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Related Manuals for Metal Samples CORR VELOX MS2801E
Summary of Contents for Metal Samples CORR VELOX MS2801E
- Page 1 Ultra Resolution ER RS-485 Transmitter (Model MS2801E) Operator’s Manual Metal Samples 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 MS2801E 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 .................. 6 a. Making Connections .................. 6 b. Grounding ...................... 7 c. Safe Area Installation .................. 7 d. Hazardous Area Installation ................ 7 3. Setup and Operation ...................... 9 a. Probe Settings ... -
Page 5: Introduction
I. Introduction A. General Description The model MS2801E 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 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. ... - Page 6 Probe Life Element Type Compatibility Thickness (Span) Tubular Loop Compatible Wire Loop Compatible Flush (Small) Compatible Cylindrical Preferred Flush (Large) Preferred 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 loss amounts as small as 0. 0001% of the probe life. For highly sensitive probes such as the 5‐mil large flush shown above, that results in a detection limit of less than one angstrom. Metal loss readings taken by the Corr Velox 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 20‐bit digital value between 0 and 1,048,575, where: 0 = 0 mils (0% Metal Loss) 1,048,575 = Probe Life* in mils (or 100% Metal Loss) *The Probe Life (or Span) of the probe being used (see table 1 above.) ...
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Page 7: Technical Specifications
C. Technical Specifications Corr Velox Model MS2801E High Resolution ER RS‐485 Modbus Transmitter Physical Data Instrument W eight: 3.70 lb. (1.68 Kg) Total 4.82”W Weight w/ Accessories: 5.76 lb. (2.61 Kg) (12.24cm) Instrument D imensions: 8.0"H x 4.0"W x 3.45”D 8.0”H (20.32cm) (20.32cm H x 12.24cm W x 8.76”D) Operating T emperature: ‐40° to 158°F (‐40° to 70°C) Storage T emperature: ‐40° to 176°F (‐40° to 80°C) Enclosure Material: Cast Aluminum (Copper‐Free) Mounting S pecifications: Direct probe mount or Remote mount 3.45”D (Up to a 2.5” (6.35cm) Dia. pole) (8.76cm) ... -
Page 8: Installation And Operation
II. Installation and Operation A. Receiving the MS2801E 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 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 Corr Velox transmitter involves the following steps: ... -
Page 9: Remote Mounting
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 Tighten Insert Coupling Nut Connector 1 2 ... -
Page 10: 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 a CAUTION: way that all hazardous area requirements are met. 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. ... -
Page 11: Grounding
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. 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 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. ... - Page 12 Special Conditions 1. All Cable Glands, blanking elements and thread adapters used with the equipment shall be suitable certified Ex db parts, providing a degree of protection of IP66 and be suitable for use in ambient temperature range of ‐40Deg C. to 70 Deg.C . 2. No more than one Hazardous area reducer shall be used on any entry. For hazardous area installations, the maximum inductance and capacitance of the field wiring CAUTION: between the connected equipment and the transmitter cannot exceed the entity parameters. Non‐Metallic Hazardous area label on the instrument may pose a potential electrostatic hazard. CAUTION: Following precautions may help to reduce risk during maintenance / handling the equipment. The static charge can be dissipated by following simple steps a. Use dampened cloth to clean the label surface before handling it. b. Body can be grounded by using ground/anti‐static wrist bands or by other means before handling. 8 ...
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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 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 and Data Connector ... -
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 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 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 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. Register Description No Address 1 40024 DAC Value (Low) 2 40025 DAC Value (Hi) To access all other registers for maintenance purpose, the Switch 1, Position # 4 (Maintenance) should be turned on. Register Description No Address 1 40001 Device Status 2 40002 Device Address 3 40003 Baud Rate 4 40024 DAC Value (Low) 5 40025 DAC Value (Hi) 6 40026 ... - Page 17 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 16 for troubleshooting or contact the factory for further assistance. ...
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Page 18: Interpreting Data
d. Interpreting Data i. Metal Loss The Corr Velox transmitter measures the Metal Loss of an ER probe and converts that value to a digital 20‐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) 1,048,575 = 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. 1048575 786431 524288 262144 0 0.0 ... -
Page 19: 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) x 365 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 ... -
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 10. Enclosure Lock Screw The Lock Screw on the instrument base must be tightened securely to prevent unauthorized CAUTION: personnel from opening the Corr Velox transmitter, and ensure that the intrinsic safety is not violated. Only qualified personnel should be allowed to install, operate, and maintenance the Corr Velox transmitter. ... -
Page 21: Troubleshooting
D. Troubleshooting If the Corr Velox transmitter does not seem to perform as expected, check the following items: Before performing any tests or maintenance on the Corr Velox 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 probes 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. ... -
Page 22: Service And Warranty Information
III. Service and Warranty Information A. Warranty Metal Samples warrants that any part of the model MS2801E 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 ... -
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 Name* Company* Return Address *If different than above. ... -
Page 24: Appendix A: Revision History
Appendix A: Revision History Revision Date Changes 10/6/2014 Initial Release Separate gas group rating listed for Stand‐Alone and Multi‐Drop 1/15/15 operation. Revised hazardous area installation (control) drawing and safe area installation drawing. 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 Revised Technical Specifications page G 3/7/17 Revised switch settings. H 4/19/17 Revised switch settings. I 5/29/18 Certification Details changed (Applicable to Serial # 401 Onwards) ... -
Page 25: Appendix B: Hazardous Area Certification Details
Appendix B: Hazardous Area Certification Details Doc.Number EXDOC-000015 Revision MS2701E/ MS2801E Hazardous Area Certification Details Date 05/08/2018 Page 1 of 1 Worldwide and Europe Ex db [ia Ga] IIC T6….T4 Gb Ex tb [ia Ga] IIIC T 80 ° C Gb -40°C ≤... - Page 26 Appendix C: Control Drawing...
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