User`s Manual in PDF - Alabama Specialty Products, Inc.
Contents
1. Always use fuses of a smaller capacity than the safe capacity of the line or equipment it Metal Samples 2014 w 2 START UP amp OPERATION RECEIVER START If the Receiver is new one removed from the package not had been used for an extended amount of time overnight weekend or holiday follow the procedure below to start the equipment Refer MS2540 Receiver connection Details for detailed receiver connections to transmitter and DCS PLC PC Ensure the transmitter connections are connected properly to the receiver unit Ensure the DCS PLC PC is connections to the receiver Ensure the power cord is connected and power is turned on The mains switch is located under the equipment The Green light start illuminates once the switch is on If receiver is turned on after a long time follow step 7 When the power is turned on the equipment boots up and Receiver title page appears for a short time and probe initialization message appears on the screen Also Probe Initialization message appears on the screen if the equipment lost the probe life data setting or if the during the program update PROBE INITIALIZATION MESSAGE Pressing OK on the message takes the display to Options Settings page you may enter the right probe life using the pop up keyboard on the screen Refer Options Page details for detailed settings PAGE 24 When the power is turned on the equipment boots up and Receiver titl2. Metal Samples Corrosion Monitoring Systems MS2540 Current Loop Receiver with RS485 Communication User Manual Metal 5 A D 152 Samples Mun E mail mscahpicom Interet wwwzmetilsumples com Houston Office 6327 Teal Mist Lane Fulshear TX 77441 Phone 832 451 6825 SECTION 1 INSTALLATION Shipping and Receiving Mounting Electrical Physical Dimensions Specifications Equipment Safety SECTION 2 START UP AND OPERATION Start Up Procedure Receiver Star Up Operation Controls Operation Title Sereen Maia Screen Setup Screen Data Chart Sereen Status Sereen Option Senings Sereen Calibration Sereen Help Sereen SECTION 3 MAINTENANCE General Preventive Maintenance Service Instructions Fuse Replacement SECTION 4 TROUBLESHOOTING Trouble Procedure 4 5 6 7 9 1 Metal Samples 2014 NOTIC The information and instructions in this document are valid and current to the best of our knowledge as of the publication date on this page Metal Samples assumes no responsibility for revising or updating this document after the publication date and therefore makes no representation or certification either expressed or implied as to the accuracy or adequacy of this data over time Copyright 2014 by Metal Samples rights reserved Metal Samples 152 Metal Samples Rd PO Bo 8 Munford AL 36268 Phone 256 358 1202
3. Tax 256 358 4515 Interne ww metalsamples com Metal Samples 1 INSTALLATION SHIPPING AND RECEIVING Equipment is carefully prepared for shipment to protect it during tra enable the user to install it with a minimum amount of reassembly Upon receipt equipment should be carefully inspected for transit damage If damage is apparent notify Metal Samples and the cartier for claims inspection UNLOADING AND LIFT iG Open the package as remove the instrument carefully The instrument contains a display screen while removing utmost care to be given to the display CLEANIN Clean the equipment thoroughly to remove any foreign material that may have accumulated during shipment STALL TION Place the receiver instrument in convenient location preferably away from heat producing sources or direct sunlight can Place the receiver instrument in Receiver supplied for wall mounting and convenient location preferably away from heat producing sources or direct sunlight Metal Samples amum Mk HT i Dus 40 Do ae on teg as 1 STEEL HET SENS GD ps 1 anger 1 pus LI Hiss wans 14A azs Metal Samples 2014 ELECTRICAL in Power Connection Connect Single Phase 100 240V AC 50 60 Hz to the
4. The Comm Light becomes green when receiver communicates successfully to the transmitter Fault 1 Fault ight becomes Red when the hardware fault occurs 2 Fault light becomes Red when interface I O fault occurs 3 Fault light becomes Red when Software issues Loop Current Displays the transmitter current Log Count Displays the log count of the receiver loop current measurement Minimum of 96 counts necessary to display the corrosion rate display on the main page Metal Samples 0204 20 DBUS DATA REGISTERS Device Status 0001 The Modbus register data of the receiver status is displays here Address 40002 Displays the receiver address Baud Rate 40003 Displays the Baud Rate settings of the receiver Metal loss 40018 Fault light becomes Red when the fault occurs on the receiver unit Transmitter Current 40022 Displays the transmitter current Corrosion Rate 40024 Displays the corrosion rate Probe Life 40027 Displays the probe data ATION BUTTONS Press Home image button to display the Main page Press Setup image button to display the ER LPR Setup page Press Options image bution to display the Options page Press Information image button to display the Help page Metal Samples O 2014 OPTIONS amp COMMUNICATION DATA SETTINGS Authorised Personel only t INSTRUMENT SETTING PORT SETTINGS 1 ER Instrument Type 2
5. data can be easily accessible real time The built in web server also can be used to monitor the display on the remote computer thru network Output The Metal loss is calculated using one of the following formulas Metal Loss mils 1 416 X Probe life Metal Loss mm 14 16 X Probe life X 25 4 Where 1 Loop Current in mA ProbeLife Usable portion of probe element thickness in mils See Table 1 Metal Samples 2014 n TABLE 1 PROBE LIFE AND ELEMENT ID Element Element Probe Life Element Identifier Type Thickness Mis 40 mil 10 mil wr 40 80 mil 20 mil we imi imi Tu imi Tmi SL oa Sep Loop 8 mil 2mil 51 08 10 mil 5 mi Cylindrical 20 mil 10 mil 50 mil 25 mil m Tomi 5 mi SPD 20 mil 10 mil SP 20 Amil 2mi FS 04 Flush Smali imi FS o8 20 mil 10 mil 520 10 mil Smi Flush Large 20 mil FL20 40 mil 20 mil FL 40 10 mil Smi 5510 Surface Strip 20 mil 8820 40 mil 20 mil 5540 CONTROLS OPERATION Metal e Samples MS 2540 The Title screen is the first screen displayed when power is activated and after the equipment boots up Metal Samples 2014 METAL LOSS IN mils Display indicates the active metal loss data in selected unit mils micron CORR RATE IN MILS Yr Display indicates the active Corrosion rate in selected unit mils mic
6. is necessary to enter Metal Samples 2014 z nage button to logout from user privile 8 Press Logout HELP SCREEN HELP Preas this image button display he main ERILPR page Prese this image button ta splay the SRILPR Setup page Press this image buton 1 display the Status Setup page Pret this immage button t display Options page Preas this image button ta dapiay carat pege AS Press this image button to display the Char display page 152 Matal Samplos Ra Munford AL 36268 Tel 001 256 358 4202 Prase ths image buttar deploy the page Fare 001256 356 4515 eMail mse atspi com wens metelsamples com ET Ce Pros this image baton to Help pape ZATION BUTTONS Press Home button to display the Main page Metal Samples 2014 n 3 MAINTENANCE 1 General Preventative Maintenance Only qualified service technicians should maintain and repair the equipment Follow all local safety regulations while servicing 1 Every 12 Months A Check and tighten electrical screw connections IL Service Instructions Main Fuse Replacement Fl 2A The mains fuse can be replaced by following the below mentioned procedure 1 Tum off the main Power switch 2 Remove the Single Phase power cord connected to the equipment Fuse pull Tab Using the small screwdriver or fuse drawer remover
7. LPR Baud Rte Select he instrument type respect To transmitter connected Ihe equipment lore TumAround Delay INSTRUMENT SETTING Follow the below steps to calibrate the receiver with respect to the transmitter current 1 Tum off the receiver power and set the transmitter switches to 20mA 2 Tum on the power Enter the address for receiver 110 32 Enter the numerals respective to the Baud Rate for the RS 485 communication 2 9 1200 332400 4 gt 4800 599600 6 9 19200 amp 729382400 Parity Enter the Parity for RS485 communication 03 None 1304 amp 2 gt Even Turnaround Delay Enter the turnaround delay for communication Note Recommended communication Settings Baud Rate J600 Parity Even amp Tum Around Delay 10 Metal Samples 2014 n CALIBRATION SCREE Authorized Personnel Calibration moni p CALIBRATION PROCEDURE Follow the below steps to calibrate the receiver with respect to the transmitter current 1 Tum off the receiver power and set the transmitter switches to 20mA Tur on the power Wait fora minute Press Calib button on the above screen Receiver calibrates automatically and on completion of the calibration the calibration light tums Press Home image button to display the Main page Press Admin image button to display the Administrator page The Administrator login
8. e page appears for short time and probe initialization message appears on the screen if the unit is new one the display changes to main page which shows the Metal loss and corrosion rate display if the equipment is tumed on after a long time After approximately a minute the display updates the current metal loss value Check and ensure the Probe life data on the Settings page if requires change the probe life according the probe connected Metal Samples 2014 OPERATION The model MS2540 is line powered current loop receiver that provides 24V DC to power 2 wire 4 20 mA instrument loop and provides a display of the loop value in metal loss and calculated corrosion rate and also the device can be connected to the DCS PLC PC via RS485 Serial Communication The corrosion rate time period can be set with different intervals of 48 hours 7 Days 15 Days and 30 Days The Corrosion rate is calculated using a simplified algorithm that calculates every 30 minutes based on the metal loss change over the previous 48 hours to 30 days according to the setting The metal loss values are stored in the compact flash card with time stamp value The same can be used for metal loss analysis at any given time Universally acceptable MODBUS protocol is used for RS485 serial communication hence no special software is required to communicate to the receiver Also up to 32 receivers can be connected to DCS PLC PC via Daisy chain The Modbus
9. er year Metal Samples 2014 The corrosion rate is calculated based on the metal loss over the previous hours Timing is settable thru settings page First time after power on or probe change out the corrosion rate starts calculates after 48 hours and displays the value even the set value is other than 48 hours If the set value is other than 48 hours once the set value time reached then it starts calculating the corrosion rate according to the set period Press Home image bution to display the Main page EAD Press Status image button to display the Status page Metal Samples 2014 Month 123 45 6 7 8 9 10 11 12 YEAR Press the Year entry box and enter the year for which the metal loss data needs to be displayed in the chart MONTH Select the month to view the metal loss data for the respective month or select to view the data for whole year Press Home image button to display the Main page Metal Samples 0204 STATUS SCREE RECEIVER STATUS MODBUS DATA Deseo Sis p pm Meses Cunt Loop Current d Corsa fate Lag count RECEIVER STATUS Power The Power light becomes green when the receiver power supply is in good condition Run lt The Run light becomes green when the receiver isin run condition and the processor is acquiring the metal loss data Comm
10. l should read this manual to become familiar with the complete operation of the Equipment Becoming familiar with all operating procedures will greatly reduce the possibility of accidents or injury ONLY QUALIFIED OPERATORS AND MAINTENANCE PERSONNEL THAT HAVE COMPLETE AND CORRECT KNOWLEDGE OF THE RECEIVER INSTRUMENT SHOULD PERFORM ALL OPERATIONS AND MAINTENANCE PROCEDURES 1 POTENTIAL HAZARDS AL Electrical Do not touch electrically live components Before performing any maintenance procedures make sure that the main switch located on the bottom of the instrument enclosure in the OFF position Receiver Instrument must be properly grounded failure to do so will result an electrical result Damaged electrical connections or wites should be replaced before power is applied covers must remain securely in place when power is applied or electrical shock may result Always follow these electrical system safety procedures Follow proper plant regional and national safety procedures while servicing the electrical systems on this equipment Remove all metal items such as rings metal necklaces and wrist watches These are electrical hazards Medical alert jewelry should be wom with caution Use insulated tools when working on electrical equipment to reduce the possibility of shock When troubleshooting with power activated know the amount of voltage present in all areas before troubleshooting
11. ns of the various control functions presented in this manu DRAGE ALLATION OIRNME Protect the receiver instrument from mechanical stress humidity dust and thermal damage Storage temperature 20 C to 60 C operating temperature is 15 C to 435 Metal Samples SICAL DIMENSIONS emm 1 pim Das 1 us 225 Hes mes 14 am pme 1 ps AL SHEL FET SVS MS 1 pus 1 sa I a p 1 Hem une 1 gu us 1 Metal Samples 2014 WEIGHT cAdbs 19 Kg DIMENSIONS 825 X 1184 X 6 83 20 98em X 30 00em X 17 34em MOUNTING Panel Mount OPERATING TEMP 32 F to 12 F 0 C S0 C POWER SUPPLY Voltage 100 240 V 1 phase 50 60 Hz Current lt 3 Amps SIGNAL Voltage WV De Current loop 4 20mA Input Impedance 250 Ohms COMMUNICATION Type RS485 Serial Protocol MODBUS No Of Units 0 units maximum NETWORK Use Cross over cable to connect the equipment directly to PC Use Straight Cable to connect to the network switch router Metal Samples 2014 EQUIPMENT SAFETY Always follow these warnings and safety procedures Before attempting to operate or perform any service functions all operators and service personne
12. ot activated Check the mains supply and ensure the switch is in on position Blown Fuse Replace the fuse Display defective Contact Distributor Manufacturer No Metal loss Value Display Current loop wires loose Check and connect properly the current loop wires Current loop Wires polarity Check the polarity of the connected current loop wires 24V missing Check 24V on current loop wires Contact Distributor Manufacturer Metal Samples 2014
13. plug provided in the bottom of the unit The maximum current requirement is 2 A Note In some cases the instrument is shipped without a connector on the power cord Each locality should inspect the power cord and install the proper connector if necessary The connector should be installed in properly grounded outlet for proper over current and earth fault protection 1 Connect Ve terminal of the transmitter to the TBI 1 terminal 2 Connect Ve terminal of the transmitter to the TB1 2 terminal Metal Samples 2014 RS485 Connections Connect D of the DCS PLC to the TB2 1 D terminal Connect D of the DCS PLC to the TB2 2 D terminal Connect Signal Ground of the DCS PLC to the TB2 3 SG terminal Connect Terminating Resistor terminal Ethernet Connections Connect the unit using Straight RJ4S cable to the Ethernet switch or Router if you are connecting to the Personnel Computer use Crossover RJ45 cable Before connecting it to the local network please contact your network administrator for proper IP address configuration of the equipment Warning Duplicated IP address may cause network failure at the installation site Consult Network Administrator Receiver functions must be adjusted and operated only by those authorized personnel who have read and who thoroughly understand the descriptio
14. push the tab shown in the above picture and pull the fuse drawer out One spare fuse will be provided in the fuse drawer you can discard the blown one and use the spare one and insert on its location Press the fuse drawer inside and ensure it is properly locked in its position 4 Connect the main cord and turn on the mains power Metal Samples as Loop Current Fuse Replacement F2 1 Tum off the main Power switch 2 Remove the loop current fuse holder cap by rotating the fuse holder cap towards the lef 3 Remove the Glass fuse from the fuse holder 4 Replace same type of fuse 5 Insert the fuse holder knob and tighten fully 6 on the power etal Samples O 2014 4 TROUBLESHOOTING Troubleshooting is the process of identifying a problem finding the cause of the problem and performing the necessary steps to correct it Fault messages displayed on the status window to identify the location and type of fault that has occurred This troubleshooting section addresses common equipment problems possible causes and recommended solutions IMPORTANT It is not the intent of this manual to provide highly detailed breakdown of all possible problems that may be encountered while using this equipment WARNIN Contact equipment Distributor Manufacturer for help if a problem cannot be easily corrected PROBLEM POSSIBLE CAUSE SOLUTION No Display Power is n
15. rons per year The corrosion rate is calculated based on the metal loss over the previous hours Timing is settable thru settings pag First time after power on or probe change out the corrosion rate starts calculates after 48 hours and displays the value even the set value is other than 48 hours If the set value is other than 48 hours once the set value time reached then it starts calculating the corrosion rate according io the set period LIVEDATA This graph window displays the live data from the transmitter in metal loss value Metal Samples Press Status image button to display the Status page d p Chartimage button to display the Chart page twy Press Information image button to display the Help page Metal Samples 2014 6 TU EEN ER SETUP PAGE Display Unit Authorised Personnal oriy Calculation Pario Probe Lre ee DISPLAY UNIT Press the Display unit button to change the display units of the metal loss and corrosion rate as mils or microns on the main page CALCULATION PERIOD This selection unit is for calculating the corrosion rate per year based on the set time This can be selectable as 48 Hours 7 days 15 Days and 30 days PRONE LIFE Set the Probe life according to the probe used on the field this setting should be in mils Display indicates the active Corrosion rate in selected unit mils microns p
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