Thermo Scientific ALPHA COND 560 User manual

Alpha COND 560
Controller
mS / µS / ºC / ºF

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Preface
This manual serves to explain the use of the Alpha COND 560 Controller. 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 560 Controller. If you have doubts in the use of the instrument, please do not
hesitate to contact your nearest Alpha Authorised Distributor.
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.
Thermo Scientific cannot accept any responsibility for damage or malfunction of the
unit due to improper use of the instrument.
Copyright © 2009
All rights reserved

TABLE OF CONTENTS
1INTRODUCTION 1
1.1 Before You Begin...................................................................................1
1.2 Intended Use .........................................................................................1
1.3 Safety Instructions .................................................................................2
1.4 Taking Out of Service / Correct Disposal of the Unit..............................2
2GETTING STARTED 3
2.1 Description of Instrument.......................................................................3
2.2 Measurement System............................................................................4
2.3 Connecting Peripherals.....................................................................5
2.4 Installation ...........................................................................................8
2.5 Display & Keypad ...............................................................................10
3OPERATION 13
3.1 Measurement mode...............................................................................13
3.2 Menu Overview......................................................................................14
4CALIBRATION MODE 15
4.1 About Calibration ...................................................................................15
4.2 Calibration..............................................................................................16
5SETUP MODE 18
5.1 Enter Setup mode..................................................................................18
5.2 Temperature Coefficient Settings...........................................................19
5.3 Temperature Settings ............................................................................20
5.4 Relay 1/Relay 2 Settings........................................................................22
5.5 Controller Settings .................................................................................24
5.6 Measuring Range Settings.....................................................................26
5.7 Configuration Settings............................................................................27
5.8 Viewing Electrode Properties.................................................................30
6TECHNICAL SPECIFICATIONS 31
7LIST OF ACCESSORIES 34
7.1 Thermo Scientific Order Codes..............................................................34
7.2 Eutech Instruments Order Code ............................................................34
8TROUBLESHOOTING 35
9GENERAL INFORMATION 36
9.1 Warranty................................................................................................36
9.2 Return of Goods.....................................................................................36
9.3 Guidelines for Returning Unit for Repair................................................36
9.4 Maintenance and Cleaning ....................................................................37
10 APPENDICES 38
10.1 Appendix 2 Conductivity of various aqueous solutions.........................38
10.2 Appendix 2 Graphical Representation of the Function of Hysteresis....39

10.3 Appendix 3 General Instructions Concerning Controller Setting...........40
10.4 Appendix 4 - Abbreviations Used in LCD...............................................41

- 1 -
1 INTRODUCTION
1.1 Before You Begin
Thank you for purchasing the Alpha COND 560 Controller.
The construction of the Alpha COND 560 Controller employs leading edge
technology and complies with safety regulations currently in force. Notwithstanding
this, improper use could lead to hazards for the user or a third-party, and/or adverse
effects on the plant or other equipment. Therefore, the operating instructions must
be read and understood by the persons involved before working with the
Conductivity Controller.
The instruction manual must always be stored close at hand, in a place accessible
to all people working with the Conductivity Controller.
If you have questions, which are not or insufficiently answered in this instruction
manual, please contact your authorized supplier. They will be glad to assist you.
1.2 Intended Use
Alpha COND 560 Controllers are intended solely for Conductivity and temperature
measurement, as described in this instruction manual.
Any other use, or use not mentioned here, that is incompatible with the technical
specifications is deemed inappropriate. The operator is solely responsible for any
damage arising from such use.
Other prerequisites for appropriate use include:
–Comply with the instructions, notes and requirements set out in this instruction
manual.
–Comply with all local safety regulations concerning safety at work.
–Comply with all information and warnings in the documentation dealing with the
products used together with the Conductivity Controller (housing, sensors, etc.).
–Comply with the local environmental and operational conditions.

1.3 Safety Instructions
•The Alpha COND 560 Controller should be installed and
operated only by personnel familiar with the instrument and
who are qualified for such work.
•A defective Conductivity Controller must neither be installed
nor put into service.
•The Alpha COND 560 must only be operated under the
specified operating conditions (see section 6).
•The Alpha COND 560 must not be repaired by the
customer.
•No modifications to the Alpha COND 560 are allowed. The
manufacturer/supplier accepts no responsibility for damage
caused by unauthorized modifications. The risk is borne
entirely by the user.
1.4 Taking Out of Service / Correct Disposal of the Unit
Taking out of Service
•First disconnect the unit from the power supply and then undo all electrical
connections.
•Remove the unit from the wall.
Correct Disposal of the Instrument
When the Alpha COND 560 is permanently taken out of service, obey the local
environmental regulations for correct disposal or send the instrument to your local
distributor, they will take care of proper disposal.
- 2 -

- 3 -
2 GETTING STARTED
2.1 Description of Instrument
The Eutech Instruments’ Alpha CON 560 Controller is used for measuring
conductivity and temperature values. The controller can be used for applications
such as water treatment and controlling, galvanic-decontamination, chemical
processing, food processing, clean or wastewater control and neutralization
processes.
The controller has many user-friendly and safety features which include:
•Push-button keypad for calibration and setup
•Built-in non-volatile memory to ensure that calibration and other
information are not erased if power supply fails
•Menu-driven program that simplifies setup
•Automatic temperature compensation (ATC)
•Manual temperature compensation setting without the ATC probe, with
independent setting for calibration and process temperature
•Large dual display LCD for easy reading with clear multiple annunciators,
operational mode indicators and error indicators
•Two switching contacts as set-point relays
•Limit (on/off) control mode
•Separately adjustable high and low set-point hysteresis (dead bands) to
prevent chattering of relays around the set points
•0 to 2000 seconds time delay adjustment on all relays – minimizes false
alarms
•Backlight LCD display

2.2 Measurement System
A typical measurement system consists of:
•A conductivity process controller
•A conductivity sensor with integrated or separate Pt100/Pt1000
temperature sensor
•An appropriate measurement cable
•An immersion, flow or process assembly
•A final control element such as pump or valve
Conductivity Controller
PowerAdaptor
(+9 V DC)
Relay Output
Measurement Cable
Housing and
Sensors
Pump or Valve
Alpha CON 560 Controller
ENT
ESC
pH Monitor
lpha pH560
Alpha COND 560
Alpha COND 560
CAL
Conductivity Controller

2.3 Connecting Peripherals
2.3.1 Connection Terminals
Remove Back Cover:
Remove the screws from the four corners at the back of the conductivity
controller. Remove the back cover. The connectors are exposed on the
back PCBA as shown in the Figure 1 below.
Connectors:
•J11 – 24V DC power connector
•J8 – 9V DC power connector (1.2mm diameter)
•J9 – Relay connections
•J10 - Conductivity electrode & Temperature probe connections (wiring
has to be done in the detachable connector
J10
J8
4. CON High Current
5. Pt 100 Compensate
6. Pt 100 Sense
7. Pt 100 GND
8. (No connection)
J9 Connections
Relay 1 & 2
J11 Connections
1. +ve
2. Gnd
J10 Connections
1. CON Low Current
2. CON Low Voltage
3. CON High Voltage
24V DC
J11
1)+ve
2)Gnd
J9
REL 1 REL 2
9V DC Power
Screw
Figure 1: Outer Side of Back PCBA

2.3.2 Switching Between PT100 & PT1000 Temperature Sensors
The controller supports both Pt100 & Pt1000 (2-wire or 3-wire) temperature
sensors. The default factory setting is Pt100. If you need to use Pt1000 temperature
sensor, you have to change the jumper setting (J7) as described below.
Remove Back Cover:
Remove screws from the four corners at the back of the conductivity controller.
Remove the back cover.
Remove Back PCBA:
Remove the screw located center of the back PCBA (Figure 1). Detach the back
PCBA from the controller. Turn over the back PCBA. Locate J7 jumper on the inner
side of the back PCBA as shown in figure 2 below.
Figure 2: Inner Side of Back PCBA
Set Jumper J7:
Set the J7 jumper to required sensor (Pt100 or Pt1000) type

2.3.3 Connecting Conductivity Electrode
Any industrial conductivity probe (2-cell or 4-cell) can be connected to the
conductivity controller.
2-Cell Conductivity Probe:
1. Short Pin 1 & 2 of J10 connector using a jumper wire.
2. Connect CON low input wire (white) to Pin 2 of J10 connector.
3. Connect CON high input wire (black) to Pin 3 of J10 connector.
4. Short Pin 3 & 4 of J10 connector using a jumper wire.
4-Cell Conductivity Probe:
5. Connect CON low input wire (black) to Pin 1 of J10 connector
6. Connect CON low input wire (white) to Pin 2 of J10 connector.
7. Connect CON high input wire (orange) to Pin 3 of J10 connector.
8. Connect CON high input wire (blue) to Pin 4 of J10 connector.
2.3.4 Connecting Temperature Probe
For Automatic Temperature Compensated (ATC) conductivity readings, an in-built
temperature sensor is usually integrated with industrial conductivity probes.
Alternatively, a separate 100ΩPt RTD temperature probe (2-wire or 3-wire) can be
connected to the controller.
3-Wire Probe:
1. Connect PT100 compensate wire to Pin 5 of J10 connector.
2. Connect PT100 sense wire to Pin 6 of J10 connector.
3. Connect PT100 GND wire to Pin 7 of J10 connector.
2-Wire Probe:
4. Short Pin 5 & 6 of J10 connector using a jumper wire.
5. Connect PT100 sense wire to Pin 6 of J10 connector.
6. Connect PT100 GND wire to Pin 7 of J10 connector.

2.4 Installation
2.4.1 Mechanical Dimensions
ENT
ESC
P
Alpha pH 600
2.4.2 Wall Mount
H/ORP RF Transmitter
CAL
Alpha COND 560
Conductivity Monitor
11
Pierce through holes at both sides
Cover the catch slots at both sides
with overlays
2

2.4.3 Panel Mount
Panel
Gasket
Prepare panel cut-out o
f
1
192.0 mm X 92.0 mm
Remove back cover o
f
2pH Monitor and slide it
through panel cut-out
Panel
Insert threaded rods through catch
4until pH Meter is held against panel
A
ttach catch to both sides
3of pH Mete
r

2.5 Display & Keypad
2.5.1 Display Overview
The Liquid Crystal Display (LCD) of Alpha COND 560 conductivity controller has
two alpha-numerical displays (Upper and a Lower).
•Upper display: Measured conductivity value is displayed when the controller is
in normal operation (measurement) mode.
•Lower display: Measured temperature value is displayed when the controller
is in normal operation (measurement) mode. In conductivity calibration mode,
measured conductivity values are displayed here.
The two displays indicate function names, options & settings in Setup mode. Refer
‘Appendix 4 - Abbreviations Used in LCD’ for more details.
The LCD also consists of various mode indicators, status annunciators and unit of
measurement indicators.
mS
R.
SETUP MEAS CA
Low
ERR
READY
8.8.
.8
L
Upper Display
er Display
ATC
°C
8.8
.8.8
-
-
HOLD
°F
µS
%
K=

Mode Indicators
MEAS Measurement mode (Refer Section 3.1 )
SETUP Setup mode (Refer Section 4.1)
CAL Calibration mode (Refer Section 4)
Status Annunciators
READY Appears when the reading is stable
HOLD Appears in Setup mode and Calibration mode to indicate that the relay
function is frozen
ATC Appears when Automatic Temperature Compensation (ATC) is enabled.
Not visible when Manual Temperature Compensation (MTC) is enabled.
Flashes if the temperature probe is faulty in its ATC mode. (Refer
Section 5.3)
ERR Appears when an error occurs
Electrode annunciator. Blinks during calibration error (Refer Section 4.2)
Buffer annunciator. Appears in calibration mode (Refer Section 4.2)
K Cell Constant (Refer Section 4.2)
Units of Measurement Indicators
mS Conductivity in Milli Siemens
µS Conductivity in Micro Siemens
R. Line Resistance in Ohms (Refer Section 5.7)
% Temperature Coefficient (Refer Section 5.2)
ºC Temperature in Celsius (Refer Section 5.3)
ºF Temperature in Fahrenheit (Refer Section 5.3)

2.5.2 Key Functions
lpha CON560
ENT
ESC
Conductivity Monito
CAL
r
Key Description
CAL
Enter Calibration mode
ENT
Enter Setup mode
Access sub screens (parameters) within a group of settings in Setup
mode
Confirm (save) setup parameters and numerical values
Start/Confirm calibration in Calibration mode.
Select a group of settings in Setup mode.
Select parameters and increment/decrement numerical values in Setup
and Calibration modes.
(When pressed continuously, speed of value increment/decrement
increases)
Returns to Measurement mode when both keys are pressed
simultaneously.
Alpha COND 560

3 OPERATION
3.1 Measurement mode
When the conductivity controller is powered on, the display shows all the LCD
segments briefly, and then automatically enters into the measurement mode.
µS
ATC
°C
25.0
MEAS
READY
The mode indicator ‘MEAS’ at the top of the display indicates that the conductivity
controller is in measurement mode. The upper alpha-numerical display shows the
measured conductivity value, while the lower display shows the temperature value.
The controller has six selectable measuring ranges. The unit of measurement and
resolution of the conductivity reading depend on the selected measuring range. If
the controller reads a conductivity reading beyond the selected measuring range,
the display shows ‘Or’ (over range) error indicator.
NOTE: To guarantee accurate readings, the measuring system (the
conductivity controller and the sensor) must be calibrated regularly.
From measurement mode you can access:
•Calibration mode (by pressing CAL key)
•Setup mode (by pressing ENT key)
For more details, refer section 4 for Calibration mode and section 5 for Setup
mode.)

3.2 Menu Overview
READ
Y
MEAS µS
°C
A
TC
ENT
SETUP
HOLD
SETUP
HOLD
SETUP
HOLD
SETUP
HOLD
SETUP
HOLD
SETUP
HOLD
SETUP
HOLD
SETUP
HOLD
ENT
ENT
ENT
ENT
ENT
ENT
ENT
CAL ENT
ENT
ENT
ENT
ENT
ENT
ENT
ENT
ENT
ENT

4 CALIBRATION MODE
4.1 About Calibration
Calibration should be carried out each time a new electrode is attached to the
controller or when you suspect that the controller/electrode is out of calibration. The
controller allows you to perform temperature calibration and conductivity calibration.
About Temperature Calibration
It is important to ensure that temperature calibration is carried out prior to
conductivity calibration since temperature readings affect the accuracy of
conductivity measurements. It is recommended that temperature calibration should
be carried out only if the temperature value displayed on the controller is different
from that of a calibrated thermometer. A temperature offset calibration of ± 10 °C/±
18 °F from the default reading is allowed. Once a temperature calibration is
performed, conductivity calibration should be carried out to ensure the accuracy of
conductivity measurements.
About Measuring Ranges & Conductivity Calibration
The controller has six selectable conductivity measuring ranges. You can only
calibrate one-point in the measuring range that you have selected for your process
application. You have to recalibrate the controller every time you change the
measuring range since the calibration data of the controller will be reset every time
a new measuring range is selected.
About Conductivity Calibration
During conductivity calibration, the controller allows a calibration window of ± 40%
from the measured default reading of the calibration standard. The minimum
allowable calibration point is 10% of the full scale reading of the measuring range
selected.
For best results, select a standard conductivity solution close to the sample value
you are measuring.