Optek CONTROL 200 User manual

I
NSTRUCTIONS-MANUAL
VERSION A1
PN:1004-1027-02(-52)
CONVERTER
CONTROL 200
Part 1 - Hardware
Part 2 - Software

I
NSTRUCTIONS-MANUAL
VERSION A1
DATED JANUARY 5TH,2005
PN: 1004-1027-02 (-52)
CONVERTER
C
ONTROL 200
Part 1 - Hardware
Part 2 - Software (see separate Documentation)

C200HARDWARE
Instruction Manual C200 Part1 A1.doc optek Danulat GmbH •D-45356 Essen •Germany page 2
Preface
This instructions manual is written in such a way that all necessary information is given to provide correct
practice and trouble-free operation.
It is explicitly pointed out that no responsibility is accepted in case of loss or damage however caused on
the use of this instructions manual and the included description of the products.
Due to reasons of printing technique, the following illustrations correspond only roughly to the real appea-
rance of the products. This instruction manual is protected by copyright. However, the user may produce
copies and translations if required for the correct operation of the products.
On request this instructions manual is available in different languages and can also be supplied on CD
(Acrobat®Reader 4.0).
Our products are under constant development - technical data is subject to change without notice.
Essen, January 2005

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Instruction Manual C200 Part1 A1.doc optek Danulat GmbH •D-45356 Essen •Germany page 3
For further information please contact us or your local agent:
optek-Danulat GmbH
Emscherbruchallee 2 • 45356 Essen • Germany
Phone ++49 - (0)201 - 63 40 9-0
Fax ++49 - (0)201 - 63 40 9-999
E-mail [email protected]
optek Geschäftsstelle Südwest
Wilhelm-Maybach-Str. 11 • Mainz • Germany
Phone ++49 - (0)6131 - 58 20 15
Fax ++49 - (0)6131 - 50 40 26
E-mail [email protected]
optek-Danulat bv
Grote Brugse Grintweg 12 • 4005 AH Tiel • Netherlands
Phone ++31 - (0)344 - 68 38 00
Fax ++31 - (0)344 - 65 39 50
E-mail [email protected]
optek-Danulat, Inc.
N118 W18748 Bunsen Drive
Germantown • WI 53022 • USA
Phone ++1-262-437-3600
Fax ++1-262-437-3699
E-mail [email protected]
INTERNET: http://www.optek.com

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Instruction Manual C200 Part1 A1.doc optek Danulat GmbH •D-45356 Essen •Germany page 4
Table of contents page
1 Converter description 5
2 Technical Data 6
2.1 General data 6
2.2 pH – C210, C211 and C221 8
2.3 Conductivity - C220, C221 and C222 9
2.4 Control 200 – configuration feasibilities 10
3 Mechanical installation 11
3.1 Front panel CONTROL 200 11
3.2 Back panel CONTROL 200 12
3.3 Dimensions Control 200 13
3.4 Front panel mounting 13
3.5 Rack mounting Control 200 14
4 Field wiring schematic 15
4.1 General instructions 15
4.2 Relay Contact Protection and Interference suppression 16
4.3 Sensor wiring 17
4.3.1 Wiring of conductivity sensors 17
4.3.2 Wiring of pH sensors 18
5 Start-up / Maintenance 19
5.1 Start-up 19
5.2 Preventive maintenance / repair 20
5.3 Spare parts 20
6 Fax-Reply Form 21

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Instruction Manual C200 Part1 A1.doc optek Danulat GmbH •D-45356 Essen •Germany page 5
1 Converter description
CONTROL 200 is the all-round converter for
continuous monitoring and control of pH and
conductivity. The converter is intended to use with
either one or two of the following optek sensors:
PF12
(glass combination electrodes)
CF60
(6-electrode conductivity probe)
Functions of converter CONTROL 200:
The complete application spectrum is realized by converter CONTROL 200 in connection with different
inline sensors for pH and conductivity. The converters of CONTROL 200 series are available in different
configurations to be used with either one or two sensors (pH and /or 4-pole conductivity).
The backlit display has been designed to operate in all types of environments and shows both the measured
parameters and on a separate display line diagnostic and computed information. For conservation of
energy, the backlit can be set to switch off automatically after 60 s of inactivity.
Converter operation and programming are performed using five tactile membrane keys on the front panel.
Programmed functions are protected from unauthorized alteration by a five-digit security code.
Beside that the dual input CONTROL 200 incorporate a real time clock and a logbook which stores data
entries for alarm events, sensor errors, power failures and sensor calibrations.
Measurements for pH and conductivity can be done temperature compensated and the measured
temperature can be attached to an output signal as well. The converter allows the connection of resistance
thermometers like Pt 100, Pt1000 or Balco 3K which are mounted in the sensor and sense the medium
temperature directly in the pipe.
The pH converters can be connected to either a standard pH input or differential pH input. The dual input pH
provide advanced diagnostic facilities and detects sensor breakages as they occur. Beside that low glass
impedance and out-of-sample/broken cable warnings are given as well. Differential pH input is designed for
use with pH electrode systems that incorporate a solution earth (ground) connection. The measuring
electrode and reference electrode signals are measured separately using two, high impedance amplifiers
and compared with the solution earth potential. The difference between the results is the value used for the
pH measurement. Furthermore the pH converters incorporate the most common buffer tables, e.g. ABB,
DIN, Merck, NIST and US Tech for automatic 1 or 2 points calibration to provide a fully ease of use.
Needless to mention that calibration can be done as well user defined.
The conductivity converters can run probes with different cell constants and provide extremely broad
measuring ranges up to 1.999 mS/cm. By means of preset (NaOH, NaCl, HCl, H2SO4, H3PO4) or user
defined 6-point concentration curves the measured conductivity can be converted directly into concentration
of the component to be measured.

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Instruction Manual C200 Part1 A1.doc optek Danulat GmbH •D-45356 Essen •Germany page 6
2 Technical Data
2.1 General data:
Mechanical Data
Panel-mount versions: IP66/NEMA4X (front only)
Dimensions 96mm x 96mm x 162mm deep
(3.78 in. x 3.78 in. x 6.38 in. deep)
Weight 0.6kg (1.32 Ib)
Power supply
Voltage requirements: 85 to 265V AC 50/60 Hz
12 to 30V DC (optional)
Power consumption: <10VA
Insulation: Mains to earth (line to ground) 2 kV RMS
Environmental Data
Operating temperature limits: -20 to 65°C (-4 to 149°F)
Storage temperature limits: -25 to 75°C (-13 to 167°F)
Operating humidity limits: Up to 95%RH non condensing
Safety
General safety: EN 61010-1
Overvoltage Class II on inputs and outputs
Pollution category 2
EMC
Emissions and immunity: Meets requirements of:
EN 61326 Class A (for industrial environment)
Languages
Languages configurable: English, French, German, Italian, Spanish
Display
Type: Dual 5-digits, 7-segment backlit LCD
Information: 16-character, single line dot-matrix
Energy-saving function: Backlit LCD configurable as ON or Auto-Off after 60s
Logbook (C211, C221 and C222): Electronic record of major process events and calibration data
Real-time clock (C211, C221 and C222): Records time for logbook and auto-manual functions
Relay Outputs – On/Off
Number of relays: Three for C210 and C220 or five for C211, C221 and C222
Number of set points: Three for C210 and C220 or five for C211, C221 and C222
Set point adjustment: Fully configurable as normal or failsafe high/low, bandwidth
alarm (composite high/low) or diagnostic alert
Hysteresis of reading: Programmable 0 to 5% in 0,1% increments
Delay: Programmable 0 to 60s in 1s intervals
Relay contacts: Single-pole changeover, Rating 5A, 115/230 V AC, 5A DC
Insulation: 2kV RMS contacts to earth/ground
Minimum load: voltage: 12V; current: 100 mA
Analog Outputs
Number of current outputs (fully isolated): Two for C210 and C220 or four for C211, C221 and C222
Output current: 0 to 10mA, 0 to 20mA or 4 to 20mA
Analog output programmable to any value between
0 and 22mA to indicate system failure

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Accuracy: ±0.25% FSD, ±5% of reading (whichever is the greater)
Resolution: 0.1% at 10mA, 0.05% at 20mA
Maximum load resistance: 750at 20mA
Configuration: Can be assigned to either measured variable or either sample
temperature
Access to Functions
Direct keypad access: Measurement, maintenance, configuration, diagnostics and
service functions
Performed without external equipment or internal jumpers
Control Function – C210 and C220 only
Controller Type: P, PI, PID (configurable)
Output: Can be assigned a maximum of two relays, two analog outputs
or one of each
Analog: Current output control (0 to 100%)
Time proportioning cycle time: 1.0 to 300.0s, programmable in increments of 0.1s
Pulse frequency: 1 to 120 pulses per minute, programmable in increments of
1 pulse per minute
Controller action: Reverse, direct or bi-directional (programmable)
Proportional band: 0.1 to 999.9%, programmable in increments of 0.1%
Integral action time (Integral reset): 1 to 7200s, programmable in increments of 1s (0 = Off)
Derivative: 0.1 to 999.9s programmable in increments of 0.1s, available
only for single set point control
Auto/Manual: User-programmable

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2.2 pH – C210, C211 and C221 only*
Inputs: One (C210 and C221) or two (C211) pH or mV inputs and
solution earth
One (C210 and C221) or two (C211) temperature sensors
Input resistance: Glass: >1 x 1013 
Reference: 1 x 1013 
Range: –2 to 16pH or –1200 to +1200mV
Minimum span: Any 2pH span or 100mV
Resolution: 0.01pH
Accuracy: 0.01pH
Temperature compensation modes: Automatic or manual Nernstian compensation
Range –10 to 200°C (14 to 392°F)
Process solution compensation with configurable coefficient
Range 0 to 100°C (32 to 212°F)
adjustable –0.05 to +0.02%/°C (–0.02 to +0.009%/°F)
Temperature sensor: Programmable Pt100, Pt1000 or Balco 3k
Calibration Ranges
Check value (zero point): 0 to 14pH
Slope: Between 40 and 105% (low limit user-configurable)
Electrode Calibration Modes: Calibration with auto-stability checking
Automatic 1 or 2 point calibration selectable from:
•ABB
•DIN
•Merck
•NIST
•US Tech
2 x user-defined buffer tables for manual entry
2-point calibration or single-point process calibration
* Enables connection to glass or enamel pH and reference sensors and Redox (ORP) sensors
Specifications may be limited by the pH electrode in use. Refer to corresponding
Instruction Manual !
*

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2.3 Conductivity - C220, C221 and C222 only
Range:
Conductivity Programmable: 0.000 to 1999mS/cm (uncompensated)
Concentration: 0.000 to 1.999 digits (user configurable)
Selectable concentration ranges 0 to 15% NaOH
0 to 18% HCl
0 to 20%H2SO4
0 to 40% H3PO4
0 to 20% NaCl
User-defined table
Temperature: –20 to 300°C (–4 to 572°F )
Sensor Full Scale Measurement Ranges
(a) TB4 Group A and AC400 cells: 0 to 1,999mS/cm (uncompensated, for sensors with cell
constant of approx. 0.5 cm-1)
(b) TB4 Group B cells: 0 to 1,999µS/cm (uncompensated, for sensors with cell
constant of approx. 0.05 cm-1)
Minimum span
(a) TB4 Group A and AC400 cells 100.0µS/cm
(b) TB4 Group B cells 10.00µS/cm
Concentration: 5% of the maximum set concentration range
Temperature: 10°C (50°F)
Resolution, Display
(a) TB4 Group A cells 0.1 µS/cm
AC400 cells 0.1mS/cm
(b) TB4 Group B cells 0.01µS/cm
Concentration 0.001 digits (configuration dependent)
Temperature 0.1°C (0.1°F)
Accuracy, Display
Conductivity ± 0.5% measurement range per decade
(199.9 µS/cm; 1999µS/cm; 19.99 mS/cm; 199.9 mS/cm;
1999 mS/cm)
Temperature ± 0.2°C
Display temperature range: –20 to 300°C (–4 to 572°F)
Temperature sensor: Pt1000 or 3k Balco
Temperature coefficient: Programmable 0 to 9.99%/°C and fixed temperature Compen
sation curves (programmable) for acids and neutral salt.
Reference temperature: 25°C (77°F)
Dosing control functions: Long-dose alarm: 0 to 10 mins. (user-configurable)
Initial charge function: 0 to 30 mins. (user-configurable)
Specifications may be limited by the sensor in use. Refer to corresponding Instruction
Manual for process limit specifications of optek sensor CF60 !
*

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Instruction Manual C200 Part1 A1.doc optek Danulat GmbH •D-45356 Essen •Germany page 10
2.4 Control 200 – configuration feasibilities
Depending on the intended use the converter Control 200 is available in 5 different configurations. The
main features and connection feasibilities are listed in the following table:
Configurations: CONTROL 200 C210 C220 C211 C221 C222
Relais-outputs 3 3 5 5 5
0-10 mA, or 0/4-20 mA-outputs 2 2 4 4 4
Connection feasibilities sensors:
1 sensor PF12 (pH) X X X
1 sensor CF60 (conductivity) X X X
2 sensors PF12 + PF12 (pH) X
2 sensors PF12 + CF60 (pH + conductivity) X
2 sensors CF60 + CF60 (conductivity) X

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Instruction Manual C200 Part1 A1.doc optek Danulat GmbH •D-45356 Essen •Germany page 11
3 Mechanical installation
3.1 Front panel CONTROL 200
0.000
Dual Cond.
0.000
uS/cm
Alarm
LEDs
Display
Lines
Lower
Display Line
Membrane Keys
uS/cm
Units
Menu Key
Sidescroll Key
Downscroll Key
Up Key
Down Key

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3.2 Back panel CONTROL 200
Te r m i n al B l o c k C
(Option Board) Terminal Block B
Te r m i n al B l o c k A
Case Earth (Ground) Stud
LLine
N Neutral
E Connect supply earth (ground) to stud on case
A4 C
A5 NC Relay 1
A6 NO
A7 C
A8 NC Relay 2
A9 NO
A10 C
A11 NC Relay 3 (see Note below)
A12 NO
A13 + Analog Output 1
A14 —
A15 + Analog Output 2
A16 —
Te r m in al B l o ck BTerminal block A
Temperature Compensator
Connections
Common
Third Lead
TC
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14
B15
B16
Common
Third Lead
TC
Temperature Compensator
Connections
Te r m in al B l o ck C
(Option Board)
C1 Not Used
C2 Not Used
C3
C4
C5
C6 Not Used
C7 C
C8 NC Relay 4
C9 NO
C10 C
C11 NC Relay 5
C12 NO
C13 + Analog Output 3
C14 —
C15 + Analog Output 4
C16 —
Earth (Ground)
Stud on Case
Used for optional
RS485 connections –
refer to IM/PROBUS
85 to 265 V AC + 12
or to Power
24 V AC – 24V DC Supplies
Sensor A
Sensor B

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3.3 Dimensions Control 200
Dimensions in mm (in.)
96 (3.78)
5.40 (0.2)
137.50 (5.41) 25
(0.98)
Panel Cut-out
+0.8
–0
92 (3.62 )
+0.03
–0
+0.8
–0
92
(3.62 )
+0.03
–0
3.4 Frontpanel Mounting
Mount in a location free from excessive vibration
Mount away from harmful vapours and/or dripping fluids
Where possible, mount the analyzer at eye level to allow an unrestricted view of the
front panel displays and controls
Insert the instrument
into the panel cut-out
Secure the analyzer by tightening the panel clamp
retaining screws (see Note below)
Loosen the retaining
screw on each panel
clamp
Remove the panel clamp and
anchors from the instrument case
Cu
t
a hole in the panel (see Fi
g
.6.4fo
r
dimensions).
Instruments may be close stacked to DIN 43835
1
2
3
4
5
6
Refit the panel clamps to the case, ensuring that the
panel clamp anchors are located correctly in their slots
*

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3.5 19” Rack Mounting Control 200
19” rack mounting (3 HE / 21 TE) can be achieved by means of an additional front plate (128.4 x 106.4 mm)
with cut out (92.6 x 92.6 mm). Installation procedure is as described in Section 3.4. Dimensions of the front
plate (PN: 1200-3333-0001-00) are shown as follows:

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4 Field wiring schematic
4.1 General Instructions
The instrument is not fitted with a switch therefore a disconnecting device such as a switch or circuit
breaker conforming to local safety standards must be fitted to the final installation. It must be fitted in close
proximity to the instrument within easy reach of the operator and must be marked clearly as the
disconnection device for the instrument.
Remove all power from supply, relay and any powered control circuits and high common mode voltages
before accessing or making any connections
The power supply earth (ground) must be connected to ensure safety to personnel, reduction of the effects
of RFI interference and correct operation of the power supply interference filter.
The power supply earth (ground) must be connected to the earth (ground) stud on the analyzer case – see
3.2 (back panel).
The metal braid in the sensor system connecting cable must be connected to the earth (ground) stud on the
analyzer case – see 3.2 (back panel)
Use cable appropriate for the load currents. The terminals accept cables up to 14AWG (2.5mm2).
The instrument conforms to Mains Power Input Insulation Category III. All other inputs and outputs conform
to Category II.
All connections to secondary circuits must have basic insulation.
After installation, there must be no access to live parts, e.g. terminals.
Terminals for external circuits are for use only with equipment with no accessible live parts.
The relay contacts are voltage-free and must be appropriately connected in series with the power supply
and the alarm/control device which they are to actuate. Ensure that the contact rating is not exceeded. Refer
also to Section 4.2 for relay contact protection details when the relays are to be used for switching loads.
Do not exceed the maximum load specification for the selected analog output range.
The analog output is isolated, therefore the –ve terminal must be connected to earth (ground) if connecting
to the isolated input of another device.
If the instrument is used in a manner not specified by the Company, the protection provided by the
equipment may be impaired.
All equipment connected to the instrument's terminals must comply with local safety standards (IEC 60950,
EN601010-1).
Earthing (grounding) – a stud terminal is fitted to the analyzer case for bus-bar earth
(ground) connection – see 3.2 (back panel).
Always route signal output/sensor cell cable leads and mains-carrying/relay cables
separately, ideally in earthed (grounded) metal conduit. Use twisted pair output
leads or screened cable with the screen connected to the case earth (ground) stud.
*

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4.2 Relay Contact Protection and Interference Suppression
If the relays are used to switch loads on and off, the relay contacts can become eroded due to arcing. Arcing
also generates radio frequency interference (RFI) which can result in analyzer malfunctions and incorrect
readings. To minimize the effects of RFI, arc suppression components are required; resistor/capacitor
networks for AC applications or diodes for DC applications. These components can be connected either
across the load or directly across the relay contacts. The RFI components must be fitted to the relay
terminal block along with the supply and load wires – see drawings below.
For AC applications the value of the resistor/capacitor network depends on the load current and inductance
that is switched. Initially, fit a 100R/0.022µF RC suppressor unit as shown in fig. A. If the analyzer
malfunctions (locks up, display goes blank, resets etc.) the value of the RC network is too low for
suppression and an alternative value must be used. If the correct value cannot be obtained, contact the
manufacturer of the switched device for details on the RC unit required.
For DC applications fit a diode as shown in fig. B. For general applications use an IN5406 type (600V peak
inverse voltage at 3A).
For reliable switching the minimum voltage must be greater than 12V and the minimum current greater
than 100mA !
NC C NO
External
DC Supply
+–
Relay Contacts
Load
Diode
A – AC Applications B – DC Applications
NC C NO
External
AC Supply
LN
Relay Contacts
C
R
Load
*

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*
4.3 Sensor wiring
4.3.1 Wiring of conductivity sensors
The wiring of conductivity sensor CF60 to a converter C200 as sensor A and/or B is described in the
following table:
Terminal Block B
Sensor B Sensor A Wire no. Color Function
B1 B9 9 Orange Temperature Compensator Common
B2 B10 10 Red Temperature Compensator 3rd lead
B3 B11 11 Blue Temperature Compensator
B4 B12 12 White Sreen
B5 B13 13 Brown Drive -
B6 B14 14 Yellow Sense -
B7 B15 15 Green Sense +
B8 B16 16 Black Drive +
For use with different sensors refer to corresponding instruction manual !
If sensor is equipped with a 2-wire temperature compensator, link terminals B9 and
B10 (and B1 and B2 if dual input analyzer) !
LLine
N Neutral
E Connect supply earth (ground) to stud on case
A4 C
A5 NC Relay 1
A6 NO
A7 C
A8 NC Relay 2
A9 NO
A10 C
A11 NC Relay 3 (see Note below)
A12 NO
A13 + Analog Output 1
A14 —
A15 + Analog Output 2
A16 —
Te r m in al B lo ck BTerminal block A
Temperature Compensator
Connections
Common
Third Lead
TC
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14
B15
B16
Common
Third Lead
TC
Temperature Compensator
Connections
Te r m in al B lo ck C
(Option Board)
C1 Not Used
C2 Not Used
C3
C4
C5
C6 Not Used
C7 C
C8 NC Relay 4
C9 NO
C10 C
C11 NC Relay 5
C12 NO
C13 + Analog Output 3
C14 —
C15 + Analog Output 4
C16 —
Earth (Ground)
Stud on Case
Used for optional
RS485 connections –
refer to IM/PROBUS
85 to 265 V AC + 12
or to Power
24 V AC – 24V DC Supplies
Sensor A
Sensor B

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*
4.3.2 Wiring of pH sensors
The converter CONTROL 200 can be connected to either a standard pH input or differential pH input. The
dual input pH is designed for use with pH electrode systems that incorporate a solution earth (ground)
connection to provide low glass impedance and out-of-sample/broken cable warnings.
The wiring of pH sensor PF12 with ABB combination electrodes to a converter C200 as sensor A and/or B is
described in the following tables:
Wiring with solution earth (ground) for inline sensor diagnostic
Terminal Block B
Sensor B Sensor A Wire no. Color Function
B1 B9 1 Grey Temperature Compensator Common
B2 B10 2 White Temperature Compensator 3rd lead
B3 B11 3 Green Temperature Compensator
B4 B12 4 Blue Reference
B5 B13 Not used Not used
B6 B14 6 Green/Yellow Solution Earth (Ground)
B7 B15 7 Red Screen/Shield
B8 B16 8 Transparent Glass Electrode
Wiring without solution earth (ground)
Terminal Block B
Sensor B Sensor A Wire no. Color Function
B1 B9 1 Grey Temperature Compensator Common
B2 B10 2 White Temperature Compensator 3rd lead
B3 B11 3 Green Temperature Compensator
B4 B12 Not used Not used
B5 B13 Not used Not used
B6 B14 4 Blue Reference
B7 B15 7 Red Screen/Shield
B8 B16 8 Transparent Glass Electrode
For use with different sensors refer to corresponding instruction manual !
If sensor diagnostics are required, ensure that Diff. Input for the relevant sensors is
set to “YES” – see Instruction Manual Control 200, Part 2 - Software !
If sensor is equipped with a 2-wire temperature compensator, link terminals B9 and
B10 (and B1 and B2 if dual input analyzer) !

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*
5 Start-up / Maintenance
5.1 Start-up
basic rules:
1. Read the instructions manual first – install later !!!
2. Installation should be done by skilled personnel only !!!
3. If something is not clear – check first – install later !!!
procedure
(referring to sections in
this instructions manual)
initial
start-up
start-up
after stop
read all of the instructions manual !!! XXX XXX
check equipment to be complete as ordered XXX
inspect parts for damage XXX
install measuring cell and sensors XXX
check line for leakage XXX
install probe cables XXX
connect cables XXX
connect power XXX
power up converter XXX XXX
allow 20 min. to warm-up XXX XXX
adjust converter (separate document) XXX
document installation XXX (XXX)
check readings for correctness XXX XXX
release measurement for control purpose XXX XXX
Check separate instructions manual for sensors !