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CORROSION MONITORING TRANSMITTER
PROCESS AUTOMATION
CorrTran® AQUA
Subject to modifications www.pepperl-fuchs.com
USA: +1 330 486 0002 Singapore: +65 6779 9091
Copyright Pepperl+Fuchs
Germany: +49 621 776 2222
CorrTran AQUA Corrosion Monitor
2
Contents
1 SAFETY INSTRUCTIONS / DISCLAIMER ................................................................... 3
1.1 Designateduse.................................................................................................... 3
1.2 Installation,commissioning,andoperation.......................................................... 3
1.3 Operationalsafety................................................................................................ 3
1.4 Notesonsafetyconventionsandsymbols............................................................ 3
1.5 Disclaimer............................................................................................................. 4
2 IDENTIFICATION ........................................................................................................... 4
2.1 Devicedesignation............................................................................................... 4
2.2 Contentsofdelivery.............................................................................................. 6
2.3 Incomingacceptance,transport,storage............................................................. 6
2.4 Certificatesandapprovals.................................................................................... 6
2.5 Registeredtrademarks......................................................................................... 6
2.6 Patents................................................................................................................. 6
3 INSTALLATION AND MOUNTING ............................................................................... 7
3.1 Dimensions............................................................................................................ 7
3.2 Mountingsafetyproceduresandhints................................................................. 8
3.3 Probespecifications........................................................................................... 12
3.4 Installationinstructions....................................................................................... 13
4 STARTUP AND WIRING ............................................................................................. 15
4.1 Quickwiringguide.............................................................................................. 15
4.2 HARTintroduction.............................................................................................. 15
4.3 WiringwithHART............................................................................................... 15
4.4 Post-installationcheck........................................................................................ 16
5 HART MODEM ............................................................................................................ 17
5.1 HARTmodemintroduction.................................................................................. 17
5.2 LoadingUS-HI-321devicedrivers..................................................................... 17
6 CONFIGURING THE DISPLAY .................................................................................. 20
CorrTranMV EVALUATION TOOL .................................................................................... 21
7.1 CorrTranMVEvaluationToolintroduction.......................................................... 21
7.2 EstablishingcommunicationwiththeCorrTranMVEvaluationTool................... 21
7.3 CorrTranMVEvaluationToolcapabilities........................................................... 23
8 TRANSFERING PROCESS DATA TO EXCEL .......................................................... 29
9 CHANGING OPERATING MODE TO REDUCE EXCITATION FREQUENCY ........... 32
10 REPLACEMENT PARTS AND ACCESSORIES ........................................................ 33
10.1 CorrTranAQUAparts......................................................................................... 33
10.2 Accessories........................................................................................................ 35
11 SYSTEM SPECS ......................................................................................................... 36
12 TROUBLESHOOTING ................................................................................................ 39
13 MEASURING PRINCIPLE ........................................................................................... 41
14 APPENDIX ................................................................................................................... 43
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1. SAFETY INSTRUCTIONS / DISCLAIMER 1.1 Designated use TheCorrTranAQUAisacompact,4-20mAcorrosiontransmitterusedtodetectgeneralcorrosion,localizedcorrosion,andconductanceinthewaterqualityindustry.Thetransmittermeasuresthecorrosionrateandpittingfactor,givingthereadoutinmil/yearora0-1pittingfactor,respectively.Italsoprovidesaconductancemeasurement.Thereadingsaretakeninrealtimeandareupdatedapproximatelyevery34minutes.
1.2 Installation, commissioning, and operation CorrTranAQUAhasbeendesignedtooperatesafelyinaccordancewithrelevanttechnicalandsafetystandards.Ifinstalledincorrectlyorusedforapplicationsforwhichitisnotintended,application-relateddangersmayarise.Forthisreason,theinstrumentmustbeinstalled,connected,operated,andmaintainedaccordingtotheinstructionsinthismanualbyappropriatelytrainedpersonnel.Thismanualmustberead,understood,andtheinstructionsmustbefollowed.Modificationsandrepairstothedevicearepermissibleonlywhentheyareexpresslyapprovedinthismanual.
1.3 Operational safety CorrTran AQUA cannot be used in a hazardous (classified) area.
1.4 Notes on safety conventions and symbols Thefollowingconventionsareusedtohighlightsafety-relevantoralternateoperatingproceduresinthismanualandareshowninthemarginwhereappropriate.
Safety conventions
Symbol Meaning
Warning
Awarningsymbolhighlightsactionsorproceduresthat,ifnotperformedcorrectly,willleadtopersonalinjury,asafetyhazard,ordestructionoftheinstrument.
Attention
Anattentionsymbolhighlightsactionsorproceduresthat,ifnotperformedcorrectly,mayleadtopersonalinjuryorincorrectfunctioningoftheinstrument.
Note
Anotesymbolhighlightsactionsorproceduresthat,ifnotperformedcorrectly,mayindirectlyaffectoperationormayleadtoaninstrumentresponsewhichisnotplanned.
Aterminalsymbolindicatesthataprotectivegrounding(earth)terminalmustbeconnectedtoearthgroundpriortomakinganyotherconnectiontotheequipment.
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1.5 Disclaimer Pepperl+Fuchs,Inc.(“P+F”)hasnopower,nordoesitundertaketopoliceorenforce,compliancewiththecontentsofthismanualorobservanceofthesafetyprecautionssetforthherein.P+Fdoesnotcertify,test,orinspecttheinstallationsofCorrTranAQUAforsafetyorotherpurposes.P+Fdisclaimsliabilityforanypersonalinjury,property,orotherdamagesofanynaturewhatsoever,whetherspecial,indirect,consequential,orcompensatory,directlyorindirectlyresultingfromthepublication,useof,orrelianceuponthismanual.P+Fmakesnoguarantyorwarranty,expressorimplied,astotheaccuracyorcompletenessofanyinformationpublishedinthismanual,anddisclaimsandmakesnowarrantythattheinformationinthismanualwillfulfillanyparticularpurposesorneeds.P+F’sonlywarrantyissetforthinthewrittenLimitedWarrantyspecificallyprovidedbyP+FinconnectionwiththepurchaseoftheCorrTranAQUA.
2. IDENTIFICATION2.1 Device designation 2.1.1 Nameplates
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2.1.2 Modelnumber
*Probe Mounting Guide and Electrode Material Guide can be found in the Appendix.
Model Number Description
CorrTranAQUA-912927 Kit,baseunitwithoutlocaldisplay,1018CSelectrodes,11”probe
CorrTranAQUAwithdisplay-912929 Kit,baseunitwithlocaldisplay,1018CSelectrodes,11”probe
Electrodes Electrodesotherthancarbonsteelmustbeorderedseparately
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2.2 Contents of delivery
Itisessentialtofollowtheinstructionsconcerningtheunpacking,transport,andstorageofthisinstrumentgiveninsection2.3,“Incomingacceptance,transport,storage.”
Unlessorderedascomponents,thecontentsofdeliveryconsistof:
• Assembledtransmitter
• Aprobe
• 3-electrodeelements(fingertelectrodesonly)
• 12’cable(forprobe)
• Accessories(ifanyareordered)
• Instructionmanual(thisdocument)
2.3 Incoming acceptance, transport, storage 2.3.1 IncomingacceptanceCheckthepackingandcontentsforanysignsofdamage.Checktheshipmenttoensurethatallpartshavebeenincludedandtoverifythattheshipmentmatchesyourorder.
Allprobesareshippedwiththeinsulatinggasketsinstalled.Uponremovingtheprotectivecap,ensurethattheO-ringsarenotloose.TheO-ringsaremadeofViton®(standard)orKalrez(onrequest).Iftheyarenotinstalled,theprobewillnotoperateproperly.PleaserefertoFigure14onpage14.
2.3.2 TransportProtectthetransmitterelectrodesfromdamage.Donotattempttocarrythetransmitterbyitselectrodes.
2.3.3 StorageAlwayspacktheinstrumentforstorageortransporttoprotectitagainstimpact.Theoriginalpackingmaterialprovidestheoptimumprotectionforthedevice.Thepermissiblestoragetemperatureis-40°Fto+176°F(-40°Cto+80°C).
2.4 Certificates and approvals TheCorrTranAQUAisdesignedtomeetrelevantsafetyrequirements.Ithasbeenfullytestedtoensurethatitisinsafeoperatingcondition.Theinstrumentcomplieswiththeapplicableregulationsinaccordancewithknownstandards.
2.5 Registered trademarks HART®RegisteredtrademarkofHARTCommunicationFoundation,Austin,USA
Viton®RegisteredtrademarkofthecompanyE.I.DuPontdeNemours&Co.,Wilmington,USA
2.6 Patents ThisinstrumentisprotectedbyoneormorepatentsregisteredintheUSPatentOffice.
Warning
Attention
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3. INSTALLATION AND MOUNTING 3.1 Dimensions
51 mm(2.00")
190 mm(7.50")
Ø 19 mm(0.75")
70 mm(2.78")
32 mm(1.25")
¾ NPTnyloncompressionthread
Adjustable epoxy glassprobe and electrode
Ø14.8
48.2
Ø10
Ø10
Ø10.8
M12x1external threads
Ø10.8
Ø14.8
45.3
M12x1internalthreads
Probecable
ProbeCableLength:3.6m(12’)
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Figure 1. CMC Probe Installation Figure 2. CMC Probe Installation
3.2 Mounting safety procedures and hints Theelectrodesselectedmustreflectthesamemetalpropertiesasthepipingorothercomponentssusceptibletocorrosion.Forexample,inapplicationswherethepipeismadeofstainlesssteelandthewaterpump’simpellerismadeofcarbonsteel,theimpellerwillcorrodefasterthanthepipe.Inthiscase,itisadvisabletoselectelectrodesthataremadeofthesamematerialasthepump’simpeller.
3.3.1 Mountingrequirements/scenarios
ThetransmittershouldnotbemountedinapipedropsincethecorrosiveliquidmaynotbeinfullcontactwiththeelectrodesasshowninFigure1.
CorrTranAQUAshouldbemountedintheriserofapipenearanelbowwherethevelocityisthehighest.Ingeneral,CorrTranAQUAshouldbemountedinpipesortanksatlocationsofhighestliquidvelocityandconstantimmersion,showninFigure2.Forvelocitiesgreaterthan20fps,theprotrudingfingerelectrodesmustbeprotected.Asnotedabove,highfluidvelocitiescanalsocauseunwantedturbulenceinthepipeduetotheextensionoftheprobe.
4 - 20 mA PROBE
Attention
Warning
4 - 20 mA PROBE
OK!
15 diameters downstream
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TheCorrTranAQUAprobecanbelocatedatanypointonthepipelinebutshouldalwaysbeimmersedinthecorrosivematerialasshowninFigure3.
Figure 3. Correct CorrTran AQUA Pipeline Position
Ateeinthecondensatereturnline(Figure4)isagoodlocationtomounttheCorrTranAQUAprobe
Figure 4. CorrTran AQUA Located in Tee
4 - 20 mA PROBE
4 - 20 mA PROBE
4 - 20 mA PROBE
Note: The line must be full at all times and electrodes must be located in the bottom half of the line. Electrodes must be covered at all times.
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TheCorrTranAQUAprobeshouldbelocateddownstreamofacontrolvalveforbestperformanceandcanalsobelocatedinthedeadlegportionofaby-pass.Notethattheprobelocatedintheby-passlegshouldbemountedinfrontofthevalveforbestperformance.SeeFigure5.Thisguaranteesthattheelectrodeswillalwaysbeimmersedinthecorrosivematerial.
Figure 5. CorrTran AQUA Located in Bypass Loop Top View
InstallingseparateCorrTranAQUAprobeswithdifferentelectrodematerialsonthesuctionsideofthepumpwillensuremonitoringofthepumpimpellerandthepipeasshowninFigure6.Thereshouldbeaminimumseparationdistanceof50cm(19.7”)betweenprobes.
Figure 6. CorrTran AQUA Probes Mounted With Different Electrodes
4 - 20 mA PROBE
4 - 20 mA PROBE
Note
15 diameters
Bypass Valve Bypass Valve
Control Valve
4 - 20 mA PROBE
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Inadditiontopipes,acondensateflashtank,showninFigure7,isalsoagoodapplication.
Figure 7. CorrTran AQUA Installed in a Condensate Flash Tank
TheCorrTranAQUAprobeshouldNOTbelocatedintheblowdownofaY-strainerasshowninFigure8.NorshoulditbelocatedinthedischargesideofthebasketstrainerasshowninFigure9.
4 - 20 mA PROBE
4 - 20 mA PROBE
4 - 20 mA
PRO
BE
Figure 8. Probe Mounted in Y-Strainer Figure 9. Probe Mounted in Basket Strainer
CorrTranAQUAmaybeimplementedinarackinplaceoftraditionalmetal-losscouponmonitoringandcanbeinstalledinanexistingcouponrack.Inthiscase,theCorrTranAQUAprobesshouldbeinsertedinplaceofthecouponholderportsasshowninFigure10.
Figure 10. CorrTran AQUA Mounted in a Coupon Rack
4 - 20 mA PROBE
Directionofflow
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Figure 11. CMP Epoxy Adjustable Probe
3.3 Probe specifications CMPepoxyadjustableprobeTheCMPepoxyadjustableprobe(Figure11)consistsofaglassepoxyprobewitha¾”NPTnyloncompressionfittingforinsertionintothesystem.Thestudsformountingtheelectrodesandthesix-pinconnectorareheldinplacebytheepoxyfillmaterial.Thisprobeisavailablein127mmand280mm(5”and11”)lengthsonly.Thisprobeisonlyavailablewiththeremotemountingoption.
Electrodesshowninthepictureareorderedseparately.
Specifications
ProbeBody Glassepoxy
EndcapSeal Epoxy
FillMaterial Epoxy
ProcessTemperature -50…65°C(-58…149°F)
PressureRating 7bar(100psi)
Mounting 3/4”NPTnylonfitting
StandardLengths 127,280mm(5,11”)
CustomLengths N/A
InsertionLength Adjustable,Max=probelength-89mm(3.5”)+EL
*EL=32mm(1.25”)forfingerand0mm(0”)forflushelectrodes
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3.4 Installation instructions 3.4.1 General
AtrainedspecialistmustperformthenecessaryinstallationandcommissioningofCorrTranAQUA.Recognizedrulesofthetechnologyandsetuprequirementsmustbemaintainedbothduringandafterinstallation.Safetyrequirementsmustbeobservedduringallinstallationsteps.
IfthepipeorvesselintowhichtheCorrTranAQUAistobeinsertedisunderpressureand/orcontainsanyhazardoussubstance,suchassteam,causticsolutions,acids,toxinsorothersubstancesspecifiedbyOSHAasphysicalorhealthhazards,thepipeorvesselmustfirstbedepressurized,anyhazardoussubstancepurgedtherefrom,andappropriatelockout/tagoutproceduresobservedinaccordancewithSection1910.147oftheOSHARegulations,beforeCorrTranAQUAcanbeinstalled.Failure to follow these procedures may result in serious injury or death.
CorrTranAQUAconsistsofthreebasiccomponents:
• Transmitter:Atransmitterhousingcontainstheelectronicsandprovidesthe4-20mAwithHARToutputsignal.
• Probe:Theremotemountprobeissuppliedwitha12’cable.
• Electrodes:Eitherfingerelectrodesorelectrodesflushtotheprobeendareused.Correctlychosenelectrodeswillcorrodeinthesamemannerasthemetalbeinginvestigated.Foraccuratemeasurements,theelectrodesmustreflectthesamemetalpropertiesasthemetalbeinginvestigated.
3.4.2 ElectrodeinstallationTheelectrodesareshippedlooseandmustbeinstalledhand-tight.Ensurethatthe
Viton(standard)orKalrez(onrequest)gasketsareinplacepriortoinstallingtheelectrodes.SeeFigure12fortheelectrodeinstallationdrawing.
Typically,carbonsteelelectrodesareinspectedevery90to180daysandyellowmetalelectrodes(copperandcopperalloy)areinspectedevery180to360days.It’snotjustthegeneralcorrosionrate,it’salsofoulingorbridgingthatoccursthatmayresultinfalsereadings.Wheninstalledincorrosioncouponracks,theprobesshouldbeinspectedwheneveracorrosioncouponisremovedandreplaced.Iftheelectrodesarefouled,theyshouldeitherbecarefullycleanedorreplaced.
Figure 12. Electrodes and Viton Gaskets
Pepperl+Fuchsrecommendsthatthepersoninstallingtheelectrodeswearaplasticgloveofthetypeusedinmedicalofficesorthetypeusedbyfoodpreparers.Or,carefullyusethecorrosionbarrierpaperthatispackedintheelectrodeenvelopeandwitheachcorrosioncouponItisimportantnottotouchtheelectrodeswithyourbarehands.
Warning
Electrodes VitonGaskets
Note
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3.4.3 ProbeinstallationCMP adjustable and fixed probes
1)Inserttheprobeintothepipe
2)Adjusttodesireddepth
3)Apply1-1/4turnsfromhand-tighttoprovidethesealasshowninFigure13.
Figure 13. CMP Adjustable and Fixed Probe Mounting
Forfixedtypeprobes(withoutthecompressionfitting)onlythe1-1/16”hexnutneedstobetightened.Note
4 - 20 mA PROBE
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4. STARTUP AND WIRING4.1 StartupThemeasurementcycleofCorrTranAQUAis34minutes.Whenpowerisfirstappliedtotheunit,theoutputwillread4mAfor34minutes.Afterthefirstreading,theoutputshouldgotohigherthan4mA,dependingonthecorrosionrate.
4.1.1 QuickwiringguideFieldinstallableV1-Gconnector(117051),Figure14.
Figure 14. Transmitter Wiring
4.2 HART introduction Pepperl+Fuchs’CorrTranAQUAprobesupportstheHARTcommunicationprotocol.HARTisanacronymforHighwayAddressableRemoteTransducer.TheHARTprotocolmakesuseoftheBell202FSKstandardtosuperimposedigitalsignalsatalowlevelontopofthe4-20mAsignal.Thisenablestwo-waycommunicationandmakesitpossibleforadditionalinformationbeyondjustthenormalprocessvariabletobecommunicatedtoandfromasmartfieldinstrument.
4.3 Wiring with HART IfyouareusingCorrTranMVwithanon-HARTcompatibleI/Oofdatacollectiondevice,theKFD2-HLC-Ex1.D,HARTLoopConverter,canintegratethethreeCorrTranAQUAvariablesintoseparate,independent4-20mAoutputs.
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Pleaseobservethefollowingguidelines:
• Alwaysuseagroundedpowersupply(ontheACside).
• EnsurethattheI/Ocardisisolatedfromground.
Figure 15. Connecting to analog auxiliary port on controller
Figure 16. Connecting with a HART modem or handheld
4.4 Post-installation check Afterwiringthetransmitterandconnectingtheprobes,performthefollowingchecks:
• Istheprobesecureandtightenedtospecifiedtorque?(Seesection3.4.3.)
• Havetheelectrodesbeencleaned?(Seesection3.4.2.)
• Istheterminalassignmentcorrect?(Seesection4.1.)
• Isthehousingcoverscrewedtight?
4-20 mA
Controller
4-20 mA
HART handheld
PACTware
250 Ω
HART modem
DC power supply unit
or Controller
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5. THE HART MODEM 5.1 HART modem introduction AnyHARTModemcanbeusedtocommunicatebetweentheCorrTranAQUAandtheCorrTranMVEvaluationTool.Pepperl+FuchsrecommendtheUS-HI-321HARTModem.
5.2 Loading US-HI-321 device drivers IfyouareusingadifferentHARTmodemyoushouldensurethatyouhavesuccessfullyistalleditsassociatedsoftware/devicedriversbeforemovingontosection3.
IfyouareusingtheUS-HI-321HARTmodemfollowthesestepstoinstallitsdevicedriver.Ifyouhavealreadyinstalledthedevicedriverthenmoveontosection3.
• InsertSmarResearchProductCDthataccompaniestheUS-HI-321intoyourcomputerCD-ROM.TheCDwillautomaticallyopentothewindowseeninFigure17.
Figure 17. SmarResearch Product DC Launch Screen
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• Byselecting‘English’thescreenshouldappearasshowninFigure18.
Figure 18. SmarResearch Product DC
• Select‘ProductDrivers’toaccesstheUS-HI-321productdriverasseeninFigure19.
Figure 19. Product Drivers
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• Select‘InstallHI321Drivers’toinstalltheUS-HI-321drivers.ThescreenseeninFigure20willappear.IftheUS-HI-321driverhasbeensuccessfullyinstalled,itwillaskyoutopressanykeytocontinue.
Figure 20. US-HI-321 Driver Installation Screen
• TheUS-HI-321DriverhasnowbeensuccessfullyinstalledandtheSmarResearchProductCDcanbeejectedfromthecomputer.
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Texmate, Inc. Tel. (760) 598-9899 • www.texmate.comPage 2 September 8, 2003 SD-50X Data Sheet (SD02)
Controls and Indicators Dip Switch Settings
Two Point Digital Scaling and Calibration - Quick Reference Guide
Digit/Descriptor Display Lock/Frequency
Default SettingWhen set to ON
displays [Lock] whenany button is pressed
Effect on Display
F
C
12
12
12
12
ON
ON
ON
ON
Dummy Zero
12
ONOFF50
ON60
Display Lock
Rejection Filter (Hz)
DefaultSetting
When set to ONdisplays [Lock] whenany button is pressed
F
CDummyZero
OFF50
ON60
Display Lock
RejectionFilter (Hz)
Rear View of the MeterUP ARROW
BUTTON
DOWN ARROWBUTTON
PROGRAM BUTTON: This button is used to move from oneprogram step to the next.When pressed simultaneously with theUP ARROW button, the Programming Mode is entered.UP ARROW BUTTON: Increases the value of the displayedparameter.DOWN ARROW BUTTON: Decreases the value of the dis-played parameter.NOTE: When the display lock switch is on and any button ispressed, the display will show only [Lock] momentarily asshown above and then return to the normal operational display.
PROGRAMBUTTON P
Enter theCalibration Mode Enter the
Calibration Mode
Operational Display
Operational Display
Operational Display
Select [cAL on]
TEXMATE
Prog.
Set DIP switchto lock OFF
TEXMATE
Prog.
Set the LOW input valueand enter the HIGH Input
[hi in] Mode
Apply the 4 mALOW inputcalibration signalto the meter.
TEXMATE
Prog.
Enter the LOW Input[Lo in] Mode
If display shows [cALErr] the calibration has been canceledand the previously calibrated scale
factors are retained in memory.(See page 2, para 5)
TEXMATE
Prog.
TEXMATE
Prog.
TEXMATE
Prog.
Pass Calibration Modeand enter Decimal Point
Setting Mode
12
ON
Set DIP Switchto Lock On
12
ON
Set DIP switchto lock ON
12
ON
Set DIP switchto lock OFF
12
ON
OR
TEXMATE
Prog.
ORPress
1
TEXMATE
Prog.
Set the HIGH input value andreturn to Operational Display
Apply the 20 mAHIGH inputcalibration signalto the meter.
Press1
TEXMATE
Prog.
Press1
Press1
TEXMATE
Prog.
Adjust the decimal pointto the desired position
Press1
Step 1
Two Point Calibration and ScalingExample: 4 to 20 mA input to read 0 to 20,000
Decimal Point Setting
Step 2
Step 3
Step 4
Step 5
Step 7
Step 2
Step 3
Step 4
Set the decimal point positionand return to Operational Display
Pressat same
timePress
at sametime
Operational DisplayTEXMATE
Prog.
Step 1
Pressat same
time
Pressat same
time
TEXMATE
Prog.
Adjust display to thedesired reading for
HIGH input
TEXMATE
Prog.
OR
Any value between-19,999 and 30,000may be selected. Reverse scaling
is accepted.
TEXMATE
Prog.
TEXMATE
Prog.
Adjust display to desiredreading for LOW input
OR
Step 6
Max differencebetween [hi in] &
[Lo in] displayvalues selectedcannot exceed32,000 counts.
If the input signal is dis-connected after Step 5, the
[Lo in] values are saved, andthe meter automatically
returns to the [hi in] mode whensignal power is re-applied.
Maximum positive reading is30,000 & maximum negativereading is -19,999. Maximumdisplay span is 50,000 counts.
6. CONFIGURING THE DISPLAY (if equipped)
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7. CorrTranMV EVALUATION TOOL7.1 CorrTranMV Evaluation Tool introductionCorrTranMVEvaluationToolissuppliedwitheveryCorrTranAQUA.(**TheCorrTranMVEvaluationToolisfunctionallyequivalenttotheCorrTranAQUA.)Itprovidesaneasy-to-usesetupfeatureforCorrTranAQUAplustheabilitytostoreAQUAdatainASCIIfilesthatcanbeimportedintoyourfavoriteanalysispackage.
TheunitmayalsobeprogrammedusingPepperl+Fuchs’PACTwareprogrammingenvironment.PleasecontactthefactoryformoreinformationonPACTware
7.2 Establishing communication with the CorrTranMV Evaluation Tool• ToestablishcommunicationbetweenyourCorrTranAQUAusingtheCorrTranMV
EvaluationTool,youmustfirstensurethatyourCorrTranAQUAandHARTmodemareconnectedasshowninsection4.3,thedevicedriversforyourHARTmodemhavebeensuccessfullyinstalled,andyouhavetheCorrTranMVEvaluationToolsoftwareinstalledonyoucomputer.
• OpenCorrTranMVEvaluationTool.Figure21showsthemain(default)screenyouwillseewhenopeningtheprogram.
Figure 21. CorrTranMV Evaluation Tool Main (default) Screen
7.2.1 AssigningtheHARTmodemtothecorrectcomportWhenfirstlaunched,theCorrTranMVEvaluationTooldefaultstoCom1andwillverylikelyneedtobechangedunlessyouareusingaRS232HARTmodem.
USBconnectionswillshowupascomportsintheCorrTranMVEvaluationToolenvironment.Ifyouarenotsurewhatcomportyourmodemisusing,gotoyourcomputer’sdevicemanagerbyopeningthefollowingwindows:
• ‘Controlpanel’>‘System’>‘Hardware’>‘DeviceManager’
• Expandthe‘Ports(COM&LPT)’tofindoutwhichcomportisbeingusedbytheUSBmodem,asseeninFigure22.
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Figure 22. Device Manager Ports (COM & LPT)
NowthatyouknowtheappropriateComPortforyourHARTmodem:
• Select‘Communication’>‘ComPort’fromthetoolbarandselecttheComPortthathasbeenassignedtoyourHARTModem.
7.2.2 ConnectiontotheCorrTranAQUA• Select‘Communication’>‘Open”fromthetool.The‘Connect’buttonwillbecome
availableasseeninFigure23.
• Pressthe‘Connect’buttontoestablishcommunicationbetweentheCorrTranAQUAandCorrTranMVEvaluationTool.IfeverythinghasbeendoneproperlyallthefieldswillbepopulatedasseeninFigure24.
Figure 23. After Communication Opened
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Figure 24. After Successfully Connected
Atthetopofthescreenthefollowingreadonlyinformationisdisplayed:
• Devicerevision• DeviceID• Hardwarerevision• Softwarerevision
7.3 CorrTran MV Evaluation Tool capabilities Onceaconnectionhasbeenestablished,informationfromtheCorrTranAQUAtransmittercanbegathered.
7.3.1 ProcessdatatabsTheprocessdatatab,seeninFigures23and24,allowsyoutoviewthemostrecentoutputsfromtheCorrTranAQUA.
• Cycle:NumberofcorrosionmeasurementcyclescompletedonCorrTranAQUAtransmittersincethedevicewaslastreset.SeeSection7.3.4forinformationonresettingthenumberofcycles.
• Update–PressingthisbuttonpopulatesallcategoriesontheprocessdatatabwiththecurrentCorrTranAQUAoutputvalues.
• Cyclic–PressingthisbuttonenablestheCorrTranMVEvaluationTooltoupdatethevaluesontheprocessdatatabeverymeasurementcycle.Whenthisbuttonisengagedthetimeremaininginthecurrentcycleisdisplayedatthebottomofthescreen.
• LogOn/Off–WhencheckeditenablesthedataloggingcapabilitiesoftheCorrTranMVEvaluationTool.Youwillneedtoplaceacheckmarkbyeachdatapointyouwishtolog.Figure27providesdataloggingofeverypossibledatapointinacyclicalmanner.FormoreinformationontheloggingcapabilitiesoftheCorrTranMVEvaluationToolseesection7.3.4.
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Adatasetcanbemanuallyaddedtothelogfilebyclickingtheupdatebutton,orloggingcanbemadeautomaticforeverymeasurementcyclebyhavingcyclicselected.
• Gen.Corr.:Currentgeneralcorrosionreadinganditsmeasurementunits.
• Loc.Corr.:Currentlocalizedcorrosionreading.
• LC.Avg:Theaveragelocalizedcorrosionvalue.ThisvalueisaverageduntiltheCycles/AvgisresetortheCorrTranAQUAisresettofactorydefault.SeeSection7.3.4forinformationonCycles/Avgresetandresettingtofactorydefault.
• Sol.Cond.:CurrentsolutionconductancemeasureinSiemens(S)
• B-Value:CurrentmeasuredStern-Gearyvalue(Bharm)
• LpCurrent:Currentloopcurrent
Figure 25. Log On For All Data Points, Cyclic Mode
7.3.2 Onlineparameters:processvariablesThedeviceSettingtab,seeninFigure26,allowsyoutoconfigurethefollowingparameters:
• PVPreferences:AllowsyoutoconfigurethePrimaryVariable(PV)aseithergeneralorlocalizedcorrosion.
Note
IfgeneralcorrosionisselectedasthePrimaryVariablethenlocalizedcorrosionbecomesthesecondary.IflocalizedcorrosionisselectedasthePrimaryVariablethengeneralcorrosionbecomestheSecondaryVariable.TheTertiaryVariable(TV)isalwaysconductanceandcannotbechanged.
Note
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• PVUnits,LRV,URV:allowsyoutoconfigurethePVunitsandrange,whengeneralcorrosionisassignedasthePV.ThedefaultvaluesontheCorrTranAQUAareinunitsofmpywitharangeof0…40mpy.ThefullrangeofCorrTranAQUAis0…1000mpy(0…25mmpy).
Note
WhenlocalizedcorrosionisassignedasthePV,nounitsorrangeareselectablebecauselocalizedcorrosionisunitlessandisonascalefrom0to1,with0beingnolocalizedcorrosionand1beingveryhigh.)
• Alarm Mode:ControlsthesettingsforanalarmthatactivateswhenthePVcorrosionrategoesbeyondtheURV.ThedefaultisAuto,andtheoptionsareasfollows:
• Auto–Outputgoesto22.5mAandresetsautomatically
• Manual–Outputgoesto22.5mAandresetsmanually
• Off–Alarmisturnedoff
• B value:ReferstotheBvalueorStern-Gearyvoltage,whichisdefaultedto25.6mV.BUserisonlyrelevantinLPRonlymode.Thisvaluedoesnotnormallyneedtobechanged.
• A Elect Area:Allowsyoutochangetheelectrodearea,whichisrequiredforthecorrosioncalculation.Thesurfaceareaisdefaultedto4.75cm2forthefingertypeelectrodes.Flushmountelectrodesaredefaultedto0.316cm2.
• K Probe Const:referstotheKprobeconstant,orcorrosionconstantK.Thisvalueisdependentonthepipe’smetalpropertiesandisrequiredforthecalculationprocess.
Thedefaultis11597.63 mm * cm2
year * cm2
K= 3270.22 * (atomic mass of metal in grams)(# of electrons in the corrosion reaction) * (density in g/cm2)
SeeElectrodeMaterialGuideTableintheAppendixforfactorycalculatedKvaluesofcommonelectrodematerials.
• Measurement Mode:Certaincorrosionmeasurementscanbeturnedofftogiveafasterresponseifnotrequiredforthecalculation.Thetwovariablesthatcanbeswitchedoffaregeneralcorrosion(GC)andlocalizedcorrosion(LC).Conductanceisrequiredforbothcorrosiontypesandcannotbeturnedoff.Ifallthreeareused,thedefaultisGC+LC+Cond.Thethreepossibleconfigurationsandcycletimesare:
• GC+LC+Con–General,Localized,Conductivity:21min.cycle
• GC+Con–General,Conductivity:4min.cycle
• LC+Con–Localized,Conductivity:17min.cycle
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• Device Mode:ThisdeterminesthewaythegeneralcorrosioncalculationisperformedbytheCorrTranAQUA.
• Normal(HDA/LPR)–Aprocess-specificStern-Gearyvoltage(Bharm)iscalculatedwitheverymeasurementcyclethroughHDA.ThisvalueisthenimplementedintheLPRcorrosionratecalculation.Thisisthedefaultsettingandshouldbeleftintacttomaintainthebestaccuracy.
• LPRonly–AuserdefinedStern-Gearyvoltage(‘BUser’)isspecifiedandusedforallLPRcorrosionratecalculations.ThisishowCorrTranAQUAisconfigured.
• Device Settings Tab Buttons:ThesebuttonsarefoundatthebottomoftheDeviceStatusTabpage.
• ResetAlarm-ThisbuttonisusedtoresetthealarmwhenoperatingtheCorrTranAQUAinManualAlarmMode.
• ReadValues-PressingthisbuttonpopulatesallcategoriesonthedevicesettingstabwiththecurrentvaluesprogrammedontheCorrTranAQUAtransmitter.
• WriteValues-PressingthisbuttonprogramstheCorrTranAQUAtransmittertoallsettingscurrentlydisplayedontheDeviceSettingsTab.
Figure 26. Device Setting Tab
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7.3.3 DevicestatustabTheDeviceStatustab,seeninFigure27,allowsyoutoviewanysystemerrorsorfaultstheCorrTranAQUAmaybeexperiencing.Errorsorfaultsappearascheckmarksnexttotheirdescriptor.
Figure 27. Device Status Tab Device
ThecauseofeacherrororfaultisdescribedinSection12,Troubleshooting,Table2.
• DeviceSettingstabbuttons:ThesebuttonsarefoundatthebottomoftheDeviceStatustabpage
• Resetconfigchangedflag:Clearsachecknexttoconfigurationchanged
• UpdateStatus:Updatesthedevicestatustabwiththemostrecentsystemerrorsorfaults
7.3.4 ToolstabTheToolstab,seeninFigure28,allowsyoutologcorrosiondata,extractpreviouslycollectedcorrosiondata,andaccesstheresettingfeaturesofCorrTranAQUA.
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Figure 28. Tools Tab
• Data Logging:TheSelectFilebuttonallowsyoutosetthelocationforandthenameoftheLogFilewheredataisstoredwhentheLogfunctionisenabledontheProcessDatatab,seesection6.3.1.Dataissavedinoneoftwoways:
• Append–Dataisaddedtopreviouslyloggeddata• Overwrite–Datareplacespreviouslyloggeddata
• History File: TheSelectFilebuttonallowsyoutosetthelocationforandthenameoftheHistoryFilewheredataisstoredwhenGetHistorybuttonispressed.Dataisretrievedandsavedinoneoftwoways:
• Append–Dataisaddedtopreviouslyretrieveddata• Overwrite–Datareplacespreviouslyretrieveddata
• View Files: ClickingtheLogFilebuttonortheHistoryFilebuttonwillopentheirrespectivefiles.
• Initial Bavg-Value:ThedefaultsettingisActualAverageandresultsaretypicallybestifleftasis.
• Num of Cycles to read:TheCorrTranAQUAstoresdatafromitslast300cyclesinitsinternalmemory.BypressingtheGetHistorybuttontheCorrTranAQUAEvaluationToolextractsthedataforauserdefinednumberofcycles(1to300)andappendsoroverwritesittotheHistoryFile.
• Loop Current:WhenusingHARTcommunicationfordatacollection,the4-20mAsignalisnolongerimportant.Youcanchoosetosettheloopcurrenttoaconstantfixedvalue.IfyougetanerrorforElectrodeBalanceoutofRangeontheDeviceStatustab,settingtheloopcurrenttoahighmAfixedvalueshouldclearthis.Ifyouwanttheloopcurrenttochangebetween4-20mAastheprimaryvariablechangesselectActualPVValue(normal)whichisthedefaultsetting.
• Special Features:
• ResetCycles/Avg–Resetsthenumberofcyclesto0,clearstheinternalmemoryofitshistoricdata,andresetstheLC.Avg.calculation.
• ResetDevice–CyclespowertotheCorrTranAQUA.• FactoryDefault–HasthesamefunctionsoftheResetCycles/Avgbutton,and
resetsallsettingstothefactorydefault.
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8. TRANSFERING PROCESS DATA TO EXCELTheCorrTranMVEvaluationToolallowsyoutoviewCorrTranAQUAprocessdataintwoways.Youcanusetheloggingfunctiontosetuparunninglogfilethatwillrecordthecorrosionvaluesyouselect.Thesecondmethodinvolvesretrievingdatafromtheinternalmemory,whichstoresdatafromthelast300cyclescreatingahistoryfile.BoththeLogFileandHistoryFilearesavedas.txtdocuments.TotransferthisdataintoExcel,clickontheviewlogfileorhistoryfilebuttononthetoolstabandtheappropriate.txtfilewillopenasseeninFigure29(forthisexample,thelogfileisused).
Figure 29. CorrTran MV Log File
• Select‘Edit’>‘SelectAll’fromthetoolbartoselectallthedatainthelogfile.
• Select‘Edit’>‘Copy’fromthetoolbartocopyallthedatainthelogfile.
• OpenanewExcelworkbookandselectcellA1.
• Select‘Edit’>‘Paste’fromtheExceltoolbartotransferallthelogdatatoExcel.AtthispointthedataisallincolumnAasatextformatandwillappearasseeninFigure30.
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Figure 30. CorrTran MV Log File
• SelectallofcolumnAasseeninFigure30,Select‘Data’>‘TexttoColumns…’fromthetoolbarandthescreeninFigure31willappear.
Figure 31. Text to Columns
• SelectFixedwidthasseeninFigure31andthenpressFinish.ThetextdatahasnowbeentransposedtothepropercolumnswiththeproperheadingsasseeninFigure32.Adjustthecolumnsizestoaccommodatethedataasneeded.
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Figure 32. Properly Sorted Data
• Youcannowtrendandanalyzethelogdataasneeded.Figure33isanexampleofhowyoucanplotgeneralcorrosion,localizedcorrosion,andconductanceovertime.
Figure 33. Example Log Data Graph
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9. CHANGING CORRTRAN AQUA OPERATING MODE TO REDUCE THE EXCITATION FREQUENCY (Factory Default Setting for CorrTran AQUA)
ThefunctionalityhereisthatundercertainconditionstheCorrTrancanreadvaluesthatare,typically,muchhigherthanexpected.Thismaybeduetoahigh-capacitanceeffectontheelectrodescausedbyfilminginhibitors.
Toseeifthiseffectispresent,itisnecessarytoreducethesinewavefrequencyinordertoeliminatethecapacitanceeffect.OperatingtheunitinEnhancedMode1or2facilitatesthelowerfrequencysinewave.Iftheeffectisnotpresent,therewillbelittlechangebetweenstandardandenhancedmodes.Ifthereisabigreductioninthecorrosionrate,thenthecapacitanceeffectisrealandEnhancedMode1or2shouldbesetpermanentlyforthatapplication.DeterminingwhichEnhancedModetooperateinisdeterminedempirically.
Figure 34 is for the CorrTran EC. It is identical on the CorrTran MV or CorrTran AQUA. Note: CorrTran AQUA is shipped from the factory defaulted to this setting.
1. ConnecttheCorrTranEvaluationTool.EstablishCommunication.
2.OntheToolsTab,underLPR/HDAPerformanceselectEnhancedMode1.PresstheSetbuttontosendthesetuptotheunit.Ifthecorrosionratedoesnotchangeafter1-2hoursofoperation,thereisnocapacitanceeffect.ReturntheunittoStandardMode.
3. Ifthereisareductionincorrosionrate,tryEnhancedMode2.Ifareductionincorrosionrateisstillproduced,useEnhancedMode2otherwisereturnsettingtoEnhancedMode1.
Figure 34. Enhanced Mode
DisconnecttheEvaluationToolandreconnectyourDCA.Note:Theevaluationtimeforacompletecyclechangesfrom21minutesinStandardModetoapproximately37minuteswhenrunningEnhancedMode2.ItisbetweenthetwoforEnhancedMode1.ThisisthereasontobackdowntoEnhancedMode1ifEnhancedMode2doesnotproduceanadditionalreductionincorrosionrate.
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10. REPLACEMENT PARTS AND ACCESSORIES 10.1 CorrTran AQUA parts PleasesubmittheserialtagnumberonthenameplatewhenorderingreplacementpartsforCorrTranAQUA.
IfthepipeorvesselintowhichtheCorrTranAQUAistobeinsertedisunderpressureand/orcontainsanyhazardoussubstance,suchassteam,causticsolutions,acids,toxinsorothersubstancesspecifiedbyOSHAasphysicalorhealthhazards,thepipeorvesselmustfirstbedepressurizedandanyhazardoussubstancepurgedtherefrom,andappropriatelockout/tagoutproceduresobservedinaccordancewithSection1910.147oftheOSHARegulations,beforeCorrTranAQUAcanberemovedortheelectrodesreplaced.Failure to follow these procedures may result in serious injury or death.
10.1.1Transmitterreplacement
C M T A - A 4 I H 3 - - G P
CertificatesDisplay/No DisplayB No DisplayD LCD, Loop Powered Display
Remote Probe Cable3 12' Cable
Electrical OutputIH 4-20 mA, HART
HousingA1 ABS Housing, Nema 4x, Cable Gland EntryA4 ABS Housing, Nema 4x, V1 (M12) connector
Corrosion TypeA CorrTran AQUA, Multivariable
Warning
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C M P - - /
Insertion Length (fixed probes only)in inches, 5" … 28", in 0.2" increments
Electrode Material0A… see electrode material guide*only needs to be specified for flush mounted electrodes
Probe Length050* 5", 3/4" NPT080 8", 3/4" NPT110* 11", 3/4" NPT120 12", 3/4" NPT or Flange180 18", 3/4" NPT or Flange240 24", 1" NPT, 3/4" NPT, or Flange300 30", 1" NPT, 3/4" NPT, or Flange754* 127 mm, 3/4" NPT756 204 mm, 3/4" NPT280* 280 mm, 3/4" NPT305 305 mm, 3/4" NPT or Flange457 457 mm, 3/4" NPT or Flange610 610 mm, 1" NPT, 3/4" NPT, or Flange762 762 mm, 1" NPT, 3/4" NPT, or Flange*epoxy probe only
Probe MountingSee probe mounting guide
Measurement Unit, Probe MaterialCB inches, 1.4435, 316LCF inches, epoxy glassDB mm, 1.4435, 316LDF mm, epoxy glass
Process ConnectionN21 3/4" NPT, ANSI B 1.20.1, 1.4435/316LN2P 3/4" NPT, ANSI B 1.20.1, adj. thread, nylonN31 1" NPTN51 1-1/2" NPTXXX Special Version
10.1.2Probereplacement*ProbeMountingGuideandElectrodeMaterialGuidecanbefoundintheAppendix
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10.1.3Electrodereplacement–fingerelectrodes
Electrodesaresoldinapackof3.
10.2 Accessories
Forinstallationsrequiringmorethenonetransmitter,P+FoffersawidevarietyofHARTmultiplexersandterminationboardsforwiringtoaPLCorDCSsystem.Themultiplexersareavailablein16and32channeloptions.
• KFD2-HMM-16 16-channelMUXmaster• KFD0-HMS-16 16-channelslave
PleasecontactP+Fforterminationboardselection.
Additional Accessories
Note
Accessories
US-HI-321 HART modem, HART to USB interfaceFor direct connection to your PC
KFD2-HLC-Ex1.D HART Loop ConverterConverts HART signal to 3 separate 4 ... 20 mA outputs
KFD2-HLC-Ex1.D.2W HART Loop ConverterConverts HART signal to 3 separate 4 ... 20 mA outputs
KFD2-HLC-Ex1.D.4S HART Loop ConverterConverts HART signal to 3 separate 4 ... 20 mA outputs
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11. SYSTEM SPECSApplicationTheCorrTranAQUAperformscontinuous(electro-chemical)corrosionmeasurementofliquidsandgasses.Probesareavailableinseveraldifferentmaterialsandprocessconnections:
• Epoxyglassprobe:3/4”NPTadjustablenylonfitting
• Adjustableprobe:3/4”NPTfitting,availablein316LSS
• Fixedprobe:3/4”NPTfittingandflangesstartingat1”ANSIB16.5150lbs,availablein316LSS
FunctionandSystemDesignMeasuringPrinciple:TheCorrTranAQUAutilizesstate-of-the-artalgorithmsanddataanalysistechniquestoaccuratelymeasuregeneralcorrosionrateandpitting.ToimprovetheperformanceoftheindustryacceptedLinearPolarizationResistance(LPR)techniquetheHarmonicDistortionAnalysis(HDA)isusedtocalculateandupdateaprocessspecificStern-Gearyvariable(Bharm)everymeasurementcycle.Tofurtherenhancetheperformance,anapplication-specificStern-Gearyvariable(B-value)iscalculatedandupdatedeverymeasuringcycle.ThereisnoneedtomanuallyupdatetheB-valuebecauseofprocesschanges.Duringthemeasurementcycle,CorrTranAQUAalsoperformsanautomatedElectrochemicalNoise(ECN)measurementwhichprovidesalocalizedcorrosion(pitting)measurement.Atthecompletionofeachmeasurementcycle,therespectivecorrosionrateandpittingvalueintheformofa4-20mA/HARTsignalisproducedandmadeavailabletoplantpersonnel.
EquipmentArchitectureSeeSection4.3WiringwithHART.
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Technical dataInput
MeasuredVariable •Generalcorrosion:Electro-chemicalcorrosionthatproceedsmoreorlessuniformlyoverthesurfaceofthematerialexposedtothecorrosiveenvironment.
•Localizedcorrosion(pitting):Electro-chemicalcorrosionthatoccursatdiscretesitesonthematerialexposedtothecorrosiveenvironment.
•Conductance:Thereciprocalofthesolutionresistance.Itisameasureofhoweasilyelectricityflowsalongacertainpaththroughanelectricalelement.
MeasuringRange •Generalcorrosion:0...1000mpy(0...25mmpy),0...40mpy(0...1mmpy)defaultvalue
•Localizedcorrosion(pitting):Unitlessnumberfrom0...1,with0beingnolocalizedcorrosionand1beingveryhigh.
•Conductance:Notadjustable.MeasuredinSiemens.
Output
OutputSignal 4-20mAwithHARTprotocol,2-wire
SignalonAlarm Errorinformationcanbeaccessedviathefollowinginterfaces:•Currentoutput,22.5mA•Digitalinterface
Auxiliary Energy
LoadHART MinimumloadforHARTcommunication:250Ω
CableEntry IndustrystandardV1(M12connector)
SupplyVoltage 11-30VDCwitoutdisplay15-30VDCwithoptionaldisplay
RatedOperatingVoltage 11VDCminatmaxloopcurrent
ConnectableLoad Max.loadat24VDC:575Ωwithalarm/650Ωwithoutalarm
B-Value(Start-up) 25.6mV
Performance Characteristics
ReferenceOperatingConditions
•Temperature:-40°Cto+70°C(-40°Fto+158°F)
•Pressure:6.8bar(100psi)
•Solutionconductance:Min4μS
•Generalcorrosionrate:0...1000mpy(0...25mmpy)
Accuracy •Voltagemeasurementandelectrodeexcitation:<0.02%
•Currentmeasurement:<0.1%
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Technical data (continued)Operating Conditions
OperatingConditions
InstallationInstructions SeeSection3.4InstallationInstructions
Environment
AmbientTemperatureRange
Ambienttemperatureforthetransmitter:
•Withdisplay:-10°Cto+50°C(-14°Fto+58°F)
•Withoutdisplay:-40°Cto+70°C(-40°Fto+158°F)
StorageTemperature -40°Cto+70°C(-40°Fto+158°F)
DegreeofProtection Housing:IP66,NEMA4X
CleaningoftheProbeandElectrodes
SeeSection3.4.2ElectrodeInstallation
Process Conditions
ProcessTemperatureLimits
Seetechnicalspecificationsforyourprobe,Section3.3ProbeSpecifications
ProcessPressureLimits Seetechnicalspecificationsforyourprobe,Section3.3ProbeSpecifications
ProcessFlowRateLimits •Fingerelectrodes:Max6.1mps(20fps)
•Flushelectrodes:None.
Mechanical Construction
Design,Dimensions SeeSection3.1Dimensions
Weight Approx.500g(16.1oz),transmitterhousing
Material •Housing:ABS
•ProcessConnections:1.4401/316LSSorNylon
•Probe:1.4401/316LSSorepoxyglass;fillmaterial:epoxy
•Endcapseal:Glass(standard)orepoxy(onrequest)
•Electrode:SeeElectrodeMaterialGuide
•O-ring:Viton(standard)orKalrez(onrequest)
ProcessConnection SeeSection2.1.2KeytoModelNumber
Human Interface
OperationConcept SeeSection4.3WiringwithHART.SeeSection5ConfigurationandCommissioning
Certificates and Approvals
Patents U.S.patents:7,239,156;7,245,132;7,265,559;7,282,928
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12. TROUBLESHOOTING IfyouencounterproblemsconfiguringorusingyourCorrTranAQUA,consultthefollowingtroubleshootingtable.Ifyoucontinuetohaveproblems,pleasecontactyourP+Frepresentativeforfurtherassistance.
Symptom Cause/Procedures Solution
No4-20mAoutput Checkvoltageandcompareitwiththespecificationsonthenameplate. Connectthecorrectvoltage
Measuringcorrectvoltagebutunitdoesnotrespond
Checkpolarityontheterminals. Seesection4.1:QuickWiringGuide
HARTcommunicationdoesnotfunction
Thecommunicationresistorisnotinstalledproperly. Seechapter4.3:WiringwithHART
Table 1. CorrTran AQUA Basic Troubleshooting Guide
Device Status Codes
Description Troubleshooting
PVoutoflimits TheprimaryvariablehasexceededeithertheLRVorURV.
ThiscanonlyhappenifGeneralCorrosionisassignedtothePVandtherangesarenotsetproperly.Extendtherangevaluestoincludecurrentdatapoint.Seesection6.3formoreinformation.
SVorTVoutoflimits
ThesecondaryortertiaryvariablehasexceededeithertheLRVorURV
ThiscanonlyhappenifGeneralCorrosionisassignedtotheSVandtherangesarenotsetproperly.Extendtherangevaluestoincludecurrentdatapoint.Seesection6.3formoreinformation.TheTVcannotbeoutoflimitsbecauseithasnolimits.
Analogoutputsaturated
Theanalogoutputhasreachedeitheritsminimumormaximum
ThiscanonlyhappenifthealarmmodeisoffandthePVexceedsitsLRVorURV.
Analogoutputfixed
TheanalogoutputsignalhasbeensettoafixedmAvalue.
ThisisaresultofsettingtheLoopCurrenttoafixedvalueonthetoolstab.Seesection6.3formoreinformation.
Morestatusavailable
ThisflagindicatesthatoneormoreoftheflagsintheMoreFieldDeviceStatussectionareset
Informationonly.
Coldstart Thisflagissetafterpowerhasbeenrecycledforonecommunicationtransaction.
Informationonly.
Configurationchanged
AchangehasbeenmadetotheCorrTranAQUAconfiguration.
ThiscanberesetbypressingtheResetConfigChangedFlagonthedevicestatustab.Seesection6.3formoreinformation.
Devicemalfunction
ThisflagindicatesthatoneormoreoftheflagsintheDeviceMalfunctionsectionareset.
Informationonly.
Table 2. Device Status Codes Troubleshooting Guide (continued on next page)
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Device Status Codes
Description Troubleshooting
Highlocalizedcorrosiondetected
Thelocalizedcorrosionrateisabove0.3.
Informationonly.
Conductanceoutofrange
Themeasuredsolutionconductanceislowerthan4μS.Thisequalsaconductivityofapproximately1μS/cmforfingerelectrodes.
TheCorrTranAQUAneedsatleast4μSofsolutionconductanceorsolutionconductivityof1μS/cmforfullaccuracy.Thiscanalsobeanindicationthatthereistoomuchbuilduponthesurfaceoftheelectrodesandtheymayneedtobecleanedortheymaynotbefullyimmersedintheprocessfluid.
Celloffsetvoltageoverflow
TheCorrTranAQUAhasdetectedavoltagedifferencebetweenthethreeelectrodeswhichistoohightocompensate.
Typicallythisisanindicationthatthereistoomuchbuilduponthesurfaceoftheelectrodesandtheyneedtobecleanedorthattheyhaveexceededtheirusefullifeandshouldbereplaced.
Corrosionratecalculationnotpossible
TheCorrTranAQUAwasnotabletogetanyusefuldata.
Checktheelectrodesfordebris,checkforotherflags,andmakesurethattheelectrodesarefullyimmersed.
Electrodebalanceoutofrange
Duetoanextremelyhighunbalancedpotential(voltagedifference)oftheelectrodes,theCorrTranAQUAisdrawingmorepowerfromtheloopthanavailable.
Onewaytodealwiththisproblemistosettheloopcurrenttoafixedvalue(maxis20mA).Thisshouldonlyoccurunderveryrarecircumstances,wherethecorrosionrateisverysmall(loopcurrentisapprox.4mA)butatthesametimethereisahugepotentialdifferencebetweentheelectrodes.Thiscanindicatecontaminationofoneormoreelectrodes,corrosionmaskingeffectsofbuildup,orthatoneelectrodeisbentormissingfromtheprobe.
Internalfailure Hardwarefailuredetected Replacetransmitter
ADCfailure ADCfailuredetected Replacetransmitter
Memoryfailure Memoryfailuredetected Replacetransmitter
Table 3. Device Status Codes Troubleshooting Guide (continued from previous page)
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13. MEASURING PRINCIPLE
Figure 35. CorrTran AQUA Corrosion Cell
GeneralcorrosionLinearPolarizationResistance(LPR)isbasedonthefactthatinacorrodingelectrodetherelationshipbetweenicorrandthepolarizationresistanceisgivebythefollowingequation:
icorr = BRp
,where Rp = ∆E∆I
with∆Ebeingtheappliedvoltageand∆Itheresultingcurrent.
HarmonicDistortionAnalysis(HDA)allowsCorrTranAQUAtodetermineicorrwithoutusingtheTafelslopes(ba,bc).Thisistypicallydonebyapplyingalowfrequencysinusoidalvoltageanddeterminingthedistanceoftheresultingcurrent.
CorrTranAQUAaccuratelymeasuresthegeneralcorrosionratebyimplementingHarmonicDistortionAnalysis(HDA)toimprovetheperformanceofLinearPolarizationResistance(LPR).Aprocess-specificStern-Gearyvoltage(Bharm)iscalculatedwitheverymeasurementcyclethroughHDA.ThisvalueisthenimplementedintheLPRcorrosionratecalculationresultinginahighlyaccurateselfadjusting,processspecificcorrosionratecalculation.CorrTranAQUAcanmeasurethegeneralcorrosionratefrom0…1000mpy(0…25mmpy).
LocalizedCorrosion(Pitting)ElectrochemicalNoise(ECN)isthemethodofmonitoringspontaneousfluctuationsgeneratedattheinterfaceofthecorrodingmetalandprocesssolution.Aslocalizedcorrosionoccurs,thesefluctuationsincrease.
TheCorrTranAQUAmonitorsforthesefluctuationsontheelectrodesurfacesfor17minutes.Itthenperformsastatisticalanalysisresultinginaunitlesspittingfactorvaluebetween0and1.Apittingfactorofnearly0representsnolocalizedcorrosionactivityandapittingfactorof1representshighlocalizedcorrosionactivity.Independentstudieshaverevealedthatasustainedpittingfactorofgreaterthan0.3iscauseforconcernandyoushouldinvestigatethesourceoftheelevatedLocalizedCorrosionrate.Formoreinformationontheinterpretationoflocalizedcorrosionpleasereviewourwhitepaper:“DetectingandInterpretingLocalizedCorrosionUsingCorrTranAQUA.”
Fe
Anodicsite
Cathodicsite
Fe2+
2H+
H2
Icorr 2e-
4 - 20 mA PROBE
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ConductanceSolutionresistanceisameasureofhoweasilyelectricityflowsalongacertainpaththroughanelectricalelement.Thereciprocalofthesolutionresistanceissolutionconductance.
TheCorrTranAQUAmeasuressolutionresistanceinordertomoreaccuratelycalculatethegeneralcorrosionrates.AsanaddedfeatureCorrTranAQUAprovidesyouwiththesolutionconductanceinunitsofSiemensasthetertiaryvariablethatisnotscalable.CorrTranAQUArequiresaminimumsolutionconductanceof4μSinordertoprovidereliablecorrosiondata.
ThesolutionconductancevaluethatCorrTranAQUAprovidescanbeusedtoapproximatesolutionconductivitybythisrelationship:
Conductivity ( Scm ) ≈ Conductance (S)
19
Solutionconductivityisafunctionofdistance.Astheelectrodescorrode,theirsizesandgeometrychangecausingthiscorrelationtodeteriorate.TheCorrTranAQUAshouldnotbeconsideredasareplacementforstandardconductivitymeters.
Note
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14. APPENDIX
Electrode material guide
Other materials are available on request.
Electrode material Key number K value UNS numberAluminum1100 0N 10940.96 A91100 2024 0O 11400.51 A920246061 0T — A960617075 1O — A97075Carbon & steel alloys1010 0S — G101001018 0A 11597.63 G101801020 1T 11401.49 G10200C4130 1R 11283.76 G41300Stainless steel1.4301 / 304 0C 11334.57 S304001.4307 / 304L 0D 11342.80 S30403 1.4401 / 316 0E 11513.39 S316001.4404 / 316L 0F 11519.53 S31603 1.4571 / 316Ti 1M 11382.15 S316351.4438 / 317L 1G 11400.62 S317031.4939 / 904L 1K 11287.19 N08904Copper alloysCDA110ETP (99.9 Cu) 0J 11686.71 C11000CDA220 (bronze) 0P 8644.02 R50400CDA443 (ARS AD. brass) 0M 12324.74 C44300CDA687 (Aluminium brass) 0L 12411.53 C68700CDA706 (Cu/Ni 90/10 0K 11513.44 C70610CDA715 (Cu/Ni 70/30) 0I 11337.86 C71500
Probe mounting guide
* Please consult Pepperl+Fuchs.
Key number Probe type Mounting Process connectionB Standard Remote mount fixedD Standard Remote mount adjustableE retractable* Remote mount adjustable* retrievable* Remote mount fixed
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Model Number Description
CorrTranAQUA-912927 Kit,baseunitwithoutlocaldisplay,1018CSelectrodes,11”probe
CorrTranAQUAwithdisplay-912929 Kit,baseunitwithlocaldisplay,1018CSelectrodes,11”probe
Electrodes Electrodesotherthancarbonsteelmustbeorderedseparately
CorrTran AQUA Model Numbers
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NOTES
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NOTES
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47
NOTES
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Subject to modifications • © 2010 PEPPERL+FUCHS, INC. • Printed in USA • Part No. 913039 • Drawing No. TDOCT-B069_USA 5/10
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