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455-63 User Manual (Ultra-Pure Water)

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2. 4 PANEL MOUNTING KIT CENTERED 8 90 INCH APART 655 455 ETC 3 MOUNTING SCREWS 6 32 PE enn 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 from 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 mai
3. 12 Sidrt up Se 65 a 12 EASY MENU 13 Remembers Where You 13 Home Base Press Sample 13 Display Feature sengen 13 PRET OW IN CVS EU Ene 14 AUTO and MANUAL 14 Standby 14 EDIFMODE 15 Temperature E 16 Input 16 Real Time i 16 CONDUCTIVITY MEASUREMENT 17 What is conductiVlity 2 17 17 What is a Cell 17 Measurement Range ie reside orte ben apes 18 Manual Range 18 Cell Constant and 18 Guide to Cell Constant Usable Ranges 18 Displayed Conductivity Units 19 CONDUCTIVITY CALIBRATION 20 Selecting a Standar Gi es 20 Calibration Using Standards 21 Calibration by Grab Sample 22 Air Zero iere onere nens 23 Temperature Compensation 24 Conductance Data for Commonly Used Chemicals 26 ERROR MESSAGES 2 Acknowledging an Error Message 27 Error Message
4. d as shown on drawing 04830022 Pipe mounting kit option 8 for 5 cm 2 in pipe P N A2500255 is shown on drawing D4950053 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 adequate 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 IC 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
5. 600 000 BERNE A SE 500 000 eS SAH 1 1 1 3 4 4 1 11111 1111114 4 LI ET HERR 98 ETEC L 12 NN eee DT e 54 400 000 CHLORIDE k POTASSIUM 300 000 2276 Jee mri LER TT Ty SODIUM CHLORIDE EY BREESE RRR ERR RAAE TETIT EETTISET TTE 3 a LELEL LITLTTI D LAS ET HET LET LLLI HHH 4 LLLI HHHH X NESZ CODES LE 21111 TI EXT IET SESE E ROBB CURIE E H H CRT Be Reese A 11111 1111 11 11 E 11 41 11 ANANE LELLELTERL BE 111111 21111 8 4 5 44
6. ON OF on on LO 1 500 5 unit 1E 3 ArnG 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 output 1 remotely is to use output 2 The following settings for output 2 will transmit the range number in 2 ArnG ON OF on Range Output 1 Output 1 Output 2 Relay Range 0 1 LO 4 LO 4 Number Full Scale Conductivity mA Contacts Number HI 4 HI 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 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
7. 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 is 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 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 17 Chemical c Ine 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 again proceed to troubleshoot or replace the sensor 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
8. 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 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 suggesti
9. CALIBRATE CAL Std 100 display units 102 5 output hold Lair Go _ do air calibration CELL 1 0 98 cell constant 100 98 26 cell constant x 100 NONE Auto SEt compensation algorithm Linear Temperature Compensation CO AL Neutral NaCl sodium chloride 1 Cation strong acid HCI hydrochloric acid NAOH Strong base NaOH sodium hydroxide pure water formula PU FO 1125 ASTM 1125 LACE Later data 1994 125 0 1 linear TC constant decimal 1tcc 2 00 change C places for alarm 4 20 0 to 9999 QEC 0 0 to 999 9 0 00 to 99 99 rES megohm cm resistivity unit 1 3 mS cm conductivity conductivity Illustration Conductivity menu 455 63 Appendix www iccontrols com Page A 3 High Purity Water Measurement High Purity Water Measurement Overview The 455 63 configuration 15 intended for use with a 402 or 403 with a 0 01 cm cell constant It will measure the conductivity or resistivity of pure water samples below 10 uS cm in continuous flowing samples In order to know the conductivity of ultra pure water it is required to do accurate temperature compensation at very low conductivities e g condu
10. 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 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 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 the list If a 9 is displayed then the digit will loop around to show 0 then the digit will loop around to show 9
11. 1 c3 d O zm2 zum 5 5 809410 m uu n 0 1 70641 ay N 5 gt 925 vee 5 gt 2 2 gt 2 2 161681 g zhN3L LTEM y 123138 829 6 40103135 39NV3 0254 HH d o DIS 3 4 0 91 8 CWDAS 02 61 NIVN SSP 13 11 um 455 212 IC Controls DRAWINGS Display Component Locat D5980176 22955200 VECES UE ewm vwuvoorixwoae AvidSIU GSN Tado 20 opouo ol403U 90 0 04 86 c v 213 Ap iim ES RE i x 051 15 18851941 4 5452 9 OvdSIG 66015851 SSW 13 VIILEIWN VITIWIW 8S02E06W OOOOOOOOOOOOOOOO dW31 9 0d dW3L Z 0d V 40103735 JONVY 40103735 35NVy 4 0 915 dW3L 4 0 91 8 wav um 455 212 www iccontrols com Page 60 DRAWINGS 66002660 pesn 442 1 13000 OV OL 131 311 LON 04 007 PAR 940 9131934 ALlINVJUd LON
12. 00 111414 LL eerie AS GER 19 pru CLET 11111111111 111111 1111 ee 42111141 LETT amp SRR p SEE Pee 29 9 1 13141111 524 STE EAA ABR LIT TEL IE El D ELERT EER SS EAT 1 E YDROXIDE Cr BY WEIGHT EEE ZEA SRSA SARE SA 15 20 FH 10 Illustration 16 Conductivity uS cm vs Chemical concentration um 455 212 www iccontrols com Page 26 IC Controls ERROR 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 Error messages are numbered Errors 1 through 5 are identified as En e where is the input number and 15
13. 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 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 thro
14. OFF um T but the alarm LEDs continue to indicate alarm condition s Press the AUTO key to return to BLINK MANUALmode AUTO mode immediately and reactivate the relays If no key is pressed for 15 minutes the 15 minute timeout will return the alarms to ON AUTO mode 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 illustration 2 for the configuration menu Select CONF AL from the menu Delayed Activation Alarm relay activation by default is 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 in the process The delay time is programmable by the operator To change or view the delay time select dLA Y from the alarm menu The default value of 0 seconds is for immediate contact activation The delay time
15. 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 100 100 90 90 80 80 E _ 70 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 6380 90 100 0 10 20 30 40 50 60 70 80 90 100 in 96 uncharacterized in 96 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 55 12 80 60
16. 10 Security access levels ENTERING A PASSWORD With security enabled select PASS from the 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 f 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 level access if password 1 18 set to 70007 when you have finished using the analyzer This is accomplished by selecting PASS from 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 pass
17. 8 TIME potacs 0 0 01 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 1 has auto range available From the menu select out1 ArnG then edit the setting to show YES With auto range enabled the range currently being used can be determined by selecting out 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 output 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 0 reflecting the range in effect on output 1 Illustration 20 Output without range switching OUTPUT 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
18. SI 01 2 1 PV2 21 55040 AOLSISAY WHO 0017 LAJSNI NV 01 ONIAIM 01494490 0 1 243 MP JYNNYW 123135 21 0109 LON 5304 5 35 3I S IOHINOOjJ arr 0000026 N d 11893 U3JdUN3JNNDJ3a lddNS 015 9 CdN31 Kel eer CdN31 3SN3S ong mE One EI 81 2 412 GAIA IHM LHM 10241 002d 1 41 Page 61 www iccontrols com IC Controls 400 Junction Box Wiring D5920095 XOH ALONAY YHOSNAS um 455 212 DRAWINGS IC Controls D4830022 Mounting Dimensions 7 8740 3 4660 4 7240 20 1700 20 8750 C CONTROLS Orangeville Ontario Canada chk DIMENSIUNS 1 0 Page 62 www iccontrols com um 455 212 IC Controls DRAWINGS D4950053 2 inch Pipe Wall Mounting Kit 8 5000 ley CONTROLS Orangeville Ontario Canada a opp __ PIPE WALL MUUNTING KIT 692 699 ETC 1 1 um 455 212 www iccontrols com Page 63 DRAWINGS IC Controls 04950054 Panel Mounting 9 5000 8 9000 BEZEL 6 2500 20 8750 NOTES _ ky iate 8 CONTROLS 1 PANEL CUTOUT 8 10W X 4 80H INCH ne 5 TWO SCREW HOLES APROX 015 DIA SIDES 2 40 FROM
19. 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 14 100 4 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 0 temperature compensation factor 90 change per 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 changes 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 50 455
20. a chemical drain where waste is contained and treated before release NOTE 2 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 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 1100005 or for flow through sensors with internal passages seal one end to form a container inside the sensor body
21. blinking or on shows the alarm condition The status of the relay contact can also be determined at a glance as it 15 activated when the LED 15 on and deactivated while the LED is only blinking 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 Illustration 23 Alarm status alarm LEDs Page 38 www iccontrols com um 455 212 IC Controls ALARM FUNCTIONS 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 is on and the analyzer alarms will activate and deactivate the 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
22. by tapping or alternately raise lower the sensor to flush them out 4 With the conductivity cell centered and no air bubbles in the cell monitor the reading for stability then calibrate Note The reading may gradually change while the sensor equilibrates to the standard temperature With micro analyzers the program acts as an expert thermal equilibrium detector and flashes its reading until the temperature stabilizes Page A 10 IC Controls CONDUCTIVITY sensor beaker Keep centred at least 1 inch above bottom Illustration 8 sensor positioning select cond CAL std from the menu then change the displayed standard value to that of the standard you are using megohm cm uS cm or mS cm depending on the setting of cond unit Press Right to start the calibration The analyzer will display a flashing concentration reading From here on the calibration process 1s automatic Acting like an analyzer expert 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 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 ls detected during calibration a caution or error message will be dis
23. for 6 pack A1100163 10 000 5 conductivity standard 500 mL A11000163 6P for 6 pack A1100164 100 000 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 11000005 6 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 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 Output 2 Input to be transmitted conductivity temperature Low setting 0 00 0 0 High setting 1000 100 0 ON OFF switch ON ON Units 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
24. 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 writing 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 27 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 20 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 stand
25. 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 temperature Change this temperature to 29 56 With multimeter common on 200 terminal 2 sheild adjust to 4 85 VDC 0 005 VDC 202 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 descri
26. 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 inch diameter brush Plastic body sensors should be washed using a soft cloth ensuring all wetted areas are cleaned This will return their appearance 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 is 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
27. 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 15 OK then the 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 adding 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 I
28. 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 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 J box only A9120098 Terminal strip 6 CKT Interconnect cable to 400 interface 9200000 Conductivity cable 4 conductor with shield D5920095 Consumable Supplies 1400051 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 1 year supply 1100161 100 uS cm conductivity standard 500 mL 11000161 6 for 6 pack A1100162 1 000 uS cm conductivity standard 500 mL 11000102 6
29. 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 0 to 1 6 per C 2 bases 1 8 to 2 2 per C 3 Salts 2 2 to 3 0 per C neutral water 2 0 per C 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 IC Controls H Git EERTE ME RHM HM EE PEPE eee ery IDOL TEE 1 TR EE 5 8 FHE vs by weight relationships as well It clearly shows that there is no conductivity constant between clear from the graph that both Sulfuric Acid H SO and Nitric Acid HNO have unusual conductivity chemical combinations 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 is Conductance Data for Commonly Used Chemicals CONDUCTIVITY CALIBRATION eH COO aA BSED ESSEX 2 Se 12222245 8 80 2 5 5 SSSR 4101 1441 1196
30. 7 101 50 0 17269 5 791 55 0 20945 4 774 60 0 25140 3 978 65 0 29875 3 347 70 0 35164 2 844 75 0 41017 2 438 80 0 47438 2 108 85 0 54440 1 837 90 0 62046 1 612 95 0 70303 1 422 100 0 79303 1 261 Table ASTM 1125 data 455 63 Appendix www iccontrols com 5 0 0 01162 86 072 5 0 01659 60 266 10 0 02312 43 256 15 0 03150 31 751 20 0 04205 23 762 25 0 05512 18 143 30 0 07105 14 074 35 0 09022 11 084 40 0 11298 8 851 45 0 13970 7 158 50 0 17071 5 858 95 0 20637 4 846 60 0 24697 4 049 65 0 29280 3 415 70 0 34410 2 906 75 0 40110 2 493 80 0 46392 2 156 85 0 53276 1 877 90 0 60775 1 645 95 0 68908 1 451 100 0 77697 1 287 Table 2 Later data 1994 Page A 7 High Purity Water Measurement Solute Algorithm Selection The temperature compensation of high purity water changes depending on the chemistry of the traces of salts or impurities present in it To properly correct for this you should select the solute compensation algorithm that best matches the chemistry of the water you are measuring Examples a Cation Demineralizer effluent application would use the Acidic algorithm b Boiler water with treatment byproduct ammonia would use the Basic algorithm c Mixed bed polisher product water with only traces of salts left would use the Neutral salt algorithm compensation algorithm Linear Temperature Compensation NACL Neutral salt NaCl sodium chloride HCl Cation stro
31. Adjusts blinking digit downward or selects the next item from the list If a 0 is displayed 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 To 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 s to 99 s with 0 there would be no damping and each r
32. C 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 with uS 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 in air Insulation value should exceed 1 megaohm if sensor If the sensor 15 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 Q 2 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 o
33. 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 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 millisiemen
34. Off Control 41 CONFIGURATION OF PROGRAIML 42 TROUBLESHOOTINGTEL 43 Troubleshooting 43 ELECTRONIC HARDWARE ALIGNMENT 45 DISPLAY PROMPTS 49 9 50 Appendix 2 51 Appendix B Output Characterization 54 Appendix C Parts 1451 55 Appendix D Default Settings 56 Appendix E Serial 57 DRA WINGS 59 D5920093 Wiring amp Component Location 59 05980176 Display Component Location 60 05920095 400 Junction Box Wiring 61 04830022 Mounting Dimensions 62 04950053 2 inch Pipe Wall Mounting Kit 63 04950054 Panel Mounting Kit 64 INDUSTRIAL PRODUCTS WARRANTY 65 INDE quem X 66 Copyright 2006 IC Controls Ltd All rights reserved Page 2 WWW Jccontrols com um 455 212 IC Controls 455 MENUS Main Menu 1E 3 1E 6 Err See Internal Data Log Menu d Bie mam OY 19 display home base SAMPLE 9 r 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 t
35. Ranging Conductivity Willi CAL C F The analyzer program allows the user to select m either manual or automatic ranging By default the us analyzer will automatically switch between ranges emm Refer to the section entitled Automatic Range x cond Switching for further details Re initializing All Settings metric or imperia Occasionally it may be desirable to reinitialize all CHIP of the program settings to bring them back to default Executing initialization will cause the vear j analyzer to reset all the program variables and 2 settings to factory defaults Parameters such as the output signal settings alarm settings and the program configuration will need to SEC hund 99 be re entered if they were different from the factory default settings Select CONF init ALL from the menu 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 7000 gives t
36. USER MANUAL MODEL 455 63 ULTRA PURE WATER CONDUCTIVITY ANALYZER CONTROLS um 455 211 63 apdx Table of Contents 455 63 Ten A 2 High Purity Water Measurement A 3 VET VIEW c A 3 455 63 and ASTM D5391 99 A 4 63 Sensor A 4 Sensor WII ue nte IDEE A 5 Instrument Shop Test Startup A 5 Conductivity Display Units A 6 TC Auto 6 Pure Water Formula Selection A 6 ASTM 1125 Formula A 7 ater TG 7 Solute Algorithm Selection A 8 Star UP SEMIN 000546 04820554 A 8 PURE WATER CALIBRATION A 9 Selecting a standard A 9 Calibration using 100 uS cm Standard A 9 Instructions for 1400051 Low Range Cond Calibration Kit A 10 Calibration Using ASTM D 11 Calibration by Grab Sample A 11 Aur Zero Calibration A 12 455 Instruction Manual eee ee 1 IC Controls Copyright 2005 IC Controls Ltd All rights reserved Page A 2 WWW iccontrols com 455 63 Appendix IC CONTROLS 455 63 Menu 455 63 Menu The conductivity input menu has a number of additional settings that control the conductivity temperature compensation and conductivity display options
37. able and laboratory conductivity instruments do not have flow sensors and use limited 2 per C temperature compensation not acceptable under ASTM D 5391 99 for High Purity Water IC Controls recommends use of a second high purity analyzer and 401 0 01 73 sensor to determine the actual conductivity of the sample 1 Obtain the following materials a second calibrated 455 63 conductivity analyzer and 401 0 01 73 sensor of known constant 2 Record the cell constant of the sensor The cell constant 1s displayed by pressing Sample and then selecting cond CELL 1 from the menu 3 Tube up the calibration cell to the outlet of your process sensor to get a representative flowing sample from the process without exposure to air In order for the procedure to work the sample you are drawing must be representative of the sample being measured by the on line analyzer 4 Record the conductivity resistivity and temperature of the sample as displayed by the on line conductivity analyzer 5 Measure the conductivity of the sample using the second 455 63 conductivity analyzer and record the conductivity reading and temperature Note For accurate results the sample must be at the same temperature and the analyzers must use the same temperature compensation method Allow considerable time for the calibration sensor to rinse down and equilibrate to the sample level A stable reading close to the on line sensor reading acts as a g
38. actor water samples because they are normally close to neutral pH Makeup water and nuclear boiling water reactor plant water are untreated and neutral mineral traces are the most common contaminants Acidic Cation HCI samples with strong acid such as hydrochloric acid which completely dissociates in water should use the acidic algorithm Cation exchangers used by the power industry remove chemicals not of interest and substitute the far more conductive hydrogen It also results 1n an acidic sample which requires use of acid compensation to achieve accuracy Cation conductivity analyzers should also use this solute selection Basic NAOH samples with strong base such as sodium hydroxide which completely dissociates in water should use the basic algorithm Boiler water with treatment byproduct ammonia would use the basic algorithm Start up Settings The 455 63 conductivity analyzer s default assumes a sensor with a cell constant of 0 01 cm which 1s stored in its memory By default the analyzer comes up reading conductivity in microsiemens per centimeter The cell constant of the sensor must match the cell constant stored in the analyzer memory If other than a 0 01 cm cell constant is used change the constant stored by the analyzer so that the analyzer will read properly Temperature has a big impact on conductivity readings At the historical rate 2 change per C 455 63 Appendix IC CONTROLS a 25 C t
39. ages 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
40. arm function ie 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 B as low alarm set at 50 US cm and use alarm A as an advance warning device by configuring it as low alarm set at 100 uS cm When alarm is activated there is still time left to take corrective action HIGH ALARM alarm on differential sample i time Illustration 25 High alarm LOW ALARM differential sample serront alarm 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 for that input Caution messages do not cause a fault alarm To use an alarm as fault alarm select FUNC from the alarm menu then select Flt 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 s
41. atory for calibration checks are not reliable due to absorption from air CAUTION Standards less than 10 uS cm made In air will dissolve CO raising conductivity 1 to 3 uS cm so are unreliable Stored demin will also have conductivity readings of 2 or 3 uS cm due to chemicals dissolved from containers and should not be used For 1 uS cm standards try first triple rinsing all vessels with sample of less than 1 uS cm conductivity then diluting the standard using sample of less than 1 uS cm Alternately contact IC Controls Customer Service Calibration Using ASTM ASTM standard with conductivity 146 93 uS cm at 25 C can be substituted for 100 uS cm standard in the above calibration procedure When using ASTM D Standard P N A1100232 users may wish to follow the procedures outlined in ASTM 11125 455 63 Appendix www iccontrols com PURE WATER CALIBRATION Calibration by Grab Sample This modified grab sample technique 1s quicker and easier 1f the sensor 15 not easily accessible and with the high probability that pure water samples of less than 10 uS em will be changed on exposure to air it is recommended This procedure describes how to calibrate the analyzer without taking the sensor out of the process To calibrate measure the sample with a second calibrated analyzer and flow sensor similar to ASTM D 5391 99 for conductivity resistivity of a flowing high purity water sample Since most port
42. ature 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 CA7 9 CA8 6 CA8 7 CA8 8 CA8 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 Connect 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 cond
43. bed below The temperature input of the 455 microprocessor analyzer requires 1 000 TC in the sensor Adjusting Electronic Calibration Remove the offset calculated by previous software calibration of the 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 TB200 terminal 2 as common Refer to drawing D5920093 Rev1 9 Place 1000 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 1 74 1 resistor across T and 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 temperature 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 kQ 1 resistor and adjust VR203 until the display reads 195 0 C 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 Select CONF in C CAL from the menu The actual temperature as measured by the temperature sensor will be displayed the displayed value to the
44. bl See Alarm Menu See Serial Menu CONF CONF Illustration 1 Menu overview um 455 212 0 Configuration www iccontrols com 455 MENUS mS cm or hS cm output hold do air calibration cell constant cm 1 cell constant cm 1x100 linear TC constant change C F 1 or 2 decimal places mS cm 5 See list of error and caution messages for conductivity cond list of available inputs ArnG mS cm available units depend on type uS cm of input selected turn automatic range switching on off range number for automatic range switching T 100 CONTEXT SENSITIVE MENUS Context sensitive accessible only when function is activated Output 1 only when ArnG YES Page 3 455 MENUS gt A OFFS 2 cond dFLt unit selection CHIP YEAr onth dAtE lt hour 2 S hund m selectable only if security enabled Illustration 2 Configuration menu Page 4 IC Controls input damping sec 100 scale 10 scale 1 scale 0 1 scale input damping sec CALIBRATE C F Offset C 5 OFF metric or imperial alarm setpoint low alarm high alarm
45. bration using 100 5 Standard These instructions use IC Controls 1400051 Low Range Conductivity Calibration Kit Page A 9 PURE WATER CALIBRATION The A1400051 18 a calibration kit containing solutions and items necessary for calibrating The kit consists of the following items 14 inch Content Description Qty amp Size Part No Conductivity standard 2 500 mL 1100161 100 uS cm Demin water 4 500 mL 1100192 Syringe 10101 740003 1 Polyethylene graduated 2 100 mL 1100007 cylinders set 2 Sensor cleaning brush 1 A1100016 Instruction sheet Instructions for A1400051 Low Range Cond Calibration Kit 1 Set up the calibration supplies where you plan to do the calibration Lay out the two graduated cylinders one for span or high end standard one for low end standard Set out the sensor cleaning brush syringe standards and rinse solutions 2 Remove the conductivity sensor from the process and examine it for deposits Use demin water to flush away any deposits within the cell measurement area Tenacious deposits may require chemical cleaning see 1400054 Kit 3 Pour approximately 75 mL of 100 uS cm high end conductivity standard into a graduate so it is about three quarters full Lower the conductivity cell into the graduate Tip Ensure there are no air bubbles inside the cell they will cause low conductivity readings Remove
46. by 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 Home base 13 Hysteresis 51 Input damping 16 Installation 9p 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 contro 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 32 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 3l yearly maintenance 32 Specifications 7 9 Standby mode 14 Startup 12 Temperature 16 Celsius 16 current output 34 error mess
47. can be set from 0 s to 9 999 s 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 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 18 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 al
48. ccur when the analyzer and sensor are hooked up and placed in service then the conductivity 1s 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 1s 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 1s likely due to cable resistance capacitance and can be zeroed out using the air zero calibration procedure Conductance uS Resistance 2 Resistance 2 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 Install 700 resistor between electrode drive and sense 200 terminals 1 and 3 Set the conductivity input to manual range and switching on range 3 From the
49. ccurate 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 5 at 25 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 15 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 Select 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 CONDUCTIVITY
50. ctivities below 10 microsiemens cm Water without any chemical impurities will still have a conductivity because of the presence of H and OH ions due to self ionization of water Ultra pure water has a conductivity of 0 55 microsiemens cm or 18 18 megohm cm at 25 C The self ionization of water is strongly temperature dependent For accurate temperature compensation the conductivity of the pure solvent must be subtracted from that of the solution to determine the conductivity of the electrolyte simply applying a linear per degree Celsius temperature adjustment will not give accurate temperature compensation in high purity waters Illustration 2 shows the conductivity of ultra pure water in microsiemen cm over the range 0 C to 100 C Since pure water conductivity measurement is detecting trace amounts of ionic contaminants in the already temperature dependent self ionizing water the installation and calibration setup must make special provisions to eliminate or reduce any trace contaminants Further the trace contaminants themselves exhibit variable temperature coefficients in pure water that can rise as high as 7 per C The 455 63 analyzer has different temperature coefficient algorithms to allow the user to select for neutral salts acidic or basic samples as well as the traditional linear per C Page A 4 WWW iccontrols com IC Controls Illustration 2 conductivity of pure water since high p
51. dard value to that of the standard you are using in mS cm or uS cm depending on the setting of cond unit 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 Exror Messages section 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 and 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 conditio
52. deviation alarm fault alarm list of available inputs mS cm available units unit depend on type 5 of input selected differential fa 9 14 m Accessible only when deviation applicable alarm function is selected S lt alarm activation delay sec Illustration 3 Alarm menu www iccontrols 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 5 1200 2400 4800 9600 m N gt co 00 D 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 fr
53. e conductivity 15 proportional to temperature The effect is predictable and repeatable for most chemicals although unique to each In High Purity Water it is of major importance and IC Controls recommends the user check the application and ensure the appropriate TC Algorithm is in use Calibration using the wrong HPW algorithm will incorporate large errors into the results Overall system accuracy 1s maintained by calibrating the sensor and analyzer together in a standard close to the expected sample concentration Calibration determines the effective cell constant of the conductivity sensor The cell constant is affected by the shape of the sensing surface and electrode surface characteristics The effective cell constant will change over time as deposits form and anything else affects either the controlled volume or the effective electrode surface area The 455 63 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 you select sample no key 15 pressed for 15 minutes c the power is interrupted so the 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 method of calibrating the 455 63 analyzer The three standards most commonly used for calibration are 100 1000 and 10 000 uS cm at 25 7771 Cali
54. e sure that display is at home base Press the Right arrow key One of the prompts In 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 is 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 4 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 the 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
55. e 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 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 C
56. eading 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 8 and 99 5 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 CONDUCTIVITY MEASUREMENT CONDUCTIVITY MEASUREMENT What conductivity Electrical conductivity is a measure of the ability of a solution to carry a current Current flow in 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 havi
57. eck calibration as described below is based on using IC Controls A1400051 low conductivity calibration kit Apply 115 240 VAC power to the analyzer 2 Set display units cond unit to 1E 6 uS cm 3 Hook up your sensor via TB200 and remove the orange protective cap for this test we need a 0 01 cm cell constant 4 With the sensor in air the 455 63 analyzer should come up reading between 0 0 uS cm and 0 5 uS cm 5 Run an Air zero calibration use wires to be field installed and allow 30 minutes warm up time for the electronics to stabilize 6 Run the Std span calibration place the sensor in 100 uS cm standard The display should read 100 uS cm 1 uS cm 7 To check for general performance place the sensor in 10 uS cm standard The display should read approximately 10 to 13 uS cm 8 Before putting analyzer into operation verify your settings to ensure that they agree with Page A 5 High Purity Water Measurement intended setup For the 4 20 mA output set high limit and low limit 9 Set preference for temperature C F units 1 CONF unit 10 Set desired input signal damping if known normally 5 second 11 Unit 15 now ready for field installation Alternatively the above calibration can be done using a resistor Note that this method does not take into account the impact of resistance and capacitance of the sensor wire 1 Substitute a 100 ohm 1 resistor for the TC a
58. ements of the standard The IC Controls 402 0 01 conductivity sensor or the 403 can be provided with factory certified cell constant traceable directly to NIST Standard Reference Material 3191 of 100 uS em Alternatively IC Controls can factory certify the sensor cell constant with Standard of ASTM method D1125 146 93 uS cm 63 Sensor Mounting It is recommended that the sensor be located as near as possible to the conductivity transmitter to minimize any effects of ambient electrical noise interference Use option 73 flowcell to exclude air contact with the sample followed by a sample take off point where an additional sensor can be installed for calibrations When in a shared sample line with pH sensors the conductivity sensor should be first pH reference electrodes leak into the sample thereby raising its conductivity Flow sensors can be in any orientation but should be mounted tip down at an angle anywhere from 15 above horizontal to vertical 15 above horizontal is best because entrained bubbles will rise to the top and grit will sink Stainless steel sample lines are recommended for pure water samples to maintain their integrity The sensors can handle pressures up to 100 psi Any sample flow rate will work however 2 meters per second 6 feet per second has been found to minimize iron oxide grit buildups Sensor Wiring The basic wiring for IC Controls conductivity sensors 15 Shown in d
59. emperature shift can produce a 50 error if the reading is not compensated Since the conductivity of high purity water has larger and non linear temperature dependence the errors could be huge The 455 63 HPW default TC correction is Auto Pure Water Formula for ASTM 1125 Chemical Solute Algorithm for NACL in theory pure water 15 neutral Both for high accuracy work and high purity water applications IC Controls recommends the user check the actual chemicals involved and change the solute selection setting if necessary Conductivity sensor effective surface areas can be changed by contact with the process At high purity water measurement conditions cabling capacitance and resistance sometimes influence the readings IC Controls recommends both an air zero calibration and a standard calibration of the conductivity sensor to determine the effective cell constant This procedure requires a conductivity or resistivity standard from which the effective sensor cell constant can be determined or a second calibrated sensor and analyzer 455 63 Appendix www iccontrols com High Purity Water Measurement PURE WATER CALIBRATION The 455 63 HPW conductivity sensor analyzer system is most easily calibrated using 100 uS cm standard conductivity solution Alternatively grab sample analysis verses a previously calibrated reference conductivity meter using an in line flow conductivity sensor can be used Ionic movement and therefor
60. ending 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 typical 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 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 or 0 uS cm to 50 uS cm on the fourth range The actual numbers depend on the setting of the HI value and is user adjustable OUTPUT 2
61. ens per centimeter from E 3 milli 1E 6 Conductivity units in microsiemens per centimeter from E 6 micro ACC n Access level for security Displayed after password entered by user AL Alarms AL A AlarmA AL b Alarm B AUto Automatic ranging of conductivity input yes no switch ASCI ASCII serial output log BAud Baud rate for serial communications C Temperature in degrees Celsius use metric units CAL Calibrate analyzer CELL Cell constant CHAr Output characterization on off CHIP Chip Is this analyzer equipped with a real time clock chip CLr Clear the internal data log cnt Count of number of readings in internal data log CLSd Normally closed alarm contact cond Conductivity input CONF Configuration of program menu Cont Continue internal data log when buffer full cur Signal output in mA or current dA Input damping in seconds dAtE Date Real time clock setting for day of the month 1 31 dEc Decimal places dEv Deviation alarm dLAY Alarm activation delay do Do press ENTER to execute the reset clear action donE Done Reset clear action has been taken Err Error or warning number Er 94 RAM checksum failed Some settings may be lost F Temperature in degrees Fahrenheit use imperial units FLt Fault alarm FrEq Frequency of internal data log updates in seconds FULL Full What to do when internal data log is full continue or stop HI High alarm hi
62. f the readings in turn 102 5 25 0 Illustration 6 Home base Display Features Main Menu 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 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 the CONF configuration refer to the Configuration of Program section PASS 4 The main sample ie the input that 1s displayed first when SAMPLE key is pressed 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 mak
63. 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 is available No special software is 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 the 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 data 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 RD A to pin 3 TD A and connect this to terminal A on in analyzer Connect pin2 TD B to pin 9 RD B and connect this to terminal B in the analyzer Connec
64. gh limit 20 mA for 4 mA to 20 mA output window Hold Output hold during calibration hour Hour Real time clock setting hund Hundredth of a second Real time clock display LOG Internal data log in Input OR Minute Real time clock setting LO Low alarm low limit 4 mA for 4 mA to 20 mA output window NodE Node number for IC Net communications NO NC Normally open Normally closed OFF Off OFFS Offset Page 48 www iccontrols com um 455 212 IC Controls ON ON OF onth OPEN out out 1 out 2 PAS 1 PAS 2 PASS rANG mG 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 channel 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 Higher ce
65. h 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 a circuit which is wired normally open will be open 1 6 the external device wired to it 15 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 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 5 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 Co
66. h 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 2400 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 temperature 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 15 unknown the default temperature of 25 C or 77 F is normally used TC for High Purity
67. he 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 Separate 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 With sensor leads removed the analyzer should read 0 uS cm mS cm depending on units selected or close to zero b Insert a 1 000 ohm 1 resistor across the sensor cell connection and a second one across the sensor TC connections NOTE Jf the temperature reading is approximately
68. hydrochloric acid or sulphuric acid Nitric acid is preferred as it has no chlorides to corrode stainless steel Acid concentrations between 0 596 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 possible 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 15 possible to reverse the out 4mA TO 20 mA OUTPUT SIGNALS list of availab
69. ifferential is adjustable from 0 S cm to 100 S cm or 0 mS cm to Accessible only when deviation 100 mS cm applicable alarm function is selected alarm activation delay sec Illustration 22 Alarm menu Use of Relay Contacts 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 is 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 OF 9 Alarm Indication The A and B LEDs on the front panel show the current State of each alarm and alarm contact In addition an no alarm condition 2 alarm condition alarm condition for an input will cause the sample BLINK 98 2 contact het activated display for that input to alternate with the alarm function either LO HI dEv or FLt This way operator can quickly determine which alarm caused ON 8 contact activated the alarm condition alarm A or alarm B LED lighted and the type of alarm An LED that is
70. ignals 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 differential sample time Illustration 27 Low control HIGH CONTROL control on SETPOINT differential sample control off time Illustration 28 High control um 455 212 www 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 is necessary Relay Contacts NO NC init The 455 program by default assumes relay xoxo AL b CLSd contacts are wired normally open A normally open MEN input damping sec relay contact will open if there is no alarm and will YES be closed by the microprocessor when there is an 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
71. 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 Simulated 4 mA to 20 mA Output Self Calibration 4 Select cur from the output 1 menu to display the present output 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 se
72. ld during calibration Stores 12 calibration records Stores alarms caution and error messages Stores running 1 000 minute conductivity trend 2 o N A U Two programmable 4 mA to 20 mA outputs 10 Two programmable alarms 1 Il Serial digital output and for remote operation 12 Optional PID control 13 Optional concentration measurement in NaOH H2SO4 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 and 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 keys LED s 2 alarms A and 1 auto 1 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 Ib 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 St
73. le 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 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 electrode 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
74. le inputs CJ mS cm available units depend on type 1E 6 of input selected ON OF OFF out2 x YES turn automatic range EN switching on off range number for rnG automatic range switching OFF 2 WEB tbl 5 21 _ 100 Illustration 18 Output menu output or flip the window by reversing the settings of the low and high scale 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 signal This is useful for verifying program settings and for testing the hardware calibration To simulate a different 4 mA to 20 mA 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 iccontrols 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 dep
75. lection 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 2 To calibrate output 1 set in 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 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 the main circuit therefore measurements are made with common at the output 2 terminal TB304 Measure output 1 zero at TP301 pin 8 of 0304 while output 1 15 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 0304 while output 2 is output
76. ll 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 or 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 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 Tm 10 siemens ohm cm 5 millisiemens per centimeter mS cm unit of conductivity 1 millisiemens per centimeter 1 000 microsiemens per centimeter Milli is the metric prefix meaning one thousandt
77. mall 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 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 is predictable and repeatable for most chemicals althoug
78. n 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 1 Obtain the following materials a asecond conductivity analyzer b sensor of known constant c calibration standards d aclean beaker for taking a sample e acalculator 2 Calibrate the second conductivity unit 3 Record the cell constant of the sensor being used with the 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
79. nd cell in step 3 2 Set the cell constant to 0 01 cm 3 The analyzer should read approximately 0 C and 10 uS cm 4 Skip steps 5 and 6 5 In step 7 substitute the sensor with a 10 kilohm 1 resistor The analyzer should read approximately 1 0 uS cm Conductivity Display Units The 455 63 analyzer displays conductivity as microsiemens cm units by default but also allows display In millisiemens cm or as resistivity in megohms cm Resistivity units are millions of ohms per centimeter of water The conversion between microsiemens cm and megohm cm ls simple since the two units are reciprocals megohm cm cm rES megohm cm resistivity unit 1 3 mS cm conductivity 6 uS cm conductivity Illustration 3 Unit selection TC Auto Manual The basic temperature compensation method is accessed as cond tc t c The options NONE no temperature compensation AUTO automatic temperature compensation and SEt Page A 6 WWW iccontrols com IC Controls manual setpoint For HIGH PURITY WATER when the basic TC selection 15 set to Auto there are additional Auto compensation algorithms selectable under CO AL below to handle the high and nonliear characteristics of Neutral Acidic and Basic background samples Automatic temperature compensation uses the temperature RTD in the conductivity sensor to measure temperature Man
80. ng opposite electrical charges For example sodium chloride separates to form and ions All 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 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 practice 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 bet
81. ng acid HCI hydrochloric acid NAOH Strong base NaOH sodium hydroxide Illustration 6 Compensation algorithm Illustration 7 shows the non linear dependence on temperature for the different solute compensation algorithms that are additive to the Pure Water Formula selected above l NaCl e A NaOH Change degree Celsius E 1 i 20 0 20 40 60 80 100 Temperature degrees Celsius Illustration 7 Additive sample chemistry compensation Linear LtC The historical temperature compensation is linear at 2 00 C compensation or can be edited to a different value The LTCC Linear Temperature Compensation Constant 1s adjusted by editing selecting cond tec from the menu and adjusting the value Refer also to the section Conductivity Calibration Temperature Compensation in the 455 user manual Page A 8 www iccontrols com IC Controls Neutral Salt NACI The 455 63 default temperature compensation is for Neutral Salt 1n theory pure water 15 neutral samples with a neutral pH close to 7 can select the sodium chloride compensation algorithm In a neutral salt solution the number of hydrogen and hydroxyl 10ns are approximately equal This algorithm ls usually satisfactory for monitoring the effluent of mixed bed ion exchange Neutral compensation 1s also applicable to boiling water re
82. nge 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 nu S cm 5 5 5 0 01 0 10 10 0 10 1 0 10 100 0 to 1 0005 0 02 0 10 20 0102 0 to 200 to 2 0005 0 1 0 10 100 0 10 10 0 to 1000 0 to 10 000 0 2 0 to 200 0 to 20 0 to 2 000 0 to 20 000 0 5 0 to 500 0 to 50 0 to 5 000 to 50 0007 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
83. 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 70002 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 Try changing the output 1 low setting Select 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 security is needed to change this setting Select 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 access Try changing the output 1 low setting again You will find that this time we can go into edit mode unhindered Select PASS from the main menu again Enter the level 2 password which is 70002 We are going to set the level 2 password to 0000 again to disable password security Password 2 is found in configuration menu and therefore requires level 2 access before it can be accessed Select CONF
84. ntenance 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 1 contact IC CONTROLS immediately for replacement To be considered for warranty the product shall have an 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
85. ntrols 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 settings except configuration menu Usage operator password must be entered before being allowed to 5 o 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 200 password security is not enabled require knowledge of setting passwords in the Pasewordscan be changed configuration section since all passwords installation management entered by selecting PASS directly from the main menu Table
86. om 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 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 5C 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 AJccontrols com Check electrode and setup un
87. om 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 1f 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 conditions 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 ho
88. ons 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 nstallation section Verify power supply has been wired for proper voltage and instrument ts suitably grounded 2 Turn on flow at sample inlet or 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 sam
89. ontrols 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 displaying conductivity The program will safely abort whatever it was doing at the time and return to displaying the conductivity reading ERE 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 o
90. ood indicator Page A 11 PURE WATER CALIBRATION 6 Calculate the new cell constant to be entered into the 455 analyzer using the following formula lab reading field reading For example if the 455 analyzer is reading 8 2 uS cm the cell constant from step 2 is 0 01 cm and the reading from the second method is 8 9 uS cm then the new cell constant becomes new cell const new cell const X 0 01 0 0109 7 Adjust the cell constant to the new value e g 0 0109 cm as in the example The cell constant is adjusted by selecting cond CELL 100 01 00 from the menu Press Enter to go into edit mode then adjust the displayed value to 01 09 Press Enter again to exit edit mode Air Zero Calibration It is not necessary to repeat Air cal every time a regular calibration is performed An air calibration should be performed anytime a new sensor 15 installed When a sensor is in air the conductivity measured by the sensor 15 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 can be due to background noise lead wire pickup antenna effect grounding problems etc 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 Do the zero cal any time a new sensor 1s installed 2 Make s
91. orage 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 s Compensation Type Function Characteristic Linear Default 2 per Adjustable 0 1 to 5 0 per C None USP 23 lt 645 gt High Purity Selectable Neutral acidic basic ASTM D1125 or latest Concentration 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 cm to 100 0 cm Cell constant x100 x1000 x10 000 or x100 000 3 access level security partial and or all settings may be protected via 3 and or 4 digit security code Two independent assignable programmab
92. played Refer to Caution or error message tables Verify your calibration by a Note the cell constant in menu under CELL and repeat steps 3 amp 4 three times or until three CELL constant readings are consistent b Rinse the sensor in demin water c Check with 10 uS cm low end standard at about 10 of scale using the procedure from 3 and 4 above www iccontrols com 455 63 Appendix IC CONTROLS Calibration Notes Used conductivity standard should be discarded because exposure to air and contamination causes the conductivity of standards to change Make low end standard by dilution Example to 100 mL graduated cylinder add 7 5 mL 100 uS cm standard then top up to 75 mL to get 10 uS cm standard CAUTION low conductivity water will dissolve from the air raising conductivity 1 to 2 uS cm plus leach contaminants in storage from containers and carry over on the sensor so 10 uS cm will likely read 11 12 or 13 uS cm possibly even more If the sensor reads correctly the calibration and sensor condition are good If the sensor reads wrong it may have had trapped bubbles inside or traces of 100 uS cm standard Re test three times or until three readings are consistent 1f problem persists try chemical cleaning A clean rinsed and dried conductivity sensor should read near zero 1n air If 1t does not troubleshoot the sensor wiring and analyzer Low conductivity grab samples taken to the labor
93. r P N 2500192 10 foot cable with RJ11 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 the 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 l Illustration 33 Wiring RS485 cabl Making a Custom Cable OE diis 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 Converter Signal Pin Number Data 2 oo Ame Data B 5 Nx J EARTH 1 Signal Ground 4 ANALYZER EARTH 1 6 Ly RJ 11 Plug End RJ 11 6 Conductor Page 58 www iccontrols com um 455 212 DRAWINGS IC Controls DRAWINGS D5920093 Wiring amp Component Location AN del 8600C69U 6wmp ge u pesn NOILV2O1 LN3NOdNWOO 7 SSP muu m 07014 aiIAabuoJD Ap STOULNOD 4 EGER J2 9SUH SIOHLNOD 0403 5 7 T dl
94. rawing D5920095 as well as a description of the model 400 interface to the analyzer This wiring scheme 1s intended for cable runs less than 20 meters 65 feet where electrical interference is low This cable is available from IC Controls as A9200000 Notes 1 The IC Controls conductivity wiring configuration uses an analyzer driven shield to minimize wire capacitance effects The driven 455 63 Appendix www iccontrols com High Purity Water Measurement shield should not be connected to ground Connecting the shield to ground will give false high conductivity readings 2 The IC Controls conductivity system uses a 1000 ohm RTD This achieves 10 times better temperature accuracy by reducing the relative impact of lead and contact resistance on error 3 Leads longer than 20 meters 65 feet require an air zero calibration to compensate for wire capacitance and resistance effects All low level sensor signals should be run through a dedicated conduit Take care to route all signal wiring away from AC power lines 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 driven shield will cause conductivity errors Avoid twisting the sensor lead to minimize possibilities for broken wire Make sure the sensor connections are clean and tight Instrument Shop Test Startup Ch
95. rd conductivity solutions Alternatively grab sample analysis on a previously calibrated laboratory reference conductivity meter can be used TE mS cm or HS cm Overall system accuracy is maintained by calibrating the sensor and analyzer Std together in a standard close to the CAL MER output hold expected sample concentration Air Calibration determines the effective cell constant of the conductivity 1 p sensor The cell constant 1s affected by the shape of the sensing surface 100 p 18828 and electrode surface characteristics The effective cell constant will change F over time as deposits form and Auto anything else that affects either the linear constant controlled volume or the effective itc MEN change C F electrode surface area The 455 features an output hold Output hold goes into effect as soon as a calibration is started output hold will stay in effect until a SAMPLE key is pressed b no key is pressed for 15 minutes do air calibration 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 a
96. s cm 0 LO 100 200 300 400 500 HI 100 500 400 90 3009 2002 80 1008 E o 70 5 pos B 60 8 9 50 lt 3 4 lt S 3 I o 20111 5 3 20 o 10 3 0 0 0 10 20 30 40 50 60 70 80 90 100 uncharacterized output Illustration 21 Bi linear output characterization um 455 212 www iccontrols com Page 37 ALARM FUNCTIONS 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 Each alarm features an adjustable set point user IC Controls alarm setpoint low alarm high alarm deviation alarm fault alarm list of available inputs selectable alarm type adjustable differential also LA called hysteresis unit selection and an on off switch The alarm types which are available are high low deviation and fault Alarms be set anywhere between 0 and 9 999 US cm or mS cm and 9 999 mS cm for the conductivity input or 10 C and 210 C for the temperature mS cm available units depend on type HS cm of input selected input The d
97. s for Conductivity 28 Error Messages for Temperature 20 IC Controls Caution Messages for 20 SENSOR INSTRUGTIONS 30 Preparation a 30 Calibration for 30 SENSON 30 Monthly 1 30 X Cally 31 Restoring Sensor 31 4 mA 20 mA OUTPUT SIGNALS 33 Reversing the 4 mA to 20 mA Output 33 Simulated 4 mA to 20 mA Output 33 OF 34 Automatic Range 34 Using the Alarm Contacts sess 35 Using the Second 4 mA to 20 mA Output 35 Output 36 ALARM FUNCTIONS iioi dete eoa tear 38 Use or Relay iia con 38 Alarm Indicatton 2 eorr 38 39 Wiring NO NC 39 Delayed Activation 39 Deviation 39 or Low 40 41 Using Alarms for On
98. 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 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 the reading from the second method is 890 uS cm then the new cell constant becomes 390 5 x 1 0 1 09 320 5 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 accurately 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 15 in air the conductivity measured by the sensor is expected to be zero It is not uncommon to find some s
99. sensor 2 _ 250 beaker 200 3 150 Cleaning and 400 conditioning ES solution 3 4 full E 4 50 N Illustration 13 Conductivity calibration Important Obtain calibration supplies such as a graduated cylinder or beaker which is large enough to submerse the conductivity sensor plus distilled or deionized water in a squeeze bottle for rinsing or an IC Controls calibration kit Remove the conductivity sensor from the process and inspect the sensor for any deposits If the sensing surface 15 coated clean the sensor before proceeding Refer to the Sensor Maintenance section Rinse the sensor cell area with distilled water Rinse the graduated cylinder or beaker with some of the standard then pour the selected higher conductivity standard into the graduated cylinder or beaker Immerse the sensor and ensure the sensor electrode area 1s completely submerged If the sensor has vent holes then the sensor must be submerged below the vent holes and there must be no air bubbles inside a Air bubbles inside the controlled volume area of the conductivity sensor 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 Select cond CAL std from the menu and press SELECT Edit the displayed stan
100. 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 TO 20 mA OUTPUT SIGNALS IC Controls Output Characterization The 455 analyzer has user programmable output characterization that 18 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 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 behaviors 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 b
101. t 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 is 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 B BLACK DB 9 Connector C f A RED EARTH SHIELD Ed Cae Pin Assignments Pin 1 RD Analyzer Pin 2 TD 2 Pin 3 TD A EARTH Pin 5 COM Pin 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 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 converte
102. temperature correction 1s important Since work in 455 63 Appendix IC CONTROLS this area 15 still ongoing the 455 analyzer allows the selection of two pure water temperature compensation formulas pure water formula PU FO x 1125 ASTM 1125 Later data 1994 Illustration 5 Pure water formula ASTM 1125 TC Formula This curve is the default curve implemented the 455 63 analyzer It is selected under PU FO 1125 Refer to table 1 Work done in the 1980 s led to the development of these generally accepted Pure Water Temperature compensation values that were included into ASTM standard D 1125 95 1999 High Purity Water Measurement Later TC Formula Ongoing work produced later data published in ULTRA PURE WATER in December 1994 This data presents slightly refined data based on new research which looks good but has not yet undergone scientific method peer testing been accepted and included in standards To give you the greatest flexibility possible the 455 63 includes this data as an option selected under PU FO LAtE C 0 0 01165 85 841 0 01661 60 217 10 0 02310 43 297 15 0 03143 31 820 20 0 04194 23 844 25 0 05501 18 180 30 0 07101 14 082 35 0 09037 11 065 40 0 11351 8 810 45 0 14082
103. the error number Messages 6 through 9 are less serious input source input number for error and caution messages Conductivity 1 and are identified as cautions instead eg CAn e Temperature 2 Off scale errors for conductivity are not numbered and 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 15 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 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 long 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 fr
104. til 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 11 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 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 2 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 Temper
105. ting 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 Relay output operation can be verified by testing for contact closure or continuity at each relay 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 normally 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 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 Actual cell constant multiplication factor 1 100 Cell constant 100 3 Conductivity units in millisiem
106. ual temperature compensation uses the temperature set by the user in cond tc SEt Note The SEt frame 15 not accessible until manual TC has been selected NONE or no temperature compensation lets the analyzer measure uncompensated conductivity or resistivity This is a requirement in the pharmaceutical industry following USP 23 lt 645 gt requirements Selecting NONE is the same as using manual TC with the setpoint set to 25 C NONE Auto auto SEt Illustration 4 Compensation method Pure Water Formula Selection Much work has been done over the years to establish the temperature dependence of pure water Early analog implementations used thermistors to achieve temperature compensation but may not have been very accurate Current microprocessor technology such as in the 455 allows for accurate continuous compensation over the entire temperature range 0 100 C The earliest widely used pure water equation was developed at the General Electric Vallecitos Nuclear Training Center This formula still agrees to within 1 with today s formulas over the range of 15 to 67 C Illustration 2 shows the temperature dependence of pure water The conductivity or resistivity of pure water without any impurities is very dependent on temperature At low temperatures close to 0 C the change in conductivity 1s about 7 per degree Celsius Clearly the implementation of pure water
107. uctivity 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 in a concentration close to the expected sample concentration The cell and analyzer can generally be calibrated two of four typical ranges 0 uS cm to 100 uS cm 0 uS cm to 1 000 uS cm 0 uS cm to 10 000 uS cm and uS cm to 100 000 uS cm IC Controls has available conductivity calibration kits which conveniently package all necessary calibration supplies These kits are available as P N A1400051 low conductivity cell constants 0 01 cm and 0 02 cm P N A1400052 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 to
108. ugh 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 approximately 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
109. ure that the sensor is dry before zeroing The analyzer should be reading a low conductivity value 3 From the menu select cond CAL and push select The analyzer will show a flashing do 4 When the sensor 15 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 Page A 12 x old cell consi WWW iccontrols com IC Controls Possible problem When you press Enter with the flashing do displayed the analyzer will not do the zero cal but instead will show the current range number e g rnG 2 For a zero cal the analyzer needs to be on range 4 the range with the highest gain If the analyzer isn t on range 4 then the sensor probably is not in air or 1s wet Correct the sensor situation and try again 455 63 Appendix USER MANUAL MODEL 455 CONDUCTIVITY ANALYZER um 455 212 CONTROLS CONTENTS CONTENTS um 455 212 CONTENTS 2 MENUS Dc 3 INTRODUCTION toca 0 0 7 INSTALLA HON Pat Eon daas 9 Analyzer oerte I Eos ess 9 Sensor Mounting 10 Sensor 10 Instrument Shop Test Startup 10 SILAR Lees hae hes mis 12 Analyzer Start up
110. urity water contains little dissolved material it 1s like a dry sponge ready to soak up any contaminant it meets Absorption of carbon dioxide on exposure to air will result in carbonic acid formation and cause a real change in conductivity of up to 2 to 3 microsiemens cm This fact can be readily demonstrated by taking a beaker of fresh demin water from a laboratory column with conductivity electrode inserted and showing less than 0 5 microsiemens cm then bubbling compressed air through it and observing the conductivity reading quickly rise to between 2 and 3 microsiemens cm Alternately if dissolved gases are in the sample on exposure to air they may escape similar to opening a bottle of pop Clearly calibrations using open containers of high purity water will have problems that the same samples In continuously flowing enclosed tubing should not encounter 455 63 and ASTM D5391 99 The IC Controls 455 63 analyzer together with a model 402 or 403 sensor with cell constant 0 01 cm and 73 flow cell is designed to meet the requirements of ASTM D5391 99 for Flowing High Purity Water Samples less than 10 5 when calibrated with 1100161 NIST traceable 100 microsiemens cm standard or 1100232 conductivity standard D 455 63 Appendix IC CONTROLS 146 93 microsiemens cm To obtain the full benefits the user should acquire a copy of the standard and ensure sampling and calibration techniques used on site meet the requir
111. ut the area of interest from 0 uS cm to 100 uS cm would occupy 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 is 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 21 For reference the 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 a 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
112. ween 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 going 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 Ra
113. wel 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 the 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
114. 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 Jccontrols 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 1mS cm 1000uS cm Normally it 15 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 are 1E 3 for mS cm 1E 3 1s scientific notation for milli or thousandth and 1E 6 for uS cm 1E 6 18 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 standa
115. word 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 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 7000 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 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 OOOO Both passwords 1 and 2 are set to 70000 and security is

455-63 User Manual (Ultra-Pure Water)

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