Aysix Technologies 2000CE User manual

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MODEL 2000CE
PROCESS ANALYZER
MODEL 10
OPTICAL DISSOLVED OXYGEN
SENSOR
MODEL 15/15L
OPTICAL SUSPENDED SOLIDS
SENSOR
REVISION – November 28, 2005
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2595 DUNWIN DR.#2
AYSIX TECHNOLOGIES

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TABLE OF CONTENTS
Product Description..................................................................................3
Packaging...................................................................................................3
INSTALLATION ..........................................................................................4
Analog Outputs..........................................................................................5
Digital Output.............................................................................................5
Relay Outputs.............................................................................................5
OPERATION................................................................................................6
Run Mode....................................................................................................6
Main Menu ..................................................................................................6
Setup Mode.................................................................................................6
Relay............................................................................................................7
Clean Mode.................................................................................................8
Demand Clean............................................................................................8
Analog Output............................................................................................8
Modbus Setup Mode.................................................................................9
SENSOR SETUP......................................................................................10
DO Sensor.................................................................................................10
SS SENSOR CALIBRATION...................................................................12
CH 2 MODE...............................................................................................13
Test Mode.................................................................................................14
ERROR MESSAGES................................................................................16
MAINTENANCE........................................................................................17
GUARANTEE AND REPAIR POLICY.....................................................17
Drawings...................................................................................................18
Appendix A- Modbus Protocol.............................................................A1
Appendix B – CA-2 Jet Clean System................................................. B1

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GENERAL INFORMATION
Product Description
The Model 2000 Process Analyzer is a two channel analyzer designed for the continuous
measurement of dissolved oxygen and/or suspended solids in mixed liquor aeration basins. The
microprocessor-based electronics of the Model 2000 analyzer provide a high degree of flexibility and ease
applications. The DO sensor to be used with this analyzer is an optical type sensor that measures the
fluorescence and quenching reactions of a ruthenium complex that is immobilized in a sol-gel matrix. The
SS sensor operates on the principle of single gap light absorption as a means of detecting the presence of
suspended solids.
The Model 10 Dissolved Oxygen sensor is designed for the continuous monitoring of dissolved
oxygen in water and wastewater where parts per million accuracy is required. The unit will display
dissolved oxygen content in either PPM, mg/l or %SAT. The resolution in PPM and mg/l mode is 0.01
over a range of 0.00 to 3.99 and 0.1 over a range of 4.0 to 20.0. The resolution in %SAT mode is
0.1%SAT over a range of 0.0 to 99.9%SAT and 1%SAT over a range of 100 to 400%SAT. Temperature
is displayed in 0.1 degree Celsius increments over a 0.0 to 50.0 degree Celsius range or 1 degree
Fahrenheit increments over a 32 to 122 degree Fahrenheit range. It incorporates self-cleaning optics via
air or water jet.
The Model 15 TSS sensor has been designed for medium ranges (0 to 30,000 mg/l) as commonly
found in aeration basins of wastewater treatment plants. The Model 15L sensor has been designed for low
ranges (0 to 1500 mg/l) as commonly found in effluent streams. Both sensors utilize an infrared emitter to
minimize color effects and compensates for emitter variations due to temperature by measuring source
brightness. They incorporate self-cleaning optics via air or water jet.
Packaging
The analyzer is housed in a NEMA 4X enclosure (see Drawing IIG01N111 for Outline and Mounting)
and is designed for outdoor mounting. For areas where the environmental temperature is expected to
drop below 14 degrees Fahrenheit (-10 degrees Celsius) for extended periods of time, the optional
automatic heater assembly is recommended.
of use. The instrument is designed to operate with any combination of Aysix sensors in a variety of

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INSTALLATION
1. The Model 2000 analyzer should be located convenient for an operator to read and technician to
install and maintain. A rear rail mounting kit is available for the standard enclosure (see Drawing
IIG01N110). This mounting kit is design for a standard 2” handrail but can be adapted to square
or angle handrails as well.
DO NOT! Locate the analyzer where it is likely to be
damaged during unrelated or other periodic maintenance such
as pressure washing catwalks.
easily mounts to most handrails and slide locks the sensor into place with out the use of tools.
(See drawings IIG02N004, IIG02N005, IIG03N004 and IIG03N005). Again, this sensor mounting
kit is design for a standard 2” handrail but can be adapted to square or angle handrails as well.
WARNING! – Before opening; switch off
the analyzer line power at the circuit breaker to avoid
risk of shock. Line power is present on terminals even
when analyzer is switched off.
WARNING! – Circuit breaker meeting IEC-
947-3 must be on line supply, in close proximity to
equipment and shall be marked as the disconnecting
device for the equipment.
3. Open the enclosure of the Process Analyzer. Pass all connection cables through glands or ½”
conduit in the bottom of the enclosure (gland and conduit are not supplied). The sensor input
connections are made to terminal blocks TB5 (labeled SENSOR 1) and TB7 (labeled SENSOR 2)
(see drawing IIG04R111). The four wires are color coded and there is a cable shield. Connect the
RED wire to the terminal labeled “RED”. Connect the GREEN wire to the terminal labeled “GRN”.
Connect the WHITE wire to the terminal labeled “WHT”. Connect the BLACK wire to the terminal
labeled “BLK”. Connect the cable SHIELD to the terminal labeled “SHLD”. The analog outputs
are available on the terminal block labeled TB1 and the relay outputs are available on the terminal
block labeled TB6.
4. Power Selector Switch: Check switch S4 on the circuit board to be sure that it is set for the type of
power being used (115 volts or 230 volts). Power connections should now be made to the
terminal block labeled TB3. Turn power "on" by using switch S3. Close and secure the enclosure.
5. Switch the circuit breaker on and the unit will now power up.
6. Once the unit is turned on, the unit will initialize and then jump into the "RUN" mode and begin
displaying Channel 1 “CH 1” content on the upper portion of the display and Channel 2 “CH 2”
content on the lower portion of the display.
2. Mount the sensor in the desired location. Aysix can supply a sensor handrail mounting kit that

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Note: The Model 10 D.O. sensor undergoes a
thorough and accurate test and calibration
procedure before shipment from the factory.
Calibration of the D.O. reading at startup is not
necessary and is not recommended.
Analog Outputs
Two isolated 4-20 or 0-20 milliamp signals capable of driving 600 ohms are available from the
terminal block labeled TB1. See drawing IIG04R111 for details. The analog #1 output, for channel #1, is
labeled "I 1" and the analog #2 output, for channel #2, is labeled “I 2”. The common or ground for these
signals are labeled "ICOM”.
Digital Output
A Modbus communications (RS-485) output is available from TB2. This is a three wire signal with a
transmit plus (labeled X+), a transmit minus (labeled X-), and a transmit ground or common (labeled X
COM). See drawing IIG04R111 for details. The RS-485 interface is electrically isolated from the
measurement and microprocessor circuitry of the Model 2000. The communications protocol for the
Digital Output is fully described in Appendix A.
RelayOutputs
There is one independent programmable set point control relay for each channel. These relays are
Form-C with contacts rated 10/6 amps resistive load at 125/250 VAC. Two Form-A relays with contacts
rated 10/6 amps resistive load at 125/250 VAC are used for the jet clean function. The connections for
the relay outputs are available from TB6. See drawing IIG04R111 for connection details.

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OPERATION
Note! – In “Normal Operation” the hinge
cover is to remain tightly screwed closed. Under no
circumstance is it necessary for the operator to open
the enclosure.
Run Mode
The RUN mode is the normal operating mode of the analyzer and is entered upon power-up. When
the Run mode is entered the analyzer will determine what types of sensors are attached to each channel.
The supplied sensors have been calibrated at the factory. The display is continuously updated with the
current measurement values. Also, the analog output and the relays are updated according to the current
conditions and their programmed functions. In the event of an error or alarm condition the display will
indicate the problem in plain English text.
Sensor information for the Model 10 D.O. sensor is stored in non-volatile memory of the sensor.
Sensor information for the Model 15/15L TSS sensor is stored in non-volatile memory of the analyzer. If a
Model 15/15L is connected to the analyzer and the sensor information does not match the information
stored in the analyzer, the analyzer will display a configuration message. The configuration message for
the Model 15/15L TSS sensor is “**Zero sensor**”. These messages will appear whenever the sensor is
changed.
While in the RUN Mode, the time to next scheduled clean cycle can be viewed by pressing and
holding either arrow key. A clean cycle can be demanded by pressing the ENTER key while in the RUN
Mode, see the section on Demand Clean.
Main Menu
The Main Menu is accessed by pressing the “MENU” key while in the RUN mode of operation. There
are three options available from the main menu. Use the arrow keys to switch between RUN, SETUP &
TEST, and then press the "ENTER" key to select.
Setup Mode
This mode of operation allows the user to customize the unit to the specific operation and needs of the
facility. There are a total of five subcategories that may be adjusted.
Operation of the SETUP MODE proceeds as follows:
First, after pressing the "MENU" key, use the “ARROW” keys to move the cursor to the SETUP
option, then press the “ENTER” key. A menu with six options will be displayed. The options are;
RELAYS
ANALOG OUTPUT
MODBUS
SENSOR 1 SETUP
SENSOR 2 SETUP
CH 2 MODE

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Second, use the “ARROW” keys to move the cursor to the desired setup function, then press the
“ENTER” key. The sub-menu for that group will be displayed. Use the “ARROW” keys to move the cursor
to specific item to be changed, then press the “ENTER” key. When the user is finished making the
adjustment, press the “MENU” key to return to the previous page.
Finally, to return to the RUN MODE, press the “MENU” key until the MAIN MENU is displayed. Use
the “ARROW” keys to move the cursor to the run option, then press the “ENTER” key.
Relay
From the setup menu, use the “ARROW” keys to move the cursor to the “1-Relays” option, and then
press the “ENTER” key. There are 11 menu options for configuring the relays.
RELAY 1 OP MODE – defines operation mode of relay 1
RELAY 1 ON SETPOINT – defines when relay 1 will energize
RELAY 1 OFF SETPOINT – defines when relay 1 will de-energize
RELAY 1 FAIL MODE – defines the relay 1 state during an alarm condition
RELAY 2 OP MODE – defines operation mode of relay 2
RELAY 2 ON SETPOINT – defines when relay 2 will energize
RELAY 2 OFF SETPOINT – defines when relay 2 will de-energize
RELAY 2 FAIL MODE – defines the relay 2 state during an alarm condition
RELAY 3 OP MODE – defines operation mode of relay 3.
CLEAN SCHEDULE – defines how often relay four will energize cleaning
CLEAN JET TIME – defines duration of time the clean relays will be energized
CLEAN RECOVERY TIME – defines how many long the reading holds.
The following section is a brief discussion of considerations for configuring the relays 1 and 2.
Note: Do not attempt to adjust relay set points
values until a working sensor has been
connected to the channel. Otherwise, the
analyzer may not display the correct units (TSS
or D.O.) for the channel.
Low Setpoint
If a relay “OP MODE” has been set as a LOW setpoint, then the corresponding relay will energize if
the reading falls below the value set in the “ON SETPOINT” parameter. Once the relay has been
energized by a low reading, it will not be deenergized until the reading rises above the value set in the
“OFF SETPOINT” parameter. The relay “OFF SETPOINT” value MUST be greater than or equal to the
“ON SETPOINT” value in this mode.
High Setpoint
If a relay “OP MODE” has been set as a HIGH setpoint, then the corresponding relay will energize if
the reading rises above the value set in the “ON SETPOINT” parameter. Once the relay has been
energized by a high reading, it will not be deenergized until the reading falls below the value set in the
“OFF SETPOINT” parameter. The relay “OFF SETPOINT” value MUST be less than or equal to the “ON
SETPOINT” value in this mode.

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Relay #3:
Relay 3 has three modes, ALARM, CA2 CLEAN, and SPECIAL.
ALARM MODE: In this mode, the relay is energized for normal operation and will become
deenergized if an error condition occurs. Consequently, loss of power can be sensed remotely as an
alarm condition.
CA2 CLEAN: This mode must be chosen if a model CA2 compressor cleaning assembly is used.
Both relays 3 and 4 are needed to operate this compressor.
SPECIAL: This mode is set if customer supplied air or water is being used with one or two solenoid
valves (see drawing IIG04R113) Or, if a CA1 compressor is being used to clean both sensors. In this
mode the analyzer will energize relay #4 for a clean duration and then de-energize #4 and energize relay
#3 for a clean duration.
Clean Mode
The jet clean system is intended to be connected to relays 4 and/or 3. The relays are connected to
drawing IIG04R113 and IIG04R112 for details.
The CLEAN SCHEDULE program parameter determines how often the jet clean cycle will occur. This
parameter can be set to values of 10 minutes to 24 hrs. Typically, a clean interval of 2 hrs works well for
aeration basins. In colder climates, condensation may form then freeze in the jet-clean tubing. To
prevent this, set the clean interval to 10 or 20 minutes. If this is set to “0” then cleaning is turned off.
The CLEAN JET TIME program parameter determines how long the jet clean cycle will last. The
CLEAN PULSE can be set to values of 1-second to 90-seconds with a 1-second resolution. Typically, a
clean pulse of 30-seconds works well for aeration basins. A clean cycle will consist of the channel 1
sensor being cleaned for the programmed clean jet time immediately followed by the channel 2 sensor
being cleaned for the programmed clean jet time. The analyzer will hold the measurement reading during
the clean cycle and the recovery period which is equal to the programmed clean jet time.
The CLEAN RECOVERY parameter determines how long the analyzer will hold the DO reading after
the cleaning jet time has expired. The default setting is 1 minute which is adequate in most applications.
However, increased recovery time may be required for applications where the sensor is in stagnant water
or dead zones.
Demand Clean
When the analyzer is in the RUN mode pressing the "ENTER" button will cause a clean cycle to begin.
Performing demand clean doesn’t affect the normal clean schedule.
Analog Output
From the SETUP menu, use the ARROW keys to select the “ANALOG OUTPUT” option, then press
the ENTER key. The ANALOG OUTPUT SETUP menu has 8 parameters for configuring these outputs.
ANALOG 1 TYPE – select either 4-20mA or 0-20mA operation for the Analog 1 output.
ANALOG 1 FULL SCALE –defines the value that will cause the Analog 1 output to go to 20mA.
ANALOG 1 MIN SCALE – defines the value that will cause the Analog 1 output to go to 0/4mA.
ANALOG 1 FAIL MODE – defines the value of the Analog 1 output during an alarm or error condition.
Choose between holding the last good reading, 0/4mA, or 20mA.
the Aysix compressor, CA-2, or a customer supplied air or water source and a shut-off valve. See

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ANALOG 2 TYPE – select 4-20mA operation, 0-20mA operation, or 4-20mA output of channel
1’s temperature (only available if channel 1 is a DO sensor) for the
Analog 2 output.
ANALOG 2 FULL SCALE –defines the value that will cause the Analog 2 output to go to 20mA.
ANALOG 2 MIN SCALE – defines the value that will cause the Analog 2 output to go to 0/4mA.
ANALOG 2 FAIL MODE – defines the value of the Analog 2 output during an alarm or error condition.
Choose between holding the last good reading, 0/4mA, or 20mA.
Modbus Setup Mode
From the setup menu, use the “ARROW” keys to select the “MODBUS” option, then press the
“ENTER” key. There are two menu options for configuring the serial digital output.
Comm Address – defines the address of the analyzer
Comm Baud Rate – defines the baud rate of the digital output
Appendix A describes the Modbus protocol implementation in the Model 2000.

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SENSORSETUP
Each channel has its own sensor setup menu. The analyzer will select the appropriate menu for the
type of sensor that is currently connected to each channel.
DO Sensor
General
The Model 10 sensor has been designed to require very infrequent calibration. Unlike polaragraphic
systems, light fouling of the sensing element should not affect the accuracy of the reading, but should only
slow the response time of the system. (However, heavy biological fouling that prevents reasonable sensor
contact with the water will cause erroneous readings.) With the sensor kept reasonably clean, the
calibration should hold for 6 months to 2 years, depending upon conditions.
Note: The Model 10 D.O. sensor undergoes a
thorough and accurate test and calibration
procedure before shipment from the factory.
Calibration of the D.O. reading at startup is not
necessaryand is not recommended.
The Model 2000 analyzer allows the user to select from two different calibration procedures. The
procedure can be selected by choosing SETUP from the main menu. Once the SETUP menu appears,
use the arrow keys to choose the “SENSOR x SETUP” option where x is the channel number of the
desired sensor.
Sensor Calibration to a Reference
Calibration to a known reference is the easiest, simplest, and also the preferred method of calibration
when calibration is required. Calibration option number 1 “Sensor Ref Cal” allows the operator to make
adjustments to the D.O. reading to agree with any other source of D.O. information. THIS CALIBRATION
PROCEDURE MUST ONLY BE USED ON A CLEAN SENSOR. IF THE SENSOR IS READING
ERRONEOUSLY DUE TO HEAVY BIOLOGICAL FOULING, USE OF THIS CALIBRATION METHOD
WILL RESULT IN UNRELIABLE RESULTS. The sensor must be stable in the water to be used as a
reference before beginning this procedure. From the SENSOR SETUP menu, choose the “Sensor Ref
Cal” option, and press ENTER. The analyzer will now read the sensor for the period of time indicated by
the “dampening” parameter, and display the result as D.O. in PPM. If this result matches the reference,
simply press ENTER to exit. Otherwise, use the arrow keys to adjust the reading to match the reference
value, and then press ENTER to store this new value. This procedure is primarily an adjustment to the
offset value of the sensor, but an adjustment in slope will also be made when this procedure is performed.
Sensor Slope Adjustment (NOT RECOMMENDED)
If performed correctly, the previously described “Sensor Calibration to a Reference” should be all that
is required by the user. “Sensor slope adjustment” should only be attempted upon recommendation from
the factory.
Sensor calibration option 2 “Sensor Slope Adj” allows the user to adjust the span of the sensor, but
this procedure must only be used immediately AFTER the sensor has been “zeroed” using calibration
option 1 with the sensor submerged in a zero oxygen solution. This zero solution may be prepared by
adding two tablespoons of sodium sulfite salt to a gallon of tap water in an open container (bucket). The
sodium sulfite salt will remove all oxygen from the water as it dissolves. Stir the water for about one