YOKOGAWA EXA DO402G User manual

User’s
Manual Model DO402G
Dissolved Oxygen Converter
[Style: S3]
IM 12J05D02-01E
IM 12J05D02-01E
9th Edition

i
IM 12J05D02-01E
uIntroduction
NOTE
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.
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.
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modicationoftherelatedinstrumentbyanengineernotauthorizedbyYokogawa.
nHow 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.ofce.Donot
dispose them as domestic household waste.
Batterytype:silveroxidebattery
Notice: The symbol means they shall be sorted out and collected as ordained in
ANNEXIIinDIRECTIVE2006/66/EC.
9th Edition: Aug. 05, 2015-00
MediaNo.IM12J05D02-01E 9thEdition:Aug.2015(YK)
All Rights Reserved Copyright © 2003, Yokogawa Electric Corporation

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IM 12J05D02-01E
uSafety Precautions
n Safety,Protection,andModicationoftheProduct
• Inordertoprotectthesystemcontrolledbytheproductandtheproductitselfandensure
safe operation, observe the safety precautions described in this user’s manual. We assume
no liability for safety if users fail to observe these instructions when operating the product.
• Ifthisinstrumentisusedinamannernotspeciedinthisuser’smanual,theprotection
provided by this instrument may be impaired.
• Ifanyprotectionorsafetycircuitisrequiredforthesystemcontrolledbytheproductorfor
the product itself, prepare it separately.
• BesuretousethesparepartsapprovedbyYokogawaElectricCorporation(hereafter
simplyreferredtoasYOKOGAWA)whenreplacingpartsorconsumables.
• Modicationoftheproductisstrictlyprohibited.
• Thefollowingsafetysymbolsareusedontheproductaswellasinthismanual.
WARNING
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.
CAUTION
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.
CAUTION
This symbol gives information essential for understanding the operations and functions.
NOTE
This symbol indicates information that complements the present topic.
ThissymbolindicatesProtectiveGroundTerminal.
ThissymbolindicatesFunctionGroundTerminal.Donotusethisterminalastheprotective
ground terminal.
nNotes on Handling User’s Manuals
• Pleasehandovertheuser’smanualstoyourenduserssothattheycankeeptheuser’s
manuals on hand for convenient reference.
• Pleasereadtheinformationthoroughlybeforeusingtheproduct.
• Thepurposeoftheseuser’smanualsisnottowarrantthattheproductiswellsuitedtoany
particular purpose but rather to describe the functional details of the product.
• Nopartoftheuser’smanualsmaybetransferredorreproducedwithoutpriorwritten
consentfromYOKOGAWA.
• YOKOGAWAreservestherighttomakeimprovementsintheuser’smanualsandproductat
any time, without notice or obligation.
• Ifyouhaveanyquestions,oryoundmistakesoromissionsintheuser’smanuals,please
contact our sales representative or your local distributor.
9th Edition: Aug. 05, 2015-00

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IM 12J05D02-01E
nWarning and Disclaimer
Theproductisprovidedonan“asis”basis.YOKOGAWAshallhaveneitherliabilitynor
responsibility to any person or entity with respect to any direct or indirect loss or damage arising
fromusingtheproductoranydefectoftheproductthatYOKOGAWAcannotpredictinadvance.
nLabel
The next warning label is put on the product.
nDrawing Conventions
Somedrawingsmaybepartiallyemphasized,simplied,oromitted,fortheconvenienceof
description.
Some screen images depicted in the user’s manual may have different display positions or
charactertypes(e.g.,theupper/lowercase).Alsonotethatsomeoftheimagescontainedinthis
user’s manual are display examples.
nWarranty 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 manufacturer.
Individual sales organisations 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, inadequate maintenance, corrosion, or by the effects of chemical processes are excluded
from this warranty coverage.
9th Edition: Aug. 05, 2015-00

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IM 12J05D02-01E
Intheeventofwarrantyclaim,thedefectivegoodsshouldbesent(freightpaid)totheservice
departmentoftherelevantsalesorganisation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failureofthedevice.
• Astatementwhetherwarrantyornonwarranty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uidsmustbedecontaminated/
disinfectedbeforeshipment.Goodsshouldcarryacerticate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.
9th Edition: Aug. 05, 2015-00

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IM 12J05D02-01E
Model DO402G
Dissolved Oxygen Converter
[Style: S3]
IM 12J05D02-01E 9th Edition
9th Edition: Aug. 05, 2015-00
TABLE OF CONTENTS
uIntroduction....................................................................................................i
uSafety Precautions .......................................................................................ii
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 CongurationchecklistforDO402 ................................................................. 1-6
1.5 SystemConguration ...................................................................................... 1-7
1.5.1 Dissolved Oxygen Sensor ................................................................. 1-7
1.5.2 The holders ........................................................................................ 1-8
2. DO402GSpecications............................................................................ 2-1
2.1 General............................................................................................................... 2-1
2.2 Operatingspecications.................................................................................. 2-4
2.3 Modelandsufxcodes .................................................................................... 2-5
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 ................................................................................................................. 3-4
3.2.1 WiringofDO30G................................................................................ 3-4
3.2.2 WiringofDO70G................................................................................ 3-5
3.2.3 Preparation ........................................................................................ 3-6
3.3 Wiring the power supply .................................................................................. 3-7
3.3.1 Generalprecautions .......................................................................... 3-7
3.3.2 Access to terminal and cable entry.................................................... 3-7
3.3.4 Groundingthehousing ...................................................................... 3-9
3.3.5 Switching on the instrument............................................................. 3-10
3.4 Wiring the contact signals ............................................................................. 3-10
3.4.1 Generalprecautions ........................................................................ 3-10
3.4.2 Contact outputs................................................................................ 3-10
3.4.3 Contact input .................................................................................... 3-11
3.5 Wiring the analog output signals .................................................................. 3-11
3.5.1 Generalprecautions ........................................................................ 3-11

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IM 12J05D02-01E 9th Edition: Aug. 05, 2015-00
3.5.2 Analog output signals....................................................................... 3-12
3.6 Wiring the standard galvanic sensor............................................................ 3-12
3.7 Wiring other galvanic sensors ...................................................................... 3-13
3.8 Wiring the standard optical sensor (DO70G)............................................... 3-14
3.9 Wiring polarographic sensors....................................................................... 3-16
3.10 Wiring RS-485 signal ...................................................................................... 3-16
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
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specicfunctions............................................................ 5-14
5.3.2 Temperature functions ..................................................................... 5-15
5.3.3 Calibration functions ........................................................................ 5-16
5.3.4 mA output settings ........................................................................... 5-17
5.3.5 Contact outputs................................................................................ 5-18
5.3.6 Userinterface................................................................................... 5-22
5.3.7 Communication setup ...................................................................... 5-23
5.3.8 General ............................................................................................ 5-24
5.3.9 Test and setup mode........................................................................ 5-24
6. Calibration Procesure.............................................................................. 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

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IM 12J05D02-01E 9th Edition: Aug. 05, 2015-00
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 dissolved oxygen 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 .......................................... 8-1
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................................................................................................................. 10-2
10.5 User setting table ............................................................................................ 10-2
Customer Maintenance Parts List (for Style: S3) ............. CMPL 12J05D02-03E
Revision Information ...............................................................................................i

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<1. Introduction and General Description> 1-1
IM 12J05D02-01E
1. Introduction and General Description
The Yokogawa EXA is a 4-wire converter 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 typical 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ofce.
Makesurethemodelnumberonthenameplateafxedtotheleftsideoftheinstrumentagrees
with your order.
CAUTION
The nameplate will also contain the serial number and power supply selection.
Besuretoapplycorrectpowertotheunit.
Checkthatallthepartsarepresent,includingmountingbracket,asspecied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Specications.
BasicPartsList: ConverterEXA402
 User’sManual(Seemodelcodeforlanguage)
 Optionalmountingbracketwhenspecied(Seemodelcode)
9th Edition: Aug. 05, 2015-00