ABB 4630 User manual

pH/Redox (ORP) Analyzers
Models 4630 & 4635
(incorporating Water Wash Versions 4631 & 4636)
Operating Instructions
IM/4600–PH_12

ABB
The Company
We are an established world force in the design and manufacture of instrumentation for
industrial process control, flow measurement, gas and liquid analysis and environmental
applications.
As a part of ABB, a world leader in process automation technology, we offer customers
application expertise, service and support worldwide.
We are committed to teamwork, high quality manufacturing, advanced technology and
unrivalled service and support.
The quality, accuracy and performance of the Company’s products result from over 100 years
experience, combined with a continuous program of innovative design and development to
incorporate the latest technology.
The UKAS Calibration Laboratory No. 0255 is just one of the ten flow calibration plants
operated by the Company and is indicative of our dedication to quality and accuracy.
Use of Instructions
Warning.
An instruction that draws attention to the risk of injury or
death.
Caution.
Aninstruction that drawsattentiontotheriskofdamageto
the product, process or surroundings.
✶
Note.
Clarification of an instruction or additional information.
Information.
Further reference for more detailed information or
technical details.
Although Warning hazardsare related to personal injury, and Caution hazards are associated withequipment or property damage,
it must be understood that operation of damaged equipment could, under certain operational conditions, result in degraded
process system performance leading to personal injury or death.Therefore, comply fully with all Warning and Caution notices.
Information in this manual is intended only to assist our customers in the efficient operation of our equipment.Use of this manual
for any other purpose is specifically prohibited and its contents are not to be reproduced in full or part without prior approval of the
Marketing Communications Department.
Health and Safety
To ensure that our products are safe and without risk to health, the following points must be noted:
1. The relevant sections of these instructions must be read carefully before proceeding.
2. Warning labels on containers and packages must be observed.
3. Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel and in accordance with the
information given.
4. Normal safety precautions must be taken to avoid the possibility of an accident occurring when operating in conditions of high pressure
and/or temperature.
5. Chemicalsmustbestoredawayfromheat,protectedfromtemperatureextremesandpowderskeptdry.Normalsafehandlingprocedures
must be used.
6. When disposing of chemicals ensure that no two chemicals are mixed.
Safety advice concerning the use of the equipment described in this manual or any relevant hazard data sheets (where applicable) may be
obtained from the Company address on the back cover, together with servicing and spares information.
EN ISO 9001:2000
Cert. No. Q 05907
R
E
G
I
S
T
E
R
E
D
EN 29001 (ISO 9001)
Lenno, Italy – Cert. No.9/90A
0255
Stonehouse, U.K.

1
CONTENTS
Section Page
1 INTRODUCTION ..........................................................2
2 PREPARATION ............................................................2
2.1 Checking the Code Number..............................2
2.1.1 Wall-/Pipe-mounted Instruments .........2
2.1.2 Panel-mounted Instruments ................2
3 MECHANICAL INSTALLATION ..................................3
3.1 Siting Requirements..........................................3
3.2 Mounting............................................................4
3.2.1 Wall-/Pipe-mounted Instruments .........4
3.2.2 Panel-mounted Instruments ................5
4 ELECTRICAL CONNECTIONS ...................................6
4.1 Access to Terminals ..........................................6
4.1.1 Wall-/Pipe-mounted Instruments .........6
4.1.2 Panel-mounted Instruments ................6
4.2 Connections, General .......................................7
4.2.1 Relay Contact Protection
and Interference Suppression .............7
4.3 Connections – Wall-/Pipe-mounted
Instruments........................................................9
4.4 Connections – Panel-mounted
Instruments......................................................10
4.5 Selecting the Mains Voltage............................ 11
4.5.1 Wall-/Pipe-mounted Instruments ....... 11
4.5.2 Panel-mounted Instruments .............. 11
5 CONTROLS AND DISPLAYS ....................................12
5.1 Displays ...........................................................12
5.2 Controls Familiarization ..................................12
6 OPERATION...............................................................13
6.1 Instrument Start-up .........................................13
6.2 Operation – pH Measurement Mode ..............13
6.2.1 Operating Page .................................14
6.2.2 Single Point pH Calibration ...............16
6.2.3 Two-point pH Calibration
(Automatic Mode) ..............................17
6.2.4 Two-point pH Calibration
(Manual Mode)...................................19
6.3 Operation – Redox (ORP)
Measurement Mode ........................................21
6.3.1 Operating Page .................................21
Section Page
7 PROGRAMMING........................................................22
7.1 Access to Secure Parameters ........................24
7.2 Language Page ...............................................24
7.3 Set Up Parameters Page ................................24
7.4 Set Up Alarms Page........................................26
7.5 Set Up Retransmission Page..........................28
8 CALIBRATION ...........................................................30
8.1 Equipment Required .......................................30
8.2 Preparation......................................................30
8.3 Factory Settings Page.....................................31
9 SIMPLE FAULT FINDING ..........................................33
9.1 Error Messages ...............................................33
9.2 Calibration Fail Message or
no Response to pH/Redox Changes ..............33
9.3 Checking the Temperature Input.....................33
10 SPECIFICATION ........................................................34

2
4600
Monitoring pH
7.00
A1
A2
4600
Monitoring pH
7.00
A1
A2
2867 Dip Electrode
(Shown for Example Only)
(Wall- /Pipe-mounted Model)
4630-31/500
Slide instrument
out of case
(Panel-mounted Model)
4635-36/500
Undo captive
screw
Remove Plug
(if fitted)
1
2
3
1 INTRODUCTION 2 PREPARATION
Fig. 1.1 System Schematic
Fig. 2.1 Checking the Code Number
(Model 4630/31)
Fig. 2.2 Checking the Code Number
(Model 4635/36)
The 4630/31 and 4635/36 pH/Redox transmitters and
associated electrode systems have been designed for
continuous monitoring and control of pH. The electrode
system can be standardized to the instrument using the built-
in calibration facility and a single point buffering facility
provides easy re-calibration after initial standardization.
The 4630/31 models are wall- or pipe-mounted instruments
and the 4635/36 models are panel-mounted, DIN sized
instruments. All instruments have a single programmable pH
input channel, and a single temperature input channel. When
making temperature compensated measurements the sample
temperature is sensed by a Pt100 resistance thermometer
which can be mounted in the electrode system.
Models 4631 and 4636 incorporate a water wash facility for
system cleaning. During the wash cycle, the Alarm 1 status
and the retransmission value are held in their pre-cycle
condition.
Instrument operation and programming is via four tactile
membrane keys located on the front panel. Programmed
functions are protected from unauthorized alteration by a five-
digit security code.
2.1 Checking the Code Number
2.1.1 Wall-/Pipe-mounted Instruments – Fig. 2.1
2.1.2 Panel-mounted Instruments – Fig. 2.2

3
IP66
C –Within Environmental Limits
55°C
Max.
–20°C
Min.
B –WithinTemperature Limits
Electrode
Maximum Distance
A – Maximum Distance of Instrument to Electrode
100m
3 MECHANICAL INSTALLATION
Fig. 3.1 Siting Requirements
3.1 Siting Requirements
Caution.
• Mount in a location free from excessive vibration.
• Mount away from harmful vapours and/or dripping fluids.
Information. It is preferable to mount the
instrument at eye level, allowing an unrestricted view of
the front panel displays and controls.

4
68 (2.68)
214
(8.43) 232 (9.13)
Fixing Centres
160 (6.3)
250
(9.84)
69 (2.72)
Fixing Centres
Allowance for
Cable Bends
200 (7.9)
42
(1.65)
61 (2
3
/ 8 ) O.D. Vertical or Horizontal Post
Dimensions in mm (in)
Mark fixing centres
(see Fig. 3.2)
Drill suitable
holes
Secure instrument to
wall using
suitable fixings
1
2
3
Position ‘U’ bolts on pipe
Position plates over ‘U’ bolts
Secure transmitter to mounting plate
Secure plates
1
2
3
4
A – Wall-mounting B – Pipe-mounting
…3 MECHANICAL INSTALLATION
Fig. 3.2 Overall Dimensions
Fig. 3.3 Wall-/Pipe-mounting
3.2 Mounting
3.2.1 Wall-/Pipe-mounted Instruments – Figs. 3.2 and 3.3

5
191 (7.52)12 (0.47)
Panel Cut-out
96 (3.78)
96
(3.78)
+0.8
–0
92
(3.62 )
+0.03
–0
+0.8
–0
92 (3.62 )
+0.03
–0
Dimensions in mm (in)
Cut a hole in the panel (see Fig. 3.4 for dimensions).
Instruments may be close stacked to DIN 43835.
Insert the instrument
into the panel cut-out.
Refit the panel clamps to the case, ensuring that
the panel clamp anchors are located correctly in their slot.
Secure the instrument by tightening the
panel clamp retaining screws.
Loosen the retaining
screw on each panel clamp.
Remove the panel clamp and
anchors from the instrument case.
4
5
6
1
3
2
3
3 MECHANICAL INSTALLATION
Fig. 3.4 Overall Dimensions
Caution. The clamp must fit flat on the
instrument casing. If the clamp is bowed, the
securing screw is overtight and sealing problems
may occur.
Fig. 3.5 Panel Mounting
…3.2 Mounting
3.2.2 Panel-mounted Instruments – Figs. 3.4 and 3.5

6
Remove nuts and
protection cover
Remove
mains cover
Mains Cover
1
2
Earth Studs
slide
down
Pull out
slightly. . .
. . . and
slide off
Remove
protection
cover
Slacken
captive
screws
1
23
4
2
4 ELECTRICAL CONNECTIONS
Fig. 4.1 Access to Terminals – Wall-/Pipe-mounted Instruments
Fig. 4.2 Access to Terminals – Panel Mounted Instruments
Warning. Before making any connections, ensure that the power supply, any high voltage-operated control circuits
and high common mode voltages are switched off.
4.1 Access to Terminals
4.1.1 Wall-/Pipe-mounted Instruments – Fig. 4.1
4.1.2 Panel-mounted Instruments – Fig. 4.2

7
NC C NO
External
A.C. Supply LN
Relay Contacts
C
R
Load
A – A.C. Applications
NC C NO
External
D.C. Supply
+–
Relay Contacts
Load
Diode
B – D.C. Applications
4 ELECTRICAL CONNECTIONS…
Fig. 4.3 Relay Contact Protection
4.2 Connections, General
Information.
•Earthing (grounding) – stud terminal(s) is fitted to the transmitter case for bus-bar earth (ground) connection – see Fig.
4.1 or 4.5.
•Cable routing – always route signal output/pH electrode cable leads and mains-carrying/relay cables separately, ideally
inearthedmetalconduit.Usetwistedpairoutput leads or use screened cable with the screen connected to the case earth
stud.
Ensurethatthecablesenterthetransmitter through the glands nearest the appropriate screw terminals and are shortand
direct. Do not tuck excess cable into the terminal compartment.
•Cable glands & conduit fittings – ensure a moisture-tight fit when using cable glands, conduit fittings and blanking
plugs/bungs (M20 holes).The M16 glands ready-fitted to wall-mounted instruments accept cable of between 4 and 7mm
diameter.
•Relays –the relay contacts are voltage-free and must be appropriately connected in series with the power supply and the
alarm/control device which they are to actuate. Ensure that the contact rating is not exceeded. Refer also to Section 4.2.1
(below) for relay contact protection details when the relays are to be used for switching loads.
•Retransmission output – Do not exceed the maximum load specification for the selected current retransmission range
– see Section 10, SPECIFICATION.
Since the retransmission output is isolated the –ve terminal must be connected to earth (ground) if connecting to the
isolated input of another device.
4.2.1 Relay Contact Protection and Interference Suppression – Fig. 4.3
If the relays are used to switch loads on and off, the relay contacts can become eroded due to arcing.Arcing also generates radio
frequency interference (RFI) which can result in instrument malfunctions and incorrect readings.To minimise the effects of RFI,
arc suppression components are required;resistor/capacitor networks for a.c. applications or diodes for d.c.applications.These
components can be connected either across the load or directly across the relay contacts. On 4600 Series instruments the RFI
components must be fitted to the relay terminal block along with the supply and load wires – see Fig 4.3.
For a.c. applications the value of the resistor/capacitor network depends on the load current and inductance that is switched.
Initially, fit a 100R/0.022µF RC suppressor unit (part no. B9303) as shown in Fig.4.3A. If the instrument malfunctions (incorrect
readings) or resets (display shows 88888) the value of the RC network is too low for suppression and an alternative value must
be used. If the correct value cannot be obtained, contact the manufacturer of the switched device for details on the RC unit
required.
For d.c. applications fit a diode as shown in Fig. 4.3B. For general applications use an IN5406 type ( 600V peak inverse voltage
at 3A – part no. B7363).
✶
Note. For reliable switching the minimum voltage must be greater than 12V and the minimum current greater than
100mA.

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…4 ELECTRICAL CONNECTIONS
Note. Electrodes are currently designed to give a reading that is compatible with analog instruments.To obtain correct
readings with the 2867 electrode system, the electrode leads need to be reversed as shown.
Table 4.1 Cable Colors for Different pH Electrode SystemTypes