P-3100:TEMPLATE 3/1/10 11:27 AM Page 1 Bulletin P-3100 Series 3100 Explosion-Proof Differential Pressure Transmitter Specifications - Installation and Operating Instructions DWYER INSTRUMENTS, INC. Phone: 219/879-8000 www.dwyer-inst.com P.O. BOX 373 • MICHIGAN CITY, INDIANA 46361, U.S.A. Fax: 219/872-9057 e-mail: info@dwyer-inst.com P-3100:TEMPLATE 3/1/10 11:27 AM Page 2 Table of Contents Chapter 1. Introduction 1.1 Using This Manual 1.2 Overview of Transmitter 1.3 Software Compatibility 1.4 Transmitter Components Chapter 2. Handling Cautions 2.1 Unpacking Transmitters and Specifications Check 2.2 Models and Specifications Check 2.3 Storage 2.4 Selecting the Installation Locations 2.5 Calibration after Installation 2.6 Pressure Connections 2.7 Waterproofing Cable Conduit Connections 2.8 Restrictions on Use of Radio Transceiver 2.9 Installation Resistance Test and Dielectric Strength Test 2.10 Installation of Explosion-Proof Transmitters 2.11 EMC Conformity Standards Chapter 3. Transmitter Functions 3.1 Overview 3.2 Safety Messages 3.3 Warning 3.4 Fail Mode Alarm 3.5 EEProm-Write Enable and Disable Mode Jumper 3.6 Configuration of Alarm and Security Jumper Procedures 3.7 Configuration of Zero and Span Procedure 3.8 Commissioning on the Bench with HHT Chapter 4. Installation 4.1 Overview 4.2 Safety Messages 4.3 Warning 4.4 Commissioning on the Bench with Hand-Held Terminal 4.5 General Considerations 4.6 Electrical Considerations 4.7 Wiring 4.8 Mechanical Considerations 4.9 Environmental Considerations Chapter 5. On-line Operation 5.1 Overview 5.2 Safety Messages 5.3 Configuration Data Review 5.4 Check Output 5.5 Basic Setup 5.6 Detail Setup 5.7 Information Variables Setup 5.8 Diagnostics and Services 5.9 Calibration Chapter 6. Maintenance 6.1 Overview 6.2 Safety Messages 6.3 Hardware Diagnosis 6.4 Hardware Maintenance Appendix I 3100 Smart Pressure Transmitter LCD Display Code Appendix II ® 3100 Smart Pressure Transmitter HART Communicator User’s Guide Appendix III 3100 Smart Pressure Transmitter Series User Guide ® HART is a registered Trademark of Hart Communication Foundation Page 1 P-3100:TEMPLATE 3/1/10 11:27 AM Page 3 Chapter 1 Introduction The 3100 Smart Pressure Transmitter is calibrated at the factory before shipping. To ensure correct and efficient use of the instrument, please read the manual thoroughly and fully understand how to operate the instrument before operation. 1. The contents of this manual are subject to change without prior notice. 2. All rights are reserved. No part of this manual may be reproduced in any form without Dwyer Instruments, Inc. written permission. 3. If any question arises, errors are found or if any information is missing from this manual, please inform Dwyer Instruments, Inc. 4. The specifications covered by this manual are limited to standard transmitters and do not cover custom-made instrument. 5. Please note that changes in the specifications, construction, or component parts of the instrument may not immediately be reflected in this manual at the time of change, provided that postponement of revisions will not cause difficulty to the user from a functional or performance standpoint. 1.1 Using This Manual The operating manual provides information on installing, operating, ® and maintaining the Mercoid Model 3100 Smart Pressure Transmitter. The Chapters are organized as follows. Chapter 2 Handling Cautions Chapter 2 provides instructions on commissioning and operating the Model 3100 Smart Pressure Transmitters. Informations on software functions, configuration parameters, and on-line variables are also included. Chapter 3 Transmitter Functions Chapter 3 contains suggestions on handling the Model 3100 Smart Pressure Transmitter. Chapter 4 Installation Chapter 4 contains mechanical, environment consideration and electrical installation instructions for the Model 3100 Smart Pressure Transmitter. Chapter 5 On-line Operation Chapter 5 describes how to configure the parameters of the Model 3100 Smart Pressure Transmitter. See the following list for the details. 1. Regulations for circuit's Input/Output characteristics; Sensor or Output Trim 2. Changing the output characteristic; Range Configuration, Output Type, Dampening, Unit 3. Changing the general data; Tag No., Date, Message etc. Chapter 6 Maintenance Chapter 6 contains hardware diagnostics, troubleshooting and maintenance task. Page 2 P-3100:TEMPLATE 3/1/10 11:27 AM Page 4 1.2 Overview of Transmitter ® The Mercoid Smart Pressure Transmitter is a microprocessor based pressure transmitter with a capacitance sensor optimized for draft measurement. The Model 3100 has a true draft analog range from 0 to 20 mA. This transmitter is explosion-proof, high precision accuracy, reliability and has digital communication for remote communication system. ® The Model 3100 is enabled with HART communication with Host, ® HHT (HART Communicator) or PC Configurator. The transmitter’s various variables in host are able to be changed, configured and ® calibrated by users. The HART Communication between DC power supply and transmitter requires a 250~ 550 Ohm resistance. 1.3 Software Compatibility ® The Mercoid Smart Pressure Transmitter's software is implemented at the factory. The following functions can be configured using a ® HHT (Hart Communicator). Function Supports Function ZERO/SPAN HART Button PC/PDA HHT Rev.58 ZERO/SPAN ● ● ● ZERO TRIM ● ● ● ZERO Adj ● ● ● Units set ● ● ● Range set ● ● ● Dampening set ● ● ● LCD decimal set ● ● Δ ● : Supported Δ : Supported but update required ® HART is a registered Trademark of HART Communication Foundation Page 3 P-3100:TEMPLATE 3/1/10 11:27 AM Page 5 Chapter 2 Handling Cautions This chapter consists of cautions for transmitter handling, storage, installation, insulation and explosion structure, etc. Step Job Job Details Instrument 1 Unpacking - Unpack transmitter packing 2 Model and - Make sure the transmitter nameplate matches the model number Specifications on the P.O. 3 Storage - In a dry, non-vibration and non-impact area - Ambient temperature around 77°F (25°C) and 65% relative humidity 4 Calibration - Configuration of the Range, Zero/Span, Unit, Tag, Dampening - HHT Time, Transfer Function, DA Trim and other parameters - Pressure Source - Galvanometer 5 Installation - Where ambient temperature are constant (Engineering) Locations - Exposure to chemical corrosion, etc. - Where shock and vibration are minimal - Where the area classification does not exceed the explosion-proof rating - Where maintenance is easy 6 Mechanical - Where the transmitter can be handled easily (Engineering) Considerations - Be cautious of process connections leaking 7 Electrical - 24 VDC (Engineering) Considerations (Power Supply is 11.9 Vdc – 45 Vdc) ® - For HART communication, resistance on transmitter terminal loop should be between 250 – 550 Ohms 8 Mounting and - When mounting the transmitter, an appropriate bracket should be used (Mounting and Installation) Installation - The transmitter should be mounted securely to prevent swing 9 Calibration on Spot - Sensor Zero Trim should be done ten seconds after differential HHT or pressure stabilizes Zero/Span button - Make sure that PV value is zero and current is 4 mA 10 Pressure - Do not apply a regulated differential pressure and line pressure (Applying pressure) - Close the equalizing valve on the 3 valve manifold and then open the valve on high and low side slowly and simultaneously 11 Operation - Make sure the transmitter operates properly Eye or HHT Page 4 P-3100:TEMPLATE 3/1/10 11:27 AM Page 6 2.1 Unpacking 2.5 Calibration after Installation When moving the transmitter to the installation site, keep it in the 1. Sensor Zero Trim should be done after transmitter is installed, original packaging. Unpack the transmitter at the installation site to because the zero point is not configured for mounting status. avoid damage on the way. 2. When calibrating the Sensor Zero Trim apply a pressure for zero in advance, Sensor Zero Trim the sensor when the pressure is 2.2 Model and Specifications Check sufficiently stabilized (after approximately 10 seconds). The model number and specifications are indicated on the 3. There are two ways to pressure zero. One way is to apply zero nameplate. Please check the specification and model number. differential pressure (making pressure the same on both the high and low side). The other is to close High and Low side of a 3 2.3 Storage valve manifold and open the equalizing valve. The following precautions must be observed when storing the 4. Sensor Zero Trimming can also be done with the Zero/Span ® instrument, especially for a long period of time. button or a HHT (HART Communicator), PC or PDA configurator. 1. Select a storage area that meets the following conditions: 5. Refer to On-line Operation for configuring other parameters. - is not exposed to rain or water. - minimal vibration and shock. 2.6 Pressure Connections - stored at normal temperature and humidity (approx. 77°F (25°C), 65% RH). Warning Instrument installed in the process under pressure. The ambient temperature and relative humidity ratings are: • Never loosen or tighten as it may cause dangerous Ambient Temperature: -40 to 185°F (-40 to 85°C) spouting of process fluid. If the process fluid is toxic or (without LCD module) otherwise harmful, take appropriate care to avoid -22 to 176°F (-30 to 80°C) contact or inhalation of vapors even after (with LCD module) disconnecting the instrument from process line for General Use: -4 to 140°F (-20 to 60°C) maintenance. Relative Humidity: 5% ~ 98% RH at 104°F (40°C) The following precautions must be observed in order to safely 2. When storing the transmitter, repack it the way it was operate the transmitter under pressure. delivered from the factory. 1. Never apply a pressure higher than the specified maximum working pressure. 3. If storing a used transmitter, thoroughly clean the diaphragm 2. Confirm the option pressure of transmitter. It is necessary to surfaces, so that no media remains. Make sure the transmitter use standardized and quality-approved parts. assemblies are securely mounted before storing. 3. There should be isolation valves in case of leakage. 2.4 Selecting Installation Locations 2.7 Waterproofing Cable Conduit Connections The transmitter is designed to withstand severe environmental Apply a non-hardening sealant (silicone or tape, etc.) to the threads conditions. However, to ensure stable and accurate operation, the to waterproof the transmitter cable conduit connections. following precautions must be observed when selecting an installation location. 2.8 Restrictions on Use of Radio Transceivers 1. Ambient Temperature Warning Avoid locations subject to wide temperature variations or a • Although the transmitter has been designed to resist significant temperature gradient. If the location is exposed to high frequency electrical noise, if a radio transceiver is radiant heat from plant equipment, provide adequate used near the transmitters external wiring, the insulation or ventilation. transmitter may be affected by high frequency noise pickup. To test for such effects, bring the transceiver in 2. Ambient Atmosphere slowly from a distance of several feet from the Avoid installing the transmitter in a corrosive atmosphere. If transmitter, and observe the measurement loop for the transmitter must be installed in a corrosive atmosphere, noise affects. Always use the transceiver outside the there must be adequate ventilation. Precautions must be put area affected by noise. into place to prevent intrusion or stagnation of rainwater in conduits. 2.9 Insulation Resistance Test and Dielectric Strength Test Since the transmitter has undergone insulation resistance and 3. Shock and Vibration dielectric strength tests at the factory, normally these tests are not Select an installation site with minimum shock and vibration required. However, if required, observe the following precautions in (although the transmitter is designed to be relatively the test procedures. resistant to shock and vibration). 1. Do not perform such tests more frequently than necessary. 4. Installation of Explosion-Proof Transmitters Even test voltages, that do not cause visible damage to the Explosion-Proof transmitters can be installed in hazardous insulation, may degrade the insulation and reduce safety areas according to the gas types for which they are certified. margins. 2. Never apply a voltage exceeding 500VDC for the insulation 5. Select a place where the transmitter can be maintenanced resistance test, or a voltage exceeding 500VAC for the easily. dielectric strength test. 3. Before conducting these tests, disconnect all signal lines from the transmitter terminals. Perform the tests in the following procedures. Page 5 P-3100:TEMPLATE 3/1/10 11:27 AM Page 7 Insulation Resistance test Chapter 3 Transmitter Functions 1. Short-circuit the + and - SUPPLY terminals in the terminal box. 3.1 Overview 2. Turn OFF the insulation tester. Then connect the This Chapter contains information on operating the Model 3100. insulation tester plus (+) lead-wire to the shorted SUPPLY Tasks that should be performed on the bench prior to installation are terminals and the minus (-) lead wire to the grounding explained in this chapter. terminal. 3. Turn ON the insulation tester power and measure the 3.2 Safety Message insulation resistance. The voltage should be applied briefly Procedures and instructions in this chapter may require special to verify that insulation resistance is at least 20MΩ. precautions to ensure the safety of the personnel performing the 4. After completing the test and being very careful not to operations. Potential safety issues are indicated by a warning touch exposed conductors. Disconnect the insulation symbol (▲). Refer to the following safety messages before tester and connect a 100kW resistor between the performing an operation preceded by this symbol. grounding terminal and the short-circuiting SUPPLY terminals. Leave this resistor connected at least three 3.3 Warning seconds to discharge any static potential. Do not touch the terminal while it is discharging. Warning Explosion can result in death or serious injury: Dielectric Strength Test • Do not remove the transmitter covers in explosion a. Short-circuit the + and - SUPPLY terminals in the terminal environments when the circuit is powered. box. b. Turn off the dielectric strength tester. Then connect the • Transmitter covers must be fully engaged to meet tester between the shorted SUPPLY terminal and the explosion-proof requirements. grounding terminal. Be sure to connect the grounding lead of the dielectric strength tester to the ground terminal. Warning c. Set the current limit on the dielectric strength tester to Electrical shock can result in serious injury: 10 mA, then turn on the power and gradually increase the • Only qualified personnel can install the transmitter. tester voltage from '0' to the specified voltage. d. When the specified voltage is reached, hold it for one minute. e. After completing this test, slowly decrease the voltage to 3.4 Fail Mode Alarm ® avoid any voltage surges. Mercoid Smart Pressure Transmitter automatically and continuously performs self-diagnostic test. If the self-diagnostic test 2.10 Explosion-Proof Rating detects a failure, the transmitter drives the output outside of the normal operation values. The transmitter will drive its output low 2-10-1. FM Certification (down) or high (up) based on the position of the failure mode alarm HAZARDOUS LOCATION ELECTRICAL EQUIPMENT jumper. See Table 3.1 for output values. Equipment Rating: Explosion-Proof for use in Class I, Division 1, Groups A, B, C and D; 4~20 mA Alarm Level 4~20 mA Saturation Dust- Ignition-Proof for Class II/III, Division 1, Groups E, F and G; ≤ 3.75 mA Low/Down 3.9 mA Nonincensive for use in Class I, Division 2, Groups A, B, C and D; ≥ 21.75 mA High/Up 20.8 mA Suitable for use in Class II, Division 2, Groups E, F and G; and Suitable for Class III, Division 1; Hazardous (classified) location, indoor and outdoor [Table 3.1 Standard Alarm and Saturation Values] (NEMA Type 4X/IP67). Warning 2.11 EMC Conformity Standards Electrical shock can result in serious injury: EMI (Emission): EN55011 • Avoid contact with the leads and terminals. High EMS (Immunity): EN50082-2 voltage, that may be present, on leads can cause electrical shock. Dwyer Instruments, Inc. recommends customer use metal conduit wiring or twisted pair shield cable for signal wiring to conform with ® EMC regulation, when installing the Mercoid 3100 transmitters. Fail Safe mode can be set via Jumper switches provided on the LCD module or the main CPU module. The jumper switch for an indicating transmitter, located on the LCD module, can be set to the right (fail down i.e. ≤ 3.75 mA) or left (fail up i.e. ≥ 21.75 mA). For non-indicating transmitters the jumper switch is located on the main CPU module, it can be set up (fail up to ≥ 21.75 mA) or down (fail down to ≤ 3.75 mA). Refer to Figure 3-1 for detailed summary of jumper settings for both CPU and LCD modules. Page 6 P-3100:TEMPLATE 3/1/10 11:27 AM Page 8 Fail Safe Mode Selection (LCD & CPU Module) Both LCD Module and Only CPU Select Fail CPU Module Module Mode LCD Module CPU Module CPU Module Fail Down D D Down U Down Fail Up U U or D Up UP Figure 3-3. CPU Module Fail Mode, EEPROM-Write Selection Jumper Switch DOWN The 3100 has two security settings. 1. Security Jumper: the transmitter configuration parameters are protected. 1. WR_EN (EEPROM Write Enable) DOWN : ENABLE 2. Physically removing Zero and Span Magnetic Buttons: you are UP : DISABLE unable to regulate zero and span locally. 2. Fail Mode(Alarm) DOWN : LOW 3.5.1 Security Jumper (EEPROM Write Protect) UP : HIGH Prevents the transmitter’s configured parameters from being changed. Fail Mode for LCD Module Selection Jumper Switch 3.5.2 Zero and Span Buttons U O O O O O O D O O O D By removing the Magnetic Buttons, you can’t configure the (If Down) FAIL MODE (If Up) transmitter using the Zero and Span locally. Figure 3-1. Fail Mode and EEPROM-Write Selection Jumper Switch 3.6 Configuration of Alarm and Security Jumper Procedures Changing jumper position. 1. If the transmitter is installed, cutoff power. 2. Open the front cover. If the transmitter is powered, don’t open the cover. 3. Move the jumper to the preferred position. 4. Close the front housing covers. You must fully engage the cover to meet explosion-proof requirements. Figure 3-2 Fail Mode Selection Jumper Switch for LCD Module 3-5. EEProm-Write Enable / Disable Mode Switch EEPROM (Electrically Erasable Programmable ROM), included on the CPU module, is used by the transmitter to save/restore configuration variables. To protect the transmitter from any unauthorized changes, a hardware lockout feature can be implemented by using the Write-Protect mode jumper switch provided on the main CPU Module. If the jumper switch is connected to DIS, this disables writing/changing of any data saved in the EEPROM. On the other hand, if the jumper switch is set to “EN”, changes can be made to the configuration data stored in the EEPROM. The factory default setting is “EN” (Enable) for all transmitters. The location of the Wire Protect Jumper Switch can be seen in Figure 3-3. Page 7 P-3100:TEMPLATE 3/1/10 11:27 AM Page 9 3.7 Configuration of Zero and Span Procedures Caution: 30 seconds without any action, the button function will The ZERO and SPAN Buttons are under the transmitter’s return to normal operation. nameplate. The ZERO, SPAN, ZERO TRIM, ZERO ADJ, Units, Range, Dampening, LCD and decimal set functions are configurable 4. How to select a numerical value using the ZERO / SPAN buttons. A Functions use numerical values: 12 Zero Adjustment, 22 Change Upper Range Value, 23 Change Lower Range Value, Zero/Span Configuration Process 24 Dampening Second Remove both name plate screws on the upper part of transmitter. B How to select numerical value: First, select an increasing rate n Remove top name plate to access the Zero and Span Buttons. (10 ), then change each decimal value to increase or (following Figure 3-4) decrease as wanted. For example, select 3810 : Select 1. Zero Configurations increasing rate 1000 -> Increase 3 times -> Select Set the current process value for Lower Range Value (4 mA). increasing rate 100 -> Increase 8 times -> Select Apply zero pressure for 10 seconds and push the Zero Button increasing rate as 10 -> Increase 1 time for 5 seconds. The LCD should display “Zero”. Push the Zero C To select the increase / decrease steps: SelInc message will button for 3 seconds, after 1 second the LCD should display be displayed on the bottom of the LCD. Select parameter and “-ZE-”. This message means the zero configuration is press the Zero button : The decimal value will be changed finished. If the zero configuration failed, the LCD will display when the Zero button is pressed. After set, press the span “SPEr” or “SEtE”, try repeating the zero configuration steps. button to execute the parameter. 2. Span Configurations D To set the required values using Zero/Span buttons: VALUE Apply the desired pressure for 10 seconds and push the Span message will be displayed on the bottom of the LCD. Button for 5 seconds. The LCD should display “Span”. Push 1. Press the Zero button, the menu will increase 1 item. the Span button for 3 seconds, after 1 second the LCD should 2. Press the Span button, the menu will decrease 1 item. display “-SP-”. This message means that the span 3. After setting, save the parameter by pressing the configuration is finished. If the span configuration failed the Zero+Span buttons. LCD will display “SPEr” or “SEtE”, try repeating the span E To set the final value, repeat C and D. configuration steps. F After setting the final parameter, exit the menu by pressing the Zero+Span buttons. • Please refer to Appendix 1 for the button error and LCD display 5. Exercises for each function message. • ZERO TRIM The other functions supported by the ZERO / SPAN Buttons are 1. Access the menu by pressing the Zero+Span buttons. below. 2. Move to the sub directory using the Span button until the 1 TRIM message appears on the display. 3. Change the Zero Trim Function by using the Span button until the 11 Z-TRIM message appears on the display. • ZERO ADJUSTMENT : Change the PV value to 14 1. Exit the menu by pressing the Zero+Span button. 2. Moving thru the sub directory using the Span button until 1 TRIM message appears. 3. Moving thru the sub directory using the Zero button until 11 Z-TRIM message appears. 4. Access the Zero Adjustment function by pressing the Span button until the 12 Z-ADJ messages appears. 5. When the SelInc message appears, press the Zero button repetitively until the 10.0 message appears on the LCD. Set the value by pressing the Span button. 6. When VALUE message appears, change the LCD value to 10.0 and press the Zero button, then press the Zero+Span buttons. 7. When Sellnc message appears, change the LCD value to 1.0 and press the Zero button, then set the value and press the Span button. Press the Zero+Span buttons after the LCD value changes to 14.0. 8. To save the settings, press the Zero+Span buttons until the SelInc message appears. • CHANGE UNITS [Menu Tree for Zero+Span Button Function] 1. Access the menu by pressing the Zero+Span buttons. 1. Moving between menus: Zero 2. Moving to next menu by pressing the Zero button until the 2. Enter or moving to sub menu: Span 1 TRIM message appears. 3. Moving to top menu: Zero+Span 3. Moving thru the sub directory press the Span button until • Press the button for 3 seconds to execute each function. After the 2 SETUP message appears. 3 seconds press the Zero+Span buttons, the LCD display 4. Press the Span button to access 21 UNIT, press Span will change from Menu to Trim. To see the next menu, press again to access Change Unit. the Zero button for 3 seconds. Use the Zero button to move 5. Save the values by pressing the Span button when the down the directory. desired value is displayed on the LCD. • Use the Span button to select the displayed menu. The same procedure will be used for the sub menus. Page 8 P-3100:TEMPLATE 3/1/10 11:28 AM Page 10 • CHANGE UPPER RANGE VALUE 3.10 Shop Commissioning using HHT 1. Access the menu by pressing the Zero+Span buttons. The 3100 Pressure Transmitter can be commissioned using an HHT 2. Move to the next menu by pressing the Zero button until before or after installation. the 1 TRIM message appears. ® 3. Press the Span button until the 2 SETUP message appears. ▲ Connect an HHT (HART HANDHELD Communicator) across the ® 4. Press the Span button until the 21 Unit message appears. COMM pins for HART communication. The TEST pin connections 5. Press the Zero button until the 22 U-RNG message appears. can be used for connecting a multimeter to measure the output 6. Press the Span button until the Zero Adjustment current directly from the transmitter. Since the 3100 is a two wire message appears. loop powered transmitter, it requires an external loop power supply ® ® • CHANGE LOWER RANGE VALUE (11.9V to 45VDC) to enable HART communication. Any HART 1. Access the menu by pressing the Zero+Span buttons. communication via HHT (or PC based configurator) requires a 2. Move the to next menu by pressing the Zero button until minimum 250 ~ 550 (max) ohm loop resistance. the 1 TRIM message appears. 3. Press the Span button until the 2 SETUP message appears. 4. Press the Span button until the 21 Unit message appears. 5. Press the Zero button until the 22 U-RNG message appears. 6. Press the Zero button until the 23 L-RNG message appears. 7. Press the Span button until the Change Lower Range Value message appears. 1. Decimal Place 1. Access the menu by pressing the Zero+Span buttons. 2. Move to the next menu by pressing the Zero button until the 1 TRIM message appears. 3. Press the Span button until the 2 SETUP message appears. 4. Press the Span button until the 3 LCD message appears. 5. Press the Span button until the 31 DEC-PL message appears. 6. Press the Span button until the Decimal Place message appears, the decimal place will appear on the second line of the LCD as follows. Display Explanation Max. Value AUTO 99999 Target value will be displayed [Figure 3-5 Connecting the Transmitter to HHT] automatically 5-0 No decimal place 99999 4-1 Display one decimal place 9999.9 3-2 Display two decimal places 999.99 2-3 99.999 Display three decimal places Display four decimal places 9.9999 1-4 7. The first line on the LCD will display 0.0. 8. The Decimal Place can be changed by pressing the Zero button. Save the setting by pressing the Span button after the decimal place has been selected. 9. The set value will display the PV value and Engineering value. 10. The LCD will display LCD_OV and the saved Unit when the pressure is over or under a set value. Figure 3-4 Transmitter Zero/Span Configuration Buttons Page 9 P-3100:TEMPLATE 3/1/10 11:28 AM Page 11 Chapter 4 Installation 4.1 Overview Start The information in Chapter 4 explains installation. 4.2 Safety Message Do you want Procedures and instructions in this chapter may require special safety measures to ensure the safety of the personnel performing the operation. Potential installation safety issues are indicated by a Yes warning symbol (▲). Refer to the following safety messages before Basic Setup installing the 3100 pressure transmitter. a) Unit Setup b) Range Setup 4.3 Warning c) Dampening Setup Warning No d) Transmitter Function Setup Explosion can result in death or serious injury : • Do not remove the transmitter covers in an explosion- proof environment when the circuit is powered. Verify • Both transmitter covers must be fully engaged to a) Pressure Support meet the explosion-proof requirements. Warning Electrical shock can result in serious injury: • Only qualified personnel can wire the pressure Do you satisfy spec? Maintenance transmitter. Warning Process leaks can cause death or serious injury: Field Install • Install and tighten before applying pressure. If you a) Jumper/Switch Setup don’t, it can cause process leaks. b) Transmitter takes up c) Transmitter leads Warning d) Transmitter for Power Supply Electrical shock can result in death or serious injury: • Avoid contact with the leads and terminals. End [Figure 4-1 Installation Flow Chart] 4.4 Commissioning on the Bench with Hand-Held Terminal The 3100 Pressure Transmitter can be commissioned before and 4.5 General Considerations after installation. Commissioning is easier if the transmitter is The transmitter can be mounted near the process to minimize piping. configured on a bench with an HHT before installation. Keep in mind that easy access is required for personnel, field calibration, and installation. Install the transmitter in an area with minimal vibration, shock, and temperature fluctuations. 4.6 Electrical Considerations (Power Supply) The transmitter housing is composed of two parts. One side is electronics, and the other side is terminal block. The terminal block side is the transmitter’s front side and is labeled “Field Terminal” on the housing. The terminal block can be accessed by removing the front cover. When wiring the power supply to the transmitter make sure the positive and negative wires are connected correctly. A HHT configurator can be connected directly across the (COMM) pin terminal located just below the power supply (PWR) terminal block connections. Page 10 P-3100:TEMPLATE 3/1/10 11:28 AM Page 12 4.6.1 Power Supply The 3100 Pressure Transmitter requires an 11.9 – 45 VDC power supply. A 250 ~ 550Ω (24 VDC) loop resistance is recommended ® for HART communication. Loop resistance is the sum of the resistance in the loop. Max. Loop Resistance [Ω] = (E-11.9) [vdc] / 0.022 [mA] 4.7 Wiring COMM COMM TEST TEST 4.7.1 Wiring Caution 1. Install the signal cables away from potential sources of electrical noise such as transformers, electrical motors, etc. Figure 4-2 Wiring the 3100 Pressure Transmitter 2. Before wiring, remove electrical conduit cap. 3. All screwed connections on the housing must be sealed with waterproof sealant. We recommend use of silicone based sealants to minimize post-hardening. 4. Avoid running DC signal and AC power cables in the same ducts/cable conduits to avoid signal noise issues. 5. All explosion-proof transmitters must meet the wiring & installation requirements specified within the applicable electrical codes. 4.7.2 Selecting the Wiring Materials 1. Use 600V shielded PVC wire or standard wire of the same class. (To ensure proper communication use 24 AWG or larger wire, and do not exceed 5000 feet) 2. Use shielded wire in areas with electrical noise. 3. In areas with high or low ambient temperatures, use wire or cable that is rated for the extreme temperatures. 4. If the wire or cable is going to be used in oil, solvent, toxic gas or liquid, make sure it is rated accordingly. 5. Process wire or cable must not be soldered to the terminal lug. Spade connectors are recommended to connect the process wires to the transmitter. Figure 4-3 Picture of Transmitter Wiring Terminal 4.7.3 Connecting External Wires to Transmitter Terminal Box 4.7.4 Wiring 1. Open the cover indicated "FIELD TERMINAL". Do not open Warning the cover if the transmitter is located in an explosion-proof Explosion can result in death or serious injury: area and powered. Connect the power supply to the terminal indicated "+PWR"(left terminal) and "-" in the • Do not remove the transmitter covers in an central terminal. Do not connect "+" power supply to "+" explosion-proof environment when the circuit is terminal "TEST". It will damage the test diode. powered. 2. Seal and close the conduit connection to prevent humidity • Both transmitter covers must be fully engaged to and explosion-proof atmosphere from entering the housing. meet explosion-proof requirements 3. Transmitter power is supplied by signal wire. Do not install near high voltage wires or high voltage equipment. 4. Close the transmitter cover. To meet the explosion-proof A. Loop Configuration ratings make sure the covers are fully engaged. ® Mercoid 3100 Pressure Transmitters use a two-wire NOTE: Do not power the transmitter with high voltage (AC). system for power, 4~20mA analog signal transmission and It can damage the transmitter. ® HART digital transmission. 5. You must connect a 250~550 Ohm Resistor in Current ® A DC Power Supply is required for the transmitter loop. The Loop (between Power Supply and Transmitter) for HART transmitter and power supply should be connected as Communication. See Figure 4-2. shown below. COMM COMM TEST TEST Page 11 P-3100:TEMPLATE 3/1/10 11:28 AM Page 13 B. Wiring Installation 4.7.5 Grounding General-use (Figure 4-4a) a. Grounding should satisfy KS requirements (grounding 1. Use metallic conduit or waterproof cable glands for wiring. resistance should be 10 ohm or less). Grounding is a. Apply non-hardening sealant to the terminal box and required for explosion-proof applications and the ground the threads on the flexible metal conduit for resistance must be below 10 ohms. waterproofing. [Note] In case of Built-in Lightening Protector, Grounding should satisfy Special KS requirements (grounding resistance, 10 ohm or less). b. There are ground terminals on the inside and outside of the transmitter. Either of these terminals may be used. c. Use 600V insulated PVC wire for grounding. 3100 Smart Pressure Transmitter Internal and External Ground Terminal Figure 4-4a Typical Mounting using Flexible Metal Conduit 4.7.6 Power Supply Voltage and Load Resistance When configuring the loop, make sure that the external load resistance is within the range (see figure below). The transmitter Explosion-proof supply voltage should be: 1. Explosion-proof metal conduit wiring (Figure 4-4b) a. A seal fitting must be installed near the terminal box • Standard : 11.9 to 45 Vdc port. • HART Communication : 17.4 to 45 Vdc b. Apply a non-hardening sealant to the threads of the terminal connection box. And maximum loop current is 24mA, Load resistance R: R = (E-11.9) / 0.022 (E = Power Supply Voltage) Figure 4-4b Typical Wiring using Explosion-Proof Conduit Page 12 P-3100:TEMPLATE 3/1/10 11:28 AM Page 14 4.8 Mechanical Considerations 4.9 Environmental Considerations Figure 4-6 is a dimensional drawing for the 3100. Figure 4-7 shows 4.9.1 Ambient Temperature how the A-630 angle bracket is mounted to a pipe. The transmitter ambient temperature range is 4 to 180°F (-20 to 60°C). If the ambient temperature is going to exceed the temperature range, precautions must be taken to keep the temperature within the temperature limits. 4.9.2 Toxic and Moist Environments The 3100 housing will protect the transmitter against moisture or toxic material. The electronic circuit is separated from the terminals. The housing covers have o-rings that seal the housing, but moisture can penetrate the housing thru the conduit. The transmitter should be mounted in a position to prevent moisture from entering the housing thru the conduit. 4.9.3 Installation in Hazardous Location The transmitter is designed with an explosion-proof housing. Installation environment must not exceed the explosion-proof rating. Chapter 5 On-Line Operation 5.1 Overview Figure 4-6. Model 3100 Outline Dimension Drawing This chapter describes how to configure the 3100 Smart Pressure Transmitter. The transmitter can be configured in On-Line or Off-Line mode. In On-Line Mode a compatible HHT or PC configuration device must be used. 5.2 Safety Message For added operator safety please pay specific attention to procedures outlined in this manual listed under the warning symbol (▲) 5.2.1 Warning Warning Explosion can result in death or serious injury: • Do not remove the transmitter covers in explosion- proof environments when the circuit is powered. • Both transmitter covers must be fully engaged to meet explosion-proof requirements. Warning Figure 4-7. A-630 Mounting Bracket Electrical shock can result in serious injury: • When installing transmitters in close proximity of high voltage sources (near power lines) the transmitter 4.8.1 Mounting leads can be subject to high voltages. Avoid installing transmitters in environments with excessive • Avoid contact with the leads and terminals. vibration. If it cannot be avoided it is highly recommended to provide adequate support when mounting. 5.2.2 Current to Passive Mode Configuration For multi-drop mode the current output must be configured as 4.8.2 Transmitter Access passive mode. Please disregard any other messages shown on When selecting the installation location, accessibility must be HHT. taken into consideration. • Housing rotation: The housing can be rotated 90°. 5.3 Configuration Data Review • Wiring terminals: The cover and wiring terminals are easily Before operating the transmitter make sure the configuration data on accessible. the nameplate matches the application. • LCD/Circuits: Install the transmitter in a location where it can be seen. For transmitters without an LCD, the cover 5.4 Configuration Verification and jumpers are easily accessible. Before the transmitter is ready for service, the configuration must be checked to confirm the settings are configured for the application. Page 13 P-3100:TEMPLATE 3/1/10 11:28 AM Page 15 5.4.1 Process Variable 5.6 Detailed Setup There are two process variables in the 3100 Smart Pressure Transmitter. The primary variable and temperature compensated 5.6.1 Set Fail Mode SV (Second Variable), the PV value outputs the 4~20mA analog When the sensor or microprocessor is not operating properly, the value. transmitter will output 3.75mA or 21.75mA based on the Fail Mode setting. 5.5 Basic Setup The correlation variable must be configured before operating the 5.6.2 Set Dampening Time transmitter. The Dampening Seconds value changes the response time of the transmitter to smooth out variations caused by rapid process 5.5.1 Select Sensor Range changes. Determine the appropriate dampening setting based on The pressure range must be selected when ordering the pressure the required response time, signal stability, and other transmitter. requirements of your system. The Dampening Seconds can be set from 0-60 seconds; the 5.5.2 Set Output Units default dampening value is 1.0 second. Select from the following engineering units: Volumetric Flow Unit: CubicFeet/min, Gallons/min, Liters/min, ImperialGallons/min, CubicMeter/hr, Ft/s, meters/s, Gallons/s, mGallons/day, Liters/s, mLiters/day, CubicFeet/s, CubicMeter/s, CubicMeter/day, ImperialGallons/hr, ImperialGallons/day, NormalCubicMeter/hr, NormalLiter/hr, StandardCubicFeet/min, CubicFeet/hr, CubicFeet/day, CubicMeters/min, Barrels/s, Barrels/min, Barrels/hr, Barrels/day, Gallons/hr, ImperialGallons/s, Liters/hr, Gallons/day Mass Flow Grams/s, Grams/min, Grams/hr, Kilograms/s, Kilograms/min, Kilograms/hr, Kilograms/day, MetricTons/min, MetricTons/hr, MetricTons/day, Pounds/s, 5.7 Configuration of Information Variable Pounds/min, Pounds/hr, Pounds/day, ShortTons/min, ShortTons/hr, ShortTons/day, LongTons/hr, LongTons/day 5.7.1 Set Tag Tags are an easy way to classify transmitters in multi Pressure transmitter application. Tags can use 8 words/numbers. kPa, mmH2O, InH2O, InHg, FtH2O, mmHg, psi, bar, mbar, g/cm^2, Kg/cm^2, Pascals, MPa, torr, ATM 5.7.2 Set Messages When using several transmitters, the user can define each Miscellaneous transmitter by using 32 words/numbers. This message is saved in % EEPROM. Time 5.8 Configuration of Breakdown Diagnostic Function Min, sec, hr, days 5.8.1 Loop Test Mass The Loop Test verifies the output of the transmitter, the integrity of Grams, kilograms, metric tons, pounds, short tons, long the loop, and the operations of any recorders or similar devices tons, ounce installed in the loop. The following procedures are required for a loop test. Volume Gallons, liters, imperial gallons, cubic meters, barrels, • Connect a reference meter to the transmitter. bushels, cubic yards, cubic feet, cubic inches, bbl liq, • Select the Loop Test on the HHT and operate the Loop normal cubic meter, normal liter, standard cubic feet, Test. hectoliters • Select current output (4mA/20mA/etc.) • If the readings match, then the transmitter and the loop are 5.5.3 4-20mA Configuration configured and functioning properly. If the readings do not Set the Zero and Span for the 4~20mA analog output. match, then you may have the current meter attached to the wrong loop, there may be a fault in the wiring, the transmitter may require an output trim, or the current meter may be malfunctioning. Page 14 P-3100:TEMPLATE 3/1/10 11:28 AM Page 16 5.9 Calibration 6.2.1 Warning The scale is implemented by calibrating the transmitter. Trim function has several calibration functions. Smart transmitters operate Warning differently than analog transmitter. A smart transmitter uses a Explosion can result in death or serious injury: microprocessor that contains information about the sensor's specific • Do not remove the transmitter covers in explosion- characteristics in response to pressure and temperature for proof environments when the circuit is powered. calculating the process variable. 4-20mA configuration sets the • Both transmitter covers must be fully engaged to transmitter’s analog output to a selected upper and lower range and meet explosion-proof requirements. can be done with or without an applied pressure. 4-20mA configuration does not change the factory characterization curve Warning stored in the microprocessor. Sensor trimming requires an accurate Electrical shock can result in serious injury: pressure input and adds additional compensation that adjusts the • When installing transmitters in close proximity of high factory characterization curve to optimize transmitter performance voltage sources (near power lines) the transmitter over a specific pressure range. 4-20mA configuration provides the leads can be subject to high voltages. ability to readjust the 4~20mA sensor inputs without an applied • Avoid contact with the leads and terminals. pressure. Reranging does not change the factory or characterization curve stored in the microprocessor. Sensor trimming requires an Warning accurate pressure input and adds additional compensation to the Electrical shock can result in death or serious injury: factory characterization curve to optimize transmitter performance • Only qualified personnel can configure and wire the over a specific pressure range. Rerange provides ability to readjust 3100 Smart Pressure Transmitter. the 4~20 mA points sensor inputs. 5.9.1 Sensor Trim The Sensor trim function adjusts the A/D signal conversion within the transmitter sensor electronics and determines how it digitally interprets any pressure changes applied to the sensor inputs. It is highly recommended to perform a sensor trim when first commissioning the transmitter on site. There are three ways to trim the sensor: Sensor zero trim, full trim and zero adjustment. Sensor zero trim is a one-point adjustment typically used to compensate for the mounting position. Two point trim is a full sensor trim, in which two accurate pressures are applied (equal to or greater than the range values), and the output is linear. You should always adjust the low trim value first to establish the correct offset. 5.9.2 D/A (Digital to Analog) Trim The D/A trim function makes minor adjustments to the analog (4- 20mA) output scaling from the transmitter. It is recommended to do a D/A trim on both hi (20mA) & low (4mA) values for best results. This function corrects any minuscule offsets within the D/A conversion of the transmitter Chapter 6 Maintenance 6.1 Overview This chapter describes diagnostic and maintenance. 6.2 Safety Message When the transmitter is in operation, operators should follow all safety messages. Potential safety issues are indicated by a warning symbol (▲). Refer to the following safety messages before performing any operation proceeded by a (▲) symbol. Page 15 P-3100:TEMPLATE 3/1/10 11:28 AM Page 17 6.3 Hardware Diagnostics If there is a failure despite a diagnostic message on the HHT, Table 6.1 can help troubleshoot the problem. Symptom Potential Source Corrective Action Transmitter does not Loop Wiring • Check for a 250-550 ohms resistance ® Communicate with HART between the power supply and HHT. Communicator • Check for adequate voltage to the transmitter (the transmitter requires 11.9 ~ 45 Vdc). • Check for intermittent shorts, open circuits, and multiple grounds. High Output Sensor Input Failure • Connect HHT and enter the transmitter test mode to isolate a sensor failure. Loop Wiring • Check for dirty or defective terminals, interconnecting pins, or receptacles. Power Supply • Check the output voltage of the power supply at the transmitter terminals. It should be 11.9 to 45 Vdc. Electronics Module • Connect HHT and enter the transmitter test mode to isolate module failure. Check the sensor limits to ensure the calibration adjustments are within the sensor range. Erratic Output • Check the output voltage of the power supply Loop Wiring at the transmitter terminals. It should be 11.9 to 45 Vdc. • Check for intermittent shorts, open circuits, and multiple grounds. • Check for proper polarity at the signal terminals. Electronics Module • Connect HHT and enter the transmitter test mode to isolate an electronics mode failure. Low Output or No Output Sensor Element • Connect HHT and enter the transmitter test mode to isolate a sensor failure. • Is the PV out of range. Loop Wiring • Check for adequate voltage to the transmitter (the transmitter requires 11.9 ~ 45 Vdc). • Check for intermittent shorts, open circuits, and multiple grounds. • Check polarity of signal terminal. • Check the loop impedance. Electronics Module • Connect HHT and check the sensor limits to ensure calibration adjustments are within the sensor range. Table 6.1 Troubleshooting 6.4 Hardware Maintenance ® The Mercoid 3100 Smart Transmitter has no moving parts and requires little maintenance. If a transmitter fails, it must be returned to Dwyer Instruments, Inc. for inspection, repair, or replacement. 6.4.1 Test Terminals The test terminals are marked TEST on the terminal block. The test and negative terminals are connected to the power terminals; so long as the voltage across the receptacles are below the diode threshold voltage, no current will pass through the diode. To ensure that current isn’t leaking through the diode, test the reading with an indicating meter. The test connection should not exceed 10 ohms. A resistance value of 30 ohms will cause an approximate 10 percent of reading error. Page 16 P-3100:TEMPLATE 3/1/10 11:28 AM Page 18 Figure 6-1 Test Terminals 6.4.2 Disassembling the Housing The transmitter is designed with dual-compartment housing; one contains the electronics module, and the other contains all wiring terminals and communication terminal. Figure 6-2 Structure of Housing 6.4.2.2 Fail Mode Jumper Switch and EEPROM-Write Fail-mode jumper switch and EEPROM-Write is located behind the front cover. Figure 6-3 Structure of Electronics Module Page 17 P-3100:TEMPLATE 3/1/10 11:28 AM Page 19 Appendix I 3100 SMART PRESSURE TRANSMITTER - LCD DISPLAY CODE Message Description ADJ-U Zero adjustment value – used to configure transmitter when it is out of range (on higher side) ADJ-L Zero adjustment value – used to configure transmitter when it is out of range (on low side) ZERO Initial message when using Zero button SPAN Initial message when using Span button BT-ERR Button Sequence error P-LOCK Button input error - Protect Locked ZT-ERR Zero Trim value is over limit (10%) -TR- Zero Trim done ZR-ERR Setting Limit error when executing Zero button function SP-ERR Setting Limit error when executing Span button function -ZR- Zero button function done -SP- Span button function done -ZA- Zero Adjustment done -DONE- Configuration completed using buttons RNGOVR Limit error when executing other setting function LCD_OV Over Values for LCD SCD-ER Sensor Code Error F-RST Flash Setting Data Reset F-LOCK Flash Setting Data Reset, Protect Locked F-FAIL Flash Setting Data Reset Failure -FR- Flash Reset done A-RST Analog EEPROM Initializing Start A-STOR Analog EEPROM Stored A-FAIL Failure in writing configuration values on to the EEPROM of transmitter CPU -AC- Analog EEPROM Configuration done S-FL Sensor Fail S-OP Sensor Overpressure AEP-RF Check error with EEPROM on CPU board TS-FL Temperature Sensor Error AEP-WF Analog EEPROM write fail EOSC Crystal Element Defect Alarm FAVE Flash Access Violation Page 18 P-3100:TEMPLATE 3/1/10 11:28 AM Page 20 ©Copyright 2010 Dwyer Instruments, Inc. Printed in U.S.A. 3/10 FR# RA-443807-00 DWYER INSTRUMENTS, INC. Phone: 219/879-8000 www.dwyer-inst.com P.O. BOX 373 • MICHIGAN CITY, INDIANA 46361, U.S.A. Fax: 219/872-9057 e-mail: info@dwyer-inst.com