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DSP4000 User Manual Rusty update 21Jan2012

1. D Modbus Option 99 Table D 5 Supported Modbus Commands Continued Function Sub Function Name Code 0x Name Code 0x PRESSURE 46 PRESS_SOURCE 00 80 PRESS_VALUE 01 81 AGC 47 AGC O1 RAGC 02 OUTPUT_4_20mA 48 FOUR_20mA_STATE 00 80 FULL_SCALE 01 81 SET_TEST 82 CALIBRATE 65 GET_CALIB_STATE 00 SET_1_POINT_HIGH 81 SET_2_POINT_ZERO 82 SET_2_POINT_HIGH 83 RESTORE_DEFAULTS 84 GET_DISPLAY_CAL 05 SEN_LOT_DISP 06 GET_MEASUREMENT 67 CH1 00 CH2 01 CH3 02 CH4 03 PROGDSP 68 00 D 5 LRC Calculator The Modbus option includes an executable that calculates the required LRC converts data values to their correct hexadecimal representation and composes the command To structure a Modbus command to the DSP4000 1 Double click LRC Calculation exe to open the LRC Calculation dialog box Figure D 2 DSP4000 Optical Process Monitor User Manual 80 04001 06 10 D Modbus Option ZciRcCakulation ae re Address hex Function Code hex SubFunction Code hex Data Integer C Float C Date C Time MM DD YYYY hh min sec Calculate LRC Clear LRC Command Figure D 2 LRC Calculation Dialog Box 2 Enter 3E in the Address field and specify the function code and sub function code in their respective fields 3 Enter values as necessary in the fields provided for Data Date or Time The Data Date and Time options are mutually exclu
2. Table 6 1 Troubleshooting the DSP4000 Continued Symptom Explanation of Problem Action The DSP4000 Inaccurate measurements 1 Verify that the DSP4000 is produces can occur for any of the relying on accurate temperature inaccurate following reasons and pressure readings to measurements e The DSP4000 is properly compensate for effects receiving inaccurate of temperature and pressure readings for 2 Refer to Calibration on temperature or pressure page 69 compensation 3 Restore default calibration e Incorrect calibration factors and then perform a factors have been used one point calibration e Calibration has not been performed properly The measurements The greatest sources of drift 1 Allow the DSP4000 to operate at drift are instrument warm up least 30 minutes after power and in the case of up measuring pH or dissolved 2 The DSP4000 should be left Oz an insufficiently under power when not in use to hydrated sensing maintain the internal membrane temperature The DSP4000 performs best 3 If a pH or dissolved O sensor when allowed to operate for has been stored dry the sensor two hours should be hydrated in the solution for at least 30 minutes before you take measurements or perform a calibration 4 Agitate the solution when measuring a parameter in liquid phase The DSP4000 is The cable may be bent or 1 Check the fiber optic cable for reporting a high crimped reducing the bending
3. Loading the appropriate sensor calibration and configuration data for each channel is critical for the operation of the DSP4000 Verify that the lot numbers in the configuration table match those for the sensors to be connected to the different channels If one of the channels has the wrong lot number you can download the correct calibration file from the Polestar web site as described in the next section and then update the configuration file on the PC and on the USB KEY 5 Click to close the configuration table 3 3 Retrieving Configuration Files from the Polestar Web Site Whenever you change a sensor element on a probe add a different sensor to the DSP4000 or move a probe to a different channel you must ensure that the DSP4000 configuration file on the USB KEY is updated accordingly The first step is to download the calibration file from the Support area at the Polestar Technologies web site In order to download the correct calibration file you need to know the Polestar lot number of the sensing element that you will be using This lot number is contained in the documents shipped with the sensing element The general form of a lot number is 123 456 789 To retrieve a calibration file 1 Go to the Support area at the Polestar Technologies web site http www PolestarTech com support If this is your first visit to the Support area do the following to register with the site e Click Register in the lower left
4. on page 24 In the example in Figure 4 9 the scale for the pH sensor in channel 2 is 5 4 to 10 1 Factors 2 and 3 and the high end of the scale for the CO sensor in channel 3 is 60 Factor 1 ad DSP Channel Configuration _ oo File Channel Lot Parameter Factor 1 Factor 2 Factor 3 1 251 006 041 02 ppm Po 66 9 Ksv 0 7 82E 3 2 269 003 112 pH pKa 7 30 pHlo 5 4 pH hi 10 1 3 272 001 064 C02 CO2 Max 60 0 4 262 003 025 pH pKa 5 02 pH lo 3 5 pH hi 7 0 Double click Lot cell then click grey button in cell to configure Channel Figure 4 9 Scaling Values in the Calibration File You can program the DSP4000 to use less than the full range for an O3 or CO measurement output For example you can set the upper limit for an O sensor output so that 20 mA equals 40 The range for pH measurement outputs is fixed Refer to Configuring the 4 20 mA Data Outputs on page 64 for instructions on enabling the output adjusting the full scale range and testing the connection DSP4000 Optical Process Monitor User Manual 80 04001 06 42 4 Electrical Connections 4 7 Configuring the RS 232 Interface The DSP4000 supports an RS 232 serial interface to a PC so that you can acquire measurement data in real time using a terminal program such as Microsoft Hyper Terminal and save the data for analysis in a spreadsheet or other PC application Each measurement record i
5. 5 DSP4000 Setup Current Setting Manual Input mmHg To change lt ENTER gt Manual Input mmHg Manual Input PSI 4 20 Input mmHg 4 20 Input PSIG Figure 5 15 Configuring the Source for Pressure Compensation 2 Select one of the manual input options and press ENTER to show the currently specified input Figure 5 15 left Pressure Manual Input 760 mmHg Pressure Manual Input 800 mmHg Figure 5 16 Specifying the Pressure Value for Manual Input 3 Press the up or down arrow to increase or decrease the setting one unit at a time or hold down the key to rapidly change the value 4 Press ENTER to accept the displayed value and return to the Setup menu 5 7 2 Configuring 4 20 mA Pressure Inputs Input from a 4 20 mA pressure sensor can be made in units of mmHg or PSIG NOTE PSIG or gauge pressure is always relative to atmospheric pressure When you are configuring a device whose output is PSIG the DSP4000 will prompt you to enter the barometric pressure so that it can determine the absolute pressure barometric pressure plus gauge pressure that will be used in adjusting the channel measurement The pressure value in the DSP4000 output is absolute pressure PSIA NOTE If the output of the pressure gauge is absolute pressure PSIA or often PSI select 4 20 Input PSIG for the input method and enter O when prompted to specify barometric pressure Bar Press i
6. ABP_ERR_INV_CMD_EXT_1 The enumeration string value is out of range ABP_ERR_OUT_OF_RANGE Returned for any of the following e Checksum mismatch of calibration file read instances e Password mismatch e Data is out of range e Unit value is not supported by the channel parameter e Attempt to select channel without User login if SecureLevel 1 e Attempt to select channel without Admin login if SecureLevel 2 ABP_ERR_INV_STATE Returned for any of the following e The DSP4000 is not in Setup mode e Attempt to modify user admin password or to set get Securelevel before Admin login success e Attempt to access channel information before selecting the channel e USB is not present when restore default command is given DSP4000 Optical Process Monitor User Manual 80 04001 06 B DSP4000 Error Messages 89 B 4 Profibus Error Codes Table B 3 lists error codes specific to Profibus Table B 3 Profibus Error Codes Code Description 0x03 Unsupported object 0x04 Unsupported instance 0x05 Unsupported command 0x06 Invalid CmdExt 0 0x07 Invalid CmdExt 1 0x08 Attribute access is not set able 0x09 Attribute access is not get able 0x0A Too much data in message data field 0x0B Not enough data in message data field 0x0C Out of range 0x0D Invalid state B 5 DeviceNet Error Messages Table B 4 lists error message specific to DeviceNet Table B 4 Dev
7. DSP4000 Optical Process Monitor User Manual 80 04001 06 User Login Security Level 1 Admin Login and Admin Menu Security Level 0 1 or 2 Run Mode Setup Mode Save Log File Turn Off DSP Run Mode Setup Mode Save Log File Turn Off DSP User Login Admin Login Enter PW 0000 Enter PW 1234 I User Login Admin Login I Enter PW 0000 I Enter PW 5678 Channel 1 Channel 2 Channel 3 Set Date Time Read Calib Modify Admin PW Modify User PW gt Enter PW m 0000 H Enter PW 3311 Channel 1 Channel 2 Channel 3 Channel 4 Set Date Time Read Calib 0 Current Level Current Level 2 Figure A 4 User and Admin Logins 87 Appendix B DSP4000 Error Messages B 1 Error Messages Shown on the DSP4000 Front Panel USB Key The DSP4000 front panel displays USB EEPROM Read Error when the DSP4000 cannot read the USB KEY or cannot access the system s read only memory EEPROM e Verify that the USB KEY is properly seated in the USB port in the DSP4000 e Contact Polestar Support if the problem persists Timing The DSP4000 displays Aggregate freq gt 1Hz Readjust or disable some channels Press any key if you specify a timing interval that is below the minimum given the number of channels in use See Timing on page 58 for details B 2 Modbus Exception
8. Figure 2 1 DSP4000 Armored Fiber Optic Cable BioProbe and Optional AC Adapter with Power Cord DSP4000 Optical Process Monitor User Manual 80 04001 06 8 2 Getting Started The bottom panel when the DSP4000 is mounted to a vertical surface includes two rows of water tight connections Figure 2 2 e The front row consists of four cord grips used for feeding wiring into the enclosure to connectors on the I O board for power analog input for temperature and pressure compensation analog measurement output and the RS 232 serial connection to a PC e The back row provides four water tight connections referred to as glands for fiber optic cables from the Polestar sensors Channel 1 is the right most gland connection Cord grips for wires and I O cables wy ee _ Gland connectors for fiber optic cables Cable for optional power adapter Figure 2 2 Cord Grips and Glands on the Bottom Panel Do the following 1 Loosen the two screws on the right side of the front panel cover and open the DSP4000 enclosure 2 Locate the power ON OFF switch in the upper right corner of the top circuit board the I O board and make sure that the switch is in the OFF position Figure 2 3 S peseeueusees ros fist TKM TRM TKM 2F MOE ERIK EREMES YY f 4 20 mA Inputs f Temperature Pressure 4 20 mA Outputs t Cable for optional power adapter Figure 2 3 DSP4000 I O Board DSP400
9. Terminal positions 21 through 28 are used for applying a 4 20 mA pressure input for each DSP4000 channel The terminals are marked as shown in Table 4 3 Table 4 3 Terminal Labels for 4 20 mA Pressure Input Channel Terminal Label Channel 1 PRESS1 4 20 IN 21 PRESS1 4 20 IN 22 Channel 2 PRESS2 4 20 IN 23 PRESS2 4 20 IN 24 Channel 3 PRESS3 4 20 IN 25 PRESS3 4 20 IN 26 Channel 4 PRESS4 4 20 IN 27 PRESS4 4 20 IN 28 The pressure input 4 20 mA loops must be powered by the devices themselves or a DC power source in the range of 15 to 28 Volts If the pressure gauge is not self powered e Connect the loop to a third party DC power source or e Tap the DSP4000 power in terminals in the upper left of the DSP4000 I O board To tap the power in terminals e Connect to 24VDC 1 e Connect to GND 2 DSP4000 Optical Process Monitor User Manual 80 04001 06 38 4 Electrical Connections To wire pressure input from a self powered device as shown for Channel 1 in Figure 4 6 1 Connect TEMPn 4 20 IN to on the pressure gauge 2 Connect TEMPn 4 20 IN to on the pressure gauge To wire a pressure input for a single channel using an external power supply as shown for channel 4 in Figure 4 6 1 Connect PRESSn 4 20 IN to on the pressure gauge 2 Connect PRESSn 4 20 IN to on the power source 3 Comp
10. e Access the Calibration menu select Restore Defaults and press ENTER e Check the connections for the sensor and for the temperature and pressure sensors DSP4000 Optical Process Monitor User Manual 80 04001 06 5 DSP4000 Setup 73 e Perform the one point calibration 5 10 4 Two Point Calibration The procedure for two point calibration is the same as one point calibration except that a second sample is measured this time with zero level For O2 and CO2 the zero point is measured under a condition in which no O2 or CO2 is present In the case of a zero point for pH a pH below the range of the sensor is required Therefore for the pH 5 5 10 sensor the zero point is pH 4 The DSP4000 is preset to calibrate at pH 4 for the zero point a pH 4 buffer is therefore required for the pH two calibration To perform a two point calibration of O2or CO2 1 Position the sensor to measure the first span gas or buffer NOTE For measurements in liquid a dry sensor element should be submerged in the sample for 20 minutes before starting the calibration and the solution should be gently agitated during the measurement 2 Select Calibration in the Setup menu and press ENTER to show the Calibration menu 3 Select Two Point Cal and press ENTER to display the default value for the first sample Figure 5 30 left 4 Adjust the value if necessary and then press ENTER The latest Operating System allows c
11. You may see the error message Aggregate freq gt 1Hz Readjust or disable some channels Press any key indicating that a specified timing interval is below the minimum given the number of channels in use 5 5 Data Smoothing 1 The user can reduce the variability of the displayed measurements by using the Data Smoothing function In the Setup Menu scroll to Data Smooth and press ENTER Insert Screen Shot here Use the Up and Down keys to change the number of readings to be used in the rolling average The rolling average can be composed of up to 9 readings Press ENTER to save the selection and return to the Run Mode It may take several readings to establish a new accurate reading depending upon the number of readings in rolling average DSP4000 Optical Process Monitor User Manual 80 04001 06 58 5 DSP4000 Setup 5 6 Configure Temperature Temperature input is required to compensate for the effect of temperature on the gas permeability of O and CO sensing membranes Temperature compensation is not used with pH sensors Options for temperature input include e Manual input of a temperature constant e 4 20 mA temperature sensor See Connecting 4 20 mA Temperature Inputs on page 35 for information on connecting the user supplied temperature sensor e Resistance temperature device RTD See Connecting RTDs on page 34 for information on wiring a Polestar or third party PT100 RTD DSP4000 Optical Proce
12. as shown for Channel 1 in Figure 4 4 1 Connect TEMPn 4 20 IN to on the temperature sensor 2 Connect TEMPn 4 20 IN to on the temperature sensor To wire the temperature input for a single channel using an external power source as shown for Channel 4 in Figure 4 4 1 Connect TEMPn 4 20 IN to on the temperature sensor 2 Connect TEMPn 4 20 IN to on the power source 3 Complete the loop by wiring on the power source to on the sensor External 15 28 V Power Self powered temperature device Figure 4 4 4 20 mA Input Loops for Temperature Compensation To configure temperature inputs for multiple channels using the same external power source as shown in Figure 4 5 1 Connect TEMPn 4 20 IN to on the temperature sensors 2 Connect TEMPn 4 20 IN to on the power source 3 Complete the loop by wiring on the power source to on the temperature sensors DSP4000 Optical Process Monitor User Manual 80 04001 06 4 Electrical Connections 37 External 15 28 V Figure 4 5 Connecting Multiple 4 20 mA Inputs Do the following after you create the 4 20 mA loops 1 Refer to the temperature sensor documentation for scaling information 2 Use the DSP4000 Setup menu to enable and scale the temperature inputs for the connected channels as described in Configuring 4 20 mA Temperature Inputs on page 60 4 5 Connecting 4 20 mA Pressure Inputs
13. as the DSP4000 does not wait for user interaction In the sequence described below you will skip the operating system upgrade as the DSP4000 has the latest version but set the time and date To start the DSP4000 1 Turn the power ON OFF switch to the ON position and close the DSP4000 NOTE At this point it is not necessary to tighten the screws on the right side of the front panel cover When deploying the DSP4000 in a production environment make sure the cover is closed and that the screws are tightened so that the gasket seal prevents moisture from entering the DSP4000 The DSP4000 will display various messages as it starts up The operating status LED is red as the DSP4000 accesses the USB KEY and then the LED is off until you begin acquiring data 2 Press the ESC key on the front panel when the display prompts you to upgrade to a new software version Figure 2 12 left The DSP4000 continues with the startup and then prompts you to set the date and time Figure 2 12 right The date and time must be set each time the DSP4000 is powered up to accurately time stamp the measurement data Current Ver 04 717 Set Date and Time Available ver 04 717 No lt ESC gt Yes lt ENTER gt Upgrade ver Yes lt ENTER gt No lt ESC gt Figure 2 12 Two Prompts During Startup 3 Press ENTER to display the Date and Time menu Date is displayed in reverse video in the Date and Time menu to indicate that it
14. at the front or sensor end Figure 6 1 Inspect and Clean the Sensing Element 5 Disconnect the BioProbe from the fiber optic cable and carefully unscrew and remove the ST connector from the back end of the probe Figure 6 2 6 Inspect the waveguide tip at the back end of the probe Fiber Optic Cable Inspect and clean the ends at the back or removed from Ofthe fiber cable end BioProbe i optic cable Figure 6 2 Inspect and Clean Optical Surfaces 7 Remove dirt and grime by first gently wiping with a damp lint free cloth and then touching the end with the sticky side of a piece of Scotch tape DSP4000 Optical Process Monitor User Manual 80 04001 06 76 6 Care and Maintenance 8 Use the same procedures to inspect and clean the ends of the fiber optic cable CAUTION Solvents such as alcohol will damage the plastic waveguide To inspect the optics within the DSP4000 s fiber optic cable gland 1 Carefully remove the gland by unscrewing it from the DSP4000 The compact optical lens is located in the center of the gland opening 2 Power up the DSP4000 and watch for a short series of blue light pulses During a pulse the optic should appear free of obstruction and evenly illuminated Figure 6 3 Figure 6 3 LED Pulse for Channel 1 3 Use compressed air or compressed nitrogen to clear any obstruction 4 Call Polestar Support if the air or nitrogen does not clear the ob
15. measurement You can purchase the RTDs from Polestar Technologies as accessories or use third party 100 Ohm Platinum RTDs The RTD inputs on the DSP4000 have been calibrated with the Polestar PT100 The terminals in the block are labeled with the channel number and Black Red or White to match the three color coded wires from the device Table 4 1 Some RTDs have two black wires and one red Either black wire can be connected to the White terminal for the channel NOTE TheRTD connections are NOT 4 20 mA loop connections Table 4 1 RTD Terminal Strip Markings Channel Terminal Labels Channel 1 RTD1_Black 1 RTD1_Red 2 RTD1_White 3 Channel 2 RTD2_Black 4 RTD2_Red 5 RTD2_White 6 Channel 3 RTD3_Black 7 RTD3_Red 8 RTD3_White 9 Channel 4 RTD4_Black 10 RTD4_Red 11 RTD4_White 12 After connecting the RTDs see RTD on page 61 for information on enabling input from the devices There is no calibration or scaling required 4 3 Read this Before Wiring the 4 20 mA Loop Inputs and Outputs The two other terminal strips on the I O board are for connecting 4 20 mA loops for each channel for e Temperature input instead of using an RTD or a manually input constant for temperature compensation e Pressure input instead of using a manually input constant for pressure compensation e Output of O pH and or CO measurements Separate instructions for each of these uses are pr
16. page 53 The Setup menu and other options are accessed from the DSP4000 Main menu The one adjustment made in this section will be to disable the channels that are not connected to a sensor To disable the unconnected channels 1 Press ESC to place the DSP4000 in Standby mode The DSP4000 stops acquiring data from the BioProbes The Status LED remains unchanged The display shows the Main menu with Run Mode selected 2 Press the down arrow to highlight Setup Mode Figure 2 15 left and press ENTER to display the Login menu Figure 2 15 right 3 Press ENTER to bypass the login and display the Channel Selection menu gun Node user Login Admin Login Save Log File Turn Off DSP4000 Figure 2 15 DSP4000 Main Menu and Login Menu 4 Press the down arrow to select Channel 2 Figure 2 16 left and then ENTER to display the Setup Menu Figure 2 16 right Enable Disable is the first item in the menu and is selected by default Channel 1 Enable Disable Units Channel 3 Timing Channel 4 Temperature Figure 2 16 Setup Menu Selected for Channel 2 5 Press ENTER to display the current state of the channel Figure 2 17 left 6 Press ENTER to display the next menu select Disable Figure 2 17 right and press ENTER to make the change and return to the Setup menu Current Setting Enable Enabled To change lt ENTER gt Figure 2 17 Disabling the Channel 7 Press
17. Configured separately for each channel to use either a user specified constant or a 4 20 mA signal from a pressure gauge User set for each channel in one second increments in the range minimum interval to 999 seconds where minimum interval equals the number of channels in use The default frequency is 4 seconds One point calibration for O2 pH and C0 Two point calibration for O3 DSP4000 Optical Process Monitor User Manual 80 04001 06 Chapter 2 Getting Started 2 1 Unpacking Optional Power Adapter This chapter describes how to set up the DSP4000 on a benchtop in a lab or instrument workshop to familiarize yourself with the equipment Follow the instructions to connect a probe to the DSP4000 and operate the system using default settings Subsequent chapters cover configuration of the DSP4000 to provide temperature and pressure compensation connecting the system to a PC and using the Setup menu to tailor the DSP4000 to meet specific application needs Upon receipt of your DSP4000 please verify that all of the components ordered have been shipped A packing list is shipped with each package to use as a reference Some of the unique packing materials are reusable please save them in case the DSP4000 needs to be returned Figure 2 1 shows the components for the DSP4000 system used in the instructions in this guide Front Panel Display Pushbutton Function Keys Armored Fiber Optic Cable
18. D 1 Configuring a Modbus Connection To access the DSP4000 using the Modbus interface 1 Connect the DSP4000 to the PC using the cabling described in Making the Cable Connection on page 42 2 Follow the directions in Connecting with Windows Hyper Terminal on page 44 to go online to the DSP4000 using Windows Hyper Terminal and the RS 232 connection The Hyper Terminal setup for a Modbus serial connection is the same as that for the RS 232 connection except that you must check the following options in the ASIT Setup dialog box Figure D 1 which is opened from the Connection Properties dialog box e Send line ends with line feeds e Echo typed characters locally DSP4000 Properties Connect To Settings ASCII Setup Function arrow and ctr keys act as Terminal keys Windows keys ASCII Sending V Send line ends with line feeds lt Check these Echo typed characters locally lt qg _ options for Modbus Line delay 0 milliseconds Backspace key sends Gi H Del Cir H Space Cirl t Emulation Character delay 0 milliseconds Auto detect v Telnet terminal ID ANSI ASCII Receiving Backscroll buffer ines 500 d Append line feeds to incoming line ends Check thi ANOPIN ALOA OE EO OLT _ Force incoming data to 7 bit ASCII it Is May SOUND ng T Wrep ii 4 option same Wrap lines that e
19. DSP4000 Optical Process Monitor User Manual 80 04001 06 5 DSP4000 Setup 69 NOTE The AGC and RAGC are indicators of useful life of the sensing element They are not indicators of measurement accuracy Because of the compensating signal gain the accuracy of the Polestar DSP4000 measurements is constant over the life of the sensing element 5 10 Calibration Each Polestar sensing element is calibrated by manufacturing lot and is ready for use when its calibration factors are read from the USB KEY and the sensor is installed on the correct channel However for best performance it is recommended that you perform a one point or a two point calibration so that the sensing element is calibrated to the specific application 5 10 1 Calibration Menu To access one point and two point calibration and related functions e Scroll to Calibration in the Setup Menu by channel and press ENTER to display the Calibration menu Figure 5 25 One Point Cal Two Point Cal Two Point Cal Restore Defaults Restore Defaults Display Cal Display Cal Figure 5 25 Calibration Menu Table 5 6 describes the selections in the Calibration menu Table 5 6 Calibration Menu Options Selection Description One Point Cal Enables you to calibrate the sensor to your applica tion by measuring a span gas mixture or liquid with a known level of O2 pH or CO3 Two Point Cal Enables you to calibrate the sensor to your ap
20. ESC to return to the Channel Selection menu and disable the other disconnected channels DSP4000 Optical Process Monitor User Manual 80 04001 06 18 2 Getting Started 8 Press ESC to return to the Main menu select Run Mode and press ENTER to resume measurement on Channel 1 The DSP4000 displays value unit of measure and parameter for Channel 1 and Disabled for the other channels Figure 2 18 The Status LED is green when the DSP400 achieves a stable measurement from the enabled channels Ch 1 Measuring ch 1 20 9 02 Ch 2 Disabled Ch 2 Disabled ch 3 Disabled ch 3 Disabled Ch 4 Disabled Ch 4 Disabled Figure 2 18 Measurement Resumed 2 8 Removing the USB KEY from the DSP4000 The next step is to remove the USB KEY from the DSP4000 so that you can copy the log file to a PC for review Follow the instructions in this section to safely remove the USB KEY using Read Calib File in the Setup menu This function allows you to remove the USB KEY without shutting down the DSP4000 Because the the DSP4000 remains under power you can quickly resume operation when you reinstall the USB KEY There will be no need to reset the date and time and no need to wait for the DSP4000 to warm up Read Calib File also closes the current log file so that you will be recording to a new log file when you return the DSP4000 to Run mode CAUTION Do not remove the USB KEY while the DSP4000 is under power without first prepar
21. Edit View Call Transfer Help 308 24 073 32 0 deg 24 412 32 0 deg 948 32 0 deg 32 8 deg 32 8 deg 690 32 0 deg 0 deg 0 deg 0 deg 0 deg 0 deg 0 deg 0 deg 0 deg 0 deg 0 deg 0 deg 0 deg 0 deg 0 deg 0 deg 0 deg 0 deg 441 AGC 84 RAGC 06 28 2010 443 AGC 85 RAGC 06 28 2010 440 AGC 84 RAGC 06 28 2010 441 AGC 84 RAGC 06 28 2010 442 AGC 84 RAGC 06 28 2010 442 AGC 85 RAGC 06 28 2010 442 AGC 84 RAGC 06 28 2010 440 AGC 84 RAGC 06 28 2010 442 AGC 84 RAGC 06 28 2010 442 AGC 84 RAGC 06 28 2010 442 AGC 84 RAGC 06 28 2010 442 AGC 84 RAGC 06 28 2010 442 AGC 85 RAGC 06 28 2010 442 AGC 85 RAGC 06 28 2010 442 AGC 84 RAGC 06 28 2010 442 AGC 84 RAGC 06 28 2010 443 AGC 84 RAGC 06 28 2010 442 AGC 84 RAGC 06 28 2010 442 AGC 84 RAGC 06 28 2010 442 AGC 84 RAGC 06 28 2010 442 AGC 84 RAGC 06 28 2010 442 AGC 85 RAGC 06 28 2010 442 AGC 84 RAGC 06 28 2010 ONNNNNNNNNNNNNNNNNNNNNM TM Auto detect 19200 8 N 1 Figure 4 16 DSP4000 Output in a Hyper Terminal Window DSP4000 Optical Process Monitor User Manual 80 04001 06 4 Electrical Connections 47 10 Choose View gt Status Bar from the Hyper Terminal menu if the connection status is not displayed at the bottom of the window The status bar shows from the left the connection status Connected
22. Monitor User Manual 80 04001 06 113 Index Numerics 4 20 mA loops configuring the 4 20 mA data output 64 outputs description 5 power requirements 34 scaling pressure inputs 63 scaling temperature inputs 60 testing a 4 20 mA output signal 67 wiring for output loops 39 wiring for pressure gauges 37 wiring for temperature sensors 35 A Admin menu 55 AGC description 4 displaying the AGC value 67 Reference AGC RAGC 67 arrow keys on the front panel 10 Automatic Gain Control See AGC AUX key 10 B BioProbe connecting the probe to the DSP4000 13 inspecting and cleaning the sensor and fiber optic path 75 c cable for RS 232 connection 42 calibration Calibration menu 69 display current calibration factors 69 one point calibration 72 overview 3 preparation wait times 71 two point calibration 73 calibration file downloading a file from the Polestar web site 25 configuration file 24 connecting an RTD 34 cord grips 31 D data outputs description 5 wiring the 4 20 mA output loops 39 date and time setting the date and time at startup 14 DB9 to RJ 11 pinouts 42 default settings DSP4000 Optical Process Monitor User Manual 80 04001 06 114 Index DSP4000 defaults 16 restoring default calibration settings 69 display 9 downloading a calibration file 25 DSP Config Utility installing the software 23 loading a configuration file 24 updating the USB KEY for a new sensor 28 DSP4000 care and maintenance
23. S a aai 7 2 2 Front Panel Display and Function KeYS eeeeeeeeee tree ee eeeeeeaeaaeaeaaaaeeeeeeeeeeeees 9 2 3 Connecting the DSP4000 to a Power SOUFCe ssssssssssssrrrrrrnrrrrrereueueunsnnnnnnnnnnnnne 10 2 4 Check Channel Assignments ssssssssssesesrsrsrnrnrnrrrnrurnnnnnnnnntnnonennnnnnnnnnnenn nnne 11 2 5 Connecting the BIOPrODE nensem iniiae daina 13 2 6 Starting System Operation esis eriseeria ein E iN Aaa AEAEE E AAEE NN EEREN 14 2O 1 RUM MOG sirinin a a A a aaa as 15 27 DSP Main MON ksen oseese teaei ba raea sea aca nt DAAD Vana R ts EASA 16 2 8 Removing the USB KEY from the DSP4000 ssesssssssssssrsrnrnnnnnnnnnnnenesesrensnnnnn 18 2 9 Reviewing the Log Filenin contested etveauteos a canud Quen veddet daa aaia aa 19 2 10 Shutting Down the DSP4000 eeeee tte rr rr rn ni iii ii iii 22 Chapter 3 Managing Configuration Files cceeeeeseeeeeeeeeeeeeeeeaeeeeeesaaaeeeeees 23 3 1 Copying the USB KEY and Installing the Configuration Utility eee 23 3 2 Reviewing the Configuration File c ccceeeeeeeeeeeeeeeeeeeeeeeeeeeaaeaaaaaaeeeeeseeeaeaees 24 3 3 Retrieving Configuration Files from the Polestar Web Site csere 25 3 4 Loading the File onto the USB KEY cceceeceeeeeseeeeeeeeeeeeeeeeeaaaaaaaaaaeeeeeeeeaeeaea 28 Chapter 4 Electrical Connections ccceeeeete eee eeeeeeeeeeeeesaeeeeaaeeesaaeeesaaeeesaaeeenas 31 DSP4000 Optical Process Monitor User Manual 80 04001 06 iv
24. acquiring meaningless measurements during high temperature operations such as SIP and autoclaving Hibernation is activated when temperature readings exceed a user defined setpoint In Hibernation mode the DSP4000 discontinues optical data sampling but continues to monitor temperature readings at the user selected frequency Optical sampling resumes when temperature readings drop back below the hibernation setpoint The default hibernation setpoint is 52 0 C DSP4000 Optical Process Monitor User Manual 80 04001 06 6 1 Introduction 1 3 Specifications Enclosure Mounting Options Power Requirement Display Operating Range Units of Measure Data Output Format NEMA 12 4X certified ABS polycarbonate 6 25 in x 6 25 in x 5 75 in 159 mm x 159 mm x 146 mm Wall pipe rack or panel see Appendix C Mounting Options 24 VDC 1 25 A 30W 4 line by 20 character vacuum fluorescent display Ambient temperature 20 C to 40 C Relative Humidity 10 to 95 Temperature C Pressure mmHg or PSI Four isolated 4 20 mA loops externally powered from a 10 to 28 VDC source providing 16 bit resolution One RS 232 serial connection Optional Modbus interface Temperature Compensation Pressure Compensation Sampling Frequency User Calibration Configured separately for each channel to use input from a 100 Ohm Platinum RTD a 4 20 mA signal from a temperature sensor or a user specified constant
25. and crimping A AGC RAGC for a signal carrying capacity of minimum bend radius of 1 5 channel with a the cable inches is recommended to avoid relatively new sensor Dirt may have accumulated damaging the fiber optic cable in one of the cable 2 Check the cable connections for connections the channel and clean the optical surfaces as described in Periodic Maintenance on page 75 DSP4000 Optical Process Monitor User Manual 80 04001 06 80 6 Care and Maintenance Table 6 1 Troubleshooting the DSP4000 Continued Symptom Explanation of Problem Action The message Over Temp is shown on the DSP4000 front panel display The message is displayed when The Hibernate setpoint is set at or below the operating temperature The temperature input is not properly configured and connected Make sure that the Hibernate temperature is set above the operating temperature see Set Hibernate Temperature on page 61 Make sure that the RTD or 20 mA input is properly connected See Connecting RTDs on page 34 and Connecting 4 20 mA Temperature Inputs on page 35 Verify that the temperature input is enabled and in the case of the 4 20 mA input properly scaled See Configure Temperature on page 59 DSP4000 Optical Process Monitor User Manual 80 04001 06 83 DSP4000 Optical Process Monitor User Manual 80 04001 06 82 6 Care and M
26. calibration data onto the USB KEY as described in Chapter 3 Managing Configuration Files Although the sensing elements are pre calibrated and ready for use you should calibrate the sensors to your specific application The DSP4000 Setup menu provides one point calibration for O pH and CO sensors and a two point calibration method for O sensors as well as the option of restoring the default calibration from the USB KEY These functions are described in Calibration on page 69 1 2 2 Temperature Compensation The DSP4000 automatically adjusts each O and CO measurement for the effects of temperature The DSP4000 must use input from one of the following for temperature compensation e 100 Ohm Platinum Resistance Temperature Device RTD e 4 20 mA analog signal from a temperature sensor e User specified constant The temperature source is configured separately for each channel Wiring of the temperature inputs is covered in Chapter 4 Electrical Connections Selection of the input method scaling of the 4 20 mA signals and other configuration steps are covered in Configure Temperature on page 59 Temperature compensation is not used with pH sensors DSP4000 Optical Process Monitor User Manual 80 04001 06 4 1 Introduction 1 2 3 Pressure Compensation The response of Polestar s optical O and CO sensors is based on measurements of O and CO quenching which is a function of the partial pres
27. calibration of the sensing element Prepare the sample gas or solution and convert the levels to the units configured in the DSP4000 for the sensor The air for a span gas mixture can be calculated from either the percent O or ppm level in the mixture using the following relationships 1 10 000 ppm Air contains 20 95 O gt or 209 500 ppm air x ppm 209500 100 where x is the concentration of O in the span gas mixture in ppm For example a span gas mixture containing 1000 ppm O has air 1000 ppm 209500 100 0 48 air When calibrating for pH or dissolved O measurement allow the sensing element to fully hydrate When starting with a dry element the element should be submerged for at least 20 minutes The solution should be gently agitated during measurement Use a mechanical agitator or gently move the sensor in the solution After the first measurement in a two point calibration of a sensor rinse the sensing element with distilled water and then allow the element to hydrate in the second solution for at least 3 minutes DSP4000 Optical Process Monitor User Manual 80 04001 06 72 5 DSP4000 Setup 5 10 3 One Point Calibration To perform a one point calibration 1 Position the sensor to measure the gas or buffer NOTE For pH or dissolved O3 or CO2 a dry sensor element should be submerged in the sample for 20 minutes before starting the calibration and the solution should be gently
28. delay fo milliseconds Emulation Auto detect Ke ASCII Receiving _ Append line feeds to incoming line ends C Force incoming data to 7 bit ASCII Telnet terminal ID ANSI V Wrap lines that exceed terminal width Backscroll buffer lines 500 put Trnsiation _ASCILSetup _ Wrap lines that should be the only option selected Figure 4 15 Setting Session Properties DSP4000 Optical Process Monitor User Manual 80 04001 06 46 4 Electrical Connections 6 Make the selections shown in Table 4 8 for the Settings tab Table 4 8 Connection Settings Option Select Function arrow and ctrl keys act as Terminal keys Backspace key sends Ctri H Emulation Auto detect Telnet terminal ID ANSI Backscroll buffer lines 500 Play sound Your preference 7 Click the Input Translation button to open the Host System Encoding Method dialog box Figure 4 15 center select Shift JIS and click OK 8 Click the ASCII Setup button un check all the options in the ASCII Setup dialog box Figure 4 15 right except Wrap lines that exceed terminal width and then click OK 9 Press OK in the Properties dialog box to return to the Hyper Terminal window The Hyper Terminal window displays the DSP4000 output as shown in Figure 4 16 with each line a comma separated text string representing a time stamped sample from one channel DSP4000 HyperTerminal File
29. in each enabled BioProbe with a light pulse to acquire data The DSP4000 pulses the probe at the configured sampling rate for the channel The default rate for each channel is once every four seconds e Pick up the BioProbe and observe the light pulse at the end of the probe The front panel displays Measuring for each of the enabled channels Figure 2 14 left for one measurement cycle and then shows the value unit of measure and parameter for the enabled channels Figure 2 14 right It may take several measurement cycles before the DSP4000 acquires a stable measurement from the probe The Status LED is green when the DSP4000 has a stable measurement from each of the enabled channels If the LED is yellow there is a warning condition for at least one channel usually that the sensing element is beginning to wear based DSP4000 Optical Process Monitor User Manual 80 04001 06 16 2 Getting Started on the amount of energy required to excite the element see Automatic Gain Control on page 4 If the Status LED is red there is a fault with at least one channel There may be a loose fiber optic connection there may be a gap between the sensing film and the end of the fiber optic cable or perhaps the sensor element needs to be replaced The Status LED will be red as three enabled channels do not have sensors connected Ch 1 Measuring ch 1 20 9 02 Ch 2 Measuring Ch 2 AGC Limit Ch 3 Measuring Ch
30. included in the record between the parameter and the date stamp Y1028600 Notepad File Edit Format View Help 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 2010 11 Figure 2 23 Example Log File with O Measurements DSP4000 Optical Process Monitor User Manual 80 04001 06 2 Getting Started 21 Managing Log Files The following are some suggestions for managing log files Use the Save As function in the text editor to save the files to a separate directory on the PC Specify files names that will enable you to easily identify them Delete a log file from the USB KEY once you have saved the file to the PC When there are multiple files on the USB KEY use the Rename File utility to name the files according to the date and time of the first measurement in the log Figure 2 24 e Double click RenameFile exe in the USB drive e Enter the name and extension of the file to be renamed Y0813340 059 in Figure 2 24 and press Enter The utility names the file using date and time stamp of the first record in the log file in the format yryymmdd_hh_mm txt nter The FileName m 0813340 059 Created Modified Accessed OldName NewName 287 0272010 2970272010 287 0272010 Y 813346 85
31. is mmHg Get pressure source Command 3E46007C Response 3E46xxyy where xx is a code for the pressure source Table D 10 and yy is the LRC Table D 10 Codes for Pressure Sources Code Pressure Source 00 Manual entry mmHg 01 Manual entry PSI 02 4 20 mA pressure gauge mmHg 03 4 20 mA pressure gauge PSIG DSP4000 Optical Process Monitor User Manual 80 04001 06 10 D Modbus Option Set the pressure source Command 3E4680xxyy where xx is a code for the pressure source Table D 10 and yy is the LRC Response 3E46xxyy Get the pressure value Command 3E46017B Response 3E46XXXXXXXXYyY where xxxxxxxx is the hex representation of the floating point value and yy is the LRC see Table D 11 for examples Table D 11 Example Pressure Values Float value Hex Representation LRC 850 0 0x44548000 64 759 6 0x443DE666 15 900 0 0x44610000 D7 Set the pressure value Command 3E468 1xxxxxxxxyy where xxxxxxxx is the hex representation of the floating point value and yy is the LRC see Table D 11 for examples Response 3E46XXXXXXXXYY D 6 7 AGC Get the Automated Gain Control AGC value Command 3E47017A Response 3E47XXXXyy where xxxx is the AGC and yy is the LRC Get the Reference AGC RAGC value Command 3E470279 Response 3E47XXXXyy where xxxx is the RAGC and yy is the LRC D 6 8 4 20 mA Output Values in 4 20 mA output get and set commands are si
32. is selected 4 Press ENTER to display and change the currently configured date Figure 2 13 left 5 Press the left and right arrows to select the month day or year field DSP4000 Optical Process Monitor User Manual 80 04001 06 2 Getting Started 15 Reverse video highlights the selected field 6 Press the up or down arrow to increase or decrease a value Set Date Set Time 06 10 BEA gt eran up down left rig up down left right to adj ESC ENTER to adj ESC ENTER Figure 2 13 Setting the Date and Time in the DSP4000 7 Press ENTER to set the date as displayed and return to the Date and Time menu 8 Press the down arrow to select TIME and then press ENTER to display the currently configured time Figure 2 13 right 9 Press the left and right arrows to select the hours minutes or seconds field Reverse video highlights the selected field 10 Press the up or down arrow to increase or decrease a value 11 Press ENTER to set the time as displayed and return to the Date and Time menu 12 Press ESC to start Run mode NOTE If the DSP4000 enters Run mode before you are able to set the time and date it will set the time to midnight on a day in 2008 You can set the DSP4000 to the correct time and date by selecting Set Date and Time from the Channel Selection menu See Figure 5 3 on page 54 2 6 1 Run Mode When the DSP4000 enters Run mode it begins exciting the sensor
33. lengths The sensing element is an encased membrane that responds to a light pulse from the DSP4000 to indicate the level of the parameter of interest The sensing element is easily removed from the probe allowing you to change the measured parameter and to replace an element that has reached the end of its useful life DSP4000 Optical Process Monitor User Manual 80 04001 06 1 Introduction 3 The DSP4000 emits a light pulse at a user set interval to each channel which excites chemistry in the sensing element for the parameter of interest Based on the luminescent response from the sensor the DSP4000 calculates the level of O2 pH or CO in the gas or liquid The DSP4000 displays the results on a four line display on the front panel and records data on a USB drive The drive referred to as the USB KEY can be removed from the DSP4000 and plugged into a PC to offload the measurement data for analysis and archival storage Chapter 2 Getting Started describes how to connect a BioProbe to the DSP4000 start up the system using default settings and copy the measurement records to a PC 1 2 1 Calibration The sensing elements are pre calibrated by manufacturing lot A calibration file containing the lot number parameter and calibration factors is stored on the USB KEY When you change an element you can download its calibration file identified by manufacturing lot number from the Polestar Technologies web site and load the
34. measure used for pressure compensation In Figure 4 16 all entries are 760 mmHg as this is the constant that was entered manually for pressure compensation See Configure Pressure on page 62 441 AGC Value and label for the Automatic Gain Control which is the additional energy applied to the light source to excite the chemicals in the sensor membrane The AGC of 441 in Figure 4 16 is well within the normal operating range of 0 to 2000 as described in AGC Display on page 67 DSP4000 Optical Process Monitor User Manual 80 04001 06 48 4 Electrical Connections Table 4 9 DSP4000 RS 232 Output Continued Line 1in woes Columns Figure 4 16 Descrpuon in Excel 84 RAGC Value and label for the Reference AGC which is a K L factor used in the calculation of the channel output Polestar Technical Support may ask you for this value to help provide support Otherwise you can ignore these two fields 06 28 2010 Date and time of the measurement based on the M N 13 10 25 DSP4000 s internal clock which was set when the DSP4000 was powered up as described in Starting System Operation on page 14 These fields are not the date and time on the PC Capturing Data for Analysis To capture the data from the DP4000 in real time and save the data to a separate file for analysis or archiving 1 Choose Transfer gt Capture Text from the Hyper Terminal menu to open th
35. sensors Figure 4 2 Cord Grips on the Bottom DSP4000 Panel 3 Feed the wire through the cord grip and tighten the locking nut You may need to use a tool to tighten the cord grip if the wire is less than 1 4 inch in diameter Tighten the grip until the wire cannot move CAUTION Do not use a tool to tighten the locking nuts on the gland connectors as this can result in damage to the fiber optic cable and the gland 4 1 Powering the DSP4000 The DSP4000 requires 24 VDC power You can use the optional AC adapter to convert power from a 110 VAC outlet or you can hard wire the DSP4000 to a 24 VDC power source NOTE The AC power adapter supplied with the DSP4000 is not watertight and therefore should not be used in wash down applications The DSP4000 power switch is located near the top of the I O board between a terminal strip and the USB KEY Figure 4 1 CAUTION Always be sure that the ON OFF switch is in the OFF position before making any connection to the DSP4000 Failure to have the power switch in the OFF position prior to making an electrical connection can result in personal injury and or damage to the equipment CAUTION Prior to connecting power or powering up the DSP4000 please review Safety Guidelines on page vii and verify the voltage source is supplying 24 VDC DSP4000 Optical Process Monitor User Manual 80 04001 06 4 Electrical Connections 33 4 1 1 AC Adapter If you ordere
36. 0 Optical Process Monitor User Manual 80 04001 06 2 Getting Started 9 The USB flash drive the USB KEY to the right of the power switch provides storage of the measurement data and contains the current DSP4000 operating software calibration for the sensors shipped with the DSP4000 and documentation There are three rows of terminals on the I O board for making electrical connections The top row includes a two wire connector for DC power on the left and a terminal strip for input from PT100 RTDs for temperature compensation If you ordered the optional AC power adapter the power connections are already wired and the power cable fed through the left most cord grip Figure 2 2 and Figure 2 3 The middle row provides connections for 4 20 mA input for temperature and pressure compensation for each of the four channels The 4 20 mA temperature sensors and pressure gauges are user supplied The bottom bank of connectors allows you to output measurements from each channel as 4 20 mA signals to a process control system 2 2 Front Panel Display and Function Keys The DSP4000 front panel Figure 2 4 features Status LED on the upper right Four line vacuum fluorescent display for showing measurements and system setup menus The selected items in the display are shown in reverse video Pushbutton function keys described in Table 2 1 l Figure 2 4 DSP4000 Front Panel DSP4000 Optical Process Monitor User Manual 80 04
37. 001 06 10 2 Getting Started Table 2 1 Function Keys on the Front Panel Key How it is Used ESC When the system is in Run mode press ESC to put the DSP4000 in Standby mode and view the Main menu When you are using the Setup menus press ESC to return to a previous menu without making a change to a setting Press ESC to say No to a system prompt ENTER Press ENTER to select a highlighted menu item apply displayed settings and say Yes to a system prompt Up and Down Use the arrows to scroll through a menu and select an item Arrows Press the up or down arrow to increase or decrease a value selected in the display such as the upper value in a range setting or the year field when changing the date When changing a selected value press and hold the key down to quickly display the desired number Left and Right Arrows These arrows are disabled for most displays but are used in others to move laterally from one field to another Use of these two buttons is usually noted in the display AUX This button is reserved for future use MODE When the DSP4000 is in Run mode press MODE to select a channel and enter Setup mode MODE is also used in the menu for enabling and disabling the 4 20 mA data output for a channel 2 3 Connecting the DSP4000 to a Power Source The DSP4000 requires 24 VDC at 1 25 A 30W There are two options e The DSP4000 can be connected to a user supplied
38. 24 VDC source as described in Powering the DSP4000 on page 32 e You can connect the optional AC adapter to a 110 VAC outlet to convert power for the DSP4000 as described in this section To connect the DSP4000 to a power source using the AC adapter 1 Make sure the power ON OFF switch on the DSP4000 I O board is in the OFF position 2 Connect the AC adapter to the power cable coming from the DSP4000 Figure 2 3 3 Use the supplied power cord to connect the adapter to a 110 VAC outlet DSP4000 Optical Process Monitor User Manual 80 04001 06 2 Getting Started 11 2 4 Check Channel Assignments The USB KEY contains the DSP4000 configuration that was used during final testing prior shipment including the channel assignments for the sensors shipped with the unit It is important to identify which sensor was tested on each channel in order to match the sensor with the correct parameter units and calibration data that were used during testing You can change the assignments later by loading each sensor s calibration file to a different channel as discussed in Chapter 3 Managing Configuration Files Do the following if the channel assignments are not noted on the shipping documents 1 Turn the ON OFF switch to ON and close the DSP4000 front panel cover The DSP4000 will display various messages as it starts up The operating status LED is red as the DSP4000 accesses the USB KEY and then the LED is o
39. 3 AGC Limit Ch 4 Measuring Ch 4 AGC Limit Figure 2 14 DSP4000 Begins Run Mode The DSP4000 logs the measurement data including values used for temperature and pressure compensation to a file on the USB KEY which you can copy to a PC to analyze or archive the data CAUTION Wait 30 minutes after powering up the DSP4000 before taking any actual measurements or calibrating the sensors 2 7 DSP Main Menu At this point the DSP4000 is acquiring data using the sensor calibration factors on the USB KEY and the parameters set for the last factory test Typically the DSP4000 is shipped with these settings Units Depends on sensor type O high level mmHg Oz medium level ppb O low level ppb pH pH CO3 Timing 4 seconds Temperature Manually set to 20 C Pressure Manually set to 14 7 PSI 4 20 mA Output Enabled and scaled for the sensor type Password Security Level 0 no password required to use the Setup menu Channels Enabled All functional channels are enabled The settings are appropriate for Channel 1 at this time as the correct sensor is connected and there are no inputs for temperature or pressure compensation As you prepare the DSP4000 for deployment in the lab or process application you will need to calibrate the sensors and adjust other settings using the Setup menu as discussed in DSP4000 Setup on DSP4000 Optical Process Monitor User Manual 80 04001 06 2 Getting Started 17
40. 32 connection Table 4 6 identifies the functions for each terminal using the pin numbers in Figure 4 11 Table 4 6 RJ 11 Pin Functions Pin Function Wire Color 1 Receive Data RxD Black 2 Transmit Data TxD Red 3 no function Green 4 Ground GND Yellow The preferred wiring for the DSP4000 serial cable is the RS 232 straight through wiring shown in Table 4 7 center column NOTE The same pins 2 3 and 5 are used on a DB15 or DB25 connector If your particular application and hardware do not communicate with the DSP4000 using a straight through serial cable try a null modem cable in which the RxD and TxD are switched or crossed over as shown in Table 4 7 right column Table 4 7 Straight Through and Cable Modem RS 232 Pinout RJ 11 DB9 PC I O Port DB9 PC I O Port DSP4000 Straight Through Null Modem Pin 1 RxD Black Pin 2 RxD Pin 3 TxD Pin 2 TxD Red Pin 3 TxD Pin 2 RxD Pin 4 Gnd Yellow Pin 5 Gnd Pin 5 Gnd Use an RS 232 breakout box to troubleshoot a connection and determine the correct pinout for your application Figure 4 12 shows an RS 232 connection being prepared in which cables from the DSP4000 and the PC will be joined with an RJ 11 to DB9 transition kit The wires have been connected for a straight through connection and the transition is about to be assembled DSP4000 Optical Process Monitor User Manual 80 04001 06 44 4 Elect
41. 6 12 2 Getting Started Login is not required because the security is not yet enabled See Modifying the Security Level and the Passwords on page 55 for information on enabling security 6 Press ENTER to access the Setup menu for Channel 1 Figure 2 7 Channel 1 BB enable pisable Channel 2 Units Channel 3 Timing Channel 4 Temperature Figure 2 7 Setup Menu Selected for Channel 1 7 Press the up arrow once to scroll to Calibration Figure 2 8 left and then press ENTER to display the Calibration menu Figure 2 8 right Pressure One Point Cal 4 20 mA AGC Two Point Cal Restore Defaults Display Cal Figure 2 8 Accessing the Calibration Menu 8 Press the up arrow once to select Sensor Lot Number Figure 2 9 left and then press ENTER to identify the sensor assigned to this channel Figure 2 9 right Two Point Cal Sensing Element Lot Restore Defaults Number 251 006 041 Display Cal lt ESC gt or lt ENTER gt Figure 2 9 Displaying the Sensor Lot Number 9 Press ESC to return to the Setup Menu and then once again to display the Channel Selection menu 10 Select the other channels in turn and display their sensor lot numbers 11 Press ESC until the Main menu is displayed select Turn Off DSP4000 Figure 2 10 left and press ENTER 12 Press ENTER at the Save log file prompt Figure 2 10 right Run Mode Save Log file amp Set
42. 75 data records viewed with Hyper Terminal 46 display data records in Excel 48 I O board 31 powering up the DSP4000 14 removing the USB KEY 18 Setup menu 54 shutting the system down 22 system components 7 E electrical connections 31 enabling a channel 57 enclosure 1 ENTER key 10 ESC key 10 F flush mounting the DSP4000 94 front panel display and function keys 9 function keys 9 H Hibernation mode description 5 specifying the setpoint 61 I I O board 7 31 L log files closing a file 18 22 example file 20 porting a file to a PC for analysis 19 login menus 53 lot number displaying the lot number for a DSP4000 channel 69 M Main menu 16 maintenance 75 inspecting and cleaning the sensor and fiber optic path 75 DSP4000 Optical Process Monitor User Manual 80 04001 06 Index 115 replacing a sensing element 77 MODE key 10 mounting options 91 93 flushed mounting sealed 94 panel mounting 93 pipe mounting 92 wall mounting 91 mounting rails 91 N null modem cable 43 o one point calibration 72 operating system version 14 optical measurement 2 P panel mounting unsealed 93 passwords 55 periodic maintenance 75 pip mounting 92 Polestar web site Support area 25 power connecting the DSP4000 to a power source 10 ON OFF switch 7 power requirements 32 power adapter 10 pressure compensation configuring 4 20 mA inputs 63 configuring manual input 62 description 4 wiring a 4 20 mA pressure inp
43. 9 26166228 _16_58 txt Any More Files Yes Press Enter No Press Escape The first record in the file was acquired at 10 58 AM on February 28 2010 H Figure 2 24 Rename File Utility e Press Enter to rename another file or Esc to exit the program Reinstalling the USB KEY Do the following when you have finished with the log files 1 Remove the USB KEY from the PC and plug it into the USB port on the DSP4000 I O board Press ENTER on the DSP4000 front panel The DSP4000 checks the USB KEY for new configuration information and updates the effected channels accordingly The DSP4000 then displays the Main menu with Run Mode highlighted 3 Press ENTER to resume system operation DSP4000 Optical Process Monitor User Manual 80 04001 06 22 2 Getting Started 2 10 Shutting Down the DSP4000 The DSP4000 should placed in Standby mode the Main menu is displayed between uses When the DSP4000 is not in use it is best left under power to maintain the internal temperature However there will be times when you need to turn the DSP4000 off e You are connecting I O as described in Chapter 4 Electrical Connections e You need to upgrade the operating system to a new version The DSP4000 will prompt you to upgrade the software when you restart the system see Figure 2 12 on page 14 e There will be an extended period between now and the next use When you restart the DSP4000 allow it to
44. AN POLESTAR DSP4000 Optical Process Monitor User Manual Revision 6 For DSP4000 operating system version 4 752 80 04001 06 January 2012 Polestar Technologies Inc 220 Reservoir Street Suite 3 Needham Heights MA 02494 Trademarks Copyright DSP4000 BioProbe and iDot are trademarks of Polestar Technologies Inc All other brand names may be trademarks of their respective owners Copyright Polestar Technologies Inc 2010 All rights reserved Warranty This product is sold by Polestar Technologies Inc only under the warranty set forth in the following terms and conditions e Such warranty is only with respect to the purchase of this product directly from Polestar Technologies Inc e Verbal statements about the DSP4000 system including its components do not constitute extensions of this warranty e The warranty of the DSP4000 system and its components does not apply to any damage caused by misuse negligence accidents incorrect connections repairs or modifications by the customer e Polestar Technologies Inc does not warrant the fitness of the DSP4000 or its components for any particular purpose e Polestar does warrant that the DSP4000 and its components are free from any defects in material or workmanship for a period of one year from the date of shipment e This warranty shall be void if the DSP4000 is dismantled by the customer in anyway e During the warranty period Polestar will r
45. Aa EAA aT aeia 75 6 1 1 Inspection Procedures ccccccscssseecesssseeeeesesseeeeseaeeenseesaeeesesaaseeesssaasaes 75 6 2 Replacing a Sensing Element ceeeeeeeeeeeeeeeeee eee ee eeeeeeeeaaeaaaaaaeeeeeeeesaeaeed 77 6 3 Troubleshoot Gista ders eani tarasi aaataverntenstatansidee einstein ae 79 Appendix A DSP4000 Menus cccsesescssseresssssessesetersseresesereseserenaearesaeessnanaees 83 DSP4000 Optical Process Monitor User Manual 80 04001 06 Contents v Appendix B DSP4000 Error Messages csccsscesessseesssseesssetessserenssereneseresaeees 87 B 1 Error Messages Shown on the DSP4000 Front Panel eeeeeeeeeeeeeeeeeeeaes 87 B 2 Modbus Exception Codes sssrini aa i iae 87 B S ABGG Error MESSAGES ad raaa a eea aa seara R aA A aea aarp inana 88 B 4 Profibus Error Codes simaan oa a e aaa aaa a a aaa aaae aAa 89 B 5 DeviceNet Error M SS GES 0 aneia ae a aaa E Aaaa 89 Appendix C Mounting OptionS sssssssssssssrssssrrssernesrrrsnrnnennrnnnnnnnnennnrnnrnnennennn 91 C i Standard Wall Mounting assiriana ieaie ui aaa a aaae 91 C22 Pipe Mounting aii eenei aaa n a A a a a aA dadaas 92 C 3 Panel MOUNTING aeaa atean aaa aaa en aeaaea Sa a EAA AE e a a E 93 C 3 1 Flush Mounting Unsealed sisisipi asnaspa a aaa a Eaa 93 C 3 2 Flush Mounting Sealed srice Sirna tadiss annatod ada aaaea inan 94 Appendix D Modbus Option sssssssssssssssssrsssrrrnsrrnsrnrnsrrnsrnnsanrnnrnrnnnrnnnnnennrnnnnne 95 D 1
46. Codes Table B 1 lists the exception codes returned by the DSP4000 in response to Modbus commands See Exception Codes on page 97 for additional information Table B 1 Modbus Exception Codes Code Description 1 Invalid function code 2 Invalid address 3 Invalid data 4 Login failure 5 Channel select failure Setup mode failure or channel not configured 6 Unsupported sub function code 7 The attribute is out of range 9 Disable one or more channels or change channel timing DSP4000 Optical Process Monitor User Manual 80 04001 06 88 B DSP4000 Error Messages B 3 ABCC Error Messages The ABCC errors listed in Table B 2 are common to the DeviceNet and Profibus protocols Table B 2 ABCD Error Messages Message Description ABP_ERR_UNSUP_CMD The command is not supported by the instance ABP_ERR_ATTR_NOT_SETABLE The instance is read only for example channel measurement instances ABP_ERR_ATTR_NOT_GETABLE The instance is write only for example channel calibration file read and user admin login instances ABP_ERR_NOT_ENOUGH_DATA The data size data length for multi element instances is less than the instance s specified size ABP_ERR_TOO_MUCH_DATA The data size data length for multi element instances is greater than the instance s specified size length ABP_ERR_INV_CMD_EXT_0 The attribute value is out of range
47. Configuring a Modbus Connection ssssssssrssssssssnnnnnrnsnnsunnnnnnnnnnenennnnnnnnnnnenee 95 D2 MODBUS Command sissie i o a E AA EEAS 96 D3 Exception CodeS caisiuccesscuvantebeden tean veatevs beet adiantada We eeeneeacteas aa Heedvah caeateteseteeds 97 D 4 DSP4000 MODBUS Command Set c ceeeeeeeeeeeeee reer eee eeeeeaeaeaaaaeeeneeeeeeees 98 DiS ERC Calculator ni sshisiva a Gehan aha dade eed eae 99 D 6 Example Commands sisi c dsis scievecteascasseesdacdesacveadadacdddstadicacateaseasaacSaavessasteare 102 Di 621 Unit Staterna dati ihre aa a A A AEEA EA 102 D G 2 Eoo lIa ETE AET E E E E E 102 D 6 3 Channel pairati aa ees ayteneien avarice taierlaread ones 103 D 6 4 SONSOF 4 acecier fen sdeunsdcheut cat cad teneedel aves sdenaudasnsen set a a 104 DOS Temperature dene enie ENR esi inieavi cee assess 106 D 6 6 Pressure Live sicsei i aceezereiis ceaeeacebeede ceciwedacabeedshe eels sbeetibeldsveeens NEENA 107 BEAC ONET si cesecacbedsctedagecuadsvedeckdeeteveiasachenac tennis T T 108 D 6 8 4 20 MA OUTPUT 2 Jcdsireosie ses cegeetetevneisversdees ainra tola yuat ie AKADE a aaia 108 D 6 9 Calibration nerenin ra e Se ie Rae a eee 110 D 6 10 Get Me SUreEMeNt surprinse o ne i REON LANE AAE 112 D 6 11 Program the DSP sianie aiia eaa aaea AE EEEE NELE 112 ING EX EAE EA E E ANE E EESE EE E E A E 113 DSP4000 Optical Process Monitor User Manual 80 04001 06 vi Contents DSP4000 Optical Process Monitor User Manu
48. Contents 4 1 Powering the DSP4000 eeeececeetce teeta ee eeee aeia araa iaaea i a 32 AAT AC AGA pter ss ieii sen gecasts aistetdey dak caed aes Eaa isin cavdvaaeenataneacds Gaia 33 4 1 2 User supplied 24 VDC SOUrCE ce ceeteeeeeeeeeee eee eaeeea eae eeeeeeeeeeeaeaeaaaaaneeenees 33 4 2 Connecting RPDS sas se coeve dacs ceeds iune aeu aaan a sete cd Ea EE st nerteeasiaene teeta 34 4 3 Read this Before Wiring the 4 20 mA Loop Inputs and Outputs ns 34 4 4 Connecting 4 20 mA Temperature INDUtS tee ieee eeeeeee 35 4 5 Connecting 4 20 MA Pressure INPUtS cee eee eeeeereaaeiees 37 4 6 Connecting 4 20 MA Data Outputs eerie 39 4 7 Configuring the RS 232 Interface ccceeeeeeeeeeee ents ee eeeeaeaea aa aa aaaaaeeeeeeeeeenees 42 4 7 1 Making the Cable Connection ccceeeeceeeeeeeeeeeeeeeeeeeeesaaeaaaaeeneeeeeeeeaeas 42 4 7 2 Connecting with Windows Hyper Terminal ccssseseeeeeeeeeeeeeeeaeaeeees 44 4 7 3 Reading the Output Display cceceeeeeeceeeeeeeeeeee trees ee eeaeaaaeeeeeeeeeeeaeea 47 Chapter 5 DSP4000 Setup ani aeina a cue snienins oh pole Eana SETEC EEEE aula 53 5 1 Modifying the Security Level and the PasswordS sssssssssssssssersrrrsssrrrrnesrrrresss 55 5 2 Enable Disable unaia a a a a a annie 57 5 3 UNITS ar a aaia aa EA eterna 57 SA TIMNA ea e a a a a a a a aa a aa a ede eaa 58 5 5 Configure Temperature isisi aadi aaia a aaan 59 5 5 1 Manual Temp
49. E44xxyy where xx is the units code Table D 7 Set the unit of measure Command 3E4481xxyy where xx is the units code Table D 7 Response 3E44xxyy Table D 7 Numeric Value for Units Code Unit of Measure 00 mmHg 01 02 Air 03 ppm 04 ppb 05 pH 06 deg 07 ppb dissolved 08 ppm gas 09 SMR Get the time that is set in DSP4000 Command 3E44027C Response 13E44xxxxxxyy where Xxxxxx is a hex representation of the time in the format hhmmss Set the DSP4000 time Command 13E4482xxxxxxyy where xxxxxx is hex representation of hhmmss as calculated by LRC Calculation exe see Figure D 4 on page 101 Response 13E44xxxxxxyy Get the date that is set in the DSP4000 Command 3E44037B Response 3E44XXXXXXXXYY where xxxxxxxx is the hex representation of date in the format MMDDYYYY DSP4000 Optical Process Monitor User Manual 80 04001 06 10 D Modbus Option Set the date in the DSP4000 Command 3E4483XXXXXXXXyY where xxxxxxxx is the hex representation of MMDDYYYY as calculated by LRC Calculation exe see Figure D 4 on page 101 Response 3E44XXXXXXXXYY D 6 5 Temperature Temperature values in get and set commands are single precision 32 bit floating point values expressed as hexadecimal numbers The unit of measure is C Get the temperature source Command 3E45007D Response 3E45xxyy where xx is the source per Table D 8 and yy is the LRC Table D 8 Ident
50. Furey BioProcess Int SIDSPCALIE Open orig DSPC print PDS 001P Edit st PDs 002 Pian PDs 003 0 scan selected files with Antivir ka Polestar D g ja Polestar D a Polestar O a Polestar O E PROG4000 B readme Dry 3 71031900 40 KB 311 KB Application PDF Complete Docu File File ___ Complete Docu 3 24 21 TB Noeped Ga XML Editor Scan with Malwarebytes Anti Malware internet Explorer DSP Config utility install E k DVD Drive E B S RCS My Pictures R gt GC Conirol Panel G Shared Documents Administrator s Documents E D Guest s Documents E amp my Network Places gj Recycle Bin t g FrameMaker Application Real Install Downloads RX Microsoft Office Excel fv Microsoft Office Word B WordPad Send To Cut Copy Create Shortcut Delete Choose Program Rename Properties lt Type File Date Modified 9 23 2010 11 28 AM Size 10 6 KB 4 My Computer Figure 2 22 Opening a Log File 2 Open the comma delimited log file using Notepad WordPad or a similar text editor Figure 2 23 shows a log file created with the configuration described in this chapter Each line in the text is the record of one measurement from one channel Channel 1 was the only one in use The record includes channel number value unit of measure parameter and date and time stamps When there are inputs for temperature and or pressure compensation those values are
51. Process Monitor User Manual 80 04001 06 4 Electrical Connections 51 G fl gt 7 CAPTURE Microsoft Excel non commercial use a o e Home za Formulas Data Review View Add Ins PF 2 xX ia E baj hal Morar a 2 Line hh Area Q E Text Box B Up Shapes pie i Scatter O Header amp Footer gq PEASE Table EHU Coumi Hyperlink F smartart E bars O other charts Al Wordart 2 Tables ildstrations J Charts mji tinks Text 8 Le 22 954 760 mmHg 295 AGC 74 RAGC 22 996 760 mmHg 295 AGC 74 RAGC 23 258 760 mmHg 295 AGC 74 RAGC 23 181 760 mmHg 295 AGC 74 RAGC 23 181 RAGC 23 702 RAGC 22 969 RAGC 22 774 i RAGC 23 016 f RAGC 22 915 Z RAGC Seriesl 23 142 R A RAGC 22 889 y RAGC 23 2 RAGC 23 29 RAGC 23 127 i 7 j RAGC 22 895 50 100 RAGC 22 933 32 degC 760 mmHg 295 AGC 75 RAGC 23 154 32 degC 760 mmHg 296 AGC 75 RAGC 23 064 32 degC 760 mmHg 295 AGC 75 RAGC 23 115 32 degC 760 mmHg 295 AGC 75 RAGC 23 11 32 degC 760 mmHg 297 AGC 75 RAGC 22 635 32 degC 760 mmHg 296 AGC 75 RAGC Figure 4 19 Sample Analysis of O Measurements 5 Choose File gt Save from the main menu and specify a file name and folder in the Save dialog box DSP4000 Optical Process Monitor User Manual 80 04001 06 52 4 Electrical Connections DSP4000 Optical Process Monitor U
52. SB KEY the DSP4000 can also be configured to output measurement data via 4 20 mA signals to a field device or process system and output to a PC via an RS 232 serial connection The 4 20 mA outputs are wired separately for each channel as described in Chapter 4 Electrical Connections The output signal represents the O pH or CO level on the connected channel The signal at the receiving device or system must be scaled and converted to engineering units so that the signal can be properly interpreted The RS 232 connection is made with cable from an RJ 11 connector in the DSP4000 to the I O port connector on the PC either DB9 or USB You can use the RS 232 connection and a terminal program such as Microsoft Hyper Terminal to view and capture a full data record for each channel each time the channel is sampled The record includes the parameter value and units the values used to compensate the effects of temperature and pressure an indication of sensor wear and a date and time stamp See Chapter 4 Electrical Connections for information on creating the RJ 11 to DB9 or RJ 11 to USB cable and setting up Hyper Terminal to go online to the DSP4000 The RS 232 connection is also used for an optional Modbus interface Appendix D Modbus Option describes the Modbus get and set commands supported by the DSP4000 1 2 6 Hibernation Mode The DSP4000 automatically enters a temperature dependent Hibernation mode to avoid
53. SB Key Update Config File Plug USB Key lt ESC gt SKIP lt ENTER gt OK Figure 2 21 Prompt to Remove the USB KEY 6 7 Open the front panel cover and carefully lift the USB KEY from its connector Leave the DSP4000 display as shown in Figure 2 21 right until you have copied the log file to the PC and reinstalled the USB KEY 2 9 Reviewing the Log File To review the log file 1 Plug the USB KEY it into a USB port on the PC You will find one or more log files in the root directory of the USB drive Log file names consist of Y followed by seven digits and a three character numeric extension The first of two log files Y1028600 059 is selected in Figure 2 22 The second file is the log started when you used Read Calib File to remove the USB KEY This file is empty DSP4000 Optical Process Monitor User Manual 80 04001 06 20 2 Getting Started File Edit View Favorites pi bad D Address Folders x Desktop fl B My Documents 4 My Computer E Local Disk C B Removable Disk D Tools OB As em il Help Name DSP Config utility install 1 80 0400 1 00 DSP 4000 Manual 1 st AN 001 Polestar Optical Sens 1 AN 002 Polestar Optical Sens it AN 003 Polestar Optical Bag P Size 324 KB 602 KB 597 KB 226 KB Type File Folder PDF Complete Docu PDF Complete Docu PDF Complete Docu PDF Complete Docu changeFileTime t Clark
54. Units of Measure by Element Type Element Type Available Units O high level ppm mmHg Air sat PPM deg Degree is a measure used by Polestar Technical Support DSP4000 Optical Process Monitor User Manual 80 04001 06 58 5 DSP4000 Setup Table 5 3 Units of Measure by Element Type Continued Element Type Available Units O gt medium PPB Dissolved level ppb PPM Gas Phase deg Degree is a measure used by Polestar Technical Support O low level PPB Dissolved sub ppb PPM Gas Phase deg Degree is a measure used by Polestar Technical Support pH pH SMR Signal Magnitude Ratio is a factor used in calculating the channel output CO gt mmHg SMR Signal Magnitude Ratio is a factor used in calculating the channel output To change the unit of measure 1 Select Units in the Setup menu and then press ENTER to display the current setting Figure 5 8 left 2 Press ENTER to display the first four options for the sensor type Figure 5 8 right Current Setting 02 mmHg 02 02 02 Air Sat To change lt ENTER gt 02 PPM Figure 5 8 Setting the Unit of Measure 3 Use the up or down arrow to scroll to the desired unit 4 Press ENTER to accept the selected unit and return to the Setup menu 5 4 Timing The DSP4000 takes periodic readings of the sensor at a user set rate The default interval is 4 seconds The
55. a once every five seconds while configuring the sampling rate for Channels 3 and 4 to 30 seconds and 90 seconds respectively The channel selection menu also includes two items that apply to all channels Figure 5 3 right e Set Date and Time which enables you to enter the current date and time after a power interruption See Starting System DSP4000 Optical Process Monitor User Manual 80 04001 06 54 5 DSP4000 Setup Operation on page 14 for information on setting the date and time e Read Calib File allows you to extract log files from the USB KEY update configuration files on the USB Key and or install another USB KEY without powering down the DSP4000 as described in Removing the USB KEY from the DSP4000 on page 18 SRE ae Channel 3 Disabled Channel 2 Disable Channel 4 Disabled Channel 3 Disabled Set Date and Time Channel 4 Disabled Figure 5 3 Channel Selection Menu 4 Use the up or down arrow to select the channel you want to configure and press ENTER to display the Setup menu Figure 5 4 Enable Disable Pressure Units 4 20 mA AGC Timing Temperature Figure 5 4 The Eight Items in the Setup Menu Table 5 1 describes the menu selections and their defaults settings Table 5 1 DSP4000 Setup Menu Menu Choice Description and Default Setting Enable Disable Toggles the selected channel On and Off To avoid system errors disable any channel t
56. agitated during the measurement 2 Select Calibration in the Setup menu and press ENTER to show the Calibration menu 3 Select One Point Cal and press ENTER The DSP4000 displays the default buffer or O2 or co2 value Figure 5 28 left 4 Press ENTER to continue using the default value or use the up or down arrow to increase or decrease the value and then press ENTER The DSP4000 takes a number of samples to verify that a stable phase is being measured Figure 5 28 right Prepare the Air Waiting for stable Saturation Condition phase 22252 Adjust 100 or To continue lt ENTER gt Figure 5 28 Starting One Point Calibration for an O Sensor NOTE The DSP4000 will time out if it is unable to achieve a stable phase Check your connections and the DSP4000 setup and then start the one point calibration again Once there is a stab the temperature and pressure are displayed for all active channels le measurement the DSP4000 collects four readings at 20 second intervals to calculate the calibration factor 5 Wait for the DSP4000 to complete the four measurements and display the results Figure 5 29 right Taking measurement Calibration results 1 of 4 P5 0 007820 To apply lt ENTER gt Figure 5 29 DSP4000 Calculates P5 Based on Four Samples 6 Review the results and press ENTER to return to the Setup menu 7 Do the following if the calibration was not performed correctly
57. aintenance Appendix A DSP4000 Menus This appendix illustrates the DSP4000 menu system Figure A 1 shows the Main menu and access to the Setup menu when security is not enabled SecureLevel 0 Bold type indicates that the menu item has been selected Figure A 2 and Figure A 3 map the eight functions in the Setup menu Figure A 4 shows User login SecureLevel 1 and Admin login required to set passwords and security level and when SecureLevel 2 Main Menu Run Mode Setup Mode Run Mode Setup Mode Run Mode Setup Mode Run Mode Setup Mode Save Log File Turn Off DSP Save Log File Turn Off DSP Save Log File Turn Off DSP Save Log File Turn Off DSP Ch1 Measuring Ch2 Measuring Ch3 Disabled Ch4 Measuring User Login Admin Login See Note below Save log file amp Create new I Ch1 20 0 O2 Ch2 7 8 pH Ch3 Disabled Ch4 1 1 CO Save log file amp Create new Set Date Set Time Channel 1 Channel 2 Channel 3 Channel 4 Set Date Time Read Calib Enable Disable Units Timing Temperature Set Date 06 21 2010 Unplug USB Update File Insert USB Set Date Set Time Set Time 13 45 51 Figure A 1 Main Menu Pressure 4 20 mA AGC Calibration Setup menu for the selected channel See next two pages Note When the securit
58. al 80 04001 06 vii Preface About this Guide This guide describes how to install configure operate and maintain the Polestar DSP4000 Optical Process Monitor Chapter 1 Introduction provides a brief overview of the product Chapter 2 Getting Started describes how to set up the DSP4000 on a lab or instrument shop benchtop power up the system measure a single parameter using default settings and port the measurement data to a PC to analysis and storage Subsequent chapters provide step by step instructions on managing calibration files connecting the sensor inputs and data outputs configuring DSP4000 operation and maintaining the system Revision Information This sixth revision of the DSP4000 Optical Process Monitor User Manual covers all of the features and functions of Version 4 717 of the DSP4000 operating system Safety Guidelines The following safety precautions must be taken while connecting and operating the DSP4000 These precautions are intended to protect both the operator and the DSP4000 e Prior to supplying the DSP4000 with power verify that the power source provides the correct voltage 24 VDC and sufficient current minimum of 1 25 A to power the DSP4000 e Be sure that the ON OFF switch on the DSP4000 I O board is in the OFF position before connecting the DSP4000 to the power source e Prior to connecting any of the 4 20 mA current loops read the instructions in Chapter 4 Elec
59. alibration of O2 up to 500 air saturation 100 02 The DSP4000 takes multiple measurements to achieve a stable phase and then takes four measurements at 20 second intervals to calculate the first calibration factor P5 The DSP4000 displays the calibration factor for the first point Figure 5 30 right Prepare the Air Calibration results Saturation Condition Adjust 100 or P5 0 007820 To continue lt ENTER gt To apply lt ENTER gt Figure 5 30 Starting Two Point Calibration for an O or CO2 Sensor 5 Review the results and then press Enter to apply the first factor The DSP4000 prompts you to position the sensor to measure the second sample NOTE If you are calibrating the sensor in a liquid phase rinse the sensing element and the rest of the probe with distilled water before inserting the element into the second solution Allow the sensing element to hydrate for 3 minutes before continuing with the calibration 6 Press ENTER when the sensor is in place for the zero level measurement Figure 5 31 left The DSP4000 again measures the sample until it achieves a stable DSP4000 Optical Process Monitor User Manual 80 04001 06 72 5 DSP4000 Setup phase and then takes four measurements at 20 second intervals to determine the zero level factor P2 DSP4000 Optical Process Monitor User Manual 80 04001 06 75 7 Review the results Figure 5 31 right and press ENTER to apply th
60. als for the 4 20 mA Output Float Value Hex Representation LRC 8 0 0x41000000 39 12 0 0x41400000 F9 16 0 0x41800000 B9 20 0 0x41A00000 99 D 6 9 Calibration In this section yy is the LRC calculated by LRC Calcaluation exe or the LRC included in the DSP4000 response Get calibration state Command 3E65005D Response 3E65xxyy where xx is the calibration state Table D 14 Table D 14 Calibration States Value Calibration Message 00 CAL_IDLE 01 CAL_IN_PROGRESS 02 CAL_SUCCESS 03 CAL_FAILURE One Point Calibration Remote one point calibration is available for O and pH sensors only Set the calibration high value and run the calibration Command 13E6581xxxxxxxxyy where xxxxxxxx is the high value Response 3E65xxyy where xx is the calibration state Table D 14 Examples To run a one point calibration of a pH sensor where the pH buffer is 7 4 Command 3E658140ECCCCD17 Response 3E65xxyy where xx is the calibration state Table D 14 DSP4000 Optical Process Monitor User Manual 80 04001 06 D Modbus Option 111 To run a one point calibration using the previous calibration value Enter 1 in the Data field in LRC Calculation dialog box Figure D 2 on page 100 and click the Integer radio button The LRC Calculation dialog box converts 1 to OXFFFFFFFF and calculates the LRC DD Command 3E6581FFFFFFFFDD Response 3E65xxyy where xx is the calibration s
61. and the elapsed time of the connection or Disconnected Emulation Mode Auto detect and the COM Port properties 19200 bits per second and 8 N 1 for eight data bits no parity and one stop bit 11 Do one of the following if the status bar shows Disconnected e Choose Call gt Call from the Hyper Terminal menu e Click s in the Hyper Terminal toolbar 4 7 3 Reading the Output Display Table 4 9 describes the comma separated fields in the output display in the Hyper Terminal window The left column in the table contains pairs of data elements from the first line in Figure 4 16 The right column refers to spreadsheet column heads when the output is imported into an Excel spreadsheet as described in the next section Table 4 9 DSP4000 RS 232 Output Line 1 in Figure 4 16 Description Columns in Excel Ch 1 02 Channel number and sensor type Channel 1 is the only channel in use in the example If other channels were in use all channels would be displayed in the order the samples were taken See Timing on page 58 A B 24 073 Value and unit of measure in this case percent O3 C D 32 0 deg C Temperature value and unit of measure used for temperature compensation In Figure 4 16 all entries are 32 0 deg C as this is the constant that was entered manually for temperature compensation See Configure Temperature on page 59 E F 760 mmHg Pressure value and unit of
62. ant to note that photo bleaching does not affect the accuracy of the measurements and that under normal conditions a Polestar sensor can provide several hundred thousand measurements The AGC display reports the amount of gain on a scale of 1 to 4000 see AGC Display on page 67 where 4000 indicates the end of the sensing element s useful life For pH and CO measurements the DSP4000 reports the Reference AGC RAGC the drive level required for detection of the reference signal AGC and RAGC are functionally the same for purposes of monitoring the useful life of the sensing element The Status LED on the front panel turns from green to yellow when the AGC for a channel exceeds 3000 indicating that sensing element is beginning to wear The light turns red when the AGC for a channel exceeds 3500 indicating that you should replace the element Refer to Replacing a Sensing Element on page 77 DSP4000 Optical Process Monitor User Manual 80 04001 06 1 Introduction 5 There are two ways to reduce photo bleaching and extend the life of a sensing element e Reduce the sampling rate to a minimum level that still meets the requirements of the application See Timing on page 58 for information on setting the sampling rate e Store the sensor in a dark place between uses and avoid exposing the element to bright sunlight 1 2 5 DSP4000 Output In addition to the front panel display and the data storage on the U
63. browse for and select the data file and then click Open to start the Text Import Wizard Figure 4 18 DSP4000 Optical Process Monitor User Manual 80 04001 06 50 4 Electrical Connections Text Import Wizard Step 1 of 3 The Text Wizard has determined that your data is Delimited ose Next or choose the data type that best describes your data If this is correct Original dats4ype This screen lets you set the delimiters your data contains You can see how your text is affected in the preview below Delimiters C Treat consecutive delimiters as one 22 317 32 deg C 760 r 25 3 32 deg C 760 mmHg 193 32 deg C 760 22 954 32 deg C 7 996 4 32 deg C 7 Text gualifier v Q a t s ooo 0oNn NN v Y oo mD D Q Q Q A A qaaoaaq Figure 4 18 Text Import Wizard 3 Click the Delimited radio button on the first wizard page and click Next 4 Select the Comma check box in Delimiters and click Finish skipping the third and final wizard page Excel pastes the data into the spreadsheet starting at cell A1 Figure 4 19 The comma separated data is distributed over columns A through N see Table 4 9 on page 47 for a description of the columns Excel provides a variety of display formats for analyzing the data For example Figure 4 19 shows a scatter plot of the data in column C the measurement value for the channel DSP4000 Optical
64. ctor and lock it in place using the spring loaded cap CAUTION Avoid getting dirt between the fiber optic cable and the optical waveguide within the probe body as dirt can obstruct the optical path and or damage the waveguide Use only Scotch tape to clean the ends of the fiber optic cable Insert the barrel end of the fiber optic cable into the gland connector for Secure the connection Channel 1 with the locking nut The nut should be finger tight BioProbe Slot on the side of the Fiber Optic ST female connector Cable Alignment tab is inside N the spring loaded cap of the ST male connector B Bo on the fiber optic cable Fiber Optic Cable Figure 2 11 Connections on the BioProbe and Fiber Optic Cable DSP4000 Optical Process Monitor User Manual 80 04001 06 14 2 Getting Started 2 6 Starting System Operation When you turn the power switch on the DSP4000 goes through a short startup sequence displaying messages on the front panel display and then automatically enters the Run mode The startup sequence includes two prompts one to upgrade the operating system to a new version and the other to set the date and time for the DSP4000 You can respond to one or both prompts by pressing ENTER or you can skip the step by pressing ESC If you do neither the DSP4000 will continue with the startup after several seconds and enter Run mode This ensures rapid recovery following power interrupts
65. d the optional AC adapter Figure 4 3 the DSP4000 is shipped with the power cable already connected to the two position terminal block in the upper left corner of the I O board Figure 4 1 Power cord Optional AC Adapter Cable for optional power adapter Ne n wi Figure 4 3 Optional AC Adapter with Power Cord To connect the DSP4000 to a power source using the AC adapter 1 Make sure the power ON OFF switch on the DSP4000 I O board is in the OFF position 2 Connect the AC adapter to the power cable coming from the DSP4000 3 Use the supplied power cord to connect the adapter to a 110 VAC outlet 4 1 2 User supplied 24 VDC Source To hard wire the DSP4000 to a 24 VDC source 1 Make sure that the power source is off and that the power ON OFF switch on the DSP4000 I O board is in the OFF position e Remove the AC adapter power cable from the DSP4000 if one is installed 2 Feed the wires from your 24 VDC source through one of the cord grips 3 Connect the 24 VDC line to the terminal marked 24VDC 1 and the ground return to GND 2 4 Tighten the cord grip DSP4000 Optical Process Monitor User Manual 80 04001 06 34 4 Electrical Connections 4 2 Connecting RTDs The 12 position terminal strip at the top of the I O board and to the right of the power in terminals is used for connecting up to four PT100 Resistance Temperature Devices RTDs to provide temperature compensation for O and CO
66. d with fluorescent indicators designed to be selectively responsive to the parameter of interest Signal detection efficiency is a function of the optical throughput of the system optics and can be adversely affected by damage and accumulation of dirt on the exposed surfaces To assure best performance from the DSP4000 you should periodically e Check the AGC or RAGC level of each channel Higher than usual readings are often an indication of damage or excess contamination of the system optics See AGC Display on page 67 for information on accessing the display from the Setup menu e Examine the fiber optic cable ends probe optical waveguide ends and the fiber optic cable gland on the DSP4000 bottom panel to confirm the integrity and cleanliness of these components DSP4000 Optical Process Monitor User Manual 80 04001 06 6 Care and Maintenance 77 To inspect the BioProbe 1 Use a magnifying glass to check the exterior of the sensing element for damage and dirt 2 Use a Chem wipe or lint free cloth dampened with de ionized water to clean any dirt from the sensing element 3 Unscrew and remove the sensing element from the BioProbe CAUTION Do not remove the optical waveguide from within the probe body 4 Use a magnifying glass to check the waveguide tip for dirt and signs of cracking Figure 6 1 Sensing element removed from BioProbe Inspect and clean the sensing element exterior Waveguide tip
67. e AGC value provides an indication of device health as follows A value in the range 1 to 2000 indicates a normal operating condition for the DSP4000 Values in the range 2000 to 3500 indicate a potential problem with sensor aging obstruction of the optical signal path or a loose connection at one or both ends of the fiber optic cable An AGC value greater than 3500 indicates a problem with the sensor or system setup The color of the Status LED in the upper right corner of the DSP4000 front panel cover indicates the health of the system based on the AGC values Green indicates that the AGC value is in the range 1 to 3000 for each of the enabled channels Yellow indicates that at least one channel is in the range 3000 to 3500 and requires your attention Red indicates that the AGC for at least one channel is in the range 3500 to 4000 For O measurements the DSP4000 reports the AGC level For pH and CO measurements the DSP4000 reports the Reference AGC RAGC the drive level required for detection of the reference signal AGC and RAGC are functionally the same for purposes of monitoring the useful life of the sensing element 2 To view the AGC RAGC Temperature and Pressure in the Run Mode press AUX The DSP4000 will display the temperature and pressure for all active channels Press AUX again and the AGC and RAGC for all active channels are displayed Press AUX again and the display is returned to the normal Run Mode
68. e Capture Text dialog box Figure 4 17 DSP4000 HyperTerminal File Edit View Call Transfer Help S a SendFile Receive File Ch 1 02 460 mmHg 300 AGC 78 RAGC 06 28 2010 11 Ch 1 02 Send TextFile 760 mmHg 300 AGC 78 RAGC 06 28 2010 11 Ch 1 02 760 mmHg 298 AGC 78 RAGC 06 28 2010 11 Ch 1 02 Se cdc deg 160 mnlig 299 AGC 18 RAGE 96 28 2019 11 Ch 1 02 23 933 a 32 0 deg GA mm 201 Ch 1 A 02 j 22 952 32 8 deg oar Text Ch 1 02 22 926 32 0 deg Ch 1 02 23 Ka 0 deg Folder C Documents and Settings Fox Ch 1 02 22 4 32 0 deg Fe uments and Settings dws CAPTURE TXT P LUE A 4 32 0 deg 1 r sh u Lsa cancel _ P Ch 1 02 22 010 11 Ch 1 02 22 sh 32 160 mmHg 298 AGC 78 RAGC 06 28 2010 11 Ch 1 02 23 y 760 mmHg 306 AGC 78 RAGC 06 28 2010 11 Ch 1 02 23 373 32 0 d 760 mmHg 307 AGC 78 RAGC 06 28 2010 11 Ch 1 02 23 932 0 768 mmHg 306 AGC 78 RAGC 06 28 2010 11 Ch 1 02 23 0 260 mmHg 306 AGC 78 RACC 06 28 2010 11 Ch 1 02 23 015 y 32 0 760 mmHg 306 AGC 78 RAGC 06 28 2010 11 Ch 1 02 23 085 32 0 760 mmHg 306 AGC 78 RAGC 06 28 2010 11 RE 0 24 54 ant PERTE 49200 8 N 1 Figure 4 17 Capturing Data from the DP4000 2 Click Browse to browse for and select the destination file for the data or type the full pathname of the file and then click Start The measurement records are added to the file CAPTURE TXT in the example
69. e enclosure cover providing access to the DSP4000 power switch USB flash drive and I O board When the cover is closed and its two locking screws are tightened a gasket provides a watertight seal The external I O panel includes e Four watertight connections called glands for fiber optic cables leading to the probes and sensing elements e Four openings with cord grips for feeding wiring for power temperature and pressure inputs and data outputs into the enclosure and to the connections on the I O board The DSP4000 is safe for use in applications where the instrument will be subjected to wash down procedures when e The glands are occupied by a fiber optic cable connector or plug and tightened e The cord grips are tightened down on the incoming cables or plugs e The front panel cover is closed and the two locking screws are tightened 1 2 Optical Measurements The DSP4000 provides four independent channels for measurement of a specific parameter A channel is an optical path between the DSP4000 processor and a sensing element One example of a fully configured channel could consist of e Armored fiber optic cable connecting a Polestar BioProbe to the channel s gland connector on the DSP4000 bottom panel e Polestar BioProbe containing a waveguide to the attached sensing element e Sensing element attached to the end of the BioProbe The probe and fiber optic cable are available in a variety of configurations and
70. e new factors Prepare the Zero Calibration results Percent condition P2 66 879997 P5 0 007820 To continue lt ENTER gt To apply lt ENTER gt Figure 5 31 Taking the Zero Level Samples DSP4000 Optical Process Monitor User Manual 80 04001 06 74 5 DSP4000 Setup Chapter 6 Care and Maintenance Proper care and maintenance of the DSP4000 will ensure reliable operation of the device throughout the life of the instrument This chapter covers inspection of the DSP4000 replacement of the sensing elements and troubleshooting 6 1 Periodic Maintenance The appropriate maintenance interval for each instrument depends on the application conditions and operating environment Applications that expose the system optics to dirt and grime may require more frequent maintenance as will applications involving higher operating temperatures and pressures Establishing the proper schedule for your application requires periodic visual inspections of the fiber optic cable and sensor AGC levels and calibration factors and zero phase setting of the system You will need the following items to inspect and maintain the DSP4000 e De ionized water e Chem Wipe or soft lint free cloth e Scotch tape e Magnifying glass e Compressed air or nitrogen e Adjustable wrench 6 1 1 Inspection Procedures Measurements made with the DSP4000 are based on variations in the fluorescence lifetimes of sensing membranes impregnate
71. e parameter for each channel is listed as None and the Lot and Factor columns are blank 2 Click File in the upper left corner of the table and choose Load Configuration File from the menu to open the Browse For Folder dialog box 3 Use the dialog box to navigate to the DSP4000 folder on the PC and click OK to load the DSPCALIB DAT file from the selected folder into the table Figure 3 2 a DSP Channel Configuration File Parameter Factor 1 Factor 3 251 006 041 02 ppm Po 66 9 Ksv 0 1 17E 2 269 003 112 pH pKa 7 30 pH lo 5 4 pH hi 10 1 CO2 CO2 Max 60 0 pKa 5 02 pH lo 3 5 pH hi 7 0 Double click Lot cell then click grey button in cell to configure Channel Figure 3 2 Current Configuration File DSP4000 Optical Process Monitor User Manual 80 04001 06 3 Managing Configuration Files 25 The table in Figure 3 2 provides examples of three different sensor types O parts per million Channel 1 pH Channels 2 and 4 and CO Channel 3 Each channel may be configured to handle a sensor from a specific manufacturing lot 251 006 041 in Channel 1 for example which in turn determines the sensor type default unit of measure and calibration factors Calibration factors can be modified in the DSP4000 as described in Calibration on page 69 When you restore a probe to its default settings the calibration factors are read from DSPCALIB DAT on the USB KEY
72. ed to the DSP4000 with the four threaded brass inserts on the back of the unit as shown in Figure C 4 Top View Side View Figure C 4 Unsealed Panel Mounting DSP4000 Optical Process Monitor User Manual 80 04001 06 94 C Mounting Options C 3 2 Flush Mounting Sealed Figure C 5 illustrates flush mounting of the DSP4000 where the mounting panel is sandwiched between the collar of the hinged front panel assembly and the body of the enclosure Flush mounting enables you to seal the interface between the mounting panel and the DSP4000 so you can open the DSP4000 to access the USB KEY without exposure to the process environment The factory engineer should contact Polestar Technical support for further information about flush mounting such as the maximum thickness of the mounting panel Enclosure body assembly Front panel cover assembly Assembly aa Control Process room environment Figure C 5 Flush Mounted DSP4000 DSP4000 Optical Process Monitor User Manual 80 04001 06 95 Appendix D Modbus Option The optional Modbus interface enables you to interact with the DSP4000 using Modbus get and set commands The Modbus interface uses the RS232 connection and a terminal program such as Microsoft Hyper Terminal as described in Chapter 4 Electrical Connections This appendix describes how to set up the Modbus connection and lists the Modbus commands supported by the DSP4000
73. eed Failure Table D 3 Here are two more examples of how the exception codes are used e The user enters the command to get the channel state but a channel has not been selected The DSP4000 responds with the error code 05 indicating that the channel has not been selected Command 3E43027F Response 3EC305FA DSP4000 Optical Process Monitor User Manual 80 04001 06 98 D Modbus Option e When the user enters the command with the function code 4304 the DSP4000 responds with the exception code 06 indicating that the function code is not supported Command 3E43047F Response 3EC306FA D 4 DSP4000 MODBUS Command Set Table D 5 lists the Modbus commands supported by the DSP4000 Get sub function codes start with O and set sub function codes start with 8 Table D 5 Supported Modbus Commands Function Sub Function Name Code 0x Name Code 0x UNIT_STATE 41 RUN_MODE 00 80 SETUP 01 81 SHUTDOWN 02 82 CURRENT_STATE 03 SAVE_LOG_FILE 04 84 LOGIN 42 ADMIN_PW 80 USER_PW 81 MODIFY_ADMIN_PW 82 MODIFY_USER_PW 83 SECURE_LEVEL 04 84 CHANNEL 43 CHNLS_ON 00 SELECT_CH 01 81 CH_STATE 02 82 CH_TIMING 03 83 SENSOR 44 GET_PARAM 00 UNITS 01 81 TIME 82 DATE 83 TEMPERATURE 45 TEMP_SOURCE 00 80 TEMP_VALUE 01 81 HYBERNATION 02 82 DSP4000 Optical Process Monitor User Manual 80 04001 06
74. elect Hibernate Temp in the Temperature menu and press ENTER to view the current setting Adjust Threshold 52 0 deg C lt ESC gt OR lt ENTER gt Figure 5 14 Setting the Hibernate Temperature 3 Use the up or down arrow to increase or decrease the value and then press ENTER to apply the displayed value and return to the Setup menu 4 Display temperature and pressure by pressing AUX twice while in the Run Mode Pressing AUX once displays AGC and RAGC see below Press AUX a third time to return to the Run Mode 5 7 Configure Pressure The DSP4000 automatically compensates for the effect of pressure on O and CO readings using either a manually input pressure value or input from a 4 20 mA pressure gauge Pressure compensation is not required in closed systems such as fluid filled pipes where there is no compressible gas phase Pressure compensation is not used for pH measurements 5 7 1 Manual Pressure Input You can manually enter a pressure value in units of mmHg or PSI Input values must be absolute pressure that is barometric pressure plus gauge pressure The default value is 14 7 PSI 760 mmHg To use a manually input value for pressure compensation 1 Select Pressure from the Setup menu and press ENTER to display the current setting Figure 5 15 left and then press ENTER to show the pressure input options Figure 5 15 right DSP4000 Optical Process Monitor User Manual 80 04001 06 62
75. epair and service any defective component of the system sold Said repairs and service are to be completed by a Polestar technician and not by the user For extended warranties please contact Polestar Technologies Inc at 781 449 2284 Contact Polestar Technologies Inc 220 Reservoir Street Suite 3 Needham Heights MA 02494 T 781 449 2284 F 781 449 1072 http www PolestarTech com Contents CONTENTS sirinin Ketar aKa AAAA A EACK NAKAKARANAS iii PUT ACG iuni iacouatateiatea aE A E E talednainy vii About this Guide nirani a a a a a a vii REVISION Informations iae a aaa vii Safety G ldelNeS rak a akaandaa aR a a aa aaao iaaa vii Technical Support anniina a i a aaia vii Chapter 1 IMtrOQuet On soineann nairat aaaea aada Eat 1 E Ea aE E E A E E esiactsuieieesse iaeys 1 1 1 1 DSP4000 EnclOSUres sieeve sstevensidvaislver hi Aeendienteadime ceed iene 1 1 2 Optical MeaSUreMeNt cee eeeeee e aaen EA EA ee A 2 122 1 Gali rations cs2c5 ice clos a a aea a E EA A S 3 1 2 2 Temperature Compensation 0 ee eer eens 3 1 2 3 Pressure COMPENSATION En Aarna ira aa AE TANE aAA ESEE 4 1 2 4 Automatic Gain Control seii seiseanan a aae aiana 4 1 2 5 DSP4000 Output niais ar ae ear A E a 5 1 2 0 Hibernation Mode ipsini aa a a E a aaa 5 1 3 Specification Shia a aaa a a ad a se 6 Chapter 2 Getting Started sssssssssrrssessrnrssnnrnnnnnrnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nunne 7 221 UNPACKING irea naaa A a a aaa A
76. equires two 5 16 18 x 2 x 3 11 16 round bend U bolts and nuts U bolt braces are not necessary To mount the DSP4000 on a standard 2 inch O D pipe 1 Attach the mounting rails to the back of the DSP4000 with the flanges extending from the top and bottom sides for a vertical pipe Figure C 3 or from the left and right sides for a horizontal pipe 2 Hang the DSP400 from the pipe with the U bolt The U bolt legs should pass through the two inner holes on the mounting rail flange Figure C 3 Pipe Mounting the DSP4000 DSP4000 Optical Process Monitor User Manual 80 04001 06 C Mounting Options 93 C 3 Panel Mounting This section shows two methods for mounting the DSP4000 in a panel In both cases the DSP4000 is inserted through a square hole cut into the panel so that the DSP4000 front panel cover is on one side of the panel and the body of the assembly and the sensor and power connections are on the other The first method is appropriate for mounting the DSP4000 in a panel on an equipment rack while the second method is appropriate for an application where the process environment must be sealed off from the DSP4000 front panel cover C 3 1 Flush Mounting Unsealed If the application does not require sealing the opening in the mounting panel the DSP4000 can be inserted in a 6 25 inch by 6 25 inch hole in the mounting panel and held in place by two pairs of locally made angled mounting brackets The brackets can be attach
77. erature Input ssssssssssrrrrrrsrresssrnnnnnrnnnnunnnsnnnunnnnnenenennn nnana 60 5 5 2 Configuring 4 20 mA Temperature Inputs ssssssssssesrsrnnrrrrneurunsnnnnnnnnenee 60 55 3 RID wis dated herein wate ditaa E deel init ionee aes 61 5 5 4 Set Hibernate Temperature ccccceeeeeeeeceeeaeeeeeeeeeeeeeeeeeaaaaaaaaeeeeeeeeeeaeea 61 5 6 COMPIQUIe PrESSUI Ennii inaa a Na a NA iaa 62 5 6 1 Manual Pressure INPUt resanni senn stenrasoerin ea d innnan naan eeeeeeeeeeaeaa 62 5 6 2 Configuring 4 20 mA Pressure INpUtS sssessssssssssrrrnnrnrnnsnsnnnnnnnnnnnenrennnnn 63 5 7 Configuring the 4 20 mA Data Outputs sssssssssssrsrrrsesesrurnnnnnnnerenrunnnnnnnnenennnne 64 5 7 1 Enable and Scale the Data Output ssssssssssssssssrrrrnsrrrsrnnrrrnssrnnnnrnrennennn 64 5 7 2 Test the 4 20MA Output an daa a aa a a a aaa aa 67 5 8 AGC Display cssedetevr ci iekiar edict addins A ed eens EAE EN E i 67 5 9 Calibration ani rere eeerecrr reer rectreet ecrtc arda aaa re ter rcer reeterrrrrrr EEE 69 5 9 1 Calibration MENU siamania e a a aaa Eana A aaa a Ea aeia 69 5 9 2 Before Y u Galibrat ismiia niant ae a a aai 71 5 9 3 One Point Calibration sssi peirassa iaia aka daaa Eia N i 72 5 9 4 Two Point Calibration sssssssssssssrnrrnsssssssnnrnnnnnnnenennnnnnnnnenenns 73 Chapter 6 Care and Maintenance ssesssssssessesssrrrsrrrnrrrssrrnnrnnernrnnrrnnnnrnnrnne 75 6 1 Periodic Maintenance cce eee eeeeeeeeeee ener eee aeaaea
78. ff until you begin acquiring data 2 Ignore messages concerning the operating system versions and the date and time When it completes the startup routine the DSP4000 will automatically enter Run mode and begin acquiring data from the sensors Figure 2 5 left Of course the measurements will be in error as there are no sensors connected at this time After several attempts to acquire a valid measurement from a channel the DSP4000 will display AGC Limit for the channel Figure 2 5 right AGC Limit means that the DSP4000 is applying maximum gain without a response from a sensor The Status LED turns red as soon as one channel reaches the limit See Automatic Gain Control on page 4 for additional information on AGC Ch 1 Measuring Ch 1 AGC Limit Ch 2 Measuring Ch 2 AGC Limit Ch 3 Measuring ch 3 AGC Limit Ch 4 0 0 SMR pH Ch 4 AGC Limit Figure 2 5 Entering Run Mode with No Connected Sensors 3 Press the ESC key on the front panel to place the DSP4000 in Standby mode and display the Main menu 4 Press the down arrow to select Setup Mode Figure 2 6 left and then press ENTER to display the Login menu Figure 2 6 right gun Node user Login Admin Login Save Log File Turn Off DSP4000 Figure 2 6 DSP4000 Main Menu and Login Menu 5 Press ENTER to bypass the login and display the Channel Selection menu Figure 2 7 left DSP4000 Optical Process Monitor User Manual 80 04001 0
79. for a CO sensor You can view the factors by opening the file in the DSP Channel Configuration dialog box as described in Reviewing the Configuration File on page 24 In the example in Figure 5 20 the scale for the pH sensor in channel 2 is 5 4 to 10 1 Factors 2 and 3 and the high end of the scale for the CO sensor in channel 3 is 60 Factor 1 fa DSP Channel Configuration Fie Channel Lot Parameter Factor 1 Factor 2 Factor 3 1 251 006 041 02 ppm Po 66 9 Ksv 0 7 82E 3 2 269 003 112 pH pKa 7 30 pH lo 5 4 pH hi 10 1 3 272 001 064 C02 CO2 Max 60 0 4 262 003 025 pH pKa 5 02 pHlo 3 5 pH hi 7 0 Double click Lot cell then click grey button in cell to configure Channel Figure 5 20 Scaling Values in the Calibration File You can program the DSP4000 to use less than the full range for an O or CO measurement output For example you can set the upper limit for an O sensor output so that 20 mA equals 40 The range for pH measurement outputs is fixed To view and adjust the range 1 Select Full Scale Adjust in the 4 20 mA menu Figure 5 19 left and press ENTER to display the range specific to the sensor type Figure 5 21 and Figure 5 22 4to20mA 4to20mA Full Scale Adjust 20mA 99 Sat Fixed at 5 4 to 10 1 pH Hit lt ENTER gt Figure 5 21 Full Scale Adjust for O left and pH right 4to20mA Scale 4mA 0 20mA 60 u
80. for each channel are marked on the lower terminal block as listed in Table 4 4 Table 4 4 Terminal Labels for 4 20 mA Data Outputs Channel Terminal Labels Channel 1 DATA 1 4 20 29 DATA 1 4 20 30 Channel 2 DATA 2 4 20 31 DATA 2 4 20 32 Channel 3 DATA 3 4 20 33 DATA 3 4 20 34 Channel 4 DATA 4 4 20 35 DATA 4 4 20 36 NOTE The polarity of each terminal is clearly marked Follow the instructions below and the wiring diagrams in Figure 4 8 to insure that you have the correct polarity to enable the output of the signal To wire the data output of a single channel using the DSP4000 internal power supply 1 Connect DATA n 4 20 to on the ammeter 2 Connect DATA n 4 20 to 24VDC 1 3 Complete the loop by wiring GND 2 to on the ammeter Figure 4 8 shows wiring for output from a single channel Channel 2 on the left and a scheme for multiple connections right using the DSP4000 internal power supply in both cases DSP4000 Optical Process Monitor User Manual 80 04001 06 40 4 Electrical Connections DSP4000 DSP4000 Power In Power In Terminals Terminals 23 89 E1 64 83 4 89 34 aN ay SE ape a ee ale a ale AE eg Ammeter Channel 2 Figure 4 8 Wiring for 4 20 mA Outputs The DSP4000 outputs only the measurement value for the specific channel The receiving application must be configured to prope
81. g C 22 9 deg C Figure 5 11 Specifying the Value for Manual Temperature Input 5 6 2 Configuring 4 20 mA Temperature Inputs To configure temperature compensation so that a 4 20 mA analog signal provides the temperature value 1 Select 4 20 Input in the Temperature Source menu and press ENTER to select the option and display the low end of the DSP4000 Optical Process Monitor User Manual 80 04001 06 60 5 DSP4000 Setup temperature span that is the temperature represented by 4 mA Figure 5 12 left Temperature Temperature 4 20 Input 4 20 Input Lo 0 deg C Lo 0 deg C Hi 50 deg C Figure 5 12 Setting Temperature Range for a 4 20 mA Input 2 Press the up or down arrow to increase or decrease the low end of the span one degree at a time or hold the key down to rapidly increase or decrease the value 3 Press ENTER to display the high end of the span that is the temperature represented by 20 mA Figure 5 12 right 4 Use the up or down arrow to increase or decrease the high end of the temperature range and then press ENTER to accept the displayed settings and return to the Setup menu 5 6 3 RTD To configure temperature compensation to use input from a PT100 RTD 1 Select RTD in the Temperature Source menu and press ENTER to select and display the option Figure 5 13 Temperature RTD Figure 5 13 Confirming Selection of an RTD for Temperature Compensa
82. gh menu Modify Admin PW and Modify User PW display the Enter PW screen which you can use to reset the Admin and User passwords respectively Select Modify SecureLevel to display the current security level Figure 5 6 right DSP4000 Optical Process Monitor User Manual 80 04001 06 5 DSP4000 Setup 57 Modify Admin PW Current SecureLevel Modify User Pw Modify SecureLevel up down to adjust lt ESC gt lt ENTER gt Figure 5 6 Changing Security Level 7 Press the up arrow to increase the level to 1 requiring login with the User password or to 2 requiring login with the Admin password 8 Press ENTER to return to the Admin menu and then press ESC to proceed to the Channel Selection menu 9 Select a channel to configure and press ENTER to display the Setup menu 5 2 Enable Disable To enable or disable a channel 1 Select Enable Disable in the Setup menu and press ENTER to display the current state of the channel Figure 5 7 left 2 Press ENTER to display the next menu select Enable or Disable Figure 5 7 right and press ENTER to make the change and return to the Setup menu 5 3 Units Disabled Current Setting To change lt ENTER gt Disable Figure 5 7 Enabling the Channel The available units of measure are dictated by the parameter type of the sensing element and in the case of O the sensor s range of operation Table 5 3 Table 5 3
83. hat is not connected to a sensor and properly configured With the default settings all functional channels are enabled See Enable Disable on page 57 Units Allows you to select the unit of measure for the channel Units are dependent on sensor type Refer to Units on page 57 Timing Specifies the frequency with which the DSP4000 acquires data from the sensor connected to the channel The default is once every 4 seconds which is the minimum sampling interval when all four channels are in use Go to Timing on page 58 Temperature Selects the input method for temperature compensation manual input of a value RTD or 4 20 mA temperature sensor The default is Manual Input of 20 C See Configure Temperature on page 59 DSP4000 Optical Process Monitor User Manual 80 04001 06 5 DSP4000 Setup 55 Table 5 1 DSP4000 Setup Menu Continued Menu Choice Description and Default Setting Pressure Selects the input method for pressure compensation manual input of a value or 4 20 mA pressure gauge The default is Manual Input of 14 7 PSI Refer to Configure Pressure on page 62 4 20 mA Enables disables 4 20 mA output of measurement data for the channel and allows you to adjust the scaling and test the output The default is all four channels enabled and scaled for the sensor type Go to Configuring the 4 20 mA Data Outputs on page 64 AGC For O senso
84. ibration on page 69 for each updated channel DSP4000 Optical Process Monitor User Manual 80 04001 06 31 Chapter 4 Electrical Connections Electrical connections to the DSP4000 are made using terminal strips and an RJ 11 socket on the I O board as shown in Figure 4 1 The exact terminal block positions for connecting power RTDs and 4 20 mA inputs and outputs are indicated on the I O board adjacent to each terminal block i 4 EEN EZE ay oe OLESTAR k hal A esceseSeee se beceoe 4 20 mA Inputs Temperature Pressure Process Monitor DSP4000MC WO 44 224 E TKM TAM TKM2Fu Power Cable to AC Adapter Figure 4 1 DSP4000 I O Board The four cord grips on the bottom panel Figure 4 2 enable you to bring connecting wires into the DSP4000 enclosure while maintaining a water tight seal To bring the wire into the DSP4000 enclosure 1 Loosen the locking nut on the cord grip and remove the cylindrical metal plug Figure 4 2 shows a DSP4000 where the left most and right most cord grips have already been used for the power cable and an RS 232 connection respectively The plug has been removed from the grip next to the RS 232 cable 2 Store the cylindrical plug in a safe place DSP4000 Optical Process Monitor User Manual 80 04001 06 32 4 Electrical Connections Cord grips for power and I O cables Gland connectors for fiber optic cables from Polestar
85. iceNet Error Messages Code Description 0 No error 2 Resources are not available 8 Service is not available 9 There is an invalid attribute value in the command 11 The device is already in request mode 12 The object state is in conflict with the command 14 The attribute is not settable 15 A permission check failed 16 The device state prohibits the command execution 17 There was no response from the network device before expiration of the timeout period 19 Not enough data received from the device DSP4000 Optical Process Monitor User Manual 80 04001 06 90 B DSP4000 Error Messages Table B 4 DeviceNet Error Messages Continued Code Description 20 The attribute is not supported 21 Too much data has been received 22 The object does not exists 23 The reply data too is large internal buffer too small 48 The device is not configured an explicit message channel is not established for the device 50 There is a format error in response telegram 54 Another get or set command is still active 55 The MAC ID in msg device_adr is out of range 57 Sequence error in fragmented response sequence 200 The device is not configured that is no database found DSP4000 Optical Process Monitor User Manual 80 04001 06 91 Appendix C Mounting Options The DSP4000 Optical Process Monitor is shipped w
86. ifying Temperature Source Method Value Manual Entry 00 4 20 mA 01 RTD 02 Set the temperature source Command 3E4580xxyy where xx is the source per Table D 8 and yy is the LRC Response 3E45xxyy Get temperature value Command 3E45017C Response 3E45XXXXXXXXYyY where xXXxxxXx is the hex representation of the floating point value and yy is the LRC see Table D 9 for examples Set temperature value Command 3E4581XXXXXXXXYyY where xxxxxxxx is the hex representation of the floating point value and yy is the LRC see Table D 9 for examples DSP4000 Optical Process Monitor User Manual 80 04001 06 D Modbus Option 107 Response 1 3E45XXXXXXXXYY Table D 9 Example Temperature Values Float Value Hex Representation LRC 20 0 0x41A00000 9C 30 0 0x41F00000 4C 50 0 0x42480000 F3 70 0 0x428C0000 AF Get the setpoint for Hibernation mode Command 3E45027B Response 1 3E45XXXXXXXXYY where xxxxxxxx is the hex representation of the floating point value and yy is the LRC see Table D 9 for examples Set the Hibernation mode temperature Command 3E4582XXXXXXXXYyY where xxxxxxxx is the hex representation of the floating point value and yy is the LRC see Table D 9 for examples Response 3E45XXXXXXXXYyY D 6 6 Pressure Pressure values in get and set commands are single precision 32 bit floating point values expressed as hexadecimal numbers The unit of measure
87. ility Install directory on the PC double click DSP Config Utility Install and follow the instructions in the setup wizard to install the program NOTE This setup program installs the required version of Microsoft NET Framework if that version is not already present on your system Loading this version will not affect already installed versions of NET Framework used by other programs on the PC DSP4000 Optical Process Monitor User Manual 80 04001 06 24 3 Managing Configuration Files The installation program will place a shortcut to the utility SS on the PC desktop 3 2 Reviewing the Configuration File You can now access the configuration file just copied from the USB KEY to verify that the correct calibration information is entered for each channel To review the backup copy of the configuration file 1 Double click the DSP Config Utility desktop icon S The utility shows a picture of the DSP4000 for a couple of seconds and then displays a channel configuration table Figure 3 1 There is a File menu on the left above the table a DSP Channel Configuration Fie Save Configuration Fi Sane Roisin ie Parameter Factor 1 Factor 2 Factor 3 Load Configuration File None None None None Double click Lot cell then click grey button in cell to configure Channel Figure 3 1 DSP Configuration Table and File Menu At this point the channels are not configured Th
88. ing the DSP4000 with the Read Calib File function You will also use the Read Calib File function when updating the configuration files on the USB KEY as described in Chapter 3 Managing Configuration Files To safely remove the USB KEY from the DSP4000 1 Press ESC until the Main menu appears The DSP4000 stops acquiring data from the sensors The Status LED remains unchanged 2 Select Setup Mode Figure 2 19 left and press ENTER to display the Login menu Figure 2 19 right Run Mode Admin Login Save Log File Turn Off DSP4000 Figure 2 19 DSP4000 Main Menu and Login Menu DSP4000 Optical Process Monitor User Manual 80 04001 06 2 Getting Started 19 3 Press ENTER to bypass the login and display the Channel Selection menu Figure 2 20 left Login is not required because the security is not yet enabled See Modifying the Security Level and the Passwords on page 55 for information on enabling security 4 Press the up arrow key to select Read Calib File Figure 2 20 right and then press ENTER crete 2 a Channel 3 Disabled Channel 4 Disabled Channel 3 Disabled Channel 4 Disabled Set Date and Time Figure 2 20 Setup Menu 5 Wait for the DSP4000 to indicate that it has closed the log file Figure 2 21 left The DSP4000 then prompts you to remove the USB KEY Figure 2 21 right Closing Log File Log File Closed Unplug U
89. ith two PVC mounting rails that enable you to attach the DSP4000 enclosure to a wall or fasten the unit to a standard 2 inch O D pipe using U bolts Other mounting options include sealed and unsealed flush panel mounting C 1 Standard Wall Mounting The standard mounting hardware includes the two rails and screws shown at the bottom of Figure C 1 The back of the DSP4000 enclosure has four raised connection points with threaded brass inserts for the mounting screws The inside face of each mounting rail has two recessed holes that fit over the connection points on the back of the DSP4000 Four equally spaced raised connection points on the back of the unit allow the rails to be attached to the top and bottom or to the left and right sides The inside of the rail has countersunk screw holes that fit over the raised connection points on the back of the DSP4000 The rail flange has pre drilled holes for wall mounting and for U bolts for attaching to a 2 inch pipe Figure C 1 Hardware for Wall Mounting e Attach the mounting rails to the back of the DSP4000 such that the flanges extend from the top and bottom of the DSP4000 Figure C 2 left or from the right and left sides Figure C 2 right DSP4000 Optical Process Monitor User Manual 80 04001 06 92 C Mounting Options Figure C 2 Attach the Rails to Back of the DSP4000 C 2 Pipe Mounting Pipe mounting r
90. lete the loop by wiring on the power source to on the gauge Pressure Pressure gauge CH 4 Self powered pressure gauge Figure 4 6 4 20 mA Input Loops for Pressure Compensation To wire pressure inputs for multiple channels using the same external power source as shown in Figure 4 7 1 Connect PRESSn 4 20 IN to on the gauges 2 Connect PRESSn 4 20 IN to on the power source 3 Complete the loop by wiring on the power source to on the gauges Figure 4 7 Wiring Multiple Pressure Loops Using the Same External Power Source DSP4000 Optical Process Monitor User Manual 80 04001 06 4 Electrical Connections 39 Do the following after you create the 4 20 mA loops 1 Refer to the pressure gauge documentation for scaling information 2 Use the DSP4000 Setup menu to enable and scale the pressure input for each connected channel as described in Configuring 4 20 mA Pressure Inputs on page 63 4 6 Connecting 4 20 mA Data Outputs The DSP4000 provides an isolated 16 bit 4 20 mA output for each channel for data acquisition and use in process control The output loops require a 24 VDC power source Source the power for the output loops from the DSP4000 internal power supply or an external DC supply in the range of 15 to 28 Volts To tap the power in terminals in the upper left of the I O board e Connect to 24VDC 1 e Connect to GND 2 Loop connections
91. lture headspace monitoring water wastewater treatment and food and beverage production Polestar sensors are available in a variety of configurations including a stainless steel BioProbe simple peel and stick puncture probes and lab probes flow cells and multi well plates Sensors are available that can be sterilized by CIP SIP autoclave and gamma radiation Measurements are not affected by ambient light Figure 1 1 DSP4000 Optical Process Monitor 1 1 Features This section covers key features of the DSP4000 with references to specific instructions in subsequent chapters 1 1 1 DSP4000 Enclosure The DSP4000 electronics are housed in a 6 25 in by 6 25 in by 5 75 in 159 mm by 159 mm by 146 mm ABS polycarbonate NEMA 12 4X certified enclosure DSP4000 Optical Process Monitor User Manual 80 04001 06 2 1 Introduction The DSP4000 can be mounted on a wall equipment rack or piping as described in Mounting Options on page 91 The preferred orientation is vertical such that the front panel cover is facing out and the external I O panel is underneath the unit The front panel includes a four line video screen for displaying measurements and system setup menus and a set of pushbutton function keys which you will use to start configure and stop the monitor A three color Status LED indicates normal operation green warnings yellow and alerts for required maintenance red The front panel is also th
92. ment s manufacturing lot and updating the USB KEY using the DSP Configuration Utility This chapter describes how to download the file install and run the configuration utility and update the configuration file on the USB KEY Even before you need to change a sensing element it is a good idea to copy the contents of the USB KEY onto a PC to create a backup of the configuration file and the DSP4000 programs 3 1 Copying the USB KEY and Installing the Configuration Utility To back up the USB key and install the configuration utility 1 Use Read Calib File in the Channel Selection menu as described in Removing the USB KEY from the DSP4000 on page 18 to safely remove the USB KEY 2 Insert the USB KEY into a USB connector on the PC and use Explorer to view the contents of the USB KEY The file DSPCALIB DAT in the root directory of the USB KEY contains the parameter and calibration information for the probes to be connected to each of the four channels The USB KEY also contains user documentation and the log files discussed in Chapter 2 The folder DSP Config Utility Install includes a setup program for the DSP Configuration Utility which is used to edit DSPCALIB DAT 3 Create a DSP4000 folder or similarly named directory on the PC and copy the entire contents of the USB KEY to the new folder to back up the USB KEY 4 Safely remove the USB KEY from the PC and return it to the DSP4000 5 Navigate to the DSP Config Ut
93. mmand 3E41037E Response 3E4100yy for Run mode 3E4101yy for Setup mode 3E4102yy for Shut Down mode Close the current log file and start a new log Command 3E4184FD Response 3E4102yy the DSP4000 is in Shutdown mode D 6 2 Login Login with the Admin password Command 3E4280xxxxyy where xxxx is the four digit password and yy is the LRC Response 13E42xxxxyy Login with the User password Command 13E4281xxxxyy Response 13E42xxxxyy Modify the Admin password Command 13E4282xxxxyy where xxxx is the new four digit password and yy is the LRC Response 13E42xxxxyy DSP4000 Optical Process Monitor User Manual 80 04001 06 D Modbus Option 103 Modify the User password Command 3E4283xxxxyy Response 13E42xxxxyy Set security level to 0 so that no password is required to enter Setup mode Command 3E428400FC Response 3E4200yy Set security level to 1 to require a User login to enter Setup mode Command 3E428401FB Response 3E4201yy Set security level to 2 to require an Admin login to access Setup commands Command 13E428402FA Response 3E4202yy Get the current security level Command 13E42047C Response 3E4200yy when security level 0 3E4201yy when security level 1 3E4202yy when security level 2 D 6 3 Channel In the following commands yy is the LRC determined by LRC Calculation exe or the LRC in the DSP4000 response Get the number of channels on Command 3E43007F Response 3E43xxyy whe
94. n Figure 5 18 See Connecting 4 20 mA Pressure Inputs on page 37 for information on wiring the pressure inputs To configure input from a 4 20 mA device for pressure compensation 1 Select Pressure from the Setup menu and press ENTER to display the current setting Figure 5 15 left and then press ENTER to show the pressure input options Figure 5 15 right 2 Choose either 4 20 Input mmHg or 4 20 Input PSIG and then press ENTER to select the option and display the Lo value that is the pressure measurement represented by a 4 mA signal Figure 5 17 left DSP4000 Optical Process Monitor User Manual 80 04001 06 5 DSP4000 Setup 65 Pressure Pressure 4 20 Input mmHg 4 20 Input mmHg Lo 0 mmHg Lo 0 mmHg Hi 1520 mmHg Figure 5 17 Setting the Pressure Range 3 Use the up or down arrow to increase or decrease the Lo value as necessary and then press ENTER to display the Hi value that is the pressure measurement represented by a 20 mA signal If you selected 4 20 Input PSIG the DSP4000 also prompts you to enter a value for the barometric pressure which will be added to the gauge pressure input to set the absolute pressure When the DSP4000 is in Run mode the displayed pressure in a Hyper Terminal window will be the total pressure of the system that is gauge pressure plus barometric pressure If the output of the pressure gauge is absolute pressure PSIA enter O in the Bar P
95. ncludes channel number parameter value unit of measure temperature and pressure values and units and date and time stamps This section covers e Making the cable connection e Going online to the DSP4000 using Hyper Terminal e Importing the data into a Microsoft Excel spreadsheet 4 7 1 Making the Cable Connection The RS 232 connection between the DSP4000 and the PC is made with an RJ 11 to DB9 cable Figure 4 10 left The RJ 11 jack is plugged into the socket on the right side of the I O board adjacent to the USB KEY see Figure 4 1 on page 31 The DB9 end of the cable is plugged into one of the I O ports on the PC If the PC does not have an I O port with a DB9 connector as is the case with many laptop computers use a DB9 to USB cable Figure 4 10 right and a USB port on the PC to complete the connection Figure 4 10 Cables for the RS 232 Connection The drawings in Figure 4 11 show the RJ 11 receptacle on the left and the RJ 11 plug on the right The plug is oriented so the hook that you press to release the plug from the socket is underneath RJ 11 Socket l in the DSP4000 RJ 11 jack The left most with hook and right most underneath terminals are not used BRGY Figure 4 11 RJ 11 Socket and Jack DSP4000 Optical Process Monitor User Manual 80 04001 06 4 Electrical Connections 43 The RJ 11 connector inside the DSP4000 has six terminals only the middle four are used for the RS 2
96. ncy check LRC value calculated on the preceding part of the message Table D 2 shows the response 3E410081 to a successful set Run mode command Table D 2 Response to Set Mode Command 3E 41 00 81 lt lt Start DSP4000 Function Run LRC Carrier address Code Mode return Unit State line feed DSP4000 Optical Process Monitor User Manual 80 04001 06 D Modbus Option 97 D 3 Exception Codes In case of errors or exceptions the DSP4000 returns exception codes as function codes with the most significant bit MSB set followed by one of the two digit codes listed in Table D 3 Table D 3 Exception Codes Code Description 01 Invalid function code 02 Invalid address the DSP4000 address is always 3E 03 Invalid data 04 Login failure 05 Channel select failure setup mode failure or channel not configured 06 Sub function code not supported 07 Out of Range 09 One or more channels disabled or channel timing is not correct For example when the security level is 1 User login required or 2 Admin login required you must be logged in before invoking the Setup mode 3E418181 Table D 4 shows the DSP4000 response 3EC104FD to the command if you are not logged in Table D 4 Response to Set Mode Command Error 3E C1 04 FD lt l Start DSP4000 Function Exception LRC Carrier address Code with Code return MSB set Login line f
97. ngle precision 32 bit floating point values expressed as hexadecimal numbers Get the state of the channel s 4 20 mA output Command 3E48007A DSP4000 Optical Process Monitor User Manual 80 04001 06 D Modbus Option 109 Response 3E48xxyy where xx is either 00 for Off or 01 for On and yy is the LRC Set the state of the channel s 4 20 mA output Command 3E4880xxyy where xx is either 00 for Off or 01 for On and yy is the LRC Response 3E48xxyy Get the full scale adjust value Command 3E480179 Response 3E48XXXXXXXXYY where xxxxxxxx is the hex representation of the floating point value that is the high end of the output scale and yy is the LRC see Table D 12 for examples Set the full scale adjust value Command 3E488 1xxxxxxxxyy where xxxxxxxx is the hex representation of the floating point value that is the high end of the output scale and yy is the LRC see Table D 12 for examples Response 3E48XXXXXXXXYY Table D 12 Example 4 20 mA Full Scale Adjust Values Float Value Hex Representation LRC 850 0 0x44548000 62 759 6 0x443DE666 13 900 0 0x44610000 D5 Test the 4 20 mA output Command 3E4882XXXXXXXXYyY where xxxxxxxx is hex representation of the floating point test value and yy is the LRC See Table D 13 for examples Response 3E48XXXXXXXXYY DSP4000 Optical Process Monitor User Manual 80 04001 06 110 D Modbus Option Table D 13 Example Test Sign
98. nitial test value 4 0 mA below the menu Figure 5 23 left 2 Press the up or down arrow to increase or decrease the value and press ENTER to output the value Figure 5 23 right The up arrow is disabled when the test value is 20 0 mA Likewise the down arrow is disabled when the test value is 4 0 mA Enable Disable Enable Disable Full Scale Adjust Full Scale Adjust Test Test 4 0 Test 6 1 Figure 5 23 Testing a 4 20 mA Data Output 3 Verify the output at the host computer or device where the output is to be read 4 Change the output again press ENTER and verify the output at the receiving device Press ESC to return to the 4 20 mA Output menu 6 Press ESC a second time to return to the Setup menu 5 9 Display of AGC RAGC temperature and pressure The DSP4000 controls the drive level of the LED light source that excites the fluorescence sensing chemistry of the Polestar sensing elements in order to maintain constant levels of recovered DSP4000 Optical Process Monitor User Manual 80 04001 06 68 5 DSP4000 Setup photodetector signal This Automatic Gain Control AGC feature optimizes the photodetector signals at the analog to digital converter of the DSP4000 microprocessor and provides a direct indication of the status of the system AGC values range from 1 to 4000 with a higher value indicating a greater amount of gain to achieve the detector signal level sought by the DSP4000 Th
99. nnel you want to configure to display the Browse button Click and then click Load File in the Channel dialog box labeled Channel 3 in Figure 3 6 Use the Open dialog box Figure 3 7 to browse for and select the downloaded file and then click Open DSP4000 Optical Process Monitor User Manual 80 04001 06 3 Managing Configuration Files 29 Open F 2 My Documents My Computer My Network O Calibration files x c Ea Q Cancel File name Places zi osP 400 Files of type Calibration File dat ZA Figure 3 7 Selecting the Calibration File 10 11 Calibration information for the lot number is displayed in the row for the selected channel Review the channel configuration table to verify that it reflects the desired configuration for the DSP4000 Click File in the upper left corner of the table and choose Save Configuration File from the menu use the Browse for Folder dialog box to select the USB KEY as the destination folder and then click OK Figure 3 8 left Click Yes in the Warning dialog box to overwrite the file on the USB KEY and then OK in DSP Config Utility message dialog box Figure 3 8 right Browse For Folder ax Browse to the destination folder x The configuration file already exists Click YES to overwrite it or NO to cancel Warning W My Compute
100. on the login page to display a registration form e Enter your name a desired username email address and a password of your choice e Click Register to return to the login page Enter your username and password to log into the Support area and click Calibration Files by Lot Number on the main Support area page Figure 3 3 left DSP4000 Optical Process Monitor User Manual 80 04001 06 26 3 Managing Configuration Files 3 Select the type of sensing element ppm O2 for example on the first File Repository page Figure 3 3 right to display links to the calibration files for various lots of the element type Main Menu File Downioada Polestar Support Site File Repository oF Containers Folders Files User Menu Your Details E Calibration Files by Lot Number Logout z amp Configuration Files 2 Documentation Submit Fil R hnok b ru PHP g Polestar Support Site File Repository Calibration Files by Lot Number Containers Fokiers Files 6 CO2 Ce oH iy ppb 02 Ge omg 02 6 Sub ppb 02 earch Repositor Submit File Figure 3 3 Navigating to a Calibration File in the Polestar Technologies Support Area 4 Page through the listings Figure 3 4 left and then click the lot number of the sensing element to place the file on the download page Figure 3 5 You can also use the Repository Search to select the file e Click Repository Search on the bottom of any of the pages
101. ovided in the next three sections As you make these connections please remember the following e Be Safe Turn the power off before making any connections The ON OFF switch is located in the upper right corner of the I O board adjacent to the USB KEY DSP4000 Optical Process Monitor User Manual 80 04001 06 4 Electrical Connections 35 e You must provide DC power for the loops They are not wired to receive power from the DSP4000 e The power source must be in the range of 15 Volts to 28 Volts e There are two options e Power the loops with a third party power supply e Use the DSP4000 internal power supply by tapping the power in terminals in the upper left of the DSP4000 I O board e Follow factory or lab policy in choosing between external power or the DSP4000 internal power supply In the absence of a defined policy or practice Polestar recommends that you use external power for the input loops and the DSP4000 internal power supply for the output loops e Polarity is important The polarity of each terminal is clearly marked on the I O board as the correct polarity is essential for the functionality of the 4 20 mA loops e You must scale the inputs to the DSP4000 using the Setup menu as described in Configure Temperature on page 59 and Configure Pressure on page 62 so that the DSP4000 can properly interpret the analog signals e You must scale the output of each channel at the receiving device or s
102. p down left right to adj ESC ENTER 4to20mA Scale 4mA O 20ma up down left right to adj ESC ENTER Figure 5 22 Full Scale Adjust for CO2 2 Adjust the scale for the sensor type For O you can change the upper end of the range e Press the up or down arrow to increase or decrease the value to the desired level and then press ENTER to apply the displayed setting DSP4000 Optical Process Monitor User Manual 80 04001 06 5 DSP4000 Setup 67 For pH the range is preset and cannot be changed e Press ENTER to return to the 4 20 mA menu For CO you can adjust both the lower and upper limits e Press the left arrow to select the 4 mA value or right arrow to select the 20 mA value e Use the up or down arrow to increase or decrease the selected value and then press ENTER to apply the displayed settings NOTE Make sure that the 4 20 mA output is scaled at the receiving device or system so that it can be correctly interpreted and that the units and other labels reflect the configuration in the DSP4000 5 8 2 Test the 4 20mA Output Testing a 4 20 mA output involves generating various signal levels from the DSP4000 and confirming the values at the host computer or device where the output is to be read If the output is not fully connected to the device use an ammeter to read the output To test the 4 20 mA output 1 Select Test in the 4 20 mA menu and press ENTER to display the i
103. plication by measuring a gas mixture or liquid with a known level of pH O2 or CO2 as well as a zero level For pH the zero level is the first value Display Shows the calibration factors currently used with the Calibration sensing element Restore Loads the original calibration factors for the Defaults sensing element from the configuration file on the USB KEY DSP4000 Optical Process Monitor User Manual 80 04001 06 70 5 DSP4000 Setup Table 5 6 Calibration Menu Options Continued Selection Description Sensor Lot Displays the lot number of the sensor so you can Number confirm that the calibration information in the USB KEY matches the attached sensor Checking the Sensor Lot Number Each sensing element has specific calibration factors which are programmed into the USB KEY delivered with the sensing element Always be sure that the correct calibration factors are being used with the associated sensors and that the correct sensing element is assigned to the particular channel You can do so by comparing the sensor manufacturing lot number on the shipping documents with the lot number in the USB KEY 1 Scroll to Sensor Lot Number in the Calibration menu and press ENTER to display the information Figure 5 26 Sensing Element Lot Number 251 006 041 lt ESC gt or lt ENTER gt Figure 5 26 Display Sensor Lot Number 2 Press ESC or ENTER to return to the Se
104. r Se Local Disk C a 2 HP_RECOVERY D RCS My Pictures R G Control Panel Q Shared Documents amp Administrator s Documents FIA Nacte Rac imente Make New Folder a Gee DSP Config Utility DSP configuration file has been written wv Figure 3 8 Saving the Configuration File to the USB KEY 12 Repeat the Save Configuration File step this time saving the file to the DSP4000 folder on the PC to update your backup file or to a different location if you are maintaining different versions of the configuration DSP4000 Optical Process Monitor User Manual 80 04001 06 30 3 Managing Configuration Files 13 Remove the USB KEY from the PC carefully insert the USB KEY into the USB connector on the DSP4000 I O Board and press the ENTER key on the DSP4000 front panel The DSP4000 reads the new configuration data for the effected channels and displays the Main menu Setup Mode Save Log File Turn Off DSP4000 Figure 3 9 Reading the Updated Configuration File 14 15 Use the Setup menu to ensure that the units and other configuration factors are appropriate see Chapter 5 DSP4000 Setup For any channel that has a new sensor lot number the DSP4000 reads the calibration factors from the USB KEY overriding the previous calibration for the channel Perform a one point calibration see Cal
105. r User Manual 80 04001 06 28 3 Managing Configuration Files 3 4 Loading the File onto the USB KEY The next step is to use the DSP Configuration Utility to save this file to the USB KEY To update the configuration file on the USB KEY 1 Choose Read Calib File in the Channel Selection menu as described in Removing the USB KEY from the DSP4000 on page 18 to safely remove the USB KEY Insert the USB KEY into a USB connector on the PC Double click the DSP Configuration Utility desktop icon Sa The utility displays a picture of the DSP4000 for several seconds and then displays the channel configuration table You can load the current configuration file directly from the USB KEY or from the DSP4000 folder on the PC Click File in the upper left corner of the table and choose Load Configuration File from the menu to open the Browse For Folder dialog box Use the dialog box to navigate to the USB KEY or to the DSP4000 folder on the PC and click OK to copy the DSPCALIB DAT file from the selected location to the table Figure 3 6 a DSP Channel Configuration File 22 Channel 3 r2 Factor 3 251 006 041 02 pp 1 17E 2 269 003 112 pH 5 4 pH hi 10 1 Clear Channel 3 5 pH hi 7 0 Cancel t Double click Lot cell then figure Channel Figure 3 6 Current Configuration File 6 Double click inside the Lot cell for the cha
106. r optic path To replace the sensing element 1 2 Unscrew the tip from the BioProbe by twisting it counter clockwise CAUTION The sensing element is designed to seal when finger tight Never use pliers or any other tool to loosen or tighten the sensing element as the tools can damage the sensing element and probe body Screw the replacement element onto the end of the probe Calibration information for the sensing element is contained in a calibration file that includes the sensor type and the calibration factors for all elements in the same manufacturing lot You can download the calibration file from the Support area on the Polestar Technologies web site Update the configuration file on the USB KEY as described in Loading the File onto the USB KEY on page 28 NOTE All Polestar sensors including sensing elements iDots peel and sticks and puncture probes are sensitive to ambient light and will photo bleach over time unless stored in a dark place between uses Bright sun light will accelerate the aging process of the sensor Photo bleaching affects the useful life of the sensing element but not the accuracy of measurements Sensing elements removed from service should be bagged identified and stored in a dark area DSP4000 Optical Process Monitor User Manual 80 04001 06 78 6 Care and Maintenance 6 3 Troubleshooting Table 6 1 provides a brief troubleshooting guide to help quickly
107. rate can be set as high as 999 seconds The sampling rate is also applied to the inputs for temperature and pressure compensation The rate set for any one channel is independent of the rates for the other channels except that the minimum rate increases by a second for each additional channel that is enabled Thus when all four channels DSP4000 Optical Process Monitor User Manual 80 04001 06 5 DSP4000 Setup 59 are enabled the minimum rate is 4 seconds Table 5 4 An entry of 0 seconds defaults to 1 second Table 5 4 Minimum Sampling Rate Channels in Use 1 2 3 4 Minimum Timing Interval per 1 sec 2 sec 3 sec 4 sec Channel The sampling rate has a direct impact on the lifetime of the sensing element as the rate of sensor aging via photo bleaching is directly proportional to the frequency of readings being taken To change the frequency of readings 1 Select Timing in the Setup menu and press ENTER to display the current sample rate Figure 5 9 left 2 Press the left and right arrows to scroll the selection between ones tens and hundreds 3 Use the up and down arrow to increase or decrease the selected digit 4 Press ENTER to apply the displayed value and return to the Setup menu Current Setting Current Setting 004 sec OMl2 sec up down left right up down left right to adj ESC ENTER to adj ESC ENTER Figure 5 9 Adjusting the Sampling Rate
108. re xx is the number of channels Select a channel Command 3E4381xxyy where xx is the channel number 01 to 04 and yy is the LRC Response 3E4301yy Channel 1 selected 3E4302yy Channel 2 selected 3E4303yy Channel 3 selected 3E4304yy Channel 4 selected Get the selected channel Command 3E43017E Response 3E4301yy Channel 1 selected 3E4302yy Channel 2 selected 3E4303yy Channel 3 selected 3E4304yy Channel 4 selected DSP4000 Optical Process Monitor User Manual 80 04001 06 10 D Modbus Option Enable the selected channel Command 3E4382017E Response 3E4301yy Disable the selected channel Command 3E4382007F Response 3E4300yy Get the channel state Command 3E43027D Response 3E4301yy channel enabled Response 3E4300yy channel disabled Set channel timing Command 3E4383xxyy where xx is the interval in seconds Response 3E43xxyy Get channel timing Command 3E43037C Response 3E43xxyy where xx is the interval in seconds D 6 4 Sensor In the following commands yy is the LRC Get the parameter name Command 3e44007E Response 13E44xxyy where xx is the code for the parameter name Table D 6 Table D 6 Codes for Parameter Names Code Parameter 00 O High 01 O Medium 02 pH 03 O Low 05 CO DSP4000 Optical Process Monitor User Manual 80 04001 06 D Modbus Option 105 Get the unit of measure Command 3E44017D Response 3
109. resolve a problem with the DSP4000 If the table does not provide an immediate remedy contact the Polestar Technical Support at 781 449 2284 Table 6 1 Troubleshooting the DSP4000 Symptom Explanation of Problem Action The DSP4000 does Insufficient or too much Disconnect power from the not display power is being applied to DSP4000 ers OF i the DSP 000 Verify that the voltage is 24 VDC and the current is at least 1 5 Amps Re connect the power The DSP4000 powers up with a USB error The USB KEY is not recognized Re seat the USB KEY Press ENTER The DSP4000 does not go into Run mode or kicks out shortly after startup The Status LED is red The AGC for at least one channel has reached 4000 the maximum value because e There is a poor optical connection e A sensor element is at the end of its life Verify all optical connections Check the AGC for each channel Replace sensing elements as needed The Status LED is yellow The AGC for at least one channel has reached 3000 because e Dirt has accumulated on an the optical surface e The sensing element is near the end of its useful life Check the AGC for each channel Clean the optical surfaces using Scotch tape as dust and dirt particles may result in signal loss Replace sensing elements as needed DSP4000 Optical Process Monitor User Manual 80 04001 06 6 Care and Maintenance 81
110. ress field 4 20 Input PSIG Lo 0 0 PSIG Hi 100 0 PSIG Bar Press 14 7 PSI Figure 5 18 Setting the Range for PSIG Input 4 Press ENTER to accept the displayed values and return to the Setup menu 5 Auxiliary display For the convenience of the user the DSP4000 can quickly display critical parameters used in the accurate measurement of pH O2 and CO2 In the Run Mode the user can press the AUX key to show temperature and pressure for all active channels A second press of AUX shows AGC and RAGC for each active channel The third press of AUX returns the display to the normal Run Mode Insert Screen shots here 5 8 Configuring the 4 20 mA Data Outputs The 4 20 mA Output menu allows you to enable and disable the output for each channel adjust the full scale span and test the 4 20 mA output See Connecting 4 20 mA Data Outputs on page 39 for important information on e Wiring the data outputs e Powering the 4 20 mA loops e Scaling the output signals at the receiving device DSP4000 Optical Process Monitor User Manual 80 04001 06 64 5 DSP4000 Setup 5 8 1 Enable and Scale the Data Output To configure the analog output for the channel 1 Scroll to 4 20 mA in the Setup menu and press ENTER to display the Output menu Figure 5 19 left 2 Select Enable Disable in the 4 20 mA menu and press ENTER to display the current state of the output Figure 5 19 right DSP4000 Optical P
111. rical Connections A cable from the PC I O port left ends in a DB9 male connector The cable will plug into one side of the RJ 11 to DB9 transition lower left Before assembling the transition plug the wires into the back of the DB9 female connector as follows e Black RxD to pin 2 e Red TxD to pin 3 e Yellow Gnd to pin 5 Remove the other wires in the transition kit and assemble the connector Plug the cable from the PC into the DB9 end of the transition and insert the RJ 11 jack from the DSP4000 into the socket at the other end Back of DB9 Female Figure 4 12 Using an RJ 11 to DB9 Transition 4 7 2 Connecting with Windows Hyper Terminal Use Microsoft Windows Hyper Terminal or a similar terminal program to access the DSP4000 from the PC via the RS 232 interface To connect the PC to the DP4000 with Hyper Terminal 1 Click Start gt Run on the PC enter hypertrm in the Run dialog box and click OK to open the Hyper Terminal window and the Connection Description dialog box Figure 4 13 Jz New Connection HyperTerminal File Edit View Call Transfer Help De ss 28 Connection Description wy New Connection Enter a name and choose an icon for the connection Name DSP4000 was aS x Auto detect Auto detect Figure 4 13 Connection Description DSP4000 Optical Process Monitor User Manual 80 04001 06 4 Electrical Connections 45 2 Enter a name
112. rly interpret the analog signal applying the scaling and units of measure set in the DSP4000 as well as time stamping and otherwise labeling the data Table 4 5 shows how the DSP4000 outputs are scaled for different sensor types and units of measure Table 4 5 Output Ranges by Sensor Type Units oe Units 4 mA 20 mA O gt mmHg 0 mmHg 5000 mmHg High Level 0 100 Air Sat 0 Saturation 100 Saturation PPM 0 PPM 5000 PPM Deg 180 180 0 PPB Dissolved 0 PPB 5000 PPB a PPM Gas Phase 0 PPM 5000 PPM Deg 180 180 0 PPB Dissolved 0 PPB 5000 PPB mana PPM Gas Phase 0 PPM 5000 PPM Deg 180 180 DSP4000 Optical Process Monitor User Manual 80 04001 06 4 Electrical Connections 41 Table 4 5 Output Ranges by Sensor Type Units Continued Sensor Units 4 mA 20 mA Parameter pH pH Scale read for the channel from DSPCALIB DAT in the USB KEY Factor 2 and Factor 3 for channels 2 and 4 in Figure 4 9 SMR 0 3 CO gt mmHg 0 mmHg High scale value F 3 read for the channel 0 from DSPCALIB DAT in the USB KEY Factor 1 for channel 3 in Figure 4 9 SMR 0 3 For a pH sensor the scale is read from the DSPCALIB DAT file on the USB KEY for the channel as is the high end of the scale for a CO sensor You can view the factors by opening the file in the DSP Channel Configuration dialog box as described in Reviewing the Configuration File
113. rocess Monitor User Manual 80 04001 06 5 DSP4000 Setup 65 Test Enable Disable Full scale Adjust 4 20 mA Output ON Figure 5 19 Enabling a 4 20 mA Data Output 3 Press MODE to toggle the output ON or OFF and then press ENTER to return to the 4 20 mA menu Scaling of the output is determined by the type of sensor and the units of measure Table 5 5 shows how the DSP4000 outputs are scaled for different sensor types and units of measure Table 5 5 Output Ranges by Sensor Type Units Sensor Units 4mA 20 mA Parameter O gt mmHg 0 mmHg 5000 mmHg High Level 0 100 Air Sat 0 Saturation 100 Saturation PPM 0 PPM 5000 PPM Deg 180 180 O gt PPB Dissolved 0 PPB 5000 PPB Medi Level Soum LSE PPM Gas Phase 0 PPM 5000 PPM Deg 180 180 O gt PPB Dissolved 0 PPB 5000 PPB Low Level PN ARNE PPM Gas Phase 0 PPM 5000 PPM Deg 180 180 pH pH Scale read for the channel from DSPCALIB DAT in the USB KEY Factor 2 and Factor 3 for channels 2 and 4 in Figure 5 20 SMR 0 3 CO gt mmHg 0 mmHg High scale value s A read for the channel 0 from DSPCALIB DAT in the USB KEY Factor 1 for channel 3 in Figure 5 20 SMR 0 3 DSP4000 Optical Process Monitor User Manual 80 04001 06 66 5 DSP4000 Setup For a pH sensor the scale is read from the DSPCALIB DAT file on the USB KEY for the channel as is the high end of the scale
114. rs displays the Automatic Gain Control AGC value on a scale of 1 to 4000 For CO and pH sensors shows the Reference AGC RAGC also on a scale of 1 to 4000 See AGC Display on page 67 for details Calibration Displays the currently set calibration factors for the sensor and allows you to calibrate the sensor using a one point or two point method The default calibration factors are those set at the factory for the sensing element lot number and stored on the USB KEY See Calibration on page 69 5 Do one of the following e Begin configuration of the selected channel using the Setup menu options e Press ESC to return to the Channel Selection menu to configure a different channel e Press ESC twice to return to the Main menu select Setup Mode again and set passwords and the security level 5 1 Modifying the Security Level and the Passwords The DSP4000 provides three levels of password protected access to the Setup menu in compliance with Code of Federal Regulations Title 21 Part 11 21 CFR Part 11 ELECTRONIC RECORDS ELECTRONIC SIGNATURES Table 5 2 Table 5 2 DSP4000 Security Levels ee Default Level Level Description Da ceword 0 No password required Any user can change any DSP4000 N A parameter except the security settings Level 0 is the default setting Press ENTER at the Login menu to proceed to the Channel Selection and Setup menus DSP4000 Optical Proces
115. s Monitor User Manual 80 04001 06 56 5 DSP4000 Setup Table 5 2 DSP4000 Security Levels Continued Level Level Description Default Password 1 Administrator assigned user password is required to access 1234 the Setup menu Press ENTER at the Login menu to display an Enter PW screen Enter the User password and press ENTER to proceed to the Channel Selection and Setup menus 2 Administrative password is required to access the Setup menu 5678 Admin Login leads to a menu that includes options for changing the security level and setting the passwords To set security 1 Press the down arrow in the Login menu to select Admin Login and press ENTER to display the screen for entering a password Figure 5 5 left The screen displays four Os that you will replace with a four digit password The Password screen is the same for the User Login and the Admin Login 2 Use the left and right arrows to select one of the four characters in the password 3 Use the up or down arrow to increase or decrease the selected digit In Figure 5 5 right the user is completing entry of the default Admin password 5678 Enter Pw Enter Pw 0009 5670 up down left right up down left right to adj ESC ENTER to adj ESC ENTER Figure 5 5 Entering the Default Admin Password 4 Press ENTER when the password is 5678 to display the Admin menu Figure 5 6 left Use the up and down arrows to scroll throu
116. ser Manual 80 04001 06 53 Chapter 5 DSP4000 Setup This chapter describes how to use the Setup menu to enable and scale temperature and pressure inputs specify data outputs calibrate sensors and otherwise configure the DSP4000 operation When the DSP4000 is powered up it reads configuration information from the USB KEY and then automatically enters Run mode acquiring measurements from the sensors attached to the channels To access the Setup menu 1 Press ESC to place the DSP4000 in Standby mode The video screen displays the Main menu with Run Mode selected Figure 5 1 left JRun Mode Run Mode Setup Mode Save Log File Turn Save Log File off DSP4000 Turn Off DSP4000 Figure 5 1 DSP4000 Main Menu The DSP4000 stops acquiring data from the sensors The Status LED remains unchanged 2 Press the down arrow to select Setup Mode and press ENTER to display the Login menu Figure 5 2 ee n Login Figure 5 2 Login Menu The DSP4000 is shipped with password security not yet enabled At this point you can proceed to the Setup menu by pressing ENTER or use the Admin Login to set passwords and specify the security level as described in the next section 3 Press ENTER to display the Channel Selection menu Figure 5 3 left The settings for each DSP4000 channel are independent of those configured for the other three channels For example you can set Channels 1 and 2 to acquire dat
117. sive e If you are specifying a value such as a code for unit of measure or a calibration value click the radio button for either Integer or Float and then enter the value in decimal in the Data field In Figure D 3 the user has entered O1 in the Data field to complete the command for setting the security level to 1 requiring a User login for access to the setup commands e When setting the date in the DSP4000 click the Date radio button and enter the date in the MM DD and YYYY fields e When setting the time in the DSP4000 click the radio button for Time and enter the setting in the hh mm and sec fields Figure D 4 DSP4000 Optical Process Monitor User Manual 80 04001 06 D Modbus Option 101 fe LRC Calculation Figure D 3 Entering the Data Value for Setting the Security Level 4 Click the Calculate LRC button to display the LRC and the full command in the fields below the button Figure D 4 fe LRC Calculation Figure D 4 Setting the DSP4000 Time 5 Click Clear to empty the fields and compose another command DSP4000 Optical Process Monitor User Manual 80 04001 06 10 D Modbus Option D 6 Example Commands D 6 1 Unit State In this section yy indicates the LRC in the DSP4000 response Set Run mode Command 3E418001 Response 3E4100yy Set Setup mode Command 3E418100 Response 3E4101yy Set Shut Down mode Command 13E4182FF Response 3E4102yy Get the current mode Co
118. ss Monitor User Manual 80 04001 06 5 DSP4000 Setup 61 To configure temperature input 1 Select Temperature in the Setup menu and press ENTER to display the main Temperature menu Figure 5 10 left 2 Press the down arrow to select Temperature Source and then press ENTER to display the currently selected option Figure 5 10 right Hibernate Temp Current Setting Temperature Source Manual Input To change lt Enter gt Figure 5 10 Changing the Temperature Source 3 Press ENTER to display the Temperature source menu which lists the three options Manual Input 4 20 Input and RTD 4 Follow the steps in the appropriate section below 5 6 1 Manual Temperature Input Manual Input allows you to specify the temperature value to use for compensation This option should only be considered for applications where there is little or no variation in temperature or where the temperature is well regulated To set the temperature manually 1 Select Manual Input in the Temperature Source menu and press ENTER to show the currently set temperature for manual input Figure 5 11 left The default is 20 C The range is 20 C to 100 C 2 Press the up or down arrow to increase or decrease the setting by 0 1 C or hold the key down to rapidly change the value 3 Press ENTER to accept the displayed setting and return to the Setup menu Temperature Temperature Manual Input Manual Input 20 0 de
119. struction CAUTION Do not use a sharp or pointed object to remove an observed obstruction as you will damage the lens surface 6 2 Replacing a Sensing Element Sensing elements that are attached to the BioProbe are designed for easy replacement whether you are changing the function of the probe or replacing a worn sensor The Status LED in the upper right corner of the DSP4000 front panel provides a visual indication of the AGC or RAGC level during operation The Status LED is e Green when the AGC or RAGC level is less than 3000 for all four channels DSP4000 Optical Process Monitor User Manual 80 04001 06 6 Care and Maintenance 79 Yellow when the level for least one channel is between 3000 and 3500 Red when the AGC or RAGC for one channel exceeds 3500 An AGC or RAGC reading of 3500 or higher indicates a need to replace the sensing element or an obstruction or break in the optical path When the Status light is red 1 Check the AGC RAGC level of each channel to identify the channel causing the Status LED alert See AGC Display on page 67 for information on accessing the display from the Setup menu Inspect the BioProbe connections and the optics on the problem channel to determine whether the high AGC is caused by an obstruction or break in the optic path See Inspection Procedures on page 75 Replace the sensing element if the AGC is still high after resolving any problems with the fibe
120. such as DSP4000 in the Name field optionally choose an icon and click OK to open the Connect To dialog box Figure 4 14 left COM Pi ertie Connect To Topera xz psP4000 Enter details for the phone number that you want to dial Bits per second 19200 Port Settings Country region Data bits 8 Area code Panty Nane Phone number g Connect using So Sop bis 1 Cancel _ Bow control Figure 4 14 Specifying Connection Properties Ignore the text boxes in the Connect to dialog box asking for country area code and phone number 3 Use the Connect using drop down list to select the appropriate communications port for your hardware typically COM1 or COM2 and click OK to open a properties dialog box for the communications port 4 Use the Port Settings pull down lists to make the selections shown in Figure 4 14 click Apply and then click OK 5 Choose File gt Properties from the Hyper Terminal menu and then click the Settings tab in the Properties dialog box Figure 4 15 left DSP4000 Properties Host System Encoding Method PR ASCII Setup Connect To Settings ASCII Sending O Send line ends with line feeds Echo typed characters locally Line delay 0 milliseconds Select Host System Encoding Method Function arrow and ctr keys act as Ieminal keys Windows keys ae Standard JIS Backspace key sends QH Del Or H Space Cri H Character
121. sure 4 20 mA AGC Pressure 4 20 mA AGC Calibration Current Setting Manual mmHg Manual mmHg Manual PSI 4 20 mmHg 4 20 PSIG II Enable Disable Scale Adjust Test Manual Input 760 mmHg Manual mmHg Manual PSI 4 20 mmHg 4 20 PSIG I 4 20 Output ON lt MODE gt Enable Disable Scale Adjust Test Full Scale Adjust 20 mA 100 Manual Input 14 7 PSI Enable Disable Scale Adjust Test Manual mmHg Manual PSI 4 20 mmHg 4 20 PSIG I Enable Disable Scale Adjust Test Test 4 0 LI Pressure 4 20 Lo 0 mmHG Hi 100 mmHg Manual mmHg Manual PSI 4 20 mmHg 4 20 PSIG I Pressure 4 20 Lo 0 0 PSIG Hi 100 0 PSIG Bar 14 7 PSI AGC 307 lt ENTER gt for Setup Menu Figure A 3 Setup Menu Continued One Point Cal Two Point Cal Restore Defaults Display Cal Sensor Lot LI Adjust Saturation 100 Testing 1 of 4 LI Calib Results P5 0 007860 One Point Cal Two Point Cal Restore Defaults Display Cal Sensor Lot I Adjust Saturation 100 I Testing 1 of 4 I Calib Results P5 0 007860 I Prepare Zero I Testing 1 of 4 I Calib Results P2 66 879997 P5 0 007860 DSP4000 Optical Process Monitor User Manual 80 04001 06 86 A DSP4000 Menus
122. sure of Oz or CO in the solution or gas samples being monitored Variation in the head pressure above a solution or in the pressure of a gas line changes the total pressure of the system under investigation which in turn changes the partial pressure of all gaseous constituents including O and CO3 The DSP4000 automatically adjusts each O and CO measurement for the effects of pressure For pressure compensation each DSP channel must be configured to use either a 4 20 mA analog signal from a pressure gauge or a user specified constant Wiring of the pressure inputs is covered in Chapter 4 Electrical Connections Selection of the input method scaling of the 4 20 mA signals and other configuration steps are covered in Configure Pressure on page 62 Pressure compensation is not used with pH sensors 1 2 4 Automatic Gain Control The DSP4000 controls the drive level of the LED light source that excites the fluorescence sensing chemistry of the Polestar sensing elements in order to maintain constant levels of recovered photodetector signal This Automatic Gain Control AGC feature optimizes the photodetector signals at the analog to digital converter of the DSP4000 microprocessor Over the life of a Polestar sensor the sensing element will gradually photo bleach from repeated light pulses from the DSP4000 and from ambient light such that the DSP4000 will apply increasing levels of gain to the light pulse It is import
123. tate Table D 14 Two Point Calibration Two point calibration is only supported for O sensors Running two point calibration for a pH or CO sensor returns an exception code Set the zero value and run the calibration Command 3E6582DB Response 3E65xxyy where xx is the calibration state Table D 14 and yy is the LRC Set the calibration high and run the calibration Command 3E6583XXXXXXXXYyY where xxxxxxxx is the calibration value Response 3E65xxyy where xx is the calibration state Table D 14 and yy is the LRC Related Functions Restore default calibration factors Command 3E6584D9 Response 3E655D on success Get calibration values Command 3E650558 Response 3E65XXXXXXXXYyY where xxxxxxxx is the calibration value and yy is the LRC Get sensor lot number Command 3E650657 Response 3E65XXXXXXXXYyY where xxxxxxxx is the sensor lot number and yy is the LRC DSP4000 Optical Process Monitor User Manual 80 04001 06 D Modbus Option 112 D 6 10 Get Measurement Get the measurement for a specific channel 3E67005B for channel 1 Command 3E67015A for channel 2 3E670259 for channel 3 3E670358 for channel 4 Response 3E67XXXXXXXXYyY where xxxxxxxx is a hex representation of the floating point value and yy is the LRC D 6 11 Program the DSP Load the operating system from the USB KEY Command 3E68005A Response 3E680159 on success 3E680258 if the USB data is invalid DSP4000 Optical Process
124. tion On board circuitry of the DSP4000 is calibrated for use with the Polestar PT100 RTD and other three wire 100 Ohm Platinum devices No scaling of the input is required 2 Press ENTER to confirm the choice and return to the Setup menu 5 6 4 Set Hibernate Temperature The DSP4000 includes a temperature dependent Hibernation mode to avoid acquiring meaningless measurements during high temperature operations such as CIP and autoclaving during which data collection is unnecessary This feature is only to be used in conjunction with the active temperature compensation modes that is input from a 4 20 mA temperature sensor or an RTD DSP4000 Optical Process Monitor User Manual 80 04001 06 5 DSP4000 Setup 63 NOTE This feature is not functional when the temperature has been entered manually If the temperature for the channel is manually set disable the channel from the Setup menu see Enable Disable on page 57 for the high temperature operation The Hibernation mode is activated when temperature readings exceed the user defined setpoint Once in the Hibernation mode the DSP4000 discontinues optical data sampling but continues to monitor temperature readings at the user selected frequency Optical sampling resumes when temperature readings drop back below the setpoint The default setpoint is 52 0 C To specify the Hibernation mode setpoint 1 Scroll to Temperature in the Setup menu and press ENTER 2 S
125. to display the Search page Figure 3 4 right e Enter the lot number in the Search For field and click Go to retrieve the file and display it on the bottom of the page e Click the file to place it on the Download page Figure 3 5 DSP4000 Optical Process Monitor User Manual 80 04001 06 3 Managing Configuration Files 27 Awe 2 f Main Menu File Downloads User Menu Your Details Logout r Polestar Support Site File Repository ppm 02 Files Jder By ID File Title Downloads Page 123456 Next Boos 1 005 041 Submitted On 68 File Size 0 25 251 006 044 Submit Date Submitter Author Submitted On 08 Jui 60 File Size 0 25 Kb Bios 1 007 081 Main Menu File Downloads User Menu e Your Details Logout F Main Repository Page Search Repository Search For 251 005 041 Search File Titles Search File Descriptions ss 605 041 ppm 02 File Size 0 25 KE Cai Search Repository Figure 3 4 Selecting the Calibration File 5 Check the details shown on the Download page Figure 3 5 and then click Download save the configuration file on your computer and log out of the Support area Main Menu File Downloads User Menu Your Details Logout Figure 3 5 251 006 041 Download Submitted On 08 File Type dat Downloads 3 Downloading the Calibration File DSP4000 Optical Process Monito
126. trical Connections e Before making any connection to the I O board in the DSP4000 make sure the ON OFF switch on the board is in the OFF position e When deploying the DSP4000 in a production environment make sure that the DSP4000 front panel cover is closed and that its locking screws are tightened Verify that the cord grips and gland connectors on the bottom panel are properly secured The DSP4000 enclosure is NEMA 12 4X certified When properly connected the DSP4000 is safe for use in applications where the instrument will be subjected to wash down procedures e Note that the optional AC adapter is not watertight and therefore should not be used in wash down applications Technical Support Contact Polestar Technical Support if you have any questions about operation of the DSP4000 not covered in this document e Call 781 449 2284 extension 1008 or e Send an email to support PolestarTech com DSP4000 Optical Process Monitor User Manual 80 04001 06 viii Preface DSP4000 Optical Process Monitor User Manual 80 04001 06 Chapter 1 Introduction The DSP4000 Optical Process Monitor Figure 1 1 manages up to four separate optical sensors for measuring O gt pH and or CO gt in a wide variety of research testing and process control applications Polestar s technology built into every DSP4000 provides accurate and precise measurements over a broad spectrum of applications including fermentation cell cu
127. tup menu Viewing the Current Calibration You may be asked during a support call to display the current calibration factors To display the current calibration for the channel 1 Scroll to Display Cal in the Calibration menu and press ENTER to display the information Figure 5 27 shows the format for an O sensor on the left and the format for a CO sensor on the right Current Calibration Current Calibration P2 66 879997 PCO2 Offset 5 28 P5 0 007820 Figure 5 27 Current Calibration Displays for O and CO Sensors 2 Press ESC or ENTER to return to the Setup menu DSP4000 Optical Process Monitor User Manual 80 04001 06 5 DSP4000 Setup 71 Restoring Default Calibration To restore the default calibration that is the lot based calibration factors that are stored on the USB KEY Scroll to Restore Defaults in the Calibration menu and press ENTER There is no change in the display while the DSP4000 loads the calibration data from the USB KEY Then after a few seconds the DSP4000 returns to the Setup menu 5 10 2 Before You Calibrate For best results do the following prior to performing a one point or two point calibration Power up the DSP4000 if it is not already in operation and allow the DSP4000 to operate for at least 30 minutes before starting the calibration Verify all connections and configuration settings Inaccurate temperature and pressure readings can adversely affect the
128. unpacking 7 USB KEY making a backup copy 23 WwW wall mounting 91 Warranty ii Windows Hyper Terminal connection to the DSP4000 44 DSP4000 Optical Process Monitor User Manual 80 04001 06 Index 117 wiring 4 20 mA outputs 39 4 20 mA pressure inputs 37 4 20 mA temperature inputs 35 making an RS 232 connection 42 RTD input 34 DSP4000 Optical Process Monitor User Manual 80 04001 06 118 Index DSP4000 Optical Process Monitor User Manual 80 04001 06
129. up Mode Create New Save Log File Yes lt ENTER gt NO lt ESC gt Turn Off DSP4000 Figure 2 10 Turning Off the DSP4000 13 Open the DSP4000 front panel cover when the display goes blank and turn the ON OFF switch to the OFF position DSP4000 Optical Process Monitor User Manual 80 04001 06 2 Getting Started 13 2 5 Connecting the BioProbe Each probe is connected to the DSP4000 with an armored fiber optic cable The probe must be connected to a specific channel to match the calibration data stored on the USB KEY To connect the probe to the DSP4000 1 Select the probe that was tested on Channel 1 2 Remove the small rubber protective caps from the ends of the fiber optic cable and insert the barrel end of the cable Figure 2 11 into the Channel 1 gland on right side of the bottom panel Insert the connector fully into the gland and secure the connection by tightening the threaded locking nut CAUTION The locking nut forms a liquid tight seal when finger tight Do not use a tool to tighten the locking nut as over tightening can result in damage to the fiber optic cable and the gland connector The probe end of the fiber optic cable is equipped with a spring loaded ST male connector that mates with the ST female connector on the end of the BioProbe Figure 2 11 3 Carefully align the tab on the ST male connector with the slot on the mating connector of the probe and then advance the conne
130. ut 37 R RAGC description 67 ranges normal AGC values for DSP4000 operation 67 Read Calib File 18 replacing a sensing element 77 RJ 11 socket on the I O board 42 RJ 11 to DB9 pinouts 42 RS 232 cabling 42 capturing DSP4000 data using Hyper Terminal 48 DSP4000 output 46 going online with Windows Hyper Terminal 44 RTD selecting an RTD as the input for temperature compensation 61 wiring an RTD 34 Run mode 15 DSP4000 Optical Process Monitor User Manual 80 04001 06 116 Index S scaling adjusting the full scale range for 4 20 mA outputs 64 DSP4000 scaling of the 4 20 mA outputs 39 Setup menu Calibration 69 configuring inputs for pressure compensation 62 configuring temperature 59 configuring the 4 20 mA data output 64 enable disable a channel 57 functions 54 security 53 security levels 55 Timing 58 Units 57 Setup mode 53 Standby mode 16 startup sequence 14 straight through RS 232 cable 43 T temperature specifying the setpoint for Hibernation mode 61 temperature compensation configuring 4 20 mA inputs 60 configuring temperature 59 description 3 manual input 60 selecting RTD input 61 wiring a 4 20 mA temperature input 35 wiring an RTD 34 terminal block power 32 RTD wiring 34 wiring 4 20 mA outputs 39 wiring 4 20 mA pressure inputs 37 wiring 4 20 mA temperature inputs 35 timing minimum interval between samples 58 troubleshooting 79 two point calibration 73 U units of measure by element type 57
131. warm up for at least 30 minutes before taking any measurements or calibrating the sensors To shut down the DSP4000 1 Press ESC to enter Standby mode and display the Main menu 2 Press the up or down arrow key to scroll to Turn Off DSP4000 in the Main menu Figure 2 25 left and press ENTER to display the Save Log screen Figure 2 25 right Run Mode Save Log file amp Setup Mode Create New Save Log File Yes lt ENTER gt NO lt ESC gt Figure 2 25 Saving the Log File 3 Press ENTER again to close the current log file and start a new file 4 Wait for the front panel display to go to black 5 Open the front panel cover and turn the ON OFF switch in the upper right of the I O board to the OFF position You can now remove the USB KEY to extract log files update configuration files and or load a new operating system version Before making electrical connections to the DSP4000 verify that the ON OFF switch is in the OFF position DSP4000 Optical Process Monitor User Manual 80 04001 06 23 Chapter 3 Managing Configuration Files As discussed in the previous chapter a configuration file on the USB KEY provides calibration information for the sensor to be connected to each channel When you change from one type of sensing element to another or replace a sensing element with the same type you need to load calibration data for the new element You do so by downloading a calibration file for the ele
132. when they are displayed in the Hyper Terminal window The file is closed when you stop the data capture although you can copy the file at any time and begin analysis of what has been captured so far If you resume data capture DSP4000 Optical Process Monitor User Manual 80 04001 06 4 Electrical Connections 49 specifying the same file and path the new measurement records are appended to the existing file Choose Transfer gt Capture Text gt Stop from the Hyper Terminal menu to end the data capture and close the file Ending an Online Session To end the Hyper Terminal session 1 Do one of the following e Choose Call gt Disconnect from the Hyper Terminal menu e Click in the Hyper Terminal toolbar Choose File gt Save from the Hyper Terminal menu if you want to be able to re use the session settings Choose File gt Exit from the Hyper Terminal menu or click J in the title bar to close the Hyper Terminal window Analyzing the Data You can open the captured text file in a variety of text editors and import the space delimited data into a database or spreadsheet application The following describes how to import the data into Microsoft Excel To view the data in an Excel worksheet 1 Start Excel and choose File gt Open from the main menu or the Office button in Office 2007 to display the Open dialog box Select Text files with the Files of the type pull down list use the dialog box to
133. xceed terminal width as RS 232 Input Translation ASCII Setup Figure D 1 ASCII Setup for Modbus Connection DSP4000 Optical Process Monitor User Manual 80 04001 06 96 D Modbus Option D 2 MODBUS Commands Modbus commands to the DSP4000 are messages consisting of 8 bit bytes each sent as a two ASCII characters 0 9 A F hex Each message is framed by a leading colon ASCII 3A hex and a trailing carrier return line feed pair ASCII OD and 0A hex Within the frame the command includes e Two character DSP4000 address always 3E e Two character function code Table D 5 e Sub function code of one or more character pairs Table D 5 Sub function codes may include parameter values also in one or more character pairs e Two character longitudinal redundancy check LRC value calculated on the preceding part of the message For example the components of the command to set Run mode 3E418081 are shown in Table D 1 Table D 1 Set Run Mode Command 3E 41 80 81 lt Start DSP4000 Function Sub code LRC Carrier address Code Set Run return Unit State Mode line feed The DSP4000 responds with a similarly formatted message framed by a colon and carrier return line feed and consisting of e Two character DSP4000 address always 3E e Two character function code e Sub function code of one or more character pairs e Two character longitudinal redunda
134. y level is 0 no login is required See Figure A 4 on page 86 for the User Login security level is 1 and the Admin login and Admin menu DSP4000 Optical Process Monitor User Manual 80 04001 06 84 A DSP4000 Menus Setup Menu Enable Disable Units Timing Temperature Enable Disable Units Timing Temperature Enable Disable Units Timing Temperature Enable Disable Units Timing Temperature Current Setting Current Setting Current Setting Hibenate Disabled 02 004 sec Enabte Disable depends on parameter for channel O02 mmHg 02 O2 Air Sat O2 PPM O2 Degree oH SMR CO CO SMR t to scroll through menu t to change value lt to change field ENTER to select a menu item ENTER to apply a value ESC to return to Setup menu MODE to toggle 4 20 output enable ee to change Temp Source 52 0 deg C Hibehal Temp Source Manual Input Manual HR 4 20 Input RTD 20 Deg C Manual Ar 4 20 Input RTD to Odeg C7 to I Hi 50 deg C Manual Input 4 20 Input RTD remperature _ RTD DSP4000 Optical Process Monitor User Manual 80 04001 06 e A DSP4000 Menus 85 Setup Menu Units Timing Temperature Pressure Timing Temperature Pressure 4 20 mA Temperature Pres
135. ystem There is a specific range for each sensor type and unit of measure see Table 4 9 on page 47 In addition you can program the DSP4000 to adjust the output scale as discussed in Enable and Scale the Data Output on page 64 4 4 Connecting 4 20 mA Temperature Inputs Terminal positions 13 through 20 on the left half of the terminal strip in the middle of the I O board are used for applying 4 20 mA temperature inputs to the DSP4000 from user supplied temperature sensors Table 4 2 shows how the temperature inputs are marked Table 4 2 Terminal Labels for 4 20 mA Temperature Input Channel Terminal Label Channel 1 TEMP 1 4 20 IN 13 TEMP 1 4 20 IN 14 Channel 2 TEMP 2 4 20 IN 15 TEMP 2 4 20 IN 16 Channel 3 TEMP 3 4 20 IN 17 TEMP 3 4 20 IN 18 Channel 4 TEMP 4 4 20 IN 19 TEMP 4 4 20 IN 20 The temperature input 4 20 mA loops must be powered by the devices themselves or a DC power source in the range of 15 to 28 Volts If the temperature transmitter is not self powered e Connect the loop to a third party DC power source or DSP4000 Optical Process Monitor User Manual 80 04001 06 36 4 Electrical Connections e Tap the DSP4000 power in terminals in the upper left of the DSP4000 I O board To tap the power in terminals e Connect to 24VDC 1 e Connect to GND 2 To wire temperature input from a self powered device

DSP4000 User Manual Rusty update 21Jan2012

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