TPS proCHEM-S User manual

Congratulations !
Your new proCHEM-S
controller is the latest in simple, reliable process
control instrumentation. With correct operation and maintenance, your
proCHEM-Swill give you many years of reliable service.
The proCHEM-Sis a breeze to operate. Th
is manual has been
designed to help you get started, and also contains some handy
application tips. If at any stage you require assistance, please contact
either your local TPS representative or the TPS factory in Brisbane.
The manual is divided into the following sections:
1. Table of Contents
Each major section of the handbook is clearly listed. Sub-
sections
have also been included to enable you to find the information you
need at a glance.
2. Introduction
The introduction has a diagram and explanation of the
display and
controls of the proCHEM-S
. It also contains a full listing of all of the
items that you should have received with the unit. Please take the
time to read this section, as it explains some of items that are
mentioned in subsequent sections.
3. Main Section
The main section of the handbook provides complete details of the
proCHEM-S
, including operating modes, calibration, troubleshooting,
specifications, and warranty terms.
4. Appendices
Appendices containing background information and application notes
are provided at the back of this manual.
proCHEM-S
Process Controller
Version : 1.0
Date : 05-Sep-2003
Author : MS

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TPS Pty Ltd
ABN 30 009 773 371
4 Jamberoo Street
Springwood, Brisbane,
Australia, 4127
Phone : [phone]
International : 61 7 32 900 400
Fax : [phone]
International : 61 7 3808 4871
Email : [e-mail]
Web : www.tps.com.au

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Contents
1. Introduction.............................................................................................. 4
1.1 proCHEM-S Illustration....................................................................... 4
1.2 Unpacking Information........................................................................ 6
1.3 Specifications..................................................................................... 7
2. Operating Modes...................................................................................... 8
3. Installation and Set-up ............................................................................ 9
3.1 Connection and Configuration Diagram .............................................. 9
3.2 Mounting the Enclosure.................................................................... 10
3.3 Mounting the Sensor......................................................................... 11
3.4 Terminal Connections....................................................................... 12
3.5 Setting the Control Limit................................................................... 15
3.6 Selecting Current or Voltage Output ................................................. 18
3.7 Selecting Standard or Custom 4 to 20 mA Output............................. 19
3.8 Calibrating the 4 to 20mA Output...................................................... 20
4. Calibration.............................................................................................. 21
4.1 Calibration Procedure....................................................................... 21
4.2 Calibration Notes.............................................................................. 22
5. Process Monitoring ............................................................................... 23
6. Automatic Control.................................................................................. 23
7. Fuse Replacement ................................................................................. 23
8. Troubleshooting.................................................................................... 25
8.1 Instrument Function Troubleshooting................................................ 25
8.2 Salinity/TDS Troubleshooting ........................................................... 26
9. Warranty................................................................................................. 28
10. Appendices......................................................................................... 30
10.1 Re-setting the Display Range ........................................................... 30
10.2 Care, Cleaning and Maintenance of Salinity/TDS Electrodes............ 32
10.3 Power Terminal connections when 12V DC option is fitted................ 34
10.4 Relay Output Wiring Examples for mains powered units................... 35
10.5 Relay Output Wiring Examples for 12V DC powered units................ 36

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1. Introduction
1.1 proCHEM-S Illustration

Page 5
Set Upper Limit Control
Adj
ust this control to the Salinity/TDS value at which the High LED
and relay output are activated. Factory-
set to activate when the
reading is above the Upper Limit. See section 3.5.
High LED
The High LED provides visual indica
tion of when the Upper Limit has
been exceeded. Factory-set to light up when the reading is above
the Upper Limit. See section 3.5.
Set Lower Limit Control
Adjust this control to the Salinity/TDS value at which the Low LED
and relay output are activated. Factory-
set to activate when the
reading is below the Lower Limit. See section 3.5.
Low LED
The Low LED provides visual indication of when the Lower Limit has
been exceeded. Factory-set to light up when the reading is below
the Lower Limit. See section 3.5.
Zero Calibrate Control
Adjust this control to calibrate the proCHEM-S
with the sensor dry
and in air. See section 4.
Span Calibrate Control
Adjust this control to calibrate the proCHEM-S
in a Salinity/TDS
standard. See section 4.
Function Switch
The Function Switch is used to select the mode of operation. See
section 2.
Display Window
The proCHEM-S
has a large, easy to read LCD display. The units of
measurement are clearly shown in the window beneath the display.
Terminal Cover
The terminal cover provides easy access to all of the connections,
relay output fuses, configuration jumpers and user-
adjustable
trimmers. The cover is water resistant to IP65.

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1.2 Unpacking Information
Before using your new proCHEM-S, please check that the following
accessories have been included: Part No
1. proCHEM-SProcess Controller ..............................................112127
2. proCHEM-SHandbook ...........................................................130050
3. 200mL of Salinity/TDS standard to suit specified range.
Options that may have been ordered with your proCHEM-S:
Sensor options…
1. k=0.1, GK Series Salinity/TDS sensor, 5m..............................112205
2. k=1.0, GK Series Salinity/TDS sensor, 5m..............................112206
3. k=10, GK Series Salinity/TDS sensor, 5m...............................112207
4. Extra cable for Salinity/TDS sensors (order by the metre).......130040
Instrument options…
1. 4-20mA loop-powered, remote LCD........................................130080
2. 12V DC Power Option.............................................................130072

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1.3 Specifications
Ranges
k=0.1 Sensor............... 0 to 10.00 ppM, 0 to 100.0 ppM or 0 to 1000 ppM
k=1.0 Sensor................0 to 100.0 ppM,0 to 1000 ppM, or 0 to 10.00 ppK
k=10 Sensor................ 0 to 1000 ppM, 0 to 10.00 ppK, or 0 to 100.0 ppK
Resolution.....................................................................0.05% of full scale
Accuracy.........................................................±0.2% of full scale at 25 OC
Linearity......................................................................±0.05% of full scale
Repeatability...............................................................±0.05% of full scale
Ambient Drift...........................................................................<0.02% / oC
Long term drift...................................................................<0.1% per year
Temperature Compensation............................... Automatic, 0 to 100.0 oC
Zero Range.........................................................................................±5%
Span Range ............................................................................70 to 130%
Sensors ....................................Platinised Platinum, k=0.1, k=1.0 or k=10
Enclosure.............................................Polycarbonate, waterproof to IP65
Display.................................12.7 mm LCD (optional remote 4-20mA loop
powered display available)
Analogue Outputs............... 4 to 20mA (500 Ohms max. loop resistance )
0 to 1 V DC (min. load 1000 Ω)
0 to 10 V DC optional (min. load 1000 Ω)
Control Outputs .............................. 2 x Clean contact changeover relays,
rated to 2A at 240V AC
Isolation.................................................Galvanic isolation of sensor input
Power........................................... 240V AC, 50/60Hz (120V AC optional)
Dimensions................................................................215 x 190 x 115 mm
Mass.........................................................Instrument only:Approx 900g
Full Kit :Approx 1.5kg
Operating Environment:............................Temperature :0 to 45 oC
Humidity :0 to 95 % R.H.

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2. Operating Modes
The function switch is used to select the required mode. The four
operating modes available are…
1. Set Upper Limit :Switch to Set Upper Limit when setting the
Salinity/TDS value at which the High LED and
relay output are activated. The relay output is
not operational in this mode.
Factory-set to activate when the reading is
above the Upper Limit. Can be user set to be a
activate when the reading is below the Upper
Limit. See section 3.5.
2. Set Lower Limit :Switch to Set Lower Limit when setting the
Salinity/TDS value at which the Low LED and
relay output are activated. The relay output is
not operational in this mode.
Factory-set to activate when the reading is
below the Lower Limit. Can be user set to be a
activate when the reading is above the Lower
Limit. See section 3.5.
3. Calibrate :Switch to Calibrate mode to place the
proCHEM-Sinto standby (eg. when
calibrating). This mode disables the two output
relays to avoid chemicals being added when
placing the sensor into calibration buffers.
4. Automatic Control :Switch to Automatic Control to enable the
Alarm LED’s and relay outputs. These will be
activated when the Salinity/TDS is outside the
Upper and Lower limit values. See section 3.5.

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3. Installation and Set-up
3.1 Connection and Configuration Diagram
The diagram below is provided as a reference for the terminal
connections, configuration jumpers and user-
adjustable trimmers that are
discussed throughout this section.

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3.2 Mounting the Enclosure
The proCHEM-Scan be wall-mounted with 3 screws. Two mounting
points are located underneath the terminal cover, and are positioned so
that they do not affect the waterproofing of the enclosure. The third
mounting point is centrally located near the top of the rear of the
enclosure, and has been designed to hook over a screw-head. The
dimensions for the mounting screw centres are provided on the rear of
the enclosure, and are also illustrated below…

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3.3 Mounting the Sensor
Mounting the sensor is a very important aspect of the installation, and is
often done incorrectly. In automatic control situations, the sensor should
always be mounted as close as possible to the injection point. This will
cause the sensor to d
etect the added chemicals immediately, and shut
the addition off until mixing has taken place. For in-
line mounting, it is
important that chemicals are injected upstream. Additionally, the line
must be run through a mixing chamber, such as a large drum, to
ensure
that the injected chemical has mixed in properly by the time the solution
flows past the sensor. There must always be adequate flow of fresh
sample past the sensor, for accurate monitoring. The diagrams below
show typical mounting arrangements for “dip” mounting and in-
line
mounting.
Dip Mounting In-line Mounting
1. Injection point close to sensor. 1. Injection point upstream from
2. Continuous stirring. and close to sensor.
2. Mixing container after injection
and before sensor.
3. A flow-through assembly for in-line
mounting is available from TPS.

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3.4 Terminal Connections
3.4.1 Power Connections
All power connections are on the main terminal block (H1), which has 18
terminals.
Note: The power connections detailed below are for normal mains
power. Refer to section 10.3 for power wiring details when the 12V
DC power option is fitted.
Terminal
No. Connection Colour
1220 / 240V AC Active input Brown (standard colour)
2Duplicate 240V AC Active contact. Brown (standard colour)
3Duplicate 240V AC Active contact. Brown (standard colour)
4220 / 240V AC Earth input Green (standard colour)
5Duplicate 240V AC Earth contact. Green (standard colour)
6Duplicate 240V AC Earth contact. Green (standard colour)
7220 / 240V AC Neutral input Blue (standard colour)
8Duplicate 240V AC Neutral
contact. Blue (standard colour)
9Duplicate 240V AC Neutral
contact. Blue (standard colour)
10 Normally Closed contact of Lower
relay output Customer Defined
11 Common contact of Lower relay
output Customer Defined
12 Normally Open contact of Lower
relay output Customer Defined
13 Normally Closed contact of Upper
relay output Customer Defined
14 Common contact of Upper relay
output Customer Defined
15 Normally Open contact of Upper
relay output Customer Defined
16 No Connection
17 +ve of current or voltage output Customer Defined

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18 -ve of current or voltage output Customer Defined

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3.4.2 Sensor Connections
All sensor connections are on the 6-way terminal block which is on the
right hand side of the enclosure.
Terminal
No. Connection Colour
1Salinity/TDS Sensor ATC Blue
2Salinity/TDS Sensor ATC White
3No Connection
4Guard Shield/Braid (when
fitted).
5Salinity/TDS Sensor Cell Black
6Salinity/TDS Sensor Cell Red

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3.5 Setting the Control Limit
The Upper and Lower control limits can both be set over the full scale of
the proCHEM-S
. The unit is set up in the factory for the Upper Limit LED
and relay to be activated when the reading rises above
the Upper Limit.
Similarly, the Low
er Limit LED and relay are factory set to be activated
when the reading drops below the Lower Limit.
See section 3.5.3 for details on how to re-
set the Upper or Lower limits
for the reverse of the default direction.
The hysteres
is around the set point can be also be adjusted if necessary.
See section 3.5.4 for an explanation of hysteresis.
3.5.1 Setting the Upper Limit value
1. Switch the proCHEM-Sto Set Upper Limit.
The Upper Limit value is now displayed. Not
e that the Alarm LED and
output relays are now disabled. The 4-20mA or 0-
1V outputs are still
active, and proportional to displayed value.
2. Adjust the Set Upper Limit
control until the display reads the desired
set point value.
3.5.2 Setting the Lower Limit value
1. Switch the proCHEM-Sto Set Lower Limit.
The Lower Limit value is now displayed. Note that the Alarm LED and
output relays are now disabled. The 4-20mA or 0-
1V outputs are still
active, and proportional to displayed value.
2. Adjust the Set Lower Limit contr
ol until the display reads the desired
set point value.

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3.5.3 Reversing the default control direction
The Upper Limit control action can be reversed to activate the Upper
Limit LED and relay when the reading drops below the Upper Limit.
Similarly, the Lower Limit control action can be reversed to activate the
Lower Limit LED and relay when the reading rises above the Lower Limit.
Having two Limits acting in the same direction can be very useful for
processes where the readings always drift in one direction. It allows the
operator to set the first Limit as a control point (eg to start a dosing
pump), and the second limit beyond that as an alarm point, in case the
control action was not effective.
The proCHEM-Smust be switched OFF before changing jumper
settings.
To reverse the action of the Lower Limit, and have two
Limits that activate the High and Low LED’s and relays
when the reading rises above the Limits, set the J3 and
J4 jumpers as shown.
To reverse the action of the Upper Limit, and have two
Limits that activate the High and Low LED’s and relays
when the reading drops below the Limits, set the J3
and J4 jumpers as shown.
To re-set the action of the Upper and Lower limits to
factory defaults, set the J3 and J4 jumpers as shown

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3.5.4 Adjusting the Hysteresis
The hysteresis is the Salinity/TDS range over which the alarm/control
output remains switched on, once the trip point has been exceeded.
For example, if the Lower Limit is set to 2.00 ppK, with a hysteresis of
±0.10 ppK, the alarm/control output is s
witched ON when the reading
goes to 1.90 (i.e. 2.00 -
0.10). The output is not switched OFF until the
reading goes back up to 2.10 (i.e. 2.00 + 0.10).
The hysteresis stops the relay “chattering” around the set point, by
providing a buffer between the point
s at which the output is switched ON
and OFF. This feature can significantly increase the life of pumps and
solenoid valves.
The factory-
set hysteresis is approximately ±10 digits (regardless of
decimal point location), as in the example above. The hystere
sis can be
increased to as high as ±40 digits with the relevant LOWER HYST
(RV2)
or UPPER HYST (RV4) trimmers in the terminal area. Turning the
trimmer
clockwise increases the hysteresis and turning it anti-
clockwise
decreases the hysteresis.
TPS DOES NOT
recommend that this setting be altered, unless it is
absolutely necessary.
The hysteresis
trimmer should only be adjusted a little at time. The
process being controlled should then be closely monitored over a time to
ensure that the desired control is being achieved.

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3.6 Selecting Current or Voltage Output
The Current/Voltage Output jumpers in terminal section can be user-set
for either 4 to 20mA or 0 to 1V DC output. The proCHEM-Smust be
switched OFF before changing jumper settings.
The jumper settings for 4 to 20 mA output are:
CVCVC
J5
The jumper settings for 0 to 1V DC output are:
CVCVC
J5
Note that the spare jumper has been fitted to a spare Current/Voltage
Output jumper pin. This is a safe place to keep it, in case the
proCHEM-Sneeds to be reset to current output in the future.

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3.7 Selecting Standard or Custom 4 to 20 mA Output
The proCHEM-S
is normally supplied to provide 4 to 20 mA for the full
scale of the readout. If a custom 4 to 20 mA output (eg. 4 to 20 mA
ou
tput for 700 to 1000 counts) is supplied, the user can still change
between this custom output and the normal 4 to 20 mA output for full
scale.
The jumper settings for the standard 4 to 20 mA output
are…
The jumper settings for the custom 4 to 20 mA output
are…

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3.8 Calibrating the 4 to 20mA Output
The 4 to 20mA output of the proCHEM-Sis factory calibrated. However,
TPS has provided calibration controls for the 4mA and 20mA points in
case this requires adjustment in the field.
Calibrating the 4 to 20mA output…
1. Connect a Digital Milliamp Meter between terminals 17 and 18.
2. Switch the proCHEM-Sto Set Upper Limit.
3. Adjust the Set Upper Limit control until the display reads 0.00 (for
the standard 4 to 20mA output) or the Salinity/TDS that corresponds
to 4 mA (for a custom 4 to 20 mA output).
4. Adjust the 4-20mA ZERO (RV1) trimmer in the terminal area until the
Digital Milliamp Meter reads 4 mA.
5. Adjust the Set Upper Limit control until the display reads 1000,
regardless of decimal point location (for the standard 4 to 20mA
output) or the Salinity/TDS that corresponds to 20 mA (for a custom
4 to 20 mA output).
6. Adjust the 4-20mA SPAN (RV3) trimmer in the terminal area until the
Digital Milliamp Meter reads 20 mA.
In the event that the LIMIT control does not have sufficient
adjustment to reach 0.00 or 1000, calculate the expected output level
and use this for calibration. Remember that the difference between 0
and 1000 is to be made 16mA.