TPS miniCHEM-Cond User manual

Congratulations !
Your new miniCHEM-Cond monitor is the latest in simple, reliable process
monitoring instrumentation. With correct operation and maintenance, your
miniCHEM-Cond will give you many years of reliable service.
The miniCHEM-Cond is a breeze to operate. This 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 miniCHEM-Cond. 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
miniCHEM-Cond, 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.
miniCHEM-Cond
Process Monitor
Version : 2.01
Date : 16-Jul-2002
Author :MS

Page 2
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 : [email protected]
Web : www.tps.com.au

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Contents
1. Introduction ..............................................................................................4
1.1 miniCHEM-Cond 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.......................................................................................10
3.4 Terminal Connections.....................................................................................11
3.5 Setting the Control Limit ................................................................................12
3.6 Selecting Current or Voltage Output ...............................................................14
3.7 Calibrating the 4 to 20mA Output...................................................................15
4. Calibration...............................................................................................16
4.1 Calibration Procedure......................................................................................16
4.2 Calibration Notes ............................................................................................17
5. Process Monitoring................................................................................18
6. Automatic Dosing...................................................................................18
7. Manual Dosing........................................................................................18
8. Fuse Replacement..................................................................................18
9. Troubleshooting.....................................................................................19
9.1 Instrument Function Troubleshooting..............................................................19
9.2 Conductivity Troubleshooting .........................................................................20
10. Warranty..............................................................................................22
11. Appendices .........................................................................................24
11.1 Re-setting the Display Range ......................................................................24
11.2 Care, Cleaning and Maintenance of Conductivity Electrodes.......................25
11.3 Terminal connections when 12V DC option is fitted ...................................28
11.4 Relay Output Wiring Examples for mains powered units.............................29
11.5 Relay Output Wiring Examples for 12V DC powered units .........................30
11.6 Drilling Template .......................................................................................31

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1. Introduction
1.1 miniCHEM-Cond Illustration

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¬Alarm LED
The Alarm LED provides visual indication of when the control limit has been
exceeded. The control limit can be set for a “too high” or a “too low” alarm.
See section 3.5.
-Limit Control
Adjust this control to the Conductivity value at which the Alarm LED and
(optional) relay output are activated. See section 3.5.
®Zero Calibrate Control
Adjust this control to Zero calibrate the miniCHEM-Cond with the sensor
dry and in air. See section 4.1.
¯Span Calibrate Control
Adjust this control to Span calibrate the miniCHEM-Cond in a Conductivity
standard. See section 4.1.
°Function Switch
The Function Switch is used to select the mode of operation. See section 2.
±Display Window
The miniCHEM-Cond has a large, easy to read LCD display. The units of
measurement are clearly shown in the window beneath the display.
ÆTerminal Cover
The terminal cover provides easy access to all of the connections, (optional)
relay output fuse, 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 miniCHEM-Cond, please check that the following
accessories have been included: Part No
1. miniCHEM-Cond Process Monitor.......................112140
2. miniCHEM-Cond Handbook ................................130050
3. Conductivity standard to suit customer-specified
range
Options that may have been ordered with your miniCHEM-Cond:
Conductivity Sensors…
1. k=0.1 Industrial Sensor, 5m ...................................112205
2. k=1.0 Industrial Sensor, 5m ...................................112206
3. k=10 Industrial Sensor, 5m ....................................112207
Instrument options…
1. Relay control output...............................................130342
2. 4-20mA loop-powered, remote LCD....................... 130080

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1.3 Specifications
Ranges
k=0.1 Sensor...................0 to 19.99 µS/cm, 0 to 199.9 µS/cm or 0 to 1999 µS/cm
k=1.0 Sensor.................. 0 to 199.9 µS/cm,0 to 1999 µS/cm, or 0 to 19.99 mS/cm
k=10 Sensor..................0 to 1999 µS/cm, 0 to 19.99 mS/cm, or 0 to 199.9 mS/cm
Resolution............................................................................0.05% of full scale
Accuracy ..............................................................................±0.2% of full scale
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 Output (optional).............................. Clean contact changeover relay,
rated to 2A at 240V AC
Isolation..........................................................Galvanic isolation of sensor input
Power...................................................240V AC, 50/60Hz (120V AC optional)
Dimensions.........................................................................172 x 160 x 71 mm
Mass..................................................................Instrument only :Approx 800g
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 LIMIT :Switch to SET LIMIT when setting the Conductivity value at
which the Alarm LED and (optional) relay output are
activated. The relay output is not operational in this mode.
See section 3.5.
2. STANDBY :Switch to STANDBY to inhibit the Alarm LED and
(optional) output relay action. Select this mode for
calibration, or when automatic dosing is not required.
3. AUTO :Switch to AUTO to enable the Alarm LED and (optional)
relay output. These will be activated when the Conductivity
is outside the limit value. See section 3.5.
4. MANUAL:Switch to MANUAL to manually dose chemicals or water
when the optional relay output is fitted. The relay output will
be activated for as long as the miniCHEM-Cond is in this
mode, regardless of the Conductivity reading. See section 7.

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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 miniCHEM-Cond can 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. The last page of this manual may be photocopied or
removed for use as a drilling template.
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
detect the added chemicals or water immediately, and shut the addition off until
mixing has taken place. For in-line mounting, it is important that injection is
upstream. Additionally, the line must be run through a mixing chamber, such as a
large drum, to ensure that the injected chemical or water 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
Note: The power connections detailed below are for normal mains power.
Refer to section 11.3 for power wiring details when the 12V DC power option
is fitted.
Terminal No. Connection Colour
1Conductivity Sensor ATC Blue
2Conductivity Sensor ATC White
3No Connection
4Guard Shield/Braid (when
fitted)
5Conductivity Sensor Cell Black
6Conductivity Sensor Cell Red
7+ve of current or voltage output Customer-defined
8-ve of current or voltage output Customer-defined
9No Connection
10 Normally Closed contact of
(optional) relay output Customer-defined
11 Common contact of (optional) relay
output Customer-defined
12 Normally Open contact of
(optional) relay output Customer-defined
13 240V AC Active input Brown (standard colour)
14 Duplicate 240V AC Active contact.
See section 11.2.Brown (standard colour)
15 240V AC Earth input Green (standard colour)
16 Duplicate 240V AC Earth contact.
See section 11.2.Green (standard colour)
17 240V AC Neutral input Blue (standard colour)
18 Duplicate 240V AC Neutral
contact. See section 11.2.Blue (standard colour)

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3.5 Setting the Control Limit
The control limit can be set over the full scale of the miniCHEM-Cond, as a “too
high” or a “too low” trip point. The hysteresis around this set point can be also be
adjusted, if necessary. See section 3.5.3 for an explanation of hysteresis.
3.5.1 Setting the limit value
1. Switch the miniCHEM-Cond to SET LIMIT.
The control limit value is now displayed. Note that the Alarm LED and
(optional) output relay are now disabled. The 4-20mA or 0-1V outputs are
still active, and proportional to displayed value.
2. Adjust the LIMIT control until the display reads the desired trip point value.
3.5.2 Setting the alarm/control direction
The control limit can be set as a “too high” or “too low” trip point using the Lo/Hi
Control jumpers in the terminal area. The miniCHEM-Cond must be switched
OFF before changing jumper settings.
The jumper settings for a “too low” trip point are…
Low High
The jumper settings for a “too high” trip point are…
Low High

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3.5.3 Adjusting the Hysteresis
The hysteresis is the Conductivity range over which the alarm/control output
remains switched on, once the trip point has been exceeded.
For example, if the limit is set to 2.00 mS/cm, as a “too low” trip point, with a
hysteresis of ±0.10 mS/cm, the alarm/control output is switched 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 points 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 hysteresis can be increased to as high as
±40 digits with the HYSTERESIS trimmer in the terminal area. Turning the
HYSTERESIS 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 miniCHEM-Cond must be switched
OFF before changing jumper settings.
The jumper settings for 4 to 20 mA output are:
CVCVC
The jumper settings for 0 to 1V DC output are:
CVCVC
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 miniCHEM-Cond needs to
be reset to current output in the future.
0 to 10V DC output is available as a factory fitted option. The jumper settings
are the same as detailed above, but the 0 to 1V DC output will no longer be
available.

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3.7 Calibrating the 4 to 20mA Output
The 4 to 20mA output of the miniCHEM-Cond is factory calibrated. However,
TPS has provided calibration controls for the 4mA and 20mA points in case this
requires adjustment in the field. Only a limited amount of adjustment is available,
as the miniCHEM-Cond is designed for 4 to 20mA output for the full scale of the
instrument.
Calibrating the 4 to 20mA output…
1. Connect a Digital Milliamp Meter between terminals 7 and 8.
2. Switch the miniCHEM-Cond to SET LIMIT.
3. Adjust the LIMIT control until the display reads 0.00.
4. Adjust the ZERO/4mA trimmer in the terminal area until the Digital
Milliamp Meter reads 4 mA.
5. Adjust the LIMIT control until the display reads 1999, regardless of decimal
point location.
6. Adjust the SPAN/20mA 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 1999, calculate the expected output level and use this for
calibration. Remember that the difference between 0 and 1999 is to be made
16mA.

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4. Calibration
4.1 Calibration Procedure
1. Switch the miniCHEM-Cond on.
2. Ensure that the Conductivity sensor is correctly connected (see section 3.4).
3. Set the function switch to STANDBY, to ensure that the (optional) relay
output is not activated when moving the Conductivity sensor between
solutions.
4. For the GK-1 sensor (part no 112206), ensure that the white protective cover
is fitted with the vent hole towards the cable end of the sensor.
5. Rinse the Conductivity sensor in distilled water and blot dry.
Zero Calibration
6. Shake the Conductivity sensor dry and hang it in air. DO NOT wipe the
platinised platinum electrode surface, as this will remove the platinum-black
layer.
7. When the reading has stabilised, adjust the ZERO control until the display
reads exactly zero.
Span Calibration
8. Place the Conductivity sensor into a small sample of Conductivity standard. A
suitable standard should be chosen for the display range of the unit.
9. For GK-1 (part no 112206) and GK-10 (part no 112207) sensors, ensure that
they are immersed at least to the vent hole in the white plastic cover. The GK-
0.1 (part no 112205) sensor does not have a cover, so it should be immersed
to the large thread (see diagrams below).

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10. When the reading has stabilised, adjust the SPAN control until the display
shows the value of the standard.
11. Rinse the Conductivity sensor in distilled water and blot dry.
12. The miniCHEM-Cond is now calibrated and ready for Conductivity
measurements.
4.2 Calibration Notes
1. The Zero calibration is quite stable long term, and only needs to be performed
monthly as a routine check. In applications where the sensor can become dirty
or coated with oils etc., a Zero calibration may need to be done weekly.
2. A Span calibration should be performed at least weekly. Of course, more
frequent calibration will result in greater confidence in results.

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5. Process Monitoring
Once the miniCHEM-Cond has been installed, connected and calibrated, it can be
used for continuous monitoring. To monitor the process, WITHOUT any control
or alarm functions switch the function switch to STANDBY.
6. Automatic Dosing
For Automatic Alarming or Control, switch the function switch to AUTO to
enable the Alarm LED and the (optional) relay output. These will be switched ON
while the Conductivity exceeds the limit value, and will switch OFF once the
Conductivity is back within the limit.
7. Manual Dosing
From time to time, a dose of chemical may be required even when the
Conductivity is within the limit value. To do this, simply switch the function
switch to MANUAL, if the (optional) relay output is fitted.
NOTE: The output will be ON continuously while the function switch is set to
MANUAL. It will not be switched OFF again until the switch is set
back to one of the other modes.
8. Fuse Replacement
If the current drain from any device connected to the output relay exceeds 1 Amp,
the output protection fuse will blow.
To replace the fuse…
1. SWITCH THE miniCHEM-Cond OFF.
2. Pull out the black fuse carrier.
3. Replace the blown fuse
4. Push the fuse carrier with the new fuse back into place.
ALWAYS REPLACE THE FUSE WITH A 1 AMP, 240V
FUSE. USING A FUSE WITH HIGHER CURRENT RATING
MAY DAMAGE YOUR CONTROLLER, VOIDING THE
WARRANTY.
Before switching the miniCHEM-Cond back to AUTO mode, ensure that the
cause of the blown fuse has been eliminated.
If the current drain of the device connected to the relay output is greater than 1
Amp, an external contactor should be used. Please consult an electrical contractor
or TPS for details.

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9. Troubleshooting
9.1 Instrument Function Troubleshooting
Symptom Possible Causes Remedy
No display 1. Mains power input not
switched on.
2. Mains power input
incorrectly connected.
3. Instrument is faulty.
Switch power ON.
Check connections (see section
3.4).
Return to TPS for repair.
Alarm LED or
(optional) relay
output do not
operate when limit
is exceeded.
1. Limit not set correctly for
“too high” or “too low”
alarm/control.
2. Optional relay output not
fitted.
3. Hysteresis too large.
4. Fuse has blown.
5. Instrument is faulty.
Set the Lo/Hi Output jumpers
correctly (see section 3.5.2).
Return unit to factory to have
relay output fitted (part no
130342).
Check and adjust the
HYSTERESIS trimmer (see
section 3.5.3). If in doubt, set
this to minimum level.
Check and replace fuse if
necessary (see section 8).
Return to TPS for repair.
Incorrect analogue
output signal. 1. Current/Voltage Output
jumpers incorrectly set for
required output.
2. 4-20mA loop resistance too
high.
3. Load on 0-1V DC output is
too low.
4. 4-20mA output is not
calibrated.
5. Instrument is faulty.
Check that the Current/Voltage
Output jumpers are correctly
set for 4-20mA or 0-1V, as per
requirements. Adjust if
necessary (see section 3.6).
Ensure loop resistance does not
exceed 500 Ohms.
Ensure load is 1000 Ohms
minimum.
Calibrate 4-20mA output (see
section 3.7).
Return to TPS for repair.

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9.2 Conductivity Troubleshooting
Symptom Possible Causes Remedy
Zero calibration
fails (insufficient
range with ZERO
control).
1. Electrode has Zero error.
2. Sensor is faulty.
Thoroughly rinse electrode in
distilled water and allow to
completely dry in air before
attempting zero calibration.
If instrument does not calibrate
at Zero with electrode
disconnected, then the
instrument is faulty.
Replace sensor.
Standard
calibration fails,
reading is too low
and cannot be
adjusted high
enough.
1. Electrode is not immersed
deeply enough.
2. Electrode may have a
build-up of dirt or oily
material on electrode
wires.
3. Platinum-black coating has
worn off.
4. Standard solution is
inaccurate.
5. Electrode is faulty.
Immerse electrode at least to
the vent hole in the white
plastic cover.
Clean electrode, as per the
instructions detailed in section
11.2.2.
Electrode requires
replatinisation.
Return to the factory, or see
details in section 11.2.3.
Replace standard solution.
Return electrode to factory for
repair or replacement.
Standard
calibration fails,
reading is too high
and cannot be
adjusted low
enough.
1. White protective cover is
not fitted (GK-1 sensor).
2. Standard solution is
inaccurate.
3. Electrode may have a
build-up of conductive
material, such as salt.
4. Electrode is faulty.
The white protective cover
MUST be fitted for correct
readings for GK-1 sensor.
Replace standard solution.
Clean electrode, as per the
instructions detailed in section
11.2.2.
Return electrode to factory for
repair or replacement.
Continued next page…