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Reference Manual 00809-0100-3414, Rev AA May 2019 ™ Rosemount MCL-220 Monochloramine System with Rosemount 1056 Transmitter...
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Read this page before proceeding! Your instrument purchase from Emerson is one of the finest available for your particular application. These instruments have been designed and tested to meet many national and international standards. Experience indicates that its performance is directly related to the quailty of the installation and knowledge of the user in operating and maintaining the instrument.
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Note Radio interference This product generates, uses, and can radiate radio frequency energy and thus can cause radio communication interference. Improper installation or operation may increase such interference. As temporarily permitted by regulation, this unit has not been tested for compliance within the limits of Class A computing devices, pursuant to Subpart J of Part 15 of FCC rules, which are designed to provide reasonable protection against such interference.
2.1 Specifications..........................11 2.2 Ordering information........................12 Chapter 3 Install...........................13 3.1 Unpack and inspect........................13 3.2 Rosemount MCL-220........................13 3.3 General installation information..................... 13 3.4 Sample requirements........................14 3.5 Mounting, inlet, and drain connections..................14 3.6 Install the sensor..........................15 Chapter 4 Wire..........................
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9.5 Troubleshooting when no error message is showing..............75 9.6 Troubleshooting when no error message is showing - general............79 9.7 Simulate inputs..........................80 9.8 Simulating temperature......................... 81 Appendix A EU Declaration of Conformity..................85 Appendix B China RoHS Table......................87 Emerson.com/Rosemount...
Reference Manual Quick Start 00809-0100-3414 May 2019 Quick Start Procedure 1. Once connections are secured and verified, apply power to the transmitter. When the transmitter is powered up for the first time, Quick Start screens appear. Using Quick Start is easy. a.
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5. Choose the desired temperature units. The main display appears. The outputs and alarms (if an alarm board is present) are assigned to default values. 6. To change outputs, alarms, and other settings, go to the Main Menu and choose Program. Follow the prompts. Emerson.com/Rosemount...
2 months (approx.) Ordering information The Rosemount MCL-220 is a complete system for the determination of monochloramine in water. It consists of a monochloramine sensor, Rosemount 1056 transmitter, Variopol cable, and constant head overflow cup to control sample flow. All components are mounted on a backplate, and the cable is pre-wired to the transmitter.
If items are missing, notify Emerson immediately. Rosemount MCL-220 The Rosemount MCL-220 consists of the following items mounted on a back plate. 1. The Rosemount 1056-03-24-38-AN with sensor cable attached. 2. Constant head overflow sampler with flow cell for monochloramine sensor.
The Rosemount MCL-220 is intended for wall mounting only. Refer to Figure 3-1 for details. The sensor screws into the flow cell adapter. Figure 3-1: Rosemount MCL-220 Monochloramine System A. Chlorine sensor B. Check valve C. Inlet D. Drain If desired, you can remove the compression fitting and replace it with a barb fitting. The inlet fitting screws into a ¼-in.
Install the sensor ™ Emerson provides the Rosemount MCL with the sensor cable pre-wired to the transmitter. The terminal end of the sensor is keyed to ensure proper mating with the cable receptacle.
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Install Reference Manual May 2019 00809-0100-3414 Emerson.com/Rosemount...
Reference Manual Wire 00809-0100-3414 May 2019 Wire Wire power Wire AC mains power supply to the power supply board, which is mounted vertically on the left hand side of the transmitter enclosure. WARNING Electrical shock Electrical installation must be in accordance with the National Electrical Code (ANSI/ NFPA-70) and/or any other applicable national or local codes.
Keep output signal wiring separate from power wiring. Do not run signal and power or relay wiring in the same conduit or close together in a cable tray. Alarm wiring The alarm relay terminal strip is located just below the power connector on the power supply board. Figure 4-2. Emerson.com/Rosemount...
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Reference Manual Wire 00809-0100-3414 May 2019 Figure 4-2: Alarm relay connections A. Alarm relay 1 B. Alarm relay 2 C. Alarm relay 3 D. Alarm relay 4 1. To remove the cover, grab it by the upper edges and pull straight out. The relay terminal strip is at the top of the board.
5. Disconnect the wires and remove the cable. 6. Insert the new cable through the gland and pull the cable through the cable slot. 7. Wire the sensor to the signal board. Figure 4-3. Emerson.com/Rosemount...
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Reference Manual Wire 00809-0100-3414 May 2019 Figure 4-3: Rosemount 499ACL-03-54-60 Sensor Wiring to Rosemount 1056 Transmitter A. White B. Resistance temperature device return C. White/red D. Resistance temperature device sense E. Red F. Resistance temperature device in G. Clear H. Resistance temperature device shield I.
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Wire Reference Manual May 2019 00809-0100-3414 Emerson.com/Rosemount...
Reference Manual Display and operation 00809-0100-3414 May 2019 Display and operation Display Figure 5-1. You can customize the display to meet your requirements. Refer to Configure the main display. Figure 5-1: Main Display When the transmitter is being programmed or calibrated, the display changes to a screen similar to the one shown in Figure 5-2.
C. You are in the middle of the list. There are more items for viewing. Scroll up or down. The arrow bar shows whether additional items in a list are available. Keypad Local communication with the transmitter is through the membrane keypad. Figure 5-4 Figure 5-5 explain the operation of the keys. Emerson.com/Rosemount...
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Reference Manual Display and operation 00809-0100-3414 May 2019 Figure 5-4: Transmitter Keypad A. Press MENU. The Main Menu screen appears. B. Press DIAG. The main diagnostic screen appears. C. Navigation keys move the cursor in the direction indicated in Figure 5-5.
4 and 20 mA analog outputs. Procedure 1. Press MENU. The main Menu screen appears. There are four items in the main menu. Calibrate is in reverse video, meaning that the cursor is on Calibrate. Emerson.com/Rosemount...
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S1 is sensor 1.. The assignments shown are the defaults for the Rosemount MCL-220. Outputs are freely assignable under the Configure menu. 5. For practice, change the 20 mA settings for output 1 to 8.5 ppm .
There are three levels of security. 1. A user can view the default display and diagnostic screens only. 2. A user has access to the calibration and hold menus only. 3. A user has access to all menus. Emerson.com/Rosemount...
Reference Manual Display and operation 00809-0100-3414 May 2019 1. If a security code has been programmed, pressing MENU causes the security screen to appear. 2. Enter the three-digit security code. 3. If the entry is correct, the main Menu screen appears. The user has access to the sub-menus the code entitles him to.
You can configure the main display to meet your requirements. Procedure 1. Press MENU. The main Menu screen appears. 2. Move the cursor to Display and press ENTER. The screen shows the present configuration. There are four items: Main Format, Language, Warning, and Contrast. Emerson.com/Rosemount...
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Reference Manual Display and operation 00809-0100-3414 May 2019 3. To make a change, move the cursor to the desired line and press ENTER. A screen appears in which the present setting can be edited. 4. Press ENTER to store the setting. 5.
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Display and operation Reference Manual May 2019 00809-0100-3414 Emerson.com/Rosemount...
Reference Manual Programming the transmitter 00809-0100-3414 May 2019 Programming the transmitter Programming overview This section describes how to make the following program settings using the local keypad. 1. Configure and assign values to the analog current outputs. 2. Configure and assign values to the alarm relays. 3.
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2. Temperature compensation Automatic or manual Automatic Security code 1. Calibrate/Hold 000 to 999 2. Program/Display 000 to 999 Calibration - analog outputs 1. 4 mA 0.000 to 22.000 mA 4.000 mA 2. 20 mA 0.000 to 22.000 mA 20.000 mA Emerson.com/Rosemount...
Reference Manual Programming the transmitter 00809-0100-3414 May 2019 Configuring, ranging, and simulating outputs 6.3.1 Purpose of configuration This section describes how to configure, range, and simulate the two analog current outputs. Important Configure the outputs first. 1. Configuring an output means a.
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Complete the following steps to configure the analog current outputs. Procedure 1. Press MENU. The main Menu screen appears. 2. Move the cursor to Program and press ENTER. The cursor is on Outputs. 3. Press ENTER. 4. Choose Configure. 5. Choose Output 1 or Output 2. Emerson.com/Rosemount...
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Reference Manual Programming the transmitter 00809-0100-3414 May 2019 The screen shows the present configuration. There are six items: Assign (S1 is sensor 1), Range, Scale, Dampening, Fault Mode, and Fault Value. To display the fifth and sixth items, scroll to the bottom of the screen and continue scrolling. 6.
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Complete the following steps to simulate an output by making the transmitter generate an output current equal to the value you enter. Procedure 1. Press MENU. The main Menu screen appears. 2. Move the cursor to Program and press ENTER. The cursor is on Outputs. 3. Press ENTER. Emerson.com/Rosemount...
Reference Manual Programming the transmitter 00809-0100-3414 May 2019 4. Choose Simulate. 5. Choose Output 1 or Output 2. 6. Enter the desired simulated output current. 7. To end the simulated current, press MENU or EXIT. Configuring alarms and assigning setpoints 6.4.1 Purpose This section describes how to configure and assign setpoints to the alarm relays, simulate...
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C. Deadband = 0.3 ppm D. Alarm deactivates E. Time F. High alarm setpoint The alarm activates when the chlorine concentration exceeds the high setpoint. The alarm remains activated until the reading drops below the value determined by the deadband. Emerson.com/Rosemount...
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Reference Manual Programming the transmitter 00809-0100-3414 May 2019 Figure 6-2: Low Alarm Logic A. Chlorine, ppm B. Alarm deactivates C. Deadband = 0.3 ppm D. Time E. Alarm activates F. Low alarm setpoint The alarm activates when the chlorine concentration drops below the low setpoint.
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Assigning a sensor and measurement to an alarm. An alarm relay can also be used as a timer. b. Selecting high or low logic. c. Choosing the deadband. d. Setting the interval timer parameters. 2. Simulating an alarm means making the transmitter energize or de-energize an alarm relay. Procedure 1. Press MENU. Emerson.com/Rosemount...
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Reference Manual Programming the transmitter 00809-0100-3414 May 2019 The main Menu screen appears. 2. Move the cursor to Program and press ENTER. 3. Choose Alarms. 4. Choose Configure/Setpoint. 5. Choose Alarm 1, Alarm 2, Alarm 3, or Alarm 4. The screens summarizes the present configuration and setpoints. There are eight items: •...
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Simulate alarms Complete the following steps to make the transmitter energize or de-energize an alarm relay. Procedure 1. Press MENU. The main Menu screen appears. 2. Move the cursor to Program and press ENTER. 3. Choose Alarms. 4. Choose Simulate. Emerson.com/Rosemount...
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Reference Manual Programming the transmitter 00809-0100-3414 May 2019 5. Choose Alarm 1, Alarm 2, Alarm 3, or Alarm 4. 6. Choose Don't simulate, De-energize, or Energize. 7. Press MENU or EXIT to end simulation. 6.4.5 Synchronize timers Synch Timers is available only if two or more alarm relays have been configured as interval timers.
If the chlorine concentration is less than 1.00 ppm (mg/L), the display resolution can be set to 0.XX or 0.XXX . 6.5.3 Configure measurement Complete the following steps to configure the transmitter to measure monochloramine. Procedure 1. Press MENU. The main Menu screen appears. Emerson.com/Rosemount...
Reference Manual Programming the transmitter 00809-0100-3414 May 2019 2. Move the cursor to Program and press ENTER. 3. Choose Measurement. The screen summarizes the present configuration for sensor 1 (monochloramine). There are four items: Measure, Units, Filter, and Resolution. 4. To make a change, move the cursor to the desired line and press ENTER. A screen appears in which the present setting can be edited.
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The screen summarizes the present sensor configuration. There are between two and three items. Units and S1 Temp Comp always appear. If you selected manual temperature compensation, the manual temperature value entered for the sensor (S1 Manual) also appears. Emerson.com/Rosemount...
Reference Manual Programming the transmitter 00809-0100-3414 May 2019 4. To make a change, move the cursor to the desired line and press ENTER. A screen appears in which the present setting can be edited. 5. To store a setting, press ENTER. For an explanation of terms, see Purpose and Definitions.
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A screen appears in which the present setting can be edited. 5. Press ENTER to store a change. The security code takes effect two minutes after pressing ENTER. 6. To return to the main display, press MENU and then EXIT. Emerson.com/Rosemount...
Reference Manual Programming the transmitter 00809-0100-3414 May 2019 Resetting the transmitter 6.8.1 Purpose This section describes how to clear user-entered values and restore default settings. There are three resets: 1. Resetting to factory default clears ALL user-entered settings, including sensor and analog output calibration, and returns ALL settings and calibration values to the factory defaults.
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Programming the transmitter Reference Manual May 2019 00809-0100-3414 5. To return to the main display, press MENU and then EXIT. Emerson.com/Rosemount...
Reference Manual Calibrate 00809-0100-3414 May 2019 Calibrate Introduction The Calibrate menu allows you to do the following: 1. Calibrate the temperature sensing element in the monochloramine sensor. 2. Calibrate the monochloramine sensor. 3. Calibrate the analog outputs. Calibrating temperature 7.2.1 Purpose The monochloramine sensor is a membrane-covered amperometric sensor.
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The time constant for the sensor is about five minutes, so it may take as long as thirty minutes for equilibration. 3. Press MENU. The main Menu screen appears. The cursor is on Calibrate. 4. Press ENTER. 5. Choose the sensor you wish to calibrate. Sensor 1 is the monochloramine sensor. 6. Choose Temperature. Emerson.com/Rosemount...
Reference Manual Calibrate 00809-0100-3414 May 2019 7. Change the display to match the temperature read from the calibrated thermometer. Press ENTER. If the present temperature is more than 5 °C different from the value entered, an error message appears. 8. To force the transmitter to accept the calibration, choose Yes. To repeat the calibration, choose No.
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(occasionally as long as overnight) to reach a minimum zero current. Important Do not start the zero routine until the sensor has been in the zero solution for at least two hours. 4. Press MENU. The main Menu screen appears. The cursor is on Calibrate. 5. Press ENTER. Emerson.com/Rosemount...
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Reference Manual Calibrate 00809-0100-3414 May 2019 6. Choose the sensor you wish to calibrate. 7. Choose Monochloramine. 8. Choose Zero Cal. The transmitter automatically starts the zero calibration. If the zero calibration was successful, the following screen appears. If the zero current is moderately larger than expected, an error message appears. Rosemount MCL...
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2. Adjust the monochloramine concentration until it is near the upper end of the operating range. Wait until the transmitter reading is stable before starting calibration. 3. Press MENU. The main Menu screen appears. The cursor is on Calibrate. 4. Press ENTER. 5. Select Sensor 1. Emerson.com/Rosemount...
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Reference Manual Calibrate 00809-0100-3414 May 2019 6. Select Monochloramine. 7. Select In Process Cal. 8. Follow the screen prompts. Once the reading is stable, press ENTER. Take the sample and press ENTER. At this point, the transmitter stores the present sensor current and temperature and uses those values in calibration.
7.4.1 Trimming analog outputs Although Emerson calibrates the analog outputs at the factory, you can trim them in the field to match the reading from a standard milliameter. You can trim both the low (0 or 4 mA) and high (20 mA) outputs 7.4.2...
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Reference Manual Calibrate 00809-0100-3414 May 2019 6. Change the value in the display to match the reading from the milliameter. If the calibration was successful, the screen below appears. If the user entered value is more than ±1 mA different from the nominal value, a possible error screen appears.
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Calibrate Reference Manual May 2019 00809-0100-3414 Emerson.com/Rosemount...
Reference Manual Maintenance 00809-0100-3414 May 2019 Maintenance Replace sensor circuit board ™ The transmitter used with the Rosemount MCL requires little maintenance. Clean the transmitter case and front panel by wiping with a clean soft cloth dampened with water only. Do not use solvents, like alcohol, that might cause a buildup of static charge.
8.2.3 Replacing the electrolyte solution and membrane WARNING HARMFUL SUBSTANCE Fill solution may cause irritation. May be harmful if swallowed. Read and follow manual. Procedure 1. Unscrew the membrane retainer. 2. Remove the membrane assembly and O-ring. Figure 8-1. Emerson.com/Rosemount...
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Reference Manual Maintenance 00809-0100-3414 May 2019 Figure 8-1: Monochloramine Sensor Parts A. Membrane retainer B. Membrane assembly C. O-ring D. Cathode E. Electrolyte fill plug (wrap with pipe tape) F. Pressure equalizing port G. Information label 3. Hold the sensor over a container with the cathode pointing down. 4.
Use a pipe cleaner or small bottlebrush to remove more adherent deposits. 2. To prevent leaks, apply a thin layer of silicone grease (or equivalent) to the two O- rings as the base of the overflow chamber and to the O-ring sealing the central overflow tube to the base. Emerson.com/Rosemount...
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Reference Manual Maintenance 00809-0100-3414 May 2019 8.3.3 Other maintenance Table 8-2 Figure 8-2 show the replacement parts for the flow controller assembly used in the Rosemount MCL. Table 8-2: Replacement Parts for Constant Head Flow Controller Assembly (Model MCL) Location in Description Figure 8-2 24039-00...
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Maintenance Reference Manual May 2019 00809-0100-3414 Emerson.com/Rosemount...
Reference Manual Troubleshoot 00809-0100-3414 May 2019 Troubleshoot Overview When the transmitter identifies a problem, the word warning or fault appears intermittently in the lower line of the main display. When the fault or warning message appears, press DIAG for more information. Use the diagnostic feature.
Sensor Board Unknown, Sensor Board with main board. HW (Hardware) or SW (Software) Mismatch, or Sensor Board Not Communicating Sensor CPU Error Sensor board software is corrupted. Sensor CPU Error Sensor RTD Open Temperature measuring circuit is Sensor RTD Open open. Emerson.com/Rosemount...
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Reference Manual Troubleshoot 00809-0100-3414 May 2019 Fault message Explanation Section S1 Not Detected No sensor board is connected to Sensor 1 Not Detected sensor 1 terminal. Sensor Factory Data Sensor board factory eeprom data is Sensor Factory Data, Sensor Board corrupted.
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RTD Open Procedure 1. Confirm that the sensor RTD wires are properly connected. 2. Confirm that the Variopol connector is properly seated. 3. Disconnect the sensor from the cable and use an ohmmeter to check the resistance across the RTD. Emerson.com/Rosemount...
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Reference Manual Troubleshoot 00809-0100-3414 May 2019 4. If the resistance is okay, connect the Variopol cable to the sensor and disconnect the three RTD wires at the transmitter. Measure the resistance across the red and white RTD leads. Figure 9-3. If the resistance is very high, the problem is with the VP cable, and it must be replaced.
3. Recalibrate the sensor. If necessary, clean or replace the membrane and check the fill solution. 4. Replace the sensor. 9.4.3 Sensor RTD Sense Open The transmitter measures temperature using a three-wire resistance temperature device (RTD). See Figure 9-3. The transmitter uses the in and return leads to measure the Emerson.com/Rosemount...
Reference Manual Troubleshoot 00809-0100-3414 May 2019 resistance of the RTD. The third lead, called the snese line, is connected to the return lead at the sensor. The sense line allows the transmitter to correct for the resistance of the in and return leads and to compensate for changes in wire resistance caused by changes in ambient temperature.
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5. When was the sensor fill solution last replaced? The monochloramine sensor loses sensitivity, that is, it generates less current per ppm of monochloramine, as it operates. Gradual loss of sensitivity can usually be compensated for by calibrating the sensor weekly. After about two or three months of operation, the sensitivity Emerson.com/Rosemount...
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Reference Manual Troubleshoot 00809-0100-3414 May 2019 may start to drop rapidly. At this point, the electrolyte solution and membrane should be replaced. Refer to Monochloramine sensor. 6. Is the membrane fouled or coated? A dirty membrane inhibits diffusion of monochloramine through the membrane, reducing the sensor current and increasing the response time.
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If the fill solution is extremely old, the sensor may be completely non- responsive to monochloramine. Replace the fill solution and membrane. See the sensor instruction manual for details. 3. Is the membrane clean? Clean the membrane with a stream of water and replace it if necessary. 4. Replace the sensor. Emerson.com/Rosemount...
Reference Manual Troubleshoot 00809-0100-3414 May 2019 9.5.7 Readings are too low. 1. Was the sample tested as soon as it was taken? Monochloramine solutions are moderately unstable. Test the sample immediately after collecting it. Avoid exposing the sample to sunlight. 2.
Procedure 1. Disconnect the anode and cathode leads from terminals 8 and 10 on TB1 and connect a decade box and 1.5 V battery as shown in Figure 9-1. Emerson.com/Rosemount...
Reference Manual Troubleshoot 00809-0100-3414 May 2019 Figure 9-1: Simulating Chlorine A. Anode shield B. Anode C. Cathode shield D. Cathode It is not necessary to disconnect the RTD leads. 2. Set the decade box to 2.4 MΩ. 3. Note the sensor current. It should be about 500 nA.
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To simulate the temperature input, wire a decade box to the transmitter or junction box as shown in Figure 9-3. Figure 9-3: Simulating Resistance Temperature Device Inputs A. Resistance temperature device return B. Resistance temperature device sense C. Resistance temperature device in D. Resistance temperature device shield Emerson.com/Rosemount...
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Reference Manual Troubleshoot 00809-0100-3414 May 2019 To check the accuracy of the temperature measurement, set the resistor simulating the resistance temperature device to the values indicated in the table and note the temperature readings. The measured temperature might not agree with the value in the table.
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Troubleshoot Reference Manual May 2019 00809-0100-3414 Emerson.com/Rosemount...
Reference Manual China RoHS Table 00809-0100-3414 May 2019 China RoHS Table Rosemount MCL...
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2019 Emerson. All rights reserved. twitter.com/rosemount_news The Emerson logo is a trademark and service mark of Emerson Electric Co. Rosemount is a Facebook.com/Rosemount mark of one of the Emerson family of companies. All other marks are the property of their youtube.com/RosemountMeasurement respective owners.