YOKOGAWA EXA DO402G User manual

User’s
Manual Model DO402G [Style: S3]
Dissolved Oxygen Converter
IM 12J05D02-01E
IM 12J05D02-01E
7th Edition

IM 12J05D02-01E
TABLE OF CONTENTS
PREFACE.....................................................................................................................1
1. Introduction And General Description ............................................................. 1-1
1-1. Instrument Check............................................................................................ 1-1
1-2. Application ...................................................................................................... 1-2
1-3. General information ........................................................................................ 1-3
1-4. Configuration checklist for DO402 .................................................................. 1-5
1-5. System Configuration ..................................................................................... 1-6
1-5-1. Dissolved Oxygen Sensor ...............................................................................................1-6
1-5-2. The holders......................................................................................................................1-7
2. DO402G SPECIFICATIONS ................................................................................ 2-1
2-1. General ........................................................................................................... 2-1
2-2. Operating specifications ................................................................................. 2-2
2-3. Model and suffix codes ................................................................................... 2-3
3. Installation And Wiring....................................................................................... 3-1
3-1. Installation and dimensions ............................................................................ 3-1
3-1-1. Installation site.................................................................................................................3-1
3-1-2. Mounting methods ...........................................................................................................3-1
3-2. Wiring.............................................................................................................. 3-3
3-2-1.Wiring of DO30G ..............................................................................................................3-3
3-2-2.Wiring of DO70G ..............................................................................................................3-3
3-2-3. Preparation ......................................................................................................................3-4
3-3. Wiring the power supply ................................................................................. 3-5
3-3-1. General precautions ........................................................................................................3-5
3-3-2. Access to terminal and cable entry .................................................................................3-6
3-3-3. AC power.........................................................................................................................3-7
3-3-4. Grounding the housing ....................................................................................................3-7
3-3-5. Switching on the instrument ............................................................................................3-7
3-4. Wiring the contact signals............................................................................... 3-8
3-4-1. General precautions ........................................................................................................3-8
3-4-2. Contact outputs................................................................................................................3-8
3-4-3. Contact input....................................................................................................................3-8
3-5. Wiring the analog output signals..................................................................... 3-9
3-5-1. General precautions ........................................................................................................3-9
3-5-2. Analog output signals ......................................................................................................3-9
3-6. Wiring the standard galvanic sensor.............................................................. 3-9
3-7. Wiring other galvanic sensors....................................................................... 3-10
3-8. Wiring the standard optical sensor (DO70G)............................................... 3-10
3-9. Wiring polarographic sensors ........................................................................3-11
3-10. Wiring RS485 signal ....................................................................................3-11
4. Operation; Display Functions And Setting ...................................................... 4-1
4-1. Operator interface........................................................................................... 4-1
4-2. Explanation of operating keys......................................................................... 4-2
4-3. Setting passcodes .......................................................................................... 4-3
4-4. Display functions (default) .............................................................................. 4-4
5. Parameter setting ............................................................................................... 5-1
5-1. Maintenance mode ......................................................................................... 5-1
5-1-1. Manual activation of Hold ................................................................................................5-2
IM 12J05D02-01E
7th Edition: Feb. 2012(YK)
All Rights Reserved, Copyright © 2003, Yokogawa Electric Corporation

IM 12J05D02-01E
5-1-2. Manual Wash start/stop...................................................................................................5-3
5-1-3. Setpoint adjustment.........................................................................................................5-4
5-2. Commissioning mode ..................................................................................... 5-5
5-2-1. Setpoints..........................................................................................................................5-6
5-2-2. Range ..............................................................................................................................5-8
5-2-3. Hold ..............................................................................................................................5-10
5-2-4. Wash .............................................................................................................................5-12
5-2-5. Service...........................................................................................................................5-13
5-3. Notes for guidance in the use of service coded settings .............................. 5-14
5-3-1. Parameter specific functions .........................................................................................5-14
5-3-2. Temperature functions...................................................................................................5-16
5-3-3. Calibration functions ......................................................................................................5-16
5-3-4. mA output settings.........................................................................................................5-18
5-3-5. Contact outputs..............................................................................................................5-20
5-3-6. User interface ................................................................................................................5-26
5-3-7. Communication setup....................................................................................................5-28
5-3-8. General .........................................................................................................................5-28
5-3-9. Test and setup mode ....................................................................................................5-28
6. CALIBRATION PROCEDURE ............................................................................. 6-1
6-1. General ........................................................................................................... 6-1
6-1-1. Calibration methods.........................................................................................................6-1
6-1-2. Diagnostic functions performed during calibration ..........................................................6-2
6-2. Calibration procedure using air calibration method ........................................ 6-2
6-2-1. Preparation ......................................................................................................................6-2
6-2-2. Procedure for air calibration ............................................................................................6-3
6-3. Calibration procedure using water calibration method.................................... 6-4
6-3-1. Preparation ......................................................................................................................6-4
6-3-2. Calibration operation (water calibration method).............................................................6-4
6-3-3. Procedure for Water calibration.......................................................................................6-5
6-4. Calibration method using manual calibration method..................................... 6-6
6-4-1. Preparation ......................................................................................................................6-6
6-4-2. Procedure for manual calibration.....................................................................................6-7
7. Maintenance........................................................................................................ 7-1
7-1. Overall dissolvedoxygen metering system ..................................................... 7-1
7-1-1. Inspection and maintenance to be implemented periodically..........................................7-1
7-1-2. Inspection and maintenance to be implemented on occasion ........................................7-1
7-2. Periodic maintenance for the EXA DO402G converter................................... 7-2
7-3. Fuse Replacement.......................................................................................... 7-2
8. Troubleshooting ................................................................................................. 8-1
8-1. Measures in the case of converter operation failure....................................... 8-1
8-1-1. No dissolved-oxygen converter operation .......................................................................8-1
8-1-2. Operation key or display failure.......................................................................................8-1
8-2. Measures in the case of failure (Error) detection............................................ 8-2
9. Spare Parts.......................................................................................................... 9-1
10. Appendix ........................................................................................................ 10-1
10-1. Setpoint....................................................................................................... 10-1
10-2. Range ......................................................................................................... 10-1
10-3. Hold ............................................................................................................ 10-1
10-4. Wash........................................................................................................... 10-1
10-5. User setting table........................................................................................ 10-2

IM 12J05D02-01E
11. Appendix 2 QUALITY INSPECTION................................................................11-1
Customer Maintenance Parts List (for Style: S3) .................. CMPL 12J05D02-03E
Revision Record ..........................................................................................................i

IM 12J05D02-01E
PREFACE
Electric discharge
The EXA analyzer contains devices that can be damaged by electrostatic discharge. When servicing
this equipment, please observe proper procedures to prevent such damage. Replacement components
should be shipped in conductive packaging. Repair work should be done at grounded workstations using
grounded soldering irons and wrist straps to avoid electrostatic discharge.
Installation and wiring
The EXA analyzer should only be used with equipment that meets the relevant IEC, American or
Canadian standards. Yokogawa accepts no responsibility for the misuse of this unit.
CAUTION
The Instrument is packed carefully with shock absorbing materials, nevertheless, the instrument may be
damaged or broken if subjected to strong shock, such as if the instrument is dropped. Handle with care.
Although the instrument has a weatherproof construction, the transmitter can be harmed if it becomes
submerged in water or becomes excessively wet.
Do not use an abrasive or solvent in cleaning the instrument.
Notice
• This manual should be passed on to the end user.
• The contents of this manual are subject to change without prior notice.
• The contents of this manual shall not be reproduced or copied, in part or in whole, without permission.
• This manual explains the functions contained in this product, but does not warrant that they are suitable
the particular purpose of the user.
• Every effort has been made to ensure accuracy in the preparation of this manual.
However, when you realize mistaken expressions or omissions, please contact the nearest Yokogawa
Electric representative or sales office.
• This manual does not cover the special specifications. This manual may be left unchanged on any
change of specification, construction or parts when the change does not affect the functions or
performance of the product.
• If the product is not used in a manner specified in this manual, the safety of this product may be
impaired.
Yokogawa is not responsible for damage to the instrument, poor performance of the instrument or losses
resulting from such, if the problems are caused by:
• Improper operation by the user.
• Use of the instrument in improper applications
• Use of the instrument in an improper environment or improper utility program
• Repair or modification of the related instrument by an engineer not authorized by Yokogawa.
Safety and Modification Precautions
• Follow the safety precautions in this manual when using the product to ensure protection and safety of
the human body, the product and the system containing the product.
The following safety symbols are used on the product as well as in this manual.
DANGER
This symbol indicates that an operator must follow the instructions laid out in this manual in order to
avoid the risks, for the human body, of injury, electric shock, or fatalities. The manual describes what
special care the operator must take to avoid such risks.
WARNINGWARNING
DANGERDANGER

IM 12J05D02-01E
This symbol indicates that the operator must refer to the instructions in this manual in order to prevent
the instrument (hardware) or software from being damaged, or a system failure from occurring.
This symbol gives information essential for understanding the operations and functions.
This symbol indicates Protective Ground Terminal
This symbol indicates Function Ground Terminal (Do not use this terminal as the protective ground
terminal.)
This symbol indicates Alternating current.
This symbol indicates Direct current.
Warranty and service
Yokogawa products and parts are guaranteed free from defects in workmanship and material under
normal use and service for a period of (typically) 12 months from the date of shipment from the manufac-
turer. Individual sales organizations can deviate from the typical warranty period, and the conditions of
sale relating to the original purchase order should be consulted. Damage caused by wear and tear, inad-
equate maintenance, corrosion, or by the effects of chemical processes are excluded from this warranty
coverage.
In the event of warranty claim, the defective goods should be sent (freight paid) to the service depart-
ment of the relevant sales organization for repair or replacement (at Yokogawa discretion). The following
information must be included in the letter accompanying the returned goods:
• Part number, model code and serial number
• Original purchase order and date
• Length of time in service and a description of the process
• Description of the fault, and the circumstances of failure
• Process/environmental conditions that may be related to the installation failure of the device
• A statement whether warranty or non-warranty service is requested
• Complete shipping and billing instructions for return of material, plus the name and phone number of a
contact person who can be reached for further information.
Returned goods that have been in contact with process fluids must be decontaminated/disinfected before
shipment. Goods should carry a certificate to this effect, for the health and safety of our employees.
Material safety data sheets should also be included for all components of the processes to which the
equipment has been exposed.
How to dispose the batteries:
This is an explanation about the new EU Battery Directive (DIRECTIVE 2006/66/EC). This directive is
only valid in the EU. Batteries are included in this product. Batteries incorporated into this product cannot
be removed by yourself. Dispose them together with this product. When you dispose this product in the
EU, contact your local Yokogawa Europe B.V.office. Do not dispose them as domestic household waste.
Battery type: silver oxide battery
Notice:
The symbol (see above) means they shall be sorted out
and collected as ordained in ANNEX II in DIRECTIVE 2006/66/EC.
WARNING
CAUTION

IM 12J05D02-01E
Introduction 1-1
1. INTRODUCTION AND GENERAL DESCRIPTION
The Yokogawa EXA is a 4-wire coverter designed for industrial process monitoring, measurement and
control applications. This instruction manual contains the information needed to install, set up, operate
and maintain the unit correctly. This manual also includes a basic troubleshooting guide to answer typi-
cal user questions.
Yokogawa can not be responsible for the performance of the EXA analyzer if these instructions are not
followed.
1-1. Instrument Check
Upon delivery, unpack the instrument carefully and inspect it to ensure that it was not damaged during
shipment. If damage is found, retain the original packing materials (including the outer box) and then
immediately notify the carrier and the relevant Yokogawa sales office.
Make sure the model number on the textplate affixed to the top of the display board of the instrument
agrees with your order.
The textplate will also contain the serial number and power supply selection.
Be sure to apply correct power to the unit.
Figure 1-1. Nameplate example
Check that all the parts are present, including mounting bracket, as specified in the option codes at the
end of the model number. For a description of the model codes, refer to Chapter 2 of this manual under
General Specifications.
Basic Parts List: Converter EXA 402
User’s Manual (See model code for language)
Optional mounting bracket when specified (See model code)
WARNINGWARNING
Made in Japan
MODEL
SUFFIX
SUPPLY
OUTPUT
No.
STYLE
DO402G 115VAC 50/60Hz MAX.10VA
0-20mADC or 4-20mADC

IM 12J05D02-01E
1-2 Introduction
1-2. Application
The EXA converter is intended to be used for continuous on-line measurement in industrial installations.
The unit combines simple operation and microprocessor-based performance with advanced self-diag-
nostics and enhanced communications capability to meet the most advanced requirements. The meas-
urement can be used as part of an automated process control system. It can also be used to indicate
dangerous limits of a process, to monitor product quality, or to function as a simple controller for a dos-
ing/neutralization system.
Yokogawa designed the EXA analyzer to withstand harsh environments. The converter may be installed
either indoors or outside because the IP65 (NEMA 4X) housing and cabling glands ensure the unit is
adequately protected. The flexible polycarbonate window on the front door of the EXA allows pushbutton
access to the keypad, thus preserving the water and dust protection of the unit even during routine main-
tenance operations.
A variety of EXA hardware is optionally available to allow wall, pipe, or panel mounting. Selecting a prop-
er installation site will permit ease of operation. Sensors should normally be mounted close to the con-
verter in order to ensure easy calibration and peak performance. If the unit must be mounted remotely
from the sensors, WF10 extension cable can be used up to a maximum of 50 metres (150 feet) with a
BA10 junction box.
The EXA is delivered with a general purpose default setting for programmable items. (Default settings
are listed in Chapter 5 and again in Chapter 10). While this initial configuration allows easy start-up, the
configuration should be adjusted to suit each particular application. An example of an adjustable item
is the type of temperature sensor used. The EXA can be adjusted for any one of four different types of
temperature sensors.
To record such configuration adjustments, write changes in the space provided in Chapter 10 of this
manual. Because the EXA is suitable for use as a monitor, a controller or an alarm instrument, program
configuration possibilities are numerous.
Details provided in this user’s manual are sufficient to operate the EXA with all Yokogawa sensor
systems and a wide range of third-party commercially available probes. For best results, read this man-
ual in conjunction with the corresponding sensor user’s manual.

IM 12J05D02-01E
Introduction 1-3
1-3. General information
Flexibility, reliability and low maintenance are among the benefits provided by the EXA DO402G dis-
solved oxygen analyzer. Designed to meet the exacting requirements of measuring dissolved oxygen in
the modern industrial environment, it contains many features to ensure the best precision whatever the
application.
This 4-wire converter is housed in a robust IP65 field mountable case. Two mA outputs, four relays, dig-
ital communication and a clear LCD make the DO402G a truly comprehensive package.
The DO402G features PI control on both the auxiliary mA output and the pulse proportional relay out-
puts, thus avoiding the need for a separate controller.
The famous EXA sensor diagnostics are now expanded with a logbook facility in combination with the
RS485 two wire communication software option. This can be used to record events like calibration and
diagnostic messages, and to update configuration of the converter remotely.
The DO402G accepts inputs from galvanic, polarographic and optical sensors. Percent saturation, mg
oxygen/l water, and ppm DO can be displayed and transmitted. Compensation for atmospheric pressure
altitude, salinity and temperature are included for the best accuracy of measurement.
Features
• Simple 3 Ievel operation
• Display mg/l, ppm, % saturation
• Air calibration or saturated water calibration
• Chloride concentration compensation can be programmed
• Automatic temperature compensation
• Built-in barometric air pressure compensation
• “Hold” function enables fixed output signal during maintenance
• Two separate mA output signals
• Wide flexibility incorporating free programmable range settings, selection of output signals and alarm
functions
• Analog output with adjustable damping time
• Password protection for each programming level
• Built-in wash timer with remote start possibility
• IP65 weather protection
• Universal mounting possibilities
• Sensor diagnostics
• RS 485 bi-directional communication
• Logbook via RS 485 link
• PI control on mA and pulsed contact controls
Method of operation
The EXA DO30 operates on a galvanic cell principle.
The sensor contains a measuring cell consisting of a silver cathode and a lead anode. The voltage gen-
erated by this electrode pair is sufficient to generate a spontaneous reduction of oxygen at the cathode,
so no external voltage source for this reaction is required. The electrodes are immersed in an electrolyte
containing potassium hydroxide. Oxygen molecules can pass through a permeable membrane into the
cell. The output current of the cell is directly related to the partial pressure of oxygen at the sample side.
In the sensor a thermistor is integrated to be able to correct for temperature changes. Both signals are
used in the converter to ensure an automatically compensated value for dissolved oxygen. Calibration
is worked out by simple air calibration to make sure that the performance of the instrument will be main-
tained.
The DO70G sensor operates based on the principle of optical (fluorescence) measurement.
The sensor comprises a fluorescent membrane, light-emitting part, light-receiving part, and internal cir-
cuit. An external power source is required. Oxygen molecules pass through the permeable membrane to
a fluorescent substance and shift the phase of fluorescent emission. The degree of this shift is inversely
proportional to the partial pressure of oxygen on the sample side, resulting in the output of a current
equivalent to the polarographic current adjusted by the internal circuit.
A temperature sensor is integrated in both sensors, and the temperature signals are used to automati-
cally compensate the measurements of dissolved oxygen.
The combination of air-saturated water calibration and zero calibration helps maintain the performance of
the instrument.

IM 12J05D02-01E
1-4 Introduction
Display functions and ranges
The display continuously gives you all necessary information at a glance. The process values are shown
in easily readable programmable units. Either mg/l. % saturation or ppm can be chosen.
The user-interface is simplified to a basic set of 6 keys accessible through the flexible window cover. It
uses a simple step by step, question and answer style to communicate with the operator by giving mes-
sages on the second line of the display and indicating which keys are to be pressed in the display.
Automatic air calibration
Calibration for a dissolved oxygen instrument is performed by simple air calibration (please refer to 6.3.1
section for the optical sensor).
Criteria for automatic calibration (stabilization time, DO values) can be set to suit the sensor.
In addition to the air calibration three additional calibration procedures can be used:
1. Span calibration using air saturated water
2. Zero calibration using sulfite saturated water
3. Process calibration using laboratory reference method
Alarm and control functions
The EXA DO402 has four built-in relay contacts. From the factory the first two contacts are pre-defined
as a high or low alarm.
The third contact its pre-defined as a wash contact. This wash contact is driven by a wash-timer with
adjustable wash-time, interval time and relaxation time to control the wash cycle.
The fourth contact is fixed to function as an alarm, indicating that the EXA has found a fault in the meas-
uring loop. FAIL safe.
Cleaning
ln combination with the appropriate sensor and immersion type fitting the wash timer with remote start
possibility can be used. Interval-time, washing time and relaxation time are free programmable.
Damping time on output signal
Under certain circumstances disturbances can cause high peaks in the output signal. To avoid these dis-
turbances the EXA DO402 has an electronic filtering which averages the output signal during a program-
mable period. This damping time is programmable between 0 and 120 seconds.
Salinity compensation
In order to take the effect of salinity into account for oxygen measurement an average chloride concen-
tration can be programmed. The chloride concentration value is set manually via the service level. The
EXA DO402 takes account of the effects of salinity and temperature simultaneously. The advantage of
this construction is that the result of the measurement is available immediately. A separate conversion
table is not necessary.
Temperature compensation
The micro-processor makes an accurate temperature compensation possible that performs well over the
entire range of the instrument. No further adjustment tables are required.
Barometric air pressure compensation
Air pressure differences, due to weather conditions or altitude, can cause a variation up to 20 % in the
dissolved oxygen concentration. A built-in air pressure sensor automatically compensates for barometric
influences between 900 to 1100 mbar (90 to 110 kPa).
Sensor diagnostics
The DO sensor is checked for low impedance between the silver electrode and an earth contact in
the liquid, to detect membrane integrity. Temperature sensor connections and sensor connections are
checked for impedance. These faults are signalled by the FAIL contact and can be signalled to the con-
trol room by an output of 0/3.5 mA or 22 mA. The fault is also signalled by a special marker held on the
display, a LED on the front and an error code in the message display.
During calibration of a DO measuring system the slope deviation from nominal value (%) and sensor out-
put (µA) at 0 mg/l are calculated and checked.
If any of these are outside the limits, an error is signalled.

IM 12J05D02-01E
Introduction 1-5
Logbook
Software record of important events and diagnostic data. Available through RS485, for use with the
Yokogawa PC402 communication software.
Serial Communication
Bi-directional according to the EIA-485 standard using HART-protocol and PC402 software.
1-4. Configuration checklist for DO402
Standard configuration Options Reference for change
Measured variable(s)
Primary inputs D.O. and Temp
DO range 0- 20 mg/l any span within 0-50 mg/l “range”
DO units mg/l ppm. % saturation code 56
Temperature range 0- 50 °C 25 °C minimum span “range”
Temperature unit Celsius Fahrenheit code 11
Outputs
Analog output 4- 20 mA for DO 0-20 mA or 4-20 mA code 30
Second output 4- 20 mA for Temp 0-20 mA or 4-20mA code 30
Output allocation DO and Temp DO, Temp, Table, Pl control code 31
Contact outputs S1= high at 19.5 mg/l (4) freely programmable “setpoint”
S2= low at 1.0 mg/l code 40. 41, 42, 43
Contact allocation mg/l and FAIL mg/l, temp, wash, Pl control, HOLD code 40- 43
Contact variables dead time= 0.2 s; hyst= 0.1 mg/l time: 0- 200 s; hyst 0- 20 mg/l code 44
Add. contact functions none time out alarm code 47
Control functions none Pl on contacts or mA2 output code 45, 46, 34 33
Digital outputs none RS485 code 60
Communication
Digital interface disabled RS485 code 60
Communication software disabled PC402 contact factory
Variables on display mg/l and temp %sat, °C, mA1, mA2, SL, ZR, REL “display”
Burn out disabled burn low (3.5)/ high (22) on mA1/ mA2 code 32
Password protection disabled for mains/ comm./ serv level code 52
Autoreturn return to measure in 10 minutes enable or disable code 50
Add. functions in MAINT disabled wash start/ setpoint adj code 51
Diagnostics
Membrane condition active enable or disable code 02
Check on Slope active enable or disable code 02, 22
Check on zero disabled enable or disable code 02, 21, 22
Check on stability 0.05 mg/l per 60 s 0-50 mg/l in 10-600 s code 20
Compatibility
DO Sensor DO30 DOX8, DO410, Ingold, DO70G code 01, 10
Temperature sensor Pt1000 Pt 100, PB36, 22k NTC code 10
Membrane thickness 50 µm ( 2 mil) 25 or 50 µm (1 or 2 mil), adj. slope code 01
Sensor principle galvanic galvanic or polarographic *1 code 01, “wiring”
Manual temp. comp. disabled disable or enable code 13
Special Features
Salinity compensation disabled comp. for 0- 100 ppt NaCI code 04
Temperature calibration none adjustment +/- 7.5 °C code 12
Zero calibration disabled disable or enable code 21
Sensor washing disabled interval < 36 hours, wash time 0.1-10 min. “Wash”
HOLD during maintenance disabled hold last or hold fix “Hold”
Contact during HOLD disabled possible on S1,S2, S3 or S4 code 40-42
Atm. press. compensation active active or manual
Soft fail alarm disabled possible for E1..E4, E7..E9, E12, E16, E22 code 53
Logbook disabled 2 volumes of 50 events code 61,62
*1: Choose a polarographic sensor for an optical dissolved oxygen sensor.

IM 12J05D02-01E
1-6 Introduction
1-5. System Configuration
(For DO30G)
Output Signal：
4 to 20 m A DC or
0 to 20 m A DC
zDO30G
zDOX8A
zDOX8 W
zDO70G zDO402G
zWTB10-DO3
Alarm Contact Output
4-Contact Point，High/Low Alarm
Cleaning Time，Alarm Contact
HOLD Contat
100V AC±15%
115V AC±15%
230V AC±15%
zGuide Pipe
PH8HG
zSubmersion Type Holder
DOX8HS
zSuspension Type Holder
HH350G
F01.EPS
zFloating Ball Holder
PB350G
Dissolved Oxygen Sensor
Spere Parts Set
Holders, Holders with Cleaning System Dissolved Oxygen Converter
PB360G
Calibration Set
zDOX10
(For DO30G)
（For DO30G）
(For DO30G) (For DO70G)
Select pin terminal
for DO402G.
No Cleaning Jet Cleaning
Terminal Box
Power Supply Unit
1-5-1. Dissolved Oxygen Sensor
The DO402G can be used with a variety of sensors. Some specific programming may be necessary to
match the converter with the sensor.
a. DO70G sensor
This sensor features temperature compensation with a 22k NTC RTD. The nominal output of this
sensor is 60 nA in air under reference conditions. Before use, enter the service mode. Select service
code 01 (*S.TYPE) and set it to 1 (polarographic sensor), then press the ENT key. Select *1.CELL2.9
and set the nominal output to 60 nA. Next, select service code 10 (*T.SENS) and set it to 3 (22k
NTC). Then select service code 21 (*0.CAL) and set it to 1 (zero calibration enabled) because two-
point calibration by air-saturated water calibration and zero calibration are required.
For details, refer to GS12J05D04-01E.
b. Model DOX8SM sensor
This sensor is a galvanic sensor with a PB36 type temperature compensator and a 25 micron
membrane (1 mil).
This sensor has a nominal output current of 7.5µA in ambient air under reference conditions. In
Service code 01 selection 1 must be programmed when this sensor is used. The membrane check
is inactive with this sensor unless external solution ground is used. ( metal holder or sample line )
c. Model DO30G sensor
This sensor is essentially the same as the DOX8SM sensor, but it has a 50 micron membrane,
fixed sensor cable, Pt1000 RTD temperature compensation and integral solution ground that allows
membrane checking. The nominal output of this sensor is 3.75 µA in air under reference conditions.
In Service item ”*I.CELL” selection 0 must be programmed when this sensor is used.
For details, refer to GS12J05D03-01E.
d. Model DO30 sensor
This sensor is specified in GS12J6K4 and it can be supplied with 50 or with 25 micron membrane.
Normally 50 micron membrane is used and no reprogramming is necessary. Otherwise Service
code 01 setting must be changed from 0 to 1.

IM 12J05D02-01E
Introduction 1-7
e. Ingold model 32 sensors with 12, 19 and 25 mm shaft
These sensors are available in many different configurations. The sensor is a polarographic sensor
and therefore settings of service code 01 has to be changed from 0 to 1.
The sensor output is normally between 30 and 100 nA in ambient air under reference conditions,
but the “large cathode” version has a current output between 200 and 700 nA. To utilize Slope
diagnostic features, it is best to read current output during first air calibration in “display” mode and
to enter that value in service code 01.
The temperature compensator is a NTC resistance and that can be chosen by entry of 3 in code 10.
The wiring of the sensor is different as well:
The red wire: the anode goes to terminal 18
The white wire: the cathode goes to terminal 17
The green/yellow wire: the shield goes to terminal 14 and the 2 black wires for NTC go to terminal
11 and 12.
The membrane checking feature cannot be used for these sensors, due to the construction of the
sensor.
1-5-2. The holders
a. PB30 floating ball holder
All Yokogawa sensors are compatible with the floating ball holder that is specified in GS12J6K4
and GS12J5A1.
b. FD30 immersion fitting
The DO30 sensor is compatible with the FD30 immersion holder as specified in GS12J6K4 and with
all flow fittings and flow fitting subassemblies that are specified in GS12D7K2.
c. DOX8HS submersion type holder
The DOX8SM and the DO30G sensor are compatible with the DOX8HS holder and all PH8 model
holders.

IM 12J05D02-01E
Specification 2-1
2-1. General
A. Input specifications
: The DO402G Dissolved Oxygen
converter measures the cur-
rent, that is generated by the
Dissolved Oxygen sensor. The
flexibility of the input circuit
allows the use of many com-
mercially available sensors,
whether they are of the Galvanic
type (driving voltage generated
internally) or Polarographic type
(driving voltage supplied by con-
verter)
The input range varies from
0.0 nA up to 500 nA for optical,
polarographic sensors and 0.0
to 50 µA for galvanic sensors.
Temperature measurement for
automatic temperature compen
sation utilizes Pt100, PT1000
RTD elements or PB36 as used
in DOX8, DO30 and DO70G
sensors, as well as the 22 k
NTC as used by the Hamilton
Oxyferm.
B. Measurement ranges
- DO : 0- 50 mg/l (ppm)
- Temperature : 0- 50 ºC (32- 122 ºF)
C. Span
- DO concentration
: minimum: 1 mg/l (ppm)
maximum: 50 mg/l (ppm)
- % saturation : minimum: 10 %
maximum : 300 %
- Temperature : minimum: 25 ºC (77 ºF)minimum: 25 ºC (77 ºF)minimum: 25 ºC (77 ºF)
maximum : 50 ºC (122 ºF)
D. Output Signals
: Two isolated outputs of 0/4- 20
mA DC with common nega-
tive. Maximum load 600 Ohm.
Auxiliary output can be chosen
from Temperature, DO, PI con-
trol, table, burn up (22 mA) or
burn down (0 or 3.5 mA) to sig-
nal failure
E. Temperature compensation
: 0- 50 ºC
Sensor types: Pt100 or Pt1000
RTD; PB36 (Yokogawa compat
ible);
22 k NTC (Ingold compatible)
Automatic or Manual tempera-
ture compensation
F. Calibration
: Semi-automatic calibration with
automatic compensation for
influence of barometric pressure
and altitude on partial pressure
of oxygen in air (or solubility
of oxygen in water). Automatic
compensation for influence of
salinity of water on solubility of
oxygen in water is programma-
ble.
The correction for pressure,
salinity and temperature meets
ISO 5814
Possible calibration routines are:
- Slope (span) calibration in
ambient air. The calibration
table is based on 70 % RH and
is determined empirically.
- Slope (span) calibration in- Slope (span) calibration in
water, saturated with air:
according ISO 5814
- Zero calibration (normally inac-
tive)
G. Serial Communication
: Bi-directional according to the
EIA-485 standard using HART
protocol and PC402 software.
H. Logbook
: Software record of important
events and diagnostic data.
Available through RS485, with
key diagnostic information avail-
able in the display.
I. Display
: Custom liquid crystal display,
with a main display of 31/2digits
12.5 mm high. Message display
of 6 alphanumeric characters, 7
mm high.
2. DO402G SPECIFICATIONS

IM 12J05D02-01E
2-2 Specification
J. Contact outputs
- General : Four (4) SPDT relay contacts
with LED indicators. For S1,
S2, and S3, the LED is on
when relay is powered.
NOTE:
For S4 (FAIL) LED lights when
power is removed (Fail safe).
Contact outputs configurable
for hysteresis and delay time.
- Capacity
: Maximum values 100 VA,
250 V AC, 5 Amps.
Maximum values 50 Watts,
250 V DC, 5 Amps.
- Status
: High/Low process alarms,
selected from process
parameters and temperature.
Contact output is also available
to signal “Hold Active
Contact S1 to S3 Contact S4
Status LED NO NC LED ON NC
Alarm,
FAIL,
OFF
On Closed Open On Open Closed
Alarm,
FAIL,
OFF
Off Open Closed Off Closed Open
Power
OFF Off Open Closed Off Open Closed
- Control function
: On/Off
PI pulsed Proportional duty cycle control
with integral term.
PI frequency Proportional frequency control
with integral term. In addition
wash cleaning control signal on
S3, and FAIL alarm for system
and diagnostic errors on S4
K. Contact input: Wash start or input remote range
change (either choice)
  Onresistance:10Ωorless
  Offresistance:100kΩormore
On time: 0.5 sec. or more
L. Power supply
Supply voltage rating
: 100, 115, 230 VAC
Applicable range
: 85 to 115, 97.8 to 132.2,85 to 115, 97.8 to 132.2,85 to 115, 97.8 to 132.2,
195.5 to 264.5 VAC
Supply frequency rating
: 50 / 60 Hz
Applicable range
: 50 Hz ± 5% / 60 Hz ± 5%
Power consumption
: Maximum 10 VA for steady
operation
M. Safety and EMC conforming standards
,
Safety : conforms to EN 61010-1,
CSA C22.2 No.1010.1 certified
EMC : EN 61326-1 Class A, Table 2
(For use in industrial locations) (Note 1),
EN 61326-2-3
EN 61000-3-2 Class A
EN 61000-3-3
Korea Electromagnetic Conformity Standard
Installation altitude: 2000 m or less
Category based on IEC 61010: II (Note 2)
Pollution degree based on IEC 61010:2 (Note
2)
Note 1: This instrument is a Class A product,
and it is designed for use in the
industrial environment. Please use
this instrument in the industrial
environment only.
Note 2: Installation category, called over-
voltage category, specifies impulse
withstand voltage. Category II is for
electrical equipment.
Pollution degree indicates the degree
of existence of solid, liquid, gas or
other inclusions which may reduce
dielectric strength. Degree 2 is the
normal indoor environment.
N. Shipping details
: Package size w x h x d
290 x 300 x 290 mm.
11.5 x 11.8 x 11.5 in.
Packed weight approx.
2.5 kg (5lb).
2-2. Operating specifications
A. Performance : DO (at t process = 25 °C)
- Linearity : ± 0.03 mg/l or ± 0.5%FS,
whichever is greater
- Repeatability: ± 0.03 mg/l or ± 0.5%FS,
whichever is greater
- Accuracy : ± 0.05 mg/l or ± 0.5%FS,
whichever is greater
B. Performance : Temperature (Pt1000, PB36,
22kNTC)
- Linearity : ± 0.3 ºC
- Repeatability : ± 0.1 ºC
- Accuracy : ± 0.3 ºC
Performance : Temperature (Pt100)
- Linearity : ± 0.4 ºC
- Repeatability : ± 0.1 ºC
- Accuracy : ± 0.4 ºC

IM 12J05D02-01E
Specification 2-3
Note on performance specifications:
The specifications are expressed with sim-
ulated inputs, because the DO402G can
be used with many different sensors with
their unique characteristics.
The following tolerance is added to above
performance.
mA output tolerance : ± 0.02 mA of
"0/4 - 20 mA"
Digital display tolerance : +1 digit
C. Response time
0- 90% : 10 s
D. Ambient operating temperature
: -10 to +55 °C (14 to 131 ºF)°C (14 to 131 ºF)C (14 to 131 ºF)
E. Storage temperature
: -30 to +70 °C (-22 to 158 ºF)°C (-22 to 158 ºF)C (-22 to 158 ºF)
F. Humidity : 10 to 90% RH non-condensing
G. Housing
Case : Cast aluminium with chemically
resistant coating
Cover : flexible polycarbonate window.
Case color : off-white (munsell 2.5Y8.4/1.2)
Cover color : moss green. ( munsell
0.6GY3.1/2.0)
Cable entry : via six Pg13.5 nylon glands.
Cable terminals: for up to 2.5 mm2finished wires.
Protection : weather resistant to IP65 /
NEMA 4X / CSA Type 3S
standards.
Mounting : Pipe, wall or panel, using
optional bracket.
H. Data protection
: Non volatile memory for
configuration and logbook, and
lithium battery for clock support.
I. Watchdog timer
: Checks microprocessor
J. Automatic safeguard
: Return to measuring mode
when no keystroke is made for
10 min.
K. Power interruption
: Less than 50 milliseconds no
effect.
L. Operation protection
: 3-digit programmable password.
M. Connection via cables:
The distance between the ensor and trans
mitter can be up to 50 m if the WTB10 junc
tion box is used. This junction box can
not be used for the DO70G, for which the
allowable maximum distance is10 m.
2-3. Model and suffix codes
[Style: S3]
Model Suffix
code
Option
code Description
DO402G ----------------- --------- Dissolved Oxygen
Converter
Type -1 --------- General
Power Supply
Voltage
-1
-2
-5
---------
---------
---------
115V +/-15% AC, 50/60 Hz
230V +/-15% AC, 50/60 Hz
100V +/-15% AC, 50/60 Hz
Language -J
-E
---------
---------
Japanese
English
Options
Mounting Hardware
Hood
Tag Plate
Conduit Adaptor
Coating
/U
/PM
/H3
/H4
/SCT
/AFTG
/ANSI
/X1
Pipe, wall mounting
bracket (Stainless steel)
Panel mounting bracket
(Stainless steel)
Hood for sun protection
(Carbon steel)
Hood for sun protection
(Stainless steel)
Stainless steel tag plate
G 1/2
1/2 NPT
Epoxy baked finish (*1)
*1: The housing is coated with epoxy resin.

IM 12J05D02-01E
Installation and wiring 3-1
3. INSTALLATION AND WIRING
3-1. Installation and dimensions
3-1-1. Installation site
This instrument is a Class A product, and it is designed for use in the industrial environment. Please use
this instrument in the industrial environment only.
The EXA converter is weatherproof and can be installed inside or outside. It should, however, be
installed as close as possible to the sensor to avoid long cable runs between sensor and converter. In
any case, the cable length should not exceed 50 meters (162 feet). For an optical dissolved oxygen sen-
sor, the allowable maximum cable length is 10 m. Select an installation site where:
• Mechanical vibrations and shocks are negligible
• No relay/power switches are in the direct environment
• Access is possible to the cable glands (see figure 3-1)
• The converter is not mounted in direct sunlight or severe weather conditions
• Maintenance procedures are possible (avoiding corrosive environments)
The ambient temperature and humidity of the installation environment must be within the limits of the
instrument specifications. (See chapter 2).
3-1-2. Mounting methods
Refer to figures 3-2 and 3-3. Note that the EXA converter has universal mounting capabilities:
• Panel mounting using optional brackets
• Surface mounting on a plate (using bolts from the back)
• Wall mounting on a bracket (for example, on a solid wall)
• Pipe mounting using a bracket on a horizontal or vertical pipe (maximum pipe diameter 50 A)
184
144
72
20
144
220
23 112
Four M6 screws, 8 (0.31) deep
80
80
36 36
36
38
ABC
DE F
Hood (optional)
Option code : /HƑ
Cable inlet port (Six-21 (0.83) dia. holes)
DIN PG13.5 cable gland
Ground terminal
(M4 screw)
Weight: Approx. 2 kg
A : Power supply for DO70G, or
contact input separately.
B : Sensor cable
C : Output signal
D : Contact output (S3 and S4)
E : Contact output (S1 and S2)
F : Power supply
Adaptor for conduit work
(option code : /AFTG, /ANSI)
Unit: mm (inch)
Approx. 55
Adaptor
G 1/2 female ( / AFTG)
1/2 NPT female ( / ANSI)
49
(7.24) (8.66) (3.15)
(3.15)
(1.93)
(2.17)
(5.67)
(5.67)
(2.83)
(0.79)
(0.91) (4.41)
(1.42) (1.42)
(1.42)
(1.50)
Figure 3-1. Housing dimensions and layout of glands
WARNINGWARNING