ABB Industrial enabled Analyzer 9437 User manual

AnalyzeIT
Low and High Level
Dissolved Oxygen Monitor
Model 9437
Instruction Manual
IM/9437_3

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 hazards are related to personal injury, and Caution hazards are associated with equipment 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
1 INTRODUCTION .............................................................2
2 MECHANICAL INSTALLATION .....................................3
2.1 Siting Requirements ................................................3
2.1.1 Instruments ..................................................3
2.1.2 Dissolved Oxygen Flowcell ..........................3
2.2 Mounting the Instrument..........................................4
2.2.1 Wall-mounted Instrument .............................4
2.2.2 Panel-mounted Instrument...........................4
2.3 Installing the Dissolved Oxygen Flowcell ................6
2.3.1 Flowcell Dimensions ....................................6
2.3.2 System Design Options................................6
2.3.3 Connecting the Sample Lines ......................6
3 ELECTRICAL CONNECTIONS ......................................7
3.1 Access to Terminals.................................................7
3.1.1 Wall-mounted Instruments ...........................7
3.1.2 Panel-mounted Instruments .........................7
3.2 Connections, General..............................................8
3.2.1 Relay Contact Protection
and Interference Suppression ......................8
3.3 Wall-mounted Instrument Connections ...................9
3.4 Panel-mounted Instrument Connections ...............10
3.5 Selecting the Mains Voltage ..................................11
3.5.1 Wall-mounted Instrument ...........................11
3.5.2 Panel-mounted Instrument......................... 11
4 SETTING UP .................................................................12
4.1 Fitting the Dissolved Oxygen Sensor ....................12
4.2 Connecting the Flowcell ........................................13
5 CONTROLS AND DISPLAYS .......................................14
5.1 Displays .................................................................14
5.2 Switch Familiarization............................................14
6 START UP AND OPERATION ......................................15
6.1 Instrument Start-up................................................15
6.2 Operation – Dissolved Oxygen
Measurement Mode ..............................................16
6.2.1 Operation Page ..........................................16
6.2.2 Calibration Page.........................................17
7 PROGRAMMING AND ELECTRICAL CALIBRATION 18
7.1 Access to Secure Parameters ...............................18
7.2 Select Language Page ..........................................18
7.3 Set Up Parameters Page ......................................19
7.4 Set Up Outputs Page ............................................20
7.5 Electrical Calibration..............................................22
7.5.1 Equipment Required ..................................22
7.6 Preparation ............................................................22
7.7 Electrical Calibration Page ....................................23
8 SIMPLE FAULT FINDING .............................................24
8.1 Maintenance ..........................................................24
8.1.1 Cleaning/Changing the Sensor ..................24
8.2 Error Messages .....................................................24
8.3 Low Sensor Output
or no Response to D.O. Changes .........................24
9 SPECIFICATION ...........................................................26
10 SPARES ........................................................................27
NOTES................................................................................28
Section Page Section Page

2
1 INTRODUCTION
This manual describes how to install and operate the 9437
Low Level Dissolved Oxygen Monitoring system. Fig. 1.1
shows a schematic of the system.
The Dissolved Oxygen (D.O.) transmitters and associated
flowcell have been designed for continuous monitoring and
control of power station boiler feed water/steam condensate.
The 4641 transmitter is a wall-mounted instrument and the
4646 model is a panel-mounted, 1/4DIN-sized instrument.
Both instruments have a single programmable D.O. input
channel, and a single temperature input channel. The sample
temperature is sensed by a Pt1000 resistance thermometer
incorporated in the flowcell.
Instrument operation and programming is via four tactile
membrane switches located on the front panel. Programmed
functions are protected from unauthorized alteration by a five-
digit security code.
Fig. 1.1 System Schematic
4600
ABB
Kent-Taylor
D.O. µg/kg
18 . 1
A1
A2
4600
ABB
Kent-Taylor
D.O. µg/kg
18 . 1
A1
A2
Model 4646
Panel-Mounted Transmitter
Model 4641
Wall-Mounted Transmitter
Flowcell Assembly
Sample
Flow
Upwards

3
2.1 Siting Requirements
2.1.1 Instruments – Fig. 2.1
Caution.
• Mount instruments in a location free from excessive
vibration.
• Mount away from harmful vapors and/or dripping
fluids.
Information. It is preferable to mount the
transmitter at eye level thus allowing an unrestricted view
of the front panel displays and controls
2 MECHANICAL INSTALLATION 2 MECHANICAL INSTALLATION…
2.1.2 Dissolved Oxygen Flowcell – Fig 2.8
Allow sufficient clearance (200 mm all around) for easy
removal of the flowcell assembly for maintenance if required –
see Section 2.3.1 for overall dimensions of units.
✶
Note. To eliminate the risk of bubbles accumulating
at the sensor, and hence giving erroneous readings, the
flowcellassemblymustbe mountedvertically asshown in
Fig. 2.8.
Fig. 2.1 Siting Requirements – Instrument/Sensor
Maximum Distance
30 metres
IP66
C – Within Environmental Limits
55 °C
Max.
–20 °C
Min.
B – Within Temperature Limits
A – Maximum Distance of Instrument to Unit
IP65

4
…2 MECHANICAL INSTALLATION
2.2 Mounting the Instrument
2.2.1 Wall-mounted Instrument – Figs. 2.2, 2.3 and 2.4
2.2.2 Panel-mounted Instrument – Figs. 2.5 and 2.6
Fig. 2.2 Overall Dimensions
Fig. 2.3 Wall Mounting
Fig. 2.4 Pipe Mounting
Fig. 2.5 Overall Dimensions
68
(2.68)
Fixing Centres
160 (6.3)
69 (2.72)
Fixing Centres
Allowance for
Cable Bends
200 (7.9)
42
(1.65)
61 (23/8) o.d.
Vertical Post
250
(9.84) 214
(8.43)
232
(9.13)
Three holes Ø 6.3 suitable
for M6 fastners Dimensions in mm (in)
Mark fixing centres
(see Fig. 2.3)
1
2
Drill suitable
holes
3
Fix instrument to
wall using
suitable fixings
Position ‘U’ bolts on pipe
1
2Position plates over ‘U’ bolts
Secure transmitter to mounting plate
Secure plates
4
3
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)

5
2 MECHANICAL INSTALLATION…
Fig. 2.6 Panel Mounting
Cut a hole in the panel (see Fig. 2.5 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.
3
1
2
3
4
5
6

6
…2 MECHANICAL INSTALLATION
2.3 Installing the Dissolved Oxygen Flowcell
2.3.1 Flowcell Dimensions
(without couplings fitted)
✶
Note.
•The sample flowrate must be between 100 and
500 ml/min.
• The Company recommends that stainless steel tubing
is used.
noisnemiD).ni(mmnieulaV
thgieH)28.3(0.79
htdiW)51.3(0.08
htpeD)82.4(6.801
Table 2.1 Flowcell Dimensions
(without couplings fitted)
2.3.2 System Design Options – Fig. 2.7
Fig. 2.7A shows a simple system with a sample line
isolation valve (V1) and a flowmeter installed. The
dissolved oxygen sensor is removed from the flowcell
for calibration in air – see Section 6.2.2.
The alternative, and recommended, system is shown in
Fig. 2.7B. Here the dissolved oxygen sensor remains in the
flowcell during calibration in air. An extra valve (V2) is fitted to
drain the sample from the flowcell prior to calibration.
2.3.3 Connecting the Sample Lines – Fig. 2.8
Mount the flowcell vertically as shown in Fig. 2.8A. Connect
the sample inlet and outlet tubes as shown in Fig. 2.8B.
Fig. 2.7 Flowcell Schematic Arrangements
A – Mounting the Sensor Block B – Connecting the Sample Lines
Fig. 2.8 Installing the Flowcell and Connecting the Sample Lines
Flowcell
Tundish
V1 = Sample Isolating Valve
V2 = Sample Drain Valve
V1
Drain
Flowmeter
Sample Flow
Flowcell
Tundish
V1
Drain
Flowmeter
Drain
V2
A – Simple System B – Recommended System
Sample Outlet
Sample Inlet
Nut
Olive
Push the outlet pipe
fully into the outlet
coupling and tighten
the nut to achieve
a leak-free seal.
Slide the nut and olive
onto the outlet pipe.
Connect the sample inlet pipe
using the procedure described
in Step 3.
Flowcell
2
3
4
Using the mounting bracket,
fix the flowcell to a vertical
surface using suitable fixings.
1
Fixing Centres
2 holes Ø6.5
67.0
(2.64)
47.0
(1.85)
Fixing Centres
Sample
Flow
Coupling
Dimensions in mm (in)

7
3 ELECTRICAL CONNECTIONS
Warning.
• Before making any connections, ensure that the power supply, any high voltage-operated control circuits and high
common mode voltage are switched off.
• Although certain instruments are fitted with internal fuse protection, a suitably rated external protection device, e.g. fuse
or miniature circuit breaker (m.c.b.), must also be fitted by the installer.
3.1 Access to Terminals
3.1.1 Wall-mounted Instruments – Fig. 3.1 3.1.2 Panel-mounted Instruments – Fig. 3.2
Fig. 3.2 Access to Terminal – Panel-mounted
Instrument (Rear View)
Fig. 3.1 Access to Terminal – Wall-mounted Instrument
3 ELECTRICAL CONNECTIONS…
Earth Studs
slide
down
1
Pull out
slightly. . . . . . and
slide off
2
2
Remove
protection
cover
Slacken
captive
screws
4
3
Remove nuts and
protection cover
1
Remove
mains cover
2
Mains Cover
Earth Stud

8
3.2 Connections, General
Information.
•Earthing (grounding) – stud terminals are fitted to the transmitter case for bus-bar earth (ground) connection – see
Fig. 3.1 or 3.2.
•Cable lengths – The cable length between the flowcell and the electronics unit is provided as ordered, and suitably
terminated at both ends.
•Cable routing – always route the signal cable and mains-carrying/relay cables separately, ideally in earthed metal
conduit.
Ensure that the cables enter the transmitter through the glands nearest the appropriate screw terminals and are short
and 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
7 mm 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 3.2.1 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 8.
Since the retransmission output is isolated the –ve terminal must be connected to earth (ground) if connecting to the
isolated input of another device.
3.2.1 Relay Contact Protection and Interference Suppression – Fig. 3.3
If the relays are used to switch loads on and off, the relay contacts can become eroded due to arcing.Arcing also generates radio
frequencyinterference(RFI) which can resultininstrumentmalfunction and incorrect readings.To minimize the effectsofRFI,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. 3.3.
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/0.022 µF RC suppressor unit (part no. B9303) as shown in Fig. 3.3A. If the instrument malfunctions (incorrect
readings) or resets (display shows 88888) the value of the RC network is too low for suppression – 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.
Ford.c. applications fit a diode as shown in Fig. 3.3B. For general applications use an IN5406 type ( 600 V peak inverse voltage
at 3 A – part no. B7363)
✶
Note. For reliable switching the minimum voltage must be greater than 12 V and the minimum current greater than
100 mA.
…3 ELECTRICAL CONNECTIONS
Fig. 3.3 Relay Contact Protection
RC
Load
LN
External
a.c. supply
Relay ContactsNC C NO
Load
+–
External
d.c. supply
Relay Contacts
A – a.c.Applications B – d.c. Applications
NC C NO
Diode