Emerson Net Safety Millennium User manual

Reference Manual
FGD-MAN-0077, Rev 7
July 2017
Millennium APM Oil Mist Detector Air Particle
Monitor

Important Instructions
Rosemount designs, manufactures and tests products to function within specific conditions. Because these products are
sophisticated technical instruments, it is important that the owner and operation personnel must strictly adhere both to the
information printed on the product nameplate and to all instructions provided in this manual prior to installation, operation, and
maintenance.
WARNING!
Installing, operating, or maintaining this product improperly could lead to serious injury or death from explosion or exposure to
dangerous substances. Comply with all information on the product, in this manual, and in any local and national codes that apply to
the product. Do not allow untrained personnel to work with this product. Use Net Safety parts and work procedures specified in this
manual.
No part of the hardware, software, or documentation may be reproduced, transmitted, transcribed, stored in a retrieval system, or
translated into any language or computer language, in any form or by any means, without prior written permission of Rosemount.
While great efforts have been made to ensure the accuracy and clarity of this document, Rosemount assumes no liability resulting
from any omissions in this document of from misuse of the information obtained herein. The information in this document has been
carefully checked and is believed to be entirely reliable with all of the necessary information included. Rosemount reserves the right
to make changes to any products described herein to improve reliability, function, or design and reserves the right to revise this
document and make changes from time to time in content hereof with no obligation to notify any persons of revisions or changes.
Rosemount does not assume any liability arising out of the application or any use of any product or circuit described herein; neither
does it convey license under its patent rights or the rights of others.
WARNING!
This manual should be read carefully by all individuals who have or will have responsibility for using, maintaining, or servicing the
product.
The Detector is not field repairable due to the meticulous alignment and calibration of the sensors and the respective circuits. Do not
attempt to modify or repair the internal circuits or change their settings, as this will impair the system's performance and void the
Rosemount product warranty.

Warranty
1. Limited Warranty . Subject to the limitations contained in Section 2 (Limitation of Remedy and Liability) herein, Seller
warrants that (a) the licensed firmware embodied in the Goods will execute the programming instructions provided by
Seller; (b) that the Goods manufactured by Seller will be free from defects in materials or workmanship under normal use
and care; and (c) Services will be performed by trained personnel using proper equipment and instrumentation for the
particular Service provided. The foregoing warranties will apply until the expiration of the applicable warranty period.
Sensors and detectors are warranted against defective parts and workmanship for 24 months from the date of purchase and
other electronic assemblies for 36 months from the date of purchase. Products purchased by Seller from a third party for
resale to Buyer (Resale Products) shall carry only the warranty extended by the original manufacturer. Buyer agrees that
Seller has no liability for Resale Products beyond making a reasonable commercial effort to arrange for procurement and
shipping of the Resale Products. If Buyer discovers any warranty defects and notifies Seller thereof in writing during the
applicable warranty period, Seller shall, at its option, (i) correct any errors that are found by Seller in the firmware or
Services; (ii) repair or replace FOB point of manufacture that portion of the Goods found by Seller to be defective; or (iii)
refund the purchase price of the defective portion of the Goods/Services. All replacements or repairs necessitated by
inadequate maintenance; normal wear and usage; unsuitable power sources or environmental conditions; accident; misuse;
improper installation; modification; repair; use of unauthorized replacement parts; storage or handling; or any other cause
not the fault of Seller, are not covered by this limited warranty and shall be replaced or repaired at Buyer's sole expense and
Seller shall not be obligated to pay any costs or charges incurred by Buyer or any other party except as may be agreed upon
in writing in advance by Seller. All costs of dismantling, reinstallation, freight, and the time and expenses of Seller's
personnel and representatives for site travel and diagnosis under this limited warranty clause shall be borne by Buyer unless
accepted in writing by Seller. Goods repaired and parts replaced by Seller during the warranty period shall be in warranty for
the remainder of the original warranty period or 90 days, whichever is longer. This limited warranty is the only warranty
made by Seller and can be amended only in a writing signed by an authorized representative of Seller. The limited warranty
herein ceases to be effective if Buyer fails to operate and use the Goods sold hereunder in a safe and reasonable manner and
in accordance with any written instructions from the manufacturers. THE WARRANTIES AND REMEDIES SET FORTH ABOVE
ARE EXCLUSIVE. THERE ARE NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED, AS TO
MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS
OR SERVICES.
2. Limitation of Remedy and Liability SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN PERFORMANCE. THE
REMEDIES OF BUYER SET FORTH IN THE AGREEMENT ARE EXCLUSIVE. IN NO EVENT, REGARDLESS OF THE FORM OF THE
CLAIM OR CAUSE OF ACTION (WHETHER BASED IN CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OTHER
TORT, OR OTHERWISE), SHALL SELLER'S LIABILITY TO BUYER AND/OR BUYER'S CUSTOMERS EXCEED THE PRICE TO BUYER
OF THE SPECIFIC GOODS MANUFACTURED OR SERVICES PROVIDED BY SELLER GIVING RISE TO THE CLAIM OR CAUSE OF
ACTION. BUYER AGREES THAT IN NO EVENT SHALL SELLER'S LIABILITY TO BUYER AND/OR BUYER'S CUSTOMERS EXTEND TO
INCLUDE INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES. THE TERM "CONSEQUENTIAL DAMAGES" SHALL INCLUDE,
BUT NOT BE LIMITED TO, LOSS OF ANTICIPATED PROFITS, REVENUE OR USE AND COSTS INCURRED INCLUDING WITHOUT
LIMITATION FOR CAPITAL, FUEL AND POWER, AND CLAIMS OF BUYER'S CUSTOMERS.

Contents
Chapter 1 Introduction ...................................................................................................................1
1.1 Models covered ............................................................................................................................1
1.2 Service support ............................................................................................................................ 1
1.3 Return of material ........................................................................................................................1
1.4 Product recycling/disposal ........................................................................................................... 2
Chapter 2 Installation .....................................................................................................................3
2.1 Unpacking and inspection ............................................................................................................3
2.2 Locate sensor ...............................................................................................................................3
2.3 Dimensions ..................................................................................................................................5
2.4 Mounting .....................................................................................................................................7
2.4.1 Duct mounting ..............................................................................................................8
2.5 Wiring ..........................................................................................................................................9
2.5.1 Field installation ............................................................................................................ 9
2.5.2 Seals ............................................................................................................................10
2.5.3 Sensor separation ........................................................................................................10
2.5.4 Board assembly ........................................................................................................... 11
2.5.5 Installation to transmitter or junction box ................................................................... 11
2.5.6 Faceplate rotation ....................................................................................................... 12
2.5.7 General requirements ................................................................................................. 13
2.5.8 Wiring sensor to transmitter ....................................................................................... 14
2.5.9 Wiring sensor to junction box ......................................................................................15
2.5.10 Wiring transmitter to control system ...........................................................................17
2.5.11 External ground ...........................................................................................................17
2.6 Current output ...........................................................................................................................18
2.7 Non-isolated and isolated power configurations ........................................................................ 19
2.8 Installation checklist .................................................................................................................. 20
Chapter 3 Operation .....................................................................................................................21
3.1 Millennium transmitter .............................................................................................................. 21
3.1.1 Display ........................................................................................................................ 21
3.1.2 Status LED ................................................................................................................... 21
3.1.3 On/Off switch ..............................................................................................................22
3.1.4 Setup button ...............................................................................................................22
3.1.5 Magnetic Reed switch ................................................................................................. 22
3.1.6 Current output check .................................................................................................. 22
3.2 Indications and outputs ............................................................................................................. 23
3.3 Alarms ....................................................................................................................................... 23
3.3.1 APM fault .................................................................................................................... 23
3.3.2 Clean window/dirty chamber ...................................................................................... 23
3.3.3 Particulate alarm ......................................................................................................... 24
3.4 Reset ..........................................................................................................................................24
3.4.1 Remote reset ...............................................................................................................24
3.4.2 Manual reset ............................................................................................................... 24
3.5 Normal .......................................................................................................................................24
3.6 Outputs ..................................................................................................................................... 24
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3.6.1 Relays ..........................................................................................................................24
3.6.2 Current ........................................................................................................................25
3.7 APM Sensor ................................................................................................................................25
3.7.1 Sensor power up ......................................................................................................... 25
3.7.2 Sensor communication ............................................................................................... 25
Chapter 4 Programming ...............................................................................................................27
4.1 Main menu .................................................................................................................................27
4.2 Accessing the main menu .......................................................................................................... 27
4.3 Main menu functionality ............................................................................................................ 27
4.3.1 Zero ............................................................................................................................ 28
4.3.2 Sensitivity settings ...................................................................................................... 29
4.3.3 Review relay settings ...................................................................................................30
4.3.4 Set relay options ..........................................................................................................30
4.3.5 Select display language ............................................................................................... 33
Chapter 5 Maintenance ................................................................................................................ 35
5.1 Response check ......................................................................................................................... 35
5.2 Cleaning .................................................................................................................................... 35
5.3 Troubleshooting ........................................................................................................................ 36
5.4 Storage ......................................................................................................................................36
5.5 Spare parts and accessories ........................................................................................................37
Chapter 6 Electrostatic sensitive device ........................................................................................39
Chapter 7 Wire resistance table ....................................................................................................41
Chapter 8 Specifications ...............................................................................................................43
8.1 Electrical .................................................................................................................................... 43
8.1.1 Operating voltage range ............................................................................................. 43
8.1.2 Power consumption .................................................................................................... 43
8.1.3 Current output ............................................................................................................ 43
8.2 Environmental ........................................................................................................................... 43
8.2.1 Storage temperature ...................................................................................................43
8.2.2 Operating temperature ............................................................................................... 43
8.2.3 Relative humidity ........................................................................................................ 43
8.2.4 Metallurgy ...................................................................................................................44
8.2.5 Ingress protection ....................................................................................................... 44
8.2.6 Weight ........................................................................................................................ 44
8.3 Separation ................................................................................................................................. 45
8.4 Warranty ....................................................................................................................................45
Chapter 9 Certifications ................................................................................................................47
9.1 North American hazardous locations ......................................................................................... 47
9.1.1 Transmitter ................................................................................................................. 47
9.1.2 APM Sensor ................................................................................................................. 47
9.1.3 Junction box (Model JB-MPD) .......................................................................................48
9.2 ATEX (-X model) .........................................................................................................................48
9.2.1 Transmitter ................................................................................................................. 48
9.2.2 APM Sensor ................................................................................................................. 48
9.2.3 Junction box (Model JB-MPD) .......................................................................................49
9.3 IECEx (-X model) ........................................................................................................................ 49
9.3.1 Transmitter (aluminum) .............................................................................................. 49
9.3.2 Transmitter (stainless steel) ........................................................................................ 49
Contents
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9.3.3 APM Sensor ................................................................................................................. 49
9.3.4 Junction Box (Model JB-MPD) .......................................................................................49
Chapter 10 Ordering information ................................................................................................... 51
Contents
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Contents
iv

1 Introduction
1.1 Models covered
The Air Particle Monitor (APM) is an infrared optical detector used in hazardous industrial
applications to monitor ambient air for the presence of particulate matter from products
of combustion such as carbon, air particulate matter, or ash.
The Millennium Transmitter is an environmentally protected electronic package contained
within an explosion-proof housing. With its scrolling 8-character display and status LEDs, it
provides instructions and status alerts.
The APM Sensor is mounted where airborne particles are anticipated to accumulate while
the Millennium Transmitter is located conveniently at eye level.
The product is available in aluminum and stainless steel (SS).
Models available are:
•MLP-AR-APM-OP - APM, 4-20mA analog output with alarm & fault relays, aluminum
housing, CSA approved
•MLP-AR-APM-OP-X - APM, 4-20mA analog output with alarm & fault relays,
aluminum housing, CSA, ATEX, and IECEx approved
•MLP-AR-APM-OP-SS - APM, 4-20mA analog output with alarm & fault relays,
stainless steel housing, CSA approved
•MLP-AR-APM-OP-SS-X - APM, 4-20mA analog output with alarm & fault relays,
stainless steel housing, CSA, ATEX, and IECEx approved
1.2 Service support
Technical support for this product can be provided by contacting your local Emerson/Net
Safety representative or by contacting the Net Safety Technical Support department at:
Toll Free + 866 347 3427 or [email protected].
1.3 Return of material
To expedite the repair and return of this product, proper communication between the
customer and the factory is important. Before returning a product for repair, call +1 403
219-0688 or e-mail [email protected] for a Material Return Authorization (MRA)
number.
On the return of the equipment, include the following information:
Procedure
1. MRA number provided to you by Net Safety
Introduction
1

2. Company name and contact information
3. Purchase order, from your company, authorizing repairs or request for quote
4. Ship all equipment, prepaid to:
Emerson Automation Solutions
158 Edinburgh Ave
Slough, United Kingdom SL 1 4UE
5. Mark all packages with as Return for Repair and include MRA number
Pack items to protect them from damage and use anti-static bags or aluminum-
backed cardboard as protection from electrostatic damage.
Important
All equipment must be shipped prepaid. Collect shipments will not be accepted.
1.4 Product recycling/disposal
Recycling of equipment and packaging should be taken into consideration and disposed of
in accordance with local and national legislations/regulations.
Introduction
2

2 Installation
2.1 Unpacking and inspection
Carefully remove all of the components from the packaging and verify them against the
enclosed packing list. Inspect all components for any obvious damage such as broken or
loose parts. If you find any components missing or damaged, notify your local Net Safety
representative or the factory immediately. Figure 2-1 outlines the components supplied
with the APM.
APM componentsFigure 2-1:
2.2 Locate sensor
Prior to the installation process, a location plan for placing the APM sensor and transmitter
should be developed. Proper location of the APM sensor is essential for providing
maximum protection. The most effective placement and number of detectors varies
depending upon conditions. The following points should be considered when planning the
installation.
•Carefully locate the APM sensor in an area where particulate may potentially
accumulate.
•The APM sensor should be located where it is safe from potential sources of
contamination such as oil film, dirt, etc.
Installation
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•Locate the transmitter where it will be accessible and visible.
•Mount the APM sensor so air currents allow particulate to flow into the optical path
of the sensor.
•If the particulate is expected to be moving horizontally due to air currents, orient the
sensor for maximum detection as shown in Figure 2-1.
•Exposure to excessive heat or vibration can cause premature failure of electronic
devices and should be avoided whenever possible.
•Seek advice from experts and refer to various regulatory publications that discuss
general guidelines for your industry.
•The APM works off of the principle of infrared energy being reflected off of
particulate matter passing through the optical path of the APM. Therefore, give
careful consideration when installing the APM to ensure that external infrared light
does not reach the sensing element.
Figure 2-2 illustrates a typical installation of an APM sensor and transmitter. The APM
sensor is mounted separately from the transmitter using the supplied junction box. The
transmitter is located at eye level, while the sensor is located where particles are most
likely to accumulate. The conduit then connects the two devices.
Installation
4

Typical installationFigure 2-2:
2.3 Dimensions
The following figures outline the dimensions of the APM connected directly to the
Millennium transmitter (Figure 2-3) or when connected directly to the multi-purpose
junction box (Figure 2-4). There are three (3) 3/4” NPT conduit entries available on the
Millennium transmitter. Adapters for M20 and ½” NPT threads are also available as spare
parts.
Installation
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Transmitter DimensionsFigure 2-3:
Junction Box & Sensor DimensionsFigure 2-4:
Installation
6

2.4 Mounting
The sensor must be mounted directly to either a transmitter or to a separate junction box
through a 3/4” NPT conduit entry. Both the transmitter and junction boxes have mounting
holes to allow mounting to a wall or pole as desired. Mounting kit hardware is required
when mounting the transmitter or junction box to a pole. Contact your local Net Safety
representative for detailed information on the pole mounting kits.
The transmitter should be mounted at eye-level and be easily accessible for monitoring
and maintenance purposes. The sensor should be placed where particles are likely to
accumulate and across the direction of the airflow to allow the particulates to pass
through the optical path. To prevent water damage, seal conduit at all points of entry to
the transmitter or junction box.
It is recommended that the APM sensor be mounted such that the air flow will pass
through the optical path of the sensor as shown in Figure 2-5.
Note
The APM works off of the principle of infrared energy being reflected off of particulate matter
passing through the optical path of the APM. Therefore, give careful consideration when installing
the APM to ensure that external infrared light does not reach the sensing element.
The APM may be affected by sudden bursts of infrared light; therefore, it is recommended
that a time delay (between two (2) to five (5) seconds) be put into the monitoring system
to prevent nuisance alarms.
Installation
7

APM Mounting LocationsFigure 2-5:
2.4.1 Duct mounting
Although the Net Safety Monitoring Air Particle Monitor has been proven to detect
particulate matter travelling at speeds of up to 20 meters per second (65.62 feet per
second)the detector is virtually unaffected by the velocity of particulate and air that it is
exposed to. Based on the application and the speed of the particulate matter, you can
perform a zero and adjust the sensitivity settings to suit the application.
Net Safety Monitoring recommends the APM be used with the UDM-001 or UDM-002
sample draw system to acquire a cross-sectional sample of air and particulate moving
through ducts. The sample is drawn through perforations along the inlet pipe into a
chamber where the APM is mounted. Particulate matter from the outlet pipe is then
returned to the duct. Refer to Figure 2-6 and the UDM-001/UDM-002 reference manual
(MAN-0116) for more information.
Installation
8

Air Flow DrawingFigure 2-6:
2.5 Wiring
2.5.1 Field installation
WARNING!
Failure to follow these installation guidelines could result in death or serious injury. Ensure that
only qualified personnel perform the installation.
Electrical shock could cause death or serious injury. Use extreme caution when making contact
with the leads and terminals.
Do not open the transmitter, sensor, or junction box enclosure when in a classified area or
when an explosive atmosphere may be present unless the power to the transmitter has been
removed.
Avoid touching electronic components as they are susceptible to electrostatic discharge (ESD).
Refer to Chapter 6 for more information.
Avoid contact with the non-metallic enclosure label as contact may create an electrostatic
charging hazard.
Installation
9

NOTICE
Wiring codes and regulations may vary. ATEX requires that supply connections wiring must be
rated at least 41 °F (5 °C) above the maximum ambient temperature of 185 °F (85 °C ). Wiring
must comply with all applicable regulations relating to the installation of electrical equipment
in a hazardous area and is the responsibility of the installer. If in doubt, consult a qualified
official before wiring the system.
When separating the sensor from the transmitter, the use of shielded cable is highly
recommended to protect against interference caused by extraneous electrical or
electromagnetic noise to meet mandatory CE mark electromagnetic compatibility (EMC)
requirements. In applications where the wiring is installed in conduit, the conduit must not
be used for wiring to other equipment.
2.5.2 Seals
The use of seals is recommended to further protect the system against any unwanted
water ingression, and equipment should be installed according to applicable local
electrical codes. Seals are especially recommended for installations that use high-pressure
or steam cleaning devices in proximity to the transmitter and/or sensor.
•Water-proof and explosion-proof conduit seals are recommended to prevent water
accumulation within the enclosure.
•Seals should be located as close to the device as possible and not more than18
inches (46 cm) away.
•Explosion-proof installations may require an additional seal where conduit enters a
non-hazardous area. Ensure conformity with local wiring codes.
•When pouring a seal, use a fiber dam to assure proper formation of the seal. Seals
should never be poured at temperatures below freezing.
•The jacket and shielding of the cable should be stripped back to permit the seal to
form around the individual wires. This will prevent air, particles, and water leakage
through the inside of the shield and into the enclosure.
•It is recommended that explosion-proof drains and conduit breathers be used. In
some applications, alternate changes in temperature and barometric pressure can
cause breathing which allows moist air to enter and circulate inside the conduit.
Joints in the conduit system are seldom tight enough to prevent thisbreathing.
2.5.3 Sensor separation
Since the APM Sensor must be located where it will pick up particulate in an air flow, and
the transmitter where it can be easily reached, it is often necessary to separate the
transmitter and sensor. This is done with the aid of the included sensor separation kit
(SEP). This kit is composed of a junction box and terminal strip. Refer to the Net Safety
Multi-purpose Junction Box manual (MAN-0081) for terminal designation.
Installation
10

The maximum separation distance between the sensor and the transmitter is limited by
the resistance of the connecting wiring, which is a function of the gauge of wire being
used. Net Safety recommends that sensor separation must not exceed 2000 feet (610
meters) while using 16 AWG (1.31 mm2) wire. Refer to Chapter 7 for wire gauges and
resistance values.
Note
When the sensor is separated from the transmitter, always ensure that the transmitter is supplying
the required voltage to the sensor terminals inside the junction box. If the 4-20 mA signal is not used,
connect a jumper between the 4-20 terminal and the COM terminal on the transmitter terminal
board.
2.5.4 Board assembly
There are three different fixed boards and a relay board which make up the PCB assembly.
Simply loosen the three locking standoffs, remove one board, insert the other board and
tighten screws. The boards are susceptible to ESD. Refer to Chapter 6 for further
information on proper handling of this equipment.
Millennium transmitter module boardsFigure 2-7:
2.5.5 Installation to transmitter or junction box
The APM sensor is supplied with a 3/4” NPT male conduit connection and is intended to be
mounted directly to an available 3/4” NPT conduit entry on the Millennium transmitter or
remotely using the supplied junction box.
The sensor should be tightly threaded to the transmitter or junction box. A minimum of
seven (7) threads need to be engaged to ensure proper water ingress protection and the
explosion proof rating of the devices. Proper care needs to be taken to ensure that no
damage is caused to the wires on the APM sensor and circuit board inside the transmitter
and junction box.
Installation
11

The use of conductive grease is recommended on the threads.
The sensor can be mounted in a number of configurations to ensure that air particulate will
pass through the optical path of the sensor. It is recommended that the APM be mounted
horizontally to ensure that build-up of dirt, dust, and debris will not affect the operation of
the sensor.
2.5.6 Faceplate rotation
In some applications, it is necessary for the Millennium transmitter to be mounted in a
non-standard orientation. To accommodate such installations and ensure that the display
will appear at the correct angle for viewing, the PCB assembly can be rotated inside the
transmitter’s housing. Figure 2-8 outlines non-standard orientations of the Millennium
transmitter.
Non-standard OrientationFigure 2-8:
WARNING!
Do not open the transmitter, sensor, or junction box enclosure when in a classified area or
when an explosive atmosphere may be present unless the power to the transmitter has been
removed.
The following section describes the steps required to rotate the Millennium transmitter
faceplate. Refer to Figure 2-9 for the components in the transmitter housing. The boards
may be susceptible to ESD. Refer to Chapter 6 for further information on proper handling of
this equipment.
Procedure
1. Remove the transmitter housing cover.
2. Turn the power to the transmitter off.
3. Unscrew both the knobs marked Pull Here.
4. Lift the transmitter faceplate from the housing and allow to the faceplate to hang
from the ribbon cable.
5. Unscrew the two metal standoffs.
6. Carefully remove the PCB assembly from the housing.
7. The rotator plate is secured to the bottom of the housing and is accessible after the
PCB assembly has been removed.
Installation
12