Thermo Scientific Thermo Scientific AquaSensors RDO Pro-X User manual

Thermo Scientific
AquaSensors
RDO Pro-X Optical Dissolved
Oxygen Measurement System
UM-279765-001 •Revision A •January 2014
User Manual

Safety Information
The Thermo Scientific™AquaSensors™ RDO® Pro-X Optical
Dissolved Oxygen System shall be installed and operated only in the
manner specified. Only a skilled, trained or authorized person should
carry out installation, setup and operation of the system.
Before using the system, make sure that it is connected as specified.
Failure to do so may result in permanent damage to the system or its
components.
Protection against electric shock will be achieved only by observance of the corresponding
installation rules.

Contents
Section 1 Introduction.............................................................................................. 5
General Information.....................................................................................................................5
Intended Use ............................................................................................................................... 6
Safety Instructions ....................................................................................................................... 6
Removal from Service/Correct Disposal of the System ............................................................... 6
Removal from Service........................................................................................................ 6
Correct Disposal of System................................................................................................ 7
Section 2 Product Description ................................................................................ 8
Serial Numbers............................................................................................................................ 9
Unpacking the Sensor ................................................................................................................. 9
Section 3 Mounting Hardware .............................................................................. 11
Immersion Hardware ................................................................................................................. 11
Wash Hardware......................................................................................................................... 13
Section 4 Wiring .................................................................................................... 14
Modbus Master with Built-in RS485...........................................................................................15
Modbus Master with Built-in RS232 (Converter Required) ........................................................15
AV38 as Modbus Master ........................................................................................................... 16
Section 5 Care and Maintenance ......................................................................... 18
Cleaning the Sensor Cap........................................................................................................... 18
Cleaning the Optical Window ...........................................................................................18
Cleaning the Sensor Body .........................................................................................................19
Cap Storage............................................................................................................................... 19
Replacing the Sensor Cap.........................................................................................................19
Section 6 AV38 Local Display Interface .............................................................. 20
Measure Screen Overview ........................................................................................................21
Menu Structure .......................................................................................................................... 21
Analog Output Overview............................................................................................................25
Relay Function Overview...........................................................................................................25
Section 7 Calibration and Configuration ............................................................. 27
Zero Calibration (Offset) ............................................................................................................ 27
Water-saturated Air (Span) Calibration......................................................................................30
1-Point Sample (Span) Calibration ............................................................................................ 32
Temperature Calibration............................................................................................................ 34
Configuration ............................................................................................................................. 37
Section 8 Modbus Register Map .......................................................................... 39
Data Formats............................................................................................................................. 41
DO Sensor Registers.................................................................................................................42
Temperature Registers.............................................................................................................. 48
Calibration Registers .................................................................................................................49
Communication Registers.......................................................................................................... 53
Status Registers ........................................................................................................................ 55
Section 9 Specifications ....................................................................................... 59

Section 10 RDO Pro-X Optical Dissolved Oxygen System Order Matrix and
Accessories .......................................................................................... 60
Accessories ............................................................................................................................... 61
Section 11 Limited Warranty .................................................................................. 62
Warranty/Replacement Plan......................................................................................................62
Section 12 Terms and Conditions ......................................................................... 64
Terms and Conditions of Sale....................................................................................................64

Thermo Scientific AquaSensors RDO Pro-X Optical Dissolved Oxygen Measurement System |5
1
Introduction
General Information
Thank you for purchasing the RDO Pro-X Optical Dissolved Oxygen System.
The product is designed for continuous use in industrial process applications and complies with
safety regulations currently in force. Improper use could lead to hazards for the user or a third-
party, and/or adverse effects to the plant or other equipment.
Thermo Fisher Scientific does not accept any liability for damage that may arise if information in
this user manual is not followed. Therefore, the operating instructions and specifications must
be read and understood by all persons involved in installation and operation of this equipment.
This user manual identifies safety instructions and additional information by means of the
following symbols:
This symbol draws attention to safety instructions and warnings of potential danger
which, if neglected, could result in injury to persons and/or damage to property.
This symbol identifies additional information and instructions which, if neglected,
could lead to inefficient operation and possible loss of production.
It is recommended that this user guide be made accessible to everyone who may need it as a
reference.
SECTION 1

Section 1|Introduction
6|RDO Pro-X Optical Dissolved Oxygen Measurement System Thermo Scientific AquaSensors
Please contact Thermo Fisher Scientific or an authorized representative with any questions.
Intended Use
The RDO Pro-X Optical Dissolved Oxygen System is used for continuous monitoring dissolved
oxygen in applications where the range of measurement is between 0 ppm and 20 ppm. The
sensor also measures temperature.
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:
1. Observing the instructions, notes and requirements set out in this user guide.
2. Observing all local safety regulations.
3. Observing all warnings and cautions in the documentation regarding all products used in
this measurement system, including the sensor, mounting hardware, AV38 electronics and
cabling.
4. Observing the prescribed environmental and operational conditions.
5. Observing chemical compatibility with all wetted materials.
Safety Instructions
The system should be installed and operated only by personnel familiar with the
system and qualified for such work.
A defective system should be returned to Thermo Fisher Scientific for repair or
replacement. Contact Thermo Fisher Scientific to obtain a Return Material Authorization (RMA)
number.
No modifications to the system are allowed. Thermo Fisher Scientific accepts no responsibility
for damage caused by unauthorized modifications. The risk is borne entirely by the user.
Removal from Service/Correct Disposal of the
System
Removal from Service
•Disconnect the cable wiring from the controller terminal block.
•Remove the system from the mounting hardware.

Introduction |Section 1
Thermo Scientific AquaSensors RDO Pro-X Optical Dissolved Oxygen Measurement System |7
Correct Disposal of System
•When the system is taken out of service, observe the local environmental regulations for
correct disposal.

8|RDO Pro-X Optical Dissolved Oxygen Measurement System Thermo Scientific AquaSensors
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Product Description
Your new RDO Pro-X Optical Dissolved Oxygen System is a rugged, reliable system designed
to deliver accurate dissolved oxygen (DO) data across a wide measuring range while reducing
maintenance costs.
It features the latest optical technology for DO measurement. The system consists of the
following:
•Cable (10 m standard, customizable to other lengths) with stripped and tinned ends
•Black sensor body with removable nose cone
•Optical DO sensing cap
•Silver thermistor
SECTION 2
Cable end, stripped
and tinned
Nose cone

Product Description |Section 2
Thermo Scientific AquaSensors RDO Pro-X Optical Dissolved Oxygen Measurement System |9
The System is used for continuous monitoring of dissolved oxygen from 0 ppm to 20 ppm. The
system also measures temperature from 0°C to 100°C. The optical sensor head is pre-
calibrated and the zero is factory set. The sensor retains calibration values and does not require
a new calibration when the system is connected to a new AV38 Display Unit, AquaPro, PC, or
PLC.
The communications supports measurement, calibration, configuration and diagnostics
functions which can be accessed locally or remotely without an analyzer or controller
electronics box.
Product Highlights:
•0 to 20 ppm Measurement Range
•Calibration stored in Sensor (Does not require recalibration after connection to
Analyzer/Controller)
•Immersion and Float Mounting Options
•0.01 ppm Resolution
•Fast Response
•Provides measurement, calibration, configuration and diagnostic functions without
Analyzer/Controller
•Works with AV38/AquaPro for local display, current output data reporting, and relay control
with sensor wash.
•Temperature measurement included
Serial Numbers
The system’s serial number is engraved on the side of the unit. The cap serial number is
programmed into the cap’s memory chip.
Unpacking the Sensor
1. Remove the sensor from the box and other packaging materials.
2. Unscrew the nose cone from the sensor and remove the red protective dust cap from the
sensor. Save the dust cap for later use.
Dust cap
Nose cone

Section 2|Product Description
10 |RDO Pro-X Optical Dissolved Oxygen Measurement System Thermo Scientific AquaSensors
3. Remove the RDO sensor cap from its shipping/storage sleeve.
4. Align the arrow on the cap with the index mark on the sensor and firmly press the cap onto
the sensor, without twisting, until it seals over the probe body.
Avoid allowing moisture, including atmospheric humidity, inside the cap. Keep the cap in its
sealed packaging until you are ready to install it. Install promptly. Make sure that o-ring
grooves are dry and the o-ring is not rolled or pinched inside the cap.
The cap's lifetime is 2 years after the first reading has been taken. Install by the date
printed on the packaging.
5. Reattach the nose cone.

Thermo Scientific AquaSensors RDO Pro-X Optical Dissolved Oxygen Measurement System |11
3
Mounting Hardware
The cable end of the sensor is internally threaded (1¼ – 11½ NPT) and can be attached to a
male threaded pipe. When deployed, make sure that the nose cone and thermistor are
completely submerged. The sensor is 9 inches long and 1.75 inches in diameter.
For immersion mounting, Thermo Scientific AquaSensors immersion mount hardware with hand
rail mounting and ball float is available.
Immersion Hardware
For immersion mounting applications the sensor is threaded on to the end of a pipe and wired
into a junction box at the other end. An extension cable is then wired from the junction box to
the controller. The standard pipe length is 7 feet and the assembly is often mounted onto a
hand rail assembly for easy repositioning of the sensor in a pond or tank.
SECTION 3
1¼–11½ NPT

Section 3|Mounting Hardware
12 |RDO Pro-X Optical Dissolved Oxygen Measurement System Thermo Scientific AquaSensors
This immersion assembly can be ordered by itself, with a hand rail mounting assembly or with a
ball float that keeps the sensor a fixed distance below the surface of the water. Part numbers
for the mounting assemblies are shown in the following table.
Mounting Hardware Description Part Number
Immersion assembly
7 ft PVC extension with junction box – RDO sensors
MH3083-RD
Immersion assembly w/
swivel rail mounting
7 ft PVC extension with junction box – RDO sensors with
swivel hand rail mount.
MH1242-RD
Immersion assembly w/
swivel and ball float
7 ft PVC extension with junction box – RDO sensors with
swivel hand rail mount and inflatable float. MH1252-RD
Ball float platform
Float platform for up to 4 RDO Pro-X Sensors or
DataSticks
TM
MHFB02-RD
Wash hardware
Attach air/water purge block to sensor body. Works with
compressor & AV38 wash relay or PLC.
MH1222-RD
Wash hardware
Attach air purge block to sensor body. Includes air
compressor; works with AV38 wash relay or PLC. MH5222-RD
Junction box extension cable
For extension cables. Terminal strip included. DataStick
extension cable
JBOXX01
DSECxx; xx=ft

Mounting Hardware |Section 3
Thermo Scientific AquaSensors RDO Pro-X Optical Dissolved Oxygen Measurement System |13
Wash Hardware
In applications where the sensor cap is quickly fouled, a wash head assembly can be attached.
The head slips over the body of the sensor. A single lock screw is tightened to secure the wash
head to the sensor. A hose is connected from the wash head to an air compressor or water
source valve that is controlled by an AV38 wash relay that is programmed with a wash interval
and duration.

14 |RDO Pro-X Optical Dissolved Oxygen Measurement System Thermo Scientific AquaSensors
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Wiring
A printed label affixed near the end of the cable indicates the wiring chart. The standard cable
length is 30 feet (~10 meters) with the idea that the cable will terminate in a junction box. It is
however possible to order additional cable up to a total maximum of 4000 ft.
The sensor has six wires and a shield. The RED and BLACK wires are for power, the BLUE
and GREEN wires are for communications, the BROWN and WHITE wires are unused and a
bare shield wire is connected to EARTH GROUND for safety and electromagnetic immunity and
emissions. Any Class 2 DC power supply that provides 24 VDC can be used.
RDO Pro-X Signal Name RDO Pro-X Wire Color
External Power (12 to 36 VDC)
Red
Ground/Return
Black
RS485 (−)
Green
RS485 (+)
Blue
Earth
Shield
SECTION 4

Wiring |Section 4
Thermo Scientific AquaSensors RDO Pro-X Optical Dissolved Oxygen Measurement System |15
Modbus Master with Built-in RS485
RDO Pro-X Signal Name RDO Pro-X Wire Color
External Power (12 to 36 VDC)
Red
Ground/Return
Black
RS485 (−)
Green
RS485 (+)
Blue
Note: Cable length must not exceed 4000 ft.
Modbus Master with Built-in RS232 (Converter
Required)
RDO Pro-X Signal Name RDO Pro-X Wire Color
External Power
(12 VDC, voltage limited by converter)
Red
Ground/Return
Black
RS485 (−)
Green
RS485 (+)
Blue

Section 4|Wiring
16 |RDO Pro-X Optical Dissolved Oxygen Measurement System Thermo Scientific AquaSensors
Note: Cable length must not exceed 20 ft.
AV38 as Modbus Master
Converter

Wiring |Section 4
Thermo Scientific AquaSensors RDO Pro-X Optical Dissolved Oxygen Measurement System |17
RDO Pro-X Signal Name RDO Pro-X Wire Color AV38 Terminal Number
External Power
Red
8
Ground/Return
Black
9
RS485 (+)
Blue
10
RS485 (−)
Green
11
Earth
Clear
12
Note that the Blue wire from the RDO Pro-X must be connected to terminal 10 (White) on
the AV38 and the Green wire from the RDO Pro-X must be connected to terminal 11
(Blue) on the AV38 for proper operation.

18 |RDO Pro-X Optical Dissolved Oxygen Measurement System Thermo Scientific AquaSensors
5
Care and Maintenance
Cleaning the Sensor Cap
1. Leave the cap and nose cone on the sensor!
2. Rinse the sensor with clean water from a squirt bottle or spray bottle.
3. Gently wipe with a soft-bristled brush or soft cloth if biofouling is present. Use Alconox®to
remove grease.
4. If extensive fouling or mineral build-up is present, soak the cap end in vinegar for 15 min.,
then soak in deionized water for 15 min.
Do not use organic solvents—they will damage the foil.
Do not remove the cap from the sensor prior to brushing.
5. After cleaning the sensor, perform a 1-point user calibration or calibration check.
Cleaning the Optical Window
Perform only when changing the cap. See full instructions in the sensor replacement
cap kit.
Do not wet the lens area with water or any solution.
Remove the cap and gently wipe the window with the supplied lens wipe.
Use only the supplied lens wipe for cleaning. Do not use any other wipe or material.
SECTION 5

Care and Maintenance |Section 5
Thermo Scientific AquaSensors RDO Pro-X Optical Dissolved Oxygen Measurement System |19
Cleaning the Sensor Body
With the sensor cap installed on sensor, gently scrub sensor body with a soft-bristled brush or
nylon dish scrubber. Use Alconox to remove grease or other matter. Soak in vinegar and
deionized (DI) water to remove mineral deposits or extensive fouling as in step 4, above.
Cap Storage
Prior to installation: Store in factory supplied container.
Installed: Keep or store in the calibration chamber with the storage cap attached (see section
2.1.1) and a few drops of clean water.
Replacing the Sensor Cap
The sensor cap has a 2 years life after the sensor takes its first reading. Replacement caps
are available from Thermo Fisher Scientific or your authorized distributor.
1. Remove the sensor nose cone.
2. Pull the used sensor cap off of the sensor, without twisting.
3. Remove the existing o-rings from the sensor.
4. Use a lint-free cloth to remove any moisture from the sensor body.
Ensure that there is no moisture in the o-ring grooves.
Avoid touching or cleaning the lens with anything other than the supplied lens
wipe.
5. Use your finger to apply a layer of lubricant around the o-ring grooves.
6. Place the o-rings on the sensor. Apply another thin layer of lubricant to the o-rings and
grooves.
Note:Do not transfer grease to the lens or sensor pins.
7. Clean the lens on the sensor with the wipe provided in the kit and allow to dry
thoroughly. Inspect for scratches or dirt.
8. Remove the new cap from its sealed packaging and attach it to the sensor, being careful
to press firmly, without twisting, until it seals over the probe body. Make sure that the o-
rings are not pinched or rolled between the cap and sensor.
9. Perform a 1-point calibration.

20 |RDO Pro-X Optical Dissolved Oxygen Measurement System Thermo Scientific AquaSensors
6
AV38 Local Display Interface
For detailed information on configuration of AV38 current outputs, relays, host communications,
please refer to the AV38 user guide (258479-001). This user guide describes basic calibration
and configuration functions directly related to DO.
The AV38 is a universal display interface for DataStick sensor
systems which includes the RDO Pro-X Optical Dissolved Oxygen
System. The enclosure has ¼ DIN dimensions for easy mounting
and is rated NEMA 4X
for outdoor use. It uses a liquid crystal display (LCD) with a high
contrast backlight for best readability and is powered with 24 volts
DC or optionally with line power (90 VAC to 240 VAC 50/60 Hz).
The AV38 automatically recognizes the type of DataStick connected to the system and provides
the appropriate calibration, configuration and diagnostic menus. It has options for two 4-20
current loops, two alarm/control/wash relays and network communications to a host computer.
In addition, the AV38 can address up to 247 DataStick sensors.
DataStick sensors connected to the AV38 communicate via Modbus RTU. As such, the AV38
can be used to select one of several DataStick sensors on the bus for display, current output
reporting and relay alarms by selecting the desired station address. When there is no DataStick
sensor connected at the selected network address, the measure screen indicates “DataStick
Absent”.
SECTION 6