EUTECH INSTRUMENTS Alpha-CON560 User manual

Technolo
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M
ade
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Instruction Manual
D
lpha-CON560
Conductivity Controller
mS
/
μ
S/ºC/ºF mete
r
68X216878 Rev 3 Aug 07
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Preface
This manual serves to explain the use of the
D
lpha-CON 560 Industrial
Conductivity Controller. The manual functions in two ways, firstly as a step by step
guide to help the user operate the instrument. Secondly, it serves as a handy
reference guide. This instruction manual is written to cover many anticipated
applications of the Dlpha-CON 560 controller. If you have doubts in the use of the
instrument, please do not hesitate to contact the nearest Eutech Instruments
Authorised Distributor.
The information presented in this manual is subject to change without notice as
improvements are made, and does not represent a commitment on part of Eutech
Instruments.
Eutech Instruments cannot accept any responsibility for damage or malfunction of the
unit due to improper use of the instrument.
Copyright 2006 All rights reserved.
Eutech Instruments Pte Ltd.
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Table of Contents
1. Introduction ...........................................................................................................1
1.1 Before You Begin................................................................................................................... 1
1.2 Intended Use.......................................................................................................................... 1
1.3 Safety Instructions.................................................................................................................. 2
1.4 Taking Out of Service / Correct Disposal of the Unit ............................................................. 2
2. Getting Started ......................................................................................................3
2.1 Description of Instrument .......................................................................................................3
2.2 Measurement and Control System......................................................................................... 4
2.3 Connecting Peripherals..........................................................................................................5
2.3.1 Connection Terminals.................................................................................................... 5
2.3.2 Switching Between Pt100 & Pt1000 Temperature Sensors.......................................... 6
2.3.3 Connecting Conductivity Probe..................................................................................... 7
2.3.4 Connecting Temperature Probe.................................................................................... 7
2.4 Installation.............................................................................................................................. 8
2.4.1 Mechanical Dimensions................................................................................................. 8
2.4.2 Wall Mount..................................................................................................................... 8
2.4.3 Panel Mount................................................................................................................... 9
2.5 Display & Keypad................................................................................................................. 10
2.5.1 Display Overview......................................................................................................... 10
2.5.2 Key Functions.............................................................................................................. 11
3. Operation .............................................................................................................13
3.1 Measurement mode ............................................................................................................. 13
3.2 Menu Overview .................................................................................................................... 14
4. Calibration Mode .................................................................................................15
4.1 About Calibration.................................................................................................................. 15
4.2 Calibration............................................................................................................................ 16
5. Setup Mode..........................................................................................................19
5.1 Enter Setup mode ................................................................................................................19
5.2 Temperature Coefficient Settings......................................................................................... 20
5.3 Temperature Settings........................................................................................................... 21
5.4 Relay 1/Relay 2 Settings...................................................................................................... 23
5.5 Controller Settings................................................................................................................ 25
5.6 Measuring Range Settings................................................................................................... 27
5.7 Configuration Settings..........................................................................................................28
5.8 Viewing Electrode Properties............................................................................................... 30
6. Technical Specifications.....................................................................................31
7. List of Accessories .............................................................................................33
8. Troubleshooting..................................................................................................34
9. General Information ............................................................................................35
9.1 Warranty............................................................................................................................... 35
9.2 Return of Goods................................................................................................................... 35
9.3 Guidelines for Returning Unit for Repair.............................................................................. 35
10. Appendices.......................................................................................................36
10.1 Appendix 2 Conductivity of various aqueous solutions....................................................... 36
10.2 Appendix 2 Graphical Representation of the Function of Hysteresis ................................. 37
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10.3 Appendix 3 General Instructions Concerning Controller Setting ........................................ 38
10.4 Appendix 4 - Abbreviations Used in LCD............................................................................. 39
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Instruction Manual Dlpha-CON 560
1
1.Introduction
1.1 Before You Begin
We thank you for purchasing the
D
lpha CON 560 controller.
The construction of the CON 560 controller employs leading edge technology
and complies with safety regulations currently in force. Notwithstanding this,
improper use could lead to hazards for the user or a third-party, and/or
adverse effects on the plant or other equipment. Therefore, the operating
instructions must be read and understood by the persons involved before
working with the controller.
The instruction manual must always be stored close at hand, in a place
accessible to all people working with the conductivity controller.
If you have questions, which are not or insufficiently answered in this
instruction manual, please contact your authorized supplier. They will be glad
to assist you.
1.2 Intended Use
Dlpha CON 560 controllers are intended solely for conductivity and
temperature measurement, as described in this instruction manual.
Any other use, or use not mentioned here, that is incompatible with the
technical specifications is deemed inappropriate. The operator is solely
responsible for any damage arising from such use.
Other prerequisites for appropriate use include:
–Comply with the instructions, notes and requirements set out in this
instruction manual.
–Comply with all local safety regulations concerning safety at work.
–Comply with all information and warnings in the documentation dealing
with the products used together with the conductivity controller (housings,
sensors, etc.).
–Comply with local environmental and operational conditions.
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Instruction Manual Dlpha-CON 560
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1.3 Safety Instructions
- The Dlpha CON 560 controller should be installed and operated only
by personnel familiar with the instrument and who are qualified for
such work.
- A defective CON controller must neither be installed nor put into
service.
- The Dlpha CON 560 must only be operated under the specified
operating conditions (see section 6).
- The Dlpha CON 560 must not be repaired by the customer.
- No modifications to the Dlpha CON 560 are allowed. The
manufacturer/supplier accepts no responsibility for damage
caused by unauthorized modifications. The risk is borne entirely
by the user.
1.4 Taking Out of Service / Correct Disposal of the Unit
Taking out of Service
xFirst disconnect the unit from the power supply and then undo all electrical
connections.
xRemove the unit from the wall / panel.
Correct Disposal of the Instrument
When the Dlpha CON 560 controller is permanently taken out of service,
obey the local environmental regulations for correct disposal or send the
instrument to your local distributor, they will take care of proper disposal.
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Instruction Manual Dlpha-CON 560
3
2.Getting Started
2.1 Description of Instrument
The Eutech Instruments’ Įlpha CON 560 controller is used for measuring
conductivity and temperature values. The controller can be used for
applications such as water treatment and controlling, galvanic-
decontamination, chemical processing, food processing, clean or wastewater
control and neutralization processes.
The controller has many user-friendly and safety features which include:
xPush-button keypad for calibration and setup
xBuilt-in non-volatile memory to ensure that calibration and other
information are not erased if power supply fails
xMenu-driven program that simplifies setup
xAutomatic temperature compensation (ATC)
xManual temperature compensation setting without the ATC probe, with
independent setting for calibration and process temperature
xLarge dual display LCD for easy reading with clear multiple annunciators,
operational mode indicators and error indicators
xTwo switching contacts as set-point relays
xLimit (on/off) control mode
xSeparately adjustable high and low set-point hysteresis (dead bands) to
prevent chattering of relays around the set points
x0 to 2000 seconds time delay adjustment on all relays – minimizes false
alarms
xBacklight LCD display
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Instruction Manual Dlpha-CON 560
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2.2 Measurement and Control System
A typical measurement system consists of:
xA conductivity process controller
xA conductivity sensor with integrated or separate Pt100/Pt1000
temperature sensor
xAn appropriate measurement cable
xAn immersion, flow or process assembly
xA final control element such as pump or valve
PowerAdaptor
(+9 V DC)
Relay Output
Measurement Cable
Housing and
Sensors
Pump or Valve
A
lpha CON 560 Controller
ENT
ESC
pH Monitor
lpha pH560
CAL
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Instruction Manual Dlpha-CON 560
5
2.3 Connecting Peripherals
2.3.1 Connection Terminals
Remove Back Cover:
Remove the screws from the four corners at the back of the conductivity
controller. Remove the back cover. The connectors are exposed on the back
PCBA as shown in the Figure 1 below.
Connectors:
xJ8 – 9V DC power connector (1.2mm diameter)
xJ9 – Relay connections
xJ10 - Conductivity electrode & Temperature probe connections (wiring has
to be done in the detachable connector
J10
J8
REL 1 REL 2
J9
9V DC Power
Screw
J10 Connections
1. CON Low Current
2. CON Low Voltage
3. CON High Voltage
4. CON High Current
5. Pt 100 Compensate
6. Pt 100 Sense
7. Pt 100 GND
8. (No connection)
J9 Connections
Relay 1 & 2
Figure 1: Outer Side of Back PCBA
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Instruction Manual Dlpha-CON 560
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2.3.2 Switching Between Pt100 & Pt1000 Temperature Sensors
The controller supports both Pt100 & Pt1000 (2-wire or 3-wire) temperature
sensors. The default factory setting is Pt100. If you need to use Pt1000
temperature sensor, you have to change the jumper setting (J7) as described
below.
Remove Back Cover:
Remove screws from the four corners at the back of the conductivity
controller. Remove the back cover.
Remove Back PCBA:
Remove the screw located center of the back PCBA (Figure 1). Detach the
back PCBA from the controller. Turn over the back PCBA. Locate J7 jumper
on the inner side of the back PCBA as shown in Figure 2 below.
Jumper Setting for
Pt100
(Factory Default)
Jumper Settings for
Pt1000
J7
Figure 2: Inner Side of Back PCBA
Set Jumper J7:
Set the J7 jumper to required sensor (Pt100 or Pt1000) type.
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Instruction Manual Dlpha-CON 560
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2.3.3 Connecting Conductivity Probe
Any industrial conductivity probe (2-cell or 4-cell) can be connected to the
conductivity controller.
2-Cell Conductivity Probe:
1. Short Pin 1 & 2 of J10 connector using a jumper wire.
2. Connect CON low input wire (white) to Pin 2 of J10 connector.
3. Connect CON high input wire (black) to Pin 3 of J10 connector.
4. Short Pin 3 & 4 of J10 connector using a jumper wire.
4-Cell Conductivity Probe:
1. Connect CON low input wire (black) to Pin 1 of J10 connector
2. Connect CON low input wire (white) to Pin 2 of J10 connector.
3. Connect CON high input wire (orange) to Pin 3 of J10 connector.
4. Connect CON high input wire (blue) to Pin 4 of J10 connector.
2.3.4 Connecting Temperature Probe
For Automatic Temperature Compensated (ATC) conductivity readings, an
in-built temperature sensor is usually integrated with industrial conductivity
probes. Alternatively, a separate 100:Pt RTD temperature probe (2-wire or
3-wire) can be connected to the controller.
3-Wire Probe:
1. Connect PT100 compensate wire to Pin 5 of J10 connector.
2. Connect PT100 sense wire to Pin 6 of J10 connector.
3. Connect PT100 GND wire to Pin 7 of J10 connector.
2-Wire Probe:
4. Short Pin 5 & 6 of J10 connector using a jumper wire.
5. Connect PT100 sense wire to Pin 6 of J10 connector.
6. Connect PT100 GND wire to Pin 7 of J10 connector.
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Instruction Manual Dlpha-CON 560
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2.4 Installation
2.4.1 Mechanical Dimensions
ENT
ESC
Conductivity Monitor
lpha CON560
CAL
2.4.2 Wall Mount
Pierce through holes at
both sides
11
Cover the catch slots at
both sides with overlays
2
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Instruction Manual Dlpha-CON 560
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2.4.3 Panel Mount
Panel
Gasket
Prepare panel cut-out of
92.0 mm X 92.0 mm
Remove back cover of
conductivity controller
and slide it through
panel cut-out
Attach catch to both sides
of conductivity controller
Insert threaded rods through catch
until conductivity controller is held
against panel
2
3
4
1
1
Panel
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Instruction Manual Dlpha-CON 560
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2.5 Display & Keypad
2.5.1 Display Overview
The Liquid Crystal Display (LCD) of Įlpha CON 560 conductivity controller
has two alpha-numerical displays (Upper and a Lower).
xUpper display: Measured conductivity value is displayed when the
controller is in normal operation (measurement) mode.
xLower display: Measured temperature value is displayed when the
controller is in normal operation (measurement) mode. In conductivity
calibration mode, measured conductivity values are displayed here.
The two displays indicate function names, options & settings in Setup mode.
Refer ‘Appendix 4 - Abbreviations Used in LCD’ for more details.
The LCD also consists of various mode indicators, status annunciators and
unit of measurement indicators.
mS
R.
SETUP MEAS CAL
Upper Display
Lower Display
ERR
ATC
°C
READY
8.8.8.8
.8.8.8
-
-
HOLD
°F
μS
%
K=
Mode Indicators
MEAS Measurement mode (Refer Section )3.1
SETUP Setup mode (Refer Section )5
CAL Calibration mode (Refer Section )4
Status Annunciators
READY Appears when the reading is stable
HOLD Appears in Setup mode and Calibration mode to indicate that the relay function
is frozen
ATC Appears when Automatic Temperature Compensation (ATC) is enabled.
Not visible when Manual Temperature Compensation (MTC) is enabled.
Flashes if the temperature probe is faulty in its ATC mode. (Refer Section )5.3
ERR Appears when an error occurs
Electrode annunciator. Blinks during calibration error (Refer Section )4.2
Buffer annunciator. Appears in calibration mode (Refer Section )4.2
K Cell Constant (Refer Section )4.2
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Instruction Manual Dlpha-CON 560
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2.5.2 Key Functions
ENT
ESC
Conductivity Monitor
lpha CON560
CAL
Key Description
CAL
Enter Calibration mode
ENT
Enter Setup mode
Access sub screens (parameters) within a group of settings in Setup
mode
Confirm (save) setup parameters and numerical values
Start/Confirm calibration in Calibration mode.
Select a group of settings in Setup mode.
Select parameters and increment/decrement numerical values in Setup
and Calibration modes.
(When pressed continuously, speed of value increment/decrement
increases)
Returns to Measurement mode when both keys are pressed
simultaneously.
Units of Measurement Indicators
Conductivity in Milli Siemens
mS
μS Conductivity in Micro Siemens
R. Line Resistance in Ohms (Refer Section )5.7
)
% Temperature Coefficient (Refer Section 5.2
Temperature in Celsius (Refer Section )
ºC 5.3
Temperature in Fahrenheit (Refer Section )
ºF 5.3
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Instruction Manual Dlpha-CON 560
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3.Operation
3.1 Measurement mode
When the conductivity controller is powered on, the display shows all the
LCD segments briefly, and then automatically enters into the measurement
mode.
μS
MEAS
ATC
°C
READY
25.0
The mode indicator ‘MEAS’ at the top of the display indicates that the
conductivity controller is in measurement mode. The upper alpha-numerical
display shows the measured conductivity value, while the lower display
shows the temperature value.
The controller has six selectable measuring ranges. The unit of measurement
and resolution of the conductivity reading depend on the selected measuring
range. If the controller reads a conductivity reading beyond the selected
measuring range, the display shows ‘Or’ (over range) error indicator.
To guarantee accurate readings, the measuring system (the
conductivity controller and the sensor) must be calibrated
regularly.
NOTE:
From measurement mode you can access:
xCalibration mode (by pressing CAL key)
xSetup mode (by pressing ENT key)
For more details, refer section 4 for Calibration mode and section 5 for Setup
mode.)
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Instruction Manual Dlpha-CON 560
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3.2 Menu Overview
MEAS
μS
°C
ATC
READY
ENT
SETUP
HOLD
SETUP
HOLD
ENT
SETUP
HOLD
SETUP
HOLD
SETUP
HOLD
SETUP
HOLD
SETUP
HOLD
SETUP
HOLD
ENT
ENT
ENT
ENT
ENT
ENT
ENT
CAL ENT
ENT
ENT
ENT
ENT
ENT
ENT
ENT
ENT
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Instruction Manual Dlpha-CON 560
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4.Calibration Mode
4.1 About Calibration
Calibration should be carried out each time a new electrode is attached to the
controller or when you suspect that the controller/electrode is out of
calibration. The controller allows you to perform temperature calibration and
conductivity calibration.
About Temperature Calibration
It is important to ensure that temperature calibration is carried out prior to
conductivity calibration since temperature readings affect the accuracy of
conductivity measurements. It is recommended that temperature calibration
should be carried out only if the temperature value displayed on the controller
is different from that of a calibrated thermometer. A temperature offset
calibration of ± 10 °C/± 18 °F from the default reading is allowed. Once a
temperature calibration is performed, conductivity calibration should be
carried out to ensure the accuracy of conductivity measurements.
About Measuring Ranges & Conductivity Calibration
The controller has six selectable conductivity measuring ranges. You can
only calibrate one-point in the measuring range that you have selected for
your process application. You have to recalibrate the controller every time
you change the measuring range since the calibration data of the controller
will be reset every time a new measuring range is selected.
About Conductivity Calibration
During conductivity calibration, the controller allows a calibration window of
± 40% from the measured default reading of the calibration standard. The
minimum allowable calibration point is 10% of the full scale reading of the
measuring range selected.
For best results, select a standard conductivity solution close to the sample
value you are measuring.
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Instruction Manual Dlpha-CON 560
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4.2 Calibration
The controller requires one-point calibration. Conductivity calibration is
always carried out in the specific measuring range selected for the controller.
Make sure, the controller is set to desired measuring range before you enter
calibration mode (Refer Section 5.6 for selecting measuring ranges).
Select a suitable standard conductivity solution so that its conductivity value
is within 10% to 100% of the full scale of the selected measuring range of the
controller. (For better accuracy, select the calibration standard to be nearly
50% of the full scale of the measuring range selected.) Prepare calibration
standard solution in two beakers – one for rinsing and the other for calibration.
Prepare separate de-ionized water for electrode rinsing.
All new calibration values will automatically override existing calibration data.
If you wish to abort the calibration, press Ÿand źkeys simultaneously and
the controller reverts to measurement mode and the controller will revert to
previous calibration data.
CAL
HOLD
CAL
HOLD
MEAS
°C
ATC
READY
ENT
12
CAL
HOLD
3
ENT
HOLD
K=
2
CAL
HOLDK=
μS
CAL
HOLD
4
READY READY
OR
μS
CAL
HOLD
3
μS
READY
ENT
2
MEAS
°C
A
TC
READY μS
From measurement mode press CAL key to enter calibration mode.
11
The display briefly shows the cell type (“2 CELL” or “4 CELL”) to which
the controller is configured (Refer section
2
5.7 for cell type settings)
Next, the last configured cell constant (k) is displayed in the upper
display. Use Ÿor źkeys to adjust the cell constant to mach the cell
constant of the conductivity probe. Adjustable range is 0.10 to 10.0.
Press ENT key to confirm the new cell constant value.
Rinse the electrode in de-ionized water and then rinse with the
calibration standard. Immerse the probe in calibration standard solution
intended for calibration and swirl gently to create a homogenous sample.
Make sure there are no any air-bubbles trapped in the sensor.
The upper display shows the currently measured conductivity value of
the solution based on last calibration (if any). The lower display shows
uncalibrated (default) reading of the solution. The buffer annunciator
appears in LCD. The ‘READY’ annunciator appears when the reading is
stable.
3
Once the reading stabilizes press the Ÿor źkey to adjust the upper
display value to that of the standard solution. Press the ENT key to
accept the value.
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NOTES: xThe acceptable calibration window is ±40% of the
displayed (default) value. For example, if the display is
1000 μS, the values to which it can be adjusted is 600 to
1400 μS.
xIf the conductivity reading of the solution is not within 10%
to 100% of the full scale of the selected measuring range,
calibration error occurs; LCD displays “ERR” and flash
electrode annunciator.
xIf the conductivity reading of the solution is beyond the
selected measuring range, calibration error occurs; LCD
displays “Or” (over range), “ERR” and flashes electrode
annunciator.
xIf calibration error occurs, exit form calibration mode by
pressing Ÿand źkeys simultaneously.
Calibration is completed. The display shows the calibration factor (FCt).
This serves as an indication of the effectiveness of the sensor which will
degrade with time and usage. An effective sensor should have a
calibration factor of 0.60 to 1.40
4
Press ENT key to return to measurement mode.
NOTES:
xIf you use a 2-cell conductivity sensor, make sure that the pin 1 and 2
are shorted and pin 3 and 4 are shorted on the J10 connector. (Refer
section 2.3.3 for more details)
xWhen calibrating with manual temperature compensation, the
controller automatically changes from the preset process temperature
to the calibration temperature. After leaving the Calibration mode, the
controller switches back to the process temperature (for setting the
calibration temperature and the process temperature, see section 5.3)
WARNING: If you change the measuring range of the controller after
calibration is done, the controller will reset back to its factory default calibration.
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