Mercoid 3200G Operating Manual

Bulletin P-3200

Series 3200 Explosion-Proof Smart Pressure Transmitter

Specifications - Installation and Operating Instructions

DWYER INSTRUMENTS, INC.

P.O. BOX 373 • MICHIGAN CITY, INDIANA 46360, U.S.A. Fax: [phone] e-mail: [e-mail]

Phone: [phone] www.dwyer-inst.com

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
.3 Storage

2

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 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 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
.9 Calibration

5

Chapter 6. Maintenance

6.1 Overview

6.2 Safety Messages

6.3 Hardware Diagnosis

6.4 Hardware Maintenance

Appendix I

3200 Smart Pressure Transmitter LCD Display Code

HART®is a registered Trademark of Hart Communication Foundation

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

Page 1

Chapter 1 Introduction

The 3200 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 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

issing from this manual, please inform Dwyer Instruments, Inc.

m

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 3200 Smart Pressure

Transmitter. The Chapters are organized as follows.

Chapter 2 Handling Cautions

Chapter 2 provides instructions on commissioning and operating
Model 3200 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 3200 Smart
Pressure Transmitters.

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 3200 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 3200 is enabled with HART
HHT (HART
various variables in host are able to be changed, configured and
calibrated by users. The HART

upply and transmitter requires a 250~ 550 Ohm resistance.

s

1.3 Software Compatibility

The Mercoid
at the factory. The following functions can be configured using a HHT
(HART

®

Communicator) or PC Configurator. The transmitter’s

®

®

Smart Pressure Transmitter's software is implemented

®

Communicator).

®

communication with Host,

Communication between DC power

Function Supports

Function

ZERO/SPAN Button

PC/PDA

HART HHT

Rev. 58

ZERO/SPAN
ZERO TRIM
ZERO Adj
Units set
Range set
Dampening set
LCD Decimal set

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●
∆

● : Supported.
∆ : Supported but update required

Chapter 4 Installation

Chapter 4 contains mechanical, environment consideration and
electrical installation instructions for the Model 3200 Smart Pressure
Transmitters.

Chapter 5 On-line Operation

Chapter 5 describes how to configure the parameters of the Model
3200 Smart Pressure Transmitter. See the following list for the
details.

1. Regulations of 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

Chapter 2 Handling Cautions

This chapter consists of cautions for transmitter handling, storage,
installation, insulation and explosion structure, etc.

Step

Job

1

Unpacking

2

Model and
S

3

Storage

4

Calibration

5

Installation
Locations

6

Mechanical
Considerations

7

Electrical
Considerations

8

Mounting and
Installation

9

Calibration
on Spot

11

Operation

pecifications

Job Details

- Unpack transmitter packing

- Make sure the transmitter nameplate matches the model number on the PO

- In a dry, non-vibration and non-impact area

- Ambient temperature around 77°F (25°C) and 65% relative humidity

- Configuration of the Range, Zero/Span, Unit, Tag, Dampening Time, Transfer
Function, DA Trim and other parameters

- Where ambient temperature are consistant

- Exposure to chemical corrosion, etc.

- Where shock and vibration are minimal

- Where the area classification does not exceed the exposion-proof rating

- Where maintenance is easy
Where transmitter can be handled easily

-

- Be cautious of process connections leaking

- 24 VDC
(Power Supply is 11.9 Vdc – 45 Vdc)

- For HART

®

communication, total resistance on transmitter terminal loop

should between 250 – 550 Ohm

- When mounting the transmitter, an appropriate bracket should be used

- The transmitter should be mounted securely to prevent swing

- Sensor Zero Trim should be done after ten seconds after the differential
pressure stabilizes

- Make sure that PV value is zero and current is 4 mA

- Make sure the transmitter operates properly

Instrument

- HHT

-Pressure Source

- Galvanometer
(Engineering)

(Engineering)

(Engineering)

(Mounting and Installation)

HHT or
Zero/Span button

Eye or HHT

Page 3

2.1 Unpacking

When moving the transmitter to the installation site, keep it in the
original packaging. Unpack the transmitter at the installation site to
avoid damage on the way.

2.2 Models and Specifications Check

The model number and specifications are indicated on the
nameplate. Please check the specification and model number.

2.3 Storage

The following precautions must be observed when storing the

nstrument, especially for a long period.

i

1. Select a storage area that meets the following conditions:

- is not exposed to rain or water.

- minimal vibration and shock.

- stored at normal temperature and humidity
(approx. 77°F (25°C), 65% RH).

The ambient temperature and relative humidity ratings are:

Ambient Temperature: -40 to 185°F (-40 to 85°C)

(without LCD module)

-22 to 176°F (-30 to 80°C)

(with LCD module)
General Use: -4 to 140°F (-20 to 60°C)
Relative Humidity: 5% ~ 98% RH at 104°F (40°C)

2. When storing the transmitter, repack it the way it was delivered
from the factory.

2.5 Calibration on Spot after Installation

1. Sensor Zero Trim should be done after transmitter is installed,
because the zero point is not configured for mounting status.

2. When calibrating the Sensor Zero Trim apply a pressure of zero in
advance, Sensor Zero Trim the sensor when the pressure is
sufficiently stabilized (after approximately 10 seconds).

3. Sensor Zero Trimming can also be done with the Zero/Span
button or a HHT (HART

®

Communicator), PC or PDA configurator.

4. Refer to On-line Operation for configuring other parameters.

2.6 Pressure Connections

WARNING

• Never loosen or tighten as it may cause dangerous spouting of process fluid. If the

process fluid is toxic or otherwise harmful, take appropriate care to avoid contact or
inhalation of vapors even after disconnecting the instrument from process line for

aintenance.

m

nstrument installed in the process under pressure.

I

The following precautions must be observed in order to safely
operate the transmitter under pressure.

1. Never apply a pressure higher than the specified maximum
working pressure.

2. Confirm the option pressure of transmitter. It is necessary to use
standardized and quality-approved parts.

3. There should be isolation valves in case of leakage.

2.7 Waterproofing Cable Conduit Connections

Apply a non-hardening sealant (silicone or tape, etc.) to the threads
to waterproof the transmitter cable conduit connections.

3. If storing a used transmitter, thoroughly clean the diaphragm
surfaces, so that no media remains. Make sure the transmitter
assemblies are securely mounted before storing.

2.4 Selecting Installation Locations

The transmitter is designed to withstand severe environmental
conditions. However, to ensure stable and accurate operation, the
following precautions must be observed when selecting an
installation location.

1. Ambient Temperature
Avoid locations subject to wide temperature variations or a
significant temperature gradient. If the location is exposed to
radiant heat from plant equipment, provide adequate insulation or
ventilation.

2. Ambient Atmosphere
Avoid installing the transmitter in a corrosive atmosphere. If the
transmitter must be installed in a corrosive atmosphere, there
must be adequate ventilation. Precautions must be put into place
to prevent intrusion or stagnation of rainwater in conduits.

3. Shock and Vibration
Select an installation site with minimal shock and vibration
(although the transmitter is designed to be relatively resistant to
shock and vibration).

4. Installation of Explosion-Proof Transmitters
Explosion-Proof transmitters can be installed in hazardous
areas according to the gas types for which they are certified.

2.8 Restrictions on Use of Radio Transceivers

WARNING

transmitter’s external wiring, the transmitter may be affected by high frequency
noise pickup. To test for such effects, bring the transceiver in slowly from a distance
of several feet from the transmitter, and observe the measurement loop for noise
affects. Always use the transceiver outside the area affected by noise.

Although the transmitter has been designed to resist high
frequency electrical noise, if a radio transceiver is used near the

5. Select a place where transmitter can be maintenanced easily.

Page 4

2.9 Insulation Resistance Test and Dielectric Strength Test

Since the transmitter has undergone insulation resistance and
dielectric strength tests at the factory, normally these tests are not
required. However, if required, observe the following precautions in
the test procedures.

1. Do not perform such tests more frequently than necessary. Even
test voltages, that do not cause visible damage to the insulation,
may degrade the insulation and reduce safety margins.

2. Never apply a voltage exceeding 500VDC for the insulation
resistance test, or a voltage exceeding 500VAC for the dielectric

trength test.

s

3. Before conducting these tests, disconnect all signal lines from the
transmitter terminals. Perform the tests using the following
procedure.

2. Operating Temperature : -20°C ≤ T

3. T6 for process ≤ 85°C;

4. T5 for process ≤ 100°C;

5. T4 for process ≤ 130°C;

NOTICE

Electrical Data

1. Supply Voltage : 42 Vdc Max

2. Output Signal : 4 to 20 mA + HART

NOTICE

NOTICE

Electrical Connection : 1/2˝-14 NPT Female

200 ATEX Certification is according to the

3
below standards

EN 60079-0 : 2006
EN 60079-1 : 2007

amb

≤ +60°C

Insulation Resistance test

1. Short-circuit the + and - SUPPLY terminals in the terminal

box.

2. Turn OFF the insulation tester. Then connect the insulation

tester plus (+) lead wire to the shorted SUPPLY terminals and
the minus (-) lead wire to the grounding terminal.

3. Turn ON the insulation tester power and measure the insulation

resistance. The voltage should be applied briefly to verify that
insulation resistance is at least 20MΩ.

4. After completing the test and being very careful not to touch

exposed conductors. Disconnect the insulation tester and
connect a 100kW resistor between the grounding terminal and
the short-circuiting SUPPLY terminals. Leave this resistor
connected at least three seconds to discharge any static
potential. Do not touch the terminal while it is discharging.

Dielectric Strength Test

1. Short-circuit the + and - SUPPLY terminals in the terminal

box.

2. Turn off the dielectric strength tester. Then connect the tester

between the shorted SUPPLY terminal and the grounding

terminal. Be sure to connect the grounding lead of the dielectric

strength tester to the ground terminal.

3. Set the current limit on the dielectric strength tester to 10mA,

then turn on the power and gradually increase the tester
voltage from '0' to the specified voltage.

4. When the specified voltage is reached, hold it for one minute.

5. After completing this test, slowly decrease the voltage to avoid

any voltage surges.

2.10 Explosion-Proof Rating

NOTICE

Installation

1. All wiring shall comply with local installation requirement.

2. The cable glands and blanking elements shall be of a certified
flameproof type, suitable for the condition of use and correctly
installed. Also those devices should be endured at the 130°C.

3. Housing Ground must be followed to “local electrical codes”. The
most efficient ground procedure is to connect directly to the earth
as least impedance.

1. How to Housing Ground:
A. Internal Ground Connection:

Internal ground connection screw is located in terminal in
housing; the screw can be identified as ground sign.

B. External Ground Assembly:

This is located in the right side of housing and identified as
ground sign. (Grounding with a cable lug)

2. When use tubing, stopping boxes must be connected with the wall
of housing directly.

3. Tubing is installed a minimum of 5 threads.

4. Sensor is to be threaded a minimum of 7 threads and prevented
from turing by tightening the housing rotation set screw.

5. Do not disassemble flameproof Joints but in an unavoidable case
to disassemble it or need the specification of flameproof Joints,
contact the manufacturer before doing.

NOTICE

WARNING

Operation

DO NOT OPEN WHEN AN EXPLOSIVE
ATMOSPHERE MAY BE PRESENT.

1. Take care not to generate mechanical spark when access to the
instrument and peripheral devices in hazardous location.

2-10-1. FM Certification

HAZARDOUS LOCATION ELECTRICAL EQUIPMENT

Equipment Rating : Explosion-Proof for use in Class I, Division 1,
Groups A, B, C and D;
Dust-Ignition-Proof for Class II/III, Division 1, Groups E, F and G;
Nonincensive for use in Class I, Division 2, Groups A, B, C and D;
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 (NEMA Type
4X/IP67).

2.10.2 DEKRA/ATEX Certification

ATEX Certification number : DEKRA 11ATEX0192X
CE 0344 II 2 G

NOTICE

Model 3200 for potentially explosive
atmosphere

1. Ex d IIC T6...T4

NOTICE

authorized representative of Dwyer/Mercoid is prohobited and will void KEMA/ATEX
explosion-proof/flame-proof.

Maintenance and Repair

The instrument modification or parts replacement by other than

2.11 EMC Conformity Standards

EMI (Emission): EN55011

EMS (Immunity): EN50082-2

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

®

3200 transmitters.

Chapter 3 Transmitter Functions

3.1 Overview

This chapter contains information on operating the Model 3200.
Tasks that should be performed on the bench prior to installation are
explained in this chapter.

Page 5