Honeywell DirectLine DL424 User manual

DirectLine®DL424/425 Sensor Module
for DL 5000 Dissolved Oxygen Probes
User Manual
70-82-25-113
Rev. 3
September 2011
Honeywell Process Solutions

Notices and Trademarks
Copyright 2011 by Honeywell
September, 2011
Warranty/Remedy
Honeywell warrants goods of its manufacture as being free of defective materials and faulty
workmanship. Contact your local sales office for warranty information. If warranted goods
are returned to Honeywell during the period of coverage, Honeywell will repair or replace
without charge those items it finds defective. The foregoing is Buyer's sole remedy and is in
lieu of all other warranties, expressed or implied, including those of merchantability
and fitness for a particular purpose. Specifications may change without notice. The
information we supply is believed to be accurate and reliable as of this printing. However, we
assume no responsibility for its use.
While we provide application assistance personally, through our literature and the Honeywell
web site, it is up to the customer to determine the suitability of the product in the application.
CE Conformity
This product is in conformance with the protection requirements of the following European
Council Directives: 89/336/EEC, the Electromagnetic Compatibility Directive and
73/23/EEC, the Low Voltage Directive. Conformance of this product with any other “CE
Mark” Directive(s) shall not be assumed.
ATTENTION
The emission limits of EN 61326 are designed to provide reasonable protection against
harmful interference when this equipment is operated in an industrial environment. Operation
of this equipment in a residential area may cause harmful interference. This equipment
generates, uses and can radiate radio frequency energy and may cause interference to radio
and television reception when the equipment is used closer than 30 m to the antenna(e). In
special cases, when highly susceptible apparatus is used in close proximity, the user may
have to employ additional mitigating measures to further reduce the electromagnetic
emissions of this equipment.
Honeywell Process Solutions
Honeywell
512 Virginia Drive
Fort Washington, PA 19034
DirectLine is a trademark of Honeywell
Other brands or product names are trademarks of their respective owners
ii DirectLine® DL424/425 Sensor Module User Manual 9/11

About This Document
Abstract
This manual contains all the information that is needed to install, configure, calibrate,
operate, and troubleshoot the DirectLine®Sensor. Insert 70-82-10-04, a quick
reference guide for configuring and calibrating the DL424/425, should accompany
this document.
Contacts
World Wide Web
The following lists Honeywell’s World Wide Web sites that will be of interest to our
customers.
Honeywell Organization WWW Address (URL)
Corporate http://www.honeywell.com
Honeywell Process Solutions https://www.honeywellprocess.com
Telephone
Contact us by telephone at the numbers listed below.
Organization Phone Number
United States and
Canada Honeywell 1-800-423-9883 Tech. Support 1-888-423-9883 Q&A Faxback
(TACFACS)
1-800-525-7439 Service
Symbol Definitions
The following table lists any symbols used in this document to denote certain
conditions.
Symbol Definition
Earth Ground. Functional earth connection. NOTE: This connection shall
be bonded to Protective earth at the source of supply in accordance with
national and local electrical code requirements.
9/11 DirectLine® DL424/425 Sensor Module User Manual iii

Contents
1. INTRODUCTION....................................................................................................................1
1.1 Overview.........................................................................................................................................1
1.2 Electronics Module .........................................................................................................................2
1.3 Operator Interface...........................................................................................................................2
1.4 Specifications..................................................................................................................................3
1.5 Model Selection Guide ...................................................................................................................4
2. INSTALLATION.....................................................................................................................5
2.1 Assembly and Wiring......................................................................................................................5
2.2 Integral Mounting............................................................................................................................7
2.3 Remote Mounting ...........................................................................................................................8
2.4 Conduit connections.....................................................................................................................12
3. CONFIGURATION...............................................................................................................13
3.1 Overview.......................................................................................................................................13
3.2 Configuration Set Up Procedure...................................................................................................15
4. CALIBRATION.....................................................................................................................19
4.1 New Probe....................................................................................................................................19
4.2 Calibration Options.......................................................................................................................19
4.3 Calibration Procedures.................................................................................................................20
5. OPERATION........................................................................................................................22
5.1 Displays........................................................................................................................................22
5.2 Diagnostic Error Messages ..........................................................................................................24
5.3 Unit Reset.....................................................................................................................................26
6. SPARE PARTS....................................................................................................................27
7. APPENDIX: CE MARK APPLICATIONS ............................................................................29
8. SALES AND SERVICE........................................................................................................30
iv DirectLine® DL424/425 Sensor Module User Manual 9/11

Tables
Table 2-1 Assembly and Wiring Procedure for Field Wiring Connector__________________________ 6
Table 2-2 Integral Mounting Procedure (refer to Figure 2-3)__________________________________ 7
Table 2-3 Remote Mounting Procedure for DL5000 Probes __________________________________ 8
Table 2-4 Dissolved Oxygen Probes Remote Connections__________________________________ 10
Table 3-1 Dependence of Barometric Pressure on Altitude__________________________________ 13
Table 3-2 Configuration Set Up Procedure ______________________________________________ 15
Table 4-1 Calibration Procedure ______________________________________________________ 20
Table 5-1 Online Parameter Descriptions _______________________________________________ 22
Table 5-2 Display Navigation Procedure ________________________________________________ 23
Table 5-3 Online Diagnostic Errors ____________________________________________________ 24
Table 5-4 Factory Default Values _____________________________________________________ 26
9/11 DirectLine® DL424/425 Sensor Module User Manual v

vi DirectLine® DL424/425 Sensor Module User Manual 9/11
Figures
Figure 1-1 DirectLine® Sensor ________________________________________________________ 1
Figure 1-2 Electronics Module_________________________________________________________ 2
Figure 2-1 Cordset Connection and Wiring _______________________________________________ 5
Figure 2-2 Field Wiring Connector______________________________________________________ 6
Figure 2-3 Integral Mounting __________________________________________________________ 7
Figure 2-4 Remote Mounting__________________________________________________________ 9
Figure 2-5 Remote Mounting Hardware_________________________________________________ 11

Introduction
1. Introduction
1.1 Overview
The DirectLine® Sensor for dissolved oxygen measurement in water consists of a
DL424/425 electronics module connected to a DL5000 DO Probe. The modular
electronics design allows the module to be separated from the probe, so that the
probe can be easily removed or replaced while retaining power to the electronics
module.
The DL424/425 electronics module is contained in a Nema Type 4x sealed
weatherproof corrosion/impact-resistant polysulfone housing. The Module can be
mounted as an integral unit directly connected to the probe or remotely using a
probe with a cable. The sealed plastic housing has plug-in connections for the
DL5000 probe and a 4-20 mA output connection.
Figure 1-1 DirectLine® Sensor
9/11 DirectLine® DL424/425 Sensor Module User Manual 1

Introduction
1.2 Electronics Module
The electronics module is loop-powered by 16-42 Vdc and will modulate its supply
current from 4 mA to 20 mA, depending upon the DO value that is measured by the
probe. The transmitted loop current is compensated for process temperature.
A 4-20 mA output connection is provided via a 6m cordset or a customer supplied
cable used in combination with a field wiring connector.
The DirectLine ® electronic module for dissolved oxygen measurements is available
in two configurations:
ppm (DL424) and ppb (DL425).
Figure 1-2 Electronics Module
1.3 Operator Interface
The DirectLine® Sensor operator interface consists of three pushbuttons and one
4-digit, 7-segment LCD display with 3 decimal points, plus (+), and minus (–) signs.
It is responsible for the display of measured values and configuration of parameter
values.
2 DirectLine® DL424/425 Sensor Module User Manual 9/11

Introduction
1.4 Specifications
General:
Displayed Process
Variable DL424: 0-20 ppm dissolved oxygen
DL425: 0-200 ppb dissolved oxygen
Displayed
Temperature Range 2.0 to 60.0 ºC (35.6 to 140ºF)
Operating
Temperature –20 °C to +60 °C (-4 °F to +140 °F)
Storage Temperature –20 °C to +70 °C (-4 °F to +158 °F)
Display Resolution DL424: 0.01 ppm
DL425: 0.1 ppb in the 0-20 ppb range; 1 ppb in the
0-200 ppb range
Output Type 4-20 mA (2-wire loop powered)
Output Scale DL424: 0-20ppm
DL425: 0-200ppb
Output Calibration 4-20 mA
Power 16-42 Vdc
Maximum Load Resistance: 250 ohms at 16 Vdc
600 ohms at 24 Vdc
1400 ohms at 42 Vdc
Calibration Options Air Cal; Sample Cal
Diagnostics Sensor and electronics
Physical Properties:
Case Weatherproof, corrosion-resistant plastic housing
Local Display and
Buttons LCD 4-digit, 7-segment
Field Wiring Cordset Shielded twisted pair. Length: 6 m (19.7’)
User Termination Tinned leads
Remote Mounting Pipe, Wall, or DIN Rail
Dimensions H 123 mm (4.84”) x W 48 mm (1.89”) x D 46 mm (1.81”)
Weight Approximately 142 g (5.0 oz.)
Approvals CE Mark - Industrial Applications
UL – General Purpose
CSA – General Purpose
IP66 Enclosure
NEMA Type 4
FM Class1, Div. 1 (I.S.)
FM Class 1, Div. 2 (non-incendive field wiring)
9/11 DirectLine® DL424/425 Sensor Module User Manual 3

Introduction
1.5 Model Selection Guide
Instructions
Select the desired key number. The arrow to the right marks the selection available.
Make the desired selections from Tables I through IV using the column below the
proper arrow. A dot ( ) denotes availability.
Key Number I II III IV
_ _ _ _
_
-
_
-
_
-
_
-
Key Number - DirectLine
®
Sensor Electronics Module
(Specify electrodes/cells/probes separately) Selection
pH For use with Durafet II, Meredian II & HPW7000 pH electrodes DL421
ORP For use with ORP electrode. DL422
Conductivity For use with Contacting Conductivity Cells DL423
DO - PPM For use with Dissolved Oxygen ppm Probes DL424
DO - PPB For use with Dissolved Oxygen ppb Probes
TABLE I - OUTPUT CABLE
Cordset - 6m (19.7 ft.) - includes connector and cable - Note 2 E
Field Wiring Connector only - customer supplies cable only-Note 2
TABLE II - SENSOR CABLE/REMOTE CONNECTOR (between electronic module and electrode, sensor or pr
o
0ddddd
6,096m (20 ft.) of sensor cable - Durafet II Remote Mounting 1 e
15,24m
(
50 ft.
)
of sensor cable - Durafet II Remote Mountin
g
e
ee
eeee
TABLE III - REMOTE MOUNTING OPTIONS
None Integral unit - mounting not required A
2" (5,08 cm) Pipe mtg. bracket, wall mtg, & DIN Rail clip B
TABLE IV - OPTIONSNone 00 _ _
Linen Customer ID Tag - 3 lines w/22 characters/line LT _ _
SS Customer ID Tag - 3 lines w/22 character/line SS _ _
Certificates None _ _ 00
Calibration & Conformance _ _ CC
Mounting Kit for
Remote Mounting
None(replacement module or customer supplied output cable)-Note 1 D
Remote Mounting Connector - Meredian II ORP
Remote Mounting Connector - HPW7000
Remote Mounting Connector - Conductivity
Remote Mounting Connector - Dissolved Oxygen
DL425
2
Remote Mounting Connector - Meredian II pH
Remote Mounting
Connector (Cable is
supplied with sensor or
probe)
3
3
4
5
6
Integral Mounting No cable or connector required
Remote Mounting Cable
- Durafet only
Availability
Output Cable for
Integral or Remote
Mounting F
_ _ _
_
Tagging
Notes:
1Customer supplies cordset o
r
cable with M12 connecter. Suppliers & P/Ns include:
Phoenix Contact Turck
Cord--set SAC-3P-5.0-PUR/M12FSSH Stainless RKV4T-6/S618
M12 Field Wiring Connector SACC-M12FS-4CON-PG7 B8141-0
Cable
2Recommended cable is 2-wire twisted shielded pair
RESTRICTIONS
Table
d
e
ORDERING INSTRUCTIONS:
1. Part numbers are provided to facilitate Distributor Stock.
2. Orders may be placed either by model selection or by part number.
3. Part numbers are shown within the model selection tables to assist with compatibility information.
4. Orders placed by model selection are systematically protected against incompatibility.
5. Compatibility assessment is the responsibility of the purchaser for orders placed by part number.
6. Items labeled as N/A are not available via the stocking program and must be ordered by model selection.
III B
Available OnlyWith Not Available With
IIl A
Selection Table
2-wire twisted shielded pair
Restriction
Letters Selection
4 DirectLine® DL424/425 Sensor Module User Manual 9/11

Installation
2. Installation
2.1 Assembly and Wiring
Depending on the customer selected output cable options, the DirectLine can be
wired to an appropriate 16-42 Vdc source using 2 different methods:
1) Cordset. See Figure 2-1 Cordset Connection and Wiring
2) Field wiring connector with customer supplied cable. See page 6.
Refer to Section 7for wiring for CE Mark applications.
2.1.1 Cordset
Electronics
Module
Black (–)
Brown (+)
Shield
Wire
(Ground)
Minimum: 16 V @ 250 ohms (max.)
Maximum: 42 V @ 1400 ohms (max.)
Power Supply
++
__
Load
Resistance
+
_
Chart Recorder,
Controller, etc.
(Use 250 ohms
for 1-5 V signal) Cordset 6m (19.7’)
*Blue wire not used *
Figure 2-1 Cordset Connection and Wiring
9/11 DirectLine® DL424/425 Sensor Module User Manual 5

Installation
2.1.2 Field Wiring Connector with customer supplied cable
Refer to Figure 2-2. The field wiring connector supports customer supplied cable with an
outer diameter of 4-6mm, 2-wire twisted shielded pair.
Table 2-1 Assembly and Wiring Procedure for Field Wiring Connector
Step Procedure
1 Disassemble field wiring connector
a) Unscrew parts to separate pressure screw, clamp type cage, gasket,
housing and female insert.
2 Insert customer supplied cable through connector parts
a) Slide pressure screw over skin and tinned customer cable (note
orientation).
b) Slide clamp type cage over cable (note orientation).
c) Slide gasket over cable.
d) Slide housing over cable (note orientation).
3 Connect wires to pins
Look closely at end of female insert to locate pin numbers. Connect
positive wire to pin 1 and negative wire to pin 4. Remaining wires and
female insert pins 2 and 3 are unused.
4 Assemble field wiring connector
a) Screw female insert to housing until female insert’s o-ring is
compressed.
b) Slide clamp type cage/gasket into housing.
c) Thread pressure screw into housing until ¼ turn past finger tight.
5 Connect cable to power supply
Wire the other end of the Output cable to a 16-42 Vdc source as indicated
in Figure 2-1. Note: your wire colors may be different.
Pressure screw
Clamp-type cage
Gasket
Housing
Female insert with 4
numbered pins
Pos +
Neg -
To Power Supply
Output cable
(Customer supplied)
Figure 2-2 Field Wiring Connector
6 DirectLine® DL424/425 Sensor Module User Manual 9/11

Installation
2.2 Integral Mounting
Table 2-2 Integral Mounting Procedure (refer to Figure 2-3)
Step Procedure
1 Connect the probe to the process source (using the appropriate mounting
from those supplied for the DL5000).
Make sure that the final position of the installed electronics module
allows the display to be easily viewed by personnel.
2 Apply a thin film of silicon grease on the ID of the electronics module’s
probe mounting cavity.
3 Align the slots on the electronics module with those on the probe and
press down to connect the electronics to the probe.
4 Tighten the locking screw on the bottom rear of the electronics module.
Do not exceed 5 in-lb.
Electronics
Module
Locking Screw in
Rear of Housing
Probe
Step 1
Step 2
Step 3 Step 4
Figure 2-3 Integral Mounting
9/11 DirectLine® DL424/425 Sensor Module User Manual 7

Installation
2.3 Remote Mounting
When the DL424 or DL425 module is specified with Table II = 6, a remote connector
assembly (part number 51500768-005) is supplied loose. The remote cable
connector is used to connect the DL5000 probe cable to the DL424/425 module.
Table 2-3 gives the mounting procedure.
Table 2-3 Remote Mounting Procedure for DL5000 Probes
Step Procedure (Refer to Figure 2-4 and Figure 2-5)
1 Remove the protective sleeve from the end of the probe cable when
ready to attach to remote connector. Be careful to keep bare fingers
away from coax cable termination.
2 Turning counterclockwise, remove strain relief/cover combination from
the remote connector assembly.
3 Loosen and remove compression cap from strain relief fitting. Carefully
push cable end through cap and strain relief fitting so that these parts are
strung back along cable jacket.
4 Connect and disconnect cable leads as follows: See Table 2-4
5 Apply a thin bead of silicone grease to cable jacket in the area of the
compression cap/strain relief. Slide cover along cable and tighten by
hand onto the remote connector assembly.
6 Slide cap along cable and tighten onto cable jacket with small wrench
until cable cannot slide within strain relief rubber bushing.
7 Apply a thin film of silicon grease to the ID of electronics module’s remote
mounting cavity.
8 Plug remote connector assembly into DL424/425 module aligning polarity
tab of module housing and mating groove on connector.
9 Secure Electronics Module with Wall, Pipe, or DIN Rail Mounting
Mount bracket with clips facing forward, smaller clip on top and
larger clip on bottom.
Wall: Use one of three through-holes to secure to wall.
Pipe: Feed hose clamp through two slots and secure to pipe.
DIN rail: Attach the appropriate DIN rail clip to the mounting bracket:
“U” DIN rail—use metal clip and shorter screw (8 mm)
“G” DIN rail—use gray clip and longer screw (10 mm). Clip
can be rotated for horizontal or vertical DIN rails.
Push electronics module onto the remote-mounting bracket until it
snaps into position.
8 DirectLine® DL424/425 Sensor Module User Manual 9/11

Installation
Figure 2-4 Remote Mounting
9/11 DirectLine® DL424/425 Sensor Module User Manual 9

Installation
Table 2-4 Dissolved Oxygen Probes Remote Connections
Connecting Sequence
Terminal DL5000 Integral Cable DL5000 Quick Disconnect Cable
1 Black Black
2 Orange Red
3 Yellow Green
4 Red Yellow
5 Green Orange
6 Coax Coax
Earth Ground (connection
outside remote connector) Blue Violet
Disconnecting Sequence
Terminnal DL5000 Integral Cable DL5000 Quick Disconnect Cable
Earth Ground Blue Violet
6 Coax Coax
5 Green Orange
4 Red Yellow
3 Yellow Green
2 Orange Red
1 Black Black
10 DirectLine® DL424/425 Sensor Module User Manual 9/11

Installation
“U” Style DIN Rail “G” Style DIN Rail
Panel PanelPanel
Terminal Connectors
View from End
Front View
View from End
Front View
Barriers, Repeater, Isolators
Hose Clamp Slot
for Pipe Mounting
Metal clip for
“U” DIN rail mounting Gray clip for
“G” DIN rail mounting
Mounting Kit
(Hose Clamp
included in kit)
Through Hole for
DIN Rail Mounting
Figure 2-5 Remote Mounting Hardware
9/11 DirectLine® DL424/425 Sensor Module User Manual 11

Installation
12 DirectLine® DL424/425 Sensor Module User Manual 9/11
2.4 Conduit connections
The DirectLine provides a male ½” NPT thread to accommodate a customer conduit
connection. Use ½” conduit coupling (min. 38.1mm (1.5”) long) on DL conduit
connection to clear cordset connector. Conduit can not be used with field wiring
connector (see Figure 2-2) due to size restriction.
Do not exceed 200in-lb. torque when attaching fixed piping.
Use wrench flats provided under the ½” NPT threads to support the DirectLine
during installation.

Configuration
3. Configuration
3.1 Overview
Configuration Parameters
Set Up consists of configuring the following functions:
Atmospheric Pressure
Compensation:
The solubility of oxygen in water and
DL5000 dissolved oxygen probe signal
directly respond to barometric pressure
and hence pressure compensation is
not required during use. For best
accuracy, the DL424/425 modules
need to know barometric pressure at
the time of probe calibration. If
barometric pressure is known, this
value can be readily entered into the
instrument at this time. This value will
be automatically accessed during air
calibration.
A major contributor to atmospheric
pressure is altitude above or below sea
level. In the absence of a specific
knowledge of barometric pressure
value, use the nominal barometric
pressure value from Table 3-1.
The factory default barometric pressure
value is 760 millimeters of mercury
(mmHg). Any value can be entered in
one step increments from 500 to 800
mm Hg.
Table 3-1 Dependence of Barometric
Pressure on Altitude
A
lt, ft P, mmHg
A
lt, ft P, mmHg
Sea Level 760 3000 681
200 755 3200 676
400 749 3400 671
600 744 3600 666
800 738 3800 661
1000 733 4000 656
1200 728 4200 652
1400 722 4400 647
1600 717 4600 642
1800 712 4800 637
2000 707 5000 632
2200 701 5200 628
2400 696 5400 623
2600 691 5600 618
2800 686 5800 614
Salinity: The solubility of oxygen in salt or brackish waters, containing much
more than 1 part per thousand (ppt) total dissolved solids, is dependent on salt
concentration. The DL424 instrument accepts the total dissolved salt
concentration in ppt and performs necessary calculations to obtain the correct
dissolved oxygen concentration over salt concentration and sample temperature.
The DL 424 factory default value is 0 ppt but valid readings can range from 0 - 40
ppt and can be entered by the user in 0.1ppt increments.
The DL425 is intended for high purity water applications; salinity compensation is
not employed here.
9/11 DirectLine® DL424/425 Sensor Module User Manual 13

Configuration
Probe Bias Voltage – The probe bias voltage value determines the voltage
applied to the DO probe's cathode, relative to the reference electrode, to drive
the reduction of oxygen to water at the cathode and thereby induce a current
which is directly proportional to the oxygen consumed.
A proper probe bias voltage allows for the complete reduction of all oxygen at the
cathode, without regard for small changes in the voltage characteristics of the
probe. This parameter can be read, calibrated or reset to the factory default
value. In the DL425, the option is only allowed when the probe has been
removed from the ppb process and is in air.
In the DL424, in applications containing carbon dioxide, it may be undesirable to
remove the probe from the process. Therefore in the DL424 there is an option to
edit the probe bias voltage directly.
Noise Suppression Frequency Selection – Selection of 50 Hz or 60 Hz.
Defaults to 60 Hz at unit reset.
Output Configuration and Calibration –Selection of Output Configuration
functions: 0% Calibration, 100% Calibration, 0% Output Range Value, 100%
Output Range Value.
Table 3-2 provides steps and entry information for the complete configuration
sequence.
14 DirectLine® DL424/425 Sensor Module User Manual 9/11