Air Monitor MASS-tron II/CEM Installation, Operation And Maintenance Manual

Microprocessor based mass flow "smart" transmitter
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Installation, Operation,
and Maintenance Manual
MASS-tron II/CEM
Microprocessor Based
Mass Flow "Smart" Transmitter
Versions 5.3X
Installation, Operation & Maintenance
Air Monitor Corporation provides complete
technical support between the hours of
7 a.m. and 5 p.m. PST, M-F
Contact our Service Department
Toll Free: 1-800-AIRFLOW
or fax us at 1-707-526-2825
MASS-tron II/CEM
Air Monitor Corporation
- IO&M Manual
116-004-94.P65 (8-31-10)

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Summary of Contents for Air Monitor MASS-tron II/CEM

  • Page 1 MASS-tron II/CEM Microprocessor Based Mass Flow "Smart" Transmitter Versions 5.3X Installation, Operation & Maintenance Air Monitor Corporation provides complete technical support between the hours of 7 a.m. and 5 p.m. PST, M-F Contact our Service Department Toll Free: 1-800-AIRFLOW or fax us at 1-707-526-2825...
  • Page 3: Table Of Contents

    TABLE OF CONTENTS MASS-tron II/CEM TABLE OF CONTENTS INSTRUMENT WARRANTY ........................i SECTION 1 – GENERAL INFORMATION DESCRIPTION ..........................1 THEORY OF OPERATION ......................1 SECTION 2 – PERFORMANCE SPECIFICATIONS TRANSMITTER ..........................2 INDICATION ............................. 2 INPUTS/OUTPUTS .......................... 2 POWER ............................2 SECTION 3 –...
  • Page 4 AUTO-span PRESSURE REFERENCE CALIBRATION ..............59 SECTION 7 – MAINTENANCE ....................... 60 SECTION 8 – TROUBLESHOOTING ....................61-62 SECTION 9 – PARTS LIST ........................63-64 SECTION 10 – CUSTOMER SERVICE ....................65 Air Monitor Corporation MASS-tron II/CEM - IO&M Manual 116-004-94.P65 (8-31-10)
  • Page 5: Instrument Warranty

    This document contains confidential technical data, including trade secrets and proprietary information which are the sole property of Air Monitor Corporation. The use of said data is solely limited to use as specified herein. Any other use is strictly prohibited without the prior written consent of Air Monitor Corporation.
  • Page 6: Section 1 - General Information

    1 – GENERAL INFORMATION 1.1 – DESCRIPTION The MASS-tron II/CEM is an ultra-low differential pressure "smart" massflow transmitter designed to convert the low magnitude pressure signals generated by airflow probes, plus process temperature and static pressure inputs into analog output signals of mass flow, temperature, pressure, and transmitter drift. Each MASS-tron II/CEM is equipped with numerous standard features: A multi-line LCD used during configuration/calibration and for display of process;...
  • Page 7: Section 2 - Performance Specifications

    MASS-tron II/CEM SECTION 2 – PERFORMANCE SPECIFICATIONS 2 – PERFORMANCE SPECIFICATIONS 2.1 – TRANSMITTER 2.3 – INPUTS/OUTPUTS Ranges. Natural Full Spans Analog Input. Analog input for temperature is available 0 to 25.00 IN w.c. and field configurable via jumper for 0-5VDC, 0-10VDC, or 0 to 0.50 IN w.c.
  • Page 8: Section 3 - Features

    3.2 – 40CFR75 COMPLIANT The MASS-tron II/CEM is designed to provide all functions and meet all data reporting requirements specified under 40CFR75: signals (4-20mADC standard; 0-5V or 0-10V optional) of mass flow and temperature; daily AUTO-cal reporting of transmitter zero and span drift;...
  • Page 9: Alarm

    3.9 – K-FACTOR The MASS-tron II/CEM is equipped with a K-Factor feature which allows for the introduction of a bias and/or gain factor into the transmitter's flow calculations. The K-Factor feature is intended to be used in two types of applications: 1.
  • Page 10: Section 4 - Installation

    SECTION 4 – INSTALLATION 4 – INSTALLATION All MASS-tron II/CEM systems are supplied to the customer either rack mount or mounted in an enclosure. Because each application is configured to specific customer requirements, previously submitted detail drawings should be consulted when performing Sections 4.3, 4.4, and 4.5.
  • Page 11: Process Connections

    – Low Port on MASS-tron II/CEM connects to Static Pressure from airflow measuring devices. Although any size of tube/pipe can be used, the response time of the MASS-tron II/CEM to process change may increase if there is a increase in tube/pipe size or an increase in tube/pipe length.
  • Page 12 If process being measured contains humidity or moisture, it is recommended a drip leg with drain on each tube/pipe be installed to preclude the migration of water into the MASS-tron II/CEM. See Figure 4.2. for typical drip leg installation. Figure 4.2 CAUTION Migration of water into the MASS-tron II/CEM will void warranty.
  • Page 13: Power/Signal Connections

    4.5 – POWER/SIGNAL CONNECTIONS All power and signal wiring is done at the terminal strip at the left side of the MASS-tron II/CEM. Figure 4.3 below represents the terminal strip and the connections for power input and the various inputs/outputs available (review Factory Set-Up Information Sheet for which inputs/outputs are included with your unit).
  • Page 14 AUTO-cal cycle. Input Power (Terminals 14, 15, and 16). Power required by MASS-tron II/CEM must be connected to Terminals 15 and 16. Earth ground should be connected to Terminal 14. When powering multiple units from one power source, polarity must be maintained.
  • Page 15 MASS-tron II/CEM SECTION 4 – INSTALLATION 4.5 – POWER/SIGNAL CONNECTIONS (con't) AUTO-cal in Progress (Terminals 24, 25, and 26). Acknowledgment contact for customer use. See Section 5.12 for contact logic. AUTO-purge "IN PROGRESS" (Terminals 29 and 30). Acknowledgment contact for customer use. Contacts close upon AUTO-purge cycle initiation, remain closed through the programmed Purge Duration.
  • Page 16: Input/Output Selection

    Inputs have a single jumper covering two pins, and outputs have two jumpers covering four pins. 4.7 – DISPLAY CONTRAST ADJUSTMENT To compensate for different ambient lighting conditions and viewing angles, the MASS-tron II/CEM display's contrast can be adjusted for optimum visibility.
  • Page 17: Section 5 - Operation

    MASS-tron II/CEM Factory Set-Up Information Sheet, included with the unit. Review this information and verify that the MASS-tron II/CEM setup is correct for your applications. If any problems or discrepancies are detected, contact Air Monitor's Customer Service Department at 1-800-AIRFLOW prior to proceeding.
  • Page 18 AUTO-cal cycle. See Section 5.12 for more specific details). During the AUTO-cal cycle, the MASS-tron II/CEM will first perform an AUTO-zero cycle which creates a zero differential pressure across the transducer. Any zero signal error is measured and stored.
  • Page 19: Configuration

    The customer can verify configuration and change certain parameters (within defined ranges) by entering the MASS- tron II/CEM's Configuration mode. This is accomplished using the four pushbuttons located on the MASS-tron II/CEM's top cover.
  • Page 20: Pushbutton Definition

    MASS-tron II/CEM SECTION 5 – OPERATION 5.5 – PUSHBUTTON DEFINITION In addition to Configuration programming, pushbuttons can be used for certain functions when in the Normal operation mode. The following list describes the pushbutton function when in the Normal operation mode and in the Operator Setup (programming).
  • Page 21: Configuration Programming

    MASS-tron II/CEM SECTION 5 – OPERATION 5.6 – CONFIGURATION PROGRAMMING With power ON and initialization complete (see Section 5.2), simultaneously press ESC and ENT, and display will indicate: OPERATOR SETUP Pressing ENT again will enter the user into the Main Menu of configuration programming. The display will indicate:...
  • Page 22 Alarm Configuration Turns alarm function ON or OFF. Allows selection of Setpoint, Deadband, and Alarm Delay. Controller Configuration Not installed with MASS-tron II/CEM. Special Function Configuration Not installed with MASS-tron II/CEM. K-Factor Configuration Turns K-Factor ON or OFF, and allows for the calculation or selection of gain and bias values.
  • Page 23 MASS-tron II/CEM SECTION 5 – OPERATION 5.6 – CONFIGURATION PROGRAMMING (con't) At any time while in the Main Menu, User can return to Normal operation mode by pressing ESC or scrolling to: EXIT and pressing ENT. Operator Setup Once the desired Selection is displayed, its sub-menu can be entered by pressing ENT.
  • Page 24: Operator Password Selection

    MASS-tron II/CEM SECTION 5 – OPERATION 5.7 – OPERATOR PASSWORD SELECTION User can select numeric password or bypass password requirement. Note: Units are sipped from the Factory with the password set to 1,111 and bypassed. Operator Password Selection Default selection shown.
  • Page 25: Transmitter Scaling & Configuration

    SECTION 5 – OPERATION 5.8 – TRANSMITTER SCALING & CONFIGURATION This Main Menu selection is where all application specific data is entered to configure the MASS-tron II/CEM for a unique application. Data is entered in sub-menu, Process Configuration, and as applicable, sub-menus, Temperature Configuration and Absolute Pressure Configuration.
  • Page 26 MASS-tron II/CEM SECTION 5 – OPERATION 5.8 – TRANSMITTER SCALING & CONFIGURATION (con't) Operator Setup Main Menu Trans. Scaling & Configuration - EXIT User Setup - Process Configuration Process Configuration  Trans. Scaling & Config. - Temperature Configuration - Absolute Pressure Configuration...
  • Page 27 MASS-tron II/CEM SECTION 5 – OPERATION 5.8 – TRANSMITTER SCALING & CONFIGURATION (con't) 1. While in Main Menu, use UP or DN to scroll to: Transmitter Scaling and Configuration 2. Press ENT to enter Transmitter Scaling & Configuration menu. Display will indicate:...
  • Page 28 MASS-tron II/CEM SECTION 5 – OPERATION 5.8 – TRANSMITTER SCALING & CONFIGURATION (con't) UNITS LIST For Process Type – Flow UNIT OF MEASUREMENT DISPLAY cubic feet per second cubic feet per minute cubic feet per hour liters per second liters per minute...
  • Page 29 MASS-tron II/CEM SECTION 5 – OPERATION 5.8 – TRANSMITTER SCALING & CONFIGURATION (con't) UNITS LIST for Process Type – Velocity UNIT OF MEASUREMENT DISPLAY feet per second feet per minute feet per hour meters per second meters per minute meters per hour...
  • Page 30 MASS-tron II/CEM SECTION 5 – OPERATION 5.8 – TRANSMITTER SCALING & CONFIGURATION (con't) UNITS LIST for Process Type – Differential Pressure UNIT OF MEASUREMENT DISPLAY inches of water column in.WC inches of mercury in.Hg pounds per square inch, gauge psig...
  • Page 31 MASS-tron II/CEM SECTION 5 – OPERATION 5.8 – TRANSMITTER SCALING & CONFIGURATION (con't) Temperature Configuration Default selection shown. Available selections: Temperature Temperature On/Off ON or OFF Off/On Selection Input Linearization Input Linearization ON or OFF Selection Thermocouple TypeE Thermocouple Type J...
  • Page 32 MASS-tron II/CEM SECTION 5 – OPERATION 5.8 – TRANSMITTER SCALING & CONFIGURATION (con't) 12. Use UP or DN to change setting. Once desired setting is displayed, press ENT, new setting will be stored in memory and display will return to the Temperature Configuration sub-menu as in Step 10.
  • Page 33 MASS-tron II/CEM SECTION 5 – OPERATION 5.8 – TRANSMITTER SCALING & CONFIGURATION (con't) 19. Use UP or DN to change setting. Once desired setting is displayed, press ENT, new setting will be stored in memory and display will return to the Absolute Pressure Configuration sub-menu as in Step 17.
  • Page 34 MASS-tron II/CEM SECTION 5 – OPERATION 5.8 – TRANSMITTER SCALING & CONFIGURATION (con't) User should not need to use the following Calculator unless: a. Process parameters have changed and new Differential Pressure or Flow values are needed. b. Mid-point operating Differential Pressure or Flow values are wanted.
  • Page 35 MASS-tron II/CEM SECTION 5 – OPERATION 5.8 – TRANSMITTER SCALING & CONFIGURATION (con't) Continued from next page Wet / Dry Flow Basis Wet / Dry Flow Basis DRY or WET Selection Percentage Water Percentage Water 0.00 to 50.00 % 0.00 % in 0.01 increments...
  • Page 36 MASS-tron II/CEM SECTION 5 – OPERATION 5.8 – TRANSMITTER SCALING & CONFIGURATION (con't) As an example of how to utilize the calculator, the following shows how to change the Operating Span if the process temperature is 150ºF. 23. While in Transmitter Scaling & Configuration menu, use UP or DN to scroll to: Calculator for Max Diff.
  • Page 37: Low Pass Filter Selection

    MASS-tron II/CEM SECTION 5 – OPERATION 5.9 – LOW PASS FILTER SELECTION User can select level of filtering applied to the transducer output*. Levels are 0 to 8, with 0 representing no filtering, 1 representing minimal filtering (0.5 sec time constant), and 8 representing maximum filtering (64 sec time constant).
  • Page 38: Auto-Zero Configuration

    MASS-tron II/CEM SECTION 5 – OPERATION 5.10 – AUTO-zero CONFIGURATION User can turn AUTO-zero function ON or OFF, and select activation interval. Operator Setup Main Menu Auto-Zero Configuration Default selection shown. Available selections: - Low Pass Filter Selection - Auto-Zero Off / On Selection Auto-Zero Off / On ...
  • Page 39: Auto-Purge Configuration

    MASS-tron II/CEM SECTION 5 – OPERATION 5.11 – AUTO-purge CONFIGURATION Refer to "smart" relay manual for configuration information. Operator Setup Main Menu - Auto-Zero Configuration Auto-Purge Configuration See I, O & M Manual - Auto-Cal Configuration Air Monitor Corporation MASS-tron II/CEM - IO&M Manual...
  • Page 40: Auto-Calibration Configuration

    MASS-tron II/CEM SECTION 5 – OPERATION 5.12 – AUTO-cal CONFIGURATION User can select method of AUTO-cal activation (Internal and External or External Only), and set the following values: Reference Value Selection. Allows for the selection of the AUTO-cal span report level in percent full scale (% FS).
  • Page 41 MASS-tron II/CEM SECTION 5 – OPERATION 5.12 – AUTO-cal CONFIGURATION (con't) Operator Setup Main Menu Auto-Cal Configuration Available selections: Default selection shown. - Auto-Cal Activation Selection - Auto-Purge Configuration Auto-Cal Activation INTERNAL&EXTERNAL Auto-Cal Configuration - Reference Value Selection or EXTERNAL ONLY INTERNAL&...
  • Page 42: Alarm Configuration

    MASS-tron II/CEM SECTION 5 – OPERATION 5.13 – ALARM CONFIGURATION User can turn Alarm function ON or OFF, and set the following values: Low Setpoint: Selected value of transmitter span, below which an alarm condition will exist. Value is selected in same units as transmitter format.
  • Page 43: Controller Configuration

    MASS-tron II/CEM SECTION 5 – OPERATION 5.13 – ALARM CONFIGURATION (con't) 1. While in Main Menu, use UP or DN to scroll to: Alarm Configuration 2. Press ENT to enter Alarm Configuration menu. Display will indicate: Alarm 1 Off/On Selection 3.
  • Page 44: K-Factor Configuration

    MASS-tron II/CEM SECTION 5 – OPERATION 5.16 – K-FACTOR CONFIGURATION Caution In the majority of applications, the use of a K-Factor is neither required nor desirable. Before using the K-Factor feature, contact the Service Department (see Section 10) to review the application and obtain assistance in determining the K-Factor gain and bias values.
  • Page 45 MASS-tron II/CEM SECTION 5 – OPERATION 5.16 – K-FACTOR CONFIGURATION (con't) 1. While in Main Menu, use UP or DN to scroll to: K-Factor Configuration 2. Press ENT to enter K-Factor Configuration menu. Display will indicate: K-Factor Off/On Selection 3. Press ENT and display will indicate current setting of K-Factor (OFF or ON).
  • Page 46: Enhanced Display Configuration

    MASS-tron II/CEM SECTION 5 – OPERATION 5.17 – ENHANCED DISPLAY CONFIGURATION User can select display parameter, for lines 2, 3, 4, and 5. Also, each line can have a level of filtering, 0 through 4 (4 is maximum) selected by User.
  • Page 47 MASS-tron II/CEM SECTION 5 – OPERATION 5.17 – ENHANCED DISPLAY CONFIGURATION (con't) 4. Press ENT, and display will indicate current setting of the filter [0 (None), 1 (Minimum), 2, 3, or 4 (Maximum)]. 5. Use UP or DN to change setting. Once desired setting is displayed, press ENT. New setting will be stored in memory and display will return to Enhanced Display Configuration menu as in Step 3.
  • Page 48 MASS-tron II/CEM SECTION 5 – OPERATION 5.17 – ENHANCED DISPLAY CONFIGURATION (con't) 17. Repeat Steps 8 through 16 for Line 3, 4, and 5. The only differences being the change of Line # in the display. 18. After Line 5 has been set, Step 16 will yield a display:...
  • Page 49 MASS-tron II/CEM SECTION 5 – OPERATION 5.17 – ENHANCED DISPLAY CONFIGURATION (con't) PARAMETER LIST for Lines 2, 3, 4, and 5 DISPLAY IN PARAMETER "NORMAL" MODE NONE DIFF. PRESSURE D. PRESS TRANSMITTER VELO VELO. TEMPERATURE TEMP. ABSOLUTE PRESSURE ABS PR...
  • Page 50: Analog Output Configuration

    MASS-tron II/CEM SECTION 5 – OPERATION 5.18 – ANALOG OUTPUT CONFIGURATION User can select which process variable Analog Output 4 represents. Process variables available for output are: – Transmitter Differential Pressure – Transmitter Differential Pressure and AUTO-cal Report – Transmitter Flow –...
  • Page 51: Transducer Span Selection

    MASS-tron II/CEM SECTION 5 – OPERATION 5.19 – TRANSDUCER SPAN SELECTION Displays the transducer's natural span and operating span. The natural span represents the maximum process pres- sure that the transducer can accept. The displayed natural span is for user/technician reference only and should not be changed unless a new transducer of different natural span has been installed.
  • Page 52: Transmitter Input Calibration

    MASS-tron II/CEM SECTION 5 – OPERATION 5.20 – TRANSMITTER INPUT CALIBRATION See Section 6.3 – Calibration for details on Transmitter Input Calibration. Operator Setup Main Menu Transmitter Input Calib. - Transducer Zero - Transducer Span - Transducer Span Selection - Abs. Pressure Zero ...
  • Page 53: Transducer Characterization Selection

    MASS-tron II/CEM SECTION 5 – OPERATION 5.23 – TRANSDUCER CHARACTERIZATION SELECTION Allows user to enter unique transducer characterization data when the transducer has been changed. CAUTION: – User should not make any changes to the data entered in the following menu items.
  • Page 54: Network Configuration

    MASS-tron II/CEM 5.24 – NETWORK CONFIGURATION Operator can turn network communications ON or OFF, select source, and assign IP addresses. Operator Setup Main Menu Network Configuration Default selection shown. Available selections: - Network Off/On Selection Network Off / On - Xdcr Characterizat'n Select...
  • Page 55: Menu Inactivity Timeout Selection

    MASS-tron II/CEM SECTION 5 – OPERATION 5.25 – MENU INACTIVITY TIMEOUT SELECTION Allows user to select a time (minutes) after which the unit returns to Normal operation if no activity in the Operator Menu. Operator Se tup Main M enu Available selections: Default selection shown.
  • Page 56: Section 6 - Calibration

    This section will detail steps necessary to calibrate the MASS-tron II/CEM. Calibration is accomplished using the four programming push buttons detailed in Section 5. This section can be accomplished with MASS-tron II/CEM mounted in its operating location or at a test bench in a calibration lab.
  • Page 57: Transmitter Input Calibration

    Transducer Span Calib: X.XX in.WC 6. Apply input pressure (as read on manometer) to the High port of the MASS-tron II/CEM. Adjust pressure to equal the transducer natural span value, which is indicated on the display. 7. Press ENT, and display will indicate:...
  • Page 58 6.3.2 Absolute Pressure Calibration. With minimum and maximum absolute pressure applied, MASS-tron II/CEM will be programmed to recognize these values for Density Compensation. 1. Prepare test equipment as shown in Figure 6.2. Have vacuum pump preset to approximately the required minimum pressure (see Factory Set-Up Information Sheet).
  • Page 59 MASS-tron II/CEM SECTION 6 – CALIBRATION 6.3 – TRANSMITTER INPUT CALIBRATION (con't) 6.3.2 (con't) Note: If zero input is less than 80% or greater than 120% of Absolute Pressure minimum input (see Factory Set-Up Information Sheet), display will indicate: Bad Input Span -- Push ESCAPE -- If this occurs, check input pressure (as read on gauge), and readjust as necessary.
  • Page 60 MASS-tron II/CEM SECTION 6 – CALIBRATION 6.3 – TRANSMITTER INPUT CALIBRATION (con't) 6.3.2 (con't) Note: If span input is less than 80% or greater than 120% of Maximum Pressure input (see Factory Set-Up Information Sheet), display will indicate: Bad Input Span -- Push ESCAPE -- If this occurs, check input pressure (as read on gauge), and readjust as necessary.
  • Page 61 2. If temperature signal is provided by temperature device, connect a voltage/current generator across Terminals 8 and 10 (see Figure 4.4). If temperature signal is powered by MASS-tron II/CEM, connect a loop powered temperature simulator across Terminals 7 and 8 (see Figure 4.5).
  • Page 62: Transmitter Output Calibration

    DMM should be reading minimum value; 0.00 ± 0.01 volts or 4.00 ± 0.01mA. 5. If DMM is reading out of tolerance, use UP or DN to adjust MASS-tron II/CEM output for an acceptable DMM reading.
  • Page 63 8. With DMM still connected as in Step 4, reading should be at maximum value; 10.00 ± 0.01 volts, 5.00 ± 0.01 volts, or 20.00 ± 0.01mA. 9. If DMM is reading out of tolerance, use UP or DN to adjust MASS-tron II/CEM output for an acceptable DMM reading.
  • Page 64: Auto-Span Pressure Reference Calibration

    MASS-tron II/CEM SECTION 6 – CALIBRATION 6.5 – AUTO-span PRESSURE REFERENCE CALIBRATION 1. Disconnect tubing at output of AUTO-span Pressure Reference. 2. Connect manometer to output of AUTO-span Pressure Reference (see Figure 6.4). 3. Using coarse adjustment, adjust pressure as read on gauge to 9.0 ± 1.0 psi (tap gauge to eliminate any hysteresis).
  • Page 65: Section 7 - Maintenance

    SECTION 7 – MAINTENANCE 7 – MAINTENANCE The MASS-tron II/CEM is a solid state device having few mechanical parts requiring special periodic maintenance. The following maintenance steps are not requirements, but guidelines for establishing a maintenance program for your specific installation.
  • Page 66: Section 8 - Troubleshooting

    MASS-tron II/CEM SECTION 8 – TROUBLESHOOTING 8 – TROUBLESHOOTING Personnel should be familiar with the operation of the MASS-tron II/CEM (see Section 5) before performing any troubleshooting. Note: Prior to performing any troubleshooting, turn power switch OFF. After 10 seconds, turn power switch ON. If problem still exists, proceed with troubleshooting steps.
  • Page 67 MASS-tron II/CEM SECTION 8 – TROUBLESHOOTING 8 – TROUBLESHOOTING (con't) Personnel should be familiar with the operation of the MASS-tron II/CEM (see Section 5) before performing any troubleshooting. Problem Solution AUTO-cal Report Timing is – Verify AUTO-cal configuration. incorrect. AUTO-cal function not –...
  • Page 68: Section 9 - Parts List

    MASS-tron II/CEM 9 – PARTS LIST The following drawing with part numbers lists components of the MASS-tron II/CEM that are easily replaced by the user. When contacting the Customer Service Department about parts, please have the applicable Factory Set-Up Information sheet available for reference.
  • Page 69 MASS-tron II/CEM 9 – PARTS LIST The following drawing with part numbers lists components of the MASS-tron II/CEM that are easily replaced by the user. When contacting the Customer Service Department about parts, please have the applicable Factory Set-Up Information sheet available for reference.
  • Page 70: Section 10 - Customer Service

    Return Authorization with shipping instructions will be sent via facsimile. Equipment to be returned to Air Monitor Corporation should be returned in its original shipping container if possible. If this is not possible, ensure equipment is packaged sufficiently to protect it during shipment.

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