Emerson MCU900 User Manual

Mobrey MCU900 Series

4–20 mA + HART® Compatible Controller

Reference Manual

IP2030/RM, Rev AA

June 2014

Reference Manual

IP2030/RM, Rev AA

Title Page

June 2014

Mobrey MCU900 Series Universal Control Unit

Read this manual before working with the product. For personal and system safety, and for optimum product performance,

make sure you thoroughly understand the contents before installing, using, or maintaining this product.

For the latest customer support information, visit the Mobrey brand pages at www.emersonprocess.com, and then click on the Mobrey Service or Product Support quick links.

The products described in this document are NOT designed for nuclear-qualified applications.

Using non-nuclear qualified products in applications that require nuclear-qualified hardware or products may cause inaccurate readings.

For information on Rosemount nuclear-qualified products, contact an Emerson Process Management Sales Representative.

Replacement equipment or spare parts not approved by Emerson for use as spare parts could reduce the capabilities of the Mobrey MCU900 Series control unit, and may render the instrument dangerous.

 Use spare parts supplied or sold by Emerson

Reference Manual

IP2030/RM, Rev AA

1Section 1: Introduction

1.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.2 Manual overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

1.3 Control unit versions and software releases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

1.4 Customer support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

1.5 Product recycling/disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

2Section 2: Control Unit Overview

2.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.2 About the Mobrey MCU900 Series Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.2.1 Wall and panel mounting options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

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2.2.2 4–20mA HART transmitter input options . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2.2.3 Control functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2.3 Control unit functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2.3.1 Standard functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.3.2 Difference, sum, and product functions (on MCU902 only) . . . . . . . . . . .5

2.3.3 Data logging functions (on MCU90F only) . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.4 Control unit front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2.4.1 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.4.2 Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2.4.3 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3Section 3: Installation

3.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

3.2 Considerations before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.2.1 Safety considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3.3 Mounting the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.3.1 Mounting the wall-mount version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3.3.2 Mounting the panel version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3.4 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.4.1 Making electrical connections on wall-mount units . . . . . . . . . . . . . . . . .13

Tab le of C ontents

3.4.2 Making electrical connections on panel-mount units . . . . . . . . . . . . . . . .15

3.4.3 Power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

3.4.4 Earthing connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

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3.4.5 Transmitter connections and cabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

3.4.6 Connecting HART transmitters to the Mobrey MCU902 . . . . . . . . . . . . .18

3.4.7 Relay connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

3.4.8 Current output connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

3.4.9 Digital control voltage-free contact inputs. . . . . . . . . . . . . . . . . . . . . . . . .21

3.4.10 RS232 connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4Section 4: Getting started

4.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.2 Switching on the MCU901 and MCU90F for the first time . . . . . . . . . . . . . . . . . . 26

4.2.1 Switching on with one new HART transmitter connected . . . . . . . . . . . .27

4.2.2 Switching on with one 4–20 mA transmitter connected . . . . . . . . . . . . .29

4.3 Switching on the MCU902 for the first time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.4 A quick tour of the menu system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.5 Programming the control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.5.1 The basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

4.5.2 Step-by-step programming of the control unit . . . . . . . . . . . . . . . . . . . . .37

4.5.3 Run App and Program operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . .38

4.5.4 Application Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

4.5.5 Optional change: system settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

4.5.6 Optional change:

transmitter input channel settings (advanced users) . . . . . . . . . . . . . . . .43

4.5.7 Programming Input Channel 1 for a 4–20 mA input

(advanced users) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

4.5.8 Programming Channel 1 for a HART input (advanced users). . . . . . . . . .48

4.5.9 Programming Channel 2 for a HART input (MCU902 only)

(advanced users) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

4.5.10 Volumetric contents and flow measurement applications

(advanced users) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

4.5.11 Set-up the volumetric contents calculations for a

popular linear / uniform vessel (advanced users). . . . . . . . . . . . . . . . . . . .52

4.5.12 Set-up the volumetric contents calculations for a popular

non-linear / non-uniform shaped vessel (advanced users). . . . . . . . . . . .53

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4.5.13 Set-up flow calculations for non-linear / non-uniform

open channel profiles (advanced users) . . . . . . . . . . . . . . . . . . . . . . . . . . .56

4.5.14 Set-up open channel flow calculations for pre-programmed flat,

parabolic, and Parshall flumes (advanced users) . . . . . . . . . . . . . . . . . . . .58

4.5.15 Set-up Kindsvater Shen (V-notch ISO1438) flow calculations. . . . . . . . .59

4.5.16 Set-up exponential flow law calculations . . . . . . . . . . . . . . . . . . . . . . . . . .59

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4.5.17 Using a plotted profile for calculating volume or flow . . . . . . . . . . . . . . .61

4.5.18 Digital inputs IN1 and IN2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

4.5.19 Data logging on the Mobrey MCU90F . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

4.5.20 Set-up the current output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

4.5.21 Set-up the relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

4.5.22 Set-up alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

4.5.23 Set-up totalizing on the Mobrey MCU901 control unit. . . . . . . . . . . . . . .95

4.5.24 Set-up totalizing on the Mobrey MCU902 control unit. . . . . . . . . . . . . . .97

4.5.25 Set-up totalizing on the Mobrey MCU90F control unit . . . . . . . . . . . . . . .99

4.5.26 Display configuration options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

4.5.27 Serial communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

4.5.28 PIN Security. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

5Section 5: Servicing and Health Checking

5.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

5.2 Servicing the MCU900 Series control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

5.2.1 Replacing the fuse on mains ac-powered control units . . . . . . . . . . . . 108

5.3 Health checking the MCU900 Series control unit . . . . . . . . . . . . . . . . . . . . . . . . 110

5.3.1 Simulation (self-test). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

5.3.2 Display test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

5.3.3 Calibration of the Current Input (I

5.3.4 Fixing the Current Output (I

out

5.3.5 Calibration of the Current Output (I

). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

). . . . . . . . . . . . . . . . . . . . . . . . . . 112

out

5.3.6 Monitoring the control unit readings. . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

5.3.7 Diagnostic data for the MCU900 Series control unit . . . . . . . . . . . . . . . 115

5.3.8 Model code, serial number, and software and hardware revisions. . . 116

AAppendix A: Reference Data

A.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

A.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

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A.1.2 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

A.1.3 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

A.1.4 Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

A.1.5 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

A.2 Dimensional drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

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BAppendix B: Product Certifications

B.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

B.2 European directive information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

B.3 Hazardous locations certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

B.3.1 ATEX intrinsically safe approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

B.3.2 IECEx intrinsically safe approvals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

CAppendix C: Menus and Parameters

C.1 Menus and parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

DAppendix D: Additional Features

D.1 Restoring the factory defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

D.1.1 How to restore the factory default settings . . . . . . . . . . . . . . . . . . . . . . 135

D.2 ADVANCED parameter access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

EAppendix E: Support for HART® Transmitters

E.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

E.2 Fully supported HART transmitters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

E.3 Generic support for HART transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

E.3.1 Compatibility between transmitter and control unit . . . . . . . . . . . . . . 139

E.3.2 Universal and common practice commands . . . . . . . . . . . . . . . . . . . . . 140

6Index

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Section 1 Introduction

Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1

Manual overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2

Control unit versions and software releases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2

Customer support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2

Product recycling/disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2

1.1 Safety messages

Procedures and instructions in this manual may require special precautions to ensure the safety of the personnel performing the operations. Information that raises potential safety issues is

indicated by a caution symbol ( ). The external hot surface symbol ( ) is used when a surface is hot and care must be taken to avoid possible burns. If there is a risk of an electrical shock the

( ) symbol is used. Refer to the safety messages listed at the beginning of each section before performing an operation preceded by this symbol.

Section 1: Introduction

June 2014

Failure to follow these installation guidelines could result in death or serious injury:

 The Mobrey MCU900 Series Control Unit must be installed, connected,

commissioned, operated, and maintained by suitably qualified personnel only, observing any national and local requirements that may apply

 Use the equipment only as specified in this manual. Failure to do so may impair the

protection provided by the equipment

Explosions could result in death or serious injury:

 Please review the approvals section of this reference manual for any restrictions

associated with an installation

Electrical shock could cause death or serious injury:

 If the control unit is installed in a high voltage environment and a fault condition or

installation error occurs, high voltage may be present on leads and terminals

 Use extreme caution when making contact with the leads and terminals  Make sure that power to the control unit is off while making connections

Section 1: Introduction

June 2014

1.2 Manual overview

This manual provides installation, configuration and maintenance information for the Mobrey MCU900 Series control unit.

Section 2: Control Unit Overview

Section 3: Installation

Section 4: Getting started

Section 5: Servicing and Health Checking

Appendix A: Reference Data

Appendix B: Product Certifications

Appendix C: Menus and Parameters

Appendix D: Additional Features

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Appendix E: Support for HART® Transmitters

1.3 Control unit versions and software releases

The following control unit versions are covered in this product manual:

 Mobrey MCU901 Standard Control Unit

 Mobrey MCU902 Differential Control Unit

 Mobrey MCU90F Logging Control Unit

The software release covered in this product manual is issue 4.00.00 (and above).

1.4 Customer support

For the latest customer support information, visit the Mobrey brand pages at www.emersonprocess.com, and then click on the Mobrey Service or Product Support

quick links.

1.5 Product recycling/disposal

Recycling of equipment and packaging should be taken into consideration. The product and packaging should be disposed of in accordance with local and national legislation.

Section 1: Introduction2

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Panel Mount

IP2030/RM, Rev AA

Section 2: Control Unit Overview

Section 2 Control Unit Overview

Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3

About the Mobrey MCU900 Series Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3

Control unit functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5

Control unit front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6

2.1 Safety messages

Procedures and instructions in this manual may require special precautions to ensure the safety of the personnel performing the operations. Information that raises potential safety issues is

indicated by a caution symbol ( ). The external hot surface symbol ( ) is used when a surface is hot and care must be taken to avoid possible burns. If there is a risk of an electrical shock the

( ) symbol is used. Refer to the safety messages listed at the beginning of each section before performing an operation preceded by this symbol.

June 2014

2.2 About the Mobrey MCU900 Series Control Unit

Note

 A full specification for the control unit is in Appendix A: Reference Data.

2.2.1 Wall and panel mounting options

The wall mounting option has a tough, weatherproof enclosure for internal or external installation.

The panel mounting option has a black enclosure, and is designed for control room panel or cabinet installation.

Figure 2-1. Mounting options

Section 2: Control Unit Overview

20mA

4mA

June 2014

2.2.2 4–20mA HART transmitter input options

4–20mA HART transmitter input options:

 The Mobrey MCU901 Standard control unit and the Mobrey MCU90F Logging control

unit accepts one 4–20mA or HART transmitter input

 The Mobrey MCU902 Differential control unit accepts two HART transmitter inputs

Note

 The Mobrey MCU900 Series is designed for non-hazardous (safe) area installation, but

can be connected to a transmitter installed in a hazardous area. See Appendix B: Product Certifications for the control unit certifications.

2.2.3 Control functionality

Control functionality is provided by five SPDT voltage-free contact relays in the control unit (see Figure 2-2 on page 4). The five relay outputs are fully field adjustable to perform a wide variety of control, fault indication, or alarm duties.

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For applications where the control unit functionality is linked to other external events, there are two digital input ports for accepting contact closure signals.

The isolated 4–20 mA signal output from the Current Output of the control unit is driven by a Primary / Process Value (PV) e.g. level.

Figure 2-2. Typical application using a Mobrey MCU900 Series control unit

A. Mobrey MSP Series Level Transmitter E. Pump B. Mobrey MCU900 Series Control Unit F. Transmitter Bottom Reference C. 4–20 mA signal output G. 4–20 mA and HART signal input D. Relay

Section 2: Control Unit Overview4

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2.3 Control unit functions

2.3.1 Standard functions

The Mobrey MCU900 Series control unit provides these standard functions:

 Calculation and display of the control unit Primary / Process Value (PV)

The control unit PV is typically a live transmitter reading, which can be any measured value e.g. level, temperature, or pressure.

Alternatively, the control unit PV is a volume or flow value calculated using the live transmitter level reading. The control unit is pre-programmed with standard tank shapes and flow algorithms to simplify the configuration for calculating volume or flow from the live transmitter level reading. A 20-point programmable look-up table is provided for non-standard applications.

 Output of measured variable as an isolated 4–20mA signal

The output signal is driven by the control unit Primary / Process Value (PV).

 Relay control functions

There are five freely assignable relay outputs. By default, Relay 5 is a fault relay but can be assigned to a control duty. The other relays are available to operate at user-entered PV values.

Section 2: Control Unit Overview

June 2014

The control unit is pre-programmed with popular pump control routines for wet well and sump control, along with energy saving overrides.

 Voltage-free (digital) contact closure inputs

There are two digital input ports for accepting contact closure signals to override control unit functions.

 HART transmitter interrogation and programming

Any HART transmitter can be connected. The control unit recognizes the transmitter as an “unknown instrument” but supports the Universal and Common Practice HART commands (see Appendix E: Support for HART® Transmitters).

When a Mobrey MSP Series HART transmitter is connected, the control unit recognizes the transmitter and allows full access to the transmitter’s configuration parameters. Refer to the reference manual of the transmitter for full information about programming the transmitter parameters (e.g. Transmitter Bottom Reference) using the MCU900 Series control unit or other HART-based devices.

2.3.2 Difference, sum, and product functions (on MCU902 only)

The Mobrey MCU902 Differential control unit has all the functions of the standard control unit, plus extra functions for calculating the difference, sum, or product of two separate inputs from HART transmitters.

2.3.3 Data logging functions (on MCU90F only)

The Mobrey MCU90F Logging control unit has all the functions of the standard control unit, plus a 7000 event logging function.

Section 2: Control Unit Overview

1.572 m

Esc

12:47

RL1 RL2 RL3 RL4

IN1 IN2

RL5

MCU

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2.4 Control unit front panel

This front panel fascia has an integral keypad, display, and health status LED.

Figure 2-3. Front panel fascia

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A. 4-line Back-lit LCD Display B. Status LED C. Keypad

2.4.1 Keypad

The membrane keypad has six function buttons (Ta bl e 2 - 1 ). The buttons are used for navigating a menu system and for viewing or changing application parameters.

Table 2-1. Keypad Function Buttons

Button What the button will do

When the Primary / Process Value (PV) is shown, use the red (ENTER) button to access the menu system. At other times, this button is for selecting a menu option and for confirming something.

When navigating the menu system, the UP-ARROW button is for moving upwards one line. At other times, this button is for scrolling through a list of alphanumeric characters or a list of options.

When navigating the menu system, the DOWN-ARROW button is for moving downwards one line. At other times, this button is for scrolling through a list of alphanumeric characters or a list of options.

The LEFT-ARROW button is for moving left e.g. to another character when editing a parameter value.

The RIGHT-ARROW button is for moving right e.g. to another character when editing a parameter value.

When navigating the menu system, use the ESCAPE button to return to a previous menu level and the Full PV Display. At other times, e.g. while editing, the button is for restoring a setting that is being edited.

2.4.2 Status LED

The LED is positioned just below the LCD (Figure 2-3 on page 6). It flashes once per second to indicate that the control unit and transmitters are operating correctly. The LED is constantly lit if there are operating difficulties e.g. a transmitter fault.

Section 2: Control Unit Overview6

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Mobrey MCU901

Mobrey MCU902

Mobrey MCU90F

IP2030/RM, Rev AA

2.4.3 Display

After the power-up and self-checks are completed, the Full PV Display is presented. The default Full PV Display typically features a digital clock, a measured variable with display units, and status icons. There are some display differences between control units:

 On the MCU901 and MCU902, a bar graph indicates the 4–20mA output signal.

(The MCU90F display can be changed to show the bar graph).

 On the MCU902, an extra icon on the first line and indicates if one or two HART

transmitters connected to the control unit.

 On the MCU90F, there are two totalizers displayed; one above and one below the

control unit Primary / Process Value (PV).

Figure 2-4. Typical displays of the MCU901, MCU902, and MCU90F

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June 2014

A. Program/Run App mode (locked padlock = Run App mode) H. HART Transmitter Communicating B. HART Transmitter Communicating (absent if Idle) (1=Tx1, 2=Tx2) C. Relay (RL) Status: O = De-energized,

A = Alarm, S = Sampler, T = Totalizer A = Alarm, S = Sampler, T = Totalizer D. Primary / Process Value (PV) of Control Unit J. Totalizer 1 E. Bar graph of 4–20mA Output K. Totalizer 2 (Daily Total) F. Digital Input Status: O = Open, G. HART Transmitter Allocated:

Left Vertical Bar = Tx1; Right Vertical Bar = Tx2

Section 2: Control Unit Overview

= Energized, I. Relay (RL) Status: O = De-energized,= Energized,

= Closed

Section 2: Control Unit Overview

1.572 m

12:47

Full PV Display

Large PV Display

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After a period of keypad inactivity, the display automatically changes to the Large PV Display. This shows only the control unit Primary / Process Value (PV) and Display units, but in a larger character size to facilitate easier viewing.

To restore the Full PV Display, press the red (ENTER) button.

Note

 The Large PV Display feature can be switched off using parameter P574.

See “Display configuration options” on page 102.

Figure 2-5. Large PV Display

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Section 2: Control Unit Overview8

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Section 3 Installation

Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9

Considerations before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10

Mounting the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 13

3.1 Safety messages

Procedures and instructions in this manual may require special precautions to ensure the safety of the personnel performing the operations. Information that raises potential safety issues is

indicated by a caution symbol ( ). The external hot surface symbol ( ) is used when a surface is hot and care must be taken to avoid possible burns. If there is a risk of an electrical shock the

( ) symbol is used. Refer to the safety messages listed at the beginning of each section before performing an operation preceded by this symbol.

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Failure to follow these installation guidelines could result in death or serious injury:

 The Mobrey MCU900 Series control unit must be installed, connected,

commissioned, operated, and maintained by suitably qualified personnel only, observing any national and local requirements that may apply

 Use the equipment only as specified in this manual. Failure to do so may impair the

protection provided by the equipment

Explosions could result in death or serious injury:

 Please review the approvals section of this reference manual for any restrictions

associated with an installation

Electrical shock could cause death or serious injury:

 If the control unit is installed in a high voltage environment and a fault condition or

installation error occurs, high voltage may be present on leads and terminals

 Use extreme caution when making contact with the leads and terminals

 Make sure that power to the control unit is off while making connections

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June 2014

3.2 Considerations before installation

Note

The Mobrey MCU900 Series is designed for non-hazardous (safe) area installation, but can power and take input from an intrinsically safe transmitter installed in a hazardous area. See Appendix B: Product Certifications for the control unit certifications.

3.2.1 Safety considerations

Guidelines

1. This product is classified type A in accordance with European EMC directive 2004/108/EC. To ensure electro-magnetic compatibility, in any member country, this product should not be installed in a residential area.

2. Do not mount the control unit on a structure that is subject to vibration, or in a position where damage may be caused by impact, thermal stress or liquid ingress.

3. The fuse must only be replaced with the type specified (see page 108 for procedure).

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IP2030/RM, Rev AA

4. If the equipment is likely to come into contact with aggressive substances, it is the responsibility of the user to take suitable precautions that prevent it from being adversely affected, thus ensuring that the type of protection is not compromised.

Aggressive Substances - e.g. acidic liquids or gases that may attack metals or solvents that may affect polymeric materials.

Suitable Precautions - e.g. regular checks as part of routine inspections or establishing from the material's data sheet that it is resistant to specific chemicals.

5. The user should not repair this equipment.

6. Terminal 30 (intrinsically safe earth/ground) of the control unit must be connected to a high integrity earth/ground point.

7. A mains powered Control Unit must not be connected to a supply exceeding 250 V r.m.s. or dc, or to apparatus containing a source of voltage exceeding 250 V r.m.s. or dc.

8. A direct current (dc) powered control unit must not be connected to a supply exceeding 30 Vdc or apparatus containing a source of voltage exceeding 30 Vdc.

9. The intrinsically safe outputs of the control unit may be connected to certified equipment used in a hazardous area. Refer to Appendix B: Product Certifications for details of relevant certifications.

10. Cable between the MCU900 Series control unit and a transmitter should be shielded, twisted-pair with the shield connected to terminal 3 (marked with earth symbol) on the MCU900 Series control unit. The shield should be left unconnected at the transmitter unless there is a terminal specifically provided for this purpose.

11. Cable runs should be separate from any high voltage or mains cables to avoid crosstalk or interference.

12. Refer to the technical data in Appendix A: Reference Data.

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3.3 Mounting the control unit

3.3.1 Mounting the wall-mount version

Guidelines

 This housing is rated IP65. It is suitable for mounting outside, but this should be above

any flood level, away from any overflow path, and away from direct sunlight

 Do not mount the control unit on a structure that is subject to vibration, or in a position

where damage may be caused by impact, thermal stress, or liquid ingress

 The mass of the mains powered unit is 1.4 kg, and the DC powered unit is 1.0 kg.

To conform with safety requirements, the wall on which the unit is mounted should be capable of supporting four times this weight

 It is not necessary, or advisable, to remove the upper part of the unit housing that

contains the LCD and keypad. There are no user serviceable parts inside. The unit must not be modified in any way

Procedure

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June 2014

1. Mount the unit on a suitable wall or structure using the fixing points shown on

Figure A-1 on page 121.

2. Make the electrical connections (see “Making electrical connections on wall-mount units” on page 13).

3.3.2 Mounting the panel version

Guidelines

 This housing is rated IP40 and is designed for panel mounting in a weatherproof

environment. An optional fascia overlay hood is available which improves the IP rating to IP65 – see Product Data Sheet IP2031 on the Mobrey brand pages at www.emersonprocess.com for ordering information

 Do not mount the control unit on a structure that is subject to vibration, or in a position

where damage may be caused by impact, thermal stress, or liquid ingress

 Where three of more units are fitted in the same cabinet or panel, ensure that there is

adequate air circulation to aid cooling. It is recommended that an air circulation fan be fitted

 The unit requires at least 6.5 in. (165 mm) clearance behind the mounting panel to

avoid cable fouling

 After mounting the control unit, all wiring is made at the rear of the unit using the two

part terminal blocks provided. (A pre-wired data download socket suitable for front panel mounting is provided on the MCU90F)

Section 3: Installation

 Mount the control unit on a panel with thickness 1.5 to 10 mm, ensuring the panel is

strong enough to support the 2.6 lb. (1.2 kg) weight of the unit

 Ensuring there is enough clearance behind the chosen position in the panel (6.5 in [165

mm] minimum), cut a horizontal slot 5.43 in. (138 mm) long by 2.68 in. (68 mm) high in the panel and remove any rough edges

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Procedure

1. Unpack the two screw clips provided.

2. Identify the moulded lugs (protrusions) in the recesses on each side of the control unit.

3. Holding the screwdriver-slot-end of the threaded spindle of one of the screw clamps

4. Remove the screw clamps from both of the screw clamp frames.

5. Slide the control unit into the panel, ensuring that the panel seal provided is in place

6. Re-fit the screw clamps, one on each side, and tighten with a screwdriver to clamp the

Reference Manual

IP2030/RM, Rev AA

(Ignore the recesses on the top and bottom of the unit).

and looking at the control unit rear, engage a screw clamp frame onto the control unit side (see Figure 3-1 on page 12) and see how the four steel lugs (protrusions) of the screw clamp frame engage with the moulded lugs of the unit. Gently pull the screw clamp for the lugs to engage with each other.

behind the front panel bezel.

control unit against the panel.

7. For electrical connections, see “Making electrical connections on panel-mount units” on page 15.

Figure 3-1. The fitted screw clamp

A. Screw Clamp Frame B. Front Panel Bezel C. Screw Clamp With Threaded Spindle

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3.4 Electrical installation

It is the responsibility of the installer to:

 Refer to safety data and electrical specifications in Appendix A: Reference Data  Refer to the certifications and control drawings in Appendix B: Product Certifications  Check and obtain any work permits required before applying power to the unit  Observe all local regulations and approval requirements  Ensure the wiring is suitable for the load current  Ensure the wiring insulation is suitable for the voltage, temperature, and environment

of the installation

 Ensure suitable cable glands or conduit connections are used when wiring to the

control unit to maintain enclosure integrity

Never remove or modify the mechanical barriers separating the terminal area from the main enclosure and separating the transmitter input terminals from other terminals.

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3.4.1 Making electrical connections on wall-mount units

All field wiring connections are accessible by removing the lower terminal cover, which is secured by two screws on the wall-mount control unit.

The cabling between the Mobrey MCU900 Series control unit and a transmitter should be a screened (shielded), twisted-pair type with the cable screen (shield) connected to terminal 3 (marked with earth/ground symbol) on the Mobrey MCU900 Series control unit. The cable screen (shield) should be left unconnected at the transmitter end unless there is a terminal specifically provided for this purpose.

Cable runs should be separate from any high voltage or mains cables to avoid crosstalk or interference.

Figure 3.4.2 on page 15 shows the layout of the control unit terminals. All terminal blocks are



suitable for wires 14 to 26 AWG (0,5 to 1,5 mm



for wires 10 AWG (2,5 mm

). Insulation should be stripped back 1/4 in. (7 mm).

Transmitter connections are made on the left side of the terminals enclosure. The intrinsically safe earth/ground (terminal 30) must be connected to a high integrity earth/ground point if the transmitter connected to terminals 1 and 2 is sited in a hazardous area.

Note

 Use only 167 F (75 C) copper conductors for field wiring.

), except the mains terminals which are suitable

Section 3: Installation

Note

 In intrinsically safe systems, apparatus connected to the MCU900 Series control unit

must not be supplied from a voltage greater than 250V r.m.s. or 250 Vdc.

Section 3: Installation

10 11 12

0VIN2IN1

789

24V

out

456

RX TX

1316141715

NO COM NC

NCCOMNO

25 26 27

COM

1922202321

NO COM NC

NCCOMNO

24V

2 3

FUSE

200mA (T)

29 30

IS EARTH

June 2014

Figure 3-2. Connection terminals layout (for mains-powered wall-mount unit)

(The direct current (dc) powered unit has a slightly different layout – terminals 31 and 32 replace terminals 28 and 29).

Table 3-1. Connection terminal descriptions (for wall-mount unit)

Ter mi na l Function Terminal marking

1 Loop supply 24V 2 Current input Iin 3 Cable screen Earth (Earth symbol) 4-6 RS232 RX-TX-0V 7-9 Current output 24V-Iout-0V 10-12 Digital input 1 and 2 IN1-IN2-0V 13-15 Relay 1 NO-COM-NC 16-18 Relay 2 NO-COM-NC 19-21 Relay 3 NO-COM-NC 22-24 Relay 4 NO-COM-NC 25-27 Relay 5 NO-COM-NC 28-29 30 I.S. Earth/Ground (Earth/Ground symbol) 31 32

(1) Mains-powered control unit only. (2) Direct current (dc) powered control unit only.

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(1)

(2)

Mains input L-N

Negative Positive +

Cable glands for the wall-mount unit

The five cable-entry positions are pre-drilled to accept M20 cable glands. The Mobrey MCU90F control unit has a data download socket factory pre-fitted in one of these cable-entry positions.

Two cable glands, rated IP65 and suitable for cable with outside diameter 4 to 7 mm, are supplied for use with the mains supply and transmitter cable. M20 blanking plugs are supplied for the other three cable entry positions.

All glands and blanking plugs are supplied in a plastic bag. The installer must fit these, or suitable equivalents, in place of the transit red-caps, to ensure weatherproofing of the control unit. The white sealing washers supplied with the cable glands and blanking plugs must be fitted on the outside of the enclosure under gland/blanking plug.

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Section 3: Installation

3.4.2 Making electrical connections on panel-mount units

Field wiring connections are made to the back of the panel-mount control unit using the two-part (plug/socket) terminal connectors provided. Figure 3-3 shows the rear panel layout.

Note

 The plug/socket terminal connectors on the panel mount unit are polarized (keyed)

to prevent inter-changeability and incorrect connection.

Cabling between the Mobrey MCU900 Series control unit and a transmitter should be a screened (shielded), twisted-pair type with the cable screen (shield) connected to terminal 3 (marked with earth/ground symbol) on the control unit. The cable screen (shield) should be left unconnected at the transmitter end unless there is a terminal specifically provided for this purpose. Cable runs should be separate from any high voltage or mains cables to avoid crosstalk or interference.

Connect terminal 30 (intrinsically safe earth/ground) to a high integrity earth/ground point if the transmitter connected to terminals 1 and 2 is sited in a hazardous area.

June 2014

Figure 3-3. Connection terminals layout (for mains-powered panel-mount unit)

(The direct current (dc) powered unit has a slightly different layout – terminals 31 and 32 replace terminals 28 and 29).

Table 3-2. Connection descriptions for panel mount unit

Ter mi na l Function Terminal marking

(1)

28-29 30 I.S. Earth (Earth symbol)

(2)

(1) Mains-powered control unit only. (2) Direct current (dc) powered control unit only.

Mains input L-N

Negative Positive +

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3.4.3 Power connections

When the control unit is powered by mains alternating current (ac) power, select the voltage as 115V or 230V using the voltage-selector slide switch.

When the control unit is direct current (dc) powered, ensure the supply is adequate (15 to 30 Vdc). Do not exceed 30 Vdc.

A switch or circuit breaker should be installed in close proximity to the instrument, and labelled as such. Although the Mobrey MCU900 Series control unit meets all European standards for surge immunity on power and signal lines, it is recommended that lightning suppressors are also fitted if local conditions make this advisable.

3.4.4 Earthing connections

The IP-rated Mobrey MCU900 Series control unit is double insulated and does not require a mains earth.

Do not connect terminal 30 to a mains earth. Terminal 30 is provided for use as an intrinsically safe (or functional) earth connection, which must be used when a transmitter is mounted in a hazardous area and is connected to terminals 1 and 2.

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Terminal 3 is to be used for connection of a twisted-pair cable screen (shield) when the control unit is powering the transmitter (see Figure 3-4 on page 17). This screen (shield) should be left unconnected at the transmitter end unless there is a terminal provided for this purpose.

When connected to equipment located in a hazardous area, not meeting the requirements of clause 6.3.12 (Isolation of circuits from earth or frame) in IEC 60079-11:2006 (EN 60079-11:2007), equipotential earthing must be ensured between the equipment and the intrinsically safe earth. An example of equipotential earthing is a cable with a cross-sectional

area greater than 4 mm

and a resistance of less than 1 ohm.

3.4.5 Transmitter connections and cabling

Connection of a transmitter to the control unit does not confer intrinsic safety on the transmitter. It is the responsibility of the user to ensure any transmitter installed in a hazardous area is suitable for use and certified accordingly. The installation should be in accordance with a recognized code of practice.

Check that the electrical parameters of the installed system of control unit, transmitter, any loop-powered devices, and interconnecting cable to ensure compliance with the product certificates and technical data. Particular attention must be given to the cable and the transmitter to ensure that the total capacitance and inductance limits stated in the technical data in Appendix B: Product Certifications are not exceeded.

Cable joins are allowable in cabling the transmitter, provided that the joint is made within an IP20/NEMA 3 (minimum) enclosure suitable for the environment, and that wiring withstands a test voltage of 500 V r.m.s. to earth.

The maximum length of cable permissible between the transmitter and control unit is determined by limits imposed by the intrinsic safety certificates of the instruments and control drawings.

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1 2 3

24 V

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No other outputs from the control unit must be routed through a hazardous area unless protected by an additional I.S. Barrier (not supplied).

It is the responsibility of the user to ensure that any transmitter is installed in accordance with the manufacturer’s instructions supplied with the transmitter.

Cable between the MCU900 Series control unit and a transmitter should be shielded twisted-pair with the shield connected to terminal 3 (marked with earth symbol) on the MCU900 Series control unit. The shield should be left unconnected at the transmitter unless there is a terminal specifically provided for this purpose.

Cable runs should be separate from any high voltage or mains cables to avoid crosstalk or interference. Multi-core cable may be used if the other cores carry only low voltage (24 Vdc nominal) signals and each pair of cores is individually screened (shielded).

Loop-powered transmitters must be connected to terminals 1, 2, and 3 on the control unit (see Figure 3-4).

The MCU900 Series control unit supplies 23 Vdc from a 400 Ohm source to power transmitters. Separately powered transmitters must be connected to terminals 2 and 3 (see Figure 3-5).

Figure 3-4. Loop-powered transmitter connections to MCU900 Series control unit

1 2 3

A. Control unit B. Transmitter

Figure 3-5. Self-powered transmitter connections to MCU900 Series control unit

A. Control unit B. Transmitter

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1 2 3

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3.4.6 Connecting HART transmitters to the Mobrey MCU902

The Mobrey MCU902 control unit takes the input from two HART transmitters and calculates the sum, difference, or product of the two inputs.

Note

 The transmitters must be HART compatible for the MCU902 to operate correctly.

Connection of the two transmitters to the MCU902 can be done by:

 cabling both transmitter cables wired directly into Current Input terminals on the

MCU902 (Figure 3-6), or

 using a single cable wired directly into Current Input terminals with the two

transmitters connected to this single cable via a suitable junction box (Figure 3-6).

Figure 3-6. Connecting two HART transmitters to the Mobrey MCU902

A. HART Transmitter Tx1 B. HART Transmitter Tx2 C. Junction box

For correct operation, each HART transmitter must be changed to “multi-drop” mode to allow them to communicate with the Mobrey MCU902 control unit through a common connection. Each HART transmitter must therefore have their poll address changed from the factory default address of “0” to a unique address.

The MCU902 control unit is used to achieve this address change, but requires the transmitters to be connected in a specific sequence as detailed here:

1. With the power supply turned off, connect the first HART transmitter to the Current Input terminals on the MCU902 control unit (see Figure 3-6).

2. Check the voltage-selector-switch is set for the correct voltage on the mains-powered control unit (115 or 230 Vac), and then turn the power on.

3. After applying power, the control unit searches for a HART transmitter.

A HART transmitter with the factory default polling address of 0 is found after 15 seconds. The control unit automatically changes the Transmitter Poll Address from “0” to “1” and it is designated “Tx1” (Transmitter 1) and assigned to Channel 1.

The control unit reads parameters from the HART transmitter and makes them available for local interrogation and programming within the menu system.

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Section 3: Installation

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4. When an un-configured Mobrey MSP Series Level Transmitter is being used for the first time, a prompt appears asking for the Trans mitter [1] B ottom Refe r ence.

If commissioning the system now, edit and save a new Transmitter Bottom Reference or keep the existing Transmitter Bottom Reference. After the start-up process is complete, the display appears showing a measurement e.g. liquid level or the menu system.

If the system is not to be commissioned at this time, simply switch off the power and the same prompt re-appears when switching on the power next time. The Transmitter Bottom Reference can be changed later, but it is better to get it correct now.

Note

 If the Re-connecting to Digital Transmitter message does not appear, check that the

operating mode of the control unit is set to Run App mode (see page 38) and that the Input Channel Source is set for a digital HART input (see page 48 or page 50)

5. Turn the power supply off and connect the second HART transmitter (see Figure 3-6), such that both HART transmitters are connected at the same time.

6. Turn the power supply on.

7. The MCU902 control unit searches for, and detects, the two connected HART transmitters.

After the second HART transmitter is found, the control unit automatically changes the Transmitter Poll Address from “0” to “2” and it is designated “Tx2” (Transmitter 2) and assigned to Channel 2.

The control unit reads parameters from the HART transmitter and makes them available for local interrogation and programming within the menu system.

8. When an un-configured Mobrey MSP Series Level Transmitter is being used for the first time, a prompt appears asking for the Trans mitter [2] B ottom Refe r ence.

9. The two HART transmitters are now known to the control unit, and will be remembered each time the power is switched off and on.

Section 3: Installation

Internally Powered Loop Powered

June 2014

3.4.7 Relay connections

The five voltage-free contact relays are grouped as shown in Tab l e 3 -3 . Whilst each relay is individually double-insulated, their arrangement is such that the insulation between relays in the same group is standard or ‘basic’ insulation. Care must be taken in order to avoid the risk of electric shock. It is allowed to use relays in the same group to control circuits with both mains and dc, or low voltage circuits.

Note

 The relay labels (NO-C-NC) in Ta b l e 3- 1 and Ta bl e 3 - 2 represent the relay terminals in

the de-energized state.

Table 3-3. Relay configuration groups

Wall Mount MCU900 Series control unit Panel Mount MCU900 Series control unit

Relay 1 and 2: Group 1 Relay 1, 2 and 3 : Group 1 Relay 3 and 4 : Group 2 Relay 4 and 5 : Group 2 Relay 5: Group 3

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3.4.8 Current output connections

The Current Output may be connected in internally-powered or loop-powered mode, as shown in

Figure 3-7. In loop-powered mode, an external power source is required. A minimum of 2.5 V dc

is required across terminals 7 and 8 for correct operation. The voltage must not exceed 30 Vdc.

Figure 3-7. Alternative output current configurations

24V

Load

24V

External Supply

Load

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3.4.9 Digital control voltage-free contact inputs

There are two trigger inputs, IN1 and IN2. Each input is connected as shown in Figure 3-8.

Figure 3-8. Connections for external trigger input

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External Contact Closure

or10 11

Section 3: Installation

Note B

Use the supplied mini-B nut to secure the socket to the panel.

Note A

Cut-out the hole in the panel to the dimensions shown in Figure A-2 on page 122.

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3.4.10 RS232 connections

The RS232 connections, terminals 4, 5 and 6, are for downloading logged data to a PC or a handheld device.

 Wall-mountable Mobrey MCU90F control units are supplied with a factory pre-fitted

RS232 data-download socket, which is also pre-wired to terminals 4, 5, and 6.

 The panel-mountable Mobrey MCU90F control unit is supplied with a data-download

socket ready to be fitted to a panel (see Figure 3-9 on page 22) and then wired to terminals 4, 5, and 6 on the rear of the control unit (see Figure 3-10 on page 23).

When there is data to be downloaded using Mobrey LOG-VIEW or other software, connect the RS232 data-download cable supplied with the socket (see Figure 3-11 on page 23).

Figure 3-9. Fitting the RS232 data-download socket to a panel

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A. RS232 socket with cap fitted. B. RS232 socket flying lead.

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