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Related Manuals for Metal Samples CORR Velox MS2800E
Summary of Contents for Metal Samples CORR Velox MS2800E
- Page 1 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...
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Page 3: Table Of Contents
Table of Contents I. Introduction .............................. 1 A. General Description ........................ 1 B. Principles of Operation ...................... 1 C. Technical Specifications ...................... 3 II. Installation and Operation ........................ 4 A. Receiving the Corr Velox transmitter .................. 4 B. Installation .......................... 4 1. Physical Mounting and Probe Connection .............. 4 a. Direct‐Probe Mounting .................. 4 b. Remote Mounting .................... 5 2. Power and Data Connections .................. 5 a. Making Connections .................. 5 b. Grounding ...................... 6 c. Safe Area Installation .................. 7 d. Hazardous Area Installation ................ 7 3. Setup and Operation ....................... 9 a. Probe Settings .................... 9 b. RS‐485 Communication Settings .............. 10 i. Baud Rate and Default Communication Parameters ...... 11 ... -
Page 5: Introduction
I. Introduction A. General Description The model MS2800E Corr Velox 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 Corr Velox 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 Velox transmitter offers user‐selectable RTU or ASCII communication protocols making it highly versatile. The Corr Velox 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 Corr Velox 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 Corr Velox 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 Velox 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 Corr Velox 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 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 Corr Velox 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 ... - Page 6 Probe Life Element Type Compatibility Thickness (Span) 4 2 Tubular Loop Compatible 8 4 40 10 Wire Loop Compatible 80 20 2 Flush (Small) Compatible 4 10 5 Cylindrical Preferred 10 25 2.5 5 Flush (Large) Preferred 10 20 Table 1. Standard ER Probe Elements The Corr Velox 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 Velox transmitter can measure metal ...
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Page 7: Technical Specifications
C. Technical Specifications Model MS2800E Corr Velox Ultra‐High Resolution ER RS‐485 Modbus Transmitter Physical Data Instrument W eight: 3.70 lb. (1.68 Kg) Total Weight w/ Accessories: 5.76 lb. (2.61 Kg) Instrument D imensions: 6.0"H x 4.0"Dia 6.0”H (15.25cm) (15.25cm H x 10.16cm Dia) 4.0” Dia (10.16cm) Operating T emperature: ‐4° to 158°F (‐20° to 70°C) Storage T emperature: ‐40° to 176°F (‐40° to 80°C) Environmental Rating: IP66 Figure 1. Overall Dimensions Enclosure Material: 316 Stainless Steel Mounting S pecifications: Direct probe mount (standard) May be pole mounted using optional hardware (Up to a 2.5” (6.35cm) Dia. pole) Performance Data Measurement T ype: ER measurement using any standard ER probe type ... -
Page 8: Installation And Operation
II. Installation and Operation A. Receiving the MS2800E Corr Velox Transmitter Check the Corr Velox Transmitter for any shipping damage when it is first received. When the unit is unpacked, verify that the following items are included: Transmitter Wiring Harness Meter Prover User’s Manual Probe Cable (optional, for remote‐mount only) 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 Using this product in any way other than that specified within this manual may impair the CAUTION: intrinsic safety protection. Installation of the Corr Velox transmitter involves the following steps: 1. Physical Mounting 2. Electrical Connection 3. -
Page 9: Remote Mounting
To mount the Corr Velox 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 Insert Connector Tighten Coupling Nut 1 Figure 2. Direct Mount Installation b. Remote Mounting When it is not practical to direct‐probe mount the Corr Velox transmitter, the unit can be remote mounted instead. In this case the 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. 5 ... -
Page 10: Grounding
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. Wiring Harness Junction Box (Not Included) Figure 4. Corr Velox 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 Velox transmitter and the control system is determined by the control system supply voltage, the electrical resistance of the cable and the load 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 Corr Velox 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. 6 ... -
Page 11: Safe Area Installation
c. Safe Area Installation The Corr Velox 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 22. When used in non‐hazardous areas, equipment must be supplied with a pre‐approved power CAUTION: 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 This section provides general guidelines for hazardous area wiring. However, regardless of CAUTION: anything stated here, the Corr Velox transmitter must be installed in full compliance with the control drawing located on page 21 and all of the local area requirements. Input supply terminal (Stand-Alone) Connector CN1 pins A & B (J2 on PCB): Input supply terminal, RS-485 terminal Ui = 23 Vdc and connector CN2 (combined) - Page 12 When used in Hazardous areas, equipment must be supplied with a pre‐approved power CAUTION: 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 < 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. 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 Velox transmitter when it is installed in a hazardous area. In the Corr Velox 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 Velox 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 Velox transmitter depends on the specific classification of the hazardous environment in question. However, the entity parameters must match those of the Corr Velox transmitter. ...
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Page 13: Setup And Operation
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 Switch 2 ‐ RS‐485 Selection Switch Configuration Switches (See Table 2 below) (See Table 3 below) Power Connector (J2) Data Connector (J9) Figure 5. Connector and Switch Details Position Setting Wire Loop Off (↓) On (↑) On (↑) Off (↓) -
Page 14: Rs-485 Communication Settings
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 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 Device Address 3 4 5 6 7 1 Off (↓) Off (↓) Off (↓) Off (↓) Off (↓) 2 On (↑) Off (↓) Off (↓) Off (↓) Off (↓) ... -
Page 15: Baud Rate And Default Communication Parameters
i. Baud Rate and Default Communication Parameters The default communication parameters for the Corr Velox 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. Modbus Modbus Serial RTU ASCII ASCII Parameter Value Value Value Baud Rate 19200 19200 2400 Data Bits 8 7 8 Parity Even Even Even Stop Bits 1 1 1 Response Time Out 3000 mS 3000 mS 3000 mS Polling Interval 1 min 1 min ... -
Page 16: Data Registers
v. Data Registers Table 5 lists the data registers of the Corr Velox transmitter. Data Register 40024 and 40025 transmitted from the transmitter is the direct probe reading value. No Register Address Description 4 40024 DAC Value (Low) 5 40025 DAC Value (Hi) To access all other registers for maintenance purpose, the Switch 1, Position # 4 (Maintenance) should be turned on. No Register Address Description 1 40001 Device Status 2 40002 Device Address 3 40003 Baud Rate 4 40024 DAC Value (Low) 5 40025 DAC Value (Hi) 6 40026 Probe Switch Setting Table 5. Modbus Data Registers ... -
Page 17: Testing The Corr Velox Transmitter With The Meter Prover
iii. Testing the Corr Velox transmitter with the Meter Prover A Meter Prover is provided to allow routine checks of the Corr Velox 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 Velox 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 Corr Velox 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 Velox transmitter to the probe. If the transmitter output shows a significant difference compared to the Meter Prover value, further troubleshooting may be required. Refer to page 17 for troubleshooting or contact the factory for further assistance. Be sure to reinstall the enclosure cover and tighten the Lock Screw when putting the Corr Velox transmitter back into service. d. Interpreting Data i. Metal Loss ... -
Page 18: Metal Loss
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 10.0 Probe Metal Loss (mils) Consumed Probe Figure 7. Output Relationship As seen here, the transmitter output begins at 0 for a new probe (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.) At this time the probe has reached its end‐of‐life and must be replaced. 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: ∆MetalLoss mils Corrosion Rate mpy ∆Time days where: ∆MetalLoss(mils) is the difference between two Metal Loss readings Time(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, ... - Page 19 In some cases it may be necessary to review the raw Metal Loss data and manually apply the Corrosion 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. 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. 15 ...
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Page 20: Commissioning
e. Commissioning Once the Corr Velox 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 The Lock Screw on the instrument base must be tightened securely to prevent unauthorized CAUTION: Velox Corr personnel from opening the transmitter and ensure that the intrinsic safety is not violated. Velox Corr Only qualified personnel should be allowed to install, operate, and maintenance the transmitter. C. Maintenance Once installed, the Corr Velox transmitter requires little maintenance. However, it is important to verify the following items periodically to ensure continued safe operation. Velox Corr Before performing any tests or maintenance on the transmitter, ensure that all CAUTION: hazardous area requirements are met. ... -
Page 21: Troubleshooting
D. Troubleshooting If the Corr Velox transmitter does not seem to perform as expected, check the following items: Velox Corr Before performing any tests or maintenance on the transmitter, ensure that all CAUTION: 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. Test the probe with a portable ER meter if available. b. Test the probe with a portable resistance or continuity meter as follows: i. Connect one 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. 2. 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. 3. Perform a visual inspection of the circuit boards to look for any signs of mechanical or electrical damage. 4. Ensure that all electrical cables and wiring are in good condition. 5. Ensure that all electrical contacts are secure and free of corrosion. 6. Ensure that there is adequate supply voltage at the power connector. 7. -
Page 22: Service And Warranty Information
III. Service and Warranty Information A. Warranty Metal Samples warrants that any part of the model MS2800E Corr Velox 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 EVENT 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 return shipping details for the repair. ... -
Page 23: Instrument Repair Form
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 ... -
Page 24: Appendix A: Drawings
Appendix A: Drawings A. Wiring Diagrams Control Drawing (Hazardous Area Wiring Diagram) – Stand Alone Control Drawing (Hazardous Area Wiring Diagram) – Multi Drop Safe Area Wiring Diagram ... - Page 26 S2/10 5 4 3 2 1 05/19/15 MODIFIED ENTITY PARAMETERS 03/20/15 POWER SUPPLY CONNECTIONS & ENTITY PARAMETERS MODIFIED.
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Page 28: Appendix B: Revision History
Appendix B: Revision History Revision Date Changes 0 8/15/2014 Initial Release Revised entity parameters, hazardous area installation (control) A 9/17/14 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. G 3/7/17 Revised switch settings. H 4/19/17 Revised switch settings. I 10/10/18 Revised entity parameters. ...
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