Emerson Millennium II Multi-Channel Transmitter M21, Millennium II Multi-Channel Transmitter M22 User Manual

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MILLENNIUM II

Multi-Channel Transmitter

User Manual

Single or Dual Channel

PartNumber:MAN-000076- RevRevAprl05

December 07, 201208

IMPORTANT INFORMATION

This manual is for informational purposes only. Although every effort has been made to ensure the correctness of the information, technical inaccuracies may occur and periodic changes may be made without notice. Net Safety Monitoring Inc., assumes no responsibility for any errors contained within this manual.

If the products or procedures are used for purposes other than as described in the manual, without receiving prior confirmation of validity or suitability, Net Safety Monitoring Inc., does not guarantee the results and assumes no obligation or liability. No part of this manual may be copied, disseminated or distributed without the express written consent of Net Safety Monitoring Inc.

Net Safety Monitoring Inc., products are carefully designed and manufactured from high quality components and can be expected to provide many years of trouble free service. Each product is thoroughly tested, inspected and calibrated prior to shipment. Failures can occur which are beyond the control of the manufacturer. Failures can be minimized by adhering to the operating and maintenance instructions herein. Where the absolute greatest of reliability is required, redundancy should be designed into the system.

WARRANTY

Net Safety Monitoring Inc warrants its electronic assemblies against defective parts and workmanship for a period of 36 months from date of purchase. No other warranties or liability, expressed or implied, will be honored by Net Safety Monitoring Inc. Contact Net Safety Monitoring Inc. or an authorized representative for details.

We welcome your input at Net Safety Monitoring. If you have any comments please contact us at the phone/ address below or visit our web site and complete our on-line customer survey: www.net-safety.com/

If further language translation for this manual is required please contact:

CONTACT INFORMATION

Net Safety Monitoring Inc

Direct: (403) 219-0688

Corporate Headquarters

Facsimile: (403) 219-0694

2721 Hopewell Place NE

E-mail: nsmsales@net-safety.com

Calgary, AB Canada T1Y 7J7

Web-site: www.net-safety.com/

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TABLE OF CONTENTS

 

IMPORTANT INFORMATION ......................................................................................................................................................

2

WARRANTY......................................................................................................................................................................................

2

CONTACT INFORMATION ...........................................................................................................................................................

2

INTRODUCTION..............................................................................................................................................................................

5

THE PRODUCT..............................................................................................................................................................................

5

TRANSMITTER/CONTROLLER..................................................................................................................................................

5

THE MANUAL...............................................................................................................................................................................

5

Special conditions of use: ...........................................................................................................................................................

5

Housing Dimensions...................................................................................................................................................................

6

SECTION 1: INSTALLATION.......................................................................................................................................................

7

1.1 UNPACK .....................................................................................................................................................................................

7

1.2 MOUNTING .................................................................................................................................................................................

7

1.2.1 Transmitter Orientation Option.........................................................................................................................................

7

1.2.2 Transmitter electronics module and Relay options ...........................................................................................................

8

1.2.3 Rotating electronics module relative to enclosure and conduit entries .............................................................................

9

SECTION 2: WIRING AND INSTALLATION ..........................................................................................................................

10

2.1 FIELD INSTALLATION ...............................................................................................................................................................

10

Guidelines.................................................................................................................................................................................

10

2.1.1 Seals.................................................................................................................................................................................

10

Guidelines.................................................................................................................................................................................

10

2.1.2 Cable choice and guidelines ............................................................................................................................................

11

2.1.3 Analog output, isolated supply, non-isolated supply and jumper configuration .............................................................

13

2.1.4 Remotely mounted sensors jumper configuration ............................................................................................................

14

2.1.5 Sensor and Transmitter terminals ...................................................................................................................................

15

2.1.6 Remote Reset ...................................................................................................................................................................

16

2.1.7 Sensor Separation/ Remote mounting of sensor ..............................................................................................................

16

2.1.8 Wiring drawings ..............................................................................................................................................................

17

2.1.9 Installation Checklist .......................................................................................................................................................

19

SECTION 3: TRANSMITTER AND FACEPLATE DESCRIPTION.......................................................................................

20

3.1 TRANSMITTER POWER UP ........................................................................................................................................................

20

3.2 DISPLAY ...................................................................................................................................................................................

20

3.3 STATUS LED ............................................................................................................................................................................

21

3.4 CURRENT LOOP MEASUREMENT (TEST JACKS) .........................................................................................................................

21

3.5 MENU BUTTONS AND ACCESS ...................................................................................................................................................

21

3.5.1 Intrusive Access ...............................................................................................................................................................

21

3.5.2 Non-Intrusive Access/Magnetic Reed switch Access .......................................................................................................

21

SECTION 4: OPERATION ...........................................................................................................................................................

22

4.1 MENU OPTIONS.........................................................................................................................................................................

22

4.2 NAVIGATING MAIN MENU .........................................................................................................................................................

22

4.2.1 Full calibration (Normal calibration) procedure ............................................................................................................

24

4.2.2 (Cont’d) Zero calibration option .....................................................................................................................................

25

4.2.3 Enable / Disable channels ...............................................................................................................................................

27

4.2.4 Viewing and setting alarm levels (points)........................................................................................................................

27

4.2.5 Setting Relay options .......................................................................................................................................................

28

4.2.6 Relay Assignment.............................................................................................................................................................

28

4.2.7 Relay Alarm Mode setting (for Oxygen sensors only) .....................................................................................................

30

 

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4.2.8 Select Display Language .................................................................................................................................................

30

4.2.9 MODBUS Setup...............................................................................................................................................................

30

4.3.0 Setup Current Date..........................................................................................................................................................

31

4.3.1 Setup Current Time..........................................................................................................................................................

31

4.3.2 View Event Log................................................................................................................................................................

32

4.3.3 Manual Reset ...................................................................................................................................................................

33

4.3.4 Self Test Relay .................................................................................................................................................................

33

4.3.5 Sensor Upper Limit (Range)............................................................................................................................................

33

4.3.6 Select Gas Type ...............................................................................................................................................................

34

4.3.7 Calibration gas value ......................................................................................................................................................

34

4.3.8 Serial Number & Firmware Version ...............................................................................................................................

34

SECTION 5: MONITORING AND OUTPUTS..........................................................................................................................

35

5.1FAULT MONITORING..................................................................................................................................................................

35

5.2 RELAYS ....................................................................................................................................................................................

35

5.3 ANALOG 4-20MA .....................................................................................................................................................................

35

Sensor Status Registers, Transmitter Status LED, Current output and Meaning .....................................................................

36

5.4 RS-485 MODBUS RTU .............................................................................................................................................................

37

5.5 HART COMMUNICATION .........................................................................................................................................................

39

SECTION 6: MAINTAINING......................................................................................................................................................

40

6.1 PERIODIC RESPONSE CHECK......................................................................................................................................................

40

6.2 TROUBLESHOOTING..................................................................................................................................................................

40

6.3 STORAGE ..................................................................................................................................................................................

41

6.4 SPARE PARTS /ACCESSORIES....................................................................................................................................................

41

6.5 HOW TO RETURN EQUIPMENT ..................................................................................................................................................

42

APPENDIX .......................................................................................................................................................................................

43

APPENDIX A: ELECTROSTATIC SENSITIVE DEVICE (ESD).............................................................................................

43

APPENDIX B: RESISTANCE TABLE .........................................................................................................................................

44

APPENDIX C: MILLENNIUM II TRANSMITTER SPECIFICATIONS ................................................................................

45

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INTRODUCTION

Building on the outstanding legacy of the Millennium Series, Net Safety’s latest innovation in this line of continuously evolving industrial transmitters and sensors, the Millennium II, pushes the boundaries of what you can expect from your detection system. Combined with state of the art “Smart” sensors, users will receive a detection system which is both versatile and reliable for fast, accurate and continuous monitoring of gases in extreme environments.

THE PRODUCT

TRANSMITTER/CONTROLLER

A Millennium II gas detection system is composed of a field mounted transmitter\controller and Millennium II series sensors which may be integrally mounted to the controller or remotely mounted as far as 2000 feet away.

The transmitter is certified for use in hazardous locations and is available as a single or dual sensor system. All operator controls including configuration and calibration can be accessed without opening the enclosure by using other communication devices and the attached magnet to actuate reed switches. If the area is non-hazardous and the enclosure (housing) is open then the operator may choose to use push-button switches and analog output test jacks on the face of the electronics module. Available outputs are: conventional 0.0 to 20mA analog, Analog/HART, electromechanical relays, solid-state relays or Modbus RTU digital.

A dual channel transmitter is available with "peak picking" functionality where there is only one analog output and this analog output follows the signal from the sensor that is responding to the highest gas concentration. This is useful in conserving analog input capacity on connected user equipment.

THE MANUAL

This manual has been designed to guide users through each procedure, ensuring that transmitters and sensors are configured, operated and maintained properly. Guidelines and warnings are included to ensure safe and proper functioning of the equipment. The manual gives the overall operational and functional features of transmitters with sensors and may not have sensor specific information. Refer to sensor manuals for information specific to each sensor including detailed calibration instructions. If you encounter any problems, see the troubleshooting section of this manual or contact factory.

Special conditions of use:

M2a-b-c, Millennium II Transmitter with enclosure:

1.In order to maintain the performance of the system, the sensor to which this instrument is connected shall also comply with the requirements of EN 61779-1 and EN 61779-4

TX-M2a-b, Millennium II Transmitter Electronics module only (w/o enclosure):

1.If the Millennium II Transmitter is installed as Category 3 equipment, then it shall be installed in an Enclosure which maintains an ingress protection rating of IP54 and meets the enclosure requirements of EN 60079-0.

2.In order to maintain the performance of the system, the sensor to which the instrument is connected shall also comply with requirements of EN 61779-1 and EN 61779-4

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Enclosure Dimensions

The Millennium II Transmitter enclosure is available in Aluminum (AL6061) and Stainless Steel (SS316). Dimensions are in inches and millimeters.

Figure 1: Transmitter Enclosure Dimensional Drawing

* M20, ½” NPT, & ½” BSP threads also available

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SECTION 1: Installation

1.1 Unpack

Carefully remove all components from the packaging and check them against the enclosed packing list. Inspect all components for obvious damage such as broken or loose parts. If you find any components missing or damaged, notify the representative or Net Safety Monitoring, immediately.

1.2 Mounting

Ensure transmitter and sensor are securely mounted, taking into consideration all requirements. Sensors may be installed directly to transmitters or remotely using a Certified Net Safety junction box. See Figure 11 when mounting sensor remotely.

1.2.1 Transmitter Orientation Option

Depending on the installation and mounting requirements, the transmitter enclosure (housing) may be mounted in different orientations as seen in Figure 2. To accommodate the different mounting orientations, the electronics module can be rotated inside the transmitter enclosure. See Section ‘1.2.3 Rotating electronics module relative to enclosure and conduit entries’ and Figure 4.

NOTE: Ensure the orientation allows proper wiring and adequate wire length inside the transmitter enclosure.

Figure 2: Different enclosure orientations

When determining suitable enclosure orientation for specific application, installers should observe all local regulations and guidelines for mounting enclosures.

* M20, ½” NPT, & ½” BSP threads also available

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Emerson Millennium II Multi-Channel Transmitter M21, Millennium II Multi-Channel Transmitter M22 User Manual

1.2.2 Transmitter electronics module and Relay options

The transmitter electronics module may be equipped with 4 electromechanical relays or 4 solid-state relays which are mounted to the main terminal board via plastic standoffs. Relay boards are field replaceable by simply unlocking the plastic standoffs with a small flat head screw driver. Remove relay board after unlocking standoffs, insert the replacement relay board, and then lock the plastic standoff with the screw driver. See Figure 3 for relay board description.

Warning Before wiring or replacement of relay boards, ensure that the power to transmitter is switched off. Do not open the transmitter enclosure in a classified area.

Warning Avoid touching electronic components, as they are susceptible to electrostatic discharge (ESD).

Refer to Appendix A, “Electrostatic Sensitive Device (ESD)”.

Figure 3: Board assembly diagram

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1.2.3 Rotating electronics module relative to enclosure and conduit entries

The electronics module consists of the relay board and faceplate (Display/CPU assembly) with main terminal board. To rotate the electronics module, follow these instructions:

1.Turn off power to transmitter and ensure area is de-classified.

2.Remove the enclosure cover.

3.Unscrew both the locking knobs and free from two metal standoffs.

4.Lift transmitter faceplate from enclosure.

5.Disconnect existing wiring.

6.Unscrew the two metal standoffs using a ¼”hex tool.

7.Carefully remove the electronics module.

8.Rotate the electronics module to desired position.

9.Align metal standoffs with the mounting holes of the electronics module and enclosure base.

10.Insert metal standoffs in the appropriate mounting holes.

11.Tighten metal standoffs with ¼” hex tool to secure electronics module.

12.Reconnect wiring.

13.Replace faceplate, then fit and hand tighten locking knobs to metal standoffs by turning clockwise.

14.Replace enclosure cover.

Warning Before wiring or rotating electronics, ensure that the power to transmitter is switched off. Do not open the transmitter enclosure in a classified area.

Warning Avoid touching electronic components, as they are susceptible to electrostatic discharge (ESD).

Refer to Appendix A, “Electrostatic Sensitive Device (ESD)”.

Figure 4: Rotating Electronics module

Note: To access enclosure grounding screw, remove the electronics module by following steps 1-7 above.

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SECTION 2: Wiring and installation

2.1 Field Installation

Warning Wiring codes and regulations may vary. ATEX requires that supply connection wiring must be rated at least 5°C above the maximum ambient temperature of 85°C. Wiring must comply with all applicable regulations relating to the installation of electrical equipment in a hazardous area and is the responsibility of the installer. If in doubt, consult qualified personnel before wiring the system.

Warning Do not open the transmitter enclosure in a classified area (Do not open when an explosive atmosphere may be present).

Guidelines

The safety ground connection of the transmitter is a Green screw found in the enclosure. See Figure 4 for Ground screw location. Note: The electronics module has to be removed to access Ground screw. Follow steps 1-7 under Section ‘1.2.3 Rotating electronics module relative to enclosure and conduit entries’, when removing electronics module.

If the 4-20mA signal is not used, connect a jumper between the 4 – 20mA terminal and the Common terminal to allow analog current levels to be monitored at the Test Jacks on the faceplate.

The use of shielded cable is highly recommended for signal, input, output and power wires. Refer to Section ‘2.1.2 Cable choice and guidelines’ for recommended cable to help eliminate interference caused by extraneous electrical or electromagnetic ‘noise’. To meet IEC 61000-1 and IEC 61000-4 EMI requirements, follow the recommendations listed under Section ‘2.1.2 Cable choice and guidelines’.

In applications where wiring is installed in conduit, conduit must not be used for wiring to any other electrical equipment.

For effective communication, Net Safety limits sensor separation to 2000 feet using 16AWG wires.

Modbus RS-485 connection 2-wire mode, multipoint serial line available. Up to 247 addresses allowed.

When developing a RS-485 chain of devices, the last device in the chain requires an end of line termination resistor (120 Ohms).

Transmitter connector terminals accommodate wire from 14 to 20 AWG wires.

2.1.1 Seals

Warning The use of conduit wiring seals is recommended to protect the system against water ingression, and equipment should be installed according to local electrical codes. Seals are especially recommended for installations that use high-pressure or steam cleaning devices in proximity to the transmitter and/or sensor. The cementing material used on the Millennium II sensors is suitable for an operating temperature range of

(-55°C to +85 °C).

Guidelines

It is recommended that explosion-proof drains and conduit breathers be used. In some applications, alternate changes in temperature and barometric pressure can cause ‘breathing’ which allows moist air to enter and circulate inside the conduit. Joints in the conduit system are seldom tight enough to prevent this ‘breathing’.

Threaded connections on the enclosure between the enclosure and conduit pipe need to be sealed with thread tape, such as Teflon tape, or something similar.

Hydrophobic filters (IPF-001) may be used to protect sensors from water.

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It is the responsibility of the installer to install conduit seals where necessary, and to design conduit runs to ensure that condensation does not accumulate and collect inside the enclosure.

2.1.2 Cable choice and guidelines

Radio Frequency Interference (RFI) can be caused by nearby electrical devices (transformers, high voltage equipment) as well as handheld communications devices/radios, which when activated, may impede the proper functioning of the transmitter and sensor. Selecting the right instrumentation cable and making proper grounding connections within the junction box will reduce or eliminate interference. Visible symptoms of Radio Frequency Interference (RFI) include inconsistent, incorrect and erratic LEL and PPM readings.

Important Wiring Guidelines

Fire and gas detection instruments are an important part of a safety alarm and shutdown system. The system is composed of:

detection instruments

customer connected equipment

wiring

Net Safety designs and manufactures its detection equipment under rigid quality control management systems and makes every effort to design for the harshest of industrial environments. The other components of the system – the customer-connected equipment and wiring – are also important contributors to the overall quality and performance of the safety system.

It is important to implement wiring that ensures the reliability and integrity of the safety system. Field wiring practices and the choice of cable type specified vary from project to project. Poor practices and choices are often found to be the source of unwanted system disruptions. Radio Frequency Interference (RFI) and Electro-Magnetic Interference (EMI) are usually very powerful disruptive forces in industrial facilities and these forces act upon the system through the wiring.

Follow the wiring specifications and guidelines in this manual carefully. The cable used should be a very high quality instrument grade, certified for the application conditions, consisting of a rugged protective outer jacket, an overall electrical shield of fine braided copper or metallic foil, and internal pairs or triads of foil shielded copper wire of suitable gauge for the power conducted over the specified length.

The shields must be electrically continuous from the instrument junction box through other junction boxes and finally to the connected equipment. The shield must be connected to a suitable ground sink as specified in the instrument manual in order to protect the system from electrical disturbances.

Recommended cable and guidelines

The type of cable and shielding practices are especially important when sensor is separated from transmitter via junction box. Net Safety recommends using CSA armored instrumentation cable (ACIC 2PR 16AWG, 300V, ISOS, PVC) when rigid (steel) conduit is not used. See Figure 5. This cable should be used between the PLC/PANEL/DCS and the Millennium II Transmitter, as well as between the Millennium II Transmitter and junction box.

Additional notes:

In general, communication cables and power cables should not run in parallel for any significant length, and should not be carried in the same cable tray. Through inductance, high currents in power cables can induce significant ‘noise’ in communication cables running parallel alongside power cables.

See cable preparation procedure on next page.

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Armored Cable preparation procedure:

1.Prepare the armored instrument cable as illustrated in Figure 5 and follow all assembly and/or preparation instructions provided by the cable and/or cable gland manufacturer.

2.Install cable gland and reducer onto the cable.

3.Ensure four (4) inches of wire length is available for connecting to terminals inside the junction box.

4.Use a small flat head screw driver when connecting wires to connector terminals. See Figure 6.

5.Connect sensor wires to the appropriate terminals. See Figure 5C, Figure 9, Figure 12 and Figure 13.

Figure 5: Cable preparation

A: Drawing showing of cable without gland

B. Picture of cable showing gland and insulation

Hazloc cable gland

4 Inches

 

 

Net Safety

Junction Box

Millennium II

Sensor

Shield wire from flexible Armored cable and sensor ground wire (Green wire) connected to Earth grounding screw in junction box

C. Picture of cable wired to junction box and sensor

Shield wires from each twisted pair connected to “GND” (Earth Ground) on terminal block.

Cable gland &

Armored cable

¾” NPT stopping plug.

Note: If required, use cable glands which have been approved for hazardous locations.

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Warning Before wiring, ensure that power to transmitter is switched off.

When connecting cable wires, use a small screwdriver to gently press down and hold the spring connector open. Insert the appropriate wire into the open connector hole, releasing the screwdriver to secure the wire. See Figure 6.

Figure 6: Connecting wires

Warning Avoid touching electronic components, as they are susceptible to electrostatic discharge (ESD).

Refer to Appendix A, “Electrostatic Sensitive Device (ESD)”.

2.1.3 Analog output, isolated supply, non-isolated supply and jumper configuration

The analog output may be powered from the main instrument power supply or a separate, independent power supply in which case an isolated wiring configuration is necessary.

To set a Non-isolated or Isolated current output, simply move the Jumpers/shorting jacks (JP3 and JP4) to either the Non-isolated or Isolated current position. For Non-isolated current output, ensure pins 3 & 2 at JP3 & JP4 location on the main terminal board are jumpered (shorted). Factory standard models ship with jumpers at JP3 & JP4 in the Non-isolated current output position (default position).

For Isolated current output, pins 1 & 2 at JP3 & JP4 should be jumpered (shorted). Note that JP3 is for configuring channel 1 and JP4 is for configuring channel 2. Jumpers and pins are located next to the Power and 4- 20 output terminals on the main terminal board. See Figure 7, also Figure 12 & Figure 13 for reference.

Figure 7: NonIsolated and Isolated current jumpers

Warning Always ensure that JP3 and JP4 jumpers are in the correct position depending on the current output configuration chosen.

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2.1.4 Remotely mounted sensors jumper configuration

Sensor separation from the transmitter may extend up to 2000 feet in which case a junction box is required.

When mounting sensor remotely (separating sensor from transmitter), Jumpers JP1 and JP2 should be installed over the pins. Jumpers and pins are located on the main terminal board near the sensor terminals. JP1 is for channel 1 and JP2 is for channel 2. Refer to Figure 8.

Figure 8: Separation Jumpers positions

Warning When separating sensor and transmitter, install JP1 and JP2 over pins.

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2.1.5 Sensor and Transmitter terminals

Warning Before wiring, ensure power to the unit is switched off. Connect the sensor wires to the sensor terminals of the transmitter and connect the transmitter’s power and output terminals to the wiring leading to the Power source/panel. Refer to the configuration tables below for sensor as well as transmitter power and output terminal designations.

Table 1: Sensor and Transmitter Terminals

 

Sensor Terminals

 

 

 

 

 

Sensor

 

Transmitter Sensor Board

 

Wires

 

Terminal designation

 

 

 

 

 

 

 

 

White

 

+Vdc(from transmitter)

 

Red

 

SigA

 

Blue

 

SigB

 

Black

 

Com

 

Green

 

Earth Ground

 

Transmitter Power Terminals

 

 

Transmitter terminal

Function

designation

 

RST

Remote Reset

+Vdc(10.5-32)

Power(+)

COM

Power(-)

4-20(CH1)

Current loop output

ISO(CH1)

+Vdc isolated 4-20 power

4-20(CH2)

Current loop output

ISO(CH2)

+Vdc isolated 4-20 power

Figure 9: Sensor wiring and terminal connections

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