Forbes Marshall Aquacon 4000 User manual

Instruction Manual
Aquacon 4000
Conductivity Controller / Transmitter
01/2004

Preface
This manual serves to explain the use of the Aquacon 4000 Series. The manual functions in two ways,
firstly as a step by step guide to help the user operate the instrument, and secondly as a handy
reference guide. This instruction manual is written to cover as many anticipated applications of the
Aquacon 4000 as possible. If you have any doubts concerning the use of the instrument, please do not
hesitate to contact the nearest office of Forbes Marshall Pvt. Ltd.
The information presented in this manual is subject to change without notice as improvements are made,
and does not represent any commitment whatsoever on the part of Forbes Marshall Pvt. Ltd.
Forbes Marshall Pvt. Ltd. cannot accept any responsibility for damage or malfunction of the unit due to
improper use of the instrument.
Copyright ©2003 All rights reserved.
Forbes Marshall Pvt. Ltd.
01/2004

Safety Information
The Forbes Marshall Controller/ Transmitter shall be installed and operated only in the manner specified
in the Instruction manual. Only skilled, trained or authorized person should carry out installation, setup
and operation of the instrument.
Before powering up the unit, make sure that power source it is connected to, is as specified in the top
label. Failure to do so may result in a permanent damage to the unit.
The unit has live and exposed parts inside. If it has to be opened, make sure that the power to the unit
is off and disconnected.
The unit is Fuse protected. In the event the fuse has to be replaced, use only those as specified in the
manual.
The degree of protection against electric shock will be achieved only by observance of the
corresponding installation rules.

TABLE OF CONTENTS
1INTRODUCTION .......................................................................................................................................... 1
1.1 AT THE VERY BEGINNING......................................................................................................................... 1
1.2 INTENDED USE.......................................................................................................................................... 1
1.3 SAFETY INTSRUCTIONS ............................................................................................................................ 2
1.4 PUTTING OUT OF SERVICE /CORRECT DISPOSAL OF THE UNIT................................................................. 2
2PRODUCT DESCRIPTION.......................................................................................................................... 3
2.1 DESCRIPTION OF UNIT .............................................................................................................................. 3
2.2 MEASUREMENT AND CONTROL SYSTEM .................................................................................................. 4
2.3 UNIT OVERVIEW....................................................................................................................................... 5
2.3.1 Display Overview ............................................................................................................................... 7
2.3.2 Key functions ...................................................................................................................................... 7
2.3.3 LED indicators ................................................................................................................................... 8
2.3.4 Security codes..................................................................................................................................... 8
2.3.5 Menu overview ................................................................................................................................... 9
3ASSEMBLY AND INSTALLATION......................................................................................................... 11
3.1 MOUNTING THE UNIT ............................................................................................................................. 11
3.2 CONNECTION DIAGRAM......................................................................................................................... 13
4NORMAL OPERATION............................................................................................................................. 17
4.1 MEASUREMENT MODE ........................................................................................................................... 17
5CALIBRATION MODE .............................................................................................................................. 18
5.1 ENTERING CALIBRATION MODE............................................................................................................. 18
5.2 CALIBRATION......................................................................................................................................... 19
5.3 VIEW ACTUAL CELL CONSTANT AND CALIBRATION FACTOR................................................................. 20
6SETUP MODE .............................................................................................................................................. 21
6.1 ENTER SETUP MODE............................................................................................................................... 21
6.2 TEMPERATURE COMPENSATION (TC) SUB-FUNCTION ........................................................................... 23
6.3 SETTING TEMPERATURE (SET °C°F) SUB-FUNCTION ............................................................................. 24
6.4 CONTROL RELAY A/RELAY B(SP1/SP2) SUB-FUNCTION ................................................................... 25
6.5 CONTROLLER (CNTR) SUB-FUNCTION.................................................................................................. 27
6.6 CURRENT OUTPUT 1SUB-FUNCTION ..................................................................................................... 30
6.7 CURRENT OUTPUT 2SUB-FUNCTION ..................................................................................................... 31
6.8 WASH RELAY (WASH) SUB-FUNCTION................................................................................................. 32
6.9 MEASURING RANGE SELECTION (RANG) SUB-FUNCTION..................................................................... 33
6.10 CONFIGURATION (CNFG) SUB-FUNCTION............................................................................................. 34
6.11 CALIBRATION (CAL) SUB-FUNCTION .................................................................................................... 35
7RELAY MODES........................................................................................................................................... 36
7.1 VIEW RELAY SET POINTS........................................................................................................................ 36
7.2 MANUAL RELAY MODE .......................................................................................................................... 37
8TECHNICAL SPECIFICATIONS............................................................................................................. 38
8.1 GENERAL SPECIFICATIONS ..................................................................................................................... 38
8.2 SPECIFICATIONS FOR WALL MOUNT VERSION ........................................................................................ 39
8.3 SPECIFICATIONS FOR PANEL MOUNT VERSION....................................................................................... 41
9ACCESSORIES ............................................................................................................................................ 42
9.1 REPLACEMENT UNIT.............................................................................................................................. 42
9.2 ASSEMBLY ACCESSORIES ............................................................... ERROR!BOOKMARK NOT DEFINED.
10 GENERAL INFORMATION...................................................................................................................... 43

10.1 WARRANTY............................................................................................................................................ 43
10.2 PACKAGING /SCOPE OF DELIVERY ........................................................................................................ 43
10.3 RETURN OF GOODS................................................................................................................................. 43
10.4 GUIDELINES FOR RETURNING UNIT FOR REPAIR .................................................................................... 43
10.5 MAINTENANCE AND CLEANING............................................................................................................. 44
11 APPENDICES ............................................................................................................................................... 45
11.1 APPENDIX 1–UNIT FUSE AND JUMPER SETTINGS.................................................................................. 45
11.2 APPENDIX 2–CONDUCTIVITY OF VARIOUS AQUEOUS SOLUTIONS AT 25 °C /77 °F............................. 47
11.3 APPENDIX 3–SIMPLE EXPLANATION ON THE FUNCTION OF HYSTERESIS ............................................. 48
11.4 APPENDIX 4–GENERAL INSTRUCTIONS CONCERNING CONTROLLER SETTING .................................... 49
11.4.1 Control characteristic of Controllers used as limit value switch .............................................. 49
11.4.2 Control characteristic of P-Controllers as proportional controller.......................................... 49
11.4.3 Control characteristic of PI-Controllers as proportional integral controller .......................... 49
11.4.4 Control signal of Pulse length Controllers................................................................................. 50
11.4.5 Control signal of Pulse Frequency Controllers ......................................................................... 51
11.5 APPENDIX 5–ABBREVIATIONS USED IN MENU DISPLAYS ..................................................................... 52

Instruction Manual Aquacon 4000
1
1INTRODUCTION
1.1 At the very beginning
We thank you for having purchased the Forbes Marshall Aquacon 4000
The construction of the Aquacon 4000 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
work is started with the Aquacon 4000
Forbes Marshall Pvt. Ltd. do not accept any liability for damage that may arise from
neglecting information given in this manual.
This instruction manual identifies safety instructions and additional information by means of
the following symbols:
This symbol draws attention to safety instructions and warnings of potential
danger which, if neglected, could result in injury to persons and/or damage to
property.
This symbol identifies additional information and instructions which, if neglected,
could lead to inefficient operation and possible loss of production.
The instruction manual must always be stored close at hand, in a place accessible to all
people working with the Aquacon 4000.
If you have questions, which are not or insufficiently answered in this instruction manual,
please contact your nearest office of Forbes Marshall Pvt. Ltd. Our engineers will be glad to
assist you.
1.2 Intended use
Forbes Marshall Pvt. Ltd. Aquacon 4000 is 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:
−observing the instructions, notes and requirements set out in this instruction manual.
−observing all local safety regulations concerning safety at work.
−observing all information and warnings in the documentation dealing with the products
used together with the transmitter (housings, sensors, etc.).
−observing the prescribed environmental and operational conditions.

Instruction Manual Aquacon 4000
2
1.3 Safety intsructions
The Aquacon 4000 should be installed and operated only by personnel familiar with
the transmitter and who are qualified for such work.
A defective transmitter must neither be installed nor put into service.
The Aquacon 4000 must only be operated under the specified operating conditions
(see section 8).
The Aquacon 4000 must not be repaired by the customer.
The Aquacon 4000 must only be opened to replace the unit fuse or to set the jumper
for Pt100/Pt1000 temperature sensor. This work must be carried out only by
personnel familiar with the transmitter and who are qualified for such work. Make sure
the mains cable is separated from the power supply before opening the unit.
No modifications to the Aquacon 4000 are allowed. The manufacturer/supplier
accepts no responsibility for damage caused by unauthorised modifications. The risk
is borne entirely by the user.
1.4 Putting out of service / Correct disposal of the unit
Putting out of service
•First disconnect the unit from the mains, then undo all electrical connections.
•Remove the unit from the wall / panel.
Correct disposal of the unit
When the transmitter is finally taken out of service, observe the local environmental
regulations for correct disposal or send the transmitter to your local office of the Forbes
Marshall Pvt. Ltd., they will take care of proper disposal.

Instruction Manual Aquacon 4000
3
2PRODUCT DESCRIPTION
2.1 Description of unit
The Forbes Marshall Aquacon 4000 is used for measuring conductivity and temperature
values. The conductivity values can be measured using limit or P/PI control. The transmitter is
available in two versions, one for panel mounting and one for wall mounting in a enclosure.
The transmitter can be used for applications such as water treatment and monitoring,
galvanic-decontamination, chemical processing, food processing, clean or wastewater control
and neutralization processes.
This transmitter has many user-friendly and safety features which include:
•Menu-driven program that simplifies set-up.
•Built-in non-volatile memory to ensure that calibration and other information are not
erased if power supply fails.
•Push-button for calibration and sensor offset adjustment from the keypad.
•Automatic temperature compensation (ATC).
•Manual temperature compensation setting without the ATC probe, with independent
setting for calibration and process temperature.
•Two galvanically isolated current outputs 0/4...20mA.
•0 to 2000 seconds time delay adjustment on all relays – minimizes false alarms.
•Separately adjustable high and low set-point hysteresis (dead bands) prevent chattering
of relays around the set points.
•Three control modes: limit controller, P controller and PI controller (P/PI controller as
pulse length or pulse frequency).
•Large dual display LCD for easy reading with clear multiple annunciators, alarm status,
operational and error messages.
•Two switching contacts as set-point relays.
•Separate alarm relay alerting you to set point limits exceeded for a certain time and if the
Pt100/Pt1000 wires are broken or disconnected during the ATC function.
•Wash relay.
•Hold function to freeze output current (0/4...20mA) and release control relays.
•LED indicators signal control activities to visually monitor transmitter status from a
distance.
•Protection against electromagnetic interference. ( Available for panel mount only)
•Back lit and UV light protected LC display.

Instruction Manual Aquacon 4000
4
2.2 Measurement and control system
A typical measurement system consists of:
•A conductivity process transmitter
•A conductivity sensor with integrated or separate temperature sensor Pt100/Pt1000.
•An appropriate measurement cable
•An immersion, flow or process assembly
•A final control element such as pump or valve
•A chart recorder
Power Mains
(80 - 250 VAC)
0/4 - 20 mA
Measurement Cable
Housing and
Sensors
Chart Recorder
A
quacon 4000 Transmitter

Instruction Manual Aquacon 4000
5
2.3 Unit overview
Wall mounting version
Panel mounting version

Instruction Manual Aquacon 4000
6

Instruction Manual Aquacon 4000
7
2.3.1 Display Overview
The LC display shows two alpha-numerical fields for parameters and measured values as well
as various mode and status indicators.
MEAS SETUP CAL
HOLD
°C °F
4
ERR
ATC
mS
µS
Mode indicators:
MEAS: measurement mode
SETUP: Set-up mode
CAL: Calibration mode
Status indicator:
HOLD: Unit in “HOLD” mode
ATC: Visible in ATC (Automatic Temperature
Compensation) mode. Not visible in the Manual
Temperature Compensation mode. “ATC”
flashes if the temperature probe is faulty in its
ATC mode
ERR: Error indicator
4: Measurement range number
2.3.2 Key functions
Key Description
Enter Calibration mode (requires access code)
Enter Set-up mode (requires access code)
Access sub functions (parameters) within a function group of Set-up mode
Confirm (store) set-up parameters and numerical values
Start/Confirm calibration in Calibration mode.
Select function group in the Set-up mode.
Set parameters and numerical values (if key is pressed continuously, the setting speed
increases).
Control the relays in MANUAL relay operation.
Returns to “Measurement mode” when both keys are pressed simultaneously.
Display limit values for SP1 and SP2 and settings for wash contact in AUTO relay
operation.
Toggle between RELAY A, RELAY B or Wash relay in MANUAL relay operation
Switch from AUTO to MANUAL relay operation (requires access code)

Instruction Manual Aquacon 4000
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2.3.3 LED indicators
Relay indicators
If REL key is pressed the LED (A, B or W) indicates to which Relay (A, B or
Wash) the displayed limit values refer.
Relay mode indicators
Auto LED lights if relay operation is set to automatic mode. Manu LED lights
if relay operation is set to manual mode.
Relay status indicators
This LED lights if limit value is exceeded or the ATC probe fails.
This LED lights green if measured value is within the limit for Relay A or
lights red if measured value exceeds limit.
This LED lights green if measured value is within the limit for Relay B or
lights red if measured value exceeds limit.
This LED lights if cleaning cycle is on.
2.3.4 Security codes
The access to Calibration mode, Setup mode and Manual relay operation mode is protected
with security codes. The security codes are set at the factory and cannot be changed by the
user. The following security codes are used:
Security code Mode Description
000 View only mode to view actual settings
11 Calibration mode to start calibration
22 Setup mode to configure parameters
22 Manual relay operation to switch relay operation mode from
automatic to manual

Instruction Manual Aquacon 4000
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2.3.5 Menu overview
CCD “000” = Check calibration parameters
(
View onl
y
mode
)
CCD “11” = Calibration mode
SCD “000” = Check setup parameters (View only mode)
SCD “22” = Setup mode
MEAS
SETUP
SETUP
SETUP
SETUP
SETUP
SETUP
SETUP
SETUP
SETUP
SETUP
HOLD
HOLD
HOLD
HOLD
HOLD
HOLD
HOLD
HOLD
HOLD
HOLD
µS
4
4
4
4
4
4
4
4
4
4
4
°C
Temperature settings
see section 6.3
Relay A (set point 1) settings
see section 6.4
Relay B (set point 2) settings
see section 6.4
Controller settings
see section 6.5
Current output 1 settings
see section 6.6
Current output 2 settings
see section 6.7
Wash contact settings
see section 6.8
Unit settings
see section 6.10
Calibration
see section 5
CAL
ENT
ENTER
ENT
ENT
ENTER
ENTER
ENT
ENT
ENT
ENT
ENT
ENT
ENT
ENT
ENT
ENT
CAL
SETUP
HOLD
4
Range settings
see section 6.9
ENT
1
1
2
2

Instruction Manual Aquacon 4000
10

Instruction Manual Aquacon 4000
11
3ASSEMBLY AND INSTALLATION
3.1 Mounting the unit
Wall mounting version
approx. 14 [.55]
39 [1.54]
Holes for wall
mounting (2X)
21.5 [.85]
6 [.24]
144 [5.67]
144 [5.67]
78 [3.07]
111.50 [4.39]
27.5 [1.08]
24 [.94]
66.5 [2.62]
80 [3.15]
90 [3.54]
57.8[2.28]
90 [3.54]
Pg13.5 (3 pcs.)
Holes for post
mounting (4X)
For P
g
13.5 cable
g
lands
Unit:
MM [INCH]
Transmitter housing for wall mounting: protection class IP 65

Instruction Manual Aquacon 4000
12
Panel mounting version
Flat gasket 1mm [.04]
(to be inserted by customer)
Panel cut out
UNIT: MM [INCH]
Transmitter housing for panel mounting: protection class IP 54 (front), IP 40 (housing)

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13
3.2 Connection Diagram
Caution: Ensure electrical mains are disconnected before proceeding.
Connections for wall mounting version
RELA RELB WASH RELAY ALARM RELAY
-+
Current
OP 2
29 28 19
GND+12V
-+
Current
OP1
3031 20 22
PT100/
PT1000
2524 26
HOLD
14 13
47 65 89
N L
3
12
21
11 10
15 16 17 18
RE LA RELB WAS H RE LAY A LAR M RE LAY
-+
Current
OP 2
29 28 19
GND+12V
-+
Current
OP1
3031 20 22
PT10 0/
PT10 00
2524 26
HOLD
14 13
476589
N L
3
12
21
11 10
15 16 17 18
1. AC mains live wire 17. 4 Cell / 2 Cell type Conductivity Input
2. AC mains neutral wire 18. 4 Cell type Conductivity Input
3. AC mains protective earth wire 19. 12V Power supply
4. Relay A (SP 1) 20. 12V ground
5. Relay A (SP 1) 21. no connection
6. Relay B (SP 2) 22. Earth ground
7. Relay B (SP 2) 23. no connection
8. Wash relay 24. Temperature ground
9. Wash relay 25. Temperature input
10. Alarm relay (NC) 26. Temperature sense (short to
11. Alarm relay common terminal 25 if using 2- wire RTD)
12. Alarm relay (NO) 27. no connection
13. Hold function 28. 4-20 mA temperature output, -ve terminal
14. Hold function 29. 4-20 mA temperature output, +ve terminal
15. 4 Cell type Conductivity Input 30. 4-20 mA Conductivity output, -ve terminal
16. 4 Cell / 2 Cell type Conductivity Input 31. 4-20 mA Conductivity output, +ve terminal
IMPORTANT: The Alarm relay functions as an “Active Low” device i.e. it switches
OFF under Alarm condition. Therefore the Alarm display device should be connected
to the ‘NC’ contacts of the relay (10 & 11).

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When using 2 Cell type Conductivity electrode, terminal 15 should be shorted to
terminal 16 and terminal 18 should be shorted to terminal 17.
NOTE:
a) Switch or circuit breaker shall included in the building installation.
b) It shall be in close proximity to the equipment and within easy reach of the
operator.
c) It shall be marked as the disconnecting device for the equipment.

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15
Connections for panel mounting version
1. AC mains live wire 17. 2 Cell type Conductivity Input
2. AC mains neutral wire 18. 4 Cell type Conductivity Input
3. AC mains protective earth wire 19. 12V Power supply
4. Relay A (SP 1) 20. 12V ground
5. Relay A (SP 1) 21. no connection
6. Relay B (SP 2) 22. Earth ground
7. Relay B (SP 2) 23. no connection
8. Wash relay 24. Temperature ground
9. Wash relay 25. Temperature input
10. Alarm relay (NC) 26. Temperature sense (short to
11. Alarm relay common terminal 25 if using 2- wire RTD)
12. Alarm relay (NO) 27. no connection
13. Hold function 28. 4-20 mA temperature output, -ve terminal
14. Hold function 29. 4-20 mA temperature output, +ve terminal
15. 4 Cell type Conductivity Input 30. 4-20 mA Conductivity output, -ve terminal
16. 2 Cell type Conductivity Input 31. 4-20 mA Conductivity output, +ve terminal
IMPORTANT: The Alarm relay functions as an “Active Low” device i.e. it switches
OFF under Alarm condition. Therefore the Alarm display device should be connected
to the ‘NC’ contacts of the relay (10 & 11).
When using 2 Cell type Conductivity electrode, terminal 15 should be shorted to
terminal 16 and terminal 18 should be shorted to terminal 17.