ABB AX480 User's Guide

User Guide IM/AX4DO Rev. H AX418, AX438, AX480, AX468 and AX488 Single and dual input analyzers for dissolved oxygen The Company EN ISO 9001:2000 We are an established world force in the design and manufacture of measurement products for industrial process control, flow measurement, gas and liquid analysis and environmental applications. Cert. No. Q 05907 As a part of ABB, a world leader in process automation technology, we offer customers application expertise, service and support worldwide. We are committed to teamwork, high quality manufacturing, advanced technology and unrivalled service and support. EN 29001 (ISO 9001) Lenno, Italy – Cert. No. 9/90A The quality, accuracy and performance of the Company’s products result from over 100 years experience, combined with a continuous program of innovative design and development to incorporate the latest technology. Stonehouse, U.K. Electrical Safety This equipment complies with the requirements of CEI/IEC 61010-1:2001-2 'Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use'. If the equipment is used in a manner NOT specified by the Company, the protection provided by the equipment may be impaired. Symbols One or more of the following symbols may appear on the equipment labelling: Warning – Refer to the manual for instructions Direct current supply only Caution – Risk of electric shock Alternating current supply only Protective earth (ground) terminal Both direct and alternating current supply Earth (ground) terminal The equipment is protected through double insulation Information in this manual is intended only to assist our customers in the efficient operation of our equipment. Use of this manual for any other purpose is specifically prohibited and its contents are not to be reproduced in full or part without prior approval of the Technical Publications Department. Health and Safety To ensure that our products are safe and without risk to health, the following points must be noted: 1. The relevant sections of these instructions must be read carefully before proceeding. 2. Warning labels on containers and packages must be observed. 3. Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel and in accordance with the information given. 4. Normal safety precautions must be taken to avoid the possibility of an accident occurring when operating in conditions of high pressure and/or temperature. 5. Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry. Normal safe handling procedures must be used. 6. When disposing of chemicals ensure that no two chemicals are mixed. Safety advice concerning the use of the equipment described in this manual or any relevant hazard data sheets (where applicable) may be obtained from the Company address on the back cover, together with servicing and spares information. CONTENTS Section Page 1 INTRODUCTION .............................................................. 2 1.1 System Description ................................................. 2 1.2 PID Control ............................................................. 2 1.3 AX400 Series Analyzer Options ............................... 2 2 OPERATION ..................................................................... 3 2.1 Powering Up the Analyzer ....................................... 3 2.2 Displays and Controls .............................................. 3 2.2.1 Membrane Key Functions ............................ 3 2.3 Operating Page ....................................................... 6 2.3.1 Single Input Dissolved Oxygen ..................... 6 2.3.2 Dual Input Dissolved Oxygen ....................... 7 2.3.3 Wash Function ............................................. 8 3 OPERATOR VIEWS ......................................................... 9 3.1 View Set Points ....................................................... 9 3.2 View Outputs ........................................................ 10 3.3 View Hardware ...................................................... 10 3.4 View Software ....................................................... 11 3.5 View Logbook ....................................................... 11 3.6 View Clock ............................................................ 14 4 SETUP ............................................................................ 15 4.1 Sensor Calibration ................................................. 15 5 PROGRAMMING ........................................................... 20 5.1 Security Code ....................................................... 20 5.2 Configure Display .................................................. 21 5.3 Configure Sensors ................................................. 22 5.4 Configure Alarms ................................................... 23 5.4.1 Wash Cycle Configuration (applicable only to Alarm 3) ........................ 26 5.5 Configure Outputs ................................................. 28 5.6 Configure Clock .................................................... 30 5.7 Configure Control .................................................. 31 5.7.1 Configure Single PID Controller .................. 32 5.7.2 Configure Power Failure Recovery Mode .... 35 5.8 Configure Security ................................................. 36 5.9 Configure Logbook ............................................... 36 5.10 Test Outputs and Maintenance .............................. 37 Section Page 6 INSTALLATION .............................................................. 39 6.1 Siting Requirements .............................................. 39 6.2 Mounting ............................................................... 40 6.2.1 Wall-/Pipe-mount Analyzers ....................... 40 6.2.2 Panel-mount Analyzers .............................. 41 6.3 Electrical Connections ........................................... 42 6.3.1 Relay Contact Protection and Interference Suppression ..................... 43 6.3.2 Cable Entry Knockouts, Wall-/Pipe-mount Analyzer ......................... 44 6.4 Wall-/Pipe-mount Analyzer Connections ................ 45 6.4.1 Access to Terminals ................................... 45 6.4.2 Connections .............................................. 46 6.5 Panel-mount Analyzer Connections ....................... 47 6.5.1 Access to Terminals ................................... 47 6.5.2 Connections .............................................. 48 7 CALIBRATION ............................................................... 49 7.1 Equipment Required .............................................. 49 7.2 Preparation ........................................................... 49 7.3 Factory Settings .................................................... 50 8 SIMPLE FAULT FINDING .............................................. 55 8.1 Error Messages ..................................................... 55 8.2 No Response to DO Changes ............................... 55 8.3 Checking the Temperature Input ............................ 55 SPECIFICATION .................................................................. 56 APPENDIX A ....................................................................... 59 A1 Oxygen Solubility in Pure Water ............................. 59 A2 Correction for Salinity ............................................ 59 A3 DO Calibration ....................................................... 60 A3.1 Zero Calibration ......................................... 60 A3.2 Span Calibration ........................................ 60 APPENDIX B ....................................................................... 61 B1 Single PID Controller ............................................. 61 B1.1 Reverse Acting Single PID Control ............. 61 B1.2 Direct Acting Single PID Control ................. 62 B2 Ouput Assignment ................................................ 62 B3 Setting Up Three Term (PID) Control Parameters ... 63 B4 Manual Tuning ....................................................... 63 1 1 INTRODUCTION 1.1 System Description 1.2 The AX480 Single Input and AX488 Dual Input Dissolved Oxygen (DO) analyzers and associated sensors have been designed for continuous monitoring and control in a wide range of applications including aeration in sewage treatment and river/ effluent monitoring. The sensor can be standardized to the instrument using the built-in calibration facility. The analyzers are available in wall-/pipe-mount or panel-mount versions with either one or two programmable DO input channels, each with its own associated temperature input channels. When making temperature compensated measurements, the sample temperature is sensed by a Pt100 resistance thermometer mounted in the sensor. PID Control – AX480 Analyzer Only The AX480 single input dissolved oxygen analyzer incorporates Proportional Integral Derivative (PID) control as standard. For a full description of PID control, refer to Appendix B. 1.3 AX400 Series Analyzer Options Table 1.1 shows the range of configurations that are possible for the AX400 Series analyzers. The analyzer detects the type of input board fitted for each input automatically and displays only the operating and programming frames applicable to that input board type. If no input board is fitted for a second input (Sensor B), Sensor B frames are not displayed. All models incorporate a wash facility for system cleaning; the alarm 3 relay can be configured to control the wash system either automatically or manually. The relay can be configured to deliver either a continuous or pulsed signal to control an external power supply to a solenoid or pump and the frequency, duration and recovery time of the wash cycle are also programmable. During a wash cycle, the analog output value is held in its precycle condition. Analyzer operation and programming are performed using five tactile membrane keys on the front panel. Programmed functions are protected from unauthorized alteration by a fourdigit security code. Model Analyzer Description Sensor A AX410 Single Input 2-Electrode Conductivity (0 to 10,000 μS/cm) 2-Electrode Conductivity Not Applicable AX411 Dual Input 2-Electrode Conductivity (0 to 10,000 μS/cm) 2-Electrode Conductivity 2-Electrode Conductivity AX413 Dual Input 2-Electrode Conductivity and 4-Electrode Conductivity 2-Electrode Conductivity 4-Electrode Conductivity AX416 Dual Input 2-Electrode Conductivity and pH/Redox(ORP) 2-Electrode Conductivity pH/Redox(ORP) AX418 Dual Input 2-Electrode Conductivity and Dissolved Oxygen 2-Electrode Conductivity Dissolved Oxygen AX430 Single Input 4-Electrode Conductivity (0 to 2,000 mS/cm) 4-Electrode Conductivity Not Applicable AX433 Dual Input 4-Electrode Conductivity (0 to 2,000 mS/cm) 4-Electrode Conductivity 4-Electrode Conductivity AX436 Dual Input 4-Electrode Conductivity and pH/Redox(ORP) 4-Electrode Conductivity pH/Redox(ORP) AX438 Dual Input 4-Electrode Conductivity and Dissolved Oxygen 4-Electrode Conductivity Dissolved Oxygen AX450 Single Input 2-Electrode Conductivity (USP) 2-Electrode Conductivity Not Applicable AX455 Dual Input 2-Electrode Conductivity (USP) 2-Electrode Conductivity 2-Electrode Conductivity AX456 Dual Input 2-Electrode Conductivity (USP) and pH/Redox(ORP) 2-Electrode Conductivity pH/Redox(ORP) AX460 Single Input pH/Redox(ORP) pH/Redox(ORP) Not Applicable AX466 Dual Input pH/Redox(ORP) pH/Redox(ORP) pH/Redox(ORP) AX468 Dual Input pH/Redox(ORP) and Dissolved Oxygen pH/Redox(ORP) Dissolved Oxygen AX480 Single Input Dissolved Oxygen Dissolved Oxygen Not Applicable A X488 Dual Input Dissolved Oxygen Dissolved Oxygen Dissolved Oxygen Table 1.1 AX400 Series Analyzer Options 2 Sensor B 2 OPERATION 2.1 Powering Up the Analyzer 2.2.1 Membrane Key Functions – Fig. 2.2 Warning. Ensure all connections are made correctly, especially to the earth stud – see Section 6.3. Menu 1 Advance to next menu 1) Ensure the input sensor(s) is/are connected correctly. 2) Switch on the power supply to the analyzer. A start-up screen is displayed while internal checks are performed, then the Operating Page (Section 2.3) is displayed as the dissolved oxygen monitoring operation starts. 2.2 Displays and Controls – Fig. 2.1 1 The display comprises two rows of 4 /2 digit, 7-segment digital displays, that show the actual values of the measured parameters and alarm set points, and a 6-character dot matrix display showing the associated units. The lower display line is a 16-character dot matrix display showing operating and programming information. Menu 2 A – Moving Between Menus Advance to next page Page 1 Frame 1 Frame 2 Frame 3 Frame 4 Page 2 Frame 1 Frame 2 Frame 3 or For majority of Frames B – Advancing to Next Page Page X Frame 1 Display Lines Lower Display Line 100.0%Sat 25.0Deg. C Advance to next Frame Units Frame 2 Frame 3 Frame 4 Dissolved Oxygen C – Moving Between Frames Alarm LEDs Parameter Value Adjust Membrane Keys Menu Key New value is stored automatically Sidescroll Key Downscroll Key Up Key D – Adjusting and Storing a Parameter Value Down Key Fig. 2.1 Location of Controls and Displays Parameter X Y Z Select New value is automatically stored E – Selecting and Storing a Parameter Choice Fig. 2.2 Membrane Key Functions 3 …2 OPERATION Use the Menu Key to scroll through the Menus Use the Sidescroll Key to scroll through the Pages within each Menu Section 2.3, Page 6 Section 3.1, Page 9 OPERATING PAGE VIEW SETPOINTS Use the Downscroll Key to scroll through the Frames within each Page Section 3.2, Page 10 Section 3.3, Page 10 VIEW OUTPUTS Section 3.4, Page 11 Section 3.5, Page 11 VIEW SOFTWARE VIEW LOGBOOK VIEW HARDWARE A1: Setpoint Analog Output 1 Sensor A Module A2: Setpoint Analog Output 2 Sensor B Module A3: Setpoint Analog Output 3 A4: Setpoint Analog Output 4 AX400/2000 Issue Section 3.6, Page 14 VIEW CLOCK Alarms Date 01:06:03 Errors Time 12:00 Power Option Board Cals A5: Setpoint Section 4.1, Page 15 SENSOR CAL Cal. User Code Sensor Cal. A Sensor Cal. B A: Cal. Type. B: Cal. Type. A: Adjust Zero B: Adjust Zero A: Adjust Span B: Adjust Span Note. Sensor calibration frames shown at left are for manual calibration only. For automatic calibration, refer to Section 4.1 page 15. Section 5.1, Page 20 SECURITY CODE Section 5.2, Page 21 CONFIG. DISPLAY Set Language English Set Temp. Units Temp. Units Set Backlight LED Backlight Section 5.3, Page 22 CONFIG. SENSORS Config. Sensor A Config. Sensor B A: Parameter B: Parameter A: Sal. Corr. B: Sal. Corr. A: Filter Time B: Filter Time Config. Alarm 1 Config. Alarm 2 Config. Alarm 3 Config. Alarm 4 Config. Alarm 5 A1: Type A2: Type A3: Type A4: Type A5: Type A1: Assign A2: Assign A3: Assign A4: Assign A5: Assign A1: Failsafe A2: Failsafe A3: Failsafe A4: Failsafe A5: Failsafe A1: Action A2: Action A3: Action A4: Action A5: Action A1: Setpoint A2: Setpoint A3: Setpoint A4: Setpoint A5: Setpoint A1: Hysteresis A2: Hysteresis A3: Hysteresis A4: Hysteresis A5: Hysteresis A1: Delay A2: Delay A3: Delay A4: Delay A5: Delay Section 5.4, Page 23 CONFIG. ALARMS * Wash Mode Wash Frequency Wash Duration Recovery Period only * toApplicable Alarm 3 Key Available only if option board fitted and analog features enabled – see Section 7.3 To CONFIG. OUTPUTS (see Fig. 2.3B) Dual input analyzer only Fig. 2.3A Overall Programming Chart 4 2 Use the Menu Key to scroll through the Menus OPERATION… Use the Sidescroll Key to scroll through the Pages within each Menu Section 5.5, Page 28 CONFIG. OUTPUTS Use the Downscroll Key to scroll through the Frames within each Page Config. Output 1 Config. Output 2 Config. Output 3 Config. Output 4 AO1: Assign AO2: Assign AO3: Assign AO4: Assign AO1: Range AO2: Range AO3: Range AO4: Range AO1: Span Value AO2: Span Value AO3: Span Value AO4: Span Value AO1: Zero Value AO2: Zero Value AO3: Zero Value AO4: Zero Value AO1: Default AO2: Default AO3: Default AO4: Default AO1: Default Val AO2: Default Val AO3: Default Val AO4: Default Val Section 5.6, Page 30 CONFIG. CLOCK Set Clock? Format dd/mm/yy Date 01:06:03 Time Press CONFIG.SERIAL 12:00 To Set Press To Abort Displayed only if option board fitted and serial communications feature enabled (Section 7.3) – see Supplementary Manual PROFIBUS Datalink Description (IM/PROBUS) Section 5.7, Page 31 CONFIG. CONTROL Controller PID Controller Power Recovery Control Action Power Rec. Mode Prop. Band Default Output Integral time Derivative time Output Type Pulses/Minute OR Cycle Time OR Output Range Section 5.8, Page 36 CONFIG. SECURITY Alter Sec.Code Alter Cal.Code Section 5.9, Page 36 CONFIG. LOGBOOK Logbook Section 5.10, Page 37 TEST/MAINTENANCE Test Outputs Maintenance Load/Save Config Test Output 1 Hold Outputs Factory Config. Test Output 2 Automatic Time User Config. Test Output 3 Press To Set Press Key To Abort Single input analyzer only Test Output 4 Available only if option board fitted and analog features enabled – see Section 7.3 To FACTORY SETTINGS (see Section 7.3, Page 50) Fig. 2.3B Overall Programming Chart 5 …2 OPERATION 2.3 Operating Page 2.3.1 Single Input Dissolved Oxygen 100.0%Sat 25.0Deg.C Dissolved Oxygen Controller set to Off – see Section 5.7 Measured Values Dissolved Oxygen. Temperature. Note. The measured dissolved oxygen value is displayed in the units set in the A: Parameter frame – see Section 5.3. 100.0 %Sat ---- Manual Control Mode Dissolved Oxygen. 100.0 %Sat 60.0 % Man. Control Output Dissolved Oxygen. 100.0 %Sat 150.0 %Sat Control Set Point Dissolved Oxygen. Control Mode Setpoint 150.00 Control Setpoint Control mode. and Use the keys to switch between manual (Manual) and automatic (Auto) control. Control output (%), manual (Man) or automatic (Auto). When Control Mode is set to Manual (see above), use the control output between 0 and 100%. and Control set point. and keys to adjust the control set point: Use the – between 0 and 250% saturation if A: Parameter set to %Sat – between 0.00 and 25.00 ppm if A: Parameter set to ppm – between 0.00 and 25.00 mg/l if A: Parameter set to mg/l keys to adjust the see Section 5.3. Sensor Output Current 25.00uA Sensor Output VIEW SETPOINTS See Section 3.1. SENSOR CAL. See Section 4.1. Wash Function Dissolved Oxygen 6 A3: Type set to Wash (Section 5.4) – see Section 2.3.3. A3: Type not set to Wash (Section 5.4) – return to top of page. 2 …2.3 Operating Page 2.3.2 Dual Input Dissolved Oxygen 100.0%Sat 9.07ppm OPERATION… Measured Dissolved Oxygen Sensor A. Sensor B. Dual D.O. Note. The displayed readings are the actual values of the sample. 20.0Deg.C 20.0Deg.C Measured Temperature Sensor A. Sensor B. Temperature Note. The displayed readings are the actual values of the sample. 25.00uA 25.00uA Sensor Output Current Sensor A. Sensor B. Sensor Output VIEW SETPOINTS See Section 3.1. SENSOR CAL. See Section 4.1. Wash Function Dual D.O. A3: Type set to Wash (Section 5.4) – see Section 2.3.3. A3: Type not set to Wash (Section 5.4) – return to top of page. 7 …2 OPERATION …2.3 Operating Page 2.3.3 Wash Function Note. The Wash function is available only if A3: Type is set to Wash – see Section 5.4. ----- Manual On Off Wash Function Wash Function Off – Wash function off. Lower display line of Operating Page shows WASH INHIBITED. On – Wash function controlled automatically. Lower display line of Operating Page shows WASH IN PROGRESS. Manual – Enables wash function to be initiated manually – see below. Note. Set Wash Function to Off before removing the sensor from the process. VIEW SETPOINTS See Section 3.1. SENSOR CAL. See Section 4.1. Press To Wash Dissolved Oxygen Dual D.O. Wash Function set to Manual – see below. Wash Function not set to Manual. The display returns to the top of the Operating Page. Press to Wash (Manual Wash only) ----Press Press Press to Wash and Press To Wash To Abort WASH IN PROGRESS Press the key to initiate the wash cycle. The display returns to the top of the Operating Page and the lower display line shows WASH IN PROGRESS until the wash cycle is completed. The Wash Function selection resets to the one that was set before Manual was selected. Dissolved Oxygen key to abort the wash cycle. The display returns to the top of Press the the Operating Page. Dual D.O. 8 to Abort are shown alternately on the lower display line. 3 OPERATOR VIEWS 3.1 View Set Points ----- VIEW SETPOINTS Sen.A View Set Points This page shows alarm set points. The value of each of the set points is shown, together with the name of the parameter it's assigned to. Alarm assignments, set point values and relay/LED actions are programmable – see Section 5.4. Those shown in the following frames are examples only. Sensor A (Dissolved Oxygen), Alarm 1 Set Point 250.0%Sat A1: Setpoint Temp.A Sensor A (Temperature), Alarm 2 Set Point 35.0Deg.C A2: Setpoint Sen.B Sensor B (Dissolved Oxygen), Alarm 3 Set Point – Dual input analyzers only 250.0%Sat A3: Setpoint Temp.B 55.0Deg.C Sensor B (Temperature), Alarm 4 Set Point – Dual input analyzers only Note. Alarm 4 available only if option board fitted and analog features enabled – see Section 7.3. A4: Setpoint Alarm 5 Set Point -----Off Note. Alarm 5 available only if option board fitted and analog features enabled – see Section 7.3. A5: Setpoint VIEW SETPOINTS VIEW OUTPUTS See Section 3.2. SENSOR CAL. See Section 4.1. 9 …3 OPERATOR VIEWS 3.2 View Outputs Theoretical Analog Output There are up to four analog outputs, each showing information for one sensor. ----- VIEW OUTPUTS 12.00mA 50.0% Analog Output 1 Note. Analog outputs 3 and 4 available only if option board fitted and analog features enabled – see Section 7.3. Live current output value being retransmitted. Current output shown as a percentage of full scale for the output range set in CONFIG. OUPUTS – see Section 5.5. VIEW HARDWARE See Section 3.3. SENSOR CAL. See Section 4.1. Analog Output 2 3.3 Advance to analog output 2 (and outputs 3 and 4 if option board fitted and analog features enabled – see Section 7.3). View Hardware ----- VIEW HARDWARE Sensor A Module Shows the type of input board fitted to the analyzer for the Sensor A input. -----D.O. D.O. – Dissolved Oxygen Sensor A Module Sensor B Module – Dual input analyzers only Shows the type of input board fitted to the analyzer for the Sensor B input. -----D.O. Sensor B Module Analog -----Pb DP Option Board Note. Displayed only if the option board is fitted. Displays the optional features enabled in the Factory Settings page – see Section 7.3. Option Board VIEW HARDWARE 10 VIEW SOFTWARE See Section 3.4. SENSOR CAL. See Section 4.1. 3 3.4 OPERATOR VIEWS… View Software ----- VIEW SOFTWARE Issue Shows the version number of the software. 7.05 AX400/2000 Issue VIEW LOGBOOK Dissolved Oxygen VIEW SOFTWARE Dual D.O. SENSOR CAL. 3.5 Option board fitted and analog features enabled (Section 7.3) and Logbook set to On (Section 5.9) – see Section 3.5. Operating Page (option board not fitted) – see Section 2.3. See Section 4.1. View Logbook Note. The View Logbook function is available only if the option board is fitted and analog features enabled (Section 7.3) and Logbook is set to On (Section 5.9). The logbook stores data entries for alarm events, sensor errors, power failures and sensor calibrations. ----- VIEW LOGBOOK Cals Power Errors Alarms ----- VIEW LOGBOOK 1A1 -----On 01:02:04 View Logbook and Use the keys to access the Alarms logbook. Note. If no entries are stored in the Alarms logbook, the display shows No More Entries. Alarms The Alarms logbook contains up to 10 entries (entry 1 is the most recent), each comprising an alarm number, alarm state (On or Off), and the date/time of the occurrence. 09:54 VIEW CLOCK Option board fitted and analog features enabled (Section 7.3) – see Section 3.6. SENSOR CAL. See Section 4.1. 2 A1 Advance to entries 2 to 10. Note. If no more entries are stored, the display shows No More Entries. 11 …3 …3.5 OPERATOR VIEWS Logbook Alarms Cals Power Errors ----- VIEW LOGBOOK 1Sen.A -----Pt100 01:02:04 View Logbook Use the and keys to access the Errors logbook. Note. If no entries are stored in the Errors logbook, the display shows No More Entries. Errors The Errors logbook contains up to 5 entries (entry 1 is the most recent), each comprising the sensor letter, error number and the date/time of the occurrence. 11:34 VIEW CLOCK Option board fitted and analog features enabled (Section 7.3) – see Section 3.6. SENSOR CAL. See Section 4.1. 2 Sen.A Advance to entries 2 to 5. Note. If no more entries are stored, the display shows No More Entries. Errors Alarms Cals Power ----- VIEW LOGBOOK 1 -----Off 29:02:04 View Logbook and Use the keys to access the Power logbook. Note. If no entries are stored in the Power logbook, the display shows No More Entries. Power The Power logbook contains up to 2 entries (entry 1 is the most recent), each comprising the power state (On or Off) and the date/time of the occurrence. 07:17 VIEW CLOCK Option board fitted and analog features enabled (Section 7.3) – see Section 3.6. SENSOR CAL. See Section 4.1. 2 Advance to entry 2. Note. If no more entries are stored, the display shows No More Entries. 12 3 …3.5 OPERATOR VIEWS… Logbook Power Errors Alarms Cals ----- VIEW LOGBOOK View Logbook Use the and keys to access the Cals logbook. Note. If no entries are stored in the Cals logbook, the display shows No More Entries. Calibration (Entry 1) The Cals logbook contains up to 5 entries (entry 1 is the most recent), each comprising 2 frames. 1Sen.A -----Passed Calibration If an entry is generated by an automatic calibration: – frame 1 contains the entry number, sensor letter and pass/fail indication. – frame 2 contains the sensor % efficiency value, together with the date/time of the calibration. 100% 28:02:04 15:39 OR 1Sen.A -----User Calibration 1.000Slope 0.000uA 03:03:04 If an entry is generated by a manual calibration: – frame 1 contains the entry number, sensor letter and User indication. – frame 2 contains the sensor zero and span (slope) values, together with the date/time of the calibration. Note. If no more entries are stored, the display shows No More Entries. 18:04 VIEW CLOCK Option board fitted and analog features enabled (Section 7.3) – see Section 3.6. SENSOR CAL. See Section 4.1. 2 Sen.A Advance to entries 2 to 5. Note. If no more entries are stored, the display shows No More Entries. 13 …3 OPERATOR VIEWS 3.6 View Clock Note. The View Clock function is available only if the option board is fitted and analog features enabled – see Section 7.3. ----- VIEW CLOCK Date Shows the current date. ----Date 05:03:04 Time Shows the current time. ----Time 08:54 Dissolved Oxygen VIEW CLOCK Dual D.O. SENSOR CAL. 14 Operating Page – see Section 2.3. See Section 4.1. 4 SETUP 4.1 Sensor Calibration Notes. • Sensor calibration involves standardizing the analyzer and the sensor using sample solutions and air. • A 5% sodium sulphite, zero calibration solution is required for an automatic, commisioning calibration. Automatic, full scale (span) calibration is carried-out either in air or air-saturated water – see Appendix A3. Sensor Calibration ----- SENSOR CAL. Sensor Calibration Security Code Note. This frame is displayed only if Alter Cal. Code is not set to zero – see Section 5.8. 0000 Cal. User Code Enter the required code number (between 0000 and 19999) to gain access to the sensor calibration pages. If an incorrect value is entered, access to the calibration pages is prevented and the display reverts to the SENSOR CAL. frame. Calibrate Sensor A ----- Sensor Cal. A Sensor Cal. B SENSOR CAL SECURITY CODE CONFIG. DISPLAY A: Cal. Type. ----- None Auto. Manual A: Cal. Type. Sensor B calibration (dual input analyzers only) is identical to Sensor A calibration. Single input analyzers only – return to main menu. Alter Sec. Code not set to zero (Section 5.8) – see Section 5.1. Alter Sec. Code set to zero (Section 5.8) – see Section 5.2. Continued below. Calibration Type Manual – manually adjust the analyzer's span reading (and zero reading if required – see next page) to match those from a reference instrument Auto. – automatic calibration None – display sensor efficiency calculated from the last successful calibration Note. Manual calibration is normally used only in conditions of extreme cold when removing the sensor from the process to calibrate in air will result in damage to the sensor membrane due to freezing. A: Adjust Zero A: Cal Method Sensor O/P #### Manual selected – continued on next page. Auto. selected – continued on next page. None selected – continued on page 17. 15 …4 …4.1 SETUP Sensor Calibration A: Cal. Type. set to Manual 0.0%Sat 0.000uA A: Adjust Zero Adjust Zero Adjust the μA value, between –2.000 and 2.000 in 0.001 μA increments, until the %Sat value matches that from the reference instrument. Although the sensor can be immersed in a 5% sodium sulphite zero calibration solution (see Appendix A3.1) and zero adjusted manually, it is strongly recommended that, if this method is required, the automatic calibration type is used. Notes. • Warning-Offset is shown on the lower display line if the μA value is adjusted outside of the range –0.100 to 0.600 – see Table 8.1, page 55. • Out-of-Range is shown on the lower display line if the μA value is adjusted to the maximum of its range (±2.000). Adjustment outside this range is not possible – see Table 8.1, page 55. 100.0%Sat 1.000Slope A: Adjust Span Adjust Span Adjust the Slope value, between 0.400 and 2.500 in 0.001 increments, until the %Sat value matches that from the reference instrument. Notes. • Warning-Low O/P is shown on the lower display line if the Slope value is adjusted above 2.000 – see Table 8.1, page 54. • Out-of-Range is shown on the lower display line if the Slope value is adjusted to the maximum of its range (0.400 to 2.500). Adjustment outside this range is not possible – see Table 8.1, page 55. Sensor Cal. B SENSOR CAL Sensor B calibration (dual input analyzers only) is identical to Sensor A calibration. Single input analyzers only – return to main menu. CONFIG. DISPLAY Alter Sec. Code not set to zero (Section 5.8) – see Section 5.1. Alter Sec. Code set to zero (Section 5.8) – see Section 5.2. Sensor O/P #### Continued on next page. SECURITY CODE A: Cal. Type. set to Auto. Water ----- Air Calibration Method Select the medium to be used for span calibration. Air – Dry the sensor thoroughly and expose to air Water – Immerse the sensor in air-saturated water A: Cal Method ----- No Yes A: Baro. Corr. Automatic Barometric Correction If the local barometric pressure is known, select Yes to enable automatic barometric correction. If the local barometric pressure is not known, select No. The analyzer functions using the standard sea-level value barometric pressure (760mm Hg) unless automatic altitude correction is selected below. A: Pressure A: Alt. Corr. 16 Yes selected – continued on next page. No selected – continued on next page. 4 …4.1 SETUP… Sensor Calibration A: Cal. Type. set to None ----- Sensor O/P #### Sensor Output The sensor efficiency calculated from the last successful calibration is displayed. When five bars are displayed, the sensor has maximum life remaining. When one bar is displayed and flashing, the sensor is exhausted. Order a replacement sensor when two bars are displayed. A: Cal. Type. Return to page 15. A: Baro. Corr. set to Yes Barometric Pressure Set the local barometric pressure in mm Hg. 760mmHg A: Pressure A: Cal. Type. Continued below. A: Baro. Corr. set to No No ----- Yes Automatic Altitude Correction If the local barometric pressure is not known but the analyzer is installed at a known altitude significantly above sea-level (e.g. above 50m [164 ft.]), select Yes to enable automatic altitude correction. A: Alt. Corr. If the local altitude is not known, select No. If neither automatic barometric correction nor automatic altitude correction have been selected, the analyzer functions at a default setting of 0m (sea-level) and 760mm Hg. No Yes Altitude Set the local altitude in metres above sea level (1m = 3.28 ft.). 50m A: Altitude Std ----- Comm A: Cal. Type. Calibration Type Select the required calibration type: Comm – (Commisioning calibration) includes a zero calibration procedure using 5% sodium sulphite. Recommended method following system installation or capsule change. Std – (Standard calibration) bypasses the zero calibration procedure. Recommended method for routine calibration. Immerse Zero Sol Immerse Span Sol Expose to Air Comm selected – continued on next page. A: Cal Method set to Water and Std selected – continued on next page. A: Cal Method set to Air and Std selected – continued on next page. 17 …4 …4.1 SETUP Sensor Calibration Zero Calibration Immerse the sensor in a 5% sodium sulphite solution. 0.0%Sat Immerse Zero Sol 0.0%Sat ##### 100% ##### A: Cal Method set to Air Press the key to initiate calibration. Note. To abort calibration, press the complete – see next page. key again at any time before calibration is The center display line shows, in the units selected in the CONFIG. SENSORS page (Section 5.3), the value to which the instrument's reading will be set following a successful zero calibration. As calibration procedes, a progress indicator appears in the lower display line. When a stable reading is detected, the lower display line shows ##### 100% ##### for 2 seconds, the display then advances automatically to the next frame. A: Cal Method set to Water 0.0%Sat Immerse Span Sol Span Calibration (Water Calibration Method) Thoroughly rinse the sensor with demineralized water and carefully dry the sensor capsule with a soft tissue. Immerse the sensor capsule in air-saturated water. Press the key to initiate calibration. Note. To abort calibration, press the complete – see next page. ##### 100% ##### 108.0%Sat Expose to Air Continued on next page. Span Calibration (Air Calibration Method) Thoroughly rinse the sensor with demineralized water and carefully dry the sensor capsule with a soft tissue. Expose the sensor to air. Press the key to initiate calibration. Note. To abort calibration, press the complete – see next page. ##### 100% ##### 18 key again at any time before calibration is Continued on next page. key again at any time before calibration is 4 …4.1 SETUP Sensor Calibration 0.0%Sat The center display line shows, in the units selected in the CONFIG. SENSORS page (Section 5.3), the value to which the instrument's reading will be set following a successful span calibration. If either automatic barometric or altitude correction were selected, the displayed value includes the correction. ##### 100% ##### As calibration procedes, a progress indicator appears in the lower display line. When a stable reading is detected, the lower display line shows ##### 100% ##### for 2 seconds, the display then advances automatically to the next frame. ----- Sensor Output Provides an indication of sensor performance. When five bars are displayed, the sensor has maximum life remaining. When one bar is displayed and flashing, the sensor is exhausted. Order a replacement sensor when two bars are displayed. Sensor O/P #### Note. If a calibration results in a sensor efficiency indication of one bar, that calibration is ignored and the values obtained from the previous calibration are used. Sensor Cal. A Return to top of page. Abort Calibration -----Yes Select Yes or No. A: Abort Cal. Sensor Cal. A ### 26% Yes selected – return to top of page. No selected – calibration continues. 19 5 PROGRAMMING 5.1 Security Code Note. This frame is displayed only if Alter Sec. Code is not set to zero – see Section 5.8. 0000 SECURITY CODE Enter the required code number (between 0000 and 19999), to gain access to the configuration pages. If an incorrect value is entered, access to the configuration pages is prevented and the display reverts to the Operating Page – see Section 2.3. CONFIG. DISPLAY 20 See Section 5.2. 5 5.2 PROGRAMMING… Configure Display ----- CONFIG. DISPLAY Set Language Sets the language to be used on all displays. ----- Set Language Language and Use the keys to select the required language. ----- English Deutsch Francais Espanol Italiano Set Language Set Temperature Units ----- Set Temp. Units Deg. F Temperature Units Use the and keys to select the sample temperature display units. Deg. C -----Off Temp. Units Set Temp. Units Set Up Display Backlight ----- Set Backlight Auto. On ----- LED Backlight Backlight Use the and keys to select the required backlight option: Backlight comes on at each button press and switches off one minute after the last button press. – Backlight is always on. Auto. – On CONFIG. DISPLAY Return to main menu. CONFIG. SENSORS See Section 5.3. Set Backlight 21 …5 PROGRAMMING 5.3 Configure Sensors ----- CONFIG. SENSORS Configure Sensor A ----- Config. Sensor A Config. Sensor B CONFIG. SENSORS ----- mg/l ppm %Sat A: Parameter Sensor B configuration (dual input analyzers only) is identical to Sensor A configuration. Single input analyzers only – return to main menu. Dissolved Oxygen Units Select the units in which to display the dissolved oxygen reading. %Sat – percentage saturation ppm – parts per million mg/l – milligrams per litre %Sat mg/l ppm No -----Yes Salinity Correction Required when monitoring the dissolved oxygen concentration in saline water (e.g. seawater and estuarine waters) – see Appendix A2. A: Sal. Corr. Salinity Enter the salinity value of the process fluid in parts per thousand (ppt) – see Appendix A2. 20ppt A: Salinity Config. Sensor B Config. Sensor A CONFIG. ALARMS Sensor B configuration (dual input analyzers only) is identical to Sensor A configuration. See Section 5.4 Filter Time Set the required filter time, between 1 and 60 seconds in 1 second increments. 10Secs A: Filter Time Config. Sensor B Config. Sensor A CONFIG. ALARMS 22 Sensor B configuration (dual input analyzers only) is identical to Sensor A configuration. See Section 5.4 5 5.4 PROGRAMMING… Configure Alarms ----- CONFIG. ALARMS Configure Alarm 1 ----- Config. Alarm 1 Config. Alarm 2 ----A1: Type Wash Status Alarm Off Alarms 2 and 3 configuration (and Alarms 4 and 5 if option board fitted and analog features enabled – see Section 7.3) is identical to Alarm 1. Alarm 3 can also be configured as a Wash alarm if A3: Type is set to Wash – see following frame. Alarm 1 Type Select the type of alarm required: – The alarm is disabled, the alarm LED is off and the relay is de-energized at all times. Alarm – The analyzer is configured using the Assign parameter (see next page) to generate an alarm in response to a specified sensor reading. Status – An alarm is generated if either a power failure or a condition occurs that causes any of the error messages in Table 8.1 (page 55) to be displayed. Wash – Alarm 3 is configured to control the wash sequence. Off Note. The Wash alarm type can be assigned only to Alarm 3 and is displayed only when the lower display line shows A3: Type. Config. Alarm 1 A1: Assign Wash Mode A1: Type set to Off or Status – return to the top of page. A1: Type set to Alarm – continued on next page. A3: Type set to Wash – see Section 5.4.1. 23 …5 …5.4 PROGRAMMING Configure Alarms A1: Type set to Alarm A–B Temp.B Sen.B Temp.A Sen.A ----A1: Assign Alarm 1 Assign Select the alarm assignment required: Sen.A Sen.B – The analyzer activates an alarm if the dissolved oxygen content of the process fluid measured by the selected sensor exceeds or drops below the value set in the Alarm 1 Set Point parameter, depending on the type of Alarm 1 Action selected – see next page. Temp.A – The analyzer activates an alarm if the temperature of the process fluid Temp.B measured by the selected sensor exceeds or drops below the value set in the Alarm 1 Set Point parameter, depending on the type of Alarm 1 Action selected – see next page. A–B – The analyzer activates an alarm if the difference between the Sensor A and Sensor B readings exceeds or drops below the value set in the Alarm 1 Set Point parameter, depending on the type of Alarm 1 Action selected – see next page. Note. The Sen.B, Temp.B and A–B alarm assignment types are applicable only to dual input analyzers and A–B is displayed only when the Parameter selection for each sensor is identical – see Section 5.3. A1: Failsafe 24 Continued on next page. 5 …5.4 PROGRAMMING… Configure Alarms Yes -----No Alarm 1 Failsafe Select Yes to enable failsafe action, otherwise select No. See also Figs. 5.2 to 5.6 (page 27). A1: Failsafe High Low ----- Alarm 1 Action Select the alarm action required, High or Low. See also Figs. 5.2 to 5.6 (page 27). A1: Action mg/l ppm %Sat 100.0 A1: Setpoint 0.0% Alarm 1 Set Point Set the Alarm set point to a value within the following ranges: %Sat – 0.0 to 250.0 % saturation ppm – 0.00 to 25.00 ppm mg/l – 0.00 to 25.00 mg/l Alarm 1 Hysteresis A differential set point can be defined between 0 and 5% of the alarm set point value. Set the required hysteresis in 0.1% increments. See also Figs. 5.2 to 5.6 (page 27). A1: Hysteresis 0Secs A1: Delay Alarm 1 Delay If an alarm condition occurs, activation of the relays and LEDs can be delayed for a specified time period. If the alarm clears within the period, the alarm is not activated. Set the required delay, in the range 0 to 240 seconds in 1 second increments. See also Figs. 5.2 to 5.6 (page 27). Config. Alarm 2 Alarms 2 and 3 configuration (and Alarms 4 and 5 if option board fitted and analog features enabled – see Section 7.3) is identical to Alarm 1. CONFIG. OUTPUTS See Section 5.5. Config. Alarm 1 25 …5 PROGRAMMING …5.4 Configure Alarms 5.4.1 Wash Cycle Configuration (applicable only to Alarm 3) A3: Type set to Wash Cont. Wash Mode Select the wash mode required. -----Pulsed Cont. Pulsed Wash Mode Hours 15Mins Wash Frequency 15 Mins Secs Wash Duration – (continuous) the relay remains energized for the wash duration – the relay is switched on and off every second for the duration of the wash, – see Fig. 5.1 Wash Frequency Set the wash frequency required. Wash frequency is set in 15 minute increments between 15 and 45 minutes, then in 1 hour increments between 1 and 24 hours. Wash Duration Set the wash duration required. Wash duration is set in 15 second increments between 15 and 45 seconds, then in 1 minute increments between 1 and 10 minutes. Recovery Period Set the recovery period required, between 0.5 and 5.0 minutes in 0.5 minute increments. 1.0Mins Recovery Period Config. Alarm 4 Option board fitted and analog features enabled (Section 7.3) – Alarm 4 configuation is identical to Alarm 1. CONFIG. OUTPUTS Option board not fitted or option board fitted and analog features disabled (Section 7.3) – see Section 5.5. Config. Alarm 3 Frequency Wash Duration Recovery Period Continuous t 1s 1s Pulsed t Fig. 5.1 Pulsed and Continuous Wash Cycles 26 5 …5.4 PROGRAMMING… Configure Alarms Note. The following examples illustrate High Alarm Actions, i.e. the alarm is activated when the process variable exceeds the defined set point. Low Alarm Actions are the same, except the alarm is activated when the process variable drops below the defined set point. Process Variable Process Variable High Set Point High Set Point Relay Energized, LED Off Relay Energized, LED On Relay De-energized, LED Off Relay De-energized, LED On Fig. 5.2 High Failsafe Alarm without Hysteresis and Delay Fig. 5.5 High Non–Failsafe Alarm without Delay and Hysteresis Process Variable Process Variable High Set Point High Set Point Hysteresis Relay Energized, LED Off Relay Energized, LED Off Delay Relay De-energized, LED On Relay De-energized, LED On Fig. 5.3 High Failsafe Alarm with Hysteresis but no Delay Fig. 5.6 High Failsafe Alarm with Delay but no Hysteresis Process Variable High Set Point Hysteresis Relay Energized, LED Off Delay Relay De-energized, LED On Fig. 5.4 High Failsafe Alarm with Hysteresis and Delay 27 …5 PROGRAMMING 5.5 Configure Outputs ----- CONFIG. OUTPUTS Configure Output 1 ----- Config. Output 1 Config. Output 2 A–B Temp.B Sen.B Temp.A Sen.A ----- AO1: Assign Output 2 configuration (and Outputs 3 and 4 if option board fitted and analog features enabled – see Section 7.3) is identical to Output 1 configuration. Assign Select the sensor and analog output required: Sen.A Sen.B Temp.A Temp.B A–B – Dissolved oxygen measurement for the selected sensor. – Temperature for the selected sensor. – Difference between the Sensor A and Sensor B readings. Notes. • Sen.B, Temp.B and A–B are applicable only to dual input analyzers. • A–B is displayed only when the Parameter selection for each sensor is identical – see Section 5.3. ----- 4-20mA 0-20mA 0-10mA Range Select the analog output current range for the selected output. AO1: Range 250.0%Sat 0.00%Sat AO1: Span Value Span Value %Sat (or ppm or mg/l) and Adjust are shown alternately on the upper display line. Use the and keys to adjust the displayed reading to the required span value: %Sat ppm mg/l – 20.0 to 250.0 %Sat (minimum differential, 20.0 %Sat) – 2.00 to 25.00 ppm (minimum differential, 2.00 ppm) – 2.00 to 25.00 mg/l (minimum differential, 2.00 mg/l) Note. The minimum and maximum span values are determined by the Zero Value setting (see next page) plus the minimum differential, e.g. to set Span Value to 20.0 %Sat, first set Zero Value to 0.0 %Sat. AO1: Zero Value 28 Continued on next page. 5 …5.5 PROGRAMMING… Configure Outputs 250.0%Sat 0.0%Sat AO1: Zero Value Zero Value %Sat (or ppm or mg/l) and Adjust are shown alternately on the center display line. Use the and %Sat ppm mg/l keys to adjust the displayed reading to the required zero value: – 0.0 to 230.0 %Sat (minimum differential, 20.00 %Sat) – 0.00 to 23.00 ppm (minimum differential, 2.00 ppm) – 0.00 to 23.00 mg/l (minimum differential, 2.00 mg/l) Note. The zero value setting plus the minimum differential determines the minimum and maximum values for the span setting, e.g. to set Span Value to 2.0 ppm, first set Zero Value to 0.00 ppm. Hold On Off mA ----- AO1: Default Config. Output 1 Off or Hold Default Output Select the system reaction to failure: Hold – Hold the analog output at the value prior to the failure. On – Stop on failure. This drives the analog output to the level set in the Default Val frame below. Off – Ignore failure and continue operation. On Default Value The level to which the analog output is driven if a failure occurs. 12.00mA Set the value between 0.00 and 22.00mA. AO1: Default Val Config. Output 2 Output 2 configuration (and Outputs 3 and 4 if option board fitted and analog features enabled – see Section 7.3) is identical to Output 1 configuration. CONFIG. CLOCK Option board fitted and analog features enabled (Section 7.3) – see Section 5.6. Option board fitted and Serial Communications feature enabled (Section 7.3) – see Supplementary Manual PROFIBUS Datalink Description (IM/PROBUS). Single input analyzer and option board not fitted – see Section 5.7. Dual input analyzer and option board not fitted – see Section 5.8. Config. Output 1 CONFIG. SERIAL CONFIG. CONTROL CONFIG. SECURITY 29 …5 PROGRAMMING 5.6 Configure Clock Note. The Configure Clock function is available only if the option board is fitted and analog features enabled – see Section 7.3. ----- CONFIG. CLOCK Set Clock Set the system clock. ----Set Clock? Return to main menu. CONFIG. CLOCK CONFIG. SERIAL CONFIG. CONTROL CONFIG. SECURITY Option board fitted and Serial Communications feature enabled (Section 7.3) – see Supplementary Manual PROFIBUS Datalink Description (IM/PROBUS). Single input analyzer and option board not fitted – see Section 5.7. Dual input analyzer and option board not fitted – see Section 5.8. Date Format Select the required date format. ----mm:dd:yy Format dd:mm:yy Set -----Day Date 01:02:04 Set -----Hours Time 12:00 ----Press Press To Set To Abort Date Set the date in the format selected above. Press Use the to move between the day, month and year fields. and keys to adjust each field. Time Set the time in the form hh:mm. Press Use the Press to move between the hours and minutes fields. and keys to adjust each field. to Wash and Press to Abort are shown alternately on the lower display line. Press the appropriate key to set the clock or abort the changes. Set Clock? 30 5 5.7 PROGRAMMING… Configure Control Notes. • PID control is applicable only to single input analyzers. • Before configuring the PID controller, refer to Appendix B for further information. ----- CONFIG. CONTROL PID Off ----- Controller Type Select the controller type: Off – Disables the controller PID – Single PID controller Controller PID Controller CONFIG. SECURITY Controller set to PID – see Section 5.7.1. See Section 5.8. 31 …5 PROGRAMMING …5.7 Configure Control 5.7.1 Configure Single PID Controller Controller set to PID ---- PID Controller Power Recovery Rev. Direct ---- See Section 5.7.2. Control Action Set the required control action: Rev. – Reverse acting – see Appendix B, Fig. B2. Direct – Direct acting – see Appendix B, Fig. B3. Control Action Proportional Band Set the required proportional band, between 0.0 and 999.9% in 0.1% increments. 100.0 % Man Prop. Band 100 Secs Integral Action Time Set the integral action time, between 1 and 7200 seconds in 1 second increments. Set to OFF to disable integral action time. Integral Time 10.0 Secs Derivative Action Time Set the derivative action time, between 0.1 and 999.9 seconds in 0.1 second increments. Set to OFF to disable derivative action time. Derivative Time Pulse Analog Time ---- Output Type Output Type Set the required output type: Time – Time proportioning (relay 1) Analog – Analog output (analog output 1) Pulse – Pulse frequency (relay 1) Cycle Time Output Range Pulses/Minute 32 Output Type set to Time – continued on next page. Output Type set to Analog – continued on next page. Output Type set to Pulse – continued on page 34. 5 …5.7 …5.7.1 PROGRAMMING… Configure Control Configure Single PID Controller Output Type set to Time 10.0Secs Cycle Time Time Proportioning Output The Time Proportioning Output is interrelated to the retention time of the vessel and the flow of the chemical reagent and is adjusted experimentally to ensure that the chemical reagent is adequate to control the dosing under maximum loading. It is recommended that the Time Proportioning Output is adjusted in Manual Mode set to 100% valve output before setting up the PID parameters. PID Controller The time proportioning output value is calculated using the following equation: control output x cycle time 100 on time = Set the cycle time, between 1.0 and 300.0 seconds in 0.1 second increments – see Appendix B, Fig. B4 Mode C. Note. Changes to the cycle time do not take effect until the start of a new cycle. Permanently de-energized Output = 0% Energized Output = 25% 2.5s 7.5s De-energized Energized 5s Output = 50% 5s De-energized Energized 7.5s Output = 75% 2.5s De-energized Output = 100% Permanently energized Cycle Time = 10s Power Recovery CONFIG. SECURITY See Section 5.7.2. See Section 5.8. Output Type set to Analog 4-20mA 0-20mA 0-10mA Analog Output Set the analog current output range. ---- Output Range PID Controller Power Recovery CONFIG. SECURITY See Section 5.7.2. See Section 5.8. 33 …5 PROGRAMMING …5.7 …5.7.1 Configure Control Configure Single PID Controller Output Type set to Pulse 60 Pulses/Minute PID Controller Pulse Frequency Ouput The pulse frequency output is the number of relay pulses per minute required for 100% control output. The Pulse Frequency Output is interrelated to the chemical reagent strength and the solution flow rate. The chemical reagent flowrate and pulse frequency is adjusted experimentally to ensure that the chemical reagent is adequate to control the dosing under maximum loading. Adjust the Pulse Frequency Output in Manual Mode and set to 100% valve output before setting up the PID parameters. For example, if the observed value on the display is 6 and the control point is 5 then the frequency needs to be increased. The actual number of pulses per minute is calculated using the following equation: Actual pulses per minute = % control output x pulse frequency output 100 Set the pulse frequency between 1 and 120 pulses per minute in 1 pulse per minute increments. Pulse Frequency Output/Minute Control Output 0 25 50 75 100 1 0 0.25 0.50 0.75 1.00 10 0 2.5 5.0 7.5 10.0 50 0 12.5 25 37.5 50 120 0 30 60 90 120 Note. If the pulse frequency of 120 is reached then concentration of the reagent needs to be increased. Note. Changes to the pulse frequency do not take effect until the start of a new cycle. Permanently de-energized Output = 0% Energized 0.3s Output = 50% 2.1s De-energized Energized Output = 100% 0.3s 0.9s 0.3s 0.9s De-energized Examples. Pulse Frequency = 50 pulses per minute (1 pulse every 1.25s) Power Recovery CONFIG. SECURITY 34 See Section 5.8.2. See Section 5.9. 5 …5.7 Configure Control 5.7.2 Configure Power Failure Recovery Mode PROGRAMMING… ---- Power Recovery Last Manual Auto ---- Power Rec. Mode 50.0 % Default Output Power Failure Recovery Mode When power to the analyzer is restored, Control Mode (Section 2.3) is set automatically according to the chosen Power Failure Recovery Mode selected in this frame. Select the required mode: Auto – Control Mode is set to Auto irrespective of its setting prior to the power failure. Manual – Control Mode is set to Manual irrespective of its setting prior to the power failure. Control Output (Section 2.3) is set to the level set in the Default Output frame below. Last – Control Mode and Control Output are set to the same state as that set prior to the power failure. Default Output Set the default output required after Power Failure Recovery, between 0 and 100% in 0.1% increments. Note. A setting of 0% represents no output. Power Recovery CONFIG. CONTROL Return to main menu. CONFIG. SECURITY See Section 5.8. 35 …5 PROGRAMMING 5.8 Configure Security ----- CONFIG. SECURITY Alter Security Code Set the security code to a value between 0000 and 19999. 00000 Alter Sec. Code Alter Calibration Code Set the sensor calibration access code to a value between 0000 and 19999. 00000 Alter Cal. Code CONFIG. SECURITY Return to main menu. CONFIG. LOGBOOK Option board fitted and analog features enabled (Section 7.3) – see Section 5.9. Alter Sec. Code 5.9 Configure Logbook Note. The Configure Logbook function is available only if the option board is fitted and analog features enabled – see Section 7.3. ----- CONFIG. LOGBOOK ----- Off On Configure Logbook and keys to to set the logbook On or Off. Use the If Off is selected, all data entries in the logbook are cleared. Logbook 36 CONFIG. LOGBOOK Return to main menu. TEST/MAINTENANCE See Section 5.10. 5 5.10 PROGRAMMING… Test Outputs and Maintenance ----- TEST/MAINTENANCE Test Outputs Displays the output test details for the analog outputs. ----- Test Outputs Note. Outputs 3 and 4 are available only if the option board is fitted and analog features enabled – see Section 7.3. Test Output 1 frame only is shown; the format of frames for the remaining outputs is identical. See below. Maintenance 4.00mA 20.0% Test Output 1 The theoretical output current value. Output current as a percentage of the full range current. Test Output 1 and keys to adjust the displayed theoretical output current value to give Use the the output required. FACTORY SETTINGS See Section 7.3. Test Output 2 Test remaining outputs. Maintenance ----- Maintenance ----- Auto. On Off Hold Outputs Enables the relay action and analog outputs to be maintained. Auto. – Changes in relay action and analog outputs are disabled during sensor Hold Outputs On Off calibration. – Changes in relay action and analog outputs are disabled. – Changes in relay action and analog outputs are not disabled. Note. The LEDs flash while the analyzer is in 'Hold' mode. Load/Save Config Continued on next page. FACTORY SETTINGS See Section 7.3. Maintenance Hold Outputs set to Off or On – return to main menu. Hold Outputs set to Auto. – continued on next page. Automatic Time 37 …5 PROGRAMMING …5.10 Test Outputs and Maintenance Hold Outputs set to Auto. 1Hrs 30Mins Automatic Time Automatic Time If required, set a time period between 1 and 6 hours, in 30 minute increments, for which the outputs are held when Hold Outputs is set to Auto. At the default setting of None, changes in relay action and analog outputs are disabled during sensor calibration and enabled automatically at the end of the procedure. If a time is set, changes in relay action and analog outputs are disabled during sensor calibration, but if the calibration is not completed within the set time, the calibration is aborted, the display returns to the Operating Page and CAL. ABORTED is displayed. Maintenance Yes No ----- Load/Save Config Continued below. FACTORY SETTINGS See Section 7.3. Load/Save Configuration Select whether a configuration is to be loaded or saved. Note. If No is selected, pressing the key has no effect. Load/Save Config Yes TEST/MAINTENANCE Return to main menu. FACTORY SETTINGS See Section 7.3. Load User/Factory Configuration Load -----Save User Config. Factory Config. Note. Applicable only if Load/Save Config is set to Yes. – resets all the parameters in the Configuration Pages to the Company Standard. Save User Config. – saves the current configuration into memory. Load User Config. – reads the saved user configuration into memory. Factory Config. User Config. and Factory Config. are displayed alternately if a User Configuration has been and keys to make the required selection. saved previously. Use the ----Press Press To Set. To Abort Press to Wash and Press to Abort are displayed alternately on the lower display line. Press the appropriate key to load/save the configuration or abort the changes. TEST/MAINTENANCE 38 6 INSTALLATION 6.1 Siting Requirements Notes. • Mount in a location free from excessive vibration, and where the temperature and humidity specification will not be exceeded. • Mount away from harmful vapors and/or dripping fluids and ensure that it is suitably protected from direct sunlight, rain, snow and hail.s. • Where possible, mount the analyzer at eye level to allow an unrestricted view of the front panel displays and controls. Dissolved Oxygen Maximum Distance 100m (275 ft) DO Sensor Dissolved Oxygen A – Maximum Distance Between Analyzer and Sensor 55°C (131°F) Max. Dissolved Oxygen –20°C (–4°F) Min. Dissolved Oxygen B – Within Temperature Limits Dissolved Oxygen IP65* Dissolved Oxygen C – Within Environmental Limits * Refer to Specification, page 56 Fig. 6.1 Siting Requirements 39 …6 INSTALLATION 6.2 Mounting 6.2.1 Wall-/Pipe-mount Analyzers – Figs. 6.2 and 6.3 Dimensions in mm (in.) Fixing Centers 210 (8.23) 94 (3.7) 192 (7.56) R1 96 (3.76) 0.4 ) 25 Ø 6. 50 (0 .2 6) 192 (7.56) 150 (5.9) Fixing Centers 175 (6.9) 0( Fig. 6.2 Overall Dimensions Position 'U' bolts on pipe 2 Position plate over 'U' bolts Drill suitable holes 1 2 61 (23/8) OD Vertical or Horizontal Post 1 Mark fixing centres (see Fig. 6.2) 3 Secure plate 3 Secure instrument to wall using suitable fixings 4 Secure transmitter to mounting plate A – Wall-mounting B – Pipe-mounting Fig. 6.3 Wall-/Pipe-mounting 40 6 …6.2 Mounting 6.2.2 Panel-mount Analyzers – Figs. 6.4 and 6.5 Dimensions in mm (in.) 137.50 (5.41) 25 (0.98) 96 (3.78) 91.60 (3.6) 96 (3.78) INSTALLATION… 92 +0.8 (3.62 +0.03 ) –0 –0 Panel Cut-out 92 +0.8 –0 (3.62 +0.03 ) –0 5.40 (0.2) Fig. 6.4 Overall Dimensions 1 Cut a hole in the panel (see Fig. 6.4 for dimensions). Instruments may be close stacked to DIN 43835 Remove the panel clamp and anchors from the instrument case 3 Insert the instrument 4 into the panel cut-out Loosen the retaining screw on each panel clamp 2 5 Refit the panel clamps to the case, ensuring that the panel clamp anchors are located correctly in their slots 6 Secure the analyzer by tightening the panel clamp retaining screws (see Note below) Note. The clamp must fit flat on the analyzer casing. The clamp uses a torque limiter, so it is not possible to over-tighten the securing screws. Fig. 6.5 Panel-mounting 41 …6 INSTALLATION 6.3 Electrical Connections Warnings. • The instrument is not fitted with a switch therefore a disconnecting device such as a switch or circuit breaker conforming to local safety standards must be fitted to the final installation. It must be fitted in close proximity to the instrument within easy reach of the operator and must be marked clearly as the disconnection device for the instrument. • Remove all power from supply, relay and any powered control circuits and high common mode voltages before accessing or making any connections. • The power supply earth (ground) must be connected to reduce the effects of RFI interference and ensure the correct operation of the power supply interference filter. • The power supply earth (ground) must be connected to the earth (ground) stud on the analyzer case – see Fig. 6.8 (wall/pipe-mount analyzers) or Fig. 6.10 (panel-mount analyzers). • Use cable appropriate for the load currents. The terminals accept cables from 20 to 14 AWG (0.5 to 2.5mm2) UL Category AVLV2. • The instrument conforms to Mains Power Input Insulation Category III. All other inputs and outputs conform to Category II. • All connections to secondary circuits must have basic insulation. • After installation, there must be no access to live parts, e.g. terminals. • Terminals for external circuits are for use only with equipment with no accessible live parts. • The relay contacts are voltage-free and must be appropriately connected in series with the power supply and the alarm/ control device which they are to actuate. Ensure that the contact rating is not exceeded. Refer also to Section 6.3.1 for relay contact protection details when the relays are to be used for switching loads. • Do not exceed the maximum load specification for the selected analog output range. The analog output is isolated, therefore the –ve terminal must be connected to earth (ground) if connecting to the isolated input of another device. • If the instrument is used in a manner not specified by the Company, the protection provided by the equipment may be impaired. • All equipment connected to the instrument's terminals must comply with local safety standards (IEC 60950, EN61010-1). USA and Canada Only • The supplied cable glands are provided for the connection of signal input and ethernet communication wiring ONLY. • The supplied cable glands and use of cable / flexible cord for connection of the mains power source to the mains input and relay contact output terminals is not permitted in the USA or Canada. • For connection to mains (mains input and relay contact outputs), use only suitably rated field wiring insulated copper conductors rated min. 300 V, 14 AWG 90C. Route wires through suitably flexible conduits and fittings. Notes. • Earthing (grounding) – a stud terminal is fitted to the analyzer case for bus-bar earth (ground) connection – see Fig. 6.8 (wall-/pipe-mount analyzers) or Fig. 6.10 (panel-mount analyzers). • Always route signal output/sensor cell cable leads and mains-carrying/relay cables separately, ideally in earthed (grounded) metal conduit. Use twisted pair output leads or screened cable with the screen connected to the case earth (ground) stud. Ensure that the cables enter the analyzer through the glands nearest the appropriate screw terminals and are short and direct. Do not tuck excess cable into the terminal compartment. • Ensure that the IP65 rating is not compromised when using cable glands, conduit fittings and blanking plugs/bungs (M20 holes). The M20 glands accept cable of between 5 and 9mm (0.2 and 0.35 in.) diameter. 42 6 …6.3 Electrical Connections 6.3.1 Relay Contact Protection and Interference Suppression – Fig. 6.6 INSTALLATION… If the relays are used to switch loads on and off, the relay contacts can become eroded due to arcing. Arcing also generates radio frequency interference (RFI) which can result in analyzer malfunctions and incorrect readings. To minimize the effects of RFI, arc suppression components are required; resistor/capacitor networks for AC applications or diodes for DC applications. These components must be connected across the load – see Fig 6.6. For AC applications the value of the resistor/capacitor network depends on the load current and inductance that is switched. Initially, fit a 100R/0.022μF RC suppressor unit (part no. B9303) as shown in Fig. 6.6A. If the analyzer malfunctions (locks up, display goes blank, resets etc.) the value of the RC network is too low for suppression and an alternative value must be used. If the correct value cannot be obtained, contact the manufacturer of the switched device for details on the RC unit required. For DC applications fit a diode as shown in Fig. 6.6B. For general applications use an IN5406 type (600V peak inverse voltage at 3A). Note. For reliable switching the minimum voltage must be greater than 12V and the minimum current greater than 100mA. NC C NO Relay Contacts NC C NO Relay Contacts Diode R C Load External L AC Supply N Load External + DC Supply A – AC Applications – B – DC Applications Fig. 6.6 Relay Contact Protection 43 …6 INSTALLATION …6.3 Electrical Connections 6.3.2 Cable Entry Knockouts, Wall-/Pipe-mount Analyzer – Fig. 6.7 The analyzer is supplied with 7 cable glands, one fitted and six to be fitted, as required, by the user – see Fig. 6.7. Release the four captive screws and remove the terminal cover plate 1 Factory-fitted cable gland 2 Secure the cable gland with the nut 6 Cable entry knockouts Place the blade of a small, flat bladed screwdriver into the knockout groove and tap the screwdriver smartly to remove the knockout (see Note below) Note. When removing knockouts, take great care not to damage wiring and components within the analyzer. 5 3 Smooth the edges of the hole with a small round or half-round file 4 Fit an 'O' ring seal to the the cable gland Insert the cable gland into the hole in the analyzer case from the outside. Tighten the gland to a torque of 3.75 Nm (33 lbf. in.) Note. The cable glands must be tightened to a torque of 3.75 Nm (33 lbf. in.) Fig. 6.7 Cable Entry Knockouts, Wall-/Pipe-mount Analyzer 44 6 6.4 INSTALLATION… Wall-/Pipe-mount Analyzer Connections 6.4.1 Access to Terminals – Fig. 6.8 Release the four captive screws and remove the terminal cover plate – see Note. Terminal Block C (Option Board) Case Earth (Ground) Stud Terminal Block A Terminal Block B Note. When refitting the terminal cover plate, tighten the captive screws to a torque of 0.40 Nm (3.5 lbf. in.) Fig. 6.8 Access to Terminals, Wall-/Pipe-mount Analyzer 45 INSTALLATION Wall-/Pipe-mount Analyzer Connections 6.4.2 Connections – Fig. 6.9 12 to 30 V DC Analog Output 4 B1 TC Link Common B2 Before making any electrical connections, see Warnings on page 42 Terminal Block B Sensor B Sensor A Sensor Connections (see Note 2 below) B1 B9 Temperature Compensator Common (Yellow) B2 B10 Temperature Compensator Third Lead (Green) B3 B11 Temperature Compensator (Black) B4 B12 Sensor +ve (Red) B5 B13 Sensor –ve (Blue) B6 B14 Screen B7 B15 Not Used B8 B16 Not Used ** Ensure polarity is correct before switching power supply on. Notes. 1 Relay 3 can be configured to control the wash facility – see Section 5.4. 2 The colors relate to the 6-core screened extension cable from the DO system's junction box. Cut the white core back to the outer insulation. 3 Tighten the terminal screws to a torque of 0.60 Nm (5.3 lbf. in.). Fig. 6.9 Connections, Wall-/Pipe-mount Analyzer 46 B3 B4 B5 B6 B7 B8 B9 TC Link Common B10 B11 B12 C16 — — A16 B13 C15 + + A15 B14 C14 — B15 C13 + + A13 — A14 B16 Analog Output 3 C12 NO Analog Output 1 C11 NC Relay 5 2 A Type T fuse (DC) Temperature Compensator Connections Temperature Compensator Connections NO A12 C10 C * 250 mA Type T fues (mains AC) or Terminal Block B NC A11 C A10 Power Supplies Terminal block A Relay 3 (see Note below) Relay 4 NC C NO C9 A9 NO C8 A8 Not used Relay 2 NC C7 A7 C C6 A6 C5 A5 NC C3 Not used C2 C4 A4 C NO Relay 1 Line Terminal Block C (Option Board) + 100 to 240 V AC Neutral * **L N ** – Connect supply earth (ground) to stud on case ** E C1 Not used Earth (Ground) Stud on Case (see Fig. 6.8) Used for optional RS485 connection. Refer to IM/PROBUS …6.4 Analog Output 2 …6 6 6.5 6.5.1 INSTALLATION… Panel-mount Analyzer Connections Access to Terminals – Fig. 6.10 Terminal Block A Earth (Ground) Stud Terminal Block C (Option Board) Terminal Block B Fig. 6.10 Access to Terminals, Panel-mount Analyzers 47 …6 INSTALLATION …6.5 Panel-mount Analyzer Connections 6.5.2 Connections – Fig. 6.11 Terminal block A * Terminal Block C (Option Board) + 12 Power 100 to 240 V AC to Supplies N ** Neutral – 30 V DC E ** Connect supply earth (ground) to stud on case C1 Not Used C2 Not Used A4 C C4 L** A5 NC Line C3 A6 NO A7 C A8 NC Relay 2 A9 NO B4 B5 C B7 C8 NC C9 NO A13 + C13 + A14 — C14 — A15 + C15 + B8 Relay 4 Relay 5 Common Link TC B9 Temperature Compensator Connections B12 Analog Output 3 Analog Output 4 Before making any electrical connections, see Warnings on page 42 * 250 mA Type T fues (mains AC) or ** Ensure polarity is correct before switching power supply on. Terminal Block B Sensor B Sensor A Sensor Connections (see Note 2 below) B1 B9 Temperature Compensator Common (Yellow) B2 B10 Temperature Compensator Third Lead (Green) B3 B11 Temperature Compensator (Black) B4 B12 Sensor +ve (Red) B5 B13 Sensor –ve (Blue) B6 B14 Screen B7 B15 Not Used B8 B16 Not Used Notes. 1 Relay 3 can be configured to control the wash facility – see Section 5.4. 2 The colors relate to the 6-core screened extension cable from the DO system's junction box. Cut the white core back to the outer insulation. 3 Tighten the terminal screws to a torque of 0.60 Nm (5.3 lbf. in.). Fig. 6.11 Connections, Panel-mount Analyzers 48 B11 B13 B15 B16 Earth (Ground) Stud on Case (see Fig. 6.10) 2 A Type T fuse (DC) B10 B14 C16 — A16 — B3 C7 C12 NO Analog Output 2 Temperature Compensator Connections B2 B6 A12 NO Analog Output 1 B1 Not Used C11 NC Relay 3 (see Note 1 below) Common Link TC C6 C10 C A10 C A11 NC Used for optional RS485 connection. Refer to IM/PROBUS C5 Relay 1 Terminal Block B 7 CALIBRATION Notes. • The analyzer is calibrated by the Company prior to dispatch and the Factory Settings pages are protected by an access code. • Routine recalibration is not necessary – high stability components are used in the analyzer's input circuitry and, once calibrated, the Analog-to-Digital converter chip self-compensates for zero and span drift. It is therefore unlikely that the calibration will change over time. • Do Not attempt recalibration without first contacting ABB. • Do Not attempt recalibration unless the input board has been replaced or the Factory Calibration tampered with. • Before attempting recalibration, test the analyzer's accuracy using suitably calibrated test equipment – see Sections 7.1 and 7.2. 7.1 Equipment Required a) Current source (sensor simulator): 0 to 100μA (in increments of 0.1μA), accuracy ±0.1%. b) Decade resistance box (Pt100 temperature input simulator): 0 to 1kΩ (in increments of 0.01Ω), accuracy ±0.1%. c) Digital milliammeter (current output measurement): 0 to 20mA. Note. Decade resistance boxes have an inherent residual resistance that may range from a few mΩ up to 1Ω. This value must be taken into account when simulating input levels, as should the overall tolerance of the resistors within the boxes. 7.2 Preparation a) Switch off the supply and disconnect the sensor(s), temperature compensator(s) and current output(s) from the analyzer's terminal blocks. b) Sensor A – Fig. 7.1: 1) Link terminals B9 and B10. 2) Connect the current source to terminals B12 (+ve) and B13 (–ve) to simulate the sensor input. Connect the current source earth (ground) to the Case Earth (Ground) Stud – see Fig. 6.8 (wall-/pipe-mount analyzer) or Fig. 6.10 (panel-mount analyzer). 3) Connect the 0 to 10kΩ decade resistance box to terminals B9 and B11 to simulate the Pt100. Sensor B: 1) Link terminals B1 and B2 (dual input analyzers only) – Fig. 7.1. 2) Connect the current source to terminals B4 (+ve) and B5 (–ve) to simulate the sensor input. Connect the current source earth (ground) to the Case Earth (Ground) Stud – see Fig. 6.8 or (wall-/pipe-mount analyzer) or Fig. 6.10 (panel-mount analyzer). 3) Connect the 0 to 10kΩ decade resistance box to terminals B1 and B3 to simulate the Pt100. c) Connect the milliammeter to the analog output terminals. d) Switch on the supply and allow ten minutes for the circuits to stabilize. d) Select the FACTORY SETTINGS page and carry out Section 7.3. Sensor Simulator Temperature Simulator +ve Sensor A Terminal Numbers B9 Sensor B Terminal Numbers B1 B10 B2 B11 B3 B12 B4 –ve Earth B13 B14 B5 B6 Terminal link Fig. 7.1 Analyzer Terminal Links and Decade Resistance Box Connections 49 …7 CALIBRATION 7.3 Factory Settings Use the Sidescroll Key to scroll through the Pages within each Menu Section 7.3, Page 51 FACTORY SETTINGS Use the Menu Key to scroll through the Menus Factory Set Code Use the Downscroll Key to scroll through the Frames within each Page To OPERATING PAGE Cal. Output 2 Cal. Output 3 Cal. Sensor A Cal. Sensor B Cal. Output 1 Calibrate I/P ? Calibrate I/P ? O1: Adjust 4mA A: Zero (0uA) B: Zero (0uA) O1: Adjust 20mA A: Span (100uA) B: Span (100uA) A:T.Zero (100R) B:T.Zero (100R) A:T.Span (150R) B:T.Span (150R) A:Ref. Checking B:Ref. Checking Cal. Output 4 O2: Adjust 4mA O3: Adjust 4mA O4: Adjust 4mA O2: Adjust 20mA O3: Adjust 20mA O4: Adjust 20mA Option Board Note. The Option Board page is displayed only if the option board is fitted. Key Available only if the option board is fitted and analog features enabled – see page 54 Dual input analyzer only Fig. 7.2 Overall Factory Settings Chart 50 Alter Fact.Code 7 …7.3 CALIBRATION… Factory Settings ----- FACTORY SETTINGS Factory Settings Access Code Enter the required code number (between 0000 and 19999) to gain access to the factory settings. If an incorrect value is entered, access to subsequent frames is prevented and the display reverts to the top of the page. 0000 Factory Set Code Calibrate Sensor A Note. The values in the display lines for sensor calibration are shown as examples only – the actual values obtained will differ. ----- Cal. Sensor A Cal. Sensor B Sensor B calibration (dual input analyzers only) is identical to Sensor A calibration. Cal. Output 1 Single input analyzers only – see page 53. Dissolved Oxygen Dual D.O. Yes -----No Calibrate I/P ? Operating Page – see Section 2.3. Calibrate Input for Sensor A ? If calibration is required select Yes otherwise select No. Note. To abort calibration, press the complete – see next page. key again at any time before calibration is No Yes 0.000 uA 0.000 Calib A: Zero (0uA) Current Zero (0μA) Set the sensor simulator reading to 0μA. The display advances automatically to the next step once a stable and valid value is recorded. Note. The upper 6-segment display shows the measured value. Once the signal is within range the lower 6-segment display shows the same value and Calib is displayed to indicate that calibration is in progress. 100.0 uA 100.0 Calib A: Span (100uA) 100.0 Ohms 100.0 Calib A: T.Zero (100R) Span (100μA) Set the sensor simulator reading to 100μA. The display advances automatically to the next step once a stable and valid value is recorded. Temperature Zero Set the temperature simulator reading to 100Ω. The display advances automatically to the next step once a stable and valid value is recorded. A: T.Span (150R) Continued on next page. 51 …7 …7.3 CALIBRATION Factory Settings 150.0 Ohms 150.0 Calib Temperature Span (150R) Set the temperature simulator to 150Ω 100.0 Ohms 100.0 Calib Reference Resistance Checking The analyzer calibrates the internal reference resistance automatically to compensate for changes in ambient temperature. A: T.Span (150R) A: Ref. Checking The display advances automatically to the next step once a stable and valid value is recorded. The display returns automatically to Cal. Sensor A once a stable and valid value is recorded. Cal. Sensor A No Abort Calibration Select Yes or No. -----Yes A: Abort Cal. A: T.Zero (100R) CAL. SENSOR A Yes selected: – before completion of A: Span (100uA) frame – calibration advances to A: T.Zero (100R) and continues. – after completion of A: Span (100uA) frame – the display returns to the Calibrate Sensor A page. No selected – calibration continues from the point at which the key was pressed. 52 7 …7.3 CALIBRATION… Factory Settings Calibrate Output 1 ----- Cal. Output 1 Note. When adjusting the 4 and 20mA output values, the display reading is unimportant and keys are and is used only to indicate that the output is changing when the pressed. Cal. Output 2 See below. Adjust 4mA and Use the 16000 O1: Adjust 4mA Note. The analog output range selected in Configure Outputs (Section 5.5) does not affect the reading. Adjust 20mA and Use the 7200 O1: Adjust 20mA keys to set the milliammeter reading to 20mA. Note. The analog output range selected in Configure Outputs (Section 5.5) does not affect the reading. Cal. Output 2 Cal. Output 1 keys to set the milliammeter reading to 4mA. See below. Dissolved Oxygen Dual D.O. Operating Page – see Section 2.3. Calibrate Output 2 ----- Note. Output 2 calibration is identical to Output 1 calibration. Cal. Output 2 Cal. Output 3 Option Board Alter Fact. Code Option board fitted and analog features enabled – continued on next page. Option board fitted, additional features disabled – continued on next page. Option board not fitted – continued on next page. 7200 O1: Adjust 20mA Cal. Output 3 Cal. Output 2 Option Board Alter Fact. Code Option board fitted and analog features enabled – continued on next page. Option board fitted, additional features disabled – continued on next page. Option board not fitted – continued on next page. Dissolved Oxygen Dual D.O. Operating Page – see Section 2.3. 53 …7 …7.3 CALIBRATION Factory Settings Option Board Fitted and Analog Features Enabled Calibrate Output 3 ----- Cal. Output 3 Notes. • Output 3 (and Output 4) calibration is applicable only if the option board is fitted and analog features enabled – see below. • Output 3 calibration is identical to Output 2 calibration. Calibrate Output 4 ----- Note. Output 4 calibration is identical to Output 3 calibration. Cal. Output 4 Option Board Fitted, Additional Features Disabled Analog -----Pb Dp Option Board Configure Option Board Notes. • This parameter is displayed only if an option board is fitted. • The software detects if an option board is fitted but cannot detect the additional features available. • If an option board is fitted, the correct selection must be made below to enable use of the available features. If an incorrect selection is made, the software menus and frames associated with that option are displayed in the Operating and Configuration pages but the features do not work. Use the and keys to enable the features for the type of option board(s) fitted: – Analog features enabled (comprising two additional analog outputs, two additional alarm relays, clock and logbook facility). Pb Dp – PROFIBUS-DP digital communications features enabled. Analog + Pb Dp – Both analog and PROFIBUS-DP features enabled. Analog Option Board Not Fitted Alter Factory Code Set the factory settings access code to a value between 0000 and 19999. 0000 Alter Fact. Code FACTORY SETTINGS Return to main menu. Dissolved Oxygen Dual D.O. 54 Operating Page – see Section 2.3. 8 SIMPLE FAULT FINDING 8.1 Error Messages If erroneous or unexpected results are obtained the fault may be indicated in the Operating Page by an error message – see Table 8.1. However, some faults may cause problems with analyzer calibration or give discrepancies when compared with independent laboratory measurements. Error Message Possible Cause/Remedy A: FAULTY PT100 Temperature compensator/associated connections for Sensor A are either open circuit or short circuit. B: FAULTY PT100 Temperature compensator/associated connections for Sensor B are either open circuit or short circuit. A: High Temp The temperature of Sensor A has exceeded 40°C (104°F). B: High Temp The temperature of Sensor B has exceeded 40°C (104°F). * Warning-Offset The μA value in the Adjust Zero frame has been adjusted beyond the range –0.100 to 0.600μA – see Section 4.1. Ensure sensor connections are clean and dry. Check zero calibration solution (if used) – see Appendix A3.1. Repeat the calibration. If the fault persists, replace the sensor. The Slope value in the Adjust Span frame has been adjusted above 2.000 – see Section 4.1. * Warning-Low O/P The sensor is becoming fatigued. Order a replacement. * Out Of Range The μA value in the Adjust Zero frame has been adjusted to the maximum of its range (± 2.000μA) – see Section 4.1. Adjustment outside this range is not possible. Check zero calibration solution (if used) – see Appendix A3.1. Repeat the calibration. If the fault persists, replace the sensor. OR The Slope value in the Adjust Span frame has been adjusted to the maximum of its range (0.400 to 2.500) – see Section 4.1. Adjustment outside this range is not possible. The sensor is exhausted, replace the sensor. 8.2 No Response to DO Changes The majority of problems are associated with the DO sensor. Replace the sensor as an initial check – refer to the appropriate instruction manual. It is also important that all program parameters have been set correctly and have not been altered inadvertently – see Section 5. If the above checks do not resolve the fault: a) Carry out an electrical calibration as detailed in Section 7 and check that the instrument responds correctly to the current input. Failure to respond to the input usually indicates a fault with the analyzer, which must be returned to the Company for repair. b) If the response in a) is correct, select the Operating Page and set the current source to a value which gives an on-scale DO reading on the analyzer. Make a note of the current source setting and the DO reading. Reconnect the sensor cable and connect the current source to the sensor end of the cable. Set the same current value on the source and check that the analyzer displays the noted reading in this configuration. If check a) is correct but check b) fails, check the cable connections and condition. If the response for both checks is correct, replace the sensor. 8.3 Checking the Temperature Input Check the analyzer responds to a temperature input. Disconnect the Pt100 leads and connect a suitable resistance box directly to the analyzer inputs – see Section 7.2. Check the analyzer displays the correct values as set on the resistance box – see Table 8.2. Incorrect readings usually indicate an electrical calibration problem. Re-calibrate the analyzer as detailed in Section 7.3. Temperature °C °F Pt100 Input Resistance (Ω) 0 32 100.00 10 50 103.90 20 68 107.79 25 77 109.73 30 86 111.67 A: Sens O/P ## Sensor A is becoming fatigued. Order a replacement. 40 104 115.54 B: Sens O/P ## Sensor B is becoming fatigued. Order a replacement. 50 122 119.40 Calibration of Sensor A has failed. Repeat the calibration. If the fault persists, replace the sensor. 60 140 123.24 A: Sens O/P # (Note. # flashing) 70 158 127.07 80 176 130.89 B: Sens O/P # (Note. # flashing) Calibration of Sensor B has failed. Repeat the calibration. If the fault persists, replace the sensor. 90 194 134.70 100 212 138.50 130.5 267 150.00 WASH INHIBITED Wash Function is set to Off in the Operating Page. Set Wash Function to On – see Section 2.3.3. Table 8.2 Temperature Readings for Resistance Inputs * Manual calibration type only Table 8.1 Error Messages 55 SPECIFICATION Dissolved Oxygen – AX480, AX488 and AX468 Range Programmable 0 ... 250% saturation, 0 ... 25 mgl–1 or 0 ... 25ppm Temperature sensor Programmable Pt100 (3-wire), Pt1000 & Balco 3k. Minimum span 0 ... 2 mgl–1 or ppm Calibration Ranges Check value (zero point) 0 ... 14 pH 0 ... 20% saturation Units of measure % saturation, mgl–1 and ppm Resolution 0.1 (% saturation), 0.01 (mgl–1) or 0.01 (ppm) Accuracy 1 (% saturation), 0.1 (mgl–1) or 0.1 (ppm) Slope Between 40 and 105% (low limit user-configurable) Electrode Calibration Modes Calibration with auto-stability checking Automatic one or two point calibration selectable from: ABB Operating temperature range 0 ... 40 ºC (32 ... 104 ºF) DIN Temperature sensor input 3-wire Pt100 NIST Salinity correction Automatic over the range 0 ... 40 parts per thousand Auto sensor life indicator Indicates conditions of remaining sensor life Merck US Tech Two x user-defined buffer tables for manual entry or Two-point calibration or single-point process calibration Display pH/Redox – AX468 only Inputs One pH or mV input and solution earth Type Dual 5-digit, 7-segment, backlit LCD One temperature sensor Information 16-character, single line dot-matrix Enables connection to glass or enamel pH and reference sensors and Redox (ORP) sensors Energy-saving function Backlit LCD configurable as ON or Auto Off after 60s Input resistance Glass > 1 x 1013Ω Reference 1 x 1013Ω Range –2 ... 16 pH or –1200 ... +1200 mV Minimum span Any 2 pH span or 100 mV Resolution 0.01 pH Accuracy 0.01 pH Temperature compensation modes Automatic or manual Nernstian compensation Range –10 ... 200 ºC (14 ... 392 ºF) Process solution compensation with configurable coefficient Range –10 ... 200 ºC (14 ... 392 ºF) adjustable –0.05 ... 0.02%/ ºC (–0.02 ... 0.009%/ ºF) 56 Logbook* Electronic record of major process events and calibration data Real-time clock* Records time for logbook and auto-manual functions *Available if option board is fitted Sensor Cleaning Function Configurable cleaning action relay contact Continuous or Pulse in 1s on and off times Frequency 5 minutes ... 24 hours, programmable in 15 minute increments up to 1 hour then in 1 hour increments for 1 ... 24 hours Duration 15s ... 10 minutes, programmable in 15s increments up to 1 minute then in 1 minute increments up to 10 minutes Recovery period 30s ... 5 minutes, programmable in 30s increments SPECIFICATION… Relay Outputs – On/Off Control Function – AX480 Only Number of relays Three supplied as standard or five with option board fitted Controller Type P, PI, PID (Configurable) Number of set points Three supplied as standard or five with option board fitted Set point adjustment Configurable as normal or failsafe high/low or diagnostic alert Hysteresis of reading Programmable 0 ... 5% in 0.1% increments Delay Programmable 0 ... 60s in 1s intervals Relay contacts Single-pole changeover Rating 5A, 115/230V AC, 5A DC Insulation 2kV RMS contacts to earth/ground Analog Outputs Number of current outputs (fully isolated) Two supplied as standard or four with option board fitted Output ranges 0 ... 10 mA, 0 ... 20 mA or 4 ... 20 mA Analog output programmable to any value between 0 and 22 mA to indicate system failure Accuracy ±0.25% FSD, ±0.5% of reading (whichever is the greater) Control Outputs Output Can be assigned a maximum of two relays, two analog outputs or one of each Analog Current output control (0 ... 100%) Time proportioning cycle time 1.0 ... 300.0s, programmable in increments of 0.1s Pulse frequency 1 ... 120 pulses per minute, programmable in increments of 1 pulse per minute Controller action Direct or reverse Proportional band 0.1 ... 999.9%, programmable in increments of 0.1% Integral action time (Reset) 1 ... 7200s, programmable in increments of 1s (0 = Off) Derivative 0.1 ... 999.9s programmable in increments of 0.1s, only available for single set point control Auto/Manual User-programmable Resolution 0.1% at 10 mA, 0.05% at 20 mA Access to Functions Maximum load resistance 750Ω at 20 mA Direct keypad access Measurement, maintenance, configuration, diagnostics or service functions Configuration Can be assigned to either measured variable or either sample temperature Performed without external equipment or internal jumpers Digital Communications Communications Profibus DP (with option board fitted) 57 …SPECIFICATION Mechanical Data EMC Wall-/Pipe-mount versions IP65 (not evaluated under UL certification) Emissions and immunity Meets requirements of: Dimensions (height, width, depth)192 x 230 x 94 mm (7.56 x 9.06 x 3.7 in) EN61326 (for an industrial environment) Weight 1 kg (2.2 lb) EN50082-2 Panel-mount versions IP65 (front only) Dimensions (height, width, depth) 96 x 96 x 162 mm (3.78 x 3.78 x 6.38 in) Weight 0.6kg (1.32 lb) Cable Entry Types Standard – 5 or 7 x M20 cable glands N. American – 7 x knockouts suitable for 1/2 in. Hubble gland EN50081-2 Approvals, Certification and Safety Safety approval UL CE Mark Covers EMC & LV Directives (including latest version EN 61010) General safety EN61010-1 Overvoltage Class II on inputs and outputs Power Supply Voltage requirements 100 to 240 V AC 50/60 Hz (90 V Min. to 264 V Max. AC) 12 to 30 V DC Pollution category 2 Languages Languages configurable English Power consumption 10 W French Insulation Mains to earth (line to ground) 2kV RMS Italian German Spanish Environmental Data Operating temperature limits –20 to 55 ºC (–4 ... 131 °F) Storage temperature limits –25 to 75 °C (–13 ... 167 °F) Operating humidity limits Up to 95%RH non condensing 58 DS/AX4DO–EN Rev. J APPENDIX A A1 Oxygen Solubility in Pure Water A2 Table A1 gives values for the solubility of oxygen in pure water at various temperatures. The solubility values are given in mg/l (ppm) and relate to pure water in equilibrium with water vapor-saturated normal air at the standard atmospheric pressure of 760 mmHg. Note. The instrument compensates automatically for solubility in pure water variations due to temperature, using the values stated in Table A1. Temperature °C Solubility in Pure Water (ppm) 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 14.59 14.19 13.81 13.44 13.08 12.75 12.42 12.12 11.82 11.54 11.27 11.01 10.75 10.52 10.28 10.07 9.85 9.64 9.44 9.25 9.07 8.90 8.73 8.55 8.40 8.24 8.08 7.94 7.80 7.66 7.54 7.41 7.28 7.15 7.04 6.93 6.82 6.71 6.61 6.51 6.41 Correction for Salinity Automatic correction for the effect of salinity on oxygen solubility is available for the measurement of dissolved oxygen concentrations in saline water, provided the salinity value of the water is known and is constant. Correction is applied by entering the known value of salinity, in parts per thousand, in the A: Salinity frame (see Section 5.3, page 22) after the instrument has been calibrated. Automatic salinity correction is based on data given in 'International Oceanographic Tables', Volume 2 (National Institute of Oceanography of Great Britain and UNESCO, 1973) and is applicable only to sea or estuarine waters. For waters containing significant amounts of dissolved salts other than sodium chloride, it may be necessary to determine appropriate oxygen solubility values experimentally, e.g. by saturating aliquots of the water with air at various temperatures, spanning the required measurement range, and determining the resulting dissolved oxygen concentrations titrimetrically. The analyzer can then be used to measure both % saturation and temperature. The required oxygen concentration can be calculated from: concentration = S x % Saturation 100 ppm where S x = experimentally determined oxygen solubility, mg/l(ppm), at measurement temperature. This table is abstracted from Table lVb of 'International Oceanographic Tables' volume 2, National Institute of Oceanography of Great Britain and UNESCO, 1973 (0 to 35°C) and from R. Weiss, Deep Sea Res., 1970 17, 721 (36 to 40°C). Table A1 Oxygen Solubility in Pure Water 59 …APPENDIX A A3 DO Calibration Note. Both the oxygen and the temperature sensors must be exposed to the calibration medium. A3.2 A3.2.1 A3.1 Zero Calibration A 5% sodium sulphite solution is required that must be prepared well in advance by dissolving 5.0g of anhydrous sodium sulphite in 100ml of demineralized water. It must be stored in a tightly closed bottle. Ideally, this bottle should have a sufficiently wide neck to allow direct insertion of the oxygen and temperature sensors. Do not store the solution for more than one week. When the oxygen sensor is dipped into the solution, ensure that no air bubbles are trapped on, or close to, the membrane and that the sensor is supported so that the membrane cannot be damaged by contact with the bottom of the bottle. When the sensors are withdrawn, all traces of sodium sulphite must be removed by rinsing them thoroughly with demineralized water. 60 Span Calibration Either air or air-saturated water may be used. Air calibration is more convenient and is likely, in practice, to be at least as accurate as calibration in air-saturated water. Air Calibration The air must be saturated with water vapour. This is conveniently achieved by suspending the sensors inside a bottle containing a few drops of water. Alternatively, the sensors can be suspended close (within a few centimetres) to the surface of a body of water. The operation of the oxygen sensor is such that the output in air is slightly higher than in air-saturated water at the same temperature. This difference is reproducible, allowing calibration in air by adjusting the instrument reading to 108% saturation (or the equivalent concentration) rather than 100%. This adjustment is made automatically in the calibration procedure. A3.2.2 Air-saturated Water Calibration The air-saturated water must be prepared, as described below, well in advance. Using an aeration stone, or a sintered glass diffuser, aerate approximately 1 litre (0.22 galls.) of demineralized water, either continuously for at least five minutes with a small pump, or intermittently for at least 15 minutes with hand bellows. These techniques are adequate for many applications provided the ambient temperature is constant. However, to obtain an accurate 100% saturation solution, the water must be maintained at constant temperature and stirred gently, without forced aeration, using a magnetic stirrer set to provide continuous agitation without breaking the liquid surface. This process must be continued for at least two hours to attain complete equilibrium. For calibration, the sensors must be suspended in the air-saturated water, which must be stirred continuously so that the flow velocity at the membrane of the oxygen sensor is at least 30cm/s (9.8 ft/s). APPENDIX B B1 Single PID Controller – Fig. B1 The single PID controller is a basic feedback control system using three-term PID control with a local set point. Manual Output Control Set Point PID Control Loop PID Output Output 1 Process Variable Fig. B1 Single PID Controller B1.1 Reverse Acting Single PID Control – Fig. B2 Reverse acting control is used when the process DO is less than the required output DO. 100% Control Output Reverse Acting 0% 0% Process Variable Range 50% 100% Fig. B2 Reverse Acting Single PID Control 61 …APPENDIX B B1.2 Direct Acting Single PID Control – Fig. B3 Direct acting control is used when the process DO is greater than the required output DO. 100% Control Output Direct Acting 0% 0% Process Variable Range 50% 100% Fig. B3 Direct Acting Single PID Control B2 Ouput Assignment The output signal is assignable to either relay 1 (Time or Pulse output type) or analog output 1 (Analog output type). 62 APPENDIX B Setting Up Three Term (PID) Control Parameters To enable a process to be controlled satisfactorily, the following conditions must apply: a) The process must be capable of reaching a natural balance with a steady load. b) It must be possible to introduce small changes into the system without destroying either the process or the product. The Proportional Band determines the gain of the system. (the gain is the reciprocal of the proportional band setting, e.g. a setting of 20% is equivalent to a gain of 5). If the proportional band is too narrow, the control loop may become unstable and cause the system to oscillate. With proportional band control only, the system normally stabilizes eventually but at a value which is offset from the set point. The addition of Integral Action Time removes the offset but, if set too short, can cause the system to go into oscillation. The introduction of Derivative Action Time reduces the time required by the process to stabilize. B4 g) Set Derivative Time to: t (for P+I+D control) 8 t (for P+D control) 12 The analyzer is now ready for fine tuning by small adjustments to the P, I and D terms, after the introduction of a small disturbance of the set point. Response Time Process Variable B3 Manual Tuning Before starting up a new process or changing an existing one: Time a) Select the Config. Control page and ensure that Controller is set to PID – see Section 5.7. Mode A b) Select the PID Controller page and set the following: Response Time – see Section 5.7.1 Notes. • If the system goes into oscillation with increasing amplitude (Fig. B4 Mode B), reset the proportional band to 200%. If oscillation continues as in Mode B, increase the proportional band further until the system ceases to oscillate. Process Variable Proportional Band – 100% Integral Time – 0 (off) Derivative Time – 0 (off) Time Mode B • If the system oscillates as in Fig. B4 Mode A, or does not oscillate, refer to step c). Process Variable c) Reduce the Proportional Band by 20% increments and observe the response. Continue until the process cycles continuously without reaching a stable condition (i.e. a sustained oscillation with constant amplitude as shown in Mode C). This is the critical point. Response Time Cycle Time t d) Note the cycle time 't' (Fig. B4 Mode C) and the Proportional Band (critical value) setting. e) Set Proportional Band to: 1.6 times the critical value (for P+D or P+I+D control) 2.2 times the critical value (for P+I control) 2.0 times the critical value (for P only control) f) Time Mode C Fig. B4 Control Conditions Set Integral Time to: t (for P+I+D control) 2 t (for P+D control) 1.2 63 NOTES 64 Products and customer support Automation Systems Customer support For the following industries: — Chemical & Pharmaceutical — Food & Beverage — Manufacturing — Metals and Minerals — Oil, Gas & Petrochemical — Pulp and Paper We provide a comprehensive after sales service via a Worldwide Service Organization. Contact one of the following offices for details on your nearest Service and Repair Centre. Drives and Motors — AC and DC Drives, AC and DC Machines, AC Motors to 1kV — Drive Systems — Force Measurement — Servo Drives Controllers & Recorders — — — — UK ABB Limited Tel: +44 (0)1453 826661 Fax: +44 (0)1453 829671 USA ABB Inc. Tel: +1 215 674 6000 Fax: +1 215 674 7183 Single and Multi-loop Controllers Circular Chart and Strip Chart Recorders Paperless Recorders Process Indicators Flexible Automation — Industrial Robots and Robot Systems Flow Measurement — — — — Electromagnetic Flowmeters Mass Flowmeters Turbine Flowmeters Wedge Flow Elements Marine Systems & Turbochargers — Electrical Systems — Marine Equipment — Offshore Retrofit and Refurbishment Process Analytics — Process Gas Analysis — Systems Integration Transmitters — — — — Pressure Temperature Level Interface Modules Valves, Actuators and Positioners — Control Valves — Actuators — Positioners Water, Gas & Industrial Analytics Instrumentation — pH, Conductivity and Dissolved Oxygen Transmitters and Sensors — Ammonia, Nitrate, Phosphate, Silica, Sodium, Chloride, Fluoride, Dissolved Oxygen and Hydrazine Analyzers — Zirconia Oxygen Analyzers, Katharometers, Hydrogen Purity and Purge-gas Monitors, Thermal Conductivity Client Warranty Prior to installation, the equipment referred to in this manual must be stored in a clean, dry environment, in accordance with the Company's published specification. Periodic checks must be made on the equipment's condition. In the event of a failure under warranty, the following documentation must be provided as substantiation: — A listing evidencing process operation and alarm logs at time of failure. — Copies of all storage, installation, operating and maintenance records relating to the alleged faulty unit. ABB Limited Process Automation Oldends Lane Stonehouse Gloucestershire GL10 3TA UK Tel: +44 1453 826 661 Fax: +44 1453 829 671 ABB Inc. Process Automation 125 E. County Line Road Warminster PA 18974 USA Tel: +1 215 674 6000 Fax: +1 215 674 7183 www.abb.com Note We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document. We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its contents in whole or in parts – is forbidden without prior written consent of ABB. Copyright© 2011 ABB All rights reserved IM/AX4DO Rev. H 07.2011 Contact us