Rosemount Millennium Air Operating Manual
Net Safety™ Millennium
Air Particle Monitor (APM) Oil Mist Detector
Reference Manual
00809-0100-4077, Rev AB
May 2018
Important instructions
Because these products are sophisticated technical instruments, it is important that the owner and operation personnel must
strictly adhere both to the information printed on the product nameplate and to all instructions provided in this manual prior to
installation, operation, and maintenance.
WARNING!
Installing, operating, or maintaining this product improperly could lead to serious injury or death from explosion or exposure to
dangerous substances. Comply with all information on the product, in this manual, and in any local and national codes that apply to
the product. Do not allow untrained personnel to work with this product.
The information in this document has been carefully checked and is believed to be entirely reliable with all of the necessary
information included.
WARNING!
All individuals who have or will have responsiblity for using, maintaining, or servicing the product must read this manual carefully.
CAUTION!
EQUIPMENT DAMAGE
The detector is not field repairable due to the meticulous alignment and calibration of the sensors and the respective circuits.
Warranty
1. Limited Warranty . Subject to the limitations contained in Section 2 (Limitation of Remedy and Liability) herein, Seller
warrants that (a) the licensed firmware embodied in the Goods will execute the programming instructions provided by
Seller; (b) that the Goods manufactured by Seller will be free from defects in materials or workmanship under normal use
and care; and (c) Services will be performed by trained personnel using proper equipment and instrumentation for the
particular Service provided. The foregoing warranties will apply until the expiration of the applicable warranty period.
Sensors and detectors are warranted against defective parts and workmanship for 24 months from the date of purchase and
other electronic assemblies for 36 months from the date of purchase. Products purchased by Seller from a third party for
resale to Buyer (Resale Products) shall carry only the warranty extended by the original manufacturer. Buyer agrees that
Seller has no liability for Resale Products beyond making a reasonable commercial effort to arrange for procurement and
shipping of the Resale Products. If Buyer discovers any warranty defects and notifies Seller thereof in writing during the
applicable warranty period, Seller shall, at its option, (i) correct any errors that are found by Seller in the firmware or
Services; (ii) repair or replace FOB point of manufacture that portion of the Goods found by Seller to be defective; or (iii)
refund the purchase price of the defective portion of the Goods/Services. All replacements or repairs necessitated by
inadequate maintenance; normal wear and usage; unsuitable power sources or environmental conditions; accident; misuse;
improper installation; modification; repair; use of unauthorized replacement parts; storage or handling; or any other cause
not the fault of Seller are not covered by this limited warranty and shall be replaced or repaired at Buyer's sole expense, and
Seller shall not be obligated to pay any costs or charges incurred by Buyer or any other party except as may be agreed upon
in writing in advance by Seller. All costs of dismantling, reinstallation, freight, and the time and expenses of Seller's
personnel and representatives for site travel and diagnosis under this limited warranty clause shall be borne by Buyer unless
accepted in writing by Seller. Goods repaired and parts replaced by Seller during the warranty period shall be in warranty for
the remainder of the original warranty period or 90 days, whichever is longer. This limited warranty is the only warranty
made by Seller and can be amended only in a writing signed by an authorized representative of Seller. The limited warranty
herein ceases to be effective if Buyer fails to operate and use the Goods sold hereunder in a safe and reasonable manner and
in accordance with any written instructions from the manufacturers. THE WARRANTIES AND REMEDIES SET FORTH ABOVE
ARE EXCLUSIVE. THERE ARE NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESSED OR IMPLIED, AS TO
MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE, OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS
OR SERVICES.
2. Limitation of Remedy and Liability SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN PERFORMANCE. THE
REMEDIES OF BUYER SET FORTH IN THE AGREEMENT ARE EXCLUSIVE. IN NO EVENT, REGARDLESS OF THE FORM OF THE
CLAIM OR CAUSE OF ACTION (WHETHER BASED IN CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OTHER
TORT, OR OTHERWISE), SHALL SELLER'S LIABILITY TO BUYER AND/OR BUYER'S CUSTOMERS EXCEED THE PRICE TO BUYER
OF THE SPECIFIC GOODS MANUFACTURED OR SERVICES PROVIDED BY SELLER GIVING RISE TO THE CLAIM OR CAUSE OF
ACTION. BUYER AGREES THAT IN NO EVENT SHALL SELLER'S LIABILITY TO BUYER AND/OR BUYER'S CUSTOMERS EXTEND TO
INCLUDE INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES. THE TERM "CONSEQUENTIAL DAMAGES" SHALL INCLUDE,
BUT NOT BE LIMITED TO, LOSS OF ANTICIPATED PROFITS, REVENUE OR USE AND COSTS INCURRED, INCLUDING WITHOUT
LIMITATION FOR CAPITAL, FUEL AND POWER, AND CLAIMS OF BUYER'S CUSTOMERS.
Contents
Contents
Chapter 1 Introduction ...................................................................................................................1
1.1 Models covered ............................................................................................................................1
1.2 Service support ............................................................................................................................ 1
1.3 Return of material ........................................................................................................................2
1.4 Product recycling/disposal ...........................................................................................................2
Chapter 2 Installation .....................................................................................................................3
2.1 Unpacking and inspection ............................................................................................................3
2.2 Locate sensor ...............................................................................................................................4
2.3 Dimensions ..................................................................................................................................5
2.4 Mount ..........................................................................................................................................7
2.4.1 Duct mount ...................................................................................................................8
2.5 Wire ...........................................................................................................................................10
2.5.1 Field installation .......................................................................................................... 10
2.5.2 Seals ............................................................................................................................10
2.5.3 Sensor separation ........................................................................................................11
2.5.4 Board assembly ...........................................................................................................11
2.5.5 Installation to transmitter or junction box ................................................................... 12
2.5.6 Faceplate rotation ....................................................................................................... 13
2.5.7 General requirements ................................................................................................. 14
2.5.8 Wiring sensor to transmitter ....................................................................................... 15
2.5.9 Wire sensor to junction box .........................................................................................17
2.5.10 Wiring transmitter to control system ...........................................................................18
2.5.11 External ground ...........................................................................................................18
2.6 Current output ...........................................................................................................................18
2.7 Non-isolated and isolated power configurations ........................................................................ 19
2.8 Installation checklist .................................................................................................................. 21
Chapter 3 Operation .....................................................................................................................23
3.1 Net Safety™ Millennium Transmitter ...........................................................................................23
3.1.1 Display ........................................................................................................................ 24
3.1.2 Status LED ................................................................................................................... 24
3.1.3 On/Off switch ..............................................................................................................24
3.1.4 Setup button ...............................................................................................................24
3.1.5 Magnetic Reed switch ................................................................................................. 24
3.1.6 Current output check .................................................................................................. 24
3.2 Indications and outputs ............................................................................................................. 25
3.3 Alarms ....................................................................................................................................... 25
3.3.1 Net Safety APM fault ....................................................................................................25
3.3.2 Clean window/dirty chamber ...................................................................................... 25
3.3.3 Particulate alarm ......................................................................................................... 26
3.4 Reset ..........................................................................................................................................26
3.4.1 Remote reset ...............................................................................................................26
3.4.2 Manual reset ............................................................................................................... 26
3.5 Normal .......................................................................................................................................26
3.6 Outputs ..................................................................................................................................... 26
Reference Manual i
Contents
3.6.1 Relays ..........................................................................................................................26
3.6.2 Current ........................................................................................................................27
3.7 Net Safety APM Sensor ...............................................................................................................27
3.7.1 Sensor power up ......................................................................................................... 27
3.7.2 Sensor communication ............................................................................................... 27
Chapter 4 Programming ...............................................................................................................29
4.1 Main menu .................................................................................................................................29
4.2 Accessing the main menu .......................................................................................................... 29
4.3 Using the main menu .................................................................................................................29
4.3.1 Zero ............................................................................................................................ 31
4.3.2 Sensitivity settings ...................................................................................................... 32
4.3.3 Review relay settings ...................................................................................................33
4.3.4 Set relay options ..........................................................................................................33
4.3.5 Select display language ............................................................................................... 35
Chapter 5 Maintenance ................................................................................................................ 37
5.1 Response check ......................................................................................................................... 37
5.2 Cleaning .................................................................................................................................... 37
5.3 Troubleshooting ........................................................................................................................ 38
5.4 Storage ......................................................................................................................................38
5.5 Spare parts and accessories ........................................................................................................38
Chapter 6 Electrostatic sensitive device ........................................................................................39
Chapter 7 Wire resistance table ....................................................................................................41
Chapter 8 Specifications ...............................................................................................................43
Chapter 9 Certifications ................................................................................................................45
9.1 North American hazardous locations ......................................................................................... 45
9.1.1 Transmitter ................................................................................................................. 45
9.1.2 APM Sensor ................................................................................................................. 45
9.1.3 Junction box (Model JB-MPD) .......................................................................................46
9.2 ATEX (-X model) .........................................................................................................................46
9.2.1 Transmitter ................................................................................................................. 46
9.2.2 APM Sensor ................................................................................................................. 46
9.2.3 Junction box (Model JB-MPD) .......................................................................................47
9.3 IECEx (-X model) ........................................................................................................................ 47
9.3.1 Transmitter (aluminum) ..............................................................................................47
9.3.2 Transmitter (stainless steel) ........................................................................................ 47
9.3.3 APM Sensor ................................................................................................................. 47
9.3.4 Junction box (Model JB-MPD) .......................................................................................48
Chapter 10 Ordering information ...................................................................................................49
ii Millennium Air Particle Monitor
1 Introduction
1.1 Models covered
The Net Safety™ Air Particle Monitor (APM) is an infrared optical detector used in hazardous
industrial applications to monitor ambient air for the presence of particulate matter from
products of combustion such as carbon, air particulate matter, or ash.
The Net Safety Millennium Transmitter is an environmentally protected electronic package
contained within an explosion-proof housing. With its scrolling 8-character display and
status LEDs, it provides instructions and status alerts.
The Net Safety APM Sensor is mounted where airborne particles are anticipated to
accumulate, while the Net Safety Millennium Transmitter is located conveniently at eye
level.
The product is available in aluminum and stainless steel (SS).
Models available are:
• MLP-AR-APM-OP: APM, 4-20 mA analog output with alarm and fault relays,
aluminum housing, CSA approved
• MLP-AR-APM-OP-X: APM, 4-20 mA analog output with alarm and fault relays,
aluminum housing, CSA, ATEX, and IECEx approved
• MLP-AR-APM-OP-SS: APM, 4-20 mA analog output with alarm and fault relays,
stainless steel housing, CSA approved
• MLP-AR-APM-OP-SS-X: APM, 4-20 mA analog output with alarm and fault relays,
stainless steel housing, CSA, ATEX, and IECEx approved
Introduction
1.2
Reference Manual 1
Service support
Technical support for this product can be provided by contacting your local Emerson/Net
Safety representative or by contacting the Net Safety Technical Support department at:
Toll Free + 866 347 3427 or Safety.CSC@emerson.com.
Introduction
1.3 Return of material
To expedite the repair and return of this product, proper communication between the
customer and the factory is important. Before returning a product for repair, call +1 403
219-0688 or e-mail Safety.CSC@emerson.com for a Material Return Authorization (MRA)
number.
On the return of the equipment, include the following information:
1. MRA number provided to you by Net Safety
2. Company name and contact information
3. Purchase order, from your company, authorizing repairs or request for quote
Procedure
1. Ship all equipment, prepaid to:
Emerson Automation Solutions
158 Edinburgh Ave
Slough, United Kingdom SL 1 4UE
2. Mark all packages with Return for Repair and include MRA number
1.4
Pack items to protect them from damage and use anti-static bags or aluminumbacked cardboard as protection from electrostatic damage.
Important
All equipment must be shipped prepaid. Collect shipments will not be accepted.
Product recycling/disposal
Consider recycling equipment and packaging and dispose of them in accordance with local
and national legislations/regulations.
2 Millennium Air Particle Monitor
2 Installation
2.1 Unpacking and inspection
Carefully remove all of the components from the packaging and verify them against the
enclosed packing list. Inspect all components for any obvious damage such as broken or
loose parts. If you find any components missing or damaged, notify your local Emerson
representative or the factory immediately. Figure 2-1 outlines the components supplied
with the Net Safety APM.
Net Safety APM ComponentsFigure 2-1:
Installation
™
A. Housing cover
B. Millennium housing
C. Junction box
D. 3/4 in. NPT
E. 3/4 in. NPT
F. Earth ground screw
G. 3/4 in. NPT
H. Optical path
I. Air particle monitor (APM)
J. Internal window/sensor chamber
K. Optical path protector plate. Uncrew to clean. Refer to Section 5.2 for cleaning instructions.
L. Millennium faceplate
Reference Manual 3
Installation
2.2 Locate sensor
Prior to the installation process, develop a location plan for placing the Net Safety APM
Sensor and Transmitter. Proper location of the Net Safety APM Sensor is essential for
providing maximum protection. The most effective placement and number of detectors
varies depending upon conditions. Consider the following points when planning the
installation.
• Carefully locate the Net Safety APM Sensor in an area where particulate may
potentially accumulate.
• Locate the Net Safety APM Sensor where it is safe from potential sources of
contamination, such as oil film, dirt, etc.
• Locate the transmitter where it will be accessible and visible.
• Mount the Net Safety APM Sensor so air currents allow particulate to flow into the
optical path of the sensor.
• If the particulate is expected to be moving horizontally due to air currents, orient the
sensor for maximum detection as shown in Figure 2-1.
• Avoid exposure to excessive heat or vibration whenever possible, because this can
cause premature failure of electronic devices.
• Seek advice from experts and refer to various regulatory publications that discuss
general guidelines for your industry.
• The Net Safety APM works off of the principle of infrared energy being reflected off
of particulate matter passing through the optical path of the Net Safety APM.
Therefore, give careful consideration when installing the Net Safety APM to ensure
that external infrared light does not reach the sensing element.
Figure 2-2 illustrates a typical installation of a Net Safety APM Sensor and Transmitter. The
Net Safety APM Sensor is mounted separately from the transmitter using the supplied
junction box. The transmitter is located at eye level, while the sensor is located where
particles are most likely to accumulate. The conduit then connects the two devices.
4 Millennium Air Particle Monitor
Installation
Typical InstallationFigure 2-2:
A. Conduit connecting junction box and controller
B. Controller/transmitter mounted at eye level
C. Particulate matter
D. Junction box
E. Net Safety APM Sensor positioned so air current allows particulate matter to flow into sensor
F. Net Safety APM Sensor
2.3
Reference Manual 5
Dimensions
The following figures outline the dimensions of the Net Safety APM connected directly to
the Net Safety Millennium Transmitter (Figure 2-3) or when connected directly to the
multi-purpose junction box (Figure 2-4). There are three (3) ¾ in. NPT conduit entries
available on the Net Safety Millennium Transmitter. Adapters for M20 and ½ in. NPT
threads are also available as spare parts.
Installation
Transmitter DimensionsFigure 2-3:
A. ¾ in. FNPT cable entry
B. ¾ in. FNPT cable
Junction Box and Sensor DimensionsFigure 2-4:
6 Millennium Air Particle Monitor
2.4 Mount
The sensor must be mounted directly to either a transmitter or to a separate junction box
through a ¾ in. NPT conduit entry. Both the transmitter and junction boxes have mounting
holes to allow mounting to a wall or pole as desired. Mounting kit hardware is required
when mounting the transmitter or junction box to a pole. Contact your local Net Safety
representative for detailed information on the pole mounting kits.
Mount the transmitter at eye-level and make it easily accessible for monitoring and
maintenance purposes. Place the sensor where particles are likely to accumulate and
across the direction of the airflow to allow the particulates to pass through the optical
path. To prevent water damage, seal conduit at all points of entry to the transmitter or
junction box.
Emerson™ recommends mounting the Net Safety APM Sensor such that the air flow will
pass through the optical path of the sensor as shown in Figure 2-5.
Note
The Net Safety APM works off of the principle of infrared energy being reflected off of particulate
matter passing through the optical path of the Net Safety APM. Therefore, give careful consideration
when installing the APM to ensure that external infrared light does not reach the sensing element.
Installation
The Net Safety APM may be affected by sudden bursts of infrared light; therefore, Emerson
recommends putting a time delay (between two [2] and five [5] seconds) into the
monitoring system to prevent nuisance alarms.
Reference Manual 7
Installation
Net Safety APM Mounting LocationsFigure 2-5:
2.4.1
A. APM sensor with junction box
B. Movement of air particulate matter
C. APM sensor with junction box
D. Movement of air particulate matter
Duct mount
Although the Net Safety Monitoring Air Particle Monitor has been proven to detect
particulate matter travelling at speeds of up to 20 meters per second (65.62 feet per
second), the detector is virtually unaffected by the velocity of particulate and air that it is
exposed to. Based on the application and the speed of the particulate matter, you can
perform a zero and adjust the sensitivity settings to suit the application.
Net Safety Monitoring recommends that the Net Safety APM be used with the UDM-001 or
UDM-002 sample draw system to acquire a cross-sectional sample of air and particulate
moving through ducts. The sample is drawn through perforations along the inlet pipe into
a chamber where the Net Safety APM is mounted. Particulate matter from the outlet pipe
is then returned to the duct. Refer to Figure 2-6 and the
UDM-001/UDM-002 reference manual (MAN-0116) for more information.
8 Millennium Air Particle Monitor
Installation
Air Flow DrawingFigure 2-6:
A. Duct surface
B. Conduit to controller
C. Junction box
D. APM sensor
E. UDM-001/UDM-002 duct mount
F. Broken lines indicate direction of air flow.
G. Direction of outlet air sample
H. Outlet pipe
I. Perforated sample draw tube (inlet pipe)
J. Direction of air sample flow
Reference Manual 9
Installation
2.5 Wire
2.5.1 Field installation
WARNING!
ELECTRIC SHOCK
Failure to follow these installation guidelines could result in death or serious injury. Ensure that
only qualified personnel perform the installation.
Electrical shock could cause death or serious injury. Use extreme caution when making contact
with the leads and terminals.
Do not open the transmitter, sensor, or junction box enclosure when in a classified area or
when an explosive atmosphere may be present unless the power to the transmitter has been
removed.
Avoid touching electronic components as they are susceptible to electrostatic discharge (ESD).
Refer to Chapter 6 for more information.
Avoid contact with the non-metallic enclosure label as contact may create an electrostatic
charging hazard.
2.5.2
NOTICE
Wiring codes and regulations may vary. ATEX requires that supply connections wiring must be
rated at least 5 °C (41 °F) above the maximum ambient temperature of 85 °C (185 °F). Wiring
must comply with all applicable regulations relating to the installation of electrical equipment
in a hazardous area and is the installer's responsibility. If in doubt, consult a qualified official
before wiring the system.
When separating the sensor from the transmitter, Emerson highly recommends the use of
shielded cable to protect against interference caused by extraneous electrical or
electromagnetic noise to meet mandatory CE mark electromagnetic compatibility (EMC)
requirements. In applications where the wiring is installed in conduit, the conduit must not
be used for wiring to other equipment.
Seals
Emerson recommends using seals to further protect the system against any unwanted
water ingression and installing equipment according to applicable local electrical codes.
Emerson especially recommends seals for installations that use high-pressure or steam
cleaning devices in proximity to the transmitter and/or sensor.
• Emerson recommends water-proof and explosion-proof conduit seals to prevent
water accumulation within the enclosure.
• Locate seals as close to the device as possible and not more than 18 inches (46 cm)
away.
• Explosion-proof installations may require an additional seal where conduit enters a
non-hazardous area. Ensure conformity with local wiring codes.
10 Millennium Air Particle Monitor
• When pouring a seal, use a fiber dam to assure proper formation of the seal. Never
pour seals at temperatures below freezing.
• Strip back the jacket and shielding of the cable to permit the seal to form around the
individual wires. This will prevent air, particles, and water leakage through the inside
of the shield and into the enclosure.
• Emerson recommends using explosion-proof drains and conduit breathers. 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.
2.5.3 Sensor separation
Since the Net Safety APM Sensor must be located where it will pick up particulate in an air
flow, and the transmitter where it can be easily reached, it is often necessary to separate
the transmitter and sensor. This is done with the aid of the included sensor separation kit
(SEP). This kit is composed of a junction box and terminal strip. Refer to the
Net Safety Multi-purpose Junction Box manual (MAN-0081) for terminal designation.
The maximum separation distance between the sensor and the transmitter is limited by
the resistance of the connecting wiring, which is a function of the gauge of wire being
used. Net Safety recommends that sensor separation must not exceed 610 m (2,000 ft)
while using 16 AWG (1.31 mm2) wire. Refer to Chapter 7 for wire gauges and resistance
values.
Installation
2.5.4
Note
When the sensor is separated from the transmitter, always ensure that the transmitter is supplying
the required voltage to the sensor terminals inside the junction box. If the 4-20 mA signal is not used,
connect a jumper between the 4-20 terminal and the COM terminal on the transmitter terminal
board.
Board assembly
There are three different fixed boards and a relay board which make up the PCB assembly.
Simply loosen the three locking standoffs, remove one board, insert the other board, and
tighten screws. The boards are susceptible to electrostatic discharge (ESD). Refer to
Chapter 6 for further information on proper handling of this equipment.
Reference Manual 11
Installation
Net Safety Millennium Transmitter Module BoardsFigure 2-7:
A. Terminal board
B. Option board
C. Sensor board
D.
PNO Fault Normally open
PCOM Common
PNC Normally closed
LNO Clean window (low) Normally open
LCOM Common
LNC Normally closed
HNO Alarm Normally open
HCOM Common
HNC Normally closed
Electromechanical Relay BoardTable 2-1:
2.5.5 Installation to transmitter or junction box
The Net Safety APM sensor is supplied with a ¾ in. NPT male conduit connection and is
intended to be mounted directly to an available ¾ in. NPT conduit entry on the Net Safety
Millennium Transmitter or remotely using the supplied junction box.
Tightly thread the sensor to the transmitter or junction box. A minimum of seven (7)
threads need to be engaged to ensure proper water ingress protection and the explosion
proof rating of the devices. Take proper care to ensure that no damage is caused to the
wires on the Net Safety APM Sensor and circuit board inside the transmitter and junction
box.
Emerson recommends using conductive grease on the threads.
The sensor can be mounted in a number of configurations to ensure that air particulate will
pass through the optical path of the sensor. Emerson recommends that the APM be
mounted horizontally to ensure that build-up of dirt, dust, and debris will not affect the
operation of the sensor.
12 Millennium Air Particle Monitor
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