man_1500-2500_pn 20001685_d_2006-02_en

Installation ManualP/N 20001685, Rev. DFebruary 2006

Micro Motion®

Model 1500 or Model 2500 Transmitters

Installation Manual

©2006, Micro Motion, Inc. All rights reserved. Micro Motion is a registered trademark of Micro Motion, Inc. The Micro Motion and Emerson logos are trademarks of Emerson Electric Co. All other trademarks are property of their respective owners.

Transmitter Installation: Model 1500 and 2500 Transmitters iii

Contents

Chapter 1 Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 Flowmeter components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 Transmitter installation procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 Flowmeter documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6 Micro Motion customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Chapter 2 Installing the Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.2 Installation architectures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.3 Determining an appropriate location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.3.1 Power source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.3.2 Maximum cable lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.4 Mounting and removing the transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.5 Mounting the core processor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.6 Grounding the flowmeter components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.7 Supplying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Chapter 3 Wiring the Transmitter to the Sensor. . . . . . . . . . . . . . . . . . . . . . . 113.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113.2 Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113.3 Wiring for 4-wire remote installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.4 Wiring for remote core processor with remote transmitter installations. . . . . . . . . . . 13

Chapter 4 I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194.2 I/O options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194.3 mA output wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204.4 Frequency output wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214.5 Discrete output wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224.6 Discrete input wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244.7 RS-485 wiring to a remote host. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254.8 Voltage and resistance charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Appendix A Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27A.1 Physical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27A.2 Functional specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29A.3 Hazardous area classifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33A.4 Performance specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

iv Transmitter Installation: Model 1500 and 2500 Transmitters

Contents

Appendix B Return Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B.1 New and unused equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B.2 Used equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Transmitter Installation: Model 1500 and 2500 Transmitters 1

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Chapter 1Before You Begin

1.1 OverviewThis chapter provides an orientation to the Micro Motion® Model 1500 or Model 2500 transmitter installation manual and installation process.

1.2 Safety

Safety messages are provided throughout this manual to protect personnel and equipment. Read each safety message carefully before proceeding to the next step.

1.3 Flowmeter components

The Model 1500 or 2500 transmitter is one component in your Micro Motion flowmeter. Other major components include:

• The sensor, which provides measurement functions

• The core processor, which provides memory and processing functions

1.4 Transmitter installation proceduresTo install the transmitter, the following procedures are required:

• Install the transmitter – see Chapter 2

• Wire the transmitter to the sensor – see Chapter 3

• Wire the transmitter I/O terminals – see Chapter 4

WARNING

Improper installation in a hazardous area can cause an explosion.

For information about hazardous applications, refer to Micro Motion approval documentation, shipped with the transmitter or available from the Micro Motion web site.

CAUTION

Improper installation could cause measurement error or flowmeter failure.

Follow all instructions to ensure transmitter will operate correctly.

2 Transmitter Installation: Model 1500 and 2500 Transmitters

Before You Begin

1.5 Flowmeter documentationTable 1-1 lists documentation resources for other required information.

1.6 Micro Motion customer service

For customer service, phone the support center nearest you:

• In the U.S.A., phone 1-800-522-MASS (1-800-522-6277)

• In Canada and Latin America, phone (303) 527-5200

• In Asia, phone (65) 6770-8155

• In the U.K., phone 0800 - 966 180 (toll-free)

• Outside the U.K., phone +31 (0) 318 495 670

Table 1-1 Flowmeter documentation resources

Topic Document

Sensor installation Installation manual shipped with sensor

Core processor installation (if mounted remotely from sensor)

This document

Transmitter configuration, transmitter startup and use, and transmitter troubleshooting

Transmitter Configuration and Use: Series 1000 and 2000 Transmitters orTransmitter Configuration and Use: Model 1500 Transmitter with Filling and Dosing Application


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Chapter 2Installing the Transmitter

2.1 OverviewThis chapter describes how to install Micro Motion Model 1500 and 2500 transmitters. The following general steps are required:

• Determine your installation architecture (see Section 2.2)

• Determine the location of the transmitter and other flowmeter components (see Section 2.3)

• Mount the transmitter (see Section 2.4)

• Mount the core processor, if required (see Section 2.5)

• Ground the flowmeter components (see Section 2.6)

• Supply power to the flowmeter (see Section 2.7)

2.2 Installation architectures

Your flowmeter installation will match one of the architectures shown in Figures 2-1 and 2-2. Mounting, sensor wiring, and grounding requirements depend on this architecture.

Figure 2-1 Installation architecture – 4-wire remote transmitter

Model 1500 or 2500 transmitter (top view)Sensor

4-wire cable(Distance x; see Table 2-2)

Hazardous area Safe area

Core processor


Installing the Transmitter

Figure 2-2 Installation architecture – Remote core processor with remote transmitter

2.3 Determining an appropriate locationTo determine an appropriate location for the transmitter, ensure that the location meets the requirements described in Appendix A.

The Model 1500 or 2500 transmitter is designed for installation in a safe area. It can be connected to a core processor located in a hazardous area. If you plan to connect the transmitter to a core processor located in a hazardous area, ensure that any cable used between the transmitter and the sensor meets the hazardous area requirements. For more information about hazardous area classifications, see Appendix A.

In addition, you must consider the location of power source, distance between the transmitter and the sensor or the core processor, and accessibility for maintenance.

2.3.1 Power source

The transmitter must be connected to a DC voltage source. Do not use an AC power supply.

See Table A-5 for power supply requirements. To size the cable, refer to Table 2-1 and use the following formula as a guideline:

CAUTION

Applying AC voltage to the transmitter will damage the device.

To avoid damaging the transmitter, do not connect it to an AC power supply.

Sensor

Core processor

Junction box 9-wire cable(Distance y; see Table 2-2)

Model 1500 or 2500 transmitter (top view)

Hazardous area Safe area

4-wire cable(Distance x ; see Table 2-2)

MinimumSupplyVoltage 19.2V CableResistance CableLength× 0.33 A×( )+=



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2.3.2 Maximum cable lengths

Maximum cable length between flowmeter components depends on the installation architecture and the cable type. See Figure 2-1 and Table 2-2.

Table 2-1 Typical power cable resistances at 20 °C

Gauge Resistance(1)

(1) These values are based on copper wire, and include the resistance of both wires in a cable. If you are using a material other than copper, refer to the resistivity specifications for your wire type.

14 AWG 0.0050 Ω/foot




2,5 mm2 0,0136 Ω/meter

1,5 mm2 0,0228 Ω/meter

1 mm2 0,0340 Ω/meter

0,75 mm2 0,0460 Ω/meter

0,5 mm2 0,0680 Ω/meter

Example The transmitter is mounted 350 feet from a DC power supply. If you want to use 16 AWG cable, calculate the required voltage at the DC power supply as follows:

Table 2-2 Maximum cable lengths

Cable type Wire gauge Maximum length

Micro Motion 9-wire (Distance y in Figure 2-2)

Not applicable 60 feet (20 meters)

Micro Motion 4-wire (Distance x in Figures 2-1 and 2-2)

Not applicable 1000 feet (300 meters)

User-supplied 4-wire (Distance x in Figures 2-1 and 2-2)

• Power wires (VDC) 22 AWG (0,35 mm2) 300 feet (90 meters)

20 AWG (0,5 mm2) 500 feet (150 meters)

18 AWG (0,8 mm2) 1000 feet (300 meters)

• Signal wires (RS-485) 22 AWG (0,35 mm2) or larger 1000 feet (300 meters)

MinimumSupplyVoltage 19.2V 0.0080 ohms/ft 350 ft× 0.33 A×( )+=

MinimumSupplyVoltage 20.1V=

MinimumSupplyVoltage 19.2 CableResistance CableLength× 0.33 A×( )+=



2.4 Mounting and removing the transmitterThe transmitter is designed to be mounted on a 35 mm DIN rail. The DIN rail must be grounded. See Figure A-1 for dimensions.

The transmitter snaps into place on the DIN rail. To remove the transmitter from the rail, pull the spring clamp away from the transmitter, using the spring clamp release loop. See Figure 2-3.

Figure 2-3 Mounting and removing the transmitter

If the temperature is above 113 °F (45 °C) and you are mounting multiple transmitters, they must be mounted at least 0.33 in (8,5 mm) apart. Use an end bracket or end stop to space the transmitters. See Figure 2-4.

Figure 2-4 Mounting multiple transmitters

DIN rail

Spring clamp

Spring clamp release loop

0.33 or greater(8,5 or greater)

End bracket or end stop0.33 in (8,5 mm) minimum spacing

Dimensions in inches(mm)



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2.5 Mounting the core processorThis step is required only for remote core processor with remote transmitter installations (see Figure 2-2). If you have a 4-wire remote installation, go to Section 2.6.

See Figure 2-5 for a diagram of the mounting bracket supplied with the transmitter. Both pipe mounting and wall mounting are shown.

Figure 2-5 Remote core processor – Wall mount or pipe mount

To mount the core processor:

1. Identify the components shown in Figure 2-6. For dimensions, see Appendix A.

2. If desired, reorient the core processor housing on the bracket.

a. Loosen each of the four cap screws (4 mm).

b. Rotate the bracket so that the core processor is oriented as desired.

c. Tighten the cap screws, torquing to 30 to 38 in-lbs (3 to 4 N-m).

3. Attach the mounting bracket to an instrument pole or wall. For pipe mount, two user-supplied U-bolts are required. Contact Micro Motion to obtain a pipe-mount installation kit if required.

Figure 2-6 Remote core processor components

Mounting bracket(wall mount)

Mounting bracket(pipe mount)

End-capMounting bracket

Core processor lid

Core processor housing

Conduit openingfor 4-wire cable

Conduit openingfor 9-wire cable



2.6 Grounding the flowmeter componentsGrounding requirements depend on the installation architecture (see Figures 2-1 and 2-2). Grounding methods for each flowmeter component are listed in Table 2-3.

If national standards are not in effect, follow these grounding guidelines:

• Use copper wire, 14 AWG (2,5 mm2) or larger wire size, for grounding.

• Keep all ground leads as short as possible, less than 1 Ω impedance.

• Connect ground leads directly to earth, or follow plant standards.

2.7 Supplying powerIn all installations, power must be provided to the transmitter. Refer to Section 2.3.1 for information on the transmitter’s power supply requirements.

Connect the power supply to terminals 11 and 12. Terminate the positive wire on terminal 11 and the negative wire on terminal 12. See Figure 2-7.

Terminals 13 and 14 are used to jumper power to another Model 1500 or 2500 transmitter. A maximum of five transmitters can be jumpered together.

CAUTION

Improper grounding could cause measurement error.

To reduce the risk of measurement error:

• Ground the transmitter to earth, or follow ground network requirements for the facility.

• For installation in an area that requires intrinsic safety, refer to Micro Motion approval documentation, shipped with the transmitter or available from the Micro Motion web site.

• For hazardous area installations in Europe, refer to standard EN 60079-14 if national standards do not apply.

Table 2-3 Grounding methods for flowmeter components

Installation architecture Components Grounding method

4-wire remote Sensor / core processor assembly

See sensor documentation.

Transmitter Ground the DIN rail. The rail clip in the base of the transmitter housing grounds the transmitter to the DIN rail.

Remote core processor with remote transmitter

Sensor See sensor documentation.

Core processor Ground the core processor according to applicable local standards, using either the internal or external ground screw.

Transmitter Ground the DIN rail. The rail clip in the base of the transmitter housing grounds the transmitter to the DIN rail.



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Figure 2-7 Wiring the transmitter power supply

–

+ –

+

Power supply jumper to a maximum of four other Model 1500 or 2500 transmitters

Primary power supply(DC)


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Chapter 3Wiring the Transmitter to the Sensor

3.1 OverviewThis chapter describes how to connect a Micro Motion Model 1500 or Model 2500 transmitter to a Micro Motion sensor.

Wiring requirements between the sensor and transmitter depend on the installation configuration (see Figures 2-1 and 2-2):

• If you have a 4-wire remote transmitter installation, review the information on 4-wire cable in Section 3.2, then follow the instructions in Section 3.3.

• If you have a remote core processor with remote transmitter installation, review the information on both 4-wire and 9-wire cable in Section 3.2, then follow the instructions in Section 3.4.

3.2 Cable types

Micro Motion offers two types of 4-wire cable: shielded and armored. Both types contain shield drain wires.

User-supplied 4-wire cable must meet the following requirements:

• Twisted pair construction

• The gauge requirements as described in Table 2-2

• The applicable hazardous area requirements, if the core processor is installed in a hazardous area (see the approval documents shipped with the transmitter or available on the Micro Motion web site)

Micro Motion offers three types of 9-wire cable: jacketed, shielded, and armored. Refer to Micro Motion’s 9-Wire Flowmeter Cable Preparation and Installation Guide for detailed descriptions of these cable types and for assistance in selecting the appropriate cable for your installation.

CAUTION

Large electromagnetic fields can interfere with flowmeter communication signals.

Improper installation of cable or conduit can cause measurement error or flowmeter failure. To reduce the risk of measurement error or flowmeter failure, keep cable or conduit away from devices such as transformers, motors, and power lines which produce large electromagnetic fields.


Wiring the Transmitter to the Sensor

3.3 Wiring for 4-wire remote installationsTo connect the cable, refer to Figure 2-1 and follow the steps below.

1. Prepare the cable as described in the sensor documentation.

2. Connect the cable to the core processor as described in the sensor documentation.

3. To connect the cable to the transmitter:

a. Identify the wires in the 4-wire cable. The 4-wire cable supplied by Micro Motion consists of one pair of 18 AWG (0,75 mm2) wires (red and black), which should be used for the VDC connection, and one pair of 22 AWG (0,35 mm2) wires (green and white), which should be used for the RS-485 connection.

b. Connect the four wires from the core processor to terminals 1–4 on the transmitter. See Figures 3-1 and 3-2. Do not ground the shield, braid, or drain wire(s) at the transmitter.

Figure 3-1 4-wire cable between enhanced core processor and transmitter

Figure 3-2 4-wire cable between standard core processor and transmitter

Core processor terminals

4-wire cable Transmitter terminals for sensor connectionMaximum cable length:

see Table 2-2

User-supplied or factory-supplied cable

RS-485/A (White)

VDC+ (Red)

RS-485/B (Green)

VDC– (Black)

RS-485/A (White)

VDC+ (Red)

RS-485/B (Green)

VDC– (Black)

Core processor terminals

Transmitter terminals for sensor connection

VDC–(Black)

RS-485/B(Green)

RS-485/A(White)

Maximum cable length:see Table 2-2

User-supplied or factory-supplied cable

VDC+(Red) RS-485/A (White)

VDC+ (Red)

RS-485/B (Green)

VDC– (Black)

4-wire cable



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3.4 Wiring for remote core processor with remote transmitter installationsThere are two subtasks in this procedure:

• Wiring the remote core processor to the transmitter (4-wire cable)

• Wiring the sensor to the remote core processor (9-wire cable)

Refer to Figure 2-2 and follow the instructions provided in this section.

Subtask 1 Wire the remote core processor to the transmitter

1. Use one of the following methods to shield the wiring from the core processor to the transmitter:

• If you are installing unshielded wiring in continuous metallic conduit that provides 360° termination shielding for the enclosed wiring, go to Subtask 1, Step 6.

• If you are installing a user-supplied cable gland with shielded cable or armored cable, terminate the shields in the cable gland. Terminate both the armored braid and the shield drain wires in the cable gland. Go to Subtask 1, Step 6.

• If you are installing a Micro Motion-supplied cable gland at the core processor housing:

- If you are using shielded cable, prepare the cable and apply shielded heat shrink to the cable (see Figure 3-3), as described in Subtask 1, Step 4. The shielded heat shrink provides a shield termination suitable for use in the gland when using cable whose shield consists of foil and not a braid.

- If you are using armored cable, prepare the cable as described in Subtask 1, Step 4, but do not apply heat shrink – omit Steps 4d, e, f, and g.

2. Remove the cover from the core processor.

3. Slide the gland nut and the clamping insert over the cable.

Figure 3-3 Micro Motion cable gland and heat shrink

4 1/2 in(114 mm)

3/4 in(19 mm)

7/8 in (22 mm) 7/8 in

(22 mm)

Shielded heat shrink

Gland body

Gland nut

Gland clamping insert



4. For connection at the core processor housing, prepare shielded cable as follows (for armored cable, omit steps d, e, f, and g):

a. Strip 4 1/2 inches (114 mm) of cable jacket.

b. Remove the clear wrap that is inside the cable jacket, and remove the filler material between the wires.

c. Remove the foil shield that is around the insulated wires, leaving 3/4 inch (19 mm) of foil or braid and drain wires exposed, and separate the wires.

d. Wrap the shield drain wire(s) around the exposed foil twice. Cut off the excess wire. See Figure 3-4.

Figure 3-4 Wrapping the shield drain wires

e. Place the shielded heat shrink over the exposed shield drain wire(s). The tubing should completely cover the drain wires. See Figure 3-5.

f. Without burning the cable, apply heat (250 °F or 120 °C) to shrink the tubing.

Figure 3-5 Applying the heat shrink

g. Position gland clamping insert so the interior end is flush with the heat shrink.

h. Fold the cloth shield or braid and drain wires over the clamping insert and approximately 1/8 inch (3 mm) past the O-ring. See Figure 3-6.



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Figure 3-6 Folding the cloth shield

i. Install the gland body into the core processor housing conduit opening. See Figure 3-7.

Figure 3-7 Gland body and core processor housing

5. Insert the wires through the gland body and assemble the gland by tightening the gland nut.

6. Identify the wires in the 4-wire cable. The 4-wire cable supplied by Micro Motion consists of one pair of 18 AWG (0,75 mm2) wires (red and black), which should be used for the VDC connection, and one pair of 22 AWG (0,35 mm2) wires (green and white), which should be used for the RS-485 connection. Connect the four wires to the numbered slots on the core processor, matching corresponding numbered terminals on the transmitter. See Figure 3-8.



Figure 3-8 Connecting the wires at the core processor

7. Reattach the core processor cover.

8. At the transmitter, connect the four wires from the core processor to terminals 1–4 on the transmitter. See Figure 3-2. Do not ground the shield, braid, or shield drain wire(s) at the transmitter.

Subtask 2 Wiring the sensor to the remote core processor

1. Refer to Micro Motion’s 9-Wire Flowmeter Cable Preparation and Installation Guide for instructions on cable shielding and preparation:

• At the sensor end, follow the instructions for your cable type.

• At the core processor end, follow the instructions for your cable type with an MVD transmitter.

CAUTION

Twisting the core processor will damage the equipment.

Do not twist the core processor.

CAUTION

Allowing the shield drain wires to contact the sensor junction box can cause flowmeter errors.

Do not allow the shield drain wires to contact the sensor junction box.

Power supply +(Red wire)

Power supply –(Black wire)

RS-485/A (White wire)

RS-485/B (Green wire)

Core processor housing internal ground screw• For connections to earth ground (if core processor cannot be grounded via sensor

piping and local codes require ground connections to be made internally)• Do not connect shield drain wires to this terminal



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2. To connect the wires, refer to Micro Motion’s 9-Wire Flowmeter Cable Preparation and Installation Guide and follow the instructions for your sensor with an MVD transmitter. Additional information for connecting the wires at the core processor is provided below:

a. Identify the components shown in Figure 2-6.

b. Remove the end-cap.

c. Insert the 9-wire cable through the conduit opening.

d. Connect the wires to the plugs supplied with the core processor.

e. Insert the plugs into the sockets inside the lower conduit ring. See Figure 3-9.

Figure 3-9 9-wire cable between sensor and core processor

BrownRed

GreenWhite

BlueGray

OrangeVioletYellow

Black(Drains from allwire sets)

Plug andsocket

Mounting screw

BlueGrayOrange

RedGreenWhite

BrownViolet

Yellow

Ground screw

Black

9-wire cable from sensor Core processor



3. Ground the cable.

If using jacketed cable:

a. Ground the shield drain wires (the black wire) only on the core processor end, by connecting it to the ground screw inside the lower conduit ring. Do not ground to the core processor’s mounting screw. Do not ground the cable at the sensor junction box.

If using shielded or armored cable:

a. Ground the shield drain wires (the black wire) only on the core processor end, by connecting it to the ground screw inside the lower conduit ring. Do not ground to the core processor’s mounting screw. Do not ground the cable at the sensor junction box.

b. Ground the cable braid on both ends, by terminating it inside the cable glands.

c. Ensure integrity of gaskets, grease all O-rings, then close the junction box housing and core processor end-cap, and tighten all screws.

CAUTION

Damaging the wires that connect the transmitter to the sensor can cause measurement error or flowmeter failure.

To reduce the risk of measurement error or flowmeter failure, when closing the housings on the sensor and core processor, make sure that the wires are not caught or pinched.


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Chapter 4I/O Wiring

4.1 OverviewThis chapter describes how to wire the I/O terminals for the Model 1500 or Model 2500 transmitter.

It is the user’s responsibility to verify that the specific installation meets the local and national safety requirements and electrical codes.

4.2 I/O optionsThe I/O options for the transmitter terminals (channels) are shown in Table 4-1. In this table:

• “Internal” means that the terminals are powered automatically by the transmitter. The I/O wiring instructions for internal power do not include power setup and power wiring.

• “Internal or external” means that the terminals can be configured for either internal or external power. If external is chosen, the terminals must be connected to an independent power supply. You can configure the power option for Channels B and C independently. The I/O wiring instructions for external power include power setup and power wiring.

Table 4-1 Terminal I/O options

Terminals (channel)

Model 1500 standardModel 1500 with filling and dosing application Model 2500

Output Power Output Power Output Power

21 & 22 (A) mA1(1) (HART)

(1) mA1 and mA2 refer to the primary and secondary mA outputs, respectively.

Internal mA1(1) Internal mA1(1) (HART) Internal

23 & 24 (B) N/A N/A DO1(2)

(2) DO1 and DO2 refer to discrete outputs 1 and 2, respectively.

Internal or external

mA2(1) Internal

FO(3) Internal or external

DO1(2) Internal or external

31 & 32 (C) FO(3)

(3) Frequency output.

Internal DO2(2) Internal or external

FO(3) Internal or external

DI(4)

(4) Discrete input.

Internal or external

DO2(2) Internal or external

DI(4) Internal or external

33 & 34 (D) RS-485 N/A RS-485 N/A RS-485 N/A


I/O Wiring

4.3 mA output wiringThe following options are shown:

• Basic mA output wiring – Figure 4-1

• HART/analog single-loop wiring – Figure 4-2

• HART multidrop wiring – Figure 4-3

Note: For Model 1500 standard and Model 2500 transmitters, HART communications may be superimposed on the primary mA output. HART communications is not available on the Model 1500 transmitter with the filling and dosing application.

Note: If you will configure the transmitter to poll an external temperature or pressure device, you must wire the mA output to support HART communications. You may use either HART/analog single-loop wiring or HART multidrop wiring.

Figure 4-1 Basic mA output wiring

Figure 4-2 HART/analog single-loop wiring

+

–+

–

mA receiving device820 Ω maximum loop resistance

Channel A (mA 1) Channel B (mA 2)

mA receiving device420 Ω maximum loop resistance

+–

820 Ω maximum loop resistance

For HART communications:• 600 Ω maximum loop resistance• 250 Ω minimum loop resistance

HART-compatible host or controller


I/O Wiring

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Figure 4-3 HART multidrop wiring with SMART FAMILY™ transmitters and a configuration tool

4.4 Frequency output wiringThe following options are shown:

• Internal power – Figure 4-4

• External power – Figure 4-5

Figure 4-4 Frequency output wiring – Internal power

ProLink II v2.0,HART Communicator, or

AMS software

HART-compatible transmitters SMART FAMILY™

transmitters

Note: For optimum HART communication, make sure the output loop is single-point-grounded to an instrument-grade ground.

24 VDC loop power supply required for

HART 4–20 mA passive transmitters

Model 1500/2500 transmitter

600 Ω maximum resistance250 Ω minimum resistance

000042+

+

–

–

000042

Counter

Output voltage level is +15 VDC ±3%with high resistance load.Refer to Figure 4-11 for output voltage versus load resistance.

Counter

Output voltage level is +15 VDC ±3% with high resistance load. Refer to Figure 4-12 for output voltage versus load resistance.

Channel C

Channel B


I/O Wiring

Figure 4-5 Frequency output wiring – External power

4.5 Discrete output wiringThe following options are shown:



CAUTION

Excessive current will damage the transmitter.

Do not exceed 30 VDC input. Terminal current must be less than 500 mA.

000042

+

+

+

–

–

–

+–

000042

Counter

Pull-up resistorSee Figure 4-13 for recommended resistor versus supply voltage.

3–30 VDC

3–30 VDC

Pull-up resistorSee Figure 4-13 for recommended resistor versus supply voltage.

Counter

Channel C

Channel B


I/O Wiring

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Figure 4-6 Discrete output wiring – Internal power

Figure 4-7 Discrete output wiring – External power

CAUTION

Excessive current will damage the transmitter.

Do not exceed 30 VDC input. Terminal current must be less than 500 mA.

+

–

+

–

Discrete output receiving deviceSee Figure 4-11 for output voltage versus load information.

Discrete output receiving deviceSee Figure 4-12 for output voltage versus load.

Channel C (DO 2)

Channel B (DO 1)

++

+

––

–

+–

3–30 VDC

Maximum sink current: 500 mA

Pull-up resistor or DC Relay

3–30 VDC

Maximum sink current: 500 mA

See Figure 4-13 for recommended resistor versus supply voltage.

Channel C (DO 2)

Channel B (DO 1)

See Figure 4-13 for recommended resistor versus supply voltage.

Pull-up resistor or DC Relay


I/O Wiring

4.6 Discrete input wiringThe following options are shown:



If external power is configured, power may be supplied by a PLC or other device, or by direct DC input. See Table 4-2 for input voltage ranges.

Figure 4-8 Discrete input wiring – Internal power

Figure 4-9 Discrete input wiring – External power

Table 4-2 Input voltage ranges for external power

VDC Range

3–30 High level

0–0.8 Low level

0.8–3 Undefined

+

–

PLC or other device

ORVDC(see Table 4-2)

Direct DC input(see Table 4-2)

+–

+

–


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4.7 RS-485 wiring to a remote hostSee Figure 4-10 for a diagram of wiring the RS-485 terminals to a remote host. For information on connecting the remote host, see Table 4-3.

Figure 4-10 Wiring to a remote host

4.8 Voltage and resistance charts

Figure 4-11 Output voltage versus load resistance – Terminals 23 & 24 (Channel B) – Internal power

Table 4-3 Terminal assignments for Modbus/RS-485

RS-485 signal Model 1500/2500 terminal

A 33

B 34

RS-485/B

RS-485/A

Remote host

0 500 1000 1500 2000 2500

Hig

h le

vel o

utp

ut

volt

age

(vo

lts)

Load resistance (ohms)

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

0

Open circuit output voltage = 15 VDC ±3%


I/O Wiring

Figure 4-12 Output voltage versus load resistance – Terminals 31 & 32 (Channel C) – Internal power

Figure 4-13 Recommended pull-up resistor versus supply voltage – External power

Open circuit output voltage = 15 VDC ±3%

Hig

h le

vel o

utp

ut

volt

age

(vo

lts)

0 1000 2000 3000 4000 5000

Load resistance (ohms)

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

0

4400

5 10 15 20 25 30

Supply voltage (volts)

Ext

ern

al p

ull-

up

res

isto

r ra

ng

e (o

hm

s)

Recommended resistor value range

400600800

42004000380036003400320030002800260024002200200018001600140012001000

Note: When using a discrete output to drive a relay, choose external pull-up to limit current to less than 500 mA.


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Appendix ASpecifications

A.1 Physical specifications

Figure A-1 Transmitter dimensions

Table A-1 Physical specifications

Housing Polyamide PA 6.6

Weight 0.52 lbs (0,24 kg)

Dimensions See Figures A-1 and A-2 for dimensions of the Model 1500 or 2500 transmitter and the remote core processor.

For sensor dimensions, refer to sensor specifications.

Mounting and cabling DIN rail transmitters are mounted on a 35 mm rail. The rail must be grounded.

Status LED Three-color LED status light on face of transmitter indicates flowmeter condition at a glance, using a solid green, yellow or red light. Zero in progress is indicated by a flashing yellow light.

Zero button A zero button on the face of the transmitter can be used to start the transmitter zero process.

4.41(112)

Bottom view

1.78(45)

1.39(35)

DIN rail


Side view

3.90(99)


Specifications

Figure A-2 Remote core processor dimensions


Ø4 3/8(111)

2 13/16(71)

2 1/4(57)

4 1/2(114)

6 3/16(158)

2X 3(76)

2 5/8(67)

4X Ø3/8(10)

2 13/16(71)

5 11/16(144)

1/2”–14 NPTOR

M20 X 1.5

3 5/16(84)

1 11/16(43)

To centerline of 2” pipe

5 3/4(146)

Pole Mount

2 1/2(64)

4 9/16(116)

Wall Mount

3/4”–14 NPT

2 3/8(61)

Note: These dimensions apply only to the core processor component in remote core processor with remote transmitter installations. See Figure 2-2.


Specifications

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A.2 Functional specifications

I

Table A-2 Electrical connections

Input/output connections Two pairs (Model 1500 standard) or three pairs (Model 1500 with filling and dosing application, Model 2500) of wiring terminals for transmitter outputsOne pair of terminals for digital communications (Modbus/RS-485)

Screw terminals accept stranded or solid conductors, 24 to 12 AWG (0,20 to 3,5 mm2)

Power connection Two pairs of terminals for the power connection:• Either pair accepts DC power

• The remaining pair is used for making a jumper connection to another transmitter

Plug connectors accept stranded or solid conductors, 24 to 12 AWG (0,20 to 3,5 mm2)

Service port connection One pair of terminals supports Modbus/RS-485 signal or service port mode. On device power-up, user has 10 seconds to connect in service port mode. After 10 seconds, the terminals default to Modbus/RS-485 mode.

Core processor connection Two pairs of terminals for the 4-wire connection to the core processor:• One pair is used for the RS-485 connection to the core processor

• One pair is used to supply power to the core processor

Plug connectors accept stranded or solid conductors, 24 to 12 AWG (0,20 to 3,5 mm2)

Table A-3 Input/output signals

Model 1500 standard One active 4–20 mA output• Not intrinsically safe

• Isolated to ±50 VDC from all other outputs and earth ground

• Maximum load limit: 600 Ω• Can report mass flow or volume flow

• Output is linear with process from 3.8 to 20.5 mA, per NAMUR NE43 (June 1994)

One active frequency/pulse output

• Not intrinsically safe• Reports same flow variable as mA output

• Scalable to 10,000 Hz

• Output voltage is +15 VDC ±3% with a 2.2 kΩ internal pull-up resistor

• Output is linear with flow rate to 12,500 Hz

One zero button, used to start the flowmeter zeroing procedure


Specifications

Model 1500 with filling and dosing application

One active 4–20 mA output

• Not intrinsically safe• Isolated to ±50 VDC from all other outputs and earth ground

• Maximum load limit: 600 Ω• Can report mass flow or volume flow, or can control discrete valve or three-position analog valve

• Output is linear with process from 3.8 to 20.5 mA, per NAMUR NE43 (June 1994)

One or two discrete outputs

• Channels B and C can be configured as discrete outputs• Can report fill in progress or fault, or can control discrete valve

• Maximum sink capability is 500 mA

• Configurable for internal or external power:- Internally powered to 15 VDC ±3%, internal 2.2 kΩ pull-up, or

- Externally powered 3–30 VDC max., sinking up to 500 mA at 30 VDC maximum

One discrete input

• Channel C can be configured as a discrete input• Configurable for internal or external power

• Can be used to begin fill, end fill, pause fill, resume fill, reset fill total, reset mass total, reset volume total, or reset all totals (includes fill total)


Table A-3 Input/output signals continued


Specifications

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Model 2500 One or two active 4–20 mA outputs

• Channel A is always an mA output; Channel B can be configured as an mA output• Not intrinsically safe

• Isolated to ±50 VDC from all other outputs and earth ground

• Maximum load limit:- Channel A: 820 Ω- Channel B: 420 Ω

• Can report mass flow, volume flow, density, temperature, or drive gain; API-enabled transmitters can also report standard volume flow and density at reference temperature

• Outputs are linear with process from 3.8 to 20.5 mA, per NAMUR NE43 (June 1994)

One active or passive frequency/pulse output

• Channels B and C can be configured as frequency/pulse outputs

• If reported through both Channel B and Channel C, functions as dual pulse output which reports a single process variable. Channels are electrically isolated but not independent

• Not intrinsically safe• Can report mass flow or volume flow, which can be used to indicate flow rate or total

• Scalable to 10,000 Hz• Configurable for internal or external power:

- Internally powered to 15 VDC ±3%, internal 2.2 kΩ pull-up, or

- Externally powered 3–30 VDC maximum, sinking up to 500 mA at 30 VDC maximum

• Output is linear with flow rate to 12,500 Hz

• Configurable polarity: active high or active low

One or two discrete outputs• Channels B and C can be configured as discrete outputs

• Can report event 1, event 2, event 1 & 2, flow direction, flow switch, calibration in progress, or fault

• Maximum sink capability is 500 mA

• Configurable for internal or external power:

- Internally powered to 15 VDC ±3%, internal 2.2 kΩ pull-up, or

- Externally powered 3–30 VDC max., sinking up to 500 mA at 30 VDC maximum

One discrete input• Channel C can be configured as a discrete input

• Configurable for internal or external power

• Can be used to start flowmeter zeroing procedure, reset mass total, reset volume total, reset corrected volume total, or reset all totals


Table A-3 Input/output signals continued


Specifications

Table A-4 Digital communications

Service port After device power up, terminals 33 and 34 are available in service port mode for 10 seconds:

• Modbus RTU protocol• 38,400 baud

• No parity

• One stop bit• Address = 111

Modbus/RS-485 After 10 seconds, terminals 33 and 34 default to Modbus/RS-485:

• Modbus RTU or Modbus ASCII protocol (default: Modbus RTU)

• 1200 to 38,400 baud rate (default: 9600)• Stop bit configurable (default: one stop bit)

• Parity configurable (default: odd parity)

HART/Bell202(1)

(1) Not available with Model 1500 transmitter with filling and dosing application.

HART Bell 202 signal is superimposed on the mA output, and is available for host system interface:• Frequency 1.2 and 2.2 kHz

• Amplitude 0.8 mA peak-to-peak

• 1200 baud• Requires 250 to 600 Ω load resistance

Table A-5 Power supply

Requires DC powerMeets Installation (Overvoltage) Category II, Pollution Degree 2 requirements

Power requirements 19.2 to 28.8 VDC, 6.3 watts maximum

At startup, transmitter power source must provide a minimum of 1.0 amperes of short-term current per transmitterLength and conductor diameter of the power cable must be sized to provide 19.2 VDC minimum at the power terminals, at a load current of 330 mA

Fuse IEC 1.6A slowblow fuse

Table A-6 Environmental limits

Ambient temperature limits • Operating: –40 to +131 °F (–40 to +55 °C)• Storage: –40 to +185 °F (–40 to +85 °C)

If temperature is above 113 °F (45 °C) and you are mounting multiple transmitters, they must be mounted at least 8.5 mm apart.

Humidity limits 5 to 95% relative humidity, non-condensing at 140 °F (60 °C)

Vibration limits Meets IEC68.2.6, endurance sweep, 5 to 2000 Hz, 50 sweep cycles at 1.0 g

Table A-7 Environmental effects

EMI effects Meets EMC directive 89/336/EEC per EN 61326 Industrial

Complies with NAMUR NE21 (May 1999)

Ambient temperature effect On analog outputs ±0.005% of span per °C


Specifications

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A.3 Hazardous area classificationsThe transmitter may have a hazardous area approvals tag which indicates suitability for the areas described below.

A.4 Performance specificationsFor performance specifications, refer to the sensor specifications.

Table A-8 Hazardous area classifications

CSA(1) and C-US

(1) CSA is a Canadian approvals agency that provides approvals accepted both in Canada and in the U.S.A. (C-US).

Transmitter Class I, Div. 2, Groups A, B, C, and D when installed in a suitable enclosure

Sensor and sensor wiring to transmitter

Class I, Div. 1, Groups C and D orClass II, Div. 1, Groups E, F, and G

ATEX(2)

(2) ATEX is a European directive.

All models CE 0575 II(2) G [EEx ib] IIB/IIC. For ATEX compliance, ambient temperature is limited to –40 to +131 °F (–40 to +55 °C).


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Appendix BReturn Policy

Micro Motion procedures must be followed when returning equipment. These procedures ensure legal compliance with government transportation agencies and help provide a safe working environment for Micro Motion employees. Failure to follow Micro Motion procedures will result in your equipment being refused delivery.

Information on return procedures and forms is available on our web support system at www.micromotion.com, or by phoning the Micro Motion Customer Service department.

B.1 New and unused equipment

Only equipment that has not been removed from the original shipping package will be considered new and unused. New and unused equipment requires a completed Return Materials Authorization form.

B.2 Used equipmentAll equipment that is not classified as new and unused is considered used. This equipment must be completely decontaminated and cleaned before being returned.

Used equipment must be accompanied by a completed Return Materials Authorization form and a Decontamination Statement for all process fluids that have been in contact with the equipment. If a Decontamination Statement cannot be completed (e.g., for food-grade process fluids), you must include a statement certifying decontamination and documenting all foreign substances that have come in contact with the equipment.


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Index

Numerics4-wire cable

maximum length 5types 11

4-wire remote installationsarchitecture 3wiring instructions 12

9-wire cablemaximum length 5types 11

AAmbient temperature effect 32Armored cable 11ATEX 33

CCable lengths 5Cable types 11Core processor 1

dimensions 28grounding 8mounting 7See also Remote core processor

CSA 33C-US 33Customer service 2

DDigital communications 32Dimensions

core processor 28transmitter 27

DIN rail 6Discrete input wiring 24Discrete output wiring 22Documentation resources 2

EElectrical connections 29EMI effects 32Environmental effects 32Environmental limits 32External power 19

FFlowmeter components 1Frequency output wiring 21

GGrounding 8

HHART multidrop output wiring 21HART single-loop output wiring 20Hazardous area classifications 33Humidity limits 32

II/O signals 29Installation

4-wire remote 3architectures 3cable lengths 5cable types 11mounting and removing the transmitter 6mounting the core processor 7multiple transmitters 6overview 1power requirements 4procedure 3remote core processor with remote transmitter 4supplying power 8wiring instructions for 4-wire remote

installations 12wiring instructions for remote core processor

with remote transmitter installations 13wiring the transmitter I/O 19

I/O options 19Internal power 19

JJacketed cable 11

LLocation, determining appropriate 4

MmA output wiring 20Micro Motion customer service 2Mounting


Index

core processor 7multiple transmitters 6transmitter 6

PPerformance specifications 33Power

requirements 4supply specifications 32

RRemote core processor with remote transmitter

architecture 4mounting the core processor 7wiring instructions 13

Remote host wiring 25Return policy 35

SSafety messages 1Sensor 1

grounding 8return policy 35wiring to transmitter 11

Shielded cable 11Specifications

digital communications 32electrical connections 29environmental effects 32environmental limits 32functional 29hazardous area classifications 33I/O signals 29performance 33physical 27power supply 32

TTemperature limits 32Transmitter 1

dimensions 27grounding 8installing 3mounting and removing 6performance specifications 33return policy 35specifications 27wiring I/O 19

I/O options 19internal vs. external power 19

wiring to sensor 11

VVibration limits 32

WWiring

sensor to transmitter 11transmitter I/O 19

discrete input wiring 24discrete output wiring 22frequency output wiring 21HART multidrop wiring 21HART single-loop wiring 20I/O options 19mA outputs 20remote host 25

Wiring distances 5Wiring instructions

4-wire remote installations 12remote core processor with remote transmitter

installations 13

©2006, Micro Motion, Inc. All rights reserved. P/N 20001685, Rev. D

*20001685*

For the latest Micro Motion product specifications, view the PRODUCTS section of our web site at www.micromotion.com

Micro Motion Inc. USAWorldwide Headquarters7070 Winchester CircleBoulder, Colorado 80301T (303) 527-5200

(800) 522-6277F (303) 530-8459

Micro Motion EuropeEmerson Process ManagementWiltonstraat 303905 KW VeenendaalThe NetherlandsT (31) 0 318 495 670F (31) 0 318 495 689

Micro Motion JapanEmerson Process ManagementShinagawa NF Bldg. 5F1-2-5, Higashi ShinagawaShinagawa-kuTokyo 140-0002 JapanT (81) 3 5769-6803F (81) 3 5769-6843

Micro Motion SingaporeEmerson Process Management1 Pandan CrescentSingapore 128461Republic of SingaporeT (65) 6777-8211F (65) 6770-8003

Micro Motion ChinaEmerson Process Management Co., Ltd.No. 1277 Xin Jin Qiao RoadJinqiao E.P.Z., PudongShanghai 201206, ChinaT (86) 21-3895 4788F (86) 21-5899 4410

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