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Model 455 User Manual

1. 100 100 90 90 80 80 a _ 70 E 60 E 60 g g E 50 E 50 o o X 40 X 40 9 39 8 30 20 20 10 10 0 0 0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100 in uncharacterized in uncharacterized Uncharacterized Characterized Input units 4 20 mA Output Output eg mS cm C output 0 LO 4 00 5 4 80 10 5 60 15 6 40 20 7 20 25 8 00 30 8 80 35 9 60 40 10 40 45 11 20 50 12 00 9 12 80 60 13 60 65 14 40 70 15 20 75 16 00 80 16 80 85 17 60 90 18 40 95 19 20 100 HI 20 00 Page 54 www iccontrols com um 455 212 IC Controls Appendix C Parts List Appendix C Parts List Part Number Description Drawing Number 455 conductivity analyzer A9051010 455 power PCB D5920093 A9051009 455 display board D5980176 A9141010 455 case complete D4830022 A9201014 16 wire interconnect cable two end A9160024 0 25 A microfuse A9160035 3 A microfuse used with option 51 timer A3200070 Hardware set 4 each of standoff lock washer 4 40 nuts A2500201 Panel mounting kit D4950054 A2500255 Pipe wall mounting kit D4950053 400 J box wall mount type A1201514 Weatherproof wall mount J box only A9120050 Terminal strip 6 CKT 400 J box pipe top explosion proof type A2101513 Explosion proof
2. EEE PEC ELLE Leo HHRHH HNT 11117 I Pi TT Tt ai ESE EN FERRE EERE CEE ELLE SS 7 EEE HHH s 0008 17 21 BEE 92 152 SS 141 enone EHHA HHHH oH 18 MR ww ERE HHTLELLLLLELLM HHH HHHH PEELE EEE SEE 1 HH 5 55 HHHH HHHH HHH HH 4 1 nuu 25242424424 HE 211111 E43 TE THESE EH ELIT 1 3 1111 1 0 5 10 15 20 25 30 35 40 45 50 55 60 65 170 75 80 85 90 95 100 BY WEIGHT Illustration 16 Conductivity uS cm vs Chemical concentration Page 26 WWW iccontrols com um 455 212 IC Controls ERRO
3. 111111 HEEEEHERH HICHEHREHHRHHHRHEHHHHEHRHHRHEHHR BSS aS AT YN A EER EEE ECE Err Eee e Se HRRR HRHRH HR H E e Ce ee 400 000 11111111 11111 e TY RF F EF FH potassium 305 59 EN
4. used Page 59 IC Controls lion Display Component Locat DRAWINGS D5980176 Og Lv SEN Sip 92108680 pew NOILVOO 1 LNANOdWOO AvidSIU SEN Tado jun oOlJ03U 86 lt 7 243 Ap 81081 0 sim _ C2 0 VISTA 1 VOS af Cu a IERI d CA 5 2 HOIH Hd t 0d dW31 9 0d dW3L Z 0d V 40193138 40193138 35NVy Hd 4 0 91 dW3L 4 0 DIS V Wav 8 wav es 18851841 5452 9 0 4510 VIILCIWN VITIWIW 076 62018861 AV1dSId SSW C 2 um 455 212 WWW Jccontrols com Page 60 DRAWINGS IC Controls Fy 66002660 apes ul pesn 37 SS IND OV OL 5 311 LON DG HLIA 007 040 21412345 LON SI 21 2 sanman 21 SSUNOV 0151534 WHO 00 LYASNI ANY ONIAIM ol4o4u0 90 2 1 243 MP JYNNYW 123135 31 OLAY LON 53004 5 35 4I 10105 arr SALON 00000 6 N d 41893 144 5 434 1503 CdN31 Eel ee CdN31 v 35 35 10
5. Converter Signal RJII Pin Number m Data A 2 Se so AIRED Data B 5 donne y EARTH 1 Signal Ground 4 WITH RS 485 EARTH Eu REI Pug Er Pu 11 8 cordudar Page 58 WWW iccontrols com um 455 212 IC Controls DRAWINGS D5920093 Wiring amp Component Location GNS LnNaNn LOH 400 11 MODEL 455 MAIN BOARD REV 1 9 um 455 212 WOOD O N S eJ z 0 x e Tuo je eil lo OIOIO 0 5 12 S 5 1 324 x 2 gt NI m 8189 BB ae in e lt CU 1 1 5 co oe gt e yore mp LM LM324 M 74 74 4052 p p LM 5 Bp 7555 T 20557 2090 oJ TE EUH 2055 0 2024 RANGE SELECTOR B 5 0 4 8 ALARM ALARM SIG TEMP SIG RANGE SELECTOR A www iccontrols com DRAWINGS G G 9 a 2 gt 0 g _ ri o l tc 2 amp COMPONENT LOCATION code 9D5920093 ged a gt code scale TITLE 455 WIRING dr EF C 6 1 28 date chk
6. eer 38 Use of Relay et coorta 38 Alarm Indication 38 Alarm We 39 Wiring and NO NC 0 39 Delayed Actvation teet rastro dee 39 Deviation 1 39 High or Low Alarnn 40 4 Using Alarms for On Off Control 4 CONFIGURATION OF 42 TROUBLESHOOTINGL eem 43 Troubleshooting 43 ELECTRONIC HARDWARE ALIGNMENT 45 DISPLAY PROMPTS eene 48 50 Appendix A 51 Appendix B Output Characterization 54 Appendix C Parts LL1St 55 Appendix D Default Settings 56 Appendix E Serial Output 57 DRAWINGS ee 50 D5920093 Wiring amp Component Location 59 05980176 Display Component Location 60 05920095 400 Junction Box Wiring 61 24830022 Mounting Dimensions 62 04950053 2 inch Pipe Wall Mounting Kit 63 04950054 Panel Mounting Kit 64 INDUSTRIAL PRODUCTS WARRANTY 65 bios d 66 Copyright 2006 IC Controls Ltd All rights reserved Page 2
7. SNIS ga 7185 412 x 419 1 0 IHM GAINC 111 CLHM 102 1 002d 1 indino inani gl 400 Junction Box Wiring XOH ALON 5 5 5920095 www iccontrols com Page 61 um 455 212 DRAWINGS IC Controls D4830022 Mounting Dimensions gt 7 8740 3 4660 4 7240 20 1700 20 8750 CONTROLS Orangeville Ontario Canada chk MOUNTING DIMENSIUNS 1 0 Page 62 www iccontrols com um 455 212 IC Controls DRAWINGS D4950053 2 inch Pipe Wall Mounting Kit 8 2000 4 0 CONTROLS Orangeville Ontario Canada chk a opp PIPE WALL MOUNTING KIT 4656659 2 i um 455 212 www iccontrols com Page 63 DRAWINGS IC Controls D4950054 Panel Mounting Kit 9 5000 8 9000 BEZEL Lr NOTES 18 CONTROLS Orangeville Ontario Canada 1 PANEL CUTOUT 840W X 4 80 INCH 2 TWO SCREW HOLES APROX 0 15 DIA chk TITLE AT SIDES 2 40 FROM oF PANEL MOUNTING KIT CENTERED 8 90 INCH APART 655 455 ETC 3 MOUNTING SCREWS 6 32 ease REY 1 0 Page 64 www iccontrols com um 455 212 IC Controls INDUSTRIAL PRODUCTS WARRANTY INDUSTRIAL PRODUCTS WARRANTY Industrial instruments are warranted to be free from defects in material and workmanship for a period of twelve 12 months fr
8. LTCC Linear Temperature Compensation Constant The default LTCC of 2 0 adjusts the conductivity reading by 2 0 per degree Celsius so that the effective conductivity at 25 C can be displayed mho the reciprocal of ohm ohm spelled backwards The equivalent of mho is siemens which is the modern naming for this unit microsiemens uS cm unit of conductivity Micro is the metric prefix meaning one millionth TS 10 siemens ohm cm u Slcm millisiemens per centimeter mS cm unit of conductivity 1 millisiemens per centimeter 1 000 microsiemens per centimeter Milli is the metric prefix meaning one thousandth Menu he series of prompts which determine the layout of the program used by the analyzer Microprocessor an integrated circuit chip which executes the program on the EPROM chip and controls all the input output functions NC Normally closed NO Normally open Normally closed each of the alarm contacts can be wired and configured as normally open or normally closed A circuit which is wired normally closed will be closed 1 6 the external device wired to it is turned on when the analyzer is not powered Normally open circuit which is wired normally open will be open 1 6 the external device wired to it is turned off when the analyzer is not powered On Off control control response in which the contact is either fully on or fully off RAM Random Access Memory Memory in a RAM chip can be both written
9. IC Controls Error Description Causes CAI 9 Display shows Conductivity value too high for the LCD OFL d 0 00 No conductivity measurement display eg the display units are uS cm and the conductivity is higher than 9 999 u S cm Sensor resistance has saturated the measuring capability of the analyzer Error Messages for Temperature Error Description E2 Temperature reading off scale less than 10 C E2 2 Temperature reading off scale greater than 210 C Causes Temperature is lower than 10 C Electronic calibration needed Temperature compensator TC not attached Temperature is higher than 210 C Electronic calibration needed Caution Messages for Alarms Caution Number CA7 6 7 7 CA7 8 7 9 8 6 CA8 7 CA8 8 9 um 455 212 Description Alarm A High alarm Alarm A Low alarm Alarm A Deviation alarm Alarm A Fault alarm Alarm B High alarm Alarm B Low alarm Alarm B Deviation alarm Alarm B Fault alarm www iccontrols com ERROR MESSAGES Solutions Change the display units from uS cm to mS cm in cond unit Open circuit sensor not connected Sensor with different cell constant should be used Solutions Verify process and sensor location Follow procedure in Hardware Alignment section Attach temperature compensator Turn off temperature input Follow Input On Off Switch procedure in Software Configuration section Conn
10. Sensor Wiring The basic wiring scheme for all IC Controls conductivity sensors is shown in drawing D5920095 including a description of the 400 interface to the analyzer This wiring scheme is intended for cable runs less than 20 m 65 ft where electrical interference is low This cable is available from IC Controls as P N A9200000 All low level sensor signals should be run through a dedicated conduit Take care to route all signal wiring away from AC power lines in order to minimize unwanted electrical interference When installing sensor cable in conduit use caution to avoid scraping or cutting the cable insulation the resulting short of the cable s internal drive shield will cause conductivity errors Avoid twisting the sensor lead to minimize potential for broken wires Ensure the sensor connections are clean and tight Instrument Shop Test Startup Note For this test example assume the conductivity sensor has a 1 0 cm cell constant 1 Apply 115 230 VAC power to the analyzer 2 Hook up the sensor via TB201 and remove orange protective cap Keep for future use 3 With the sensor dry and in air the 455 conductivity analyzer should display a reading of 0 0 uS cm 0 5 uS cm 4 Perform an zero calibration use wires to be field installed and allow 30 minutes warm up time for the electronics to stabilize 5 Run the Std span calibration place the sensor in 1000 uS cm standard The display should read ap
11. 0 4 00 0 0 0 LO a 4 00 5 4 80 20 0 25 7 20 10 5 60 40 0 50 10 40 15 6 40 60 0 75 13 60 20 7 20 80 0 100 c 16 80 25 8 00 81 3 125 17 00 30 8 80 82 5 150 17 20 35 9 60 83 8 175 17 40 40 10 40 85 0 200 17 60 45 11 20 86 3 225 17 80 50 12 00 87 5 250 18 00 55 12 80 88 8 275 18 20 60 13 60 90 0 300 18 40 65 14 40 91 3 325 18 60 70 15 20 92 5 350 18 80 75 16 00 93 8 375 19 00 80 16 80 95 0 400 19 20 85 17 60 96 3 425 19 40 90 18 40 97 5 450 19 60 95 19 20 98 8 475 19 80 100 20 00 100 0 500 HI b 20 00 Table 8 Characterization for Bi Linear Example uncharacterized conductivity millisiemens cm 0 LO 100 200 300 400 500 HI 100 500 400 90 3009 2002 80 1008 5 8 70 B 60 6 9 9 50 S D lt 8 40 4 5 s 3 5 I 5 Ji 5 32 20 z o 10 1 eo 3 0 0 10 20 30 40 50 60 70 80 90 100 uncharacterized output in Illustration 21 Bi linear output characterization um 455 212 www iccontrols com Page 37 ALARM FUNCTIONS IC Controls ALARM FUNCTIONS Two alarms alarm A and alarm B are a standard feature Each alarm has an alarm contact associated with it which can be used for remote alarm indication or for control functions The two alarms function independently of each other Either alarm can monitor the conductivity or the temperature input
12. Alarm Override For normal alarm operation the alarms are said to operate in auto mode If the operator wishes to intervene and switch off the alarm contacts temporarily while attending to a problem the alarms can be switched to manual override using the MANUAL key In AUTO mode The green AUTO LED 15 on and the analyzer alarms will activate and deactivate relay contact as programmed Press the MANUAL key to temporarily deactivate the alarm contacts In MANUAL mode The green AUTO LED will blink The relay contacts are deactivated OFF OFT OF but the alarm LEDs continue to indicate alarm condition s Press the AUTO key to return to BUNK MANUAL mode AUTO mode immediately and reactivate the relays If no key is pressed for 15 minutes the a 15 minute timeout will return the alarms to ON moda AUTO mode Illustration 24 Alarm override status AUTO LED Wiring and NO NC Contacts The alarm contacts for alarms A and B may be wired as normally open or normally closed By default the analyzer assumes the alarm contacts are wired normally open A normally open alarm contact will be inactive if there is no alarm condition and will be active when there is an alarm condition If the program configuration and the wiring for each alarm do not match then the incorrectly configured alarm contact will generate an alarm when there is no alarm condition and vice versa Refer to
13. access if password 1 is set to 000 when you have finished using the analyzer This is accomplished by selecting PASS from the main menu then pressing ENTER with 0000 displayed ENABLING PASSWORD SECURITY When security is disabled both password 1 and password 2 are set to 0000 Security is enabled by setting password 2 to a non zero value Level 2 Select CONF PAS 2 from the menu The analyzer will display 0000 Use the arrow keys to change the display to the desired password for level 2 You can press SAMPLE at any time to safely cancel password entry Press ENTER to enter the password into memory and to enable password security The analyzer program automatically returns to the configuration menu With only password 2 set to a non zero value level 2 access is required to make changes in the configuration menu but all other settings are unprotected Effectively the user will always have at least level 1 access um 455 212 www iccontrols com Page 51 Appendix A Security IC Controls Level 1 At this point password 1 is still 000 You may optionally enable operator access control or level 1 security by changing the level 1 password from 000 to a non zero value Change the password by selecting CONF PAS 1 from the menu then entering an appropriate 3 digit password RECORDING YOUR PASSWORDS You may want to write down the passwords you set and store them in a secure place Once a password has
14. 5 1200 2400 4800 9600 1 N 2 co QJ gt IN Illustration 5 Serial menu Page 5 INTRODUCTION IC Controls INTRODUCTION The model 455 is IC Controls industrial quality remote operational CONDUCTIVITY analyzer designed to give maximum flexibility reliability and ease of use The model 455 is shipped from the factory calibrated at 0 uS cm to 1 000 uS cm and 4 mA to 20 mA and should not require recalibration other than sensor cell constant installation if different from 1 0 cm It has four auto ranging input ranges two isolated 4 mA to 20 mA outputs two 10 A SPDT relays plus a serial communication port Its microprocessor intelligence recognizes specific conductivity standards to auto calibrate holds output during calibration notifies user of diagnosed sensor or analyzer faults plus stores in memory the last 12 calibration records 1 000 minute measurement trend alarms power outages and diagnostic messages all date and time stamped The 455 is one of a series of 115 230 VAC process analyzers supplied in a corrosion resistant IP65 NEMA 4X water and dust tight case These analyzers are also available for pH ORP dissolved oxygen and chlorine plus as two wire versions with an optional explosion proof rating In the case of conductivity the analyzer powers a sensor and measures the resulting signal corresponding to the actual conductivity and temperature The analyzer con
15. Input is at maximum Conductivity shows negative value Poor electrode performance sample is not stable interference Incorrect or contaminated standard used for calibration Incorrect or contaminated standard used for calibration Gap between ranges Sample outside of TC operating range of 10 C to 210 C The internal A D analog to digital converter is at the top of the scale The analyzer cannot measure higher at this range Linear temperature compensation constant LTCC is set to high www iccontrols com Check electrode and setup until stable reading is achieved redo calibration Redo calibration using correct or fresh standard Refer to Troubleshooting section Redo calibration using correct or fresh standard Refer to Troubleshooting section Electronic calibration adjustment needed Turn automatic range switching off manually switch between ranges Use manual temperature compensation Check TC connections or install TC If conductivity input is in manual range switching change to automatic range switching so that the analyzer can automatically shift up to the next input range If conductivity input is already on range 4 then the analyzer is at the limit of it s measuring capability Use a different sensor with a higher cell constant Determine a lower LTCC to use to correctly compensate for temperature A typical value is 2 00 for 2 change per C um 455 212
16. low alarm high alarm deviation alarm fault alarm Each alarm features an adjustable set point user a selectable alarm type adjustable differential also AA called hysteresis unit selection and an on off AL b switch The alarm types which are available are E 1E 3 ms cm TS onis high low deviation and fault Alarms can be set 1 6 uS em of input selected anywhere between 0 US cm 9 999 US cm or 0 mS cm and 9 999 mS cm for the conductivity input or 10 C and 210 C for the temperature input The differential is adjustable from ees 0 uS cm to 100 uS cm or 0 mS cm to Accessible only when deviation 100 mS cm applicable function is selected alarm activation delay sec Use of Relay Contacts Illustration 22 Alarm menu By default the relay contacts will be used to indicate alarm conditions If there is an alarm condition then it will be indicated using both the LED and the relay contact This function of the relay contacts can be selected by setting CONF AL AL A FUNC and CONF AL AL b FUNC to AL If another use 15 selected for the relay contacts then the alarm cannot simultaneously use the contact however the alarm function continues using the LED display messages and serial communication The relay contacts can also be used for remote indication of range number for the first 4 mA to 20 mA output PID pump pulse outputs PID time proportional control etc Al
17. conductivity sensor from the process and examine it for deposits Use the sensor cleaning brush with tap water to loosen and flush away any deposits within the cell measurement area Detergent can be added to remove oil films and non tenacious deposits Hard scales and other tenacious deposits may require chemical cleaning um 455 212 www iccontrols com Page 31 SENSOR INSTRUCTIONS IC Controls CHEMICAL CLEANING Fill a beaker 34 full of cleaning and conditioning solution P N A1100005 or for flow through sensors with internal passages seal one end to form a container inside the sensor body CONDUCTIVITY sensor d Lower the conductivity cell into the center of the beaker until the top hole is submerged or pour the solution in until the flow sensor 15 full beaker e Keep removing and re immersing the sensor until the sensor electrodes appear clean Stubborn deposits can be worked on with the brush and syringe to squirt cleaner into hard to reach areas CAUTION Use great care when brushing and squirting ee acid Wear rubber gloves and facial protection solution 3 4 full f Rinse the cleaned sensor thoroughly in tap water and squirt with deionized water to rinse before calibrating Illustration 17 Chemical cleaning Check the sensor against a conductivity standard near full scale If the sensor 1s still not developing the proper cell constant 5 or reading near the standard value clean a
18. d Q A lt hour S m selectable only if security enabled Illustration 2 Configuration menu Page 4 IC Controls CLSd input damping sec m 100 scale 10 scale 2 8 8 lt E NE 1 scale 0 1 scale input damping sec CALIBRATE C F Offset C metric or imperial alarm setpoint low alarm high alarm deviation alarm fault alarm list of available inputs mS cm available units depend on type uS cm of input selected differential Accessible only when deviation applicable alarm function is selected alarm activation delay sec Illustration 3 Alarm menu WWW ccontrols com um 455 212 IC Controls internal data log menu when not logging start internal data log list of available inputs frequency of log update in seconds continue logging overwriting oldest data stop logging when data log is full number of data points currently in data log clear the buffer deleting all data points simultaneous ASCII output on serial port input being logged cond 10 frequency of log update in seconds continue logging overwriting oldest data stop logging when data log is full number of data points currently in data log simultaneous ASCII output on serial port Illustration 4 Internal data log menu um 455 212 www iccontrols com 455 MENUS ais
19. one or more of the following measures Reorient the receiving antenna Relocate the meter with respect to the receiver Move the meter away from the receiver Plug the meter into a different outlet so that the meter and receiver are on different branch circuits If necessary the user should consult the dealer or an experienced radio television technician for additional suggestions The user may find the following booklet prepared by the Federal Communications Commission helpful How to Identify and Resolve Radio TV Interference Problems This booklet is available from the U S Government Printing Office Washington D C 20402 Stock No 004 000 00345 4 CANADA This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications Le present appareil num rique n met pas de bruits radio lectriques depassant les limites applicables aux appareils num riques de la class A prescrites dans le R glement sur le brouillage radio lectrique dict par le minist re des Communications du Canada um 455 212 www iccontrols com Page 11 STARTUP IC Controls STARTUP Analyzer Start up Tests 1 Install the model 455 analyzer according to the instructions in the nstallation section Verify power supply has been wired for proper voltage and instrument ts suitably grounded 2 Turn on flow at sample inlet o
20. output signal press ENTER to access edit mode Edit the displayed mA value to display the desired output needed for testing the output signal Press ENTER to select the displayed value The output signal will be adjusted to put out the desired current This process can be repeated as often as necessary The output signal is held at the displayed level until the program leaves this part of the menu um 455 212 WWW Jccontrols com Page 33 4 mA TO 20 mA OUTPUT SIGNALS IC Controls Units for Outputs The output menu will be using different units for its settings depending on the input selected Select unit from the output menu to display the units in use for this output The unit setting affects the LO and HI settings For conductivity the unit selection can be set to 1E 6 for microsiemens US cm or 1E 3 for millisiemens mS cm For temperature the unit selection can be set to C for degree Celsius or F for degree Fahrenheit Decimal Places for Conductivity The number of decimal places for high and low conductivity output can be adjusted to 0 1 or 2 decimal places Select cond dEc from the menu TYPICAL 4 20 mA OUTPUT WITH AUTOMATIC RANGE SWITCHING Automatic Range Switching Automatic range switching enhances the resolution capability of the 4 mA to 20 mA output An application could track the conductivity input from 0 mS cm to 500 mS cm When the conductivity level drops below about 50 mS cm a typic
21. than 1 0 cm is used change the constant stored by the analyzer so that the analyzer will read properly Temperature has a big impact on conductivity readings typically 2 change per C A 25 C temperature shift can produce a 50 error if the reading is not compensated The 455 default correction is 2 per C 1 11 per F For high accuracy work and high purity water applications IC Controls recommends that the user check the actual chemical rate and change the setting if necessary A conductivity sensor s effective surface area can be changed by contact with the process IC Controls recommends a calibration of the conductivity sensor to determine the effective cell constant This procedure requires a conductivity standard from which the effective cell constant can be determined Page 12 WWW iccontrols com um 455 212 IC Controls EASY MENU EASY MENU The layout of the program is shown in the 455 Menus starting on page 3 Remembers Where You Were The analyzer remembers where SAMPLE is The sample display is home base for the program The program also remembers which menu selections were used last and loops around the columns The menu can be accessed using the arrow keys to find any parameter then press SAMPLE to return to the displayed reading Then using the Right arrow key return to exactly where you were Home Base Press Sample display home base From anywhere in the menu the SAMPLE key can be used to return to displa
22. the set point and is cleared when the conductivity or temperature drops to below the set point minus the differential refer to illustration 25 A low alarm is set when the value of the conductivity or temperature drops below the set point and 15 cleared when the conductivity or temperature rises to above the set point plus the differential refer to illustration 26 The differential has the effect of setting the sensitivity of the alarm The differential provides a digital equivalent of a hysteresis A two stage alarm can be implemented by choosing the same alarm function le high or low alarm for both alarms but selecting different set points Example The conductivity of a critical process may not drop to below 50 Use alarm as a low alarm set at 50 US cm and use alarm A as an advance warning device by configuring it as a low alarm set at 100 uS cm When alarm is activated there 15 still time left to take corrective action HIGH ALARM alarm on differential sample i time Illustration 25 High alarm LOW ALARM differential sample alarm on time Illustration 26 Low alarm Page 40 WWW iccontrols com um 455 212 IC Controls ALARM FUNCTIONS Fault Alarm A fault alarm for an input will be set when anything goes wrong with that input Something is wrong with an input if the input is off scale or an unacknowledged error message exists fo
23. to and read from The contents of RAM will disappear as soon as the RAM chip loses power The RAM chip has a battery backup device which preserves the contents of the RAM chip for a considerable time even if the analyzer is turned off Al settings are stored in RAM siemens per centimeter S cm unit of conductivity 1 ohm Temperature compensator Temperature compensation correction for the influence of temperature on the sensing electrode The analyzer reads out concentration as if the process were at 25 C or 77 F regardless of actual solution temperature Page 50 www iccontrols com um 455 212 IC Controls Appendix A Security Appendix A Security The analyzer has a built in password protection system This security system is disabled by default and does not need to be enabled if no password protection is necessary If you choose not to enable the password protection system then the user will have unrestricted access to all analyzer settings available through the menu as described in this manual Having security disabled gives the user the same access to the program as being at access level 2 at all times With security enabled anyone can view settings Access level Description anywhere in the program When you do not have proper access rights the program will display PASS for 2 seconds indicating that a proper 1 Access to all settings except configuration menu Usage operator password
24. www iccontrols com um 455 212 IC Controls 455 MENUS Main Menu display home base SAMPLE CHANGES Areas shaded in dark orange indicate program settings which can be changed by the user Menu areas shaded in light blue indicate view only Illustration 1 Menu overview um 455 212 Err 455 MENUS ALIBRATE mS cm or HS cm output hold do air calibration cell constant cm cell constant 1 100 linear TC constant change C F 0 1 or 2 decimal places 1 3 mS cm 1E 6 uS cm See list of error and caution messages for conductivity See Internal Data Log Menu cond list of dn available inputs ArnG mS cm available units depend on type of input selected unit 5 I 2 turn automatic range switching on off 5 range number for automatic range switching x T T tbl See Alarm Menu HB See Serial Menu See Configuration Menu 100 CONTEXT SENSITIVE MENUS Context sensitive accessible only when function is activated Output 1 only when ArnG YES www iccontrols com Page 3 455 MENUS dFLt unit selection mE CHIP YEAr onth dAtE
25. 21 For reference conductivity values corresponding to the uncharacterized output are shown at the top of the diagram There are three points on the graph that are of most interest 0 output corresponds to the LO setting of 0 uS cm and 4 00 mA output b Normal 100 output corresponds to the HI setting of 500 uS cm and 20 00 mA output c At 100 uS cm 80 output is required 4 Once the points of interest are identified plot them on the graph and connect them with straight lines 5 The column marked characterized output can now be filled in by reading the coordinates off the graph For example to find the required table value for 10 locate 10 on the horizontal scale follow the line up until it hits the curve The table value is the value on the vertical axis in this case 40 Refer to the arrows in illustration 21 6 Once the columns in the table have been completed enter the table values in the program Select tbL from the output menu then enter each output value 21 points must be entered values cannot be skipped Table 8 illustrates the completed table for the example 7 To activate output characterization set CHAr in the output menu to on Page 36 WWW iccontrols com um 455 212 IC Controls 4 mA TO 20 mA OUTPUT SIGNALS Uncharacterized Uncharacterized 4 mA Characterized Corresponding Corresponding 4 mA to 20 mA Output to 20 mA Output Output Conductivity 5 Output characterized
26. 9 RD B Illustration 31 RS485 wiring um 455 212 WWW iccontrols com Page 57 Appendix E Serial Output IC Controls Portable Laptop Hookup RS232 to RS485 Converter The P N A7900015 is a port powered half duplex RS232 to RS485 converter The unit supports two wire RS485 communications The converter handles the enabling and disabling of the transmitter This works regardless of the operating system or program you are running The RS232 side has a DB9 female connector The RS485 side has six position RJ11 connector Illustration 32 Port powered RS232 to RS485 converter Material List P N A7900015 RS232 to RS485 converter P N A2500192 10 foot cable with connector at one end data wires at other end Installation 1 It is good practice to first turn off the analyzer before connecting a serial cable 2 Bring the RS485 cable into the analyzer through the center hole Wire RS485 cable into the terminal block located on the display board Connect the black to terminal B red to terminal A and the clear to EARTH 3 Connect the converter to a free COM port on your laptop computer 4 Insert the cable s RJ11 connector into the converter f Illustration 33 Wiring RS485 cabl Making a Custom Cable Wing cable A cable has been provided with the adapter If this cable is not long enough use the following information to create your own cable Connect shield at one end only
27. Count of number of readings in internal data log Normally closed alarm contact Conductivity input Configuration of program menu Continue internal data log when buffer full Signal output in mA or current Input damping in seconds Date Real time clock setting for day of the month 1 31 Decimal places Deviation alarm Alarm activation delay Do press ENTER to execute the reset clear action Done Reset clear action has been taken Error or warning number RAM checksum failed Some settings may be lost Temperature in degrees Fahrenheit use imperial units Fault alarm Frequency of internal data log updates in seconds Full What to do when internal data log is full continue or stop High alarm high limit 20 mA for 4 mA to 20 mA output window Output hold during calibration Hour Real time clock setting Hundredth of a second Real time clock display Internal data log Input OR Minute Real time clock setting Low alarm low limit 4 mA for 4 mA to 20 mA output window Node number for IC Net communications Normally open Normally closed Off Offset www iccontrols com um 455 212 IC Controls ON ON OF onth OPEN out out 1 out 2 PAS 1 PAS 2 PASS rANG rnG rtc SEC SEr SEt StAr StOP tbL unit YEAr um 455 212 DISPLAY PROMPTS On On off switch Month Real time clock setting Normally open alarm contact Output menu First 4 mA to 20 mA analog output chan
28. GU 1111 12 40 HE EEE EEE et dH cS Pe Bus ee e Aco 300 000 2111 1 cn S00 00 6 7 GOSS 088 111 11 0 11 1111111 111111 11109111 117111111111111111111117 1 1111 EHE HERE CP PT H CHLORIDE 200 000 CHW CHS 1111 11111114 E D
29. Home 13 Hysteresis 51 Input damping 16 Installation Keypad arrow keys 14 AUTO key 14 CANCEL key 15 DOWN key 15 ENTER key 15 MANUAL key 14 SELECT key 15 UP key 15 Page 66 www iccontrols com um 455 212 IC Controls LED 27 39 51 Linear TC constant 25 MANUAL key 14 40 Manual range switching 18 Manual temperature compensation 24 Menu edit settings 15 home 13 Menu Layout Microsiemens 19 51 Millisiemens 19 51 Normally closed 43 51 Normally open 43 51 Output characterization 37 Output hold 20 Password 52 Process control 42 Range switching 35 enabling 35 manual 18 output signals 35 range indication 36 Re initializing settings 43 Real time clock 16 Relays 48 SAMPLE key 13 Security access level 52 disabling 53 enabling 22 password 52 INDEX password 1 52 password 2 52 time out 13 Sensor calibration 31 cleaning 32p monthly maintenance 31 preparation 31 restoring response 32 storage 31 yearly maintenance 32 Specifications 7 9 Standby mode 14 Startup 12 Temperature 16 Celsius 16 current output 34 error messages 29 Fahrenheit 16 input calibration 43 units 16 Temperature compensation 24 51 Timer 15 minute time out 13 security time out 13 Troubleshooting 44p Units 19 conductivity 19 temperature 16 Wiring 9 um 455 212 www iccontrols com Page 67
30. J box only A9120098 Terminal strip 6 CKT Interconnect cable to 400 interface A9200000 Conductivity cable 4 conductor with shield D5920095 Consumable Supplies A1400051 Low conductivity calibration kit for cell constants 0 01 cm to 0 2 cm 1 year supply A1400052 Medium conductivity calibration kit for cell constants 1 0 cm to 5 0 cm 1 year supply A1400053 High conductivity calibration kit for cell constants 10 0 cm to 50 0 cm 1 year supply A1400054 Conductivity chemical cleaning kit year supply A1100161 100 5 conductivity standard 500 mL A11000161 6P for 6 pack A1100162 1 000 uiS cm conductivity standard 500 mL A11000162 6P for 6 pack A1100163 10 000 US cm conductivity standard 500 mL A11000163 6P for 6 pack A1100164 100 000 uS cm conductivity standard 500 mL A11000164 6P for 6 pack A1100192 Deionized rinse water 500 mL A11000192 6P for 6 pack A1100005 Cleaning and conditioning solution 500 mL A11000005 6P for 6 pack A1100007 Plastic 100 mL graduated cylinder for sensor cell constant 0 01 cm A1100020 Plastic 250 mL beaker A1100016 Sensor cleaning brush inch A740003 1 Syringe 120 mL um 455 212 www iccontrols com Page 55 Appendix D Default Settings IC Controls Appendix D Default Settings The following program settings are the default settings for the analyzer New analyzers will have these settings unless the setup has already been customized for your application Outputs Output 1 Out
31. R MESSAGES ERROR MESSAGES Detected errors and or cautions can be displayed by the analyzer From the main menu select Err If there are no error or caution messages NONE will be displayed otherwise scroll through the error list using the Up and Down arrow keys Errors and cautions cannot be removed from this list directly each error or caution will be removed automatically when appropriate eg errors associated with improper calibration will be cleared after a successful calibration b Error messages are numbered Errors 1 through 5 are MGR pee S er for error identified as En e where n is the input number and e is ANA CAUNON MESSASES the eror number Messages 6 through 9 are less serious Conductivity 1 and are identified as cautions instead eg CAn e Temperature 2 Off scale errors for conductivity are not numbered and are rmm 7 identified as Err and Err depending on whether the input is at the top or the bottom of the scale The off scale Alarm B 8 error 1s displayed instead of the sample reading and does not show up in the error menu with the numbered error Table 4 Input numbers messages if any Error message indicators can be annoying when one has already been made aware of them A method has been provided to turn off the error LED and the fault alarm for a particular error message Refer to the heading Acknowledging an Error Message below for the exact procedure The error LED will remain on as lon
32. The entire display or a single digit will blink to indicate that the analyzer is in edit mode Press the ENTER key again to leave edit mode and accept the new value ENTER Adjusts blinking digit upward or selects the previous item from list is displayed then the digit will loop around to show 0 then the digit will loop around to show 9 Adjusts blinking digit downward or selects the next item from the list If a 0 is displayed gt Numeric values only move to the right one digit If blinking is already at last digit the display will loop to the sign on the left SELECT Numeric values move left one digit If blinking is at the sign then blinking goes to last 44 character Settings restore the initial value if it was changed Otherwise leaves edit mode without CANCEL doing anything Illustration 10 Edit keys um 455 212 WWW iccontrols com Page 15 EDIT MODE IC Controls Temperature C or F By default the analyzer will use metric units This means that temperature will be displayed using degrees Celsius and that the prompt for the temperature input will be C The analyzer can also use imperial units For imperial units temperature will be displayed using degrees Fahrenheit and the prompt for the first temperature input will be F instead of C In this instruction manual the temperature input is always identified as C throughout the menus T
33. UCTIVITY MEASUREMENT CONDUCTIVITY MEASUREMENT What 15 conductivity Electrical conductivity is a measure of the ability of a solution to carry a current Current flow liquids differs from that in metal conductors in that electrons cannot flow freely but must be carried by ions Ions are formed when a solid such as salt is dissolved in a liquid to form electrical components having opposite electrical charges For example sodium chloride separates to form and ions ions present in the solutions contribute to the current flowing through the sensor and therefore contribute to the conductivity measurement Electrical conductivity can therefore be used as a measure of the concentration of ionizable solutes present in the sample Conductivity Units Electrical resistivity uses the unit of ohm meter or Q m Electrical conductivity is the reciprocal of electrical resistivity Rather than use the units in 1971 the unit siemens symbolized by the capital letter S was adopted by the General Conference on Weights and Measures as an SI derived unit The unit for electrical conductivity becomes siemens per meter The siemens unit 1s named after Werner von Siemens the 19 century German inventor and entrepreneur in the area of electrical engineering MEASUREMENT UNITS resistance ohm conductance siemens mho resistivity ohm conductivity siemens cm Table 1 Electrical conductivity measuring units North American pra
34. USER MANUAL MODEL 455 CONDUCTIVITY ANALYZER um 455 212 CONTROLS CONTENTS CONTENTS um 455 212 NT 2 455 MENUS 3 INTRODUCTION wis 6 ai 0 SPCC HAC ee 7 INSTALLA 9 Analyzer Mounting 9 AN a Sensor Mounting et 10 10 Instrument Shop Test Startup 10 12 Analyzer Start up Tests cesses 12 Dtart up 12 En 13 Remembers Where You 13 Home Base Press 13 Display Pear 13 Arrow Edi m M 14 AUTO and MANUAL 14 Standby 14 EDIT MODE 15 Temperature C 16 Input Ta 10 ne 10 CONDUCTIVITY MEASUREMENT 17 What is conductiVity 2 17 Conductbvity UTI eon ont apo 17 What is a Cell 17 Measurement Range 18 Manual Range Switching ee 18 Cell Constant and 18 Guide to Cell Constant Usable Ranges 18 Displayed Conductivity Units 19 CONDUCTIVITY CALIBRATION 20 Selecting AS LANG AL e 20 Calibration Using Standar
35. al recorder would be able to show very little resolution refer to illustration 20 96 OUTPUT 1 TIME With automatic range switching in effect for output 1 the zz gt output will adjust automatically over 4 ranges moving from range 1 which is 100 of full scale to range 4 which is 0 1 of full scale This means that with a full scale setting of HI 500 mS cm the output will automatically switch down to 0 mS cm to 0 05 mS cm 0 uS cm to 50 uS cm on the fourth range The actual numbers depend on the setting of the HI value and 15 user adjustable OUTPUT 2 TIME pontacts _ 0 0 0 1 1 0 1 1 Illustration 19 Output with automatic range A hysteresis is built into the output logic to avoid having the output switch between ranges too frequently thereby painting the chart recorder The output will not switch downscale until the output reaches 9 5 of the current scale The output will switch upscale again when the output reaches 100 of the current scale Enabling Automatic Range Switching Only output has auto range available From the menu select out out1 ArnG then edit the setting to show YES With auto range enabled the range currently being used can be determined by selecting out 0411 rnG from the menu Example of Range Switching TYPICAL 4 20 mA OUTPUT WITHOUT AUTOMATIC RANGE SWITCHING Illustration 19 shows the effect of using automatic range switching on the 4 mA to 20 mA out
36. arm Indication OFF 2 alarm condition The A and B LEDs on the front panel show the current state of each alarm and alarm contact In addition an u alum condition alarm condition for an input will cause the sample BLINK J contact net activated display for that input to alternate with the alarm function either LO HI dEv FLt This way alam condition the operator can quickly determine which alarm caused ON contact activated the alarm condition alarm A or alarm B LED lighted and the type of alarm An LED that is blinking or Illustration 23 Alarm status alarm LEDs on shows the alarm condition The status of the relay contact can also be determined at a glance as it 1s activated when the LED 15 on and deactivated while the LED is only blinking or off The alarm LED will blink while the alarm override is in MANUAL because this situation deactivates the alarm contacts Each alarm will simultaneously generate a caution number in the error menu Refer to Caution Messages for Alarms in section entitled Error Messages for a description of each alarm caution The alarm cautions will not cause the error LED to come on because the error LED only comes on if there are any errors To view alarm caution s using the error menu select Err from the main menu then use the Up or Down arrow key to scroll through the list of errors and cautions if any Page 38 www iccontrols com um 455 212 IC Controls ALARM FUNCTIONS
37. ations He HHAH RIZA EE E 14511551 BEENA n AREJEE H HH POP LaL PETTITT LoL et CCC SSC 11 ae 4 GREGG S TE EEEEEHHH HH HHHH HEREC Ee SN pue 800 000 2 Coe TICLE ELLE EEL SEE EHS EES ES HHA FE Hn E 951109 4 HET ETRRETTD as inap NTT MENE HEHH E NUES EEEE BEE 5 HNE 700 000 4 3 PRENE nu TBA mK PCCP ARSS SEF ELLEN REEE EE EET EEEE A a a A S TEH EEFE EEEE EENE EE TaN 600 000 1 Sees
38. been set there is no way to redisplay it Since passwords are set in the configuration menu level 2 access 1s required to change either password If you have forgotten the level 2 password there is no simple way to regain access to the analyzer Contact the factory if you find yourself locked out of the analyzer DISABLING PASSWORD SECURITY Password security can be disabled by setting the level 2 password to OOOO In order to change the password you must first have level 2 access to the program Select CONF PAS 2 from the menu then press ENTER when the program displays 0000 Both passwords and 2 are set to 0000 and security is now disabled The main menu will be changed to exclude the PASS frame and the configuration menu will no longer have the PAS 1 frame PASSWORD EXAMPLE A QUICK TOUR With security disabled select CONF PAS 2 from the menu Set the level 2 password to 0002 Select CONF PAS 1 from the menu Set the level 1 password to 001 Security is now enabled Select PASS from the main menu Press ENTER with 0000 displayed The analyzer will display 0 to indicate we are now at access level 0 Try changing the output 1 low setting Select out LO from the menu The current value will display Press ENTER to go into edit mode The analyzer will display PASS for 2 seconds because we need to enter a password first Level 1 security is needed to change this setting Selec
39. bration supplies These kits are available as P N 1400051 low conductivity cell constants 0 01 cm and 0 02 cm P N 41400052 medium conductivity cell constants 0 1 cm to 5 0 cm and P N A1400053 high conductivity cell constants 10 cm to 50 cm Where to Perform Conductivity Calibrations A suitable place to conduct a calibration is at a counter or bench with a sink in an instrument shop or laboratory However IC Controls conductivity calibration kits are kept small and portable so that they can be taken to installation sites together with a bucket of water for cleaning rinsing and a rag or towel for wiping drying NIST Traceable IC Controls QC s manufactured conductivity standards using NIST National Institute of Standards and Technology materials Certificates of traceability to NIST are available as P N A1900333 Sensor Storage Short term Rinse the sensor electrodes in deionized water allow to dry and store dry Long term Rinse the sensor electrodes in deionized water allow to dry cover sensor tip with the plastic shipping cap and store dry Monthly Maintenance A monthly maintenance check is recommended by grab sample calibration since the sensor is typically installed in the process and not easy to remove Whenever possible calibration using a conductivity standard close to the process conductivity value is suggested Follow the appropriate calibration procedure in Conductivity Calibration section Keep a log of t
40. ce to like new condition and remove sites for buildups to occur Check the sensor calibration against a conductivity standard and calibrate if necessary If the sensor 15 still not responding properly proceed to the Chemical Cleaning of Sensor procedure otherwise return the sensor to the process Chemical Cleaning of Sensor Obtain a supply of IC Controls conductivity sensor cleaning and conditioning solution P N 1100005 or as available in conductivity chemical cleaning kit P N 1400054 NOTE 1 A suitable place to do chemical cleaning is at a counter or bench with a laboratory sink with a chemical drain where waste is contained and treated before release NOTE 2 JC Controls kits are kept small and portable so that they can be taken to installation sites together with a bucket of water for rinsing and a rag or towel for wiping drying Waste materials particularly acid leftovers should be returned to the laboratory sink for disposal CAUTION Use extra caution when handling cleaning solution as it contains acid Wear rubber gloves and adequate facial protection when handling acid Follow all P N 1100005 MSDS safety procedures a Set up the cleaning supplies where cleaning 15 to be performed Lay out the sensor cleaning brush syringe cleaning and rinse solutions plus the beakers and sensor if already at hand NOTE Ensure your cleaning solution beaker is on a firm flat surface since it will contain acid b Remove the
41. ctance 9 Resistance Q Resistance 1 0 cell constant 0 1 cell constant 1 1 000 000 100 000 10 100 000 10 000 100 10 000 1 000 1 000 1 000 100 10 000 100 10 100 000 10 1 1 000 000 1 0 1 Table 9 Resistance values for simulation Page 44 www iccontrols com um 455 212 IC Controls ELECTRONIC HARDWARE ALIGNMENT ELECTRONIC HARDWARE ALIGNMENT Alignment of Conductivity Detection Circuit 1 2 Install a 700 resistor between electrode drive and sense TB200 terminals and 3 Set the conductivity input to manual range and switching on range 3 From the menu select CONF in cond AUTO and change the setting to no no auto ranging Then select CONF in cond rANG from the menu and set the range to rNG 3 Set up a precision volt meter Fluke 8050A or equivalent to read 4 000 VDC Use sensor shield connection TB200 terminal 2 as common and left side of R212 Refer to drawing D5920093 Rev 1 9 Adjust electronic standardize with blue trim pot VR200 at left edge of board for a reading of 4 000 VDC which is approximately 600 mV peak to peak square wave Set the analyzer to manual temperature compensation and set the manual TC temperature to 25 C Set manual temperature compensation by selecting cond from the menu If the analyzer displays Auto press ENTER to go into edit mode and press Down arrow key to display SEt then press ENTER Press Right arrow key to display the manual TC te
42. ctice continues to see the use of unit mho cm to measure conductivity where the unit mho is a reciprocal ohm The word mho is the word ohm spelled backwards Because of the history of conductivity measurements in micromho cm and millimho cm it is common to see these measurements translated to microsiemens cm and millisiemens cm because there is a one to one correspondence between these units What is a Cell Constant The volume of the liquid between the electrodes must be exact so that the analyzer can determine how much current will flow through a known amount of liquid The controlled volume of a conductivity sensor is referred to as its cell constant A cell constant of 1 0 cm describes a cell with an enclosed volume equal to 1 0 cm A cell constant of 1 0 cm is the easiest constant to work with as conductivity describes the amount of current flow per centimeter A cell constant is usually chosen to produce a steady flow of current between the two electrodes Moderate current and voltage levels can usually be achieved by selecting the proper cell constant A high cell constant is used for solutions with high conductivity and a low cell constant is used for solutions with low conductivities um 455 212 WWW iccontrols com Page 17 CONDUCTIVITY MEASUREMENT IC Controls Measurement Range The 455 conductivity analyzer is an auto ranging analyzer The input circuit has four ranges and will switch automatically to avoid goin
43. d b no key is pressed for 15 minutes dEc 0 1 or 2 decimal places mS cm 5 Illustration 12 Conductivity menu c the power is interrupted and analyzer reboots The output hold feature avoids false alarms and erratic signal output caused by a routine calibration Selecting a Standard Conductivity standards provide the simplest and most accurate method for calibrating the 455 analyzer The analyzer has been programmed to recognize the three standards most commonly used for calibration 100 uS cm 1 000 uS cm and 10 000 uS cm at 25 C 77 F Simply place the sensor in the standard and the analyzer will use the correct temperature adjusted value for the standard Temperature dependence of standards To achieve greater accuracy the temperature compensated values for the 100 uS cm 1 000 uS cm and 10000 uS cm conductivity standards are calculated by the analyzer If manual temperature compensation has been selected then the manual temperature compensation set point is used as the standard temperature Other standards or custom standards If a custom value conductivity standard is to be used press SELECT Cal SELECT 100 then ENTER to edit to the known value Values entered this way should be the known value at the current temperature as they are not temperature compensated by the analyzer Page 20 www iccontrols com um 455 212 IC Controls CONDUCTIVITY CALIBRATION Calibration Using Standards S
44. ding a fast flow loop with the sensor in a short side stream or by shortening the line Slow response can also be caused by a buildup of dirt in the sample line In this case the problem may be alleviated by changing the take off point or by installing a knock out pot Alternatively a dirty water sample system may be needed Readings consistently low or spike low Characteristic of bubbles in the sample line passing through the sensor or hanging up in the sensor Review the installation instructions provided with the conductivity sensor um 455 212 www iccontrols com Page 43 TROUBLESHOOTING IC Controls Readings gradually falling The analyzer can no longer be calibrated properly This problem is typical of scale or sludge slime deposits in the sensor the sensor will need to be cleaned Refer to the Yearly Maintenance procedure in this manual or in the sensor manual Readings at maximum message under all conditions First verify that the analyzer is displaying conductivity using mS cm units The analyzer will display Err if conductivity is above 9 999 uS cm with n S cm units selected for the display This condition is indicated by CA1 9 If unit selection is not the problem then either the sensor is shorted or there is a problem with the wiring analyzer setup This condition is indicated by 1 6 Test for shorts by disconnecting sensor from analyzer and checking impedance between black and white leads with sensor i
45. ditions and digitizes the signal for maximum accuracy and then sends it out as a digital output and or on 4 mA to 20 mA outputs Features The 455 CONDUCTIVITY analyzer features Intuitive user friendly program easy to use Auto calibration recognizes specific conductivity standards Auto ranging over 4 input ranges Self and sensor diagnostics Output hold during calibration Stores 12 calibration records Stores alarms caution and error messages Stores running 1 000 minute conductivity trend NTN A U Nel Two programmable 4 mA to 20 mA outputs 10 Two programmable alarms 11 Serial digital output and for remote operation 12 Optional PID control 13 Optional concentration measurement in NaOH gt 5 and NaCl 14 measurement of TDS resistivity and salinity 15 Three level security to protect settings 16 Hidden alignment accessible when needed 17 Durable housing IP65 NEMA 4X Page 6 www iccontrols com um 455 212 IC Controls INTRODUCTION Specifications Physical Data PROPERTY CHARACTERISTIC Display Four and one half LCD digits 1 5 cm 0 6 in displays for conductivity temperature error codes prompts and diagnostic information back lit display optional Display Ranges Conductivity 0 uS cm to 1 uS cm 0 uS cm to 1 000 uS cm 0 mS cm to 1 000 mS cm Temperature 10 0 C to 210 C 14 0 F to 410 F Keypad 8 pushbutton entry key
46. ds 21 Calibration by 27 Air Zero 23 Temperature Compensation TC 24 Conductance Data for Commonly Used Chemicals PP 26 ERROR MEBESSAQGES eeeeeeee secte entente 27 Acknowledging an Error Message 2 Error Messages for Conductivity 28 Error Messages for Temperature 20 IC Controls Caution Messages for 20 SENSOR 8 30 Preparation fOr US Cs ooo oci deitate 30 Calibration for Conductivity ssssss 30 STOTIS E 30 Monthly Maintenance pp 30 Yearly Malintenance ee 31 Restoring Sensor 31 4 mA TO 20 mA OUTPUT SIGONALS 33 Reversing the 4 mA to 20 mA Output 33 Simulated 4 mA to 20 mA Output 33 Units for 34 Automatic Range 5 34 Using the Alarm ContactS 35 Using the Second 4 mA to 20 mA Output 35 Output 7 36 ALARM
47. e 1 3 for mS cm 1E 3 18 scientific notation for milli or thousandth and 1E 6 for uS cm 1E 6 15 scientific notation for micro or millionth mS cm 5 Illustration 11 Units for conductivity input um 455 212 www iccontrols com Page 19 CONDUCTIVITY CALIBRATION IC Controls CONDUCTIVITY CALIBRATION The conductivity loop is usually calibrated using standard conductivity solutions Alternatively grab sample analysis on a previously calibrated laboratory reference conductivity meter can be used mS cm hS cm Overall system accuracy 15 maintained by calibrating the sensor and analyzer Std together in a standard close to the CAL 1025 output noia expected sample concentration Air Calibration determines the effective cell constant of the conductivity sensor The cell constant is affected 3 do air calibration by the shape of the sensing surface 100 p 18826 constant em x100 and electrode surface characteristics The effective cell constant will change ome SE C F over time as deposits form Auto anything else that affects either the controlled volume or the effective itc j GEN change C F electrode surface area The 455 features an output hold Output hold goes into effect as soon as a calibration is started The output hold will stay in effect until a SAMPLE key is presse
48. e for example to transmit two conductivity signals each using separate high low adjustments To adjust the output span or output window for conductivity or temperature signals set LO to correspond to the low end of the scale or 4 mA output and set HI to correspond to the high end of the scale or 20 mA output The analyzer will automatically scale the output according to the new settings Reversing the 4 mA to 20 mA Output The low scale setting will normally be lower than the high scale setting It 1s possible to reverse the output or flip the window by reversing the settings of the low and high scale out Simulated 4 mA to 20 mA Output Select cur from the output menu to display the output current in mA that is presently being transmitted by the output signal The display will be updated as the output signal changes based on the input signal and the program settings From here one can watch the output respond to the change in the input li Ww 4 mA TO 20 mA OUTPUT SIGNALS available available units depend on type 1E 6 of input selected ON OF OFF ie YES turn automatic range switching on off range number for rnG automatic range switching OFF 22 WEB WEB 1 WEB tbl 5 9 5 GU 100 Illustration 18 Output menu signal This is useful for verifying program settings and for testing the hardware calibration To simulate a different 4 mA to 20 mA
49. ect resistor to TC terminals to simulate a constant temperature Refer to Hardware Alignment section Verify process and sensor location Follow procedure in Hardware Alignment section Page 29 SENSOR INSTRUCTIONS IC Controls SENSOR INSTRUCTIONS Preparation for use 1 Moisten the sensor body with tap water and remove the lower plastic storage cap Keep the storage cap for future use Rinse the exposed conductivity elements with tap water 2 For first time use or after long term storage immerse the tip of the sensor in a conductivity standard for 30 minutes This wets the conductivity electrodes and prepares them for stable readings with test solutions NOTE Controls sensor s are shipped dry These electrodes are often ready for use immediately with a typical accuracy of 2 conductivity without calibration It is recommended that the sensor be soaked in standard plus calibrated using an appropriate conductivity standard in order to achieve optimal results Calibration for Conductivity Overall system accuracy is maintained by calibrating the sensor and analyzer together a concentration close to the expected sample concentration The cell and analyzer can generally be calibrated in two of four typical ranges 0 uS cm to 100 uS cm uS cm to 1 000 uS cm 0 uS cm to 10 000 uS cm uS cm to 100 000 uS cm IC Controls has available conductivity calibration kits which conveniently package all necessary cali
50. elect a conductivity standard with a concentration that is close to the expected sample concentration A second conductivity standard can be used to verify that the conductivity sensor is responding properly This second standard can be any value but typically 10 of the first standard works well giving checks at 100 and 10 of range 1 Obtain calibration supplies such as a graduated cylinder or beaker which is large enough to submerse the conductivity CONDUCTIVITY sensor plus distilled or deionized water in a squeeze bottle for rinsing an IC Controls calibration kit 2 Remove the conductivity sensor from the process and inspect the sensor for any deposits If the sensing surface is coated clean the sensor before proceeding Refer to the Sensor Maintenance section Rinse the sensor cell area with distilled water beaker 200 3 Rinse the graduated cylinder or beaker with some of the standard then pour the selected higher conductivity standard into the graduated cylinder or beaker eo Cleaning and conditioning solution 3 4 full 4 Immerse the sensor and ensure the sensor electrode area is completely submerged If the sensor has vent holes then the sensor must be submerged below the vent holes and there Illustration 13 Conductivity calibration must be no air bubbles inside N Important a Air bubbles inside the controlled volume area of the conductivity sens
51. erature compensation is not available manual temperature compensation may be used If the temperature of the sample is constant set the manual TC temperature to reflect the process temperature If the process temperature varies or is unknown the default temperature of 25 C or 77 F is normally used TC for High Purity Water Very low conductivity water or high purity water is highly temperature dependent The presence of trace impurities such as acids salts and bases each dramatically and uniquely affect the TC curve required Page 24 WWW iccontrols com um 455 212 IC Controls CONDUCTIVITY CALIBRATION Setting the Linear TC Constant Depending on the chemical involved the value for temperature compensation will vary The values change from approximately 1 to 3 Table 3 is a general guide for typical applications The formula for the temperature corrected conductivity value is K cell 1 1 c 100 T 25 conductivity where conductivity is the temperature compensated reading in siemens cm Keen cell constant in typically in the range 0 01 cm to 50 cm R measured resistance in ohms temperature compensation factor as change C typically close to 2 0 T current temperature in degrees Celsius The linear TC constant is normally displayed as percent change per degree Celsius If the units for temperature are changed from C to F then the linear TC constant automatically chan
52. g as there is an unacknowledged error or caution message or as long as any input is off scale Each source of error must be removed or acknowledged before the error LED will go off Acknowledging an Error Message Select Err from the main menu Use the Up or Down arrow key until the error message to be acknowledged is displayed Errors are displayed with either a positive sign or a negative sign in front The sign is used to indicate an active or unacknowledged error the sign indicates an inactive or acknowledged error Acknowledging the error will change the sign from to Press ENTER to go into edit mode The or sign will be flashing Use the Up or Down arrow key to change the sign then press ENTER again An acknowledged error message is cleared for one occurrence of the error only If the error reappears the sign changes from to and the error message must be acknowledged again um 455 212 www iccontrols com Page 27 ERROR MESSAGES IC Controls Error Messages for Conductivity Error Description Causes Solutions 1 1 1 2 E1 3 1 4 1 5 1 6 1 7 Page 28 Electrode has not stabilized after 5 minutes of calibration Effective cell constant would be less than 0 001 Previous cell constant retained Effective cell constant would be greater than 100 Previous cell constant retained Range switching error Temperature compensator TC is off scale
53. g off scale The range e g 0 uS cm to 10 000 uS cm is determined by the gain used by the analyzer plus the cell constant of the sensor Ranges in this manual are based on a cell constant of 1 0 cm The analyzer gains are 100 1 000 10 000 and 100 000 Table 2 Guide to Cell Constants and their Usable Ranges indicates maximums for the ranges using available cell constants Manual Range Switching By default the analyzer is in auto range mode To change to manual mode go to configuration menu CONF in cond AUtO edit from YES to no The range can now be manually adjusted by changing the setting in CONF in cond rANG Cell Constant and Range Changing the cell constant to 0 01 achieves ranges of 1 uS cm 10 uS cm 100 uS cm and 1 000 uS cm while 20 cm achieves 2 000 uS cm 20 000 uS cm 200 000 uS cm and 2 000 000 uS cm If the sensor is replaced with a sensor having a different cell constant the cell constant needs to be changed in memory Select CONF cond CELL 1 from the menu then edit the cell constant The program will allow cell constants between 0 001 cm and 99 99 cm to be entered Guide to Cell Constant Usable Ranges CELL CONSTANT DESIGN RANGE LOWEST RANGE HIGH RANGE OVER RANGE 1 cm uS cm uS cm uS cm uS cm 0 01 0 to 10 0 to 1 0 to 100 0 to 1 000 0 02 0 to 20 0 to 2 0 to 200 0 to 2 000 0 1 0 to 100 0 to 10 0 to 1 000 0 to 10 000 0 2 0 to 200 0 to 20 0 to 2 000 0 to 20 000 0 5 0 t
54. gain proceed to troubleshoot or replace the sensor 8 h A clean rinsed and dried conductivity sensor should read near zero in air If it does not troubleshoot the sensor wiring and analyzer If the sensor cannot be returned to good condition it may need to be replaced The cell constant as calculated by the analyzer should be within 25 of the original or intended value stamped on the sensor NOTE f none of the above procedures succeed in restoring your sensor response it is near the end of its useful life and should be replaced Alternatively available acids can be used such as nitric acid hydrochloric acid or sulphuric acid Nitric acid is preferred as it has no chlorides to corrode stainless steel Acid concentrations between 0 5 acid and 10 0 acid approximately 50 dilution of concentrated acid can typically be used depending on the severity of the application Page 32 www iccontrols com um 455 212 IC Controls 4 mA 20 mA OUTPUT SIGNALS Two assignable 4 mA to 20 mA output channels are provided The user may configure the analyzer to determine which input signal will be transmitted by each 4 mA to 20 mA output channel Each output channel can be independently configured to transmit a conductivity or a temperature signal The output channels function independent of each other Each output channel has a separate on off switch and adjustable low and high span or scale adjustments This makes it possibl
55. ges to percent change per degree Fahrenheit Some chemicals that are frequently diluted for use have non linear temperature compensation requirements As a result Controls has provided special program versions with TC curves in the memory for some common chemicals used in industry such as NaOH 455 21 5 455 22 455 23 and NaCl 455 24 that read out in concentration plus TDS Total Dissolved Solids 455 25 resistivity 455 26 and very low conductivity or high purity water 455 63 Substance change per C acids 1 096 to 1 6 per C 36 e bases 1 8 to 2 2 per C 81 oe 2 8 18 salts 2 2 to 3 0 per C 3 17 fe yk neutral water 2 0 per C 1 2 1 Table 3Typical temperature response 12 20 0 20 40 60 80 100 Temperature degrees Celsius Illustration 15 Non linear temperature um 455 212 www iccontrols com Page 25 CONDUCTIVITY CALIBRATION IC Controls Conductance Data for Commonly Used Chemicals Examples of conductance of various materials with changing concentration are shown below Sodium Hydroxide NaOH also exhibits quite variable temperature related rates of concentration change It 15 clear from the graph that both Sulfuric Acid 50 and Nitric Acid HNO have unusual conductivity vs by weight relationships as well It clearly shows that there is no conductivity constant between chemical combin
56. haviors to be described with high resolution Each of the two outputs has its own independent characterization capability Example Bi linear output Goal Record the conductivity input between 0 uS cm and 500 uS cm while giving 80 of the scale to the area between 0 uS cm and 100 uS cm The purpose is to give maximum recorder resolution to the main area of interest which is 0 uS cm to 100 uS cm yet still maintain a record of the times that the conductivity would go over this limit If output characterization were not available the LO and HI could still be set to 0 uS cm and 500 u S cm respectively but the area of interest from 0 uS cm to 100 uS cm would occupy only 20 at the bottom of the scale To correct this the center of the scale will be expanded and the high area will be shrunk To achieve the desired output characterization the 21 point characterization table and the high and low settings need to be defined 1 Set the boundaries for conductivity output LO 0 uS cm and HI 500 uS cm The characterization table will now automatically characterize the output so that 0 0 uS cm and 100 500 uS cm 2 It 15 probably easiest to draw or sketch the characterization curve before entering any table values A blank worksheet has been provided in Appendix B This worksheet can be copied and can also serve as documentation for your analyzer setup 3 The characterization curve for the example is shown in illustration
57. he analyzer is taken out of standby While in standby the entire menu and all of the settings are accessible to the operator as before None of the settings will take effect until the analyzer is returned to normal operation The standby feature is protected by security level 2 StbY Illustration 9 Standby menu Page 14 www iccontrols com um 455 212 IC Controls EDIT MODE EDIT MODE Edit mode is used to change a numeric value or to select between different options Values and settings which can be edited are identified by the darker shading in the menu Any frame which has a white background cannot be modified Editing by Selecting a Setting Editing a value is like picking an option from a list only one item on the list can be seen at a time To change the setting press ENTER to go into edit mode The display will start blinking Use the Up or Down arrow key to switch between the possible options and then press ENTER again to accept the new setting and leave edit mode Example Turn alarm A off From the menu select Al Al A ON OF The analyzer will now display either ON or OFF which are the two choices To change the setting press ENTER to go into edit mode The display will start blinking Use the Up or Down arrow key to switch between the possible options When ON is displayed press ENTER again to accept the new setting and leave edit mode Summary of Key Functions in Edit Mode Enters edit mode
58. he cell constant at each monthly calibration Page 30 WWW iccontrols com um 455 212 IC Controls SENSOR INSTRUCTIONS Yearly Maintenance Follow the monthly maintenance procedure Check the cell constant log If the cell constant has changed more than 20 over the past year it may need to be chemically cleaned follow the Chemical Cleaning of Sensor procedure O rings and teflon sealing ferrules should be replaced on conductivity sensor models 402 403 414 and 425 The condition of electrical connections in 400 junction boxes should be examined for signs of corrosion and tight connections replace if corroded The condition of the safety cables on model 403 sensors should be examined for rust or bent mounting screws Replace if deterioration shows Restoring Sensor Response Mechanical Cleaning of Sensor The sensor will require cleaning if sludge slime or other tenacious deposits build up in the internal cavities of the sensor Wherever possible clean with a soft brush and detergent General debris oil films and non tenacious deposits can be removed in this way For flat surface sensors use a potato brush and a beaker or bucket of water with a good liquid detergent Take care not to scratch the electrode surfaces Internal cavities of standard sensors can be brushed with a soft 4 inch diameter brush Plastic body sensors should be washed using a soft cloth ensuring all wetted areas are cleaned This will return their appearan
59. he model 455 The cell constant is displayed by pressing SAMPLE and then selecting cond CELL 1 from the menu 4 Draw a sample from the process In order for the procedure to work properly the sample taken must be representative of the sample being measured by the 455 conductivity analyzer 5 Record the conductivity and temperature of the sample as displayed by the 455 conductivity analyzer 6 Measure the conductivity of the sample using the second conductivity analyzer and record the conductivity reading For accurate results the sample must be at the same temperature and the analyzers must use the same temperature compensation method Page 22 WWW iccontrols com um 455 212 IC Controls CONDUCTIVITY CALIBRATION 7 Calculate the new cell constant to be entered into the 455 analyzer using the following formula lab reading X old cell tant field reading new cell constant For example if the 455 analyzer is reading 820 5 the cell constant from step 2 is 1 0 cm and the reading from the second method is 890 uS cm then the new cell constant becomes 890 uS cm 0 1 09 820 u S cm new cell constant 8 Adjust the cell constant to the new value e g 1 09 cm as in the example The cell constant is adjusted by selecting cond CELL 1 from the menu Press ENTER to get into edit mode then adjust the displayed value 9 The analyzer should now read accu
60. illustration 2 for the configuration menu Select CONF AL from the menu Delayed Activation Alarm relay activation by default 1s immediate upon alarm condition or may be delayed Delay gives the operator a chance to correct alarm situations before the relay contacts activate or can eliminate alarms based on temporary or spurious change the process The delay time is programmable by the operator To change or view the delay time select dLAY from the alarm menu The default value of 0 seconds is for immediate contact activation The delay time be set from 0 to 999 Deviation Alarm A deviation alarm is practical when the process is expected to stay within a certain range An alarm will be set if the input deviates too far from a set point Please note that the dEv frame only shows up in the menu after the alarm function has been changed to deviation alarm since it would have no effect for a high low or fault alarm Example If the conductivity is expected to stay between 100 and 200 US cm then we would set in to cond Func to dEv SEt to 150 and dEv to 50 Effectively a high alarm at 200 and low alarm at 100 US cm has been set The differential setting will continue to function as for high and low alarms um 455 212 www iccontrols com Page 39 ALARM FUNCTIONS IC Controls High or Low Alarm A high alarm is set when the value of the conductivity or temperature rises above
61. ing and signed by one of its officers um 455 212 www iccontrols com Page 65 INDEX INDEX Acknowledging error messages 27 Alarms 39 caution messages 21 default settings 57 delayed activation 40 deviation 39p differential 39 42 fault 39 42 function 39 high 41 indication of 39 low 41 manual override 40 on off control 42 sensitivity of 4 set point 39 two stage 41 use of contacts 39 AUTO key 14 40 Automatic range switching 35 Calibration 20p air zero 23 cell constant 20 electronic 46 grab sample 22 output 47 output hold 20 software 47 standards 20 Caution messages 27 29 Cell constant 12 17p 51 Characterization example 37 output signal 37 conductivity 17 Conductivity cell constant 17 detection circuit 46 error messages 28 units 19 Units 17 Configuration input on off switch 13 re initializing 43 units conductivity 19 IC Controls units temperature 16 Current output 34 calibration 47 characterization 37 default settings 57 output hold 20 reversing 34 settings 34 simulating 34 span 34 standby mode 14 units 35 Damping of inputs 16 Decimal places 35 Default settings 57 Display prompts 49p Edit Mode change settings 15 example 15 key functions 15 numeric values 15 Electronic alignment 46 Error messages 27 29 sign 27 sign 27 acknowledging 27 alarm 30 clearing 27 conductivity 28 temperature 29 Error messages 28 Fault alarm 42
62. is wet Correct the sensor situation and try again um 455 212 www iccontrols com Page 23 CONDUCTIVITY CALIBRATION IC Controls Temperature Compensation TC Ionic movement and therefore conductivity measurement is directly proportional to temperature The effect 16 predictable and repeatable for most chemicals although unique to each chemical The effect 15 instantaneous and quite large typically between a 1 to 3 change per degree Celsius with reference to the value at 25 C Many industrial applications encounter fluctuating temperature and thus require automatic compensation Controls conductivity sensors include a temperature compensator built into the sensor The 455 analyzer uses a linear temperature compensation method with a default setting of 2 C 2 C is an average value commonly found in many water samples containing some dissolved solids Over wide temperature spans e g 0 C to 100 C the temperature compensation factor often does not remain constant making it difficult to obtain a good value If the temperature curve of the sample is known set the linear TC constant to match the curve in the temperature range the analyzer will be measuring in 2800 2600 2200 2000 1800 1600 1400 1200 Conductivity microsiemens per centimeter 0 20 40 60 80 100 Temperature degrees Celsius Illustration 14 Typical temperature response Manual Compensation If automatic temp
63. mally open normally closed configuration from open to closed Press ENTER to accept the new value A closed contact should open and an open contact should close Repeat step 1 for for the Alarm B contact If so desired all software settings can be returned to factory default condition by following the procedure in Configuration of Program Re initializing All Settings um 455 212 WWW iccontrols com Page 47 DISPLAY PROMPTS IC Controls DISPLAY PROMPTS 1 100 1E 3 1E 6 ACC n AL AL A AL b AUto ASCI BAud C CAL CELL CHAr CHIP CLr cnt CLSd cond CONF Cont cur dA dAtE dEc dEv dLAY do donE Err Er 94 F FLt FrEq FULL Hold hour hund in LO NodE NO NC OFF OFFS Page 48 Actual cell constant multiplication factor 1 Cell constant x100 Conductivity units in millisiemens per centimeter from E 3 milli Conductivity units in microsiemens per centimeter 6 micro Access level for security Displayed after password entered by user Alarms AlarmA Alarm B Automatic ranging of conductivity input yes no switch ASCII serial output log Baud rate for serial communications Temperature in degrees Celsius use metric units Calibrate analyzer Cell constant Output characterization on off Chip Is this analyzer equipped with a real time clock chip Clear the internal data log
64. mperature Change this temperature to 231 With multimeter common on TB200 terminal 2 sheild adjust to 4 85 VDC 0 005 VDC TP202 or pin 1 of 0203 using VR201 blue span adjust potentiometer just to left of pinl Return conductivity input to automatic range switching by selecting CONF in cond Auto from the menu and changing the no setting to YES Alignment of Temperature Input Circuit The temperature input can be adjusted both by making electronic adjustments and or by having the program compensate for differences in offset Both procedures are described below The temperature input of the 455 microprocessor analyzer requires a 1 000 TC in the sensor Adjusting Electronic Calibration 1 Remove offset calculated by previous software calibration of temperature input Select CONF in C OFFS from the menu and edit the offset to read 0 0 Set up a precision multimeter Fluke 8051A or equivalent to read VDC Use 200 terminal 2 as common Refer to drawing 05920093 Rev1 9 Place a 1 000 1 resistor across T and T terminals Adjust blue trim pot VR202 located at the top right side of TB201 for a reading of 0 200 V at TP203 Place a 1 74 1 resistor across T and T terminals Adjust blue trim pot VR203 located at the top right side of U203 for a reading of 4 80 V at TP203 Close the case and press SAMPLE followed by the Down arrow key to display the tempe
65. must be entered before being allowed to 5 8 OP access no changes can be made to proceed configuration and passwords cannot be changed 0 View only access to all settings This appendix contains instructions for setting passwords in the configuration section of the menu 2 Access to all settings This gives the Daily usage of the analyzer by the operator does not sang pro erant password security is not enabled require knowledge of setting passwords in the Passwords can be changed Usage configuration section since all passwords are installation management entered by selecting PASS directly from the main menu Table 10 Security access levels ENTERING A PASSWORD With security enabled select PASS from main menu The analyzer will display 0000 Use the arrow keys to display your level 1 or level 2 password then press ENTER The program will display good followed by your access level before returning to the main menu If an incorrect password was entered the program displays bAd instead Refer to illustration 30 flow chart to determine how the program validates a password You will now have level 1 or level 2 access for as long as you are working with the analyzer The access level will automatically be restored to level 0 after no key has been pressed for 15 minutes This 15 minute timeout will also return to display the main sample It is good practice to return the analyzer to level 0 access or level
66. n Selectable NaOH 5 HCl or NaCl Automatic 1000 RTD Auto 10 0 C to 210 C 14 0 F to 410 F Manual 10 0 C to 210 C 14 0 F to 410 F 0 001 to 100 0 cm Cell constant x100 1000 10 000 or x 100 000 3 access level security partial and or all settings may be protected via 3 and or 4 digit security code Two independent assignable programmable configurable failsafe NO NC or auto range BCD alarm relays SPDT Form C rated 10 A 115 V 5 A 230 V 5 position BCD contact closure Single PID optional standard pump pulser or time proportional Two continuous assignable programmable 4 mA to 20 mA or 0 mA to 20 mA outputs isolated max load 600 Convertible from 1 VDC to 5 VDC or 0 VDC to 5 VDC Via RS485 bidirectional serial data port require IC Net 2000 software es 455 1 2 WWW Jccontrols com um 455 212 IC Controls INSTALLATION INSTALLATION Analyzer Mounting The conductivity sensor is typically supplied with at least a 1 5 m 5 ft lead as standard The 455 analyzer should be kept within the sensor lead length and mounted on a wall ideally at eye level Position the analyzer to allow the sensor still connected to the analyzer to be removed and the electrode tip placed in a beaker on the floor for cleaning or calibration Assume the safest place for the beaker is on the floor the service person stands on Horizontal separation between rows of analyzers should allow for electr
67. n air Insulation value should exceed 1 megaohm if sensor If the sensor is OK then substitute resistors for the sensor to test the wiring and the analyzer If the problem persists with the resistors in place then it is an analyzer problem Use the following formula or consult the table below for resistance values to use cell constant X 10 resistance uS cmof solution at 25 C If the sensor tests OK i e no shorts as per above test procedures and the analyzer and wiring work OK with substitute resistors as in table 9 but the Err message and E1 6 still occur when the analyzer sensor are hooked up and placed in service then the conductivity is too high for the cell constant used Resolve by determining the actual conductivity and selecting a new conductivity sensor with the correct cell constant Elevated readings on low conductivity The analyzer reads high at the low end of the range In some cases the analyzer will give a low reading even with the conductivity sensor in air Large zero signals are indicative of a wiring problem Look first at shielding between leads and ensure the shield is connected to the analyzer shield terminal rather than electrical ground Other known causes include incorrect cable or cable lengths too long for the application Where the elevated zero is small it 15 likely due to cable resistance capacitance and can be zeroed out using the air zero calibration procedure Condu
68. nd or manually adjust the cell constant by selecting cond CELL 1 from the menu b The sensor condition can be verified by measuring the concentration of a second standard Rinse the sensor surface with deionized water and then measure the concentration of the second standard refer to step 4 If the analyzer reads correctly the sensor condition is good If the analyzer does not read correctly the sensor may not be responding properly and may need to be cleaned C It is possible that electrical pickup may cause an erroneous reading such as an elevated zero with the sensor in air Normally an air calibration for zero is only needed if the sensor has been replaced CAUTION To get an accurate air calibration the sensor must be completely dry for zero air calibration Calibration by Grab Sample The grab sample technique is quicker and easier if the sensor is not easily accessible This procedure describes how to calibrate the analyzer without removing the sensor out of the process The procedure requires that the sample be measured using a second analyzer Typically a laboratory analyzer is used to determine the actual conductivity of the sample Obtain the following materials a a second conductivity analyzer b sensor of known constant c calibration standards d a clean beaker for taking a sample e acalculator 2 Calibrate the second conductivity unit 3 Record the cell constant of the sensor being used with t
69. nel Second 4 mA to 20 mA analog output channel Set password 1 operator access Set password 2 complete access Enter password to change access level Analyzer conductivity input range selection Range number Real time clock Seconds Real time clock setting Serial communications menu Setpoint Select manual temperature compensation Start internal data log Stop internal data log Characterization table Display setting of units Year Real time clock setting WWW iccontrols com Page 49 GLOSSARY IC Controls GLOSSARY Cell constant describes enclosed volume between electrodes in the conductivity sensor Units are cm Higher cell constants produce higher analyzer ranges lower cell constants produce lower ranges Conductivity the amount of electrical current that flows through a liquid Generally reported as microsiemens per centimeter uS cm millisiemens per centimeter mS cm EPROM Erasable Programmable Read Only Memory The EPROM chip holds the program which determines the functioning of the 455 analyzer Replacing the EPROM chip with a chip containing a new or an updated program changes the way the analyzer functions The EPROM chip is programmed by the manufacturer Hysteresis reading at which an alarm is turned on is not the same reading at which the alarm is turned off again This phenomenon is referred to as the hysteresis LED Light Emitting Diode LEDs are used as on off indicators on the front panel of the 455
70. nu The Illustration 29 Configuration menu display will flash do Nothing will happen if you press CANCEL or SAMPLE The analyzer will re initialize only when the user presses ENTER Password Security The factory default is no security No password security should be necessary if you are the only user and no protection of settings is needed Password security should be implemented for critical applications where program settings may only be changed by authorized personnel For minimal security IC Controls advises that the user set a level 2 password Leaving the level 1 password at 000 gives the operator complete access to all areas of the program but does not allow settings to be changed in the configuration menu With minimal security in place unauthorized users are prevented from enabling password security Appendix A describes how to enable or disable security Temperature Input Calibration Refer to the Electronic Hardware Alignment Alignment of Temperature Input Circuit section for the procedure on calibrating the temperature input Page 42 WWW iccontrols com um 455 212 IC Controls TROUBLESHOOTING TROUBLESHOOTING When trying to determine what the problem is with a conductivity loop there are a few simple steps to follow Isolating the Problem FIRST Write down the symptoms a conductivity reading b temperature reading c conductivity cell constant in analyzer d sensor cell constant on the label SECOND Sepa
71. o 500 0 to 50 0 to 5 000 0 to 50 000 1 0 0 to 1 000 0 to 100 0 to 10 000 0 to 100 000 2 0 0 to 2 000 0 to 200 0 to 20 000 0 to 200 000 5 0 0 to 5 000 0 to 500 0 to 50 000 0 to 500 000 10 0 0 to 10 000 0 to 1 000 0 to 100 000 0 to 1 000 000 20 0 0 to 20 000 0 to 2 000 0 to 200 000 0 to 1 000 000 50 0 0 to 50 000 0 to 5 000 0 to 500 000 0 to 1 000 000 Note use over range with caution Some sensor designs may limit when used on over range and may not reach the maximum shown Table 2 Cell constant usable ranges Page 18 WWW iccontrols com um 455 212 IC Controls CONDUCTIVITY MEASUREMENT Displayed Conductivity Units When the analyzer is reading conductivity as microsiemens and the conductivity goes above 9 999 uS cm the analyzer shows Err instead of a reading Internally the analyzer is still calculating the conductivity reading correctly but it cannot be displayed properly When this condition occurs CA1 9 will appear in the error menu Conductivity can be displayed using either uS cm or mS cm units where 1 5 1 000 5 Normally it is best to display the conductivity using uS cm units for maximum resolution and to switch to millisiemens per centimeter mS cm only if the sample exceeds 9 999 uS cm By changing the display units a reading of 9 000 uS cm would change to 9 00 mS cm By default the analyzer reads in uS cm To change the displayed conductivity units edit the setting in cond unit The options ar
72. o select imperial units for the analyzer select unit from the configuration menu then go into edit mode and change the C setting to F Input Damping The conductivity and temperature measurements can be damped to provide the user with a means to alleviate rapidly varying or noisy signals The available damping range is 3 5 to 99 s with 0 there would be no damping and each reading the analyzer made would be used to directly update the display and 4 mA to 20 mA output The factory default of 5 s adds the next four seconds worth of readings to the first and divides by five this provides a fast response Selecting 99 s adds the readings for 99 s and divides by 99 providing smooth damping out of turbulent readings Any selection between 3 s and 99 s can be made Select CONF in from the menu Use the up or down arrow key to select the input to be adjusted then select the dA frame Press ENTER to edit the input damping to the selected seconds Press ENTER to leave edit mode Real Time Clock The analyzer clock is used for internal date time stamping of system events and the internal data log Both the system events and the internal data log are accessed using the IC Net Intelligent Access Program which 15 available as option 35 Analyzers purchased with option 34 have a real time clock which will maintain the correct time and date even when the analyzer power is turned off Page 16 www iccontrols com um 455 212 IC Controls COND
73. ode leads which need periodic replacement and the electrical conduit IC Controls recommends a minimum separation of 10 cm 4 in between rows columns As standard the 455 comes with four internal 0 43 cm 0 17 in holes for surface mounting screws spaced 18 8 cm 7 41 in wide and 8 8 cm 3 47 in high Case dimensions are 20 cm x 12 cm x 7 5 cm w h d or 7 87 in x 4 72 in x 2 75 in w h d as shown on drawing D4830022 Pipe mounting kit option 8 for 5 cm 2 in pipe P N A2500255 is shown on drawing 04950053 It may also be used to surface mount the analyzer by removing the 2 inch U bolts and using the holes in the mounting plate for wall studs using customer supplied studs The mounting plate dimensions are 20 3 cm x 21 6 cm 8 in x 8 5 in with elongated U bolt holes Panel mounting kit option 9 P N A2500201 is shown on drawing D4950054 It requires a customer supplied panel cut out 20 6 cm 8 1 in wide x 12 2 cm 4 8 in high with two 0 4 cm 0 15 in screw holes centered 22 6 cm 8 9 in apart and 6 1 cm 2 4 in below top of cutout The panel bezel dimensions are 24 1 cm x 15 9 cm 9 5 in x 6 25 in Wiring Power for the 455 analyzer is 115 230 VAC 10 single phase 50 60 Hz and 0 25 A Connections are made at TB400 inside the instrument enclosure refer to drawing D5920093 The microprocessor requires a suitable ground to ensure stable operation A power line with the third wire connected to earth ground should be adequa
74. om the date of installation or eighteen 18 months from the date of shipment from IC CONTROLS whichever is earlier when used under normal operating conditions and in accordance with the operating limitations and maintenance procedures in the instruction manual and when not having been subjected to accident alteration misuse or abuse This warranty is also conditioned upon calibration and consumable items electrodes and all solutions being stored at temperatures between 5 C and 45 C 40 F and 110 F in a non corrosive atmosphere CONTROLS consumables or approved reagents must be used or performance warranty is void Accessories not manufactured by IC CONTROLS are subject to the manufacturer s warranty terms and conditions Limitations and exclusions Industrial electrodes and replacement parts are warranted to be free from defects in material and workmanship for a period of three 3 months from the date of installation or eighteen 18 months from the date of shipment when used under normal operating conditions and in accordance with the operating limitations and maintenance procedures given in the instruction manual and when not having been subjected to accident alteration misuse abuse freezing scale coating or poisoning ions Chemical solutions standards or buffers carry an out of box warranty Should they be unusable when first out of box contact IC CONTROLS immediately for replacement be considered fo
75. or cause major upsets to ion flow and result in large errors in the reading b If the analyzer is not reading on scale it may be because the automatic ranging is OFF and the wrong range has been manually selected Refer to Configuration of Program section 5 Select cond CAL std from the menu and press SELECT Edit the displayed standard value to that of the standard you are using in mS cm or uS cm depending on the setting of cond unit 6 Press SELECT to start the calibration The analyzer will display a flashing concentration reading From here on the calibration process is automatic the analyzer will wait until the reading has stabilized then calculate the cell constant using the temperature compensated value of the conductivity standard The display stops blinking and shows the conductivity of the standard upon completion of calibration NOTE a It is possible to repeat or restart the calibration at any time Simply press CANCEL then SELECT to restart or to repeat the calibration b If a problem is detected during calibration a caution or error message will be displayed Refer to Error Messages section 7 The conductivity sensor and analyzer pair are now calibrated Used conductivity standard should be discarded because exposure to air and contamination causes the conductivity value of standards to change um 455 212 www iccontrols com Page 21 CONDUCTIVITY CALIBRATION IC Controls NOTE a You can inspect a
76. proximately 1000 uS cm 10 uS cm 6 To check for general performance place the sensor in 100 uS cm standard The display should read approximately 100 uS cm 5 uS cm 7 Before placing analyzer into operation verify settings to ensure that they coincide with the intended setup Refer to Appendix D Default Settings section For the 4 mA to 20 mA output set high limit and low limit 8 Set preference for temperature units as C or F in CONF unit 9 Set desired input signal damping if known default is 5 seconds 10 Install password security if desired 11 The unit is now ready for field installation Page 10 www iccontrols com um 455 212 IC Controls INSTALLATION NOTICE OF COMPLIANCE US This meter may generate radio frequency energy and if not installed and used properly that is in strict accordance with the manufacturer s instructions may cause interference to radio and television reception It has been type tested and found to comply with the limits for a Class A computing device in accordance with specifications in Part 15 of FCC Rules which are designed to provide reasonable protection against such interference in an industrial installation However there is no guarantee that interference will not occur in a particular installation If the meter does cause interference to radio or television reception which can be determined by turning the unit off and on the user is encouraged to try to correct the interference by
77. put Illustration 20 shows the conductivity level decreasing with no resolution at the low levels The upper graph of illustration 19 depicts the 4 mA to 20 mA staying within 10 to 100 of scale by switching ranges in output 1 The lower graph shows the 4 mA to 20 mA of output 2 96 OUTPUT 1 TIME reflecting the range effect on output 1 Illustration 20 Output without range switching Page 34 www iccontrols com um 455 212 IC Controls 4 mA TO 20 mA OUTPUT SIGNALS To achieve results similar to those in illustration 19 use the settings in Table 5 Setting Output 1 Output 2 in cond ArnG ON OF on on LO 0 1 HI 500 5 unit 1E 3 AmG YES Table 5 Output settings Using the Alarm Contacts The alarm contact method uses the two alarm contacts to distinguish between ranges With two contacts there are four possible combinations The on off combinations for the A and B contacts are shown in Table 6 To use the alarm contacts for range indication set CONF AL AL A Func to rnG While the relay contacts are being used for remote range indication of output 1 range the alarms will continue to function ie LED indication and alarm caution messages in the SAMPLE frame plus IC Net alarms It is not possible to use the relay contacts for alarm indication and range indication at the same time Using the Second 4 mA to 20 mA Output A more versatile method for indicating the range number for outpu
78. put 2 Input to be transmitted conductivity temperature Low setting 0 00 0 0 High setting 1000 100 0 ON OFF switch ON ON Units 1E 6 uS cm Alarms Alarm A Alarm B Input for alarm conductivity conductivity Alarm function High Low ON OFF switch OFF OFF Set point 900 100 Differential 10 0 10 0 Units uS cm uS cm Global units metric units temperature in degrees Celsius Alarm contacts Configured normally open Security Not enabled Temperature compensation Automatic TC using temperature input Linear temperature compensation constant set to 2 0 change per degree Celsius Input signal damping Signal damping for Conductivity 5 seconds Temperature 5 seconds Page 56 www iccontrols com um 455 212 IC Controls Appendix E Serial Output Appendix E Serial Output RS485 can be used to send ASCII format serial pH and temperature default frequency is 60 seconds or aS a two way communication port for remote operation if an interface format program 1s available No special software 15 needed on the computer to receive ASCII data The ASCII data port function can be turned on off and controlled from the internal data log menu both ASCII and serial must be on Data transmitted by the analyzer is in simple ASCII format No special software is needed on computer to receive the ASCII data only an ASCII terminal program such as Hyperterminal on MS Windows systems The 656 continuous output consists of four da
79. r warranty the product shall have RA Return Authorization number issued by IC CONTROLS service department for identification and shall be shipped prepaid to IC CONTROLS at the above address In the event of failure within the warranty period IC CONTROLS or its authorized dealer will at IC CONTROLS option repair or replace the product non conforming to the above warranty or will refund the purchase price of the unit The warranty described above is exclusive and in lieu of all other warranties whether statutory express or implied including but not limited to any implied warranty of merchantability or fitness for a particular purpose and all warranties arising from the course of dealing or usage of trade The buyer s sole and exclusive remedy is for repair or replacement of the non conforming product or part thereof or refund of the purchase price but in no event shall IC CONTROLS its contractors and suppliers of any tier be liable to the buyer or any person for any special indirect incidental or consequential damages whether the claims are based in contract in tort including negligence or otherwise with respect to or arising out of the product furnished hereunder Representations and warranties made by any person including its authorized dealers distributors representatives and employees of IC CONTROLS which are inconsistent or in addition to the terms of this warranty shall not be binding upon IC CONTROLS unless in writ
80. r insert sensor in sample 3 Power up the 455 analyzer 4 The startup procedure will begin by alternately flashing tESt and while performing memory tests 5 The analyzer will display in sequence the analyzer model number in this case 455 and the program version number eg 2 10 6 The display test lights each of the implemented display segments in turn At the same time each of the LEDs will be lighted turn 7 If the analyzer passes all the tests then the hardware is functioning properly and the analyzer will proceed to display the conductivity reading 8 If the analyzer displays Err this indicates that the conductivity input is off scale The error LED will be lit as long as an input is off scale An off scale error can indicate that the sensor is not in solution is off scale or is not connected properly If the error LED remains lit press the ERROR key to see what errors have been detected by the analyzer 9 After completing the above steps the analyzer is now in normal operational mode Analyzer settings and parameters can be viewed and or changed at any time using the keypad Refer to 455 Menus on page 3 to 5 Start up Settings The 455 analyzer default assumes a sensor with a cell constant of 1 0 cm which is stored in its memory By default the analyzer displays conductivity The cell constant of the sensor must match the cell constant stored in the analyzer memory If a cell constant other
81. r that input Caution messages do not cause a fault alarm To use an alarm as a fault alarm select FUNC from the alarm menu then select To enable the alarm make sure the on off switch is set to on Also set the input in the alarm menu to the desired input either conductivity or temperature The set point and differential for the alarm have no effect when the alarm is used as a fault alarm Using Alarms for On Off Control The alarms can also be used for process control the alarm contacts will then function as on off signals for switches controlling a valve pump motor etc The set point determines the control point of the system and the setting of the differential controls the amount of corrective action before a controlled shut off occurs Examples of high and low control using the alarms are shown in the following illustrations LOW CONTROL control off differential sample SETPOINT control on time Illustration 27 Low control HIGH CONTROL control on SETPOINT differential sample L 1 LLLI LL d control off time Illustration 28 High control um 455 212 WW iccontrols com Page 41 CONFIGURATION OF PROGRAM IC Controls CONFIGURATION OF PROGRAM The 455 analyzer has been designed with ease of use in mind In most cases the analyzer factory configuration will handle the application and no configuration of the analyzer i
82. rate the sensor from the analyzer so that the problem can be isolated Disconnect the sensor from the analyzer at the terminal block it is much easier to test and determine if the problem is in the conductivity sensor or in the analyzer this way THIRD See if the analyzer reads correctly without the sensor a With sensor leads removed the analyzer should read 0 uS cm or mS cm depending on units selected or close to zero b Insert a 1 OOO ohm 1 resistor across the sensor cell connection and a second one across the sensor TC connections NOTE the temperature reading is approximately 0 C or 32 F then the analyzer looks alright c Change the analyzer cell constant setting to 1 00 and TC to manual set at 25 C NOTE f the conductivity reading is approximately 1 000 uS cm or 1 00 mS cm then the analyzer looks alright d If the reading is far from 1 000 uS cm perform a calibration with Cal set to 1 000 uS cm and note the calculated conductivity cell constant in CELL e When finished set TC back to auto and remove both resisters FOURTH Problem isolated If the CELL 15 within 10 of 1 00 then the analyzer appears OK If the analyzer is OK then problem is likely with the sensor If the CELL is greater than 10 out the problem may be in the analyzer Troubleshooting Hints Slow Response Typically due to excessive sample line length and low flow producing long sample transport lags Resolve by ad
83. rately Air Zero Calibration It is not necessary to repeat an Air calibration every time a regular calibration is performed An air calibration should be performed anytime a new sensor is installed When a sensor is in air the conductivity measured by the sensor is expected to be zero It is not uncommon to find some small conductivity signal with the dry sensor in air or even with no sensor connected at all This measurement may be attributed to background noise lead wire pickup antenna effect or grounding problems The air calibration is designed to subtract the small errors of this interference signal from the real measurement in order to give a true zero reading 1 Perform a zero calibration any time a new sensor is installed 2 Ensure that the sensor is dry before zeroing The analyzer should be reading a low conductivity value 3 From the menu select cond Air and press SELECT The analyzer will show a flashing do 4 When the sensor is ready to be calibrated press ENTER 5 Press SAMPLE With the sensor still dry and in air the conductivity should read 0 00 uS cm Potential problem When you press ENTER with the flashing do displayed the analyzer will not perform the zero calibration but will show the current range number eg rnG 2 For a zero calibration to be successful the analyzer needs to be on range 4 the range with the highest gain If the analyzer is not on range 4 the sensor is likely not in air or
84. rature reading Re insert the 1 000 1 resistor and adjust VR202 until the display reads 0 0 C 0 1 C 7 Re insert the 1 74 1 resistor and adjust VR203 until the display reads 195 0 0 2 C um 455 212 www iccontrols com Page 45 ELECTRONIC HARDWARE ALIGNMENT IC Controls Software Calibration To do a software calibration of the temperature input the correct temperature needs to be known 1 Select CONF in C CAL from menu The actual temperature as measured by temperature sensor will be displayed Edit the displayed value to the known correct temperature Press ENTER to leave edit mode then SELECT to start the calibration The current temperature will be shown using a flashing display When the input appears to be stable press ENTER to set the new temperature The software offset for the temperature input will be adjusted automatically The calculated offset in degrees Celsius can be viewed by selecting CONF in C OFFS from the menu Whenever the hardware alignment is correct the offset will be 0 0 The displayed offset can be edited Calibration of 4 mA to 20 mA Outputs Use one of the following two approaches to get the analyzer to output the desired current level and then make electronic adjustments to calibrate the output Approach 1 Simulated 4 mA to 20 mA Output Self Calibration l 4 Select cur from the output 1 menu to display the present o
85. s LED s 2 alarms A and auto error Case Dimensions 12 0 cm H x 20 0 cm W x 7 5 cm D 4 7 in H x 7 9 in W x 3 0 in D Weight 1 1 kg 2 5 Shipping Weight 2 3 kg 5 0 Ib Shipping Dimensions 30 cm x 23 cm x 23 cm 12 in x 9 in x 9 in Environmental Data PROPERTY CHARACTERISTIC Temperature Operational 5 0 C to 45 C 41 0 F to 113 F Storage 10 0 C to 55 C 14 0 F to 131 F Relative Humidity 95 maximum non condensing Environment Ratings Housing IP65 Nema 4X Pollution Degree 2 Installation Category II Electrical Ratings 115 230 VAC 0 25 A 50 60 Hz Electrical Requirements 115 230 VAC 10 50 W 455 1 2 um 455 212 www iccontrols com Page 7 INTRODUCTION Specifications PROPERTY Accuracy Precision Response Time Temperature Compensation Cell Constant Range Auto Range Multipliers Security Alarms Controls Outputs Communication Page 8 IC Controls Operational Data CHARACTERISTIC Conductivity 0 2 of measured range Temperature 0 1 C Conductivity 0 1 or 2 digits whichever is greater Temperature 1 digit 0 1 C 90 within 5 s default function of flow and temperature Damping adjustment 3 s to 99 5 Compensation Type Function Characteristic Linear Default 2 per C Adjustable 0 1 to 5 0 per C None USP 23 lt 645 gt High Purity Selectable Neutral acidic basic ASTM D1125 or latest Concentratio
86. s necessary Relay Contacts NO NC Cnt The 455 program by default assumes relay contacts are wired normally open A normally open dA input damping sec relay contact will open if there is no alarm and will 5 be closed by the microprocessor when there is Auto alarm condition If the program configuration and the wiring do not match the incorrectly configured relay it will generate an alarm when there is no alarm and vice versa 100 scale 10 scale 1 scale 0 1 scale Auto Ranging Conductivity WEB The analyzer program allows the user to select cat oe OFFS Offset C either manual or automatic ranging By default the analyzer will automatically switch between ranges onor pm Refer to the section entitled Automatic Range cond Switching for further details Re initializing All Settings metric or imperia Occasionally it may be desirable to reinitialize all of the program settings to bring them back to default Executing an initialization will cause the year j 25058 analyzer to reset all the program variables and uj settings to factory defaults um Parameters such as the output signal settings alarm settings and the program configuration will need to E hund 99 be re entered if they were different from the factory default settings select CONF init ALL from the me
87. sed can be changed By default the main input 15 cond Change StbY the default in CONF in dFLt Refer to the Configuration of Program section for further details Illustration 7 Main menu um 455 212 www iccontrols com Page 13 EASY MENU IC Controls Arrow Keys The four arrow keys on the keypad are used to move around in the menu Example Press SAMPLE to make sure that display is at home base Press the Right arrow key One of the prompts the column starting with out will be displayed Use the Up or Down arrow keys to display the prompt above or below If the prompt at the top or the bottom is displayed the program will loop around Press the Up or Down key until AL 15 displayed Press the Left key to return to the sample display Press the Right key again and AL will be displayed AUTO and MANUAL Keys The AUTO and MANUAL keys are used to implement the alarm override feature on analyzers that do not use the PID option Refer to the Alarm Override heading in the Alarm Functions section for a description of these key functions MANUAL ENTER SAMPLE lt o AUTO CANCEL SELECT Illustration 8 Analyzer keypad Standby Mode In standby the alarms will not function and the 4 mA to 20 mA outputs will go to 4 00 mA When SAMPLE is pressed the inputs will show StbY The analyzer will not resume normal operations until t
88. t remotely is to use output 2 The following settings for output 2 will transmit the range number in ArnG ON OF on Range Output 1 Output 1 Output 2 Relay Range LO 0 1 LO 4 LO 4 Number Full Scale Conductivity mA Contacts Number 4 4 HI 1 0 mS cm OUT2 OFF 4 00 4 00 4 00 4 00 1 100 500 4 00 A 0 B 0 1 8 00 4 00 20 00 20 00 2 10 50 8 00 A 0 B 1 2 12 00 9 33 14 67 16 00 3 1 0 5 0 12 00 A 1 B 0 3 16 00 14 67 9 33 12 00 4 0 1 0 5 16 00 A 1 1 4 20 00 20 00 4 00 8 00 Table 6 Example of range switching Table 7 Using output 2 for range indication Also set the HI and LO parameters to indicate which values represent 4 00 mA and 20 00 mA Table 7 shows the relationship between the range number and some of the possible LO HI settings um 455 212 www iccontrols com Page 35 4 mA 20 mA OUTPUT SIGNALS IC Controls Output Characterization The 455 analyzer has user programmable output characterization that 15 off by default but can be turned on by the user Output characterization could be used to provide more accurate control over an output device such as a non linear ball valve the output could be customized to meet specific application needs A 21 point output table allows the user to specify the behavior of the output in increments of 5 of the uncharacterized output signal The table links uncharacterized output values to desired output values allowing a wide variety of non linear be
89. t PASS from the main menu again Change the displayed value to 0001 which is the level 1 password Press ENTER The analyzer will display good followed by ACC 1 indicating that the password is valid and that we now have level 1 access Try changing the output low setting again You will find that this time we can go into edit mode unhindered Select PASS from main menu again Enter the level 2 password which 15 0002 We are going to set the level 2 password to 0000 again to disable password security Password 2 is found in the configuration menu and therefore requires level 2 access before it can be accessed Select CONF PAS 2 from the menu Press ENTER with 0000 displayed Both passwords are set to 0000 again and password security is disabled Page 52 www iccontrols com um 455 212 IC Controls ENTER PASSWORD Appendix A Security Illustration 30 Password logic um 455 212 www iccontrols com PASSWORD YES 2 ENTERED NO PASSWORD YES 1 ENTERED NO 0000 YES ENTERED NO ACCESS ACCESS ACCESS ACCESS LEVEL 0 LEVEL 0 LEVEL 1 LEVEL VIEW ONLY VIEW ONLY OPERATOR COMPLETE DISPLAY DISPLAY DISPLAY DISPLAY bAd good good ACC O ACC O ACC 1 ACC 2 Page 53 Appendix B Output Characterization IC Controls Appendix B Output Characterization
90. ta fields containing input values separated by commas Each line of data is terminated by a linefeed newline Comma separated fields make it easy to import the data into other programs for analysis for example into a spreadsheet Wiring and Enabling 1 It is good practice to first turn off the analyzer and the computer before connecting a serial cable 2 Wire the RS485 cable into the terminal block located on the display board Refer to illustration 31 Connect pinl RD A to pin TD A and connect this to terminal A on TBI in the analyzer Connect pin2 TD B to pin 9 RD B and connect this to terminal B in the analyzer Connect earth or shield at one end only 3 Turn on the analyzer and the computer 4 Configure the analyzer for the desired baud rate Select SEr baud from the menu Baud rates from 1200 to 38400 baud can be selected the default is 9600 baud For RS485 systems with automatic send data control the lowest baud rate that can be used 1s 9600 5 To enable serial transmission by the analyzer set the serial ON OFF switch to ON select SEr ON OF and edit to display on 6 Turn on ASCII output select ILOG ASCII and edit to display on DB 9 Connector TB1 9 RED EARTH SHIELD SHIELD Pin Assignments Pin 1 RD Analyzer Pin 2 TD 7173 2 Pin 3 TD A EARTH Pin 5 COM N Pin
91. te however a local earth rod may prove more fitting There are three 2 0 cm 0 875 in holes for 0 5 inch conduit in the bottom of the enclosure Controls recommends that AC be brought in through the right hand entrance for power and alarms 4 mA to 20 mA and digital low voltage wiring be brought in through the center entrance and sensor leads be passed through the left hand entrance Conduit should be flexible watertight and sealed using a gasket to maintain environmental integrity within the enclosure Connect the two relay alarm contacts Alarm A contact TB300 Alarm B contact TB301 Connect the two isolated 4 mA to 20 mA outputs Output 1 contact TB303 Output 2 contact TB304 um 455 212 www iccontrols com Page 9 INSTALLATION IC Controls Sensor Mounting It is recommended that the sensor be located as near as possible to the conductivity analyzer to minimize any effects of ambient electrical noise interference Flow sensors can be in any orientation but should be mounted tip down at an angle anywhere from 15 degrees above horizontal to vertical 15 degrees above horizontal is best because air bubbles will rise to the top and debris will sink both bypassing the sensor Submersion sensors should not be mounted where a lot of air bubbles rise in the tank they will cause spikes in the conductivity readout If an air bubble is allowed to lodge in the sensing tip electrical continuity between the electrodes may be disrupted
92. tput 2 terminal TB304 Measure output 1 zero at TP301 pin 8 of U304 while output 1 is outputting 4 00 mA The reading should be between 0 870 VDC and 1 250 VDC Adjust 2 voltage with VR300 Change analyzer output to 20 00 mA switch multimeter to mA and measure terminal of output 1 at TB303 and adjust VR301 so that the current reads 20 00 mA Return analyzer output to 4 00 mA and trim actual output to 4 00 mA using VR300 Check again at 20 00 mA and repeat adjustments until satisfied Measure output 2 zero at TP300 pin 7 of U304 while output 2 is outputting 4 00 mA The test point should read between 0 870 VDC and 1 250 VDC Adjust 2 zero voltage with VR302 Change output at output 2 to 20 00 mA switch multimeter to mA and measure terminal of output 2 at TB304 and adjust VR303 span pot until the current reads 20 00 mA NOTE Zero and span are very wide range adjustments which show small interactions Recheck zero and span to confirm good calibration If so desired all software settings can be returned to factory default condition by following the procedure in Configuration of Program Re initializing All Settings Testing Relay Outputs l Relay output operation can be verified by testing for contact closure or continuity at each relay To activate a relay select CONF NO NC AL A from the menu Press ENTER to go into edit mode then press the Up or Down arrow key to change the nor
93. utput current in mA The display will be updated as the output current changes based on the input signal and the program settings To simulate a different 4 mA to 20 mA output signal press ENTER to select edit mode Use the arrow keys to display the desired output needed for testing the output signal Press ENTER to select the displayed value The output signal will be adjusted to put out the desired current This process can be repeated as often as necessary to output different signal levels The output signal is held at the displayed level until the program leaves this menu selection Make calibration adjustments while the analyzer shows the output at 20 00 mA Repeat the above steps for output 2 Approach 2 Use Voltage Source to Adjust Input This faster calibration approach requires a voltage source for the input l 2 To calibrate output 1 set 1n C Input a low enough signal to cause analyzer to indicate Err the analyzer will output 4 00 mA Reverse the polarity or input a high enough signal to cause the analyzer to indicate Err analyzer will output 20 00 mA Repeat step 1 for output 2 Tip Both outputs can be simultaneously calibrated if you set in C for both inputs Page 46 www iccontrols com um 455 212 IC Controls ELECTRONIC HARDWARE ALIGNMENT Adjusting Electronic Calibration 1 The outputs are isolated from main circuit therefore measurements are made with common the ou
94. ying conductivity The program will safely abort whatever it was doing at the time and return to displaying the conductivity reading A The conductivity display is the default sample display for the analyzer The analyzer s inputs conductivity and temperature are arranged underneath each other at the left hand side of the menu Use the Up or Down arrow key to display each of the readings in turn 102 5 25 0 Illustration 6 Home base Display Features Main Menu play MEM 1 The analyzer has a built in timer which returns the program to displaying cond conductivity if no key is pressed for 15 minutes This time out has the same effect as pressing the SAMPLE key If security has been enabled then the time out will change the access level back to 0 or 1 automatically which gives the user read only access The user will have to enter an appropriate password to go to a higher access level out 2 When the sample value is displayed pressing the Left arrow key will show which of conductivity or temperature is displayed Pressing Right arrow key displays the sample reading again SEr 3 Each input can be turned off and thereby effectively disappear from the menu if it is turned off in the configuration menu To change _CONF configuration refer to the Configuration of Program section PASS 4 The main sample ie the input that is displayed first when the SAMPLE key is pres

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