GEORGE FISCHER SIGNET 9040 Intelek-Pro User manual

+GF+SIGNET
+GF+SIGNET 9040 Intelek-Pro
Instruction Manual
ORP Controller
GEORGE FISCHER +GF+

CAUTION: Remove AC power to unit prior to
wiring input and output connections.
Important Safety Information!
Remove AC power before opening unit. Electrical
shock hazard exists

Table of
Contents
Chapter Page
1 Introduction 1
1.1 Introduction 1
1.2 Front Panel Description 2
1.3 Rear Panel Description 3
2 Installation and Operation 4
2.1 Mounting Instructions 4
2.2 Power Connections 5
2.3 Input Connections 6
2.4 2-Relay Output Connections 7
2.5 Dual Proportional Relay Connections 8
2.6 Verifying Analog Outputs 9
2.7 Analog Output Connections 10
3 System Configuration 10
3.1 Introduction 10
3.2 Calibration Menu, ORP Sensor Inputs 12
3.3 Calibration Menu, Analog Inputs 12
3.4 2-Relay Operation 14
3.5 Dual Proportional Relay Operation 14
3.6 Calibration Menu, Relay Outputs 16
3.7 Calibration Menu, Analog Outputs 18
3.8 View-Only Menus 19
4 Technical Support 20
4.1 Accessing Internal Options 20
4.2 AC Power Configurations 21
4.3 Security Code Function 21
4.4 Installing Input/Output Options 22
4.5 Input Card Introduction Mode 22
4.6 Option Cards and Accessories 27
4.7 Output Card Configurations 28
4.8 Troubleshooting 29
Specifications 30
Warranty 32

Unpacking and Inspection
Your ORP controller package includes the
following items:
•+GF+SIGNET 9040 Intelek-Pro ORP Controller
• Two stainless steel mounting brackets
• Mounting Instructions w/self-adhesive template
• Panel gasket
• Instruction manual w/warranty card
Please fill out and return warranty card as soon as
possible.
Warranty Record
For your protection, record your unit's purchase
date and serial number for future reference. The
serial number decal is located on the instrument's
rear panel.
Model: +GF+SIGNET 9040 Intelek-Pro ORP
Controller
Purchase Date: _______________________
Serial Number: ________________________
Purchased From: _______________________
Purchase Order Number: _______________

Chapter 1
Introduction
1.1 Introduction
Your new +GF+SIGNET 9040 Intelek-Pro ORP
Controller has been specifically designed for ORP
measurement in process control applications. The
controller's compact 1/4 DIN enclosure (front) is
NEMA 4X/IP65 rated and ideal for installation
into instrumentation panels with limited space.
Modular "plug-in" input/output option cards allow
you to customize your ORP controller to your
system's requirements. The controller's unique
"slide-out" chassis design makes option installation
fast and simple. Smart self-configuring
microprocessor based circuitry automatically
inventories installed options during power-up,
allowing you to upgrade your system in seconds
without the need for additional equipment.
The unit's front panel features a highly visible
4.5-digit (seven segment) and 8-digit (alpha-
numeric) liquid crystal display with adjustable
contrast. Active ORP and alarm relay status
information is quickly accessed at a glance.
During calibration the user is prompted with clear
step-by-step instructions on the unit's front panel
display.
The +GF+SIGNET 9040 Intelek-Pro ORP
Controller is fully compatible with all +GF+
SIGNET ORP sensor products, yet also accepts
other analog inputs, such as 4 to 20 mA or
0 to 5 VDC etc.
1
The technical data given in
this publication is for general
information purposes only. It
implies no warranty of any
kind.

2
1.2 Front Panel Description
A) Accesses the CAL "view-only" menu B) Used in conjunction with MOD key to
access the main CAL menu
A) Accesses the OUTPUT "view-only" menu B) Used in conjunction with the
"MOD" key to access the OUTPUT calibration menu
A) Accesses the RELAY "view-only" menu B) Used in conjunction with MOD key
to access the RELAY calibration menu
A) Accesses one of three calibration menus: CAL, RELAY, OUT B) Enables a
calibration parameter for modification C) Restores a calibration parameter to
it's original value during calibration.
1. Relay An-
nunciators:
3.
5.
6.
7.
Indicate activation status of optional output "alarm" relays 1 & 2 and additional
relays 3 & 4 (proportional or on/off control)
Shows ORP, raw sensor mV, and relay activation status information2. LCD
Display:
A) Stores a calibration value into memory after modification B) Used to
display available input/output options during normal operation.
4.
Decreases the value of a selected calibration digit8.
Item Function
A) Displays raw sensor mV B) Increases the value of a selected calibration digit
9.
10.
ENTER
A) Returns the unit to normal operation mode B) Selects a digit for modification
during calibration.
MOD
CAL
RELAY
OUTPUT
mV
ORP CONTROLLER
ENTER MOD
CAL RELAY OUTPUT
+GF+SIGNET
2
3
4
5
6
1
7
8
9
10
ORP mV
RLY 1
RLY 2
RLY 3
RLY 4
ORP

3
1.3 Rear Panel Description
ItemFunction
90 to 132 VAC or 180 to 264 VAC system power
connection 1. AC IN
17 to 30 VDC system power connection 2. DC IN
Analog output #1 from option socket #1 (optional) 5. ANL1
6. INPUT
±5 VDC @ 1 mA power output for ORP sensor pre-amp circuit 7. PRE-AMP
Serial outputs (future availability) 8. SERIAL
Analog output #2 from option socket #2 (optional) 9. ANL2
Alarm relay #1 (COM, NO, NC) contact set for external
device control (optional) 3. RLY1
Alarm relay #2 (COM, NO, NC) contact set for external
device control (optional) 4. RLY2
Proportional control relay #4 (COM, NO) contact set for
external device control (optional) 10. RLY4
Proportional control relay #3 (COM, NO) contact set for
external device control (optional) 11. RLY3
Note: Rear terminals
accept 18 to 22 AWG
wire
ORP sensor input connections
Note: Terminal #12 (T+) not used for ORP measurement
1 2 3 4 5 6 7 8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28
CNO
RLY3 RLY4 SERIAL
Tx GND Rx
PRE-AMP
V+ V- T+ Ain ISO
INPUT
L 1
AC IN
+ GND NO C NC
RLY1DC IN
NO C NC
RLY2
R+ R-
ANL1
CNO
ANL2
R+ R-
11 10 9876
123 4 5
N

4
Chapter 2
Installation
and
Operation
2.1 Mounting Instructions
The +GF+SIGNET Intelek-Pro ORP Controller's
1/4 DIN enclosure is specifically designed for
panel mounting. Adjustable mounting brackets
allow mounting in panels up to one inch (25 mm)
thick. An adhesive template and instructions are
included to insure proper installation.
For outdoor and/or stand alone installations the
splash-proof NEMA 4X/IP65 back cover kit is
recommended (ordered separately).
Figure 1
External dimensions
Panel Cutout Instructions
Recommended panel cutout 3.54 inch (90 mm) square. Maximum panel cutout 3.62 inch
(92 mm) square, DO NOT exceed. Use adhesive backed template (included)
5.7 in./145 mm
6 in./152 mm
7.2 in./183 mm
Mounting Clamp (included, 2 ea.)
*Optional NEMA 4X/IP65 Rear Cover
3.8 in. sq.
96 mm 3.5 in.
88 mm
Mounting Panel
Max. panel thickness = 1 in./25 mm
Panel
Gasket
SIDE VIEW
6.5 in./165 mm

5
2.2 Power Connections
AC Power Connections
Note: AC/DC power can be connected simultaneously,
using DC power as an uninterrupted power source.
*A direct or low impedance earth ground must be used
for optimum performance
Instructions
1. Jumper selectable for 90 to 132 OR 180 to 264
VAC operation. Confirm AC power configuration before
applying power. See section 4.2
2. *A direct or low impedance AC ground (earth
ground) MUST be used for proper operation.
3. To reduce the possibility of noise interference, AC
power lines must be isolated from signal lines.
Figure 2
AC power wiring
Note: DC power
recommended when ground
fault interruption devices
(GFI's) are used.
DC Power Connections
Figure 3
DC power wiring
L 1
N
AC IN
+ GND NO C NC
RLY1DC IN
NO C NC
RLY2
R+ R-
ANL1
17 to 30 VDC @ 0.5 A
GND
15 16 17 18 19 20 21 22 23 24 25 26 27 28
*
15 16 17 18 19 20 21 22 23 24 25 26 27 28
L 1
N
AC IN
+ GND NO C NC
RLY1DC IN
NO C NC
RLY2
R+ R-
ANL1
90 to 132 VAC
OR
180 to 264 VAC
AC Hot
AC Ground*
AC Neutral

CNO
RLY3 RLY4 SERIAL
Tx GND Rx
PRE-AMP
V+ V- T+ Ain ISO
INPUT
CNO
ANL2
R+ R-
#6 (ISO)
#5 (V-)
#4 (V+)
#3 (AO)
#2 (T-)
#1 (T+)
+GF+ SIGNET
3-2711.100
In-Line ORP
Sensor
External DC
Power Supply
OR
OR
Analog Inputs R+
R-
N/C
1 2 3 4 5 6 7 8 9 10 11 12 13 14
+GF+ SIGNET 3-2712.391-3
Submersible ORP
Pre-amp Assembly
SILVER (SHLD)
BLACK (V-)
RED (V+)
BROWN (AO)
+GF+ SIGNET 3-2711.101
In-Line ORP Sensor
OR
GREEN (T+)
WHITE (T-)
A
+GF+ SIGNET 3-2720
Pre-amplifier/Sensor
System
BLUE
BLACK
RED
GREEN
WHITE
BROWN
B C
N/C
N/C
D
E
SIGNET
pH/ORP Transmitter
+GF+
+GF+ SIGNET
8710
+-
+
-
SILVER
(Earth ground)
6
2.3 Input Connections
Three input options are available, providing a
wide range of compatibility for most applications.
ORP Input Card
Provides isolated ORP sensor input capability,
requiring no internal configuration.
Analog Input Cards
Two analog input options available:
• Analog (isolated) current, 4 to 20/0 to 20 mA
• Analog (isolated) voltage, 0 to 5/0 to 10 VDC
Input ranges are software selectable, requiring no
internal configuration.
Figure 4
Input Wiring
Note: See section 4.6 for a
listing of available input cards
To reduce the possibility of noise
interference, separate input lines
from AC power lines and/or
AC relay lines.

7
2.4 2-Relay Output Connections
The 2-Relay option provides two relays for external
device control. Each relay's contacts are rated for
a 5 A maximum. Both NO and NC contacts may
be used simultaneously or individually as shown.
Figure 5
2-Relay wiring
Device A is powered during
normal operation. Power is
discontinued when relay is
energized. Device B is not
powered during normal
operation. Power is applied
after relay is energized.
To reduce the possibility of
noise interference, separate
AC relay lines from input/
output lines.
Note: Relay contacts are rated as 5 A @ 250 VAC or
5 A @ 30 VDC maximum load.
L1
AC IN
+ GND NO C NC
RLY1DC IN
NO C NC
RLY2
R+ R-
ANL1
Device A
Device B
External
AC/DC
Power
Source
+
-
+
+
-
-
15 16 17 18 19 20 21 22 23 24 25 26 27 28
N

Trig. A
Trig. A
Metering
Pump A
Trig. B
Trig. B
-
+
+
-
Metering
Pump B
+
-
-
+
External
AC/DC
Power
Source
External
AC/DC
Power
Source
1 2 3 4 5 6 7 8 9 10 11 12 13 14
CNO
RLY3 RLY4 SERIAL
Tx GND Rx
PRE-AMP
V+ V- T+ Ain ISO
INPUT
CNO
ANL2
R+ R-
8
2.5 Dual Proportional Relay Connections
The Dual Proportional Relay Card provides two
relays (relays 3 and 4) for external device control.
Proportional or alarm operation is selectable
during calibration. Both relays MUST be like
configured, meaning one relay cannot be selected
for proportional operation while the other is
selected for alarm operation.
If alarm operation is selected, relays 3 and 4
operate as on/off controls similar to relays 1 and
2. The main distinction is the lack of the normally
closed (NC) contact, see section 2.4 Figure 5.
If proportional operation is selected, relays 3 and
4 are configured to provide a varying pulse rate to
control metering pumps. Relay 3 is dedicated to
low range control and relay 4 to high range
control.
Figure 6
Proportional Control Wiring
Note: Relay contacts are
rated as 5 A @ 250 VAC or
5 A @ 30 VDC maximum
load.
To reduce the possibility of
noise interference, separate
AC relay lines from input/
output lines.

2.6 Verifying Analog Outputs
Installed output options can be configured to either
of the unit's rear analog output terminals: ANL1 or
ANL2. Configuration is determined by which
sockets the options are installed. Options installed
in option socket #1 are configured to the rear
ANL1 terminals, options installed in socket #2 are
configured to the rear ANL2 terminals, see
section 4.4.
Prior to connection, determine which options are
configured to terminals ANL1 and ANL2 as
follows:
1. Apply power to unit.
2. Press:
ENTER
Available input/output options are
individually prompted on the display.
3. Record option configurations for ANL1 and
ANL2 in the spaces provided. This information is
necessary for wiring analog outputs in the next
section.
9
ANL1=
(i.e. 4 to 20 mA)
ANL2=
(i.e. N/A)
Option Record
Note:
The unit display's
N/A for unavailable options

Analog Ouput #2
(i.e. 0 to 5 VDC)
etc.
-
+
L1
AC IN
+ GND NO C NC
RLY1DC IN
NO C NC
RLY2 ANL1
-Analog Output #1
(i.e. 4 to 20 mA*)
etc.
+
15 16 17 18 19 20 21 22 23 24 25 26 27 28
R+ R-
1 2 3 4 5 6 7 8 9 10 11 12 13 14
CNO
RLY3 RLY4 SERIAL
Tx GND Rx
PRE-AMP
V+ V- T+ Ain ISO
INPUT
CNO
ANL2
R+ R-
N
10
2.7 Analog Output Connections
0 to 20/4 to 20 mA isolated or non-isolated
output as well as 0 to 5/0 to 10 VDC isolated or
non-isolated outputs are available. See section
4.6 for a list of available output cards.
Figure 7
Analog output wiring
Chapter 3
System
Configuration
3.1 Introduction
All the functions which can be modified are
contained in three menus:
The CAL (calibrate) menu contains those functions
which pertain to the input signal and how it is
interpreted by the instrument (i.e. ORP standard,
ORP slope). The CAL menu also provides access
to the security code and display contrast features.
The RELAY menu contains all the functions neces-
sary to control any output relays, such as relay
Note: The maximum loop impedance for the 4 to 20 mA/0 to 20 mA output is 425 Ω .
The minimum load impedance for the 0 to 5/0 to 10 V output is 1 k
Ω (1000 Ω ). To
reduce the possibility of noise interference, separate output lines from AC power/relay lines.
*The 4 to 20 mA
option is jumper
configurable for 0 to
20 mA operation,
see section 4.7.

CAL Menu
(Sensor input)
• ORP standard
• ORP slope
• Sensor gain
• Contrast adjust
• Security code
(Analog)
• Range select
• Minimum ORP setpoint
• Maximum ORP setpoint
• Contrast adjust
• Security code
11
setpoint, hysteresis etc.
The Output menu provides access to the functions
which define and control all analog output signals,
i.e. 4 to 20 mA, 0 to 5 VDC etc.
OUTPUT Menu
• Minimum ORP value
• Maximum ORP value
• Low output adjust
• High output adjust
RELAY Menu
(LO/HI)
• Relay 1 LO/HI
• Relay 1 setpoint
• Relay 1 hysteresis
• Relay 2 LO/HI
• Relay 2 setpoint
• Relay 2 hysteresis
(Proportional)
• Relay 3 and 4 Pulse
• Relay 3 setpoint
• Relay 3 deviation
• Relay 3 pulse value
• Relay 4 setpoint
• Relay 4 deviation
• Relay 4 pulse value
All menus operate using a standard sequence:
1. Press:
MOD
to enable calibration sequence.
2. Enter security code (when active) using:
mV
ORP
; press: ENTER
3. Select menu: CAL
RELAY
OUTPUT
; press menu key to select item.
4. Press:
MOD
to enable modifying item.
5. Alter item using:
mV
ORP
; press:
ENTER
to save entry.
6. Press corresponding menu key to advance to next menu item.
7. Repeat steps 4-6 for each menu item. Exit menu by pressing:
ORP
Note: A security function is
provided which allows the user
to "lock out" the calibration
menus, restricting access to
calibration settings, see section
4.3 for additional information.
All menus are loop type menus
which repeat until
ORP
is
pressed.
CAL
RELAY
OUTPUT

If you ever replace your input card, a special
input card introduction mode MUST be accessed.
This function is used to compensate for component
level tolerances between cards, see section 4.5.
Factory installed input cards are pre-configured
and DO NOT require this procedure.
12
4 to 20 mA option illustrated
MOD
Security
Code?
Yes
Unlock security
code using:
ENTER
Modify?
No
Yes
Select
next
item?
Yes
CAL
Press to select
operation range:
(4-20 or 0-20 mA)
MOD
Normal
operation
ENTER
Recall original value
MOD
No
CAL
No
4
mA 0 or 4
ORP
Note: The unit's software
recognizes which input card/
configuration is inserted,
therefore displaying the
corresponding calibration
value.
3.3 Calibration Menu, Analog Inputs
See Note*
See Note*
*Sensor inputs require wet
calibration using pH buffers
saturated with Quinhydrone.
+GF+SIGNET offers a pH
buffer kit, see section 4.6.
The negative "-" sign only
displays when selected.
Remove or select by shifting
selected digit to far left
position.
MOD Security
Code?
Yes
Unlock security
code using:
ENTER
Modify?
No
Yes
Select
next
item?
Yes
CAL
Press to set
standard mV with sen-
sor in pH 7.0 buffer*
0087
SET STD
MOD
Normal
operation
ENTER
MOD
No
CAL
No
ENTER
Modify?
No
Yes
Select
next
item?
Yes
CAL
Press to set
slope mV with sensor in
pH 4.0 buffer*
0264
SET SLP
MOD
Normal
operation
Recall original value
Recall original value
MOD
No
Go to
A
ORP
ORP
3.2 Calibration Menu, ORP Sensor Inputs

13
Note:
The negative "-" sign
only displays when selected.
Remove or select by shifting
the selected digit to far left
position.
• Use x 1 gain for +GF+
SIGNET 3-2720
Pre-amplifier/sensor systems
or other unity gain pre-
amplifier inputs
• Use x -3 gain for +GF+
SIGNET 2711 ORP Sensors/
3-2712.391-3 Submersible
Pre-amplifier/sensor systems.
Note: Menu repeats until
ORP
is pressed.
ENTER
Modify?
No
Yes
Yes
CAL
MOD
Normal
operation
0000
20mA IS
MOD
No
Select
next
item?
Press to
enter maximum ORP
mV value
ENTER
Modify?
No
Yes
Select
next
item?
Yes
CAL
Press to
enter minimum ORP
mV value
MOD
Normal
operation
Recall original value
Recall original value
MOD
No
0000
4mA IS
Go to B
ORP
ORP
ENTER
Modify?
No
Yes
Select
next
item?
Yes
CAL
Press to select
pre-amp gain, unity
(X1) or (X-3)
1
GAIN
MOD
Normal
operation
MOD
No
ENTER
Modify?
No
Yes
Repeat
Menu?
Yes
CAL
Press to select
personal security
code (0000-9999)
0000
SEC CODE
MOD
Normal
operation
MOD
No
ENTER
Modify?
No
Yes
Select
next
item?
Yes
CAL
Press to select
best display contrast
18888
CONTRAST
MOD
Normal
operation
Recall original value
Recall original value
Recall original value
MOD
No
B
A
ORP
ORP
ORP

14
3.4 2-Relay Operation
The 2-Relay option allows you to configure
individual setpoints, LO or HI operation, and
hysteresis values for two independent on/off
relays.
• Relay Setpoints: Setpoints represent the ORP at
which each relay is energized.
• Relay Hysteresis: Hysteresis values directly
effect the LO and HI relay modes, specifying how
far the ORP will rise above (LO Relay Mode) or fall
below (HI Relay Mode) each relay's setpoint prior
to de-energizing the relay. The main purpose for
hysteresis is to eliminating relay "chatter", caused
by a ORP hovering around a relay's setpoint.
Hysteresis values are programmed in direct ORP
units and must be less than the corresponding relay
setpoint, maximum 500 mV. Hysteresis only
applies when exiting an alarm condition.
• LO Relay Operation: In LO operation, the relay
is energized when the ORP drops below the
setpoint, and is de-energized when the ORP rises
above the setpoint plus hysteresis, see Figure 8
• HI Relay Operation: In HI operation, the relay
is energized when the ORP rises above the
setpoint and is de-energized when the ORP falls
below the setpoint plus hysteresis, see Figure 9
3.5 Dual Proportional Relay Operation
The dual proportional relay option allows you to
configure relays 3 and 4 to operate as dual
proportional control (pulse) relays or as on/off
relays which operate identical to the 2-Relay
option.
Figure 8
LO relay operation mode
Figure 9
HI relay operation mode
= LO setpoint
= Hysteresis
= Relay energized
= Relay de-energized
ORP
= HI setpoint
= Hysteresis
= Relay energized
= Relay de-energized
ORP

15
The dual proportional relay configuration is
primarily designed to control external metering
pumps. Setpoints, deviation ranges, and maxi-
mum pulse rates are selected via the relay menu.
• Setpoint: ORP value at which relay pulsing
begins. Relay 3 setpoint must be less than or
equal to relay 4 setpoint.
• Deviation: ORP mV range from setpoint to
maximum pulse rate. Deviation values cannot
extend beyond the ±3000 mV range*.
• Pulse Rate: Pulse rate selected from 0 to 120
pulses per minute maximum.
Figure 10
Dual Proportional relay
examples
Note: Relay 3 setpoint
cannot exceed relay 4
setpoint
LO
289
mV
HI
-312
mV
-1000
mV 1000
mV
max. pulses (0-120 pulses/minute)
Relay 4
Deviation=
1312 mV
Relay 3
Deviation=
1289 mV
LO
-168
mV
HI
126
mV
-1000
mV 1000
mV
Correct
max. pulses (0-120 pulses/minute)
Relay 4
Deviation=
546 mV
Relay 3
Deviation=
832 mV
672
mV
LO and HI
100 mV
-1000
mV 1000 mV
max. pulses (0-120 pulses/minute)
Relay 4
Deviation=
667 mV
Relay 3
Deviation=
863 mV
767
mV
-763
mV
Correct
INCORRECT
*Note:
+GF+SIGNET
3-2720 pre-amplifier/sensor
inputs and other unity gain
sensor inputs require the x 1
gain selection. Sensor
deviation is limited to
± 3000 mV.
+GF+SIGNET 2711 ORP
sensors/3-2712.391-3
Pre-amplifier inputs require the
x -3 gain selection. Sensor
deviation is limited to
± 1000
mV range.

16
3.6 Calibration Menu, Relay Outputs
RELAY
Select
next
item?
Yes
RELAY
Normal
operation
Recall original value
ENTER
Modify?
No
Yes
Press to select
LOW, HIGH or
PULSE operation
PULS
RLY3 4
MOD
MOD
No
Pulse
Mode
?
Yes
No
B
C
Go to
A
ORP
MOD
Security
Code?
Yes
Unlock security
code using:
Select
next
item?
Yes
RELAY
Normal
operation
ENTER
Recall original value
ENTER
Modify?
No
Yes
Press to select
LOW or HIGH op-
eration
LO
RLY1 IS
MOD
MOD
No
ENTER
Modify?
No
Yes
Select
next
item?
Yes
RELAY
Press to set
relay ORP setpoint
in millivolts (mV)
0000
SET RLY1
MOD
Normal
operation
Recall original value
MOD
ENTER
Modify?
No
Yes
Select
next
item?
Yes
Press to set
relay hysteresis,
(500 mV maximum)
0000
SET HYS1
MOD
Normal
operation
Recall original value
MOD
RELAY
No
No
No
Relay 2 go to:
Relay 3 or 4,
go to:
A
A
B
ORP
ORP
ORP