Thermo Scientific ALPHA COND 1000 User manual

Alpha COND 1000
Controller/Transmitter
uS/cm / mS/cm / ºC

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Preface
This manual serves to explain the use of the Alpha COND 1000 process
controller/transmitter. The manual functions in two ways, firstly as a step by step
guide to help the user operate the instrument. Secondly, it serves as a handy
reference guide. This instruction manual is written to cover as many anticipated
applications of the Alpha COND 1000 process controller/transmitter. If you have
doubts in the use of the instrument, please do not hesitate to contact the nearest
Authorized Distributor.
Thermo Scientific will not accept any responsibility for damage or malfunction of
the unit due to improper use of the instrument.
The information presented in this manual is subject to change without notice as
improvements are made, and does not represent a commitment on part of
Thermo Scientific.
Copyright ©2009
All rights reserved.

Safety Information
The 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.

TABLE OF CONTENTS
1INTRODUCTION................................................................................1
1.1 Description of Unit.....................................................................................1
1.2 Applications ..............................................................................................1
2ASSEMBLY AND INSTALLATION ...................................................2
2.1 Measurement and Control System............................................................2
2.2 Unit Dimensions........................................ Error! Bookmark not defined.
3ELECTRICAL CONNECTION............................................................3
3.1 Connection Diagram.................................................................................3
3.2 Back Panel................................................................................................4
4OVERVIEW ........................................................................................5
4.1 Keypad and Display..................................................................................5
4.1.1 Keypad ................................................................................5
4.1.2 Display.................................................................................5
4.2 Function Groups .......................................................................................6
4.2.1 How to view operating parameters without access to
change them:......................................................................................6
4.3 Control Concept........................................................................................7
5MEASUREMENT ...............................................................................8
5.1 Display in Measurement mode..................................................................8
5.1.1 Check electrode performance.............................................8
5.1.2 Checking set points.............................................................8
5.2 Security Codes..........................................................................................9
5.2.1 How to enter and change parameters in Calibration mode.9
5.2.2 How to enter and change parameters in Advanced Setup
mode 9
6CALIBRATION MODE.....................................................................11
6.1 Conductivity Calibration..........................................................................11
7ADVANCED SET-UP MODE...........................................................13
7.1 Temperature Coefficient sub-function.....................................................13
7.1.1 Selecting Pure-water or Linear Temperature Coefficient..13
7.2 Temperature Calibration (ATC mode only) .............................................14
7.2.1 Setting Manual Temperature Compensation ....................14
7.3 Control Relay A/Control Relay B (SP1/SP2) sub-function ......................15
7.3.1 Entering the Set point 1 (or Set point 2) sub-function.......15
7.3.2 Selecting the set point values............................................15
7.3.3 Choosing High or Low set points.......................................16
7.3.4 Selecting a hysteresis (dead band) value .........................16
7.3.5 Setting an on-delay time lag..............................................17
7.3.6 Setting an off-delay time lag..............................................17
7.4 Controller (Cntr) sub-function..................................................................18

7.4.1 Entering the Controller sub-function..................................18
7.4.2 Choosing the controller type (limit or proportional) ...........19
7.4.3 Choosing Break/Make Contact Relay Type......................19
7.4.4 Selecting Proportional Range Value, Xp...........................20
7.4.5 Maximum Pulse Length (tPL) or Maximum Frequency (FPF)
20
7.5 Measurement Range sub-function..........................................................21
7.5.1 Selecting the Measuring Range sub-function ...................21
7.6 Current Output (rng) sub-function...........................................................22
7.6.1 Entering current output sub-function.................................22
7.6.2 Choosing the output type ..................................................22
7.6.3 Selecting Conductivity value at 0(4)mA.............................22
7.6.4 Selecting Conductivity value at 20mA...............................23
7.7 Configuration (ConF) sub-function..........................................................23
7.7.1 Entering the Configuration sub-function............................23
7.7.2 Selecting Filter Function and the Alarm or Wash Function
23
7.7.3 Selecting the alarm time lag..............................................24
7.7.4 Selecting steady or pulse contact for the alarm relay .......24
7.7.5 Wash contact (if the relay 3 is set to Wash)......................25
7.7.6 Input Line Resistance Adjust.............................................25
7.7.7 Reverting to factory default settings..................................25
7.8 Calibration (CAL) sub-function............................................................26
7.8.1 Entering Calibration mode from Advanced Set-up mode..26
8AUTO/MANUAL MODE...................................................................27
8.1 Auto mode (mode after switch-on)..........................................................27
8.2 Manual mode..........................................................................................27
9TECHNICAL SPECIFICATIONS .....................................................28
10 ACCESSORIES ...............................................................................29
11 GENERAL INFORMATION..............................................................29
11.1 Warranty .............................................................................................29
11.2 Packaging...........................................................................................29
11.3 Return of Goods..................................................................................29
11.4 Guidelines for Returning Unit for Repair .............................................30
12 APPENDICES ..................................................................................30
12.1 Appendix 1 – Jumper Positions...........................................................30
12.2 Appendix 2 – Measurement Ranges available in the Controller..........31
12.3 Appendix 3 – Conductivity at Related Temperature Coefficients (25 °C)
31
12.4 Appendix 4 – Conductivity of Various Aqueous Solutions at 25 C....33
12.5 Appendix 5 - Simple Explanation on the Function of Hysteresis.........34
12.6 Appendix 6 – General Instructions Concerning Controller Setting......35

1
1 INTRODUCTION
1.1 Description of Unit
Thank you for purchasing the ¼ DIN Alpha COND 1000 series Conductivity
process controllers. This unit is used for measuring the Conductivity of a
solution, either in micro-Siemens or milli-Siemens, one at a time, and the
operational mode is switchable from the menu. You can use this unit to measure
Conductivity with limit control. This controller has many user-friendly and safety
features which include:
•Menu-driven program that simplifies set-up
•Ten ranges of Conductivity measurements-software selectable (Appendix
2).
•Built-in memory backup to ensure that calibration data and other
information are not erased if power supply fails
•Automatic temperature compensation (ATC) with Pt100 or Pt 1000
•Manual temperature compensation with independent setting for
calibration and process temperature
•Temperature coefficient variable between 0.00 to 10.00 % per oC. Separate
pure water compensation curve stored in memory. Reference temperature
at 25oC.
•0 to 1999 second time delay adjustment on all relays – minimise false
alarms
•Separately adjustable high and low set point hysteresis (dead bands)
prevents chattering of relays around the set points. Selectable Filter
function stabilises rapid measurement changes
•Four operating modes: limit, display monitor , proportional pulse length or
proportional pulse frequency control.
•Large dual display LCD for easy reading with clear multiple annunciators,
alarm status and operational message annunciators
•Two switching contacts as set-point triggering relays and an alarm
output relay
•Separate alarm relay alerts you when set points have exceeded the limits
and if the Pt100/Pt1000 wires are broken or disconnected during the ATC
function
•Hold function freezes output current (0/4...20mA) and releases control
relays
•LED indicators signal control activities to monitor controller status from a
distance
•Protection against electromagnetic interference - galvanically isolated
0/4 - 20mA output provides safety for data logging and control purposes
1.2 Applications
Use this controller in panel mounted enclosures for applications in water treatment
and demineralization, waste water treatment and neutralization processes.

Operating Instructions Thermo Scientific Alpha COND 1000
2
2 ASSEMBLY AND INSTALLATION
2.1 Measurement and Control System
A typical measurement system consists of:
•a Alpha COND 1000 process controller
•a suitable Conductivity electrode with the appropriate Cell constant and
integrated temperature sensor Pt 1000 or Pt 100,
•an immersion, flow or process assembly
•a final control element such as pump or valve and
•a chart recorder.
Power Mains
(220/110 VAC)
Alpha-CON1000 Controller
Flow Assembly
to Dosing Pumps
Process Assembly
with Electrode
Chart Recorder
Pt100/Pt1000
Temperature Sensor
A
lpha-CON1000
Alarm / Siren
System
2.2 Unit Dimensions
The field-tested control panel housing is 96 x 96 mm; with protection class IP 54
(front).
max. 175 max. 45
Mounting Cut-Out
Flat
G
asket
(
1mm
)
(To be Inserted By Customer)
Note: The Taped Corners Have to Be On Top
92
32
56
96
92 + 0.5
92 + 0.5
Alpha COND 1000

Operating Instructions Thermo Scientific Alpha COND 1000
3
3 ELECTRICAL CONNECTION
ENSURE that the power cable is physically separated from the power
supply.
3.1 Connection Diagram
Signal OutputHold Input
Alarm
Relay 2
Relay 1
Power Mains
Cond.
mA
-
+
PE/S
PEAC: NL
125
4
36
78 9 10 11 12 13 14 15 17
15 16
* ) indicated contact positions are for currentless or no error conditions
Pt 100
Signal Input Conductivity
S/
V
PE/S
Cond.
18 19 20 21 22
S/

Operating Instructions Thermo Scientific Alpha COND 1000
4
3.2 Back Panel
The back panel consists of two connectors. The first connector is the 17-way PCB
edge connector and the other is the 5-way connector.
ENSURE that the power cable is physically separated from the power
supply.
Connection for the 17-way screw terminals (from left to right):
1. AC mains live wire 10. Alarm relay resting position (NO)
2. AC mains neutral wire 11. Alarm relay common
3. AC mains protective earth wire 12. Alarm relay working position (NC)
4. Low set relay resting position (NC) 13. Hold function switch terminal 1
5. Low set relay common 14. Hold function switch terminal 2
6. Low set relay working position (NO) 15. No connection
7. High set relay resting position (NC) 16. 0/4 - 20 mA for -ve connection
8. High set relay common 17. 0/4 - 20 mA for +ve connection
9. High set relay working position (NO)
Connections for the 5-way screw terminals:
18. Pt1000/Pt100 lead 1 terminal
19.Pt1000/Pt100 sense lead terminal
20.Pt1000/Pt100 lead 2 terminal
21. Conductivity lead 1
22. Conductivity lead 2
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.
Pt100/
RELAY1
L NPE
63mA (F)
FUSE 250VAC
HOLD
ALARM RELAY2
Pt1000
NC
-
+
cell
J2

Operating Instructions Thermo Scientific Alpha COND 1000
5
4 OVERVIEW
4.1 Keypad and Display
4.1.1 Keypad
•Perform rapid calibration
•Allows entry to Set up mode
•Select individual functions within the function group of Set up mode
•Store input data in the Set up mode
•Start calibration in the calibration mode
•Select various function groups in the Set up mode.
•Set parameters and numerical values in sub functions of Set up mode
If pressed continuously, the setting speed increases
•Control the relays in the MANUAL function
•Return to the Measurement mode when both keys are pressed
together
•Switch between AUTO and MANUAL relay operation using a code
•Display limit set-point values for the switch contacts in AUTO relay
operation mode
•Switch between RELAY A and RELAY B in MANUAL relay operation
mode
4.1.2 Display
The LCD display features two numerical displays that show status messages and
measured values for easy, quick reference. The display provides short-text
information for setting parameters and configuration.
SETUP MEAS CAL
HOLD
mS
μ S
ATC
° C
READY
-8.8.8.8
8
-1.8.8.8
•HOLD: Relay position and current output are
frozen
•SETUP: Set-up mode of function groups
•MEAS: Measurement mode
•CAL: Calibration mode of Conductivity
•READY: Comes on after a successful
calibration
•ATC: Comes on in the ATC mode. Disappears
in the Manual temperature Compensation
mode. “ATC” flashes if the temperature probe
is faulty in its ATC mode
•8: Indicates the measurement range selected.
Refer to Appendix 2.
•Display for RELAY A/B. Green LED indicates measured value within
limit while RED LED indicates measured value outside limit.
•Alarm display if limit value overshoot or the ATC connection is broken.

Operating Instructions Thermo Scientific Alpha COND 1000
6
4.2 Function Groups
The main function and sub-function groups are organised in a matrix format for
configuration and selection of parameters. The main function groups are:
1) Temperature Coefficient settings (tc). See Section 7.1.
2) Temperature Measurement / compensation settings (SEt oC). See Section 7.2.
3) Control relay 1 configuration (SP1). See Section 7.3.
4) Control relay 2 configuration (SP2). See Section 7.3.
5) Control type (Cntr). See Section 7.4.
6) Current output (rng). See Sections 7.5 & 7.6.
7) Configuration (ConF). See Section 7.7.
8) Calibration (CAL Con). See Sections 6 & 7.8.
HOLD SETUP HOLD SETUP HOLD HOLDSETUP SETUP
Sp1 Sp2
HOLD SETUP
° C
HOLD SETUP
Cal
HOLD SETUP HOLD SETUP
C
The set-up parameters can be viewed or changed by entering a security code. See
Section 5.2 for security code information.
4.2.1 How to view operating parameters without access to change them:
a) Press the ENTER key. The display will prompt the
user to enter a security code (S.Cd). Leave the
security code at “000” (do not enter a security code).
b) Press ENTER key again. This allows you only to
view (not change) any sub-functions’ settings.
c) Press the ▲or ▼keys to scroll through the sub-
functions.
d) Press the ENTER key at a particular sub-function to view in detail.
e) Press the ENTER key to return to the sub-function menu.
f) Press the ▲or ▼keys simultaneously (as an Escape key) at any time to return
to the Measurement mode.
Note: To simplify operations, the controller will not display parameters that are not
relevant to a particular sub-function. For example: If the user set the controller for
Limit control, it will not display pulse length/frequency settings.
000

Operating Instructions Thermo Scientific Alpha COND 1000
7
4.3 Control Concept
The main function and sub-function groups are organised in a matrix format as
shown below. These functions can be accessed via the front keypad for
configuration and selection of parameters.
MEASURE
CODE
tc
SET C
SET-POINT 2
CONTROLLER
OUTPUT
RANGE
CONFIGURATION
CALIBRATION
SET-POINT 1
Set value 1
Switch On /
Off ATC
Temp Coeff Pur / Lin Set Coeff
Controller type
Process temp.
(MTC)
MIN / MAX
Function
Set value 2
N.O./N.C.
contact Proportional
Band Cycle time
Current Ouput
0..20 / 4..20 mA
Range
Selection
Line Resistance
Adjustment
Set Cell
Constant K
Conductivity
at 0/4 mA
Display Cal
Ratio
Hysteresis 2
Calib. temp.
(MTC) Calibrate Pt100
Pick-up delay
contact 1
Dropout delay
contact 2
Set Filter
Function Select /Load
Factory Default
Calibrate to
Standard
MIN / MAX
Function
Conductivity
at 20 mA
Hysteresis 1
Pick-up delay
contact 2
Dropout delay
contact 1
The controller offers two levels of password protection: (1) for direct access to
calibration function and (2) for setting or editing specific controller parameters or
functions in the SETUP mode to suit individual requirements.
Note: The passwords are not user-defined and have been set by factory. It is very
important to keep these passwords strictly confidential to avoid unauthorised
tampering of the system at all times.
Note: If the user reads parameters only, the controller automatically reverts to
Measurement mode if none of the keys is pressed for 30 seconds.

Operating Instructions Thermo Scientific Alpha COND 1000
8
5 MEASUREMENT
5.1 Display in Measurement mode
When the controller is initially powered on, it automatically enters into the
Measurement mode after the large dual LCD displays all segments briefly.
The upper display shows the measured Conductivity value, while the lower display
shows the temperature value. Annunciators at the right side of the display indicate
whether the controller is set for μS or mS measurement. Similarly annunciators or
icons at the top or left side of the display shows the current status of controller, e.g.
“HOLD”, “SETUP”, “MEAS”, “CAL”, “READY”, etc.
5.1.1 Check electrode performance
To read current electrode slope and offset values without changing them:
1) Press the CAL key followed by the ENTER key without adjusting the security
code (leave code at “000”). The upper display shows the condition of the probe.
The lower display reading shows the temperature reading.
Note: If security code is changed to a value other than “000”, pressing the
ENTER key will return to the Measurement mode, without displaying electrode
information.
2) Press the ENTER key a second time to return to Measurement mode.
5.1.2 Checking set points
To read current set point values without changing them:
•Press the RELAY Selection (Rel A / Rel B) key. The upper display shows
the set point for Relay A; the lower display shows “SP1”.
•After two seconds the upper display shows the set-point value for Relay B;
the lower display shows “SP2”.
•After an additional two seconds, the controller returns to the Measurement
mode.

Operating Instructions Thermo Scientific Alpha COND 1000
9
5.2 Security Codes
This controller has two levels of security protection with separate security codes.
The first level allows entry into the Calibration mode: security code = 11; the second
allows entry into the SETUP mode: security code = 22.
The security codes protect the controller from unauthorised tampering of its current
setting. The parameters cannot be changed unless the security code is entered.
5.2.1 How to enter and change parameters in Calibration mode
1) Press the CAL key. The upper display shows “000”
and the lower display shows “C.Cd” to prompt the
user to enter the Calibration security code.
2) Press the ▲or ▼keys to scroll upper display to
Calibration security code “11”.
3) Press the ENTER key. The display shows “CAL
CON”.
4) Press ENTER key again to begin calibration. Refer to Section 6 for full details on
calibration.
5) Press the ▲or ▼keys simultaneously (escape) to return to the Measurement
mode.
NOTE: To view (not change) the SETUP parameters, push the ENTER key
when the security code reads “000”.
5.2.1.1 Clearing the Calibration security code from the display
The calibration security code automatically resets from “11” to “000” after you return
to Measurement mode, so you do not need to clear the security code from the
display.
5.2.2 How to enter and change parameters in Advanced Setup mode
1) Press the ENTER key once. The upper display shows “000” and the lower
display shows “S.Cd” to prompt you to enter the Advanced Setup security code.
2) Press the ▲or ▼keys to scroll the display to Setup security code “22”. NOTE:
Pressing the ENTER key at a value other than “22” causes the controller to
revert to the Measurement mode.
3) Press the ENTER key.
4) The upper display reads “tc”.
5) You are now in the Advanced Setup mode. See Section 7 for complete
instructions. To return to Measurement mode, press the ▲or ▼keys
simultaneously (escape).
NOTE: If you want to view (not change) set up parameters, push the ENTER
key when the security code reads “000”.
11

Operating Instructions Thermo Scientific Alpha COND 1000
10
5.2.2.1 Clearing the Advanced Setup security code from the display
After you have entered the security code and returned to the Measurement mode,
the security code “22” still appears on the display whenever you press the ENTER
key. To conceal the security code, you must manually reset the code. To clear the
Advanced Setup security code from the display:
1) Press the ENTER key in the Measurement mode.
2) Set to any security code (not 11 or 22) and complete by pressing ENTER.
NOTE: When you enter the Calibration mode with code “11” or Advanced Setup
mode with security code “22”, the unit automatically enters into the HOLD mode
until you return back to Measurement mode. The HOLD annunciator is
displayed at the upper left of the display. While on HOLD, the current output is
frozen and set point relays are deactivated.

Operating Instructions Thermo Scientific Alpha COND 1000
11
6 CALIBRATION MODE
You can reach the Calibration mode directly from the Measurement mode by
pressing the CAL key and entering the Calibration security code. You can also
reach the Calibration mode from the Advanced Setup mode.
6.1 Conductivity Calibration
Calibration is always carried out in the specific range selected. The Conductivity
Controller allows a one-point calibration.
1) Enter Calibration mode. While in the Measurement
mode, push the CAL key and scroll to Calibration
code “11”. Push the ENTER key again. The upper
display reads “CAL” and the lower display shows
“Con”.
2) Press the ENTER key.The controller displays its
last set Cell Constant (k) of the cell as a percentage
of the theoretical value. Using the ▲and ▼keys, the
value can be set to anywhere from 80 to 120% (e.g.
real cell constant is 0.98 with nominal =1, enter
98%). . Press the ENTER key once again to carry
out calibration.
3) Immerse the Conductivity cell in a suitable standard
solution, whose value is within the measurement
range selected in the controller. Agitate the Cell in
the solution to remove any trapped air-bubbles.
Note: The calibration standard should have a value that
is between 20% to 100% of the range selected. For
example, if the range in the controller is selected to be
2000 µS (range 6), then the calibration standard value
should be 400 µS to 2000 µS.
4) Once the reading has stabilized, use the ▲or ▼
keys to adjust the measured value to that of the
standard solution. Press the ENTER key to accept the value and the controller
displays the revised condition of the probe. The lower display shows the factor
“FCt” while the upper display shows the ratio of ideal to adjusted calibration
value.
Note: The acceptable calibration window is ±40% of the displayed (default) value. If
the display is 1000 µS, the values to which it can be adjusted is 600 to 1400 µS. If
there is calibration error, the controller displays “ERR” annunciator. To re-calibrate
repeat step 3. To exit from calibration, push both ▲and ▼keys (escape) to resume
to Measurement mode.
5) Press the ENTER key. If you entered the calibration mode using the CAL key,
the controller will return to the Measurement mode. If you entered the calibration
mode from the Advanced Set-up mode, the controller will return to the sub-
function menu.
HOLD
HOLD
HOLD
HOLD
SETUP
CAL
CAL
CAL
%
6
6
6
6
Cal
100.0
1.01
1413
CEL
fc
25.0
μ S
ATC
° C
C

Operating Instructions Thermo Scientific Alpha COND 1000
12
Note: When calibrating with manual temperature compensation, the controller
automatically changes from the preset process temperature to the calibration
temperature. After leaving the Calibration mode, the controller switches back to
process temperature (for setting the calibration temperature and the process
temperature, see section 7.2.1).