Yokogawa User's Manual Model DC402G Converter for Dual Cell Conductivity and Resistivity

User’s Manual Model DC402G Converter for Dual Cell Conductivity and Resistivity [Style: S2] IM 12D08E02-01E IM 12D08E02-01E 6th Edition i u Introduction Thank you for purchasing the DC402G Converter for Dual Cell Conductivity and Resistivity. Please read the following respective documents before installing and using the DC402G. The related documents are as follows. General Specifications: User’s Manual: GS 12D08E02-01E IM 12D08E02-01E (this manual) * the “E” in the document number is the language code. NOTE Electric discharge The DC402G contains devices that can be damaged by electrostatic discharge. When servicing this equipment, please observe proper procedures to prevent such damage. Replacement components should be shipped in conductive packaging. Repair work should be done at grounded workstations using grounded soldering irons and wrist straps to avoid electrostatic discharge. Installation and wiring The DC402G should only be used with equipment that meets the relevant IEC, American or Canadian standards. Yokogawa accepts no responsibility for the misuse of this unit. The Instrument is packed carefully with shock absorbing materials, nevertheless, the instrument may be damaged or broken if subjected to strong shock, such as if the instrument is dropped. Handle with care. Although the instrument has a weatherproof construction, the transmitter can be harmed if it becomes submerged in water or becomes excessively wet. Do not use an abrasive or solvent in cleaning the instrument. Yokogawa is not responsible for damage to the instrument, poor performance of the instrument or losses resulting from such, if the problems are caused by: • Improper operation by the user. • Use of the instrument in improper applications • Use of the instrument in an improper environment or improper utility program • Repair or modification of the related instrument by an engineer not authorized by Yokogawa. n How to dispose the batteries This is an explanation about the new EU Battery Directive(DIRECTIVE 2006/66/EC).This directive is only valid in the EU. Batteries are included in this product.Batteries incorporated into this product cannot be removed by yourself.Dispose them together with this product. When you dispose this product in the EU,contact your local Yokogawa Europe B.V.office.Do not dispose them as domestic household waste. Battery type: silver oxide battery Notice: The symbol means they shall be sorted out and collected as ordained in ANNEX II in DIRECTIVE 2006/66/EC. n Product Disposal The instrument should be disposed of in accordance with local and national legislation/ regulations. Media No. IM 12D08E02-01E 6th Edition : Feb. 2016 (YK) All Rights Reserved Copyright © 2007, Yokogawa Electric Corporation IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00 ii u Safety Precautions n Safety, Protection, and Modification of the Product • In order to protect the system controlled by the product and the product itself and ensure safe operation, observe the safety precautions described in this user’s manual. We assume no liability for safety if users fail to observe these instructions when operating the product. • If this instrument is used in a manner not specified in this user’s manual, the protection provided by this instrument may be impaired. • If any protection or safety circuit is required for the system controlled by the product or for the product itself, prepare it separately. • Be sure to use the spare parts approved by Yokogawa Electric Corporation (hereafter simply referred to as YOKOGAWA) when replacing parts or consumables. • Modification of the product is strictly prohibited. • The following safety symbols are used on the product as well as in this manual. WARNING This symbol indicates that an operator must follow the instructions laid out in this manual in order to avoid the risks, for the human body, of injury, electric shock, or fatalities. The manual describes what special care the operator must take to avoid such risks. CAUTION This symbol indicates that the operator must refer to the instructions in this manual in order to prevent the instrument (hardware) or software from being damaged, or a system failure from occurring. CAUTION This symbol gives information essential for understanding the operations and functions. NOTE This symbol indicates information that complements the present topic. This symbol indicates Protective Ground Terminal. This symbol indicates Function Ground Terminal. Do not use this terminal as the protective ground terminal. n Notes on Handling User’s Manuals • Please hand over the user’s manuals to your end users so that they can keep the user’s manuals on hand for convenient reference. • Please read the information thoroughly before using the product. • The purpose of these user’s manuals is not to warrant that the product is well suited to any particular purpose but rather to describe the functional details of the product. • No part of the user’s manuals may be transferred or reproduced without prior written consent from YOKOGAWA. • YOKOGAWA reserves the right to make improvements in the user’s manuals and product at any time, without notice or obligation. • If you have any questions, or you find mistakes or omissions in the user’s manuals, please contact our sales representative or your local distributor. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00 iii n Warning and Disclaimer The product is provided on an “as is” basis. YOKOGAWA shall have neither liability nor responsibility to any person or entity with respect to any direct or indirect loss or damage arising from using the product or any defect of the product that YOKOGAWA can not predict in advance. n Label The next warning label is put on the product. n Drawing Conventions Some drawings may be partially emphasized, simplified, or omitted, for the convenience of description. Some screen images depicted in the user’s manual may have different display positions or character types (e.g., the upper / lower case). Also note that some of the images contained in this user’s manual are display examples. n Warranty and service Yokogawa products and parts are guaranteed free from defects in workmanship and material under normal use and service for a period of (typically) 12 months from the date of shipment from the manufacturer. Individual sales organisations can deviate from the typical warranty period, and the conditions of sale relating to the original purchase order should be consulted. Damage caused by wear and tear, inadequate maintenance, corrosion, or by the effects of chemical processes are excluded from this warranty coverage. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00 iv In the event of warranty claim, the defective goods should be sent (freight paid) to the service department of the relevant sales organisation for repair or replacement (at Yokogawa discretion). The following information must be included in the letter accompanying the returned goods: • • • • • • • Part number, model code and serial number Original purchase order and date Length of time in service and a description of the process Description of the fault, and the circumstances of failure Process/environmental conditions that may be related to the failure of the device. A statement whether warranty or nonwarranty service is requested Complete shipping and billing instructions for return of material, plus the name and phone number of a contact person who can be reached for further information. Returned goods that have been in contact with process fluids must be decontaminated/ disinfected before shipment. Goods should carry a certificate to this effect, for the health and safety of our employees. Material safety data sheets should also be included for all components of the processes to which the equipment has been exposed. n Authorized Representative in EEA The Authorized Representative for this product in EEA is Yokogawa Europe B.V. (Euroweg 2, 3825 HD Amersfoort, The Netherlands). IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00 Toc-1 Model DC402G Converter for Dual Cell Conductivity and Resistivity [Style: S2] IM 12D08E02-01E 6th Edition TABLE OF CONTENTS u Introduction.....................................................................................................i u Safety Precautions........................................................................................ii 1. Introduction and General Description.................................................... 1-1 1.1 Instrument Check............................................................................................... 1-1 1.2 Application.......................................................................................................... 1-2 2. 3. DC402G Specifications............................................................................. 2-1 2.1 General specifications...................................................................................... 2-1 2.2 Operating specifications................................................................................... 2-3 2.3 Model and suffix codes..................................................................................... 2-5 Installation and Wiring.............................................................................. 3-1 3.1 Installation and dimensions............................................................................. 3-1 3.1.1 Installation site.................................................................................... 3-1 3.1.2 Mounting methods.............................................................................. 3-1 3.2 Preparation......................................................................................................... 3-5 3.3 3.4 3.5 4. Wiring the power supply................................................................................... 3-6 3.3.1 General precautions........................................................................... 3-6 3.3.2 Access to terminal and cable entry..................................................... 3-6 3.3.3 AC power............................................................................................ 3-8 3.3.4 Grounding the housing....................................................................... 3-8 3.3.5 Switching on the instrument................................................................ 3-9 Wiring the contact signals................................................................................ 3-9 3.4.1 General precautions........................................................................... 3-9 3.4.2 Contact outputs................................................................................... 3-9 3.4.3 Contact input..................................................................................... 3-10 Wiring the analog output signals................................................................... 3-10 3.5.1 General precautions......................................................................... 3-10 3.5.2 Analog output signals........................................................................ 3-11 3.6 Sensor wiring................................................................................................... 3-11 3.7 Sensor connection using junction box and extension cable..................... 3-12 3.8 Other sensor systems..................................................................................... 3-12 Operation; Display Functions And Setting............................................. 4-1 4.1 Operator interface.............................................................................................. 4-1 4.2 Explanation of operating keys.......................................................................... 4-2 IM 12D08E02-01E 6th Edition: Feb. 16, 2016-00 Toc-2 5. 4.3 Setting passcodes............................................................................................. 4-3 4.4 Display example................................................................................................. 4-3 4.5 Display functions............................................................................................... 4-4 Parameter setting...................................................................................... 5-1 5.1 5.2 Maintenance mode............................................................................................ 5-1 5.1.1 Manual activation of Hold.................................................................... 5-2 5.1.2 Setpoint adjustment............................................................................ 5-3 Commissioning mode....................................................................................... 5-4 5.2.1 Setpoints............................................................................................. 5-5 5.2.2 Range.................................................................................................. 5-7 5.2.3 Hold..................................................................................................... 5-9 5.2.4 Temperature compensation.............................................................. 5-11 5.2.5 Service.............................................................................................. 5-13 5.3 Notes for guidance in the use of service coded settings............................ 5-14 5.3.1 Parameter specific functions............................................................ 5-14 5.3.2 Temperature functions...................................................................... 5-15 5.3.3 Temperature compensation functions.............................................. 5-16 5.3.4 mA output functions.......................................................................... 5-17 5.3.5 Contact outputs................................................................................. 5-20 5.3.6 User interface.................................................................................... 5-24 5.3.7 Communication setup....................................................................... 5-26 5.3.8 General............................................................................................. 5-26 5.3.9 Test and setup mode......................................................................... 5-26 6. Calibration.................................................................................................. 6-1 6.1 When is calibration necessary?....................................................................... 6-1 6.2 Calibration procedure....................................................................................... 6-2 6.3 Calibration with HOLD active........................................................................... 6-3 7. Maintenance............................................................................................... 7-1 7.1 Periodic maintenance for the DC402G converter.......................................... 7-1 7.2 Periodic maintenance of the sensor................................................................ 7-1 7.3 Fuse Replacement............................................................................................. 7-2 8. Troubleshooting........................................................................................ 8-1 9. Spare Parts................................................................................................. 9-1 10. Appendix.................................................................................................. 10-1 10.1 User setting for non-linear output table (code 31, 35 and 36)..................... 10-1 10.2 User entered matrix data (code 23 to 28)...................................................... 10-1 10.3 Matrix data table (user selectable in code 22).............................................. 10-2 10.4 Sensor Selection.............................................................................................. 10-3 10.4.1 General............................................................................................. 10-3 10.4.2 Sensor selection............................................................................... 10-3 10.4.3 Selecting a temperature sensor....................................................... 10-3 IM 12D08E02-01E 6th Edition: Feb. 16, 2016-00 Toc-3 10.5 Setup for other functions................................................................................ 10-3 10.6 User setting table............................................................................................. 10-4 10.7 Configuration checklist for DC402G.............................................................. 10-6 10.8 USP <645> Water Purity Monitoring.............................................................. 10-7 10.9 WHAT IS DUAL CONDUCTIVITY?.................................................................. 10-8 Customer Maintenance Parts List.......................................CMPL 12D08E02-02E Revision Information................................................................................................i IM 12D08E02-01E 6th Edition: Feb. 16, 2016-00 Blank Page  1. <1. Introduction and General Description> 1-1 Introduction and General Description The Yokogawa DC402G is a 4-wire converter designed for industrial process monitoring, measurement and control applications. This instruction manual contains the information needed to install, set up, operate and maintain the unit correctly. This manual also includes a basic troubleshooting guide to answer typical user questions. Yokogawa can not be responsible for the performance of the DC402G if these instructions are not followed. 1.1 Instrument Check Upon delivery, unpack the instrument carefully and inspect it to ensure that it was not damaged during shipment. If damage is found, retain the original packing materials (including the outer box) and then immediately notify the carrier and the relevant Yokogawa sales office. Make sure the model number on the nameplate affixed to the left side of the instrument agrees with your order. CAUTION The nameplate will also contain the serial number and power supply selection. Be sure to apply correct power to the unit. Check that all the parts are present, including mounting bracket, as specified in the option codes at the end of the model number. For a description of the model codes, refer to Chapter 2 of this manual under General Specifications. Basic Parts List: Converter DC402G Instruction Manual English Optional mounting hardware when specified (See model code) IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  1-2 <1. Introduction and General Description> 1.2 Application The DC402G converter is intended to be used for continuous on-line measurement in industrial installations. The unit combines simple operation and microprocessor-based performance with advanced self-diagnostics and enhanced communications capability to meet the most advanced requirements. The measurement can be used as part of an automated process control system. It can also be used to indicate dangerous limits of a process, to monitor product quality, or to function as a simple controller for a dosing/neutralization system. Yokogawa designed the DC402G to withstand harsh environments. The converter may be installed either indoors or outside because the IP65 (NEMA 4X) housing and cabling glands ensure the unit is adequately protected. The flexible polycarbonate window on the front door of the DC402G allows pushbutton access to the keypad, thus preserving the water and dust protection of the unit even during routine maintenance operations. A variety of DC402G hardware is optionally available to allow wall, pipe, or panel mounting. Selecting a proper installation site will permit ease of operation. Sensors should normally be mounted closely to the converter in order to ensure easy calibration and peak performance. If the unit must be mounted remotely from the sensors, WF10 extension cable can be used up to a maximum of 50 metres (150 feet) with a BA10 junction box. The DC402G is delivered with a general purpose default setting for programmable items. (Default settings are listed in Chapter 5 and again in Chapter 10). While this initial configuration allows easy start-up, the configuration should be adjusted to suit each particular application. An example of an adjustable item is the type of temperature sensor used. The DC402G can be adjusted for any one of five different types of temperature sensors. To record such configuration adjustments, write changes in the space provided in Chapter 10 of this manual. Because the DC402G is suitable for use as a monitor, a controller or an alarm instrument, program configuration possibilities are numerous. Details provided in this instruction manual are sufficient to operate the DC402G with all Yokogawa sensor systems and a wide range of third-party commercially available probes. For best results, read this manual in conjunction with the corresponding sensor instruction manual. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  2-1 <2. DC402G Specifications> 2. DC402G Specifications 2.1 General specifications l Input specifications Two inputs , each 2-electrode measurement with square wave excitation, using cell constants(C) from 0.008 to 50.0 cm-1, with up to 60 metres (200ft) connection cable. l Detection method Frequency, read-pulse position and reference voltage are dynamically optimized. l Input ranges Minimum : Maximum : - Resistivity : 1μS x C at process temperature (underrange 0.000 μS/cm). 25 mS x C at process temperature (overrange 30 mS x C). 0.00 kΩ - 999 MΩ/C at 25 °C (77 °F) reference temperature. Minimum : Maximum : 40 Ω/C at process temperature (underrange 0.001 kΩ x cm). 1 MΩ/C at process temperature (overrange 999 MΩ x cm). - Temperature Pt1000 : -20 to +250 °C (0 to 500 °F) Pt100 and Ni100 : -20 to +200 °C (0 to 400 °F) 8K55 NTC : -10 to +120 °C (10 to 250 °F) PB36 NTC : -20 to +120 °C (0 to 250 °F) l Span Conductivity/Resistivity: Min. span : 0.010 μS/cm; 0.001 kΩ x cm up to 90% maximum zero suppression. Max. span : 1500 mS/cm; 999 MΩ x cm Ratio (cell1/cell2): Min. span : 00.0 Max. span : 19.99 Difference (cell1- cell2): Min. span : 0.010 μS/cm Max. span : 400 mS/cm % Passage (100x[cell2/cell1] ): Min. span : 00.0 Max. span : 199.9 % Rejection (100x[( cell1-cell2)/cell1] ): Min. span : 0.1 Max. span : 400 % Deviation (100x[(cell2-cell1)/cell1] ): Min. span : 0.1 Max. span: 400 VGB-directive 450 L: Min. span : 1.0 pH Max. span : 14.0 pH Temperature: Min. span : 25 °C (50 °F) Max. span : 250°C (500 °F) Difference Temperature: Min. span : 25 °C (50 °F) Max. span : 250 °C (500 °F) l Transmission Signals Two isolated outputs of 0/4-20 mA DC with common negative. Max. load : 600 Ω. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  2-2 <2. DC402G Specifications> Auxiliary output can be chosen from conductivity, linearized conductivity, resistivity, temperature, differential temperature calculated value or PI control of conductivity/resistivity. Burn up (22 mA) or Burn down (0/3.5 mA) to signal failure. l Temperature compensation Automatic, for temperature ranges mentioned under C (input ranges). - Reference temperature : programmable from 0 to 100 °C or 30 to 210 °F (default 25 °C). l Compensation algorithm According IEC 60746-3 NaCl tables (default). Two independent user programmable temperature coefficients, from 0% to 3.5% per °C (°F) by adjustment or calibration. - Matrix compensation : with conductivity function of concen-tration and temperature. Choice of 5 preprogrammed matrixes and a 25-points userprogrammable matrix. l Display Custom liquid crystal display, with a main display of 3 1/2 digits 12.5 mm high. Message display of 6 alphanumeric characters, 7 mm high. Warning flags and units (mS/cm, kΩ·cm, μS/cm and MΩ·cm) as appropriate. l Contact Outputs - General : Four (4) SPDT relay contacts with LED indicators. For S1, S2, and S3, the LED is on when relay power is removed. NOTE: For S4 (FAIL) LED lights when relay is deenergised (Fail safe). Contact outputs configurable for hysteresis and delay time. - Switch capacity : - Status : Maximum values 100 VA, 250 VAC, 5 Amps. Maximum values 50 Watts, 250 VDC, 5 Amps. High/low process alarms, selected from conductivity, resistivity and temperature. Contact output is also available to signal “Hold active” - Control function : On/Off PI pulsed : Proportional duty cycle control with integral term. PI frequency : Proportional frequency control with integral term. (PI control on Conductivity/Resistivity only) In addition FAIL alarm for system and diagnostic errors on S4. l Power Supply Supply voltage rating: 115, 230 VAC Applicable range: 97.8 to 132.2, 195.5 to 264.5 VAC Supply frequency rating: 50 / 60 Hz Applicable range: 50 Hz ± 5% / 60 Hz ± 5% Power consumption: Maximum 10 VA for steady operation l Shipping Details Package size : W x H x D 290 x 300 x 290 mm. 11.5 x 11.8 x 11.5 in. Packed weight : Approx. 2.5 kg (5lb). IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  2.2 <2. DC402G Specifications> 2-3 Operating specifications l Performance : Conductivity Linearity: ± 0.5 % FS Repeatability: ± 0.5 % FS Accuracy: ± 0.5 % FS l Performance : Resistivity Linearity: ± 0.5 % FS Repeatability: ± 0.5 % FS Accuracy: ± 0.5 % FS l Performance : Temperature with Pt1000Ω, Ni100Ω and PB36 NTC Linearity: ± 0.3 ºC Repeatability: ± 0.3 ºC Accuracy: ± 0.3 ºC l Performance : Temperature with PT100Ω and 8k55Ω Linearity: ± 0.4 ºC Repeatability: ± 0.4 ºC Accuracy: ± 0.4 ºC Note: The following tolerance are added to above performance. mA output tolerance : ± 0.02 mA of “0/4 - 20 mA” Digital display tolerance: +1 digit l Performance : Temperature compensation NaCl table: ± 1% Matrix: ± 3% Step response: 90 % (< 2 decades) in ≤ 6 seconds l Ambient operating temperature -10 to +55 °C (14 to 131 ºF) l Storage temperature -30 to +70 °C (-22 to 158 ºF) l Humidity 10 to 90% RH non-condensing l Housing Cast aluminium case with chemically resistant coating, cover with flexible polycarbonate window. Case color is off-white and cover is moss green. Cable entry is via six PG13.5 nylon glands. Cable terminals are provided for up to 2.5 mm finished wires. Weather resistant to IP65, NEMA 4X, CSA Type 3S. Pipe wall or panel mounting, using optional hardware. l Data protection EEPROM for configuration and lithium battery for clock. l Watchdog timer Checks microprocessor IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  <2. DC402G Specifications> 2-4 l Automatic safeguard Return to measuring mode when no keystroke is made for 10 min. l Power interruption Less than 50 milliseconds no effect. l Operation protection 3-digit programmable password. l Safety and EMC conforming standards Safety: conforms to EN 61010-1 EN 61010-2-030 EN 61010-2-201 CAN/CSA No.61010-1 UL Std. No. 61010-1 CSA C22.2 No. 94.2 UL 50E EMC: EN 61326-1* Class A, Table 2 (Note 1) EN 61326-2-3 EN 61000-3-2 Class A EN 61000-3-3 RCM: EN61326-1 Class A Korea Electromagnetic Conformity Standard Class A 한국 전자파적합성 기준 *: Influence of immunity environment (Criteria A): Output shift is specified within ±25% of F.S. Installation altitude: 2000 m or less Category based on IEC 61010: II (Note 2) Pollution degree based on IEC 61010:2 (Note 2) Note 1: This instrument is a Class A product, and it is designed for use in the industrial environment. Please use this instrument in the industrial environment only. A급 기기　(업무용 방송통신기자재) 　이 기기는 업무용(A급) 전자파적합기기로서 판매자 또는 사용자는 이 점을 주의하시기 바라며, 가정외의 지역에서 사용하는 것을 목적으로 합니다. Note 2: Installation category, called overvoltage category, specifies impulse withstand voltage. Category II is for electrical equipment. Pollution degree indicates the degree of existence of solid, liquid, gas or other inclusions which may reduce dielectric strength. Degree 2 is the normal indoor environment. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  <2. DC402G Specifications> 2.3 2-5 Model and suffix codes [Style: S2] Model Suffix code Option code Description DC402G •••••••••••••••••• ••••••••••••••••• Dual Conductivity Converter Type -1 ••••••••••••••••• General Power Supply -1 ••••••••••••••••• 115 V +/-15% AC, 50/60 Hz (*2) Voltage -2 ••••••••••••••••• 230 V +/-15% AC, 50/60 Hz Language -E ••••••••••••••••• English -J ••••••••••••••••• Japanese Pipe, wall mounting bracket (Stainless steel) Options /U Panel mounting bracket (Stainless steel) /PM Hood for sun protection (Carbon steel) /H3 Hood for sun protection (Stainless steel) /H4 Stainless steel tag plate /SCT G 1/2 /AFTG 1/2 NPT /ANSI Epoxy baked finish (*1) /X1 *1: *2: The housing is coated with epoxy resin. When CSA safe standard conformity product is needed, select 115V “-1” of Power Supply Voltage. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00 Blank Page  3-1 <3. Installation and Wiring> 3. Installation and Wiring 3.1 Installation and dimensions CAUTION Installation must be performed by a qualified personnel. If this rules is not followed and a damage occurs, Yokogawa will not be held responsible. 3.1.1 Installation site CAUTION This instrument is a Class A product, and it is designed for use in the industrial environment. Please use this instrument in the industrial environment only. The DC402G converter is weatherproof and can be installed inside or outside. It should, however, be installed as close as possible to the sensor to avoid long cable runs between sensor and converter. In any case, the total cable length should not exceed 60 meters (200 feet). Select an installation site where: • Mechanical vibrations and shocks are negligible • No relay/power switches are in the direct environment • Access is possible to the cable glands (see figure 3.1) • The converter is not mounted in direct sunlight or severe weather conditions • Maintenance procedures are possible (avoiding corrosive environments) The ambient temperature and humidity of the installation environment must be within the limits of the instrument specifications. (See chapter 2). 3.1.2 Mounting methods Refer to figures 3.2 and 3.3. Note that the DC402G converter has universal mounting capabilities: • • • • Panel mounting using optional brackets Surface mounting on a plate (using bolts from the back) Wall mounting on a bracket (for example, on a solid wall) Pipe mounting using a bracket on a horizontal or vertical pipe (maximum pipe diameter 50 A) IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  3-2 <3. Installation and Wiring> □ Hood (optional) Option code : /H□ 184 Four M6 screws, 8 (0.31) deep 220 (7.24) 80 (8.66) (3.15) 72 (2.83) 144 20 (0.79) (5.67) 80 (3.15) 112 23 144 (5.67) Adaptor for conduit work (option code : /AFTG, /ANSI) (4.41) (0.91) A D B E 36 C F A : For sensor cable B : For sensor cable 36 (1.42) C : For output signal D : For contact output (S3 and S4) E : For contact output (S1 and S2) 38 (1.50) F : For power supply 49 (1.93) 36 (1.42) (1.42) Ground terminal (M4 screw *) Adaptor Approx. 55 (2.17) Cable inlet port (21 (0.83) dia. holes) equivalent to DIN PG13.5 cable gland Weight: Approx. 2 kg *: Tightening torque: 1.2 N·m. G 1/2 female ( / AFTG) 1/2 NPT female ( / ANSI) F17.ai Figure 3.1 Housing dimensions and layout of glands 23 (0.91) 12 max.(panel thickness) M6, 4 screws * Panel cutout dimensions (0.47) M5, 2 screws 137 +20 100 (3.94) (5.43) 137 +20 178 (7.01) (5.43) *: Tightening torque: 2 N·m. F14-2.ai Figure 3.2 Panel mounting diagram (Option Code: /PM) IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  3-3 <3. Installation and Wiring> Example of bracket used for pipe mounting 188 M6, 4 screws * (7.40) 174 (6.85) 200 (7.87) 50 (1.97) Nominal 50A (O.D 60.5mm) (2 inch) mounting pipe 100 (3.94) Example of bracket used for wall mounting 135 (5.31) 13 M6, 4 screws * (0.51) 224 200 (8.82) (7.87) 35 (1.38) 15 (0.59) 70 (2.76) *: Tightening torque: 2 N·m. 10mm dia., 3 holes (0.39) 100 (3.94) F14-1.ai Figure 3.3 Wall and pipe mounting diagram (Option Code: /U) IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  3-4 <3. Installation and Wiring> Figure 3.4 Internal view of DC402G wiring compartment CAUTION Wiring must be performed by a qualified personnel. If this rules is not followed and a damage occurs, Yokogawa will not be held responsible. WARNING Never apply power to the DC402G converter and other instruments connected to the DC402G converter until all wiring is completed. WARNING This product complies with the CE marking. Where compliance with the CE marking and relevant standard is necessary, the following wiring is required. 1. 2. 3. 4. 5. Install an external switch or circuit breaker to the power supply of the DC402G converter. Use an external switch or circuit breaker rated 5A and conforming to IEC 60947-1 or IEC 60947-3. It is recommended that the external switch or circuit breaker be installed in the same room as the DC402G converter. The external switch or circuit breaker should be installed within reach of the operator and identified with marking as a power supply switch to the DC402G converter. Power lines such as power cables and contact outputs should be fixed securely onto a wall or construction using cable racks, conduit tubing, nylon bands or other appropriate ways. Accidental removal from terminals by pulling may result in electric shock. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  3-5 <3. Installation and Wiring> 3.2 Preparation Refer to figure 3.4. The relay contact terminals and power supply connections are under the screening (shielding) plate. These should be connected first. Connect the sensor and outputs. To open the DC402G for wiring: 1. Loosen the four frontplate screws and remove the cover. 2. Use the rubber knob in the lower right hand corner and swing open the display board to the left. 3. The upper terminal strip is now visible. 4. Remove the screen (shield) plate covering the lower terminal strip. 5. Connect the power supply and contact outputs. Use the three glands at the back for these cables. 6. Replace the screen (shield) plate over the lower terminals. WARNING Always replace the screen plate over the power and contact outputs for safety and to avoid interference. 7. Connect the analog output(s) and the sensor input. 8. Use the front three glands for analog output, sensor input, contact input and communication cabling (see figure 3.5). 9. Close the display board and switch on the power. Commission the instrument as required or use the default settings. 10. Replace the cover and secure frontplate with the four screws. Tighten four frontplate screws to 1.5 N·m torque. CAUTION For wiring, use cables with a heat resistance of at least 70°C. CAUTION Tighten the cable glands to 1.5 N•m torque. Torque less than 1.5 N•m cannot maintain the IP65 protection level. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  3-6 <3. Installation and Wiring> High Voltage Section CONTACT (S3, S4/FAIL) OUTPUT CABLE(S) SENSOR CABLE(S) CONTACT (S1, S2) OUTPUT CABLE(S) SENSOR CABLE(S) POWER CABLE ANALOG OUTPUTS CABLE Suitable for cables with an outside diameter between 6 - 12 mm (0.24 - 0.47 in.) Figure 3.5 Glands to be used for cabling 3.3 Wiring the power supply 3.3.1 General precautions Make sure the power supply is switched off. Also, make sure that the power supply is correct for the specifications of the DC402G and that the voltage specified on the nameplate on the left side of the DC402G is satisfied. Local health and safety regulations may require an external circuit breaker to be installed. The instrument is protected internally by a fuse. The fuse rating is dependent on the supply to the instrument. The 250 VAC fuses should be of the “time-lag” type, conforming to IEC60127. The internal fuse is located next to the power terminals (in the lower right hand corner). WARNING Use only a fuse of the specified current, voltage and type ratings to prevent fire. For fuse replacement, refer to Section 7.3, “Fuse Replacement.” 3.3.2 Access to terminal and cable entry Terminals 1 and 2 on the bottom terminal strip are used for the power supply. Guide the power cables through the gland closest to the power supply terminals. Use 2.5 mm2 (14 AWG) wires to connect to the terminals. We recommend that the cables be terminated with pin terminals (see figure 3.6). Connect the wires as indicated in the wiring diagram (refer to figure 3.7). CAUTION Use cables whose outer diameter is 6 to 12 mm. For power cables, use cables that comply with UL2556VW-1 or equivalent. Tighten the cables to 0.5 N•m torque. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  3-7 <3. Installation and Wiring> 2.2mm or less Figure 3.6 Pin terminal Table 3.1 Connection method Power supply, contact output Others Power supply Pin form crimp terminal with the insulation sleeve connection method Conformity shape 2.5 mm2 (14 AWG) 0.13 to 2.5 mm2 (26 to 14 AWG) Clamping torque 0.5 N•m Crimp terminal Product made in Product made in wide Muller: (include the left model) example wide Muller: H2.5/7, H0.25/5, H0.5/6, H0.5/10, H0.75/6, H0.75/10, H1/6, H1/10, H1.5/7, H1.5/10, (Type) H2.5/10, H2.5/12, H1.5/12, H1.5/18, H0.14/10, H0.14/12, H0.25/10, H0.25/12, H0.34/10, H2.5/18, H2.5/14D, H0.34/12, H0.5/10, H0.5/12, H0.5/14, H0.5/16, H0.75/12, H0.75/14, H2.5/18D, H2.5/24D H0.75/16, H0.75/18H1/12, H1/14, H1/16, H1/18, H1.5/14, H1.5/16, H1.5/24 WARNING When connecting an external device, install and wire it so that requirements of the standard to which the device complies are met. FRONT GLANDS REAR GLANDS Sensors Power S1 0/4-20 mA Output signals Contact output 0/4-20 mA S2 S3 S4/FAIL Contact input Figure 3.7 System configuration IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  3-8 <3. Installation and Wiring> Sensor inputs 22 21 11 12 14 15 mA Outputs 11 12 14 15 Screen 23 Temp Contact Sensor 1 Temp Sensor 2 63 66 65 62 61 95 94 93 92 91 mA1 mA2 Screen mA Outputs REFER TO INSTRUCTION MANUAL FOR CONNECTIONS Relay Contacts Power Supply 71 72 73 51 52 53 41 42 43 31 32 33 250VAC 5A 100VA 3 2 1 G N L FUSE 250VDC 5A 50W C NC NO C NC NO C NC NO C NC NO S3 S1 S4 S2 250VAC; T 200mA 250VAC; T 100mA 115 VAC 230 VAC Figure 3.8 Input and output connections 3.3.3 AC power Connect terminal 1 to the phase line of the AC power and terminal 2 to the zero line. The size of conductors should be at least 1.25 mm2. The overall cable diameter should be between 6 & 12 mm (0.24 & 0.47 in). CAUTION Should be used the cable beyond 300 V AC. 3.3.4 Grounding the housing WARNING Protective grounding must be made to prevent electric shock. To protect the instrument against interference, the housing should be connected to ground by a large area conductor. This cable can be fixed to the rear of the housing using a braided wire cable. See figure 3.9. This is separated from input ground by a galvanic isolation. The internal grounding terminal is not the protective grounding terminal. CAUTION Please be sure to connect protective grounding of DC402G with cable of 1.25 mm2 or larger cross section in order to avoid the electrical shock to the operators and maintenance engineers and prevent the influence of external noise. In addition, use cables whose colors are green and yellow stripes. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  3-9 <3. Installation and Wiring> And further connect the grounding wire to the mark (100 Ω or less). Location of grounding terminal (M4 Screw) F0308.ai Figure 3.9 Grounding the housing 3.3.5 Switching on the instrument After all connections are made and checked, the power can be switched on from the power supply. Make sure the LCD display comes on. All segments will illuminate, then the instrument will momentarily display its unique serial number. After a brief interval, the display will change to the measured value. If errors are displayed or a valid measured value is not shown, consult the troubleshooting section (Chapter 8) before calling Yokogawa. 3.4 Wiring the contact signals WARNING There are high-voltage sections on the DC402G. Be sure to turn off the power before wiring. 3.4.1 General precautions The contact output signals consist of voltage-free relay contacts for switching electrical appliances (SPDT). They can also be used as digital outputs to signal processing equipment (such as a controller or PLC). It is possible to use multi-core cables for the contact in and output signals and shielded multi-core cable for the analog signals. We recommend that the cables be terminated with pin terminals (see figure 3.6). 3.4.2 Contact outputs The DC402G unit’s four contact outputs can be wired to suit your own custom requirements (Figure 3.7). In the Non-Alarm or Power Off states, contacts S1, S2 and S3 are OFF, Common (C) and Normally Closed (NC) are in contact. In the “Fail” or Power Off states, contact S4 is ON, Common (C) and Normally Closed (NC) are in contact. You can either use them to switch AC power, or switch a DC Voltage for digital interfacing. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  3-10 <3. Installation and Wiring> Default settings • • • • The contact S1 is pre-programmed for high alarm function. The contact S2 is pre-programmed for a low alarm function. The contact S3 is pre-programmed for wash function. The contact S4 is pre-programmed for FAIL. The three control contacts (S1 to S3) can be used for simple process control by programming their function (Chapter 5). The FAIL contact is programmed to signal a fault in the measuring loop. Always connect the FAIL contact to an alarm device such as a warning light, sound annunciator, or alarm panel to make full use of the fault detection possibilities (self diagnostics) of the DC402G converter. CAUTION Should be used the cable beyond 300 V AC. When using ON/OFF signals whose voltage is 33 VAC or 70 VDC or higher, use 2.5 mm2 (AWG14) wires. If using voltages lower these voltages, select wires in the range of 0.13 to 2.5 mm2 (AWG26 to AWG14) according to the current capacity of the connected load. Use cables that comply with UL2556VW-1 or equivalent and whose outer diameter is 6 to 12 mm. Tighten the cables to 0.5 N•m torque. 3.4.3 Contact input Voltage-free contact (do not apply voltage) Wash start or input remote range change (either choice) It is necessary to use screening/shielding on the output signal cables. Screw (M3) 23 is used to connect the shielding. Select wires in the range of 0.13 to 2.5 mm2 (AWG26 to AWG14) according to the current capacity of the connected load. Use cables that comply with UL2556VW-1 or equivalent and whose outer diameter is 6 to 12 mm. Tighten the cables to 0.5 N•m torque. 3.5 Wiring the analog output signals 3.5.1 General precautions The analog output signals of the DC402G transmit low power standard industry signals to peripherals like control systems or strip-chart recorders (Figure 3.7). Do not apply voltage. CAUTION Should be used the cable beyond 30 V AC. Select wires in the range of 0.13 to 2.5 mm2 (AWG26 to AWG14) according to the current capacity of the connected load. Use cables that comply with UL2556VW-1 or equivalent and whose outer diameter is 6 to 12 mm. Tighten the cables to 0.5 N•m torque. We recommend that the cables be terminated with pin terminals (see figure 3.6). IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  3.5.2 3-11 <3. Installation and Wiring> Analog output signals The output signals consist of active current signals of either 0-20 mA or 4-20 mA. The maximum load can be 600 ohms on each. It should be necessary to use screening/shielding on the output signal cables. Terminal 63 is used to connect the shielding. 3.6 Sensor wiring Refer to figure 3.9, which includes drawings that outline sensor wiring. The DC402G can be used with a wide range of commercially available sensor types if provided with shielded cables, both from Yokogawa and other manufacturers. The sensor systems from Yokogawa fall into two categories, the ones that use fixed cables and the ones with separate cables. To connect sensors with fixed cables, simply match the terminal numbers in the instrument with the identification numbers on the cable ends. Note that the DC402G uses the 2 electrode measuring principle. Yokogawa sensors and cables are prepared for compatibility with 4-electrode measuring systems. To avoid problems either cut off and insulate the wires tagged 13 &16 or connect the wires in tandem 13 &14 into terminal 14 or 15 &16 into terminal 15. CONDUCTIVITY RESISTIVITY CONVERTER 11 TEMPERATURE 12TEMPERATURE 14 CELL 15 CELL SEPARATE SENSORS WITH WU40-LH.. CABEL 11 TEMPERATURE 12 TEMPERATURE 1 2 1 BROWN BROWN YELLOW/GREEN 2 RED 11 TEMPERATURE 12 TEMPERATURE 14 OUTER ELECTRODE 15 INNER ELECTRODE SX42-SX . . - . F SENSORS Note: Use shielded cable 14 OUTER ELECTRODE 15 INNER ELECTRODE SC4A... SENSORS WITH INTEGRATED CABEL Figure 3.10 Sensor wiring diagrams IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  3.7 <3. Installation and Wiring> 3-12 Sensor connection using junction box and extension cable Where a convenient installation is not possible using the standard cables between sensors and converter, a junction box and extension cable may be used. The Yokogawa BA10 junction box and the WF10 extension cable should be used. These items are manufactured to a very high standard and are necessary to ensure that the specifications of the system can be met. The total cable length should not exceed 60 metres (e.g. 10 m fixed cable and 50 m extension cable). NOTE Numbers 17 of both WF10 and BA10 do not need to be used. 3.8 Other sensor systems To connect other sensor systems, follow the general pattern of the terminal connections as listed below: 11 and 12 Always used for temperature compensation resistor input (Pt1000, Ni100, Pt100, PB36 and 8k55) 14 Normally used for the outer electrode 15 Used for inner electrode In case a 4-electrode measuring system will be used, 14 and 16 should be used for the current electrodes. Please ensure that shielded cabling will be used. In figure 3.10 this is shown in a schematic way. 11 12 14 15 TEMPERATURE SENSOR t CELL ELECTRODE 2-electrode configuration Figure 3.11 Connection diagram for other sensors IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  <3. Installation and Wiring> Sensor Inputs 3-13 mA Outputs 22 21 11 12 14 15 11 12 14 15 63 66 65 62 61 95 94 93 92 SCREEN 91 mA1 mA2 SCREEN 23 CONT SENSOR 1 SENSOR 2 mA OUTPUT DC402 REFER TO INSTRUCTION MANUAL FOR CONNECTIONS Relay Contacts Power Supply 71 72 73 51 52 53 41 42 43 31 32 33 3 G 250VAC 250VDC 5A 100VA 5A 50W 1 L FUSE 250V T200mA C NC NO C NC NO C NC NO C NC NO S4 2 N S3 S2 115 VAC S1 Figure 3.12 Terminal identification labels example Figure 3.13 Sensor cable connections IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00 Blank Page  4-1 <4. Operation; Display Functions And Setting> 4. Operation; Display Functions And Setting 4.1 Operator interface This section provides an overview of the operation of the DC402G operator interface. The basic procedures for obtaining access to the three levels of operation are described briefly. For a stepby-step guide to data entry, refer to the relevant section of this instruction manual. Figure 4.1 shows the DC402G operator interface. l LEVEL 1: Maintenance These functions are accessible by pushbutton through a flexible front cover window. The functions make up the normal day-to-day operations that an operator may be required to complete. Adjustment of the display and routine calibration are among the features accessible in this way. (See table 4.1). l LEVEL 2: Commissioning A second menu is exposed when the DC402G front cover is removed and the display board is revealed. Users gain access to this menu by pressing the button marked * in the lower right of the display board. This menu is used to set such values as the output ranges and hold and wash features. It also gives access to the service menu. (See table 4.1). l LEVEL 3: Service For more advanced configuration selections, press the button marked * , then press “NO” repeatedly until you reach SERVICE. Now push the “YES” button. Selecting and entering “Service Code” numbers in the commissioning menu provide access to the more advanced functions. An explanation of the Service Codes is listed in chapter 5 and an overview table is shown in chapter 10. Table 4.1 Operations overview Maintenance Commissioning Service (Access to coded entries from the commissioning level) Routine SETPOINTS CALIB 1(2) DISPLAY 1(2) HOLD SETPOINTS RANGE SET HOLD TEMP SERVICE Function Adjust alarm setpoints (when activated) Calibration with a standard solution or a sample Read auxiliary data or set message display Switch hold on/off (when activated) Adjust alarm setpoints Adjust the output range Activate the hold function Select method of temperature compensation Fine tune the specialized functions of the converter Chapter 5 6 4 5 5 5 5 5 5 NOTE: All three levels may be separately protected by a password. See Service Code 52 in chapter 5 Service Code table for details on setting passwords. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  4-2 <4. Operation; Display Functions And Setting> Output hold flag Main display Fail flag HOLD FAIL Menu pointer flags Units MODE cm k mS/cm M cm S/cm Message display YES NO ENT MEASURE CAL 1 CAL 2 DISPLAY 1 DISPLAY 2 HOLD SETPOINTS RANGE SET HOLD TEMP. SERVICE Key prompt flags YES NO MODE CONTACTS * S1 Selection keys Yes: Accept setting No: Change setting Adjustment keys : Choose digit to adjust : Adjust digit ENT: Confirm change Commissioning function menu Commissioning mode access key S2 ENT Relay contact status indicators S3 FAIL YOKOGAWA Measure/Maintenance mode key MARKINGS WITHIN INCLOSURE Broken line indicates area that can be seen through front cover Figure 4.1 DC402G operator interface 4.2 Explanation of operating keys MODE key This key toggles between the Measuring and Maintenance modes. Press once to obtain access to the maintenance function menu. SETPOINTS CAL.1/CAL.2 DISP.1/DISP.2 HOLD Press again to return to the Measuring mode (press twice when hold is activated). YES/NO keys These are used to select choices from the menu. YES is used to accept a menu selection. NO is used to reject a selection, or to move ahead to the next option. DATA ENTRY keys (˃ ˄ ENT) ˃ is used as a “cursor” key. Each press on this key moves the cursor or flashing digit one place to the right. This is used to select the digit to be changed when entering numerical data. ˄ is used to change the value of a selected digit. Each press on this key increases the value by one unit. The value can not be decreased, so in order to obtain a lower value, increase past nine to zero, then increase to the required number. ENT When the required value has been set using the > and ^ keys, press ENT to confirm the data entry. Please note that the DC402G does not register any change of data until the ENT key is pressed. * key This is the Commissioning mode key. It is used to obtain access to the Commissioning menu. This can only be done with the cover removed or opened. Once this button has been used to initiate the Commissioning menu, follow the prompts and use the other keys as described above. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  4.3 4-3 <4. Operation; Display Functions And Setting> Setting passcodes In Service Code 52, DC402G users can set passcode protection for each one of the three operating levels, or for any one or two of the three levels. This procedure should be completed after the initial commissioning (setup) of the instrument. The passcodes should then be recorded safely for future reference. When passcodes have been set, the following additional steps are introduced to the configuration and programming operations: l Maintenance Press MODE key. The display shows 000 and *PASS* Enter a 3-digit passcode as set in Service Code 52 to obtain access to the Maintenance Mode l Commissioning Press * key. The display shows 000 and *PASS* Enter a 3-digit passcode as set in Service Code 52 to obtain access to the Commissioning Mode. l Service From the commissioning menu, select *Service by pressing YES key. The display shows 000 and *PASS* Enter a 3-digit passcode as set in Service Code 52 to obtain access to the Service Mode. NOTE See Service Code 52 for the setting of passcodes. 4.4 Display example The next page shows the sequence of button presses and screens displayed when working in default configuration. More or less options will be made available by the configuration of some service codes, or by choices made in the Commissioning menu. The following deviations are possible: Items marked are omitted when switched off in commissioning mode and/or service code 51.  Temperature compensation will be displayed dependent on chosen compensation method: NaCl, TC 2.1 or matrix.  DISP.2 only appears if mA2 is configured for a 2nd (different) temperature compensation or if % by weight.2 is enabled in code 55.   W/W % only appears if switched on in service code 55.  IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  4.5 4-4 <4. Operation; Display Functions And Setting> Display functions Computed value µS / c m Cell temperature µS / c m Displ. 1 = Sensor 1 Calculation type Displ. 2 = Sensor 2 MODE NO NO Uncompensated SC (if USP is enabled in service code 57) µS / c m YES YES NO µS / c m YES NO YES (See Setpoint menu Chapter 5-1) NO NO µS / c m µS / c m YES NO YES (See Calibration menu Chapter 6) NO DISP.1 or DISP.2 YES NO NO NO µS / c m µS / c m YES Reference temperature Software release number NO YES NO YES NO NO YES µS / c m YES µS / c m NO NO NO NO µS / c m YES YES µS / c m NO YES NO µS / c m YES NO w/w % 2nd compensated value NO NO µS / c m YES µS / c m Only if enabled NO Process temperature NO HOLD FAIL NO ENT YES NO MODE MEASURE CAL 1 CAL 2 DISPLAY 1 DISPLAY 2 HOLD Actual Cell Constant SETPOINTS RANGE SET HOL D TEMP. SERVICE CONTACTS S1 S2 ENT YOKOGAWA YES NO NO µS / c m MODE k W .c m mS/cm M W .c m mS / c m YES NO * YES NO NO Press YES to fix the selected second line of display µS / c m Current output YES NO S3 NO FAIL/S4 MARKINGS WITHIN INCLOSURE Note:The variety of display screens depends on the configuration of the service settings (see section 5) Temperature compensation for conductivity 1 µS / c m YES IM 12D08E02-01E NO 6th Edition: Feb. 19, 2016-00  5-1 <5. Parameter setting> 5. Parameter setting 5.1 Maintenance mode Standard operation of the DC402G instrument involves use of the Maintenance (or operating) mode to set up some of the parameters. Access to the Maintenance mode is available via the six keys that can be pressed through the flexible window in the instrument front cover. Press the “MODE” key once to enter this dialog mode. (Note that at this stage the user will be prompted for a pass code where this has been previously set up in service code 52, section 5.) Setpoint Select and adjust setpoint (when enabled in service menu section 5.3, service code 51). See adjustment procedure 5.2.2. Calibrate See “calibration” section 6. Display setting See “operation” section 4. Hold Manually switch on/off “hold” (when enabled in commissioning menu). See adjustment procedure 5.2.4. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5.1.1 <5. Parameter setting> 5-2 Manual activation of Hold MODE S/cm MEASURE YES NO SETPOINTS RANGE SET HOLD TEMP. SERVICE CONTACTS MODE * S1 S2 S3 ENT FAIL/S4 MARKINGS WITHIN INCLOSURE YOKOGAWA MODE NO S/cm YES CAL 1 NO NO NO NO NO S/cm YES YES S/cm YES NO NO HOLD NO YES HOLD S/cm MEASURE YES NO DISPLAY 1 Note: The HOLD feature must first be activated in the commissioning mode section 5.2.4 IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5-3 <5. Parameter setting> 5.1.2 Setpoint adjustment Note: To enable adjustments of setpoints in maintenance mode, Service Code 51 must be set to "ON". Setpoints available will depend on their configuration in the Service Code. MODE S/cm MEASURE YES NO CONTACTS MODE S1 SETPOINTS RANGE SET HOLD TEMP. SERVICE * S2 S3 ENT FAIL/S4 MARKINGS WITHIN INCLOSURE YOKOGAWA MODE S/cm YES CAL 1 NO NO NO NO NO For adjustments, follow procedures as in section 5.2.2 S/cm YES NO YES YES YES NO S/cm YES NO S/cm YES YES NO IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5.2 5-4 <5. Parameter setting> Commissioning mode In order to obtain peak performance from the DC402G, you must set it up for each custom application. Setpoints Alarms are set by default S1 - high process alarm S2 - low process alarm S3 - not activated S4 - Fail The setpoints are at arbitrary default value. Therefore, you must set these to meaningful values, or set them to off. (See service codes 40 to 49 and user interface codes 50 to 59.) Output ranges mA output 1 is set as default to 0-100 μS/cm or 0-19.99 MΩ•cm. For enhanced resolution in more stable measuring processes, it may be desirable to select 5-10 μS/cm range, for example, and maybe 0-25 °C temperature range. Service codes 30 to 39 can be used to choose other output parameters on mA output 2. Choose from Table, temperature or PI control. Hold The DC402G converter has the ability to “HOLD” the output during maintenance periods. This parameter should be set up to hold the last measured value, or a fixed value to suit the process. Service This selection provides access to the service menu. What follows are pictorial descriptions of typical frontplate pushbutton sequences for each parameter setting function. By following the simple YES/NO prompts and arrow keys, users can navigate through the process of setting range, setpoints, hold and service functions. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5-5 <5. Parameter setting> 5.2.1 Setpoints MODE M cm MEASURE CAL 1 CAL 2 DISPLAY 1 DISPLAY 2 HOLD SETPOINTS RANGE SET HOLD TEMP. SERVICE * YES YES NO YES NO YES NO NO NO YES YES NO NO S/cm YES NO ENT ENT repeated keystrokes NO S/cm YES S/cm NO S/cm ENT ENT S/cm S/cm ENT ENT S/cm S/cm ENT ENT NO YES NO NO YES NO NO IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5-6 <5. Parameter setting> Process Alarms on S.3 and S.4 are only available when enabled in Service Codes 40-49 Analog control setpoint is only available when enabled in Service Code 31 NO YES NO YES NO NO NO YES NO YES NO YES mS / c m YES NO ENT > Adjust setpoint value using > ENT keys as shown for setpoint 1. Setpoint confirmed. Return to mode ENT commissioning. mS / c m ENT ENT ENT ENT ENT ENT ENT ENT ENT ENT ENT mS / c m ENT Negative signs only appear for temp. settings. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5-7 <5. Parameter setting> 5.2.2 Range MODE S/cm S/cm MEASURE CAL 1 CAL 2 DISPLAY 1 DISPLAY 2 HOLD SETPOINTS RANGE SET HOLD TEMP. SERVICE ENT * YES S/cm See facing page NO ENT NO NO YES S/cm YES YES NO NO ENT NO YES S/cm YES YES NO NO ENT YES NO YES S/cm S/cm ENT ENT NO NO ENT mS/cm S/cm YES NO ENT NO YES ENT ENT NO NO IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5-8 <5. Parameter setting> Choose Range to adjust, then set begin scale (0%) and end scale (100%) of the mA output signal, using the > >, and ENT keys. Selection of mA output(0-20 / 4-20 mA) is in Service Code 30. The decimal point and unit setting can be changedas described before in Setpoint Settings. Range Selection Options are determined by Service Code 31 Note: Range 2 does not appear when PI control set on mA2 YES YES YES NO NO YES YES YES NO NO S/cm YES NO ENT ENT ENT ENT S/cm ENT ENT ENT ENT Range values set, return to commission mode. YES YES NO IM 12D08E02-01E NO 6th Edition: Feb. 19, 2016-00  5-9 <5. Parameter setting> 5.2.3 Hold MODE S/cm MEASURE CAL 1 CAL 2 DISPLAY 1 DISPLAY 2 HOLD SETPOINTS RANGE SET HOLD TEMP. SERVICE * YES NO NO YES NO NO YES YES YES YES NO NO NO YES YES NO NO NO NO HOLD deactivated, return to commissioning menu. YES NO YES HOLD HOLD YES NO YES NO NO YES YES NO YES NO HOLD active last measured value. NO NO YES IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5-10 <5. Parameter setting> HOLD values set, return to commissioning menu. HOLD HOLD ENT ENT HOLD HOLD ENT ENT ENT Set HOLD "fixed value" for mA2. HOLD ENT HOLD YES Set HOLD "fixed value" for mA1. ENT IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5-11 <5. Parameter setting> 5.2.4 Temperature compensation 1. Why temperature compensation? The conductivity of a solution is very dependent on temperature. Typically for every 1 °C change in temperature the solution conductivity will change by approximately 2 %. The effect of temperature varies from one solution to another and is determined by several factors like solution composition, concentration and temperature range. A coefficient (a) is introduced to express the amount of temperature influence in % change in conductivity/°C. In almost all applications this temperature influence must be compensated before the conductivity reading can be interpreted as an accurate measure of concentration or purity. Table 5.1 NaCl-compensation according to IEC 60746-3 with Tref = 25 °C T 0 10 20 25 30 40 50 Kt 0.54 0.72 0.90 1.0 1.10 1.31 1.53 a 1.8 1.9 2.0 --2.0 2.0 2.1 T 60 70 80 90 100 110 120 Kt 1.76 1.99 2.22 2.45 2.68 2.90 3.12 a 2.2 2.2 2.2 2.2 2.2 2.2 2.2 T 130 140 150 160 170 180 190 200 Kt 3.34 3.56 3.79 4.03 4.23 4.42 4.61 4.78 a 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2. Standard temperature compensation From the factory the DC402G is calibrated with a general temperature compensation function based on a sodium chloride salt solution. This is suitable for many applications and is compatible with the compensation functions of typical laboratory or portable instruments. A temperature compensation factor is derived from the following equation: a= Kt - Kref T - Tref x 100 K ref In which: a = Temperature compensation factor (in %/ °C) T = Measured temperature (°C) Kt = Conductivity at T Tref = Reference temperature (°C) Kref = Conductivity at Tref 3. Manual temperature compensation If the standard compensation function is found to be inaccurate for the sample to be measured, the converter can be set manually for a linear factor on site to match the application. The procedure is as follows: 1. Take a representative sample of the process liquid to be measured. 2. Heat or cool this sample to the reference temperature of the converter (usually 25 °C). 3. Measure the conductivity of the sample with the DC402G and note the value. 4. Bring the sample to the typical process temperature (to be measured with the DC402G). 5. Adjust the display indication to the noted value at the reference temperature 6. Check that the temperature compensation factor has been changed 7. Insert the conductivity cell into the process again. 4. Other possibilities (section 5.3.3) 1. Enter calculated coefficient. 2. Enter matrix temperature compensation. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5-12 <5. Parameter setting> MODE µS / c m MEASURE CAL 1 CAL 2 DISPLAY 1 DISPLAY 2 HOLD SETPOINTS RANGE SET HOLD TEMP. SERVICE * After briefly displaying*WAIT* it will be possible to adjust the display reading to the correct value using> >, ,ENT . NO µS / c m YES NO ENT NO NO YES ENT YES YES NO NO *TEMP.1 NO NO Briefly*WAIT* YES or TEMP.2 * YES YES YES NO NO NO After enabling TC it possible to directly enter the coefficient in service code 21 YES YES NO NO YES NO NO IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5-13 <5. Parameter setting> 5.2.5 Service MODE M cm MEASURE CAL 1 CAL 2 DISPLAY 1 DISPLAY 2 HOLD SETPOINTS RANGE SET HOLD TEMP. SERVICE * YES After changing the parameter, the instrument first goes into reset to load the parameter specific default values. NO NO M YES cm NO NO Example: Service Code 01 Select main parameter ENT for SC YES for RES NO ENT > With the >, ,ENT keys NO ENT YES NO ENT ENT NO YES NO ENT NO YES YES NO ENT NO IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5.3 5-14 <5. Parameter setting> Notes for guidance in the use of service coded settings Don’t set or input service code numbers other than the code numbers defined in this manual. Setting an undefined service code may make the converter malfunction. When an undefined service code is input by some accident, push the MODE key and escape from the service level. 5.3.1 Parameter specific functions Code 1 *SC.RES Choose the required parameter, either conductivity or resistivity. If the parameter is changed the instrument will go into reset to load parameter specific default values, followed by starting measurement. For all other service codes the instrument will return to commissioning mode after the service code setting is finished. Note: For resistivity a fixed display format is used. Code 3 *CC1 *CC2 Enter the factory calibrated cell constant mentioned on the nameplate or on the fixed cable. This avoids the need for calibration. Any value between 0.005 and 50.0 /cm may be entered. First choose to set the constant for Cell 1or Cell 2 (*CC1 or *CC2). The cell constant is set as a combination of a number in the main display, and a factor in the second line. This gives the necessary resolution and decimal point placement. Example: To set 0.00987 cm-1 first set factor 0.01xC1 in second line then set number 0.987 in main display. *NOTE: If the actual cell constant is changed after a calibration or if the entered cell constant differs from previous value, then the message “RESET?” will appear on the second line display. After pressing “YES” the entered value becomes the new nominal and calibrated cell constant. After pressing “NO” the update procedure of the cell constant entry is cancelled. Code 4 *AIR 1 *AIR 2 *AIR 1 and *AIR 2 select by the “NO” key To eliminate cable influences on the measurement, a “zero” calibration with a dry sensor may be done. If a connection box (BA10) and extension cable (WF10) will be used, “zero” calibration should be done including the connection equipment. Code 5 *POL.CK The DC402G has a polarisation check capable of monitoring the signal from the cell for distortion of capacitive or polarisation errors. If there is a problem with the installation or the cell becomes fouled, this will trigger E1. For some application this error detecting can cause unwanted signals during operation. Therefore this code offers the possibility to disable/ enable this check. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5-15 <5. Parameter setting> Code Display Function Parameter Specific functions 01 *SC.RES Select main parameter 02 03 04 05 *CC1/ *CC2 Set cell constant *AIR 1/ Zero calibration *AIR 2 *START *”WAIT” *END *POL.CK Polarization check 0609 5.3.2 Function detail X Y Z Conductivity Resistivity Not used Press NO to step through choice of multiplying factors on the second display. 0.10xC 1.00xC 10.0xC 100.xC 0.01xC Press YES to select a factor Use >, ^, ENT keys to adjust MAIN digits Zero calibration with dry cell connected Press YES to confirm selection Press YES to start, after briefly displaying “WAIT”, *END will be displayed Press YES to complete Polarization check off Polarization check on Not used 0 1 Default values 0 Cond. 0.100 cm-1 0.10xC 1.000 0 1 1 On Temperature functions Code 10 *T.SENS Selection of the temperature compensation sensor. The default selection is the Pt1000 Ohm sensor, which gives excellent precision with the two wire connections used. The other options give the flexibility to use a very wide range of other conductivity/resistivity sensors. Note: The temperature sensor for both conductivity cells must be the same. Code 11 *T.UNIT Celsius or Fahrenheit temperature scales can be selected to suit user preference. Code 12 *T.ADJ 1 First select sensor 1 or sensor 2 for temperature adjustment (*T.ADJ 1 or *T. ADJ 2). With the process temperature sensor at a stable known temperature, the temperature reading is adjusted in the main display to correspond. The calibration is a zero adjustment to allow for the cable resistance, which will obviously vary with length. The normal method is to immerse the sensor in a vessel with water in it, measure the temperature with an accurate thermometer, and adjust the reading for agreement. *T.ADJ 2 Code Display Function Temperature Measuring Functions 10 *T.SENS Temperature sensor 11 *T.UNIT Display in °C or °F 12 *T.ADJ 1 *T.ADJ 2 Calibrate temperature 1319 Function detail X Y Z Default values Pt1000 Ni100 PB36 Pt100 8k55 °C °F Adjust reading to allow for cable resistance. Use >, ^ , ENT keys to adjust value Not used 0 1 2 3 4 0 1 IM 12D08E02-01E 0 Pt1000 0 °C None 6th Edition: Feb. 19, 2016-00  5-16 <5. Parameter setting> 5.3.3 Temperature compensation functions Code 20 *T.R.°C Choose a temperature to which the measured conductivity (or resistivity) value must be compensated to. Normally 25°C is used, therefore this temperature is chosen as default value. Limitations for this setting are: 0 to 100 °C. If *T.UNIT in code 11 is set to °F, default value is 77°F and the limitations are 32 - 212°F. Code 21 *T.C.1/T.C.2 In addition to the procedure described in section 5.2.5 it is possible to adjust the compensation factor directly. If the compensation factor of the sample liquid is known from laboratory experiments or has been previously determined, it can be introduced here, for sensor 1 and/or sensor 2. Adjust the value between 0.00 to 3.50 % per °C. In combination with reference temperature setting in code 20 a linear compensation function is obtained, suitable when enabled as in section 5.2.6 the matrix may be selected for each sensor input for all kinds of chemical solutions. Code 22 *MATRX The DC402G is equipped with a matrix type algorithm for both inputs, accurate temperature compensation in various applications. Select the range as close as possible to the actual temperature/concentration range. The DC402G will compensate by interpolation and extrapolation. Consequently, there is no need for a 100% coverage. If 9 is selected the temperature compensation range for the adjustable matrix must be configured in code 23. Next the specific conductivity values at the different temperatures must be entered in codes 24 to 28. See section 5.2.6 for how to enable MATRIX compensation. Code 23 *T1, *T2, *T3, Set the matrix compensation range. It is not necessary to enter equal *T4 & *T5 °C temperature steps, but the values should increase from T1 to T5, otherwise the entry will be rejected. Example: 0, 10, 30, 60 and 100 °C are valid values for the T1....T5. The minimum span for the range (T5 T1) is 25 °C. Code 24-28 *L1xT1 - *L5xT5 In these access codes the specific conductivity values can be entered for 5 different concentrations of the process liquid; each one in one specific access code (24 to 28). The table below shows a matrix entering example for 1 - 15% NaOH solution for a temperature range from 0 - 100 °C. Notes: 1. In chapter 10 a table is included to record your programmed values. It will make programming easy for duplicate systems or in case of data loss. 2. Each matrix column has to increase in conductivity value. 3. Error code E4 occurs when two standard solutions have identical conductivity values at the same temperature within the temperature range. Table 5.2 Example of user adjustable matrix Matrix Code 23 Code 24 Code 25 Code 26 Code 27 Code 28 Temperature Solution 1 (1%) Solution 2 (3%) Solution 3 (6%) Solution 4 (10%) Solution 5 (15%) T1...T5 L1 L2 L3 L4 L5 Example 0 °C 31 mS/cm 86 mS/cm 146 mS/cm 195 mS/cm 215 mS/cm Example 25 °C 53 mS/cm 145 mS/cm 256 mS/cm 359 mS/cm 412 mS/cm Example 50 °C 76 mS/cm 207 mS/cm 368 mS/cm 528 mS/cm 647 mS/cm Example 75 °C 98 mS/cm 264 mS/cm 473 mS/cm 692 mS/cm 897 mS/cm IM 12D08E02-01E Example 100 °C 119 mS/cm 318 mS/cm 575 mS/cm 847 mS/cm 1134 mS/cm 6th Edition: Feb. 19, 2016-00  Code Display Function Temperature compensation functions 20 *T.R.°C Set reference temp. 21 *T.C.1 Set temp. coef. 1 22 23 24 25 26 27 28 29 5.3.4 5-17 <5. Parameter setting> *T.C.2 Set temp. coef. 2 *MATRX Select matrix X= Sensor 1 Y= Sensor 2 *T1 °C (°F) *T2.. *T3.. *T4.. *T5.. *L1xT1 *L1xT2 .... *L1xT5 *L2xT1 *L3xT1 *L4xT1 *L5xT1 Set temp. range Enter conductivity values for lowest concentration Concentration 2 Concentration 3 Concentration 4 Concentration 5 Function detail X Y Z Default values Use >, ^, ENT keys to set value Adjust compensation factor for mA1 output, if set to TC in section 5.2.5. Set value with >, ^, ENT keys Adjust compensation factor for mA2 output, if set to TC in section 5.2.5. Set value with >, ^, ENT keys Choose matrix if set to matrix comp. in section 5.2.5, using >, ^, ENT keys Matrix selected in section 5.2.6 HCl (cation) pure water (0-80 °C) Ammonia pure water (0-80 °C) Morpholine pure water (0-80 °C) HCl (0-5 %, 0-60 °C) NaOH (0-5 %, 0-100 °C) User programmable matrix Enter 1st (lowest) matrix temp. value Enter 2nd matrix temp. value Enter 3rd matrix temp. value Enter 4th matrix temp. value Enter 5th (highest) matrix temp. value Value for T1 Value for T2 25 °C 2.1 % per °C 2.1 % per °C 1 2 3 4 5 9 1 2 3 4 5 9 Value for T5 Similar to code 24 Similar to code 24 Similar to code 24 Similar to code 24 Not used mA output functions Code 30 *mA Select 4-20mA or 0-20mA according to associated equipment (recorders, controllers etc.) Code 31 *OUTP.F Note: For resistivity measurement, read resistivity in stead of conductivity. Output mA1 Conductivity linear (terminals 61&62) Conductivity with 21 point output table. (The table can be configured to give an output linear to concentration, see example at the end of this page). Output mA2 Conductivity linear (terminals 65&66) Conductivity with 21 point output table. Temperature linear PI control on conductivity (analog output control signal with proportional and integral functions). Direct or reverse action of the mA control output. Direct gives rising output with rising measurement. Reverse gives falling output with rising measurement. Code 32 *BURN Diagnostic error messages can signal a problem by sending the output signals upscale or downscale (22mA or 0/3.5mA). This is called upscale or downscale burnout, from the analogy with thermocouple failure signalling of a burned-out or open circuit sensor. In the case of the DC402G the diagnostics are extensive and cover the whole range of possible sensor faults. Code 33 *RG.mA1(2) This function sets the proportional range for the mA output control signal. The range setting is expressed in % of setpoint. Code 34 *tI.mA1(2) This function sets the integral time for the mA output control signal IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  <5. Parameter setting> 5-18 Code 35-36 *TABL1(2) The table function allows the configuration of an output curve by 21 steps (intervals of 5%) The following example shows how the table may be configured to linearize the output with a W/W% curve. On the next page some other possibilities are shown. Code 37 *DAMP Transmission signal damping (not mA control output). Conductivity (mS/cm) Output in % 1.000 100 800 80 600 60 400 40 % Output 200 20 0 0 2 4 6 8 10 12 14 16 18 20 22 24 Conductivity 0 Concentration (% by weight) Fig. 5.1 Linearization of output Example: 0-25% Sulfuric acid Table 5.3 Code Output 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 mA 0-20 mA 4-20 4 4.8 5.6 6.4 7.2 8 8.8 9.6 10.4 11.2 12 12.8 13.6 14.4 15.2 16 16.8 17.6 18.4 19.2 20.0 % H2SO4 0 1.25 2.5 3.75 5 6.25 7.5 8.75 10 11.25 12.5 13.75 15 16.25 17.5 18.75 20 21.25 22.5 23.75 25 mS/cm 0 60 113 180 218 290 335 383 424 466 515 555 590 625 655 685 718 735 755 775 791 IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5-19 <5. Parameter setting> Code Display Function mA output functions 30 *mA mA output range 31 *OUTP.F Function detail mA output functions Direct/reverse action (For PI control only) 32 33 34 35 36 37 3839 *BURN Burn function *RG. PI range mA1(2) *tI.mA1(2) Integral time (for PI control) Output table for mA1 *TABL1 *0% *5% *10% ... ... *90% *100% *TABL2 Output table for mA2 *DAMP Damping time X Y Z Default values mA1 = 0-20 mA mA1 = 4-20 mA mA2 = 0-20 mA mA2 = 4-20 mA Calculated value (Service Code 58) Meas. conductivity linear Meas. conductivity table Meas. temperature T1-T2 For rising signal, set for increasing mA out. For rising signal, set for decreasing mA out. mA 1 No burnout mA 1 Burnout downscale mA 1 Burnout upscale mA 2 No burnout mA 2 Burnout downscale mA 2 Burnout upscale Proportional range for mA control signal (use >, ^, ENT keys to adjust value) 0 1 0 1 2 3 4 5 6 0 1 2 1.1 0 1 0 1 2 3 4 5 6 0 1 2 Linearization table for mA1 in 5% steps. The measured value is set in the main display using the >, ^, ENT keys, for each of the 5% interval steps. Where a value is not known, that value may be skipped, and a linear interpolation will take place. Similar to code 35 Damping on mA output 0-120 sec. Not used 4-20 4-20 1.1 Cond.1/2 (direct) (reverse) 0.0 No Burn. No Burn. 0. sec. % of output range 100 B C A 50 D 0 0 Fig. 5.2 10 50 % of conductivity range 100 110 Percentage of mA-output range versus percentage of conductivity range EXAMPLES: A = bi-lineair B = hyperbolic (2 decades) C = logarithmic (2 decades) D = linear IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5-20 <5. Parameter setting> Table 5.4 Example of output tables Output 0% 5% 10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% 95% 100% bi-lin 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0 110.0 log 2 1.0 1.3 1.6 2.0 2.5 3.2 4.0 5.0 6.3 7.9 10.0 12.6 15.8 20.0 25.1 31.6 39.8 50.1 63.1 79.4 100.0 log 3 0.10 0.14 0.20 0.28 0.40 0.56 0.79 1.12 1.58 2.24 3.16 4.47 6.31 8.91 12.6 17.8 25.1 35.5 50.1 70.8 100.0 hyp 2 1.00 1.20 1.82 1.90 2.00 3.75 4.80 5.92 7.00 8.31 10.00 11.85 14.00 16.65 19.50 23.80 29.55 36.70 48.50 68.60 100.0 hyp 3 0.10 0.27 0.43 0.61 0.83 1.10 1.36 1.68 2.05 2.49 3.00 3.66 4.33 5.22 6.80 8.25 11.0 14.8 21.8 36.5 100.0 bi-lin = bi-lineair over 2 decades log 2 = logarithmic over 2 decades log 3 = logarithmic over 3 decades hyp 2 = hyperbolic over 2 decades hyp 3 = hyperbolic over 3 decades NOTE: Multiply the values from the table with appropriate factors to get the end-scale value you want. 5.3.5 Contact outputs Code 40, *S1, *S2 41, 42 *S3, *S4 and 43 Process relays can be set for a variety of alarm and control function. Digit “Y” sets the control action: Process alarm is a simple On/Off trip controlled by the high/low setpoint. Proportional duty cycle control has a pulse width modulation for proportional dosing with solenoid valves. Proportional frequency control is used for controlling electrically positioned valves. Temperature alarm is an On/Off trip on the measured temperature. Digit “Z” sets the control parameter: Alarm on main process Control on main process (Main process means conductivity/resistivity depending on the setting of service code 01). Digit “X” sets the type of trigger: Off means that the relay is not active Low setpoint means that the relay is triggered by a decreasing measurement. High setpoint means that the relay is triggered by an increasing measurement “HOLD” active means that there is maintenance activity in progress so the measurement is not live. For *S4 There is the extra possibility to set up for “FAIL” indication. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5-21 <5. Parameter setting> Code Display Function Contact Settings 40 *S1 Relay 1 settings Note: Main process means cond. or resist. whichever is set in code #1 41 *S2 Relay 2 settings Note: “HOLD” active relay contact is used to indicate when the measuring mode is interrupted 42 43 *S3 *S4 Relay 3 settings Relay 4 settings Note: “FAIL” relay contact is used to indicate when the diagnostics detect a problem Function detail Off Low setpoint High setpoint “HOLD” active Process alarm Proportional duty cycle control ** Proportional frequency control ** PI duty cycle ** PI pulse freq. ** USP contact Calculated value Meas cond/res. value cell 1 Meas cond/res. value cell 2 Meas temp. value cell 1 Meas temp. value cell 2 Meas temp. T1-T2 Off Low setpoint High setpoint “HOLD” active Process alarm Proportional duty cycle control Proportional frequency control PI duty cycle ** PI pulse freq. ** USP contact Calculated value Meas cond/res. value cell 1 Meas cond/res. value cell 2 Meas temp. value cell 1 Meas temp. value cell 2 Meas temp. T1-T2 Off Low setpoint High setpoint “HOLD” active Process alarm Proportional duty cycle control Proportional frequency control PI duty cycle ** PI pulse freq. ** USP contact Calculated value Meas cond/res. value cell 1 Meas cond/res. value cell 2 Meas temp. value cell 1 Meas temp. value cell 2 Meas temp. T1-T2 Off Low setpoint High setpoint “HOLD” active Fail alarm Process alarm Proportional duty cycle control Proportional frequency control PI duty cycle ** PI pulse freq. ** USP contact Calculated value Meas cond/res. value cell 1 Meas cond/res. value cell 2 Meas temp. value cell 1 Meas temp. value cell 2 Meas temp. T1-T2 X Y Z Default values 0 1 2 3 0 1 2 3 0 1 2 3 0 1 2 3 4 IM 12D08E02-01E 2.0.1 High 0 1 2 3 4 5 Alarm 0 1 2 3 4 5 Cell 1 1.0.1 0 1 2 3 4 5 Low Alarm 0 1 2 3 4 5 Cell 1 0.0.0 Off 0 1 2 3 4 5 0 1 2 3 4 5 4.0.0 0 1 2 3 4 5 FAIL Alarm 0 1 2 3 4 5 6th Edition: Feb. 19, 2016-00  5-22 <5. Parameter setting> Code 44 *D.TIME The delay time sets the minimum relay switching time. This function can be adjusted to give a good alarm function in a noisy process, preventing the relay from “chattering” or repeatedly switching when the signal is close to the setpoint. The hysteresis is the value beyond the setpoint that the measured value must exceed before the control function will start working. For conductivity this setting is expressed in % of programmed setpoint value. *SC.HYS *T.HYST *C.HYST Code 45 *RANGE Proportional range is the value above (or below) the setpoint that generates full output in proportional control. This is expressed in % of the programmed output span. *PER. The time period of the overall pulse control cycle (one ON and one OFF period). See fig 5.4. *FREQ. The maximum frequency for the pulse frequency control. See fig 5.5. Code 46 *tI.CNT The integral time for the PI control settings. Code 47 *EXPIR When a system is set up to control on the relay outputs, the expiry time can be enabled to warn of an ineffective control. In other words, when the setpoint is exceeded for more than 15 minutes an error message is generated. This can mean, for example, that the reagent tank is empty. *tE.min Code 48 *SC1 For proportional or PI control on the conductivity level, a working range *SC1 must be set. When *SC1 is set as an output on mA1 and *SC2 is set as an output on mA2, code 48 has no relevance. When using mA1 as mA2 for calculated values or temperature etc. the range for control setting of the relays should be done in code 48. After activating code 48 *SC1 is displayed. Press YES to set range *SC1 or NO to go to *SC2. Code Display Function Contacts Settings 44 *D.TIME Delay time *SC.HYS Process hysteresis *T.HYST Hysteresis temp. *C.HYST *RANGE Calculation hysteresis Proportional range *PER. *FREQ. Duty cycle period Maximum frequency 46 *tI.CNT Integral time 47 *EXPIR Expiry time 48 *tE.mn *SC1 Set expiry time Set control range 0% *100% Set begin scale Set end scale 45 49 Function detail X Y Z Default values Minimum relay switching time Minimum change of process value for relay reset after switching Minimum temperature change for relay reset after switching (fig. 5.3) When proportional control selected in code 40, 41, 42 or 43 Pulse control On time + Off time (fig. 5.4) 100% value for frequency control (fig. 5.5) Integral time for relay controls when PI is set Warning of ineffective control action On Warning of ineffective control action Off Set expiring time using >, ^, ENT keys Set range for *SC1 (*SC2) for proportional contact control when *SC1 (*SC2) are not used on mA1 (mA2) Use >,^, ENT keys to set value Use >,^, ENT keys to set value Not used 0.2 sec. 2.0 % 1 °C 0 10.0 % 10 sec. 70 p/m 1 0 IM 12D08E02-01E 0 100 sec. Off 15 min 6th Edition: Feb. 19, 2016-00  <5. Parameter setting> 5-23 Cond./Resist. Setpoint Hys. LED off LED on Delay time LED off Delay time t (sec) Fig. 5.3 % duty cycle control 10% 90% 100 50 50% 50% ton toff 10% 90% 0 Proportional range Setpoint Fig. 5.4 SC Pulse period Time % of output range Duty cycle control % controller output 100 Maximum pulse frequency 0.3s 50 0 50 % pulse frequency Proportional range Setpoint Fig. 5.5 SC No pulses Time % of output range Pulse frequency control IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5.3.6 <5. Parameter setting> 5-24 User interface Code 50 *RET. When Auto return is enabled, the converter reverts to the measuring mode from anywhere in the configuration menus, when no button is pressed during the set time interval of 10 minutes. Code 51 *MODE The adjustment of the contact setpoints can be setup for operation in the maintenance mode. (Through the closed front cover). Code 52 *PASS Passcodes can be set on any or all of the access levels, to restrict access to the instrument configuration. Code 53 *Err.01 Error message configuration. Two different types of failure mode can be set. Hard fail gives a steady FAIL flag in the display, and a continuous contact closure. All the other contacts (controls) are inhibited (except HOLD contacts), and a Fail signal is transmitted on the outputs when enabled in code 32. Soft fail gives a flashing FAIL flag in the display, and the relay contacts are pulsed. The other contacts (controls) are still functional, and the controller continues to work normally. The call for maintenance is a good example of where a SOFT fail is useful. If set to 1, soft fail gives a flashing FAIL flag in the display and no pulsing contact. *SOFT Code 54 *E5.LIM *E6.LIM Limits can be set for shorted and open measurement. Dependent on the main parameter chosen in code 01, the DC402G will ask for the absolute conductivity/resistivity (without influence of absolute cell constant or Temp. comp). Code 55 *% For some applications the measured parameter values may be (more or less) linear to concentration. For such applications it is not needed to enter an output table, but 0 and 100% concentration values directly can be set. Code 56 *DISP The display resolution is default set to autoranging for conductivity reading. If a fixed display reading is needed, a choice can be made out of 7 possibilities. For resistivity the default reading is fixed to xx.xx MΩ·cm. Code 57 *USP Input 1 and/or Input 2 can be set to give automatic checking for compliance with the water purity standard set in USP <645> (United States Pharmacopea directive 23). For more detailed description see Appendix 10.8. Code 58 *CALC A calculation type can be chosen to suit a variety of applications. See appendix 10.9 for more details. For conductivity a choice can be made from 7 options. For Resistivity only “differential” or “no calculation” is possible. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5-25 <5. Parameter setting> Code Display User Interface 50 *RET Auto return 51 *MODE Mode setup 52 *PASS 53 Function Passcode Note # = 0 - 9, where 0 = no passcode, 1=111, 2=333, 3=777, 4=888, 5=123, 6=957, 7=331, 8=546, 9=847 *Err. 1. 1(2) Error setting *Err. 5. 1(2) *Err. 6. 1(2) *Err. 7. 1(2) *Err. 8. 1(2) *Err. 13. 1(2) *Err. 22. 1 *SOFT 54 SOFT FAIL CONTACT *E5.LIM 1(2) E5 limit setting *E6.LIM 1(2) E6 limit setting 55 *% Display mA in w/w% Set w/w% for range 1 56 *%1 *0% *100% *%2 *0% *100% *DISP 57 *USP 58 *CALC USP setting X=Cell 1 Y= Cell 2 Calculation setting Set w/w% for range 2 Display resolution Function detail X Y Z Default values Auto return to measuring mode Off Auto return to measuring mode On Setpoints in maintenance mode Off Setpoints in maintenance mode On Maintenance passcode Off Maintenance passcode On Commissioning passcode Off Commissioning passcode On Service passcode Off Service passcode On Polarisation too high Soft fail Polarisation too high Hard fail Shorted measurement Soft fail Shorted measurement Hard fail Open measurement Soft fail Open measurement Hard fail Temperature sensor open Soft fail Temperature sensor open Hard fail Temp. sensor shorted Soft fail Temp. sensor shorted Hard fail USP <645> limit exceeded Soft fail USP <645> limit exceeded Hard fail Control time-out Soft fail Control time-out Hard fail Pulsing contact No Pulsing contact Maximum conductivity value (Minimum resistivity value) Maximum conductivity value (Minimum resistivity value) mA1-range displayed in w/w% off mA1-range displayed in w/w% on mA2-range displayed in w/w% off mA2-range displayed in w/w% on Press YES to access 0% value adjustm. Set 0% output value in w/w% Set 100% output value in w/w% Press YES to access 0% value adjustm. Set 0% output value in w/w% Set 100% output value in w/w% Auto ranging display Display fixed to X.XXX μS/cm or MΩ•cm Display fixed to XX.XX μS/cm or MΩ•cm Display fixed to XXX.X μS/cm or MΩ•cm Display fixed to X.XXX mS/cm or kΩ•cm Display fixed to XX.XX mS/cm or kΩ•cm Display fixed to XXX.X mS/cm or kΩ•cm Display fixed to XXXX mS/cm or kΩ•cm Disable the E13 (USP limit passed) Enable the E13 (USP limit passed) Choose the main parameter for display Ratio (a/b) Differential (a-b) % passage b/a % rejection (100 (a-b)/a) Deviation (100 X (b-a)/a) No calculation SC1 in display VGB directive 450L, pH calculation 0 1 0 1 0 # 1 0 0.0.0 Off 0 # 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 2 3 4 5 6 7 0 1 0 1 2 3 4 5 6 On Off Off Off 0 # 1 Hard 1 Hard 1 Hard 1 Hard 1 0 Hard Soft 0 Soft 0 Pulsing 25 0.04 1 1 0.0 mS kΩ μS MΩ Off 0 1 0 1 Off 0 Auto 0.0 Off/Off 5 No calc. When set for resistivity measuring, only selection 1 and 5 are available IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  5.3.7 <5. Parameter setting> 5-26 Communication setup Please do not use the Code 61 due to the factory use. Code 61 *HOUR *MINUT *SECND *YEAR *MONTH *DAY 5.3.8 General Code 70 *LOAD 5.3.9 The load defaults code allows the instrument to be returned to the default set up with a single operation. This can be useful when wanting to change from one application to another. Test and setup mode Code 80 *TEST Not used Note: Attempting to change data in this service code, or others in the series 80 and above without the proper instructions and equipment, can result in corruption of the instrument setup, and will impair the performance of the unit. Code Display Function Communication Clock setup 61 *HOUR *MINUT *SECND *YEAR *MONTH *DAY 6269 Code Display General 70 *LOAD 7179 Function detail Adjust to current date and time using >, ^ and ENT keys Not used Function Load defaults Code Display Function Test and setup mode 80 *TEST Test and setup X Y Z Default values Function detail X Y Z Default values Reset configuration to default values Not used Function detail X Y Z Default values Not used IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  6-1 <6. Calibration> 6. Calibration 6.1 When is calibration necessary? Calibration of conductivity/resistivity instruments is normally not required, since Yokogawa delivers a wide range of sensors, which are factory calibrated traceable to NIST standards. The cell constant values are normally indicated on the top of the sensor or on the integral cable. These values can be entered directly in service code 03 (section 5.3.1). If the cell has been subjected to abrasion (erosion or coating) calibration may be necessary. In the next section two examples are given. Alternatively calibration may be carried out with a simulator to check the electronics only. NOTE During calibration the temperature compensation is still active. This means that the readings are referred to the reference temperature as chosen in service code 20 (section 5.3.3, default 25 °C). Calibration is normally carried out by measuring a solution with a known conductivity value at a known temperature. The measured value is adjusted in the calibration mode. On the next pages the handling sequence for this action is visualized. Calibration solutions can be made up in a laboratory. An amount of salt is dissolved in water to give a precise concentration with the temperature stabilized to the adjusted reference temperature of the instrument (default 25 °C). The conductivity of the solution is taken from literature tables or the table on this page. Alternatively the instrument may be calibrated in an unspecified solution against a standard instrument. Care should be taken to make a measurement at the reference temperature since differences in the type of temperature compensation of the instrument may cause an error. NOTE The standard instrument used as a reference must be accurate and based on an identical temperature compensation algorithm. Therefore the Model SC72 Personal Conductivity Meter of Yokogawa is recommended. Typical calibration solutions. The table shows some typical conductivity values for sodium-chloride (NaCl) solutions which can be made up in a laboratory. Table 6.1 NaCl values at 25 °C Weight % 0.001 0.003 0.005 0.01 0.03 0.05 0.1 0.3 0.5 1 3 5 10 mg/kg 10 30 50 100 300 500 1000 3000 5000 10000 30000 50000 100000 Conductivity 21.4 µS/cm 64.0 µS/cm 106 µS/cm 210 µS/cm 617 µS/cm 1.03 mS/cm 1.99 mS/cm 5.69 mS/cm 9.48 mS/cm 17.6 mS/cm 48.6 mS/cm 81.0 mS/cm 140 mS/cm NOTE For resistivity measurement the standard resistivity units of the calibration solution can be calculated as follows: R = 1000/G (kΩ•cm if G = μS/cm) Example: 0.001% weight R = 1000/21.4 = 46.7 kΩ•cm IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  6.2 6-2 <6. Calibration> Calibration procedure Press the MODE key. The legend CAL.1/CAL.2 appears, and the YES/NO key prompt flags flash. If the SETP legend appears, press NO first. MODE MΩ.cm MEASURE CAL 1 CAL 2 DISPLAY 1 DISPLAY 2 HOLD YES NO MODE CONTACTS S1 S2 ENT S3 FAIL/S4 YOKOGAWA MODE MΩ.cm YES NO Note: See section 4-5 for full display access details NO MΩ.cm YES MΩ.cm YES NO MΩ.cm Put the sensor in standard solution. Press YES. ENT Set the value using the >, , ENT key. MΩ.cm > ENT MΩ.cm Select the flashing digit with the > key. Increase its value by pressing the key > ENT When the correct value is displayed, press ENT to enter the change. After briefing displaying WAIT, the CAL.END message appears. MΩ.cm YES The calibration is now complete. Put the sensor back in the process and press YES to return to the measuring mode. IM 12D08E02-01E NO 6th Edition: Feb. 19, 2016-00  6.3 6-3 <6. Calibration> Calibration with HOLD active Press the MODE key. The legend CAL.1/CAL.2 appears, and the YES/NO key prompt flags flash. If the SETP legend appears, press NO first. MODE mS / c m MEASURE CAL 1 CAL 2 DISPLAY 1 DISPLAY 2 HOLD YES NO MODE CONTACTS S1 S2 ENT S3 FAIL/S4 YOKOGAWA MODE HOLD mS / c m YES NO Note: See section 4-5 for full display access function NO HOLD mS / c m YES NO YES HOLD mS / c m HOLD YES NO mS / c m HOLD Put the sensor in standard solution. Press YES. ENT mS / c m HOLD Set the value using the >, , ENT key. mS / c m > ENT > Select the flashing digit with the > key. Increase its value by pressing the key When the correct value is displayed, press ENT to enter the change. HOLD mS / c m After briefing displaying WAIT, the CAL.END message appears. YES NO The calibration is now complete. Put the sensor back in the process and press YES. HOLD will be displayed. Press NO to turn off HOLD and return to the measuring mode. HOLD mS / c m YES IM 12D08E02-01E NO 6th Edition: Feb. 19, 2016-00 Blank Page  7-1 <7. Maintenance> 7. Maintenance 7.1 Periodic maintenance for the DC402G converter The DC402G converter requires very little periodic maintenance. The housing is sealed to IP65 (NEMA 4X) standards, and remains closed in normal operation. Users are required only to make sure the front window is kept clean in order to permit a clear view of the display and allow proper operation of the pushbuttons. If the window becomes soiled, clean it using a soft damp cloth or soft tissue. To deal with more stubborn stains, a neutral detergent may be used. NOTE Never used harsh chemicals or solvents. In the event that the window becomes heavily stained or scratched, refer to the parts list (Chapter 9) for replacement part numbers. When you must open the front cover and/or glands, make sure that the seals are clean and correctly fitted when the unit is reassembled in order to maintain the housing’s weatherproof integrity against water and water vapor. The measurement otherwise may be prone to problems caused by exposure of the circuitry to condensation. The DC402G instrument contains a lithium cell to support the clock function when the power is switched off. This cell needs to be replaced at 5 yearly intervals (or when discharged). Contact your nearest Yokogawa service centre for spare parts and instructions. 7.2 Periodic maintenance of the sensor NOTE Maintenance advice listed here is intentionally general in nature. Sensor maintenance is highly application specific. In general conductivity/resistivity measurements do not need much periodic maintenance. If the DC402G indicates an error in the measurement or in the calibration, some action may be needed (ref. chapter 8 trouble shooting). In case the sensor has become fouled an insulating layer may be formed on the surface of the electrodes and consequently, an apparent increase in cell constant may occur, giving a measuring error. This error is: 2x Rv Rcel x 100 % where: Rv = the resistance of the fouling layer Rcel = the cell resistance NOTE Resistance due to fouling or to polarization does not effect the accuracy and operation of a 4-electrode conductivity measuring system. If an apparent increase in cell constant occurs cleaning the cell will restore accurate measurement. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  7-2 <7. Maintenance> Cleaning methods 1. For normal applications hot water with domestic washing-up liquid added will be effective. 2. For lime, hydroxides, etc., a 5 ...10% solution of hydrochloric acid is recommended. 3. Organic foulings (oils, fats, etc.) can be easily removed with acetone. 4. For algae, bacteria or moulds, use a chlorous solution (bleaching liquid*). * Never use hydrochloric acid and bleaching liquid simultaneously. The very poisonous gas chlorine will result. 7.3 Fuse Replacement This section describes how to replace the power supply fuse. WARNING • Use only a fuse of the specified current, voltage and type ratings to prevent fire. • Power to the instrument must be turned off at the external breaker before replacing the fuse. After replacing the fuse, install a high-voltage shield plate before turning the power on. • Do not short circuit the fuse holder. n Specified Ratings of the Power Supply Fuse The power supply fuse (recommended fuse) used in the DC402G is as follows. l 115 V AC version Rated breaking current: 35 A or 10 times the rated current, whichever is greater (low breaking) Maximum rated voltage: 250 V Maximum rated current: 200 mA Compliance: UL, CSA, VDE, Japan’s Electrical Appliance and material Safety Law Part number: A1105EF l 230 V AC version Rated breaking current: 35 A or 10 times the rated current, whichever is greater (low breaking) Maximum rated voltage: 250 V Maximum rated current: 100 mA Compliance: UL, CSA, VDE, Japan’s Electrical Appliance and material Safety Law Part number: A1103EF l How to replace the fuse 1. Before replacing the fuse, turn off power to the instrument at the external breaker. 2. Remove the instrument cover and the high-voltage shield plate. 3. Remove the cover from the fuse holder by pulling out by hand. 4. Remove the fuse and install a new, recommended or equivalent fuse on the holder. 5. Put the fuse cover back on the holder securely. 6. Install the high-voltage shield plate. It is recommended that the fuse be replaced every two years even if it has not blown. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  <7. Maintenance> 7-3 Fuse Cover Fuse Holder Shield Plate Figure 7.1 How to replace the fuse IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00 Blank Page  <8. Troubleshooting> 8-1 8. Troubleshooting The DC402G is a microprocessor-based analyzer that performs continuous self-diagnostics to verify that it is working correctly. Error messages resulting from faults in the microprocessor systems itself are few. Incorrect programming by the user can be corrected according to the limits set in the following text. In addition, the DC402G also checks the sensor to establish whether it is still functioning within specified limits. The DC402G makes a distinction among diagnostic findings. All errors are signaled by the FAIL area in the display. Only faults in the measuring circuits activate the FAIL contact switching. What follows is a brief outline of some of the DC402G troubleshooting procedures, followed by a detailed table of error codes with possible causes and remedies. n Diagnostics l Off-line checks The DC402G converter incorporates a diagnostic check of the adjusted cell constant value at calibration. If the adjusted value stays within 80 - 120 % of the nominal value set in service code 03, it is accepted. Otherwise, the unit generates an error (E3). The DC402G also checks the temperature compensation factor while performing manual temperature compensation as described in section 5.2.5. If the the TC factor stays within 0.00% to 3.50% per °C, it is accepted. Otherwise, E2 will be displayed. l On-line checks The DC402G performs several on-line checks to optimize the measurement and to indicate a fault due to the fouling or polarization of the connected sensor. The fault will be indicated by the activation of the FAIL-contact, the lighting of the LED and the flag in the display. During measurement the DC402G adjusts the measuring frequency to give the best conditions for the actual value being measured. At low conductivity there is a risk of error due to the capacitive effects of the cable and the cell. These are reduced by using a low measuring frequency. At high conductivity the capacitive effects become negligible and errors are more likely to be caused by polarisation or fouling of the cell. These errors are decreased by increasing the measuring frequency. At all values the DC402G checks the signal from the cell to search for distortion which is typical of capacitive or polarisation errors. If the difference between pulse front and pulse rear is > 20% an error E1 will be displayed and the FAIL alarm will be activated. In service code 05 it is possible to turn this check on and off. The following error message table gives a list of possible problems that can be indicated by the DC402G. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  <8. Troubleshooting> 8-2 Table 8.1 Error Codes Code Error description E1 Polarization detected on cell E2 E3 E4 E5 E6 E7 E8 E9 E10 E13 E15 E17 E18 E19 E20 E21 E22 E24 Possible cause Sensor surface fouled Conductivity too high Incorrect field calibration of TC Suggested remedy Clean sensor and calibrate Replace sensor Temperature coefficient out of Re-adjust limits (exceeds 0-3.5%/°C range) Set calculated TC Calibration out of limits Calibrated value differs more Check for correct sensor than +/- 20 % of nominal value Check for correct unit (μS/cm, programmed in code 03. mS/cm, kΩ•cm or MΩ•cm) Repeat calibration Matrix compensation error Wrong data entered in 5x5 matrix Re-program Conductivity too high or resistivity Incorrect wiring Check wiring (Sec. 3.6) too low (Limits set in service code Internal leakage of sensor Replace sensor 54) Defective cable Replace cable Conductivity too low or resistivity Dry sensor Immerse sensor too high (Limits set in service code Incorrect wiring Check wiring (Sec. 3.6) 54) Defective cable Replace cable Temperature sensor open Process temperature too high or Check process (Pt1000 : T > 250°C or 500°F) too low Check model code sensor (Pt100/Ni100 : T > 200°C or 400°F) Wrong sensor programmed Check connections and cable (8k55 : T < -10°C or 10°F) Incorrect wiring (PB36 : T < -20°C or 0°F) Temperature sensor shorted Process temperature too high or Check process (Pt1000/Pt100/Ni100 : too low Check model code sensor T < -20°C or 0°F) Wrong sensor programmed Check connections and cable (8k55/PB36 : T > 120°C or 250°F) Incorrect wiring Air set impossible Too high zero due to cable Replace cable capacitance EEPROM write failure Fault in electronics Try again, if unsuccessful contact Yokogawa USP Limit exceeded Poor water quality Check-ion exchangers Cable resistance influence to Cable resistance too high Check cable temperature exceeds +/- 15°C Corroded contacts Clean and reterminate Wrong sensor programmed Reprogram Output span too small Incorrect configuration by user Reprogram Table values make no sense Wrong data programmed Reprogram Programmed values outside Incorrect configuration by user Reprogram acceptable limits All programmed data lost Fault in electronics Contact Yokogawa Very severe interference Checksum error Software problem Contact Yokogawa Alarm activation time exceeded Process control not effective Check control equipment within set time Adjust value in code 47 Calculation out of limits Incorrect configuration Check settings Extreme process condition Check process IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  9. <9. Spare Parts> 9-1 Spare Parts See Customer Maintenance Parts List. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00 Blank Page  10-1 <10. Appendix> 10. Appendix 10.1 User setting for non-linear output table (code 31, 35 and 36) Output signal value 10.2 % Output mA 0-20 mA 4-20 000 005 010 015 020 025 030 035 040 045 050 055 060 065 070 075 080 085 090 095 100 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 00.4 04.8 05.6 06.4 07.2 00.8 08.8 09.6 10.4 11.2 0.12 12.8 13.6 14.4 15.2 0.16 16.8 17.6 18.4 19.2 20.0 User entered matrix data (code 23 to 28) Medium: Code 23 Temperature T1...T5 Code 24 Solution 1 L1 Code 25 Solution 2 L2 Code 26 Solution 3 L3 Code 27 Solution 4 L4 Code 28 Solution 5 L5 Medium: Code 23 Temperature T1...T5 Code 24 Solution 1 L1 Code 25 Solution 2 L2 Code 26 Solution 3 L3 Code 27 Solution 4 L4 Code 28 Solution 5 L5 T1 data T2 data T3 data T4 data T5 data T1 data T2 data T3 data T4 data T5 data IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  10-2 <10. Appendix> 10.3 Matrix data table (user selectable in code 22) Matrix, Solution HCL-p (cation) selection 1 Ammonia-p selection 2 Morpholine-p selection 3 Hydrochloric Acid selection 4 Temp (°C) 0 10 20 30 40 50 60 70 80 Data 1 0 ppb 0.0116 µS 0.0230 µS 0.0419 µS 0.0710 µS 0.1135 µS 0.173 µS 0.251 µS 0.350 µS 0.471 µS Data 2 4 ppb 0.0228 µS 0.0352 µS 0.0550 µS 0.085 µS 0.129 µS 0.190 µS 0.271 µS 0.375 µS 0.502 µS Data 3 10 ppb 0.0472 µS 0.0631 µS 0.0844 µS 0.115 µS 0.159 µS 0.220 µS 0.302 µS 0.406 µS 0.533 µS Data 4 20 ppb 0.0911 µS 0.116 µS 0.145 µS 0.179 µS 0.225 µS 0.286 µS 0.366 µS 0.469 µS 0.595 µS Data 5 100 ppb 0.450 µS 0.565 µS 0.677 µS 0.787 µS 0.897 µS 1.008 µS 1.123 µS 1.244 µS 1.373 µS 0 10 20 30 40 50 60 70 80 0 ppb 0.0116 µS 0.0230 µS 0.0419 µS 0.0710 µS 0.113 µS 0.173 µS 0.251 µS 0.350 µS 0.471 µS 2 ppb 0.0229 µS 0.0337 µS 0.0512 µS 0.0788 µS 0.120 µS 0.178 µS 0.256 µS 0.356 µS 0.479 µS 5 ppb 0.0502 µS 0.0651 µS 0.0842 µS 0.111 µS 0.149 µS 0.203 µS 0.278 µS 0.377 µS 0.501 µS 10 ppb 0.0966 µS 0.122 µS 0.150 µS 0.181 µS 0.221 µS 0.273 µS 0.344 µS 0.439 µS 0.563 µS 50 ppb 0.423 µS 0.535 µS 0.648 µS 0.758 µS 0.866 µS 0.974 µS 1.090 µS 1.225 µS 1.393 µS 0 10 20 30 40 50 60 70 80 0 ppb 0.0116 µS 0.0230 µS 0.0419 µS 0.0710 µS 0.113 µS 0.173 µS 0.251 µS 0.350 µS 0.471 µS 20 ppb 0.0272 µS 0.0402 µS 0.0584 µS 0.0851 µS 0.124 µS 0.181 µS 0.257 µS 0.357 µS 0.481 µS 50 ppb 0.0565 µS 0.0807 µS 0.108 µS 0.140 µS 0.181 µS 0.234 µS 0.306 µS 0.403 µS 0.528 µS 100 ppb 0.0963 µS 0.139 µS 0.185 µS 0.235 µS 0.289 µS 0.351 µS 0.427 µS 0.526 µS 0.654 µS 500 ppb 0.288 µS 0.431 µS 0.592 µS 0.763 µS 0.938 µS 1.12 µS 1.31 µS 1.52 µS 1.77 µS 0 15 30 45 60 1% 65 mS 91 mS 114 mS 135 mS 159 mS 2% 125 mS 173 mS 217 mS 260 mS 301 mS 3% 179 mS 248 mS 313 mS 370 mS 430 mS 4% 229 mS 317 mS 401 mS 474 mS 549 mS 5% 273 mS 379 mS 477 mS 565 mS 666 mS 1% 31 mS 53 mS 76 mS 97.5 mS 119 mS 2% 61 mS 101 mS 141 mS 182 mS 223 mS 3% 86 mS 145 mS 207 mS 264 mS 318 mS 4% 105 mS 185 mS 268 mS 339 mS 410 mS 5% 127 mS 223 mS 319 mS 408 mS 495 mS Sodium Hydroxide selection 5 0 25 50 75 100 IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  10.4 <10. Appendix> 10-3 Sensor Selection 10.4.1 General The inputs of the DC402G transmitter are freely programmable for ease of installation. Standard 2-electrode type sensors with a cell constant of 0.100/cm and a Pt1000 temperature sensor, need no special programming. The DC402G indicates a fault with a signal in the display field if there is a mismatch of sensors in the connection. 10.4.2 Sensor selection The DC402G is pre/programmed to accept standard 2-electrode sensors with a Pt1000 temperature sensor. The DC402G is universally compatible with all 2- and 4-electrode type of sensors with a cell constant within the range of 0.008/cm to 50.0/cm. 10.4.3 Selecting a temperature sensor The DC402G reaches its highest accuracy when used with a PT1000 temperature sensor. This may influence the choice of the conductivity/resistivity sensor, as in most cases the temperature sensor is integrated in the conductivity/resistivity sensor. 10.5 Setup for other functions ● Contact Outputs Alarms, trips and proportional control are all possible with the relay outputs, and the configuration is by Service codes 40 - 49. In addition, FAIL alarm is available. ● Current Outputs Transmission signals for the measured parameters and control signals can be set up in service codes 30 - 39. ● Diagnostic checks Polarization check and checks on the calibrated cell constant and the adjusted Temperature Coefficient, are included in the DC402G. Note: On the next page a reference list for the configuration of the DC402G is shown. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  <10. Appendix> 10.6 10-4 User setting table FUNCTION SETTING DEFAULTS Parameter specific functions 01 *SC.RES 0 SC 03 *0.10xC 0.10xC Factor C.C.1 1.000 /cm C.C.2 1.000 /cm 04 *AIR Perform zero calibration 05 *POL.CK 1 On Temperature measuring functions 10 *T.SENS 0 Pt1000 11 *T.UNIT 0 °C 12 *T.ADJ 1 None *T.ADJ 2 None Temperature compensation functions 20 *T.R.°C 25 °C 21 *T.C.1 2.1 %/°C *T.C.2 2.1 %/°C 22 *MATRX None, see 5.2.5 23 *T1°C T. range See sep. table, §10.2 24 *L1xT1 Cond. C1 See sep. table, §10.2 25 *L2xT1 Cond. C2 See sep. table, §10.2 26 *L3xT1 Cond. C3 See sep. table, §10.2 27 *L4xT1 Cond. C4 See sep. table, §10.2 28 *L5xT1 Cond. C5 See sep. table, §10.2 mA outputs 30 *mA 1.1 both 4-20mA 31 *OUTP.F 1.1 SC1 & SC2. *D/R 0 Reverse (control) 32 *BURN 0.0 both off 33 *RG.mA2 prop band only for PI control 34 *tI.mA2 integ. time only for PI control 35 *TABL1 21 pt table see code 31, §10.1 36 *TABL2 21 pt table see code 31, §10.1 37 *DAMP 0 sec Output damping Contacts 40 *S1 2.0.1 high SC1 Al. 41 *S2 1.0.1 low SC2 Al. 42 *S3 0.0.0 43 *S4 4.0.0 FAIL 44 *D.TIME 0.2 sec *SC.HYS 2.0 % setpoint value *T. HYST 1 °C *C.HYST 0 % setpoint value 45 *RANGE 1 % output span *PER 10 sec *FREQ 70 p/min 46 *tI.CNT 100 sec 47 *EXPIR 0 off *tE.min 15 min 48 *SC1 0 100µS/cm control range 0 20MΩ•cm *SC2 0 100µS/cm control range 0 20MΩ•cm User Interface 50 *RET 1 on USER SETTINGS IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  <10. Appendix> FUNCTION 51 *MODE 52 *PASS 53 *Err.1.1/1.2 *Err.5.1/5.2 *Err.6.1/6.2 *Err.7.1/7.2 *Err.8.1/8.2 *Err.13.1/13.2 *Err.22 54 *E5.LIM1 *E6.LIM1 *E5.LIM2 *E6.LIM2 55 56 *% *%1 *0% *100% *%2 *0% *100% *DISP 0 0.0.0 1 1 1 1 1 0 0 25 0.04 1 1 25 0.04 1 1 0.0 0 (2) 0.0 5 57 *USP 58 *CALC Communication 61 *HOUR General 70 *LOAD reset Test and setup mode 80 *TEST SETTING DEFAULTS off all off hard fail hard fail hard fail hard fail hard fail soft fail soft fail mS/cm kΩ•cm µS/cm MΩ•cm mS/cm kΩ•cm µS/cm MΩ•cm Both off 10-5 USER SETTINGS Auto ranging (SC) (xx.xx MΩ•cm) (RES) Both disabled SC1 defaults IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  10-6 <10. Appendix> 10.7 Configuration checklist for DC402G Standard Configuration Options Measured Variable(s) primary inputs Conductivity (SC) and Temp conductivity range 0.000 µS/cm - 100 µS/cm Resistivity i.s.o Conductivity any span within 0.000µS/cm 1999mS/cm Choice out of fixed µS/cm or mS/cm any span within 0.000kΩ•cm 999MΩ•cm Auto ranging or other fixed values any span in -20 ... +250 Fahrenheit code 01 “range” 0- 20 mA or 4- 20 mA 0- 20 mA or 4- 20 mA SC, Resistivity, Temp, Table, PI control (4) freely programmable code 30 code 30 code 31 µS/cm, mS/cm, kΩ•cm, MΩ•cm, temp, PI control, HOLD, FAIL time: 0- 200 s; hyst 0.1- 100% time out alarm PI on contacts or mA output – code 40- 43 – TC, %w/w, °C, mA1, mA2, CC, TR, REL burn low (3.5)/ high (22) on mA1/ mA2 for maint/ comm./ serv level enable or disable setpoint adj code 60 “display” enabled active active enable or disable code 05 “calibrate” “temp.” SC40, SX42 Pt1000 0.100/cm SC8SG, L&N compatible Ni100, PB36, Pt100, 8k55 from 0.008/cm up to 50.0/cm code 10 code 10 code 03 conductivity units Auto ranging µS/cm - mS/cm resistivity range 0 - 19.99 MΩ•cm resistivity units MΩ•cm temperature range temperature unit Outputs analog output second output output allocation 0 - 100 °C Celsius contact outputs S1= high at 100 µS/cm S2= low at 100 µS/cm S4= FAIL mS/cm and FAIL contact allocation 4- 20 mA for SC 4- 20 mA for Temp SC and Temp contact variables add. contact functions control functions digital outputs Communication digital interface variables on display dead time= 0.2 s; hyst= 0.1% none none none (Don’t use.) burn out disabled password protection autoreturn add. function in MAINT Diagnostics check on polarization check on cell constant check on TC coefficient Compatibility SC sensor temperature sensor cell constant Special Features temperature calibration zero calibration temp. comp. disabled return to measure in 10 min. disabled HOLD during maintenance contact during HOLD soft fail alarm Reference for change disabled (Don’t use.) µS/cm (mS/cm) and temp code 56 “range” code 56 “range” code 11 “setpoint” code 40. 41, 42, 43 code 44 code 47 code 45, 46, 34, 33 code 60 code 32 code 52 code 50 code 51 none adjustment +/- 15 °C none adjustment -1 µS/cm acc to NaCl tables IEC 60746-3 NaCl, manual TC, matrix code 20 - 28 disabled hold last or hold fix code 12 code 04 “temp.”, disabled disabled code 40- 42 code 53 possible on S1,S2 or S3 possible for E1, E5...E13, E22 IM 12D08E02-01E “Hold” 6th Edition: Feb. 19, 2016-00  10.8 10-7 <10. Appendix> USP <645> Water Purity Monitoring l What is USP? USP stands for United States Pharmacopeia and it is responsible for issuing guidelines for the pharmaceutical industry. Implementing these guidelines is highly recommended for companies wishing to market drugs in the US. This means that USP is important for pharmaceutical companies worldwide. This new USP, aims at the replacement of 5 antiquated laboratory tests by simple conductivity analysis. l How have we accomplished this in DC402G? 1. In Software Rev. 1.1, (and later versions) we have defined an Error Code: E13. This is independent of what range the customer is measuring or what temperature compensation method he is using for water quality monitoring. When the display shows E13, then the water quality exceeds the USP limits, and the FAIL contact closes to signal that the system needs urgent attention. 2. We have introduced uncompensated conductivity in the DISPLAY menu. In the LCD display the user can read the temperature and the raw conductivity to compare his water quality with the USP table. 3. We have added a USP function to the contact allocation. All 4 contacts can be selected as USP alarms. The contact closes when the USP limit is approached. It is possible to adjust a safety margin for the water quality. For example, if the temperature is 64 °C. and the safety margin is adjusted for 20%, then the contact closes at 0.8 x 2.2 μS/cm. = 1.76 μS/cm. (2.2μS/cm is the USP limit at 64°C). 4. We have kept all the DC402G functionality: It is even possible to have the mA Output and Display readings in resistivity units. Most users will have very good water quality and in the resistivity mode they will have better resolution on the recorder or DCS. The readings are simply the reciprocal values of the conductivity values. In the example mentioned above the contact will close at an uncompensated resistivity of 1/1.76 μS/cm. = 0.568 MΩ•cm. l Setting up DC402G for USP First enable USP in service code 57. Change the setting from 0 (default) to 1 (enabled). This activates uncompensated conductivity in the display menu. The E13 alarm feature is also enabled. For E13 the FAIL alarm (S4) is triggered when the uncompensated conductivity exceeds the relevant value in the graph. USP warning alarms can be selected for any of the 4 relay outputs. Service codes 40 to 43 are for these alarms. Set to 2.5.1 for input one, or 2.5.2 for input two. The setpoint is the safety margin in %, and is set as described in sections 5.1.3 & 5.2.2. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  <10. Appendix> 10-8 Conductivity limit as a function of Temperature 3.5 3 μS/cm 2.5 2 1.5 1 0.5 0 0 25 50 75 Temperature in ºC 100 Fig. 10.1 10.9 WHAT IS DUAL CONDUCTIVITY? Dual cell conductivity is a precise, comparative measurement. The DC402G receives inputs from two conductivity cells located at different points in the process and compares them according to one of six programmed user-selectable formula - Ratio (a/b) - Differential or linear difference (a-b) - Percent passage (b/ax 100) - Percent rejection {(a-b)/a x100} - Deviation {(b/a) a x100} - pH calculation acc. VGB directive 450L The output signal corresponds directly to the formulas. The DC402G also displays the absolute value of each cell on a second display line, as desired by the user. The unit displays all values in conductivity units (μS/cm or mS/cm), percentage (%), resistivity (MΩ•cm) or pH. The pH value of the (boiler) water/condensate is calculated from the conductivity value before and after the cation filter according the VGB directive 450L. pH as function of differential Conductivity 12 11 pH 10 9 8 7 0.1 1.0 10 SC(before) - SC(cation) / 3 100 IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  10-9 <10. Appendix> This pH calculation requires two conductivity values which are compensated to 25ºC. Normally matrix compensation for morpholine/ammonia and cation are used (service code 22 should be set to 2.1 or 3.1). Consequently the pH value displayed corresponds to 25ºC. RETURN LINE DUAL CELL CONDUCTIVITY COOLING TOWER MAKE-UP WATER RATIO A/B B A BLOW DOWN LINE COOLING WATER SYSTEM Fig. 10.2 Ratio output controls blow-down of cooling tower based on concentration factor. DIFFERENTIAL A-B A B WASHING PROCESS Fig. 10.3 Differential output water flow to optimize washing efficiency. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  <10. Appendix> 10-10 DEVIATION B-A X 100 A B SEA WATER DIFFERENTIAL TEMPERATURE (TA - TB) SEA WATER A CONDENSATE Fig. 10.4 HEAT EXCHANGER Deviation output alarms directly after leakage in the heat exchanger. SAMPLE COOLER A pH = f(A, B) B CONDENSATE OR STEAM CATION EXCHANGER Fig. 10.5 pH output as a function of two conductivity values before and after the cation exchanger. IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00  <10. Appendix> 10-11 l Error codes Code Error description E1 Polarization detected on cell E2 E3 E4 E5 E6 E7 E8 E9 E10 E13 E15 E17 E18 E19 E20 E21 E22 E24 Possible cause Sensor surface fouled Conductivity too high Incorrect field calibration of TC Suggested remedy Clean sensor Replace sensor Temperature coefficient out of limits Re-adjust (exceeds 0 to 3.5%/ºC range) Set calculated TC Calibration out of limits Calibrated value differs more Check for correct sensor than +/- 20 % of nominal value Check for correct unit (µS/cm, programmed in code 03. mS/cm, kΩ•cm or MΩ•cm) Repeat calibration Matrix compensation error Wrong data entered in 5x5 matrix Re-program Conductivity too high or resistivity too low Incorrect wiring Check wiring (Sec. 3.6) (Limits set in service code 54) Internal leakage of sensor Replace sensor Defective cable Replace cable Conductivity too low or resistivity too high Dry sensor Immerse sensor (Limits set in service code 54) Incorrect wiring Check wiring (Sec. 3.6) Defective cable Replace cable Temperature sensor open Process temperature too high or Check process (Pt1000 : T > 250°C or 500°F) too low (Pt100/Ni100 : T > 200°C or 400°F) Wrong sensor programmed Check model code sensor (8k55 : T < -10°C or 10°F) Incorrect wiring Check connections and cable (PB36 : T < -20°C or 0°F) Temperature sensor shorted Process temperature too high or Check process (Pt1000/Pt100/Ni100 : T < -20°C or 0°F) too low (8k55/PB36 : T > 120°C or 250°F) Wrong sensor programmed Check model code sensor Incorrect wiring Check connections and cable Air set impossible Too high zero due to cable Replace cable capacitance EEPROM write failure Fault in electronics Try again, if unsuccessful contact Yokogawa USP Limit exceeded Poor water quality Check-ion exchangers Check cable Cable resistance influence to Cable resistance too high Clean and reterminate temperature exceeds +/- 15°C Corroded contacts Reprogram Wrong sensor programmed Output span too small Incorrect configuration by user Reprogram Table values make no sense Wrong data programmed Reprogram Programmed values outside acceptable Incorrect configuration by user Reprogram limits All programmed data lost Fault in electronics Contact Yokogawa Very severe interference Checksum error Software problem Contact Yokogawa Alarm activation time exceeded Process control not effective Check control equipment within set time Adjust value in code 47 Calculation out of limits Incorrect configuration Check settings Extreme process condition Check process IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00 Blank Page Customer Maintenance Parts List Model DC402G [Style: S2] Dual Cell Conductivity and Resistivity Converter 5 13 15 4 3 7 2 8 10 9 14 11 16 Item 1 12 Part No. Qty Description K9664CL K9215DB K9663MC K9672AV 1 1 1 1 K9672HB K9672HC 1 1 Cover Assembly Hinge pin Flat Cable Digital Assembly Analog Assembly For 115 V AC For 230 V AC K9432AH K9215DJ K9663MM 1 1 1 1 A1105EF A1103EF 1 1 Cable Gland Assembly 6 units Fuse (Time Lag Fuse) For 115 V AC Power, 0.200 A,T For 230 V AC Power, 0.100 A,T 10 11 12 A1565EF K9672BJ K9664DH 1 1 1 Fuse Holder Bracket Assembly Stainless steel screw assembly to fix cover 13 14 K9664DK 1 K9672BG K9672BH K9664AR 1 1 1 K9171SU K9316AF 1 1 Screw Assembly Bracket Assembly for Analog Board For 115 V AC Power For 230 V AC Power Bracket Assembly for Digital Board Adapter Assembly For G1/2 screw when /AFTG specified (5 units). For 1/2NPT screw when /ANSI specified (5 units). 1 2 3 *4 *5 7 8 9 15 *16 Housing Polyurethane Coating Epoxy-polyester Coating * Do not exchange these parts. Call serviceman. All Rights Reserved, Copyright © 2007, Yokogawa Electric Corporation. Subject to change without notice. CMPL 12D08E02-02E 1st Edition : Mar. 2007 (YK) 2nd Edition : Sep. 2012 (YK) Pipe/Wall Mounting Hardware (Option Code : /U) Panel Mounting Hardware (Option Code : /PM) 7 2 8 3 3 9 4 5 6 1 3 Sun Protection Cover (Option Code: /H3, /H4) 10 Item 1 2 3 4 5 Part No. K9171SS Y9608KU D0117XL-A K9171SY K9171SX Qty 1 4 1 1 1 Description Mounting Set (/U) Screw U-Bolt Assembly Plate Bracket 6 7 8 9 K9171ST Y9520LU K9171SW Y9608KU 1 2 2 4 Mounting Set (/PM) Screw Bracket Screw K9664CA K9664CC 1 1 Sun Protection Cover Cabon steel (/H3) Stainless steel (/H4) 10 CMPL 12D08E02-02E 2nd Edition : Sep. 2012 (YK) i Revision Information  Title : Model DC402G Converter for Dual Cell Conductivity and Resistivity [Style: S2]  Manual No. : IM 12D08E02-01E Feb. 2016/6th Edition EN 61010-2-201 addition, etc. Aug. 2015/5th Edition Review all for a document software change. Note addition for CSA safety standards, etc. (Pages iii, 1-1, 2-3, 2-4, 2-5, Chapter 3, 7-2) Delete chapter 11. Feb. 2014/4th Edition Page 2-3, 3-3 Safety standard is revised. Appendix 2 Quality Inspection added. PREFACE, Addition of “How to dispose the batteries”. Page Appendix 2 11-1 to 11-4 QIS 12D08E02-01E, QIC-12D08E02-01 revised (some change of withstanding voltage test). CMPL 12D08E02-02E revised to 2nd edition (some of P/N changed). Oct. 2007/3rd Edition Appendix 2 Quality Inspection added. Jul. 2007/2nd Edition Page 2-3: Some of E. Housing and K. Safety and EMC conforming standards description revised (addition of CSA certified); Page 3-3: Terminal label of Figure 3-4 revised, CSA added to WARNING; Page 3-4: The torque to tighten frontplate screws added; Page 3-9: Terminal label of Figure 3-11 revised; Page 5-14: Some caution added to 5-3. Notes for guidance in the use of service code settings; Page 5-15: Code 12 description page moved; Page 5-17: Code 22 *MATRX description corrected; Page 5-25: Default value of code 58 added Mar. 2007/1st Edition Newly published IM 12D08E02-01E 6th Edition: Feb. 19, 2016-00 Blank Page