YSI 5200A User manual

YSI Incorporated
5200A Monitor and Control
Instrument
User Manual

YSI 5200A
3
YSI 5200A
2
tem # 605876
Rev F
Drawing # A605876
May 2015
Copyright
©2015 YSI Incorporated.
Manufacturer:
YSI, Incorporated
A Xylem Brand
1700/1725 Brannum Lane
Yellow Springs, OH 45387 USA
937-767-7241 www.ysi.com
All trademarks herein are
registered to YSI Incorporated
unless otherwise noted.
Teon is a trademark of DuPont.
Microso and Windows are registered trademarks of the Microso
Corporation in the United States and other countries.
Pentium is a registered trademark of Intel Corporation.
Document information Table of Contents
Table of Contents
1 Introduction............................................................ 9
Introduction .....................................................................................10
Product Description .............................................................................11
Preview of User Manual.......................................................................12
Product Specications .........................................................................13
Environmental Specications.........................................................13
Input System Specications ...........................................................14
Component and System (Non Input) Specications ......................16
2 Safety ....................................................................... 19
THIS IS IMPORTANT ..........................................................................20
Warnings and Cautions..................................................................20
Warnings ..................................................................................21
Cautions ...................................................................................23
Health and Safety (calibration solutions & desiccant)....................23
Health and Safety (Calibration Solutions) ........................24
Calibration Solutions ................................................................24
3 Installation & Wiring .............................................. 25
Hardware Installation ...........................................................................26
Step 1 Install 5200A.......................................................................27
Location Considerations...........................................................27
Mount the 5200A......................................................................28
Surface Mount ....................................................................28
Rail Mount ..........................................................................28
Panel Mount .......................................................................29
Install the Weather Shield...................................................33
Step 2 Locate and Install Probe/Cable Assembly ..........................34
Location Considerations...........................................................34
YSI 5561 Probe Assembly .......................................................35
YSI 5562 Probe Assembly .......................................................36
Wiring Information..........................................................................37
PCBs ........................................................................................37
5200A Bulkhead Fittings ..........................................................38
Accessing the I/O Board ..........................................................39
Open Front Panel to Access I/O Board ....................................40
Close Front Panel ....................................................................40
Control Board ...........................................................................41
Step 3 Ground 5200A ....................................................................41
Directions to Ground 5200A.....................................................42
Step 4 Wire Power .........................................................................43
Wire AC Power.........................................................................43
Directions to Wire AC Power ..............................................43

YSI 5200A
5
YSI 5200A
4
Wire DC Power and backup power ..........................................44
Directions to Wire DC Power/DC Backup Power ...............45
Step 5 Wire Relay Outputs ............................................................46
Directions to Wire Relay Outputs .............................................46
Wiring a Contactor ...................................................................48
Wire aux digital input device ....................................................48
Wire aux analog input device ...................................................48
Step 6 Wire Aux Inputs ..................................................................49
Directions to Wire Aux Inputs ..................................................49
Step 7 Wire Network ......................................................................52
Directions to Wire Network......................................................53
Step 8 Wire Communication Equipment ........................................58
Email Alarming .........................................................................58
RS232 Communication ......................................................58
Ethernet (TCP/IP) Module Communication ........................60
Step 9 Connect Probe/Cable Assembly.........................................60
Step 10 Install and Wire IOEM/REM Instruments..........................61
Lightning and Surge Protection......................................................61
Sealants, Desiccants, and Securing 5200A...................................62
4 Conguring 5200A Systems ................................. 65
5200A Conguration and Monitoring ...................................................66
Front Panel Keys ...........................................................................67
Softkeys ...................................................................................67
Run Screen ....................................................................................69
Run Screen Icons.....................................................................70
Menus ............................................................................................72
Submenu Screen Types...........................................................74
Main Menu .....................................................................................75
Calibration Menu............................................................................75
Getting Ready to Calibrate.......................................................76
Calibration Log .........................................................................78
Conductivity..............................................................................78
Directions to Calibrate Conductivity Sensor .......................78
DO............................................................................................80
Directions to Calibrate DO Sensor %Sat Value..................80
Directions to Calibrate DO Sensor mg/L Value ..................82
ORP..........................................................................................83
Directions to Calibrate ORP Sensor...................................83
pH.............................................................................................84
Directions to Calibrate pH Sensor ......................................84
Local vs Remote Instruments ........................................................86
System Menu .................................................................................86
Adjust Contrast.........................................................................87
BackLight Timer .......................................................................88
Table of Contents
Buzzer ......................................................................................88
Communication ........................................................................89
Email Alarming....................................................................90
Ethernet..............................................................................92
Node Network.....................................................................96
Send Test Email Msg..........................................................99
Email Retry Delay...............................................................100
Baud Rate RS232 ..............................................................100
Force Serial Port.................................................................101
Non-Networked (Stand Alone) 5200As ..............................101
Congure AUX .........................................................................101
Probe Name .......................................................................102
Input Type...........................................................................102
Congure E-Aux.......................................................................107
Probe Name .......................................................................108
Instrument...........................................................................108
Channel ..............................................................................109
Input Type...........................................................................110
Data Logging............................................................................116
Data Logging ......................................................................116
Event Logging ....................................................................118
Clear Logs ..........................................................................119
Date/Time.................................................................................120
Display Settings .......................................................................122
Updating 5200A Firmware........................................................123
Firmware Updater Directions..............................................123
Force Firmware Download .................................................127
General Alarm ..........................................................................128
Alarm Hold Off....................................................................129
Relay ..................................................................................129
Name Devices/Sensors............................................................131
Password .................................................................................134
Power Fail Menu ......................................................................135
Serial Number ..........................................................................136
Service .....................................................................................137
Reset Clean Probes ...........................................................137
Reset To Factory ................................................................138
Output Test ...............................................................................141
Service Hold.............................................................................144
Version .....................................................................................144
AquaManager and the System Menu ............................................145
Sensor Setup .................................................................................146
Table of Contents

YSI 5200A
6
YSI 5200A
7
Table of Contents
Control Mode............................................................................149
Set Point Control ................................................................150
Timed versus Normal (non timed) Control..........................153
Validation Error and Autox - Set Point Control Only .........154
PID/PWM and PID 4/20mA Control mode ..........................155
Aux and E-Aux Relay Digital ....................................................161
Aux and E-Aux Analog (0-1VDC, 0-5VDC and 4/20mA)..........163
Temperature .............................................................................165
Conductivity..............................................................................168
Temperature Compensation ...............................................168
Congure Conductivity System ..........................................169
DO............................................................................................170
Salinity & Temperature Compensation for DO Readings ...170
Two Range Controls for DO ...............................................171
Congure DO Sensor System ............................................171
ORP..........................................................................................173
Congure ORP sensor system ...........................................173
pH.............................................................................................174
Congure pH system..........................................................174
Salinity......................................................................................175
Enable Salinity System.......................................................176
E-Aux system Ofine ..........................................................177
Congure sensor system as a 4/20mA output....................178
AquaManager and the Sensor Setup Menu.............................179
Timers ............................................................................................180
Timers 1-4 ................................................................................181
Feed Smarttm Timer...................................................................182
Feed Mode .........................................................................183
Daily Weight ......................................................................185
Daily Feedings ...................................................................185
FCR ...................................................................................185
Sensors ..............................................................................187
Calibrate .............................................................................188
AquaManager and the Timer Menu..........................................190
Control Menu .................................................................................192
Msg’s Menu....................................................................................193
Calibration Logs ......................................................................194
Event Logs ...............................................................................194
Sensor Logs .............................................................................195
Svr Hold Menu ...............................................................................195
5 AquaManager ......................................................... 197
Installing AquaManager .......................................................................198
PC Requirements and Features ....................................................198
Software Installation.......................................................................199
Table of Contents
Getting started..........................................................................199
AquaManager Windows.................................................................200
Explorer Window ......................................................................200
Node (Graph) Window .............................................................201
Systems Management........................................................202
Database Management..................................................................203
Autopoller.......................................................................................204
Mapping ...................................................................................205
AquaManager Alarm Emails.....................................................205
6 Maintenance ........................................................... 207
Maintenance ........................................................................................208
Probe Maintenance at the Deployment Site ..................................208
Algae and Debris ...........................................................................208
Minimizing the Effect of Algae and Debris................................208
Calibration Checks.........................................................................208
Recommended Quality Assurance Protocol ..................................209
Alternative Quality Assurance Protocol (quick check and adjustment)
211
Sensor Care and Maintenance ......................................................211
DO Sensor ...............................................................................211
Silver Anode Cleaning ........................................................212
Gold Cathode Cleaning ......................................................212
pH and Combination pH/ORP Sensor Cleaning.......................213
Temperature/Conductivity Sensor Cleaning.............................214
Recommended Cleaning of the 5200A and Accessories ...............215
Storage ..........................................................................................215
Short Term Storage ..................................................................215
Long Term Storage...................................................................215
Probe/Cable Assembly Storage .........................................216
Sensor Storage ..................................................................216
Sensor Replacement .....................................................................217
Charging DC batteries ...................................................................217
AquaManager Database Maintenance ..........................................217
Replacement Parts & Accessories.................................................217
Appendices............................................................... 219
Appendix 1 - Unpacking and Inspection ..............................................220
Appendix 2 - Troubleshooting..............................................................221
Sensor Troubleshooting ...........................................................221
Relay (Outputs) Troubleshooting .............................................222
Email Alarm Troubleshooting ...................................................223
Network Troubleshooting .........................................................224
5200A Systems Troubleshooting..............................................224
Firmware Updater Troubleshooting..........................................225

YSI 5200A
8
1 Introduction
-5200A Product Description
-User Manual Guide
-Specications
Feed Timer Troubleshooting ....................................................225
AquaManager Troubleshooting ................................................225
Appendix 3 - Menu Maps.....................................................................226
Menu Map Key...............................................................................227
Appendix 4 - Declaration of Conformity ...............................................253
Appendix 5 Parts and Accessories ......................................................257
Appendix 6 SMS Messaging................................................................261
Appendix 7 Warranty ...........................................................................262
Appendix 8 Contact Us ........................................................................263
Ordering and Technical Support ....................................................263
Service Information ........................................................................263
Appendix 9 Recycling ..........................................................................264
Recycling .......................................................................................264
Battery Disposal.............................................................................264
Index .............................................................................. 265
Table of Contents

YSI 5200A
11
YSI 5200A
10
Introduction
ank you for purchasing the YSI 5200A. e YSI 5200A is a fully programmable
aquatic control monitor with alarming capability. e 5200A monitors, controls,
and alarms DO (dissolved oxygen), conductivity, ORP, pH, two Aux (auxiliary)
inputs and 8 E-Aux systems. (E-Aux systems require using an optional IOEM.) In
addition, the 5200A has four (4) 10 event timers and one (1) feed timer system.
Peripheral devices connected to the 5200A respond to user-dened conguration to
ensure that stable water conditions are maintained. e 5200A’s on-site and remote
access capability are suitable for a variety of applications.
5200A features:
- DO, conductivity, ORP, pH, and temperature (or DO and temperature only)
monitoring with control and alarm capability from one multiparameter
probe and cable assembly;
- two (2) independent Aux input systems - [digital or analog (0-1VDC,
0-5VDC, or 4-20mA)];
- eight (8) E-Aux input systems. E-Aux systems are used to monitor, control
and alarm inputs wired to an optional IOEM;
- four (4) onboard relays - 240VAC@ 5AMPs; 110VAC@10AMPS;
- universal AC power option (only available on AC instruments);
- DC power option with low battery alarm;
- four (4) ten event daily timers;
- one (1) feed timer;
- two (2) 32-bit processors;
- non-volatile memory of sensor, event, calibration, and conguration* data
logs;
- 2000 data set memory for sensor data;
- eld upgradable soware and rmware;
- backlit LCD with timer function - input and output data displayed con-
tinuously;
- menu-driven programming with four (4) sokeys;
- networking capability - connect up to (32) 5200A and/or 5X00s on one
network via RS485 protocol;
- networked instruments can utilize another instruments output for a local
system control or alarm;
- IOEM inputs and outputs can be used for a variety of uses - see IOEM/REM
Installation and Safety Guide;
- optional AquaManager® PC soware** serves as a monitor management
tool via direct (RS232) or TCP/IP connection. (AquaManager is required to
congure IOEM instruments on a network.);
NEW
NEW
Introduction
- email alarming via TCP/IP from instrument and/or AquaManager (local or
TCP/IP) connection;
- NEMA 4X, IP65 enclosure;
See Product Specications - page 13 for complete details on all 5200A features.
*A conguration log records any changes made to the 5200A setup. For example,
changing a set point for an alarm would be recorded in the conguration log.
**AquaManager displays real time data from 5200A instruments and provides data
logging, graphing, autopolling, mapping, and system conguration control from a
PC. AquaManager is a valuable tool for remote and local access applications.
Product Description
e 5200A system manages aquatic environments by automating control and alarm
devices to maintain stable water conditions.
A 5200A system is congured by the user. erefore, each system setup is unique
to the application. An example of a 5200A system could include*:
- 5200A instrument(s);
- 5200A components such as power, communication, and network devices;
- input peripheral devices (i.e. oat switch, probe assembly);
- output peripheral devices (i.e. aerator);
- 5200A user-dened conguration;
- AquaManager PC interface (optional);
*All of the items listed are not included with the purchase of a 5200A instrument.
Input devices send data to the 5200A. is data is processed based on the 5200A
conguration. For example, a DO sensor (input) reports a 5.4 mg/L value and
relay #3 (output) is congured to activate an aerator when value is ≤5.5 mg/L. e
aerator wired to relay #3 will be energized until the 5200A receives a DO sensor
reading ≥ the set point value.
Figure 1.1 shows the 5200A front panel and enclosure. e front panel includes an
LCD, which continuously displays current system conditions. Front panel keys are
used to navigate screens and program congurations. Compression ttings located
at the bottom of the enclosure provide liquid-tight connections for wiring peripheral
devices and 5200A components.
Introduction

YSI 5200A
13
YSI 5200A
12
Figure 1.1
Preview of User Manual
is manual includes information on installing, conguring, operating, and main-
taining a 5200A system.
Read Chapter 2 “Safety Information” starting on page 20 before installing or
conguring 5200A systems.
Chapter 3 “Installation” starting on page 26 provides information on how to in-
stall the 5200A, 5200A components, and peripheral devices. Only qualied people
should install a 5200A system. Do not attempt to install or congure this device
if you are not qualied to do so. If information is not clear, DO NOT PROCEED
until clarication can be obtained. All wiring involving connections to main power
must be performed by a qualied licensed electrician and must conform to all locally
applicable electrical codes. At times “5X00” will be used in this manual to identify
the entire YSI family of instruments being 5200A, 5400 and 5500D instruments.
Chapter 4 “Conguring 5200A Systems” starting on page 66 provides information
on menu structure and conguring 5200A instruments. At times “5X00” will be
used in this manual to identify the entire YSI family of instruments being 5200A,
5400 and 5500D instruments.
Introduction
Chapter 5 “AquaManager” starting on page 198 provides general information re-
garding the PC soware program. e AquaManager program includes an extensive
help system, which contains detailed information that is not provided in this manual.
is icon is used throughout the manual to indicate helpful information for Aqua-
Manager users.
Is used to bring attention to new 5X00 instrument and AquaManager features and
functionality.
Chapter 6 “Maintenance” starting on page 208provides information on maintaining
the 5200A system including the monitor and sensor service.
“Notes” at the end of each manual section provide additional information to help
clarify certain 5200A operations and features.
Appendices include information on Unpacking & Inspection, Troubleshooting,
Menu Maps, Declaration of Conformity, Parts and Accessories, SMS Messaging.
Warranty, Contact Us and Recycling information.
An index is provided starting on page 265.
Product Specications
To ensure accurate and reliable performance, operate the 5200A system according to
specications provided in the following tables. Damage and/or incorrect operation
could result if these specications are not followed.
Product specications are subject to change without notice. Visit www.ysi.com to
view the most recent product specications.
Environmental Specications
Environmental Category Operating Range
Temperature -15 to 70C (5 to 158F)
Enclosure Rating NEMA 4X (direct exposure to outside conditions),
IP65
Compression Fitting Rating IP 68/NEMA 6 (liquid tight)
Electrical Safety IEC compliant*
Other RoHS compliant
See Appendix 4 Declaration of Conformity - page 253.
NEW
Introduction

YSI 5200A
15
YSI 5200A
14
Input System Specications
Aux Systems ere are 2 Aux input systems that allow digital or analog (0-
1.0VDC, 0-5.0VDC, or 4-20mA) conguration.
Aux System
Type
Digital Analog
Range dry contact open/
close
0 -1.0 VDC, 0-5.0 VDC, or 4-20mA
Accuracy n/a 0-1.0VDC: ± 3% ± 10 mV
0-5.0VDC: ± 3% ±15 mV
4-20 mA: ± 3% ±100A
Resolution n/a user selectable (0), (0 .0), or (0.00)
Probe assembly 5562 (DO, temperature, pH, ORP, and conductivity sensors)
Probe assembly 5561 (DO and temperature sensors)
Cable grade military-spec (MS) connector
Cable lengths 4, 10, 20 m (special order up to 100m for DO and temp only)
Temperature
Sensor type 10,000 ohm @ 25°C thermistor
Range 0-45°C (32-113°F)
Accuracy ± 0.2°C
Resolution 0.1°C
Dissolved Oxygen
Sensor type Membrane covered, steady-state polarographic
Range 0 to 500% air saturation
0 to 60 mg/L
Accuracy ±2% or ± 0.2 mg/L, whichever is greater for 0-200%
±6% of reading for 200-500%
Resolution 0.1% (0.0-99.9%); 1% (> 99.9)
0.01 mg/L (0-10 mg/L); 0.1 mg/L (10-60 mg/L)
Response Time 95% of reading in 17 seconds for 2.0 mil PE membrane;
95% of reading in 36 seconds for 2.0 mil Teon membrane.
Allow approximately 10-15 minutes aer 5200A is powered
on, or the DO sensor is serviced, for the polarographic sensor
to stabilize.
Introduction
Flow requirements minimum ow rate of 3 inches per second or 7.62 cm/second
for 2.0 mil PE membrane; 6 inches per second or 15.24 cm/
second for 2.0 mil Teon membrane
Other Automatic salinity compensation for DO readings when a
conductivity sensor is in use and enabled. Manual salinity
compensation for DO readings when a conductivity sensor is
not in use.
pH
Range 0.00 to 14.00 pH
Accuracy ± 0.1 pH
Resolution 0.01 pH
ORP
Range -2000 mV to +2000 mV
Accuracy ± 20 mV
Resolution 1 mV
Conductivity
Sensor type 4 electrode, Cell constant of 5.0 ±5%
Ranges* 0 to 200 S
0 to 2000 S
0 to 20 mS
0 to 200 mS
Accuracy 0 S to 100 mS, ±0.5% of range
100 mS to 200 mS, ± 1.0% of reading
Resolution range dependent
0.1 S (0 to 200 S)
1.0 S (0 to 2000 S)
0.01 mS (0 to 20 mS)
0.1 mS (0 to 200 mS)
Salinity
Parameter Source 1) calculated from temperature & conductivity systems when
enabled
OR
2) user ppt input in DO sensor setup menu
Range 0-80 ppt
Note: When not using a conductivity sensor, the manual
input range is 0-50 ppt.
Introduction

YSI 5200A
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YSI 5200A
16
Accuracy ± 2% or ± 0.1 ppt
Resolution 0.1 ppt
*Conductivity auto ranges based on the measured value.
Component and System (Non Input) Specications
Hardware
System System Feature Specication
Display/LEDs back-lit graphic LCD
(320X240) with timer
readings updated 2 times per
second
diagnostic troubleshooting
LEDs
Outputs 4 on-board relays 240VAC@ 5AMPs switching
capacity; 110VAC@10AMPS;
type: SPDT
Timer Systems 4 timers 10 daily events per timer system
1 feed timer includes sensor & FCR control
Power: ere are two 5200A versions available. e DC version can only be pow-
ered by DC power. e AC version can be powered by AC or DC power.
Power for DC
Version:
external 12VDC power
source
9-16.5VDC; 800 mA
Power for AC
Version:
internal AC switching power
supply
100-240VAC; 50-60Hz; 300 mA
Both AC and
DC versions:
lithium battery (for real time
clock)
2032 lithium ion
Electronics ARM7 embedded micropro-
cessor
DSP (digital signal process-
ing)
Digital processing of 5200A
information ensures accurate
and repeatable readings.
Introduction
Firmware
Feature Specication
Flash Memory Firmware eld upgradable with
local PC connection
Data Logging non-volatile data log memory
storage of 3750 records
sensor log (1000 records)
event log (1250 records)
calibration log (500 records)
Congurationlog data (1000
records)
Security password protection
Data ltering reads 2-3 times per second and
readings are averaged
Communication
Feature Specication
RS232 up to 100  (30m)
OR Optional ethernet module remote TCP/IP PC access and/
or email alarming
Instrument to Instrument Networking
Feature Specication
Network 2 to 32 isolated
5200A and/or 5400 instru-
ments
RS485 up to 4000  (1220m)
entire network distance
AquaManager
Feature Other PC Requirements
Runs on Windows 2000/XP/
Vista/Windows 7 operating
systems 32-bit and 64-bit
PC capable of running Windows
2000
VGA display card
CD-ROM Drive
Total RAM Installed: 16MB or
greater
100 MB free hard-disk space
Introduction

YSI 5200A
18
is page le intentionally blank.
2 Safety
-IMPORTANT safety information.
Read this chapter before installing 5200A components and
peripheral devices.

YSI 5200A
21
YSI 5200A
20
THIS IS IMPORTANT
Take time to be safe when working on electrical circuits and equipment. It could
save your life. Avoid unsafe acts and conditions. Do not operate or install the 5200A
before reading this chapter. Installing the 5200A involves wiring high voltage equip-
ment. Follow all provided safety information. Installation must be performed by
someone who understands the dangers of, and is qualied to, wire electrical devices.
If information or instructions are not clear, DO NOT PROCEED until clarication
can be obtained.
ALWAYS:
Follow basic safety rules when working with or near high voltage circuits. e
5200A is a high voltage instrument using 110v. Peripheral devices may also be
high voltage devices.
Consider the result of each act. Keep away from live circuits. Do not change
parts or make adjustments inside the equipment with high voltages on.
Do not service alone.
Do not tamper with interlocks. Safety devices such as interlocks, overload re-
lays, and fuses should never be altered or disconnected except for replacement.
Safety protection devices should never be changed or modied without a clear
understanding of what eect the modication will have on the system.
Do not ground yourself.
Do not energize equipment if there is any evidence of water leakage.
Warnings and Cautions
Safety information is presented in this manual in one of two ways:
- WARNING - RISK OF ELECTRIC SHOCK is symbol identies
installation and operation procedures that can result in personal injury
or death if safety information is not followed.
- AVERTISSEMENT – RISQUE DE CHOC ÉLECTRIQUE. Ce symbole
identie les procédures d’installation et d’opération pouvant entraîner
des blessures ou la mort si les consignes de sécurité ne sont pas suivies.
Safety
- CAUTION - RISK OF DANGER is symbol identies installation
and operation procedures that can result in personal injury or damage
to equipment if safety information is not followed.
ese symbols ( ) ( ) appear in the le margin of the page to highlight
safety information as it applies to a particular installation or operation step.
A complete list of all safety cautions is provided below. All warnings are provided
in English and French.
Install and use the 5200A only in accordance with information documented in this
manual.
Warnings
WARNINGS are used when personal injury or death can result if safety informa-
tion is not followed.
WARNING: All wiring that involves connections to mains power must be
performed by a qualied licensed electrician, and must conform to all locally
applicable electrical codes.
AVERTISSEMENT: tous les câblages comportant une connexion à l’alimentation
secteur doivent être réalisés par un électricien qualié et doivent être conformes
aux codes électriques applicables.
WARNING: Do not make connections while power is applied. Turn o power and
assure power “Lockout” before installing or servicing to avoid contact with electri-
cally powered circuits. is includes working on devices connected to the relay
outputs and auxiliary input systems. Disconnect external power to the 5200A
before connecting or disconnecting components and/or peripheral devices.
AVERTISSEMENT: n’eectuez aucune connexion alors que le circuit est sous
tension. Coupez l’alimentation et assurez l’interdiction du courant avant toute
installation ou tâche d’entretien an d’éviter d’entrer en contact avec des circuits
sous tension. Cela comprend tout travail sur des appareils connectés à des sorties
de relais et des systèmes d’entrée auxiliaires. Déconnectez l’alimentation externe
du modèle 5200A avant de connecter ou de déconnecter des composants et/
ou des appareils périphériques.
Safety

YSI 5200A
23
YSI 5200A
22
WARNING: A switch or circuit breaker shall be included in the building where
the 5200A is installed. e disconnecting device should be in close proximity to
the equipment and within easy reach of the operator. e disconnecting device
shall be marked for the equipment.
AVERTISSEMENT: un commutateur ou disjoncteur doit être installé dans le
bâtiment où le modèle 5200A est installé. Le dispositif de déconnexion doit se
trouver à proximité de l’équipement et à portée de l’opérateur. Le dispositif de
déconnexion doit indiquer l’équipement auquel il se rapporte.
WARNING: e covers of fuse boxes and junction boxes should be kept securely
closed except when servicing.
AVERTISSEMENT: le couvercle des boîtes à fusibles et des boîtes de dérivation
doit être maintenu fermé sauf lors des tâches d’entretien
WARNING: Electric sparks and chemical exposure are potential dangers when
working with batteries. Use necessary precautions and follow all manufacturer’s
directions.
AVERTISSEMENT: l’exposition à des étincelles ou produits chimiques est un
danger potentiel inhérent à tout travail sur des batteries. Observez les précautions
nécessaires et suivez les consignes du fabricant.
WARNING: Ground the 5200A. See Ground 5200A - page 41. e sensitivity
and stability of the 5200A will be impaired if the 5200A is not grounded. To avoid
possible electrical shock or damage to the equipment, connect earth ground to
the 5200A I/O board. In addition to grounding the 5200A, all tanks should be
electrically grounded using a ground probe.
AVERTISSEMENT: mettez le modèle 5200A à la terre. Voir Mise à la terre du
modèle 5200A. La sensibilité et la stabilité du modèle 5200A seront aectées
s’il n’est pas mis à la terre. Pour éviter toute possibilité de choc électrique ou
d’endommagement de l’équipement, connectez le l de terre à la carte d’E/S du
modèle 5200A. En plus de la mise à la terre du modèle 5200A, tous les réservoirs
doivent être mis à la terre.
WARNING: Do not overload relays. Verify that the surge current at startup
does not exceed the relay load ratings. Be familiar with all safety information
regarding installing and servicing peripheral devices.
Safety
AVERTISSEMENT: ne surchargez pas les relais. Vériez que la surtension de
démarrage ne dépasse pas la capacité de charge nominale du relais. Prenez con-
naissance de toutes les consignes de sécurité concernant l’installation et l’entretien
des appareils périphériques
WARNING: e 5200A is not fused. Fuses used in any peripheral equipment
should be removed and replaced only aer the circuit has been de-energized.
When a fuse blows, it should be replaced only with a fuse of the same current and
voltage ratings. Circuits should be carefully checked before fuse replacement. A
burned out fuse is oen the result of circuit fault.
AVERTISSEMENT: le modèle 5200A ne contient pas de fusible. Les fusibles
utilisés par les équipements périphériques doivent être retirés et remplacés
uniquement après que le circuit a été mis hors tension. Lorsqu’un fusible est
grillé, il doit être remplacé uniquement par un fusible d’une tension et d’un
ampérage nominaux identiques. Les circuits doivent être soigneusement vériés
avant le remplacement d’un fusible. Un fusible grillé est souvent le résultat d’une
défaillance de circuit
WARNING: Do not apply power to the 5200A until all electrical connections
are veried and secured.
AVERTISSEMENT: ne mettez pas le modèle 5200A sous tension tant que les
connexions électriques n’ont pas été vériées et sécurisées.
Cautions
CAUTIONS are used when personal injury or damage to equipment can result if
safety information is not followed.
CAUTION: e 5200A utilizes sensitive solid state devices that can be damaged
by static shock. Installers must observe accepted ESD (Electro-Static Discharge)
procedures while connecting wires to the 5200A control board.
CAUTION: Sensors are powered by the 5200A instrument and use a “oating”
ground reference. is requires that the probe not be individually grounded.
CAUTION: Power supply voltage above 16.5 VDC may permanently damage
the 5200A. See Wire DC Power - page 45.
Safety

YSI 5200A
24
3 Installation & Wiring
-Installing & wiring 5200A, components, and peripheral
devices.
CAUTION: Surge protectors are strongly recommended to protect from second-
ary surges and lightning. Surge suppression devices should be located on the AC
line supplying power to the 5200A and any signal lines connecting the 5200A.
See Lightning and Surge Protection - page 61.
CAUTION: It is essential that all low voltage wiring, including sensor wiring be
run in a separate cable or conduit from high voltage wiring.
Health and Safety (Calibration Solutions)
Calibration Solutions
CAUTION: Reagents used to calibrate and check this instrument may be haz-
ardous to your health. Some calibration solutions may require special handling.
Refer to the Material Safety Data Sheet (MSDS) of the reagent being used for
product specic safety information. MSDSs can be obtained from the company
who supplied or manufactured the reagent.
Safety

YSI 5200A
27
YSI 5200A
26
Hardware Installation
Correctly install 5200A system components and peripheral devices to ensure accu-
rate data collection and reliable operation. First, determine what monitor, control,
and alarm functions the 5200A system will perform. Because system components
are wired to the 5200A instrument, it is important to determine where and how
components will be installed and congured. Preparing a system schematic (gure
3.1) is helpful.
Figure 3.1
Hardware installation steps (not all steps required for all applications):
Step 1 - install 5200A instrument
Step 2 - locate and install probe/cable assembly
Step 3 - ground 5200A
Step 4 - wire power
Step 5 - wire relays (output devices)
Step 6 - wire aux inputs
Step 7 - wire a network of 2 - 32 instruments
Step 8 - install and wire communication equipment
Step 9 - connect probe assembly
Step 10 - install and wire IOEM and REM instruments (optional). IOEM/REM
Installation information is included in a separate manual. See IOEM/REM
Installation and Safety Guide.
Installation and Wiring
See Chapter 4 “Conguring 5200A Systems” starting on page 66 for directions on
programming 5200A instruments.
Tools and supplies needed for hardware installation:
•Phillips-head screwdriver to remove 5200A front panel to access I/O board
and lower board assembly
•necessary tools for cutting mounting holes in mounting brackets (rail
mount) and/or control panel (panel mount)
•5/32” Allen wrench (panel mount only)
•electric drill and bits for mounting 5200A (panel or rail) and for drilling
rubber grommets in bulkhead ttings
•small at-head screwdriver to terminate wires on the I/O board’s plug-
gable terminal strips
•wrench to tighten the bulkhead ttings following system component wiring
•tweezers to replace gasket in YSI 5561 probe
•wire strippers
•distilled water for mixing DO membrane electrolyte solution
•contactors may be required for relay wiring; see contactor wiring - page 48
Optional accessories for hardware installation:
•surface mount hardware (included)
•rail mount hardware
•panel mount hardware
•weather shield hardware
•serial to ethernet device
•wiring for network wiring
•wiring not supplied with components and/or peripheral devices
Step 1 Install 5200A
Select a mounting location and method to mount the 5200A.
Location Considerations
e 5200A must be located:
•above any level where water damage can occur
•away from extremely high or low temperature sources
•away from vibrating surfaces
•at least two (2) feet (.7 m) from any high voltage conduit
•away from electromagnetic, radio, AC motor, transformer, or antennas
•so the front panel can be fully opened and serviced
•so system component wires are run as specied in this manual and ac-
cording to all local applicable electrical codes
Installation and Wiring

YSI 5200A
29
YSI 5200A
28
Mount the 5200A
Select surface, rail, or panel mount option. Install the weather shield for outdoor
installations.
Surface Mount
Mount 5200A to any at surface using mounting brackets. Mounting brackets and
screws are included with the 5200A.
1. Fasten the mounting brackets to the back of the 5200A with the mounting
screws - gure 3.2.
2. Tighten the screws, securing the brackets to the back of the 5200A en-
closure.
3. Fasten the 5200A mounting brackets to the mounting surface with the
mounting screws provided - gure 3.2. Make sure screws adequately
secure 5200A to surface.
4. Tighten the screws, securing the 5200A to the surface.
Figure 3.2
Rail Mount
Mount 5200A to handrail or pipe 1 to 1.5” (2.5 to 3.8cm) in diameter. e rail
Installation and Wiring
mount kit (YSI model number 6509) includes u-bolts, a pre-drilled metal plate,
washers, and nuts.
1. Drill holes in the mounting brackets to t the u-bolts. Use the pre-drilled
metal plate as a template.
2. Fasten the mounting brackets to the back of the 5200A with the mounting
screws as shown in gure 3.2.
3. Tighten the screws, securing the brackets to the 5200A.
4. Place the u-bolts around the rail securing the 5200A to the pipe or rail by
feeding through the pre-drilled holes on the mounting brackets as shown
in gure 3.3.
5. Secure the metal plate over the u-bolts and around the rail or pipe using
washers and nuts provided.
6. Tighten the screws, securing the 5200A to the rail.
Figure 3.3
Panel Mount
Panel mount the 5200A if the 5200A’s front panel is to be mounted on a control panel
or any vertical surface where only the front panel will be accessible from the mount-
ing surface. e panel mount kit (YSI model number 6510) includes the standos
and frame necessary to mount the 5200A to any panel 9.5” l x 7.5” w (~24x19cm).
e space behind the panel must be at least 5.5” (14cm) deep.
WARNING: Disconnect external power to the unit before opening front panel.
Installation and Wiring

YSI 5200A
31
YSI 5200A
30
AVERTISSEMENT: déconnectez l’alimentation externe de l’unité avant d’ouvrir
le panneau avant.
1. See Open Front Panel to Access I/O Board - page 39 to remove front
panel from 5200A enclosure.
Figure 3.4
2. Disconnect front panel ribbon cable by pressing the two IDC header
connectors located on the front panel out (away from the IDC header)
- gure 3.5.
Installation and Wiring
Figure 3.5
3. Remove and retain the four screws that secure the display board into front
panel enclosure - gure 3.6. (e display board is mounted on panel that
is attached to 5200A front panel. e I/O Board wiring diagram is located
on the display board panel.)
gure 3.6
4. Carefully li out the display board and remove the lanyard from the display
board panel - gure 3.7. Set display board panel and front panel aside.
Installation and Wiring

YSI 5200A
33
YSI 5200A
32
Figure 3.7
5. Fasten the mounting brackets to the back of the 5200A enclosure with the
mounting screws - gure 3.2, page 28.
6. Tighten the screws, securing the brackets to the 5200A.
7. Drill a hole in the panel for 5200A enclosure (dimensions provided with
kit).
8. Place standos between 5200A mounting brackets and panel surface -
gure 3.8.
9. Secure 5200A to panel with frame using washers and bolts provided.
Figure 3.8
Installation and Wiring
10. Reattach lanyard by placing lanyard at proper location of display board
panel. Make sure lanyard is fully seated on display panel boss to ensure
proper clearance when front panel is closed - gure 3.7.
11. Replace four screws to reattach display board panel to front panel enclo-
sure - gure 3.6.
12. Connect 5200A display board to ribbon cable -gure 3.5.
13. Secure the 5200A front panel to the frame using mounting screws. Follow
procedures provided at Close Front Panel - page 40 to secure 5200A and
protect internal electronics.
14. Tighten the screws, securing the 5200A to the panel.
Install the Weather Shield
Install the weather shield for outdoor installations. e weather shield can be used
with either a surface or a rail mount. e weather shield kit (model number 6505)
includes a weather shield, u-bolts, pre-drilled metal plate, washers, and nuts.
1. First complete steps 1-2 under Surface Mount or steps 1-3 under Rail
Mount depending on the type of installation. Note: You may need to
modify the pre-drilled holes in the weather shield depending on the
mounting location.
2. At step 3 (surface mount) or step 4 (rail mount), attach the weather shield
to the surface or rail with the metal plate installed to secure the weather
shield to the surface or rail. Figure 3.9 shows the weather shield installed
for a rail mounted 5200A.
3. Tighten the screws, securing the weather shield.
Figure 3.9
Installation and Wiring

YSI 5200A
35
YSI 5200A
34
Step 2 Locate and Install Probe/Cable Assembly
Use a YSI probe /cable assembly 5561 (with DO and temperature sensors) or a YSI
5562 (with DO, temperature, conductivity, pH, and ORP sensors) on the 5200A.
See Chapter 4 “Conguration”, beginning on page 66, for directions on congur-
ing the 5200A sensor systems. User dened sensor conguration options include:
- Display Formats (i.e. units of measure. For example, mg/L or % saturation,
°C or °F)
- Set point, Control, and Alarm values and ranges
- Control and Alarm relay enabling
Aer selecting a probe/cable assembly and installing the sensors on the cable, see
Connect Probe Assembly - page 60.
Location Considerations
Measurements taken at the probe location are data logged and processed by the
5200A instrument. Output control and alarm devices are congured to respond
to these measurements. erefore, it is essential to have accurate measurements
at the sensors’ location. Locate the sensors of the probe assembly according to the
following specications.
Place the sensor end of the probe assembly:
•in a location that represents the entire system
•where the water ow is at least 3 inches per second (7.6 cm/sec) if using
the 2.0 mil PE membrane or at least 6 inches per second (15.24 cm/sec)
for 2.0 mil Teon membrane
•in a location that is free from debris (e.g. algae); ideally at a 45˚ angle from
vertical position and directed with the ow - gure 3.10
Installation and Wiring
Figure 3.10
•in a well mixed, free-owing area; midstream and mid-depth typically gives
representative readings; the probe assembly and cable are fully submersible
up to the cable connector
•submersed at all times so liquid level uctuations do not expose the sen-
sors to the atmosphere
•so probe cabling is not routed near rotating machinery and/or equipment
involving electrical switching or regulation
•so that the probe assembly and cabling are located away from sources of
electrical interference such as UV sterilizers, orescent lighting, ballasts,
pumps, any high voltage peripheral devices, etc.
CAUTION: run high and low voltage cabling through separate bulkhead tting
and conduit
•where regular maintenance, including calibration can easily be done.
Calibrations are performed using the 5200A front panel.
Note:
- All YSI sensors, except the temperature sensor on the 5561 cable, are eld re-
placeable. Individual sensors can be ordered and replaced by the user without
returning the probe/cable assembly to the factory.
YSI 5561 Probe Assembly
e YSI 5561 probe assembly includes a DO and temperature sensor. e DO sensor
is shipped with a dry membrane. A new membrane with fresh electrolyte must be
installed on the DO sensor prior to use. Complete instructions are provided with
the sensor and membrane kits.
Installation and Wiring

YSI 5200A
37
YSI 5200A
36
Notes:
- Replace the dry, shipping cap membrane with a 2 mil PE (blue) membrane
or 2.0 mil Teon (gray) membrane following the instructions provided with
the membrane kit.
- Do not discard the calibration/storage cup. It is used for calibrating and stor-
ing the sensor when not in use.
- Allow approximately 10 to 15 minutes aer the 5200A is powered on, or aer
servicing the DO sensor, for the polarographic sensor to stabilize.
Figure 3.11 shows the external parts of the YSI 5561 probe assembly.
Figure 3.11
YSI 5562 Probe Assembly
e YSI 5562 probe assembly includes DO, temperature, conductivity, pH, and ORP
sensors. 5200A sensor systems are user selectable. e DO sensor is shipped unin-
stalled and with a dry membrane. Install the DO sensor onto the probe assembly.
Instructions are provided with the probe assembly. A new membrane with fresh
electrolyte must be installed on the DO sensor prior to use.
Notes:
- Replace the dry, shipping cap membrane with a 2 mil PE (blue) membrane
or 2.0 mil Teon (gray) membrane following the instructions provided with
the membrane kit.
- Do not discard the calibration/storage cup. It is used for calibrating and stor-
ing the sensors when not in use.
- Allow approximately 10 to 15 minutes aer the 5200A is powered, or aer
servicing the DO sensor, for the polarographic DO sensor to stabilize.
Installation and Wiring
Figure 3.12 shows the external parts of the YSI 5562 probe assembly.
Figure 3.12
Wiring Information
System components must be wired correctly to ensure reliable performance and
accurate data collection. Directions are provided in this section for wiring all com-
ponents and peripheral devices.
PCBs
ere are three printed circuit boards (PCBs) inside the 5200A enclosure. ey are:
-Display board (mounted in the front panel)
-I/O board is attached to a metal plate inside the enclosure and is visible when front
panel is removed
-Control board (connected to the under side of the I/O board)
Notes:
- I/O and Control boards are attached to a metal plate and are referred to as the
“lower board assembly”. See Control Board - page 41.
- No 5200A components or peripheral devices are wired to the display board.
Most components including: power, Aux input, network, relay output, and RS232
communication components are terminated on the I/O board. 5X00 ground wire
and sensor ground wires (also called drain wires) are terminated to the metal plate
that is attached to the lower board assembly. e optional serial to ethernet device is
installed on the control board. e front panel must be removed when wiring 5200A
components and peripheral devices (except for the probe assembly). See Accessing
the I/O Board - page 39. It is recommended that some system conguration and
Installation and Wiring

YSI 5200A
39
YSI 5200A
38
testing be done in conjunction with hardware installation. is will ensure that
the 5200A system is wired correctly. Necessary conguration information (from
Chapter 4 - “Conguration”) is referenced in the applicable test system procedures.
WARNING: Follow all safety information and local electrical codes when wiring
5200A system components and peripheral devices. Proper wire gauge should
be determined based on voltages and wire/cable length. Incorrect wiring can
result in damage to you or to the equipment. Improper wiring can also result
in ground loops.
AVERTISSEMENT: suivez toutes les consignes de sécurité et les codes électriques
en vigueur lors du câblage des composants du système 5200A et des appareils
périphériques. Le calibre correct des câbles doit être déterminé en fonction des
tensions et de la longueur des câbles/ls. Un câblage incorrect peut entraîner
des blessures et endommager l’équipement. Un câblage incorrect peut également
entraîner des boucles de mise à la terre.
5200A Bulkhead Fittings
ree bulkhead ttings [2@ 3/4” (1.905cm) and 1@ 3/8” (.9525cm)] located at the
bottom of the 5200A enclosure provide watertight entry points for 5200A system
wiring. e probe/cable assembly connector is located below the bulkhead ttings
- gure 3.13. Rubber grommets must be “pushed out” of the compression tting
housing and drilled for wiring installation. e drill bit diameter should be slightly
smaller than the wire diameter so that a watertight seal can be made. Rubber
grommets can be frozen (put in a freezer for 1 hour) and then easily drilled to the
required diameter. Some pre-drilled rubber grommets are supplied with the 5200A.
Figure 3.13
Installation and Wiring
Accessing the I/O Board
e I/O board is accessible when the 5200A front panel is removed. e letters
on the metal plate, which is attached to the lower board assembly, identify ground
wire termination locations and pluggable terminal strip locations on the I/O board.
Letters on the metal plate correspond to the wiring diagram located on the inside of
the front panel - gure 3.14. A ribbon cable connects the display board (mounted
in the front panel) to the I/O board. When the 5200A front panel is removed, a
lanyard protects against stress on the ribbon cable. See Open Front Panel to Access
I/O Board - page 40.
Figure 3.14
Installation and Wiring