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Summary of Contents for Metal Samples MS2701E
- 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 2: Table Of Contents
.............. 10 i. Baud Rate and Default Communication Parameters ...... 11 ii. Device Address .................. 11 iii. Communication Protocols .............. 11 iv. Termination Resistor ................ 11 v. Data Registers .................. 11 c. Calibration and Testing ................. 12 i. Calibration .................... 12 ii. Testing output zero and span .............. 12 iii. Testing the MS2701E transmitter with the Meter Prover ....... 12 d. Interpreting Data ................... 13 i. Metal Loss .................... 13 ii. Calculating Corrosion Rate ............... 14 e. Commissioning .................... 15 C. Maintenance .......................... 15 D. Troubleshooting ........................ 16 III. Service and Warranty Information ....................... 17 A. Warranty ........................... 17 B. Obtaining Service and Returning the Instrument for Repair ............ 17 ... -
Page 3: Introduction
I. Introduction A. General Description The model MS2701E transmitter is a 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 MS2701E 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 MS2701E transmitter offers user‐selectable RTU or ASCII communication protocols making it highly versatile. The MS2701E 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 MS2701E 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 MS2701E transmitter is available as direct‐mount 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 MS2701E 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 MS2701E 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 MS2701E transmitter is designed to work with any standard ER probe, but it is recommended that ... - Page 4 This allows the unit to detect much smaller amounts of metal loss, thus responding faster to corrosion events and upsets. At 16‐bit resolution the MS2701E transmitter can measure metal loss amounts as small as 0.0015% of the probe life. Metal loss readings taken by the MS2701E 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 16‐bit digital value between 0 and 65535, where: 0 = 0 mils (0% Metal Loss) ...
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Page 5: Technical Specifications
C. Technical Specifications Model MS2701E High Resolution ER RS-485 Modbus Transmitter Physical Data Instrument Weight: 3.70 lb. (1.68 Kg) 4.82”W Total Weight w/ Accessories: 5.76 lb. (2.61 Kg) (12.24cm) Instrument Dimensions: 8.0"H x 4.82"W x 3.45”D 8.0”H (20.32cm H x 12.24cm W x 8.76”D) (20.32cm) -
Page 6: Installation And Operation
II. Installation and Operation A. Receiving the MS2701E Transmitter Check the MS2701E Transmitter for any shipping damage when it is first received. When the unit is unpacked, verify that the following items are included: Transmitter Meter Prover User’s Manual Probe Cable (for remote‐mount only) Mounting Hardware (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 MS2701E transmitter involves the following steps: 1. Physical Mounting 2. Electrical Connection 3. Setup and Programming ... -
Page 7: Remote Mounting
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 Tighten Insert Coupling Nut Connector 3 1 2 Figure 2. Direct Mount Installation b. Remote Mounting When it is not practical to direct‐probe mount the MS2701E 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 probe extension cable. ... -
Page 8: Power And Data Connections
2. Power and Data Connections a. Making Connections The RS‐485 field wiring enters the transmitter through the 1/2" female NPT conduit port shown in Figure 4 below. When used in a hazardous area, the conduit or cable connections must be made in such CAUTION: a way that all hazardous area requirements are met. Cable Glands and blanking plugs must be certified for protection types ‘d’,’tb’ and it should be rated for IP66. Probe Connector Stem or Probe Cable 1/2” FNPT Conduit Port for Field Wiring Entry Figure 4. RS‐485 Connector Electrical connections are made to the main PCB via the terminal blocks J2 and J9 as shown in Figure 6. NOTE: Do not connect cable shielding to the Transmitter. The shield must remain floating at the Transmitter. The RS‐485 protocol allows up to 32 transmitters to be daisy‐chained which simplifies installation and reduces costs. Figure 5 shows an example of a typical arrangement. Full wiring details are shown on pages 21 and 22. Be sure to observe the appropriate gas group rating listed on page 3 for stand‐alone or CAUTION: multi‐drop operation. Figure 5. Typical daisy‐chain arrangement, where ‘n’ is the number of the last transmitter. 6 ... -
Page 9: Grounding
The maximum permissible length of the field wiring between the MS2701E 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 MS2701E 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 MS2701E 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. 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 MS2701E transmitter must be installed in full compliance with the control drawing located on page 20 and all of the local area requirements. ... - Page 10 1. Probe dielectric rating < 500V r.m.s. Do not exceed. 2. Do not install the probe (exposed portion of the sensing elements) in the explosion dust atmosphere (Group III). 3. Networked (“daisy‐chained”) arrangement not for use in Group IIC/IIIC environment. 4. Up to 32 transmitters are allowed in the daisy‐chain arrangement. 5. Only Certified cable glands and blanking plugs of protection types ‘d’ and ‘tb’ should be used. Protection rating of IP66 should be maintained. 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 MS2701E transmitter when it is installed in a hazardous area. In the MS2701E 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 MS2701E 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 MS2701E transmitter depends on the specific classification of the hazardous environment in question. However, the entity parameters must match those of the MS2701E transmitter. ...
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Page 11: 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 6 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 (J1) 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 6. Connector and Switch Details Position Setting Wire Loop Off (↓) On (↑) On (↑) Off (↓) Operating Tube Loop/Flush On (↑) Off (↓) On (↑) -
Page 12: 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 6. 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 13: Baud Rate And Default Communication Parameters
The default communication parameters for the MS2701E 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 MS2701E 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. Be sure to observe the appropriate gas group rating listed on page 3 for stand‐alone or CAUTION: multi‐drop operation. iii. Communication Protocols The MS2701E transmitter offers user‐selectable RTU or ASCII communication protocols, giving the unit a broader range of compatibility. The communication protocol is set using Position 8 of Switch 2, as illustrated in Table 3. iv. Termination Resistor ... -
Page 14: Calibration And Testing
1) Zero Output – Forces a digital output of 0. 2) Maximum Output – Forces a digital output of 65535. 3) Full Scale Sweep – Causes the output to continually cycle from 0 up to 65535. These test modes can be useful when troubleshooting communication problems between the transmitter and the DCS/PLC system. iii. Testing the MS2701E transmitter with the Meter Prover A Meter Prover is provided to allow routine checks of the MS2701E 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 MS2701E 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 MS2701E 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 MS2701E transmitter to the probe. If the ... -
Page 15: Interpreting Data
The MS2701E transmitter measures the Metal Loss of an ER probe and converts that value to a digital 16‐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 = 0 mils (0% Metal Loss) 65535 = Probe Life in mils (100% Metal Loss) The Probe Life can be found in Table 1 and is also listed on the Metal Samples probe tag (as the “Multiplier”.) Figure 7. Metal Samples Probe Tag Figure 8 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. 65535 49151 32768 16384 10.0 Probe Metal Loss (mils) Probe Consumed Figure 8. 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 65535 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. 13 ... -
Page 16: Calculating Corrosion Rate
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, 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 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 9. 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 ... -
Page 17: Commissioning
Once the MS2701E 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 10. Enclosure Lock Screw The Lock Screw on the instrument base must be tightened securely to prevent unauthorized CAUTION: personnel from opening the MS2701E transmitter, and ensure that the intrinsic safety is not violated. Only qualified personnel should be allowed to install, operate, and maintenance the MS2701E transmitter. C. Maintenance Once installed, the MS2701E transmitter requires little maintenance. However, it is important to verify the following items periodically to ensure continued safe operation. Before performing any tests or maintenance on the MS2701E transmitter, ensure that all CAUTION: hazardous area requirements are met. Inspection Item Frequency Inspect the enclosure o‐ring for any signs of damage. Replace as necessary. Annually Inspect the probe connector o‐ring for any signs of damage. Replace as necessary. Annually Inspect all electrical connections for signs of corrosion, mechanical damage, or foreign Annually ... -
Page 18: Troubleshooting
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. Verify that the supply voltage polarity is correct. 8. If there is insufficient supply voltage on the power connector, check the safety barrier (if applicable) for a blown fuse or any other failure. 9. Test the MS2701E 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 it is determined that the MS2701E transmitter is malfunctioning, or if you need further assistance in troubleshooting, contact Metal Samples Technical Support. If the MS2701E transmitter shows any signs of damage, remove it from service immediately and CAUTION: consult the factory. ... -
Page 19: Service And Warranty Information
III. Service and Warranty Information A. Warranty Metal Samples warrants that any part of the model MS2701E 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 20: 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 21: Appendix A: Drawings
Appendix A: Drawings A. Wiring Diagrams Control Drawing (Hazardous Area Wiring Diagram) Safe Area Wiring Diagram ... - Page 23 S2/10 5 4 3 2 1 07/30/15 ENTITY PARAMETERS CHANGED 03/25/15 POWER SUPPLY CONNECTIONS AND ENTITY PARAMETERS CHANGED...
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Page 25: Appendix A - Revision History
Appendix B: Revision History Revision Date Changes 0 10/6/2014 Initial Release Separate gas group rating listed for Stand‐Alone and Multi‐Drop A 1/15/15 operation. Revised hazardous area installation (control) drawing and safe area installation drawing. B 2/4/15 Revised entity parameters and hazardous area installation (control) drawings. C 3/2/15 Revised Special Conditions. D 3/25/15 Revised Entity Parameters. E 8/14/15 Revised Entity Parameters. F 2/6/17 Revisions to Technical Specifications page ...
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