee n I e ttr etd rcv alice RER 19 Control Drawing Hazardous Area Wiring Diagram enne nnns 20 Safe Area Wiririg DIaBralm tas emnt tee EE Ee PHAR E od ese EYES Ee ERR TENE OR 21 Appendix B Revision History ccccccccssssssssececeesessssaeeceesessauseeseseceesessaeaesececsessausauseseceseueaaeaeseceeseseauaaes 23 I Introduction A General Description The model MS2800E Conn VzZZX transmitter is an ultra high resolution instrument designed to measure and transmit corrosion metal loss data from an Electrical Resistance ER probe to a plant control system or other recording device The Conn VzZZX transmitter utilizes RS 485 communication which allows multiple units to be daisy chained simplifying installation and reducing associated costs The use of the RS 485 protocol also allows the transmitter to be placed great distances from the control system or recorder while maintaining good noise rejection Practical distances can be up to 4000 feet Additionally the CORR VzZZX transmitter
8. instrument is mounted to a separate mounting pole using the optional Remote Mounting Hardware Kit The transmitter is then connected to the ER probe via the optional probe extension cable When possible the transmitter should be mounted within 10 3m of the probe to keep the probe cabling short and minimize signal degradation 2 Power and Data Connections a Making Connections The RS 485 connections are made via the external 6 pin circular connector CN1 as shown in Figure 3 This hermetically sealed connector prevents moisture ingress and eliminates the need for internal wiring by an operator thus reducing the risk of physical damage to the circuit board i uw Connector CN1 Power and Data Figure 3 RS 485 Connector To facilitate wiring a three foot 1 meter wiring harness is provided This wiring harness connects directly to the 6 pin connector and extends to a nearby junction box not included to make the necessary power and data wiring connections from the control DCS PLC system gt Junction Box Not Included Figure 4 Corr VeZ X Transmitter Wiring Harness NOTE Do not connect cable shielding to the Transmitter The shield must remain floating at the Transmitter The maximum permissible length of the field wiring between the Corr VzZZX transmitter and the control system is determined by the control system supply voltage the electrical resistance of the cable and the load
9. BE FURNISHED OTHERS WITHOUT EXPRESS WRITTEN CONSENT FROM ASPI NOR MAY IT BE USED IN ANY WAY THAT IS OR MAY BE HARMFUL TO ASPI THIS PRINT WILL BE RETURNED UPON REQUEST TO ASPI Metal samples A DIVISION OF ALABAMA SPECIALTY PRODUCTS INC CE 152 METAL SAMPLES gt MUNFORD AL 36268 Control Drawing Pit est ase ante MS2700E MS2800E ER RS 485 Transmitter Stand Alone SENE Ts NOI TOT WO OWG 3 EXWDB 000077 HAZARDOUS AREA SAFE AREA MS2700E HIGH RESOLUTION ER RS 485 TRANSMITTER MS2800E ULTRA RESOLUTION ER RS 485 TRANSMITTER DESCRIPTION BY T CHED CN1 INPUT SUPPLY TERMINAL Ui 23 6 l 352 8 mA PI 2 3W HSS CERTIFIED SAFETY ISOLATOR IS POWER SUPPLY Uo 23 6Vdc lo 352 8mA Po 2 3W MAXIMUM OUTPUT ENTITY PARAMETERS AT CN2 PROBE TERMINALS 0 Uo 5 0 Vdc Liz 0 lo 23528 mA Po 0 44 W CN1 RS 485 TERMINAL AT EACH LINE Ui 3 7 h 225 mA PI 0 206 W Uo 5 0 Vdc lo 51 mA Po 64 mW Y CN1 INPUT SUPPLY TERMINAL RS 485 TERMINAL AND CN2 PROBE TERMINAL COMBINED U 23Vde Probe Cable Assembly k 538mA i Sold Separately P207W 20 30Vdc Q 68uF Vdc 0 ER Probe Simple Device Co 32uF OPTIONAL D SUB 9 PIN Sold Separately Lo 0 14mH DATA CONNECTOR
10. E E E 6 Safe Area Installation RR ae Enn 7 d Hazardous Area Installation 7 3 Setup and OPE ration rte rere Eee E tee Paare 9 a Probe Settings mein 9 b RS 485 Communication Settings 10 i Baud Rate and Default Communication Parameters 11 Device Address cue erit nme ee TEC e REAPER 11 Communication Protocols esses eene nennen 11 iv Termination Resistor Teo rnuia aeiiaaie aa ener nennen nennen nnne 11 V Data Registers ctetu e E Ree ERR ERSTER EE 11 c Calibration and Testing nere eR EH 12 k Calibration ETIN ET 12 ii Testing output zero and span 12 iii Testing the Corr VzZZX transmitter with the Meter Prover 12 ds interpreting Data a u y eee ete E RETE 13 Metal LOSS ors E E 13 ii Calculating Corrosion Rates u ii a i a 14 e CommlissiOnlhng 5 sooo e E 15 C Maintenance aiia aeinn M A 15 D Troubleshooting ecce ei eee eese EE EA eem EET Qa 16 IIl
11. NFORMATION MAY NOT BE REPRODUCED OR COPIED IN WHOLE OR IN PART NOR MAY IT BE FURNISHED TO OTHERS WITHOUT EXPRESS WRITTEN CONSENT FROM ASPI NOR MAY IT BE USED IN ANY WAY THAT IS OR MAY BE HARMFUL TO ASPI THIS PRINT WILL BE RETURNED UPON REQUEST TO ASPI b RS 485 SIGNAL INTERFACE PC PLC DCSJ NOTE PRE APPROVED POWER SUPPLY UNIT OR APPROVED EQUIPMENT WITH THE FOLLOWING MAXIMUM INPUT PARAMETERS SHOULD BE USED BY CHKD DESCRIP TION DATE OOOOOO POWER SUPPLY UNIT 21 5 30 Vdc BY CHKD REV DESCRIP TION DATE BY CHKD REV GROUND CONNECTION ENCLOSURE AND CONNECTOR EEW DESCRIP TION 1 J2 TERMINALS U 23 6Vdc l 88 2mA AND P 0 519W CN1 A amp B EN 2 J9 TERMINALS U 3 7Vde 1 225 AND P 0 206W CN1 D amp E Ee RT 01 31 14 Ew ex sop Metal gt 152 METAL SAMPLES MUNFORD AL 36268 am le PHONE 256 358 4202 FAX 256 358 4515 A DIVISION OF ALABAMA SPECIALTY PRODUCTS INC Safe Area Wiring MS2700E MS2800E ER RS485 Transmitter SALE SHt R T To WO 1 1 WDB 000076 Appendix B Revision History Revision Date Changes 0 8 15 2014 Initial Release A 9 17 14 Revised entity parameters hazardous a
12. ONAL D SUB 9 PIN Lo 0 14mH DATA CONNECTOR 3 P CN1 RS 485 TERMINAL AND CN2 PROBE CONNECTOR 8 amp m COMBINED De o m 68uF sa NN L t xs 32uF Lo 0 14mH EDS D1061 9 uj CERTIFIED RS485 ISOLATING REPEATER 00 00 EIN E 2 ale ER Probe Simple Device Uo 3 7Vde lo 225mA Po 0 206W EE Sold Separately E 5 5 ol Iz RS 485 SIGNAL INTERFACE PC PLC DCS ERES Ei 2 alo NOTE EE 1 PROBE DIELECTRIC RATING 500V R M S DO NOT EXCEED E Za 2 THE MAXIMUM EXTERNAL CAPACITANCE Co THAT CAN BE E CONNECTED BETWEEN RS 485 TERMINALS CN1 AND 2 e PROBE TERMINALS CN2 IS 32uF NOTE PRE APPROVED POWER SUPPLY UNIT OR APPROVED EQUIPMENT WITH 2 Si THE MAXIMUM EXTERNAL INDUGTANGE Lo THAT BE THE FOLLOWING MAXIMUM INPUT PARAMETERS SHOULD BE USED g CONNECTED BETWEEN RS 485 TERMINALS CN1 AND a PROBE TERMINALS CN2 IS 0 14mH 1 J2 TERMINALS U 23 6Vde 88 2mA AND Pi 0 519W CN1 A amp B i ea bea 2 J9 TERMINALS U 3 7Vdc 1 225 AND P 0 206W CN1 D amp E 3 8 8191 I T ORT mE ut CRT 02 03 14 GREE cree wr BP EEW BKF SDP ALABAMA SPECIALTY PRODUCTS INC 2001 THIS DOCUMENT INCLUDING THE INFORMATION HEREIN IS THE PROPERTY OF ALABAMA SPECIALTY PRODUCTS INC ASPI IT CONTAINS PROPRIETARY INFORMATION AND MAY NOT BE REPRODUCED OR COPIED IN WHOLE OR IN PART NOR MAY IT
13. VENT SHALL METAL SAMPLES BE LIABLE FOR SPECIAL OR CONSEQUENTIAL DAMAGES OR FOR ANY DELAY IN THE PERFORMANCE OF THIS WARRANTY DUE TO CAUSES BEYOND ITS CONTROL The technical information and suggestions contained herein are believed to be reliable but they are not to be construed as warranties since conditions of use are beyond our control B Obtaining Service and Returning the Instrument for Repair If you experience problems with your instrument please contact the factory at 256 358 4202 and ask for customer support for instrumentation Our customer support department will assist you in troubleshooting your instrument Most issues can be resolved over the phone but in some cases it may be necessary to return your instrument for further evaluation and repair In this case please obtain a Return Materials Authorization RMA number from the sales person or support technician This RMA number will ensure that your instrument is routed to the correct department when it is received at the factory After receipt of an RMA number you may pack your instrument for return Be sure to pack your instrument in a sturdy box and to pad it sufficiently to avoid damage during transit Also be sure to complete the Instrument Repair Form on the next page and include a copy with your repair This will ensure that the repair department has sufficient information regarding the problems you are experiencing with your instrument as well as the billing contact and
14. am Multi Drop Safe Area Wiring Diagram 19 HAZARDOUS AREA MS2700E HIGH RESOLUTION ER RS 485 TRANSMITTER MS2800E ULTRA RESOLUTION ER RS 485 TRANSMITTER SAFE AREA BY CHKD SI 2 T N S E Q 1 E e LIS SI A 54 e Rn 0 H m m INPUT SUPPLY TERMINAL la Pn 23Vde VO 88 2mA P MAXIMUM OUTPUT ENTITY PARAMETERS Bev P 0 52W PSD1001 AT CN2 PROBE TERMINALS EE C 0 CERTIFIED SAFETY ISOLATOR lo Uo 5 0Vdc E D he 0 Up 23 6Vdc lo 88 2mA Po 0 519W Ed lo 503mA 56 Po 0 7W a Ox b D CN1 RS 485 TERMINAL AT EACH LINE vo o o 1 P a S O _ x eo 21 5 30Vdc m 225m Os 4 8 2 Vc OVdc 0 206W 595 K p 7 A CN1 INPUT SUPPLY TERMINAL RS 485 TERMINAL AND ES CN2 PROBE TERMINAL COMBINED I 23Vdc 0 0 r Probe Cable Assembly 1 538mA amp os T ro O Sold Separately P 07W Pe o Pra Me 20 30Vde C 68uF loss O vo 0Vdc uc 2 po ER Probe Simple Device 1 Sold Separately Co 32uF OPTI
15. ce with the control drawing located on page 20 and all of the local area requirements Input supply terminal Stand Alone In ly terminal RS 4 rminal Ui 23 n nn r CN2 combin li 2 88 2 mA Ui 23 Vdc Pi 20 52W li 538 Ci 20 Pi 0 7W Li 0 Ci 68uF Li 0 BS 485 channel at each line Co 32uF Connector CN1 pins D amp E J9 on Lo 0 14 mH Ui 3 7 Vdc li 225 mA Probe connector CN2 J1 on Pi 0 206 W U 25V U 5V l 51 mA l 129 mA P 0 064W 0 442 W nnector CN1 pins A amp B J2 on PCB Input supply terminal RS 485 terminal Ui 23 6 Vdc li 352 8 mA Ci 68uF Pi 2 3 W Li 0 Ci 0 Co 32uF Li 0 Lo 1 2 mH RS 485 channel at each line Probe connector CN2 J1 on PCB Connector CN1 pins D amp E 9 on Ui 3 7 Vdc U 5V li 225 mA l 352 8 mA Pi 0 206 W 0 44 W U 25V 51 mA P 2 64 mW CAUTION When used in Hazardous areas equipment must be supplied with a pre approved power supply unit or approved equipment via a certified intrinsically safe barrier or a galvanically isolated barrier with the entity parameters listed on the previous page Special Conditions 1 Probe dielectric rating lt 500V r m s Do not exceed 2 Probe cannot be installed in the explosion dust atmosphere Group III 3 Networked daisy chained arrangement not for use in Group IIC IIIC environment 4 Maximum 32 transmitters are allowed in the daisy chain arrangement
16. compared to the Meter Prover value further troubleshooting may be required Refer to page 16 for troubleshooting or contact the factory for further assistance Be sure to reinstall the enclosure cover and tighten the Lock Screw when putting the Conn VzZZX transmitter back into service 12 d Interpreting Data i Metal Loss The Conn VzZZX transmitter measures the Metal Loss of an ER probe and converts that value to a digital 20 bit RS 485 Modbus output This output is directly proportional to the cumulative Metal Loss of the ER probe at any given time The overall span of the output is proportional to the life of the probe in use so for DCS PLC programming the RS 485 Modbus output can be scaled as follows 0 2 0 mils 096 Metal Loss 1 048 575 Probe Life in mils 10096 Metal Loss The Probe Life can be found in Table 1 and is also listed on the Metal Samples probe tag as the Multiplier Part Serial O Alloy Check Initial Figure 6 Metal Samples Probe Tag Figure 7 illustrates the relationship between the digital output and Metal Loss In this example a probe with a 10 mil life is assumed However the X axis could be changed to represent any Probe Life 1048575 786431 524288 262144 F2 RS 485 Modbus Output 0 0 0 2 5 5 0 7 5 10 0 New Probe Probe Metal Loss mils Consumed Figure 7 Output Relationship As seen here the transmitter output begins at O for a new pr
17. e of compatibility The communication protocol is set using Position 8 of Switch 2 as illustrated in Table 3 iv Termination Resistor To ensure proper operation the RS 485 network must be terminated properly with a termination resistor To facilitate this each CoRR VzZZX transmitter has a built in 1200 termination resistor that can be switched on or off using Position 10 of Switch 2 Once all units have been installed be sure to enable the termination resistor of the last unit in the network The termination resistors of all other transmitters should be turned off v Data Registers Table 5 lists the data registers of the Conn VzZZX transmitter No Register Address Description 4 40024 DAC Value Low 40025 DAC Value Hi 6 40026 Probe Switch Setting Table 5 Modbus Data Registers 11 c Calibration and Testing i Calibration The Conn VzZZX transmitter is fully calibrated when shipped from the factory The calibration settings are fixed to avoid accidental change which could result in erroneous data No field calibration is required However it is important to test the unit upon installation and during periodic maintenance inspections to ensure the unit is operating properly ii Testing output zero and span The Conn VzZZX transmitter Probe Selection Switches page 9 offer three test settings that allow the unit to be placed into various diagnostic modes as follows 1 Zero Output Forces a digita
18. est the Conn VzZZX transmitter using the supplied Meter Prover see page 12 These basic checks should indicate the source of any problem probe power supply wiring etc If itis determined that the Corr VzZZX transmitter is malfunctioning or if you need further assistance in troubleshooting contact Metal Samples Technical Support CAUTION If the CORR 22 transmitter shows any signs of damage remove it from service immediately and consult the factory 16 III Service and Warranty Information A Warranty Metal Samples warrants that any part of the model MS2800E Corr VzZZX transmitter and accessories which proves to be defective in material or workmanship within one year of the date of original shipment to Purchaser will be repaired or replaced at Metal Samples option free of charge This warranty does not cover 1 probe assemblies 2 items expendable in nature or 3 items subject to damage from normal wear misuse or abuse or failure to follow use and care instructions All damaged items are to be shipped at Purchaser s expense to and from Metal Samples which shall have the right to final determination as to the existence and cause of a defect The foregoing shall constitute the sole and exclusive remedy of any purchaser of Metal Samples products for breach of warranty and IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES EXPRESSED IMPLIED OR STATUTORY INCLUDING THE IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS IN NO E
19. l Dimensions Direct probe mount standard May be pole mounted using optional hardware Up to a 2 5 6 35cm Dia pole ER measurement using any standard ER probe type Wire Loop Tube Loop Cylindrical Flush Strip etc 0 100 of probe life 0 000126 of Probe Life 20 bit 75 Seconds 10 to 28 VDC 30 ft 9 1 m RS 485 Modbus RTU or ASCII Protocol Switch Selectable 2400 4800 9600 19 2K Selectable Baud 32 Maximum Units Addresses 1 to 32 Hazardous Location Certifications Intrinsic Safety USA Canada Europe and Worldwide ATEX and IECEx X see Special Conditions page 7 Included Accessories Conforms to ANSI UL Std 60079 0 60079 11 61010 1 CAN CSA Std E66079 0 E60079 11 amp CAN CSA C22 2 No 61010 1 For Stand Alone Use For Multi Drop Use Class 1 ZoneO AEx ia IIC T4 Ga Class 1 ZoneO AEx ia IIB T4 Ga Zone 20 AEx ia T130 C Da Zone 20 AEx ia IIIB T130 C Da 20 C lt Ta lt 70 C 20 C lt Ta lt 70 C For Stand Alone Use I 1 G Ex ia IIC T4 Ga For Multi Drop Use I 1 G Ex ia IIB T4 Ga 11 D Ex ia T130 C Da I 1 D Ex ia IIIB T130 C Da 20 C lt Ta lt 70 C 20 C lt Ta lt 70 C ATEX Certificate No ITS14ATEX28092X IECEx Certificate No IECEx ITS 14 0052X 3 1M Wiring Harness Meter Prover Operations Manual Optional Accessories Probe Extension Cable Remote Mounting Hardware Il Installation and Operation A Receiving the MS2800E
20. l output of O 2 Maximum Output Forces a digital output of 1 048 575 3 Output Sweep Causes the output to continually cycle from 0 up to 1 048 575 These test modes can be useful when troubleshooting communication problems between the transmitter and the DCS PLC system iii Testing the Corr VzZZX transmitter with the Meter Prover A Meter Prover is provided to allow routine checks of the CoRR VzZZX transmitter The Meter Prover simulates a Wire Loop type probe at a fixed value To test the unit with the Meter Prover 1 Disconnect power 2 Disconnect the Corr VzZZX transmitter from the probe or if the unit is remote mounted disconnect the probe extension cable from the probe 3 Connect the Meter Prover to the probe connector stem or to the probe extension cable if the Conn VzZZX transmitter is remote mounted 4 Loosen the Enclosure Lock Screw 5 Unthread and remove the transmitter cover 6 Change the Probe Selection Switches to the Wire Loop position see page 9 7 Reconnect power and allow the instrument to measure for several minutes to stabilize 8 After several minutes observe the transmitter output The output should closely match the value printed on the Meter Prover label If the transmitter output matches the Meter Prover value you may return the Probe Selection Switches to their previous setting and reconnect the Corr VzZZX transmitter to the probe If the transmitter output shows a significant difference
21. n Rate formula to periods of interest For example look at the graph below and see how much the calculated Corrosion Rate can vary depending on the time period used 525 ri P 2 43 METAL LOSS mils q 427005 Sus 5102005 I 51602005 5715 2005 6132005 Date Figure 8 Corrosion Rates calculated from Metal Loss data While each of the results is valid for the selected time period the one of most interest is the value of 11 81 mpy which represents some type of system upset When the Corrosion Rate is calculated automatically on a pre selected time period there is no guarantee that the selected time period will always coincide with system upsets such as this That is why manual review and interpretation of Metal Loss data is also helpful 14 e Commissioning Once the Conn VzZZX transmitter has been installed tested and properly configured for the probe in use it can then be closed and put into service First perform one last visual inspection to ensure that all electrical connections are secure and that the enclosure o ring is in place and is in good condition Then thread the enclosure lid onto the base fully Once the lid has been threaded into place tighten the Lock Screw to prevent unauthorized tampering Figure 9 Enclosure Lock Screw CAUTION The Lock Screw on the instrument base must be tightened securely to prevent unauthorized personnel from opening
22. ng items CAUTION Before performing any tests or maintenance the CORR VZZZ transmitter ensure that all hazardous area requirements are met 1 Ensure that the probe is operational and is not completely corroded This can be done in two ways a Testthe probe with a portable ER meter if available b Testthe probe with a portable resistance or continuity meter as follows i Connectone test lead to pin A of the probe s 6 pin connector ii Measure continuity to each of the other pins There should be continuity low resistance to each pin NOTE Continuity on each pin does not ensure that the probe is good However if you find an open circuit on any pins then it is almost certain that the probe is bad and should be replaced Ensure that the Probe Selection Switches are set correctly for the probe being used Confirm the probe type and refer to Table 2 on page 9 to verify the appropriate switch settings Perform a visual inspection of the circuit boards to look for any signs of mechanical or electrical damage Ensure that all electrical cables and wiring are in good condition Ensure that all electrical contacts are secure and free of corrosion Ensure that there is adequate supply voltage at the power connector Verify that the supply voltage polarity is correct If there is insufficient supply voltage on the power connector check the safety barrier if applicable for a blown fuse or any other failure T
23. ns the maximum inductance and capacitance of the field wiring between the safety barrier and the transmitter cannot exceed the entity parameters of the selected barrier 3 Setup and Operation a Probe Settings The probe selection switches are located on the top left corner of the main board as illustrated in Figure 5 below These switches are used to set the ER probe type They also allow the instrument to be placed into several test modes which output fixed values allowing verification of the output signal Table 2 gives the switch settings for each probe type and the various test modes Probe Cable Connector Switch 1 Probe Selection Switch See Table 2 below Switch 2 RS 485 Configuration Switches See Table 3 below Power Connector 12 39 Figure 5 Connector and Switch Details Wire Loop ott onm On Off a Tube Loop Flush On t onm Off Cylindrical off on ott Zero Output 0 On t On 1 Off Off J Switch 1 E su ea Ga Full Scale Sweep On 1 Off J Off Off J Table 2 Probe Switch Settings Cylindrical probe setting is illustrated 9 b RS 485 Communication Settings The RS 485 configuration switches are located on the top right corner of the main board as illustrated in Figure 5 These are used to set the instrument address baud rate communication
24. obe zero Metal Loss and increases as the probe element corrodes eventually reaching a maximum of 1 048 575 when the probe sensing element has been completely consumed by corrosion in this case 10 mils of Metal Loss Atthis time the probe has reached its end of life and must be replaced 13 ii Calculating Corrosion Rate As explained previously ER probes and instruments report Metal Loss However the value that is of ultimate interest is Corrosion Rate The Corrosion Rate is essentially Metal Loss over time so the Corrosion Rate can be calculated using the following formula AMetalLoss mils x 365 ATime days Corrosion Rate mpy where AMetalLoss mils is the difference between two Metal Loss readings ATime days is the time difference between those two readings It is a common practice to program this formula into the control DCS PLC system and have it calculate Corrosion Rate on a continual basis from the Metal Loss data The challenge in doing this is selecting an appropriate time interval Using an interval that is too short may give erratic results while selecting an interval that is too long may give results that are insensitive to system upsets The ideal time period depends on many factors and will vary from system to system It may take some trial and error to settle on the best time period for your installation In some cases it may be necessary to review the raw Metal Loss data and manually apply the Corrosio
25. of the control system input If the Transmitter is to be installed in a safe area refer to section c Safe Area Installation for details If the Transmitter is to be installed in a hazardous area refer to section d Hazardous Area Installation b Grounding The Conn VzZZX transmitter enclosure is grounded internally through the wiring harness but an additional external grounding terminal is provided as well The enclosure should be grounded properly using the external grounding terminal to ensure safe operation c Safe Area Installation The Conn VzZZX transmitter is approved for use in hazardous areas but can be used in non hazardous areas as well For basic safe area wiring information refer to the circuit diagram shown on page 21 CAUTION When used in non hazardous areas equipment must be supplied with a pre approved power supply unit or approved equipment which meets the entity parameters shown below The pre approved equipment must be certified to the electrical safety standards for equipment in ordinary locations for example EN IEC CSA UL 61010 1 or EN IEC CSA UL 60950 1 Failure to meet these requirements will void the intrinsic safety certification of the equipment and prohibit its future use in hazardous areas d Hazardous Area Installation CAUTION This section provides general guidelines for hazardous area wiring However regardless of anything stated here the Corr VzZZX transmitter must be installed in full complian
26. offers user selectable RTU or ASCII communication protocols making it highly versatile The Conn VzZZX transmitter is compatible with all types of Metal Samples ER probes as well as any standard ER probe from other manufacturers Unlike competitors products the Conn VzZZX transmitter does not require factory modification to accommodate different probe types The probe type can be easily changed at any time using the on board probe selection switches see page 9 The Conn VzZZX transmitter is available as direct mount standard or remote mount The direct mount version is mounted directly to the ER probe This option offers the simplest installation and minimizes noise problems The remote mount option allows the Corr VzZZX transmitter to be mounted independently from but in close proximity to the ER probe It is then connected to the probe via a short probe cable See pages 5 and 6 for mounting diagrams and specifications B Principles of Operation The Conn VzZZX transmitter operates on the Electrical Resistance ER technique and is used in conjunction with an ER probe The ER probe utilizes a resistive sensing element manufactured from the material of interest or a close approximation which is exposed to a corroding environment This is called the Exposed or Corroding Element The resistance of the Exposed Element is directly related to its thickness so as the element corrodes the resulting loss of metal causes a proportional increase
27. protocol and to enable the termination resistor Table 3 gives the switch settings for each of these parameters and they are explained in more detail below Position Communication Position Protocol 8 ASCII On 1 RTU Off 1 Termination Position Resistor 10 Active On 1 Inactive Off N A Table 3 RS 485 Configuration Switch Settings 10 i Baud Rate and Default Communication Parameters The default communication parameters for the Conn Ve X transmitter are provided in Table 4 below If necessary the baud rate can be changed using Positions 1 and 2 of Switch 2 as illustrated in Table 3 Parameter Value Baud Rate 19200 Data Bits 8 Parity Even Stop Bits 1 Table 4 Default Communication Parameters ii Device Address Up to 32 Corr VzZZX transmitters may be connected in a multi drop network daisy chained using a single cable run However each transmitter must be set to a unique device address to avoid conflicts This is done using Positions 3 through 7 of Switch 2 as illustrated in Table 3 CAUTION Be sure to observe the appropriate gas group rating listed on page 3 for stand alone or multi drop operation iii Communication Protocols The Conn VzZZX transmitter offers user selectable RTU or ASCII communication protocols giving the unit a broader rang
28. rea installation control drawing and safe area installation drawing B 10 9 14 Revised entity parameters and hazardous area installation control drawing C 1 15 15 Separate gas group rating listed for Stand Alone and Multi Drop operation Revised hazardous area installation control drawing D 2 4 15 Revised entity parameters hazardous area installation control drawings and safe area installation drawing E 3 25 15 Revised entity parameters F 8 14 15 Revised entity parameters 23
29. return shipping details for the repair Once you have obtained an RMA number completed the Instrument Repair Form and packed your instrument securely please ship it prepaid to the following address Metal Samples 152 Metal Samples Road Munford AL 36268 ATTN RMA NOTE Be sure to list your RMA number in the attention line shown as blanks in the example above 17 C Instrument Repair Form This form may be photocopied for use when returning an instrument to Metal Samples for repair Please fill in all known information and enclose a copy of the completed form with the instrument General Information Model Serial Number Number RMA Date of Number Purchase If known Contact Information for Repair Contact Name Company Phone E mail Number Address Return Shipping Information Recipient Name Company Return Address different than above Reason for Return Provide as much detail as possible Attach additional pages if required Invoice Instructions For non warranty repairs Invoice me for the repair Reference Requires an open account with Metal samples POH DJ Contact me for credit card information For security purposes do not list credit card information on this form 18 Appendix A Drawings A Wiring Diagrams Control Drawing Hazardous Area Wiring Diagram Stand Alone Control Drawing Hazardous Area Wiring Diagr
30. s in a detection limit of less than one angstrom Metal loss readings taken by the Conn VzZZX transmitter are output as a digital RS 485 signal which can be fed into a plant control system or other recording devices The Metal Loss is represented by a 20 bit digital value between 0 and 1 048 575 where 0 0 mils 0 Metal Loss 1 048 575 Probe Life in mils or 10096 Metal Loss The Probe Life or Span of the probe being used see table 1 above The Metal Loss data can be used to calculate the corrosion rate between any periods of interest This is covered in more detail on pages 13 and 14 More information on ER probes their theory selection and use can be found on our web site at http www alspi com erintro htm C Technical Specifications Model MS2800E Conn VzZZX Ultra High Resolution ER RS 485 Modbus Transmitter Physical Data Instrument Weight Total Weight w Accessories Instrument Dimensions Operating Temperature Storage Temperature Environmental Rating Enclosure Material Mounting Specifications Performance Data Measurement Type Range Resolution Cycle Time Electrical Data Power Requirements Maximum Probe Cable Distance Output Specifications 3 70 Ib 1 68 Kg 5 76 Ib 2 61 Kg 6 0 H x 4 0 Dia 6 0 H 15 25cm H x 10 16cm Dia 15 25cm 4 to 158 F 20 to 70 10 16cm 40 to 176 40 to 80 2 IP66 316 Stainless Steel Figure 1 Overal
31. the CORR 22 transmitter and ensure that the intrinsic safety is not violated Only qualified personnel should be allowed to install operate and maintenance the CORR VALOK transmitter C Maintenance Once installed the Corr VzZZX transmitter requires little maintenance However it is important to verify the following items periodically to ensure continued safe operation CAUTION Before performing any tests or maintenance on the Conn ZZZY transmitter ensure that all hazardous area requirements are met Inspection Item Inspect the enclosure o ring for any signs of damage Replace as necessary Frequency Annually Inspect the probe connector o ring for any signs of damage Replace as necessary Annually Inspect the external electrical connections for signs of corrosion mechanical damage or foreign matter that could cause damage or cause an electrical short Clean as necessary Annually Ensure that the locking screw is in place and is secure Annually The Conn Vz4ZX transmitter enclosure is made of corrosion resistant 316 stainless steel However it should still be checked periodically for any signs of corrosion Annually Check for any signs of moisture ingress within the enclosure Contact Metal Samples for replacement parts or if instrument repair is necessary 15 Annually D Troubleshooting If the Conn VzZZX transmitter does not seem to perform as expected check the followi
32. ting The Conn VzZZX transmitter is designed for direct probe mounting which eliminates the need for additional hardware and transmitter to probe cabling This greatly simplifies installation reduces costs and minimizes electrical noise that can be coupled onto probe cabling from nearby electrical equipment Before mounting the Corr VzZZX transmitter first ensure that the probe is installed properly and securely During installation it is important that you do not apply excessive force on the probe or seals as doing so could break the seal and result in system leakage 4 To mount the Conn Vz4ZX transmitter 1 Align the keyways of the transmitter and probe connectors 2 Insert the transmitter connector plug fully into the probe connector receptacle 3 Secure the transmitter to the top of the probe by tightening the coupling nut NOTE Hand tight is sufficient Do not over tighten the coupling nut NOTE Never force the connectors to mate If there is resistance stop and check for bent pins on the probe and for foreign material in the female sockets of the transmitter connector Gently straighten any bent pins and clear any foreign material that may be found Align Key l E Insert Connector Tighten Coupling Nut b Remote Mounting Figure 2 Direct Mount Installation When it is not practical to direct probe mount the Corr VzZZX transmitter the unit can be remote mounted instead In this case the
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