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1. and OFF When is displayed press Enter again to install the new setting and leave edit mode Selecting C or F By default the analyzer will use metric units meaning that temperature will be displayed using degrees Celsius and that the prompt for the temperature input will be C The analyzer can also be made to use degrees Fahrenheit and the prompt for the temperature input will be F instead of C throughout the program For practical reasons the temperature input is identified as C throughout this instruction manual and in the menus To select Fahrenheit units for the analyzer select unit from the configuration menu then go into edit mode and change the C prompt to F Input Damping The Chlorine and temperature measurements can be damped to provide the user with a means to deal with rapidly varying or noisy signals Damping range is 3 to 99 seconds With 0 there would be no damping and each reading the analyzer makes is used to directly update the display and 4 20 mA output The factory default 5 second adds the next four seconds readings to the first and divides by five this gives fast response Selecting 99 seconds adds the readings for 99 seconds and divides by 99 providing smooth damping out of turbulent readings Any selection between 3 and 99 can be made Select CONF in from the menu Use the up or down arrow key to select the input to be adjusted th
2. USED ICTRI RED WHT BLK 2nd 4 20mA LOOP RED IBLKI 1ST 4 20mA LOOP RED RELAY B 519 IPOWI RELAY A SIG IPOWI 115 230 VAC 50 60 HZ d i OTP 300 c 4 c ES 5 ol 4 role e i w 5 p 8 S FEL P 301 m 8 184 e 998 T3GOMN L1 LUE 0 81 toea 10681 H S O S gs hajas ley dete 0 CONTROLS dr EF C 8 0 09 Orangeville Ontario Canada chk Tl tt MODEL 875 WIRING DIAGRAM of scale sheet Page 50 www iccontrols com 875 Instructions IC CONTROLS Drawings Mounting Dimensions D4830022 7 8740 3 4660 4 7240 20 1700 E 2 9527 20 8750 loy date 16 CONTROLS Orangeville Ontario Canada TITLE MOUNTING DIMENSIONS code ioc ne D4830022 RE V Page 51 www iccontrols com 875 Instructions Drawings 2 Pipe Wall Mounting Kit D4950053 IC CONTROLS 8 5 000 Yet AN 9 229 A I LL ss ee I M 16 CONTROLS Orangev
3. from the menu Press Enter to go into edit mode then press the Up or Down arrow key to change the normally open normally closed configuration from open to closed Press Enter again to accept the new value A closed contact should open an open contact should close Repeat step 1 for for the Alarm B contact If so desired all software settings can be returned to factory default condition by following the procedure in Configuration of Program Factory Defaults Re initializing All Settings 875 Instructions IC CONTROLS Parts list Troubleshooting Part Number Reference Drawing Description 875 Chlorine Analyzer A9051059 Assembly 875 Chlorine power PCB D5020260 A9051009 Assembly M55 micro display board D5980176 A9141028 Assembly 875 case complete D4830022 A9201014 16 wire interconnector cable two end A9160024 0 25 Amp microfuse A9160029 0 10 Amp microfuse A2500201 Panel mounting kit 55 series D4950054 A2500255 Pipe wall mounting kit 55 series D4950053 835 25 Assy 875 835 sample system on SS panel Chlorine Sensor Mounting see 835 spec sheet for other options A2300090 CPVC flowcell and insertion fitting 11 2 inch slip Chlorine Sensor Standard Replacement see 835 spec sheet for options 835 Galvanic Chlorine Sensor with Temperature Compensator Calibration Consumables A7010001 Chlorine calibration kit
4. V9T9W2W 6ZOLSSEW SSW OOOOOOOOOOOOOOOO Q 6 NId 8 NId T NId AQT Hd D I TND2 S 0d Hd r 0d dW31 9 0d dW31 L 0d V 3012313S 8 40193135 Hd 4 0 915 4 0 915 8 8 GDAS WD2 OWDI 2 875 Instructions www iccontrols com Page 45 IC CONTROLS Drawings Main Board Component Location D5020260 5 1 oltage Select MAIN BOARD COMPONENT LOCATION d 9 55020260 HDSC30F Orangeville Ontario Canada CONTROLS IC CONTROLS in A9051059 same as 855 used 400 M sosct 781 49 Loe dE O n 0405 8LO6AC TP303 n 9 e er A lai axe 5 TQ gt E I Itc e tc D lt lt oo o 5 z lt gt 9 5 el md ea m 1 o 5 2 A Woo A voza 1024 002 O O lt lt OR 24 5 Bus Ow c ua a Page 49 www iccontrols com 875 Instructions Drawings Wiring Diagram NOT SENSOR M IC CONTROLS D5020261 USED ISHLDI
5. Fault alarm 29 Free available chlorine 13 15 38 Grab sample 17 Hypochlorite ion 13 19 Hypochlorous acid 13 15 19 Hysteresis 38 IC Net 32 36 baud rate 32 caution messages 29 internal data log 32 875 Instructions IC CONTROLS node number 32 wiring and enabling 31 Input damping 12 36 Installation 7 10 36 Internal data log 32 Internal date time clock 33 Real time clock 33 Keypad arrow keys 11 LED 10 29 38 MANUAL key 11 Manual temperature compensation selecting 19 setpoint 19 Measurement history internal log 33 Memory test 10 Menu 11 38 Nernst equation 38 Output hold 20 Password 65 entering 65 pH SEE ALSO Calibration current output 28 pH compensation Page 55 chlorine 19 Poise 18 ppm 38 Process control 30 38 Prompts 37 Range switching D O measuring circuit 39 Real time clock 12 33 36 Relays 40 Repair and service 42 RS232 81 RS485 81 SAMPLE key 11 20 Sample menu 11 Security 65 66 access level 65 66 disabling 66 enabling 66 password 65 password 1 65 password 2 65 timeout 11 Simulated current output 28 Sodium hypochlorite 13 Standby mode 11 Startup diagnostics 10 display 11 error checking 10 www iccontrols com Index loss of power 10 Program Initialization 36 Temperature current output 28 Temperature compensation 38 chlorine 19 manual 19 selecting type 19 Terminology combined chlorine 14 free available chlorine 14 total f
6. However if after calibration the sensor response is slow replace the electrolyte and wipe the coils and surface lightly using a soft wipe or a little more vigorous cleaning can be done using a toothbrush Recharge with fresh electrolyte Calibrate and return the sensor to service Semi Annual Maintenance Replace the membrane module and electrolyte Unscrew the electrode cap and dump the contents Flush the cell internals with demin water and rinse with electrolyte Examine the coils for brown or black discoloration or heavy gray coating Such coatings should be removed for best performance caution the Silver coils are soft metal never use force in cleaning Clean light fouling by wiping in the direction of the coils until a shine appears Heavier foulings may come off with a toothbrush worked along the coils so the bristles get down in the cracks followed by rinse and wiping to achieve a shine If a shine does not appear the sensor needs to be chemically cleaned Remove the old membrane module from the cell and replace with anew one Re assemble the cell calibrate check efficiency and if above 50 percent place in service 875 Instructions Sensor Instructions Chemical Cleaning Chlorine sensors can be refreshed with p n A1100227 Chlorine sensor renew solution This procedure should be done over a sink Wear plastic or rubber gloves as the solution is acidic Wash hands thoroughly with lots of water if the solut
7. Thu Dec 18 17 47 31 1997 E2 2 Sat Dec 20 10 11 21 1997 7 6 HI 6 Sat Dec 20 12 31 43 1997 7 6 HI Ow WN F The first number is sequential The next part of each line is the date time stamp The final part is the event record Different time date formats are available Page 33 www iccontrols com IC Net Features Calibration Records Each time a calibration for Chlorine or temperature is changed the change is recorded in a date time stamped calibration history The history is written when a normal calibration is performed and when an efficiency is manually adjusted Change in any factor affecting calibration is recorded The internal record is not written until the analyzer has not been used for 15 minutes then a single record is written If two calibrations are done then manual efficiency changes these only create a single log entry rather than filling say 6 of the 12 available calibration spaces For the Chlorine the following are logged Chlorine Efficiency result of calibration Chlorine value used for calibration Temperature at time of calibration manual or auto temperature compensation For temperature the following factor is logged Temperature correction offset Internal Clock The analyzer maintains an internal date time clock for stamping of events and the internal data log To check if your analyzer has a real time clock chip select CONF r
8. reached CAUTION do not force the cap beyond the stop The parts are plastic and can break 6 Dry the Chlorine sensor and blot the tip Examine the tip the membrane should be smooth with no wrinkles or cuts and the surface contours of the gold electrode should be clear There should be no lines from trapped bubbles between the membrane and the gold electrode If there are no visible problems as described here then the Chlorine sensor is ready to be put into service Inserting a Chlorine Sensor in the Flow Fitting 1 Inspect the inside of the Quick Union fitting for any foreign matter and wipe out any dirt which may be inside It should appear clean shiny and bright 2 Install the Union Ring nut and push sleeve on the assembled and calibrated Chlorine sensor by sliding it down the lead wire 3 Check that the sealing O ring is on the electrode body on the sensing tip side of the ledge or in the O ring groove of the flow cell 875 Instructions IC CONTROLS 4 Insert the Chlorine sensor into the fitting Rock the sensor back and forth to pass the and press firmly all the way down so that the O ring firmly seats in it s groove 5 hand turn the Union nut until finger tight For higher pressures it may be necessary to use a wrench however the components are plastic and care is needed to avoid breakage CAUTION do not use a large wrench to turn the sensor The plastic components of the Chlorine sens
9. total free chlorine concentration of the sample using a different method When grab sample calibration is used it is the responsibility of the user to ensure that the grab sample taken and the total free chlorine value recorded for it are accurate A7010001 Chlorine Calibration Kit A chlorine calibration kit part A7010001 is available from IC CONTROLS which makes it relatively simple to get a total free chlorine measurement for calibration purposes in the 0 1 or 1 5 ppm concentration ranges The calibration kit uses a reagent which develops a violet color which is proportional to the amount of total free chlorine in the sample The kit contains 30 ampoules sample cup and low amp high range comparators Note Keep the kit closed when not in use The comparators need to be stored in the dark Standardizing Chlorine 1 Press SAMPLE to display the HOCI reading Press SELECT to reach the first menu then use the up or down arrow key to display tFCI 2 Press SELECT then the up or down arrow to display CAL 3 Press SELECT then the up or down arrow to Get Then SELECT again to display a Page 17 www iccontrols com Chlorine Calibration Using the low range comparator flashing DO LEAVE ANALYZER FLASHING Obtain from the analyzer outlet a representative grab sample cup full of water then immediately go and press ENTER on the 875 Take an ampoule from the kit and place the
10. A7010002 Chlorine refill kit with 30 ampoules A7010004 0 01 ppm Chlorine precision portable colorimeter A7010005 30 ampoule Chlorine refill for A7010004 meter A1100233 Galvanic Chlorine Fill Solution 100 ml bottle A1100227 Chlorine Sensor Renew Solution 30 ml bottle A1100225 Zero Free Chlorine Standard 500 ml bottle A1100192 Deionized Rinse Water 500ml bottle A1100020 Beaker Tuff Plastic 250ml for field calibration A1100014 Squeeze Bottle for rinsing electrode tip 120ml Page 41 www iccontrols com 875 Instructions Troubleshooting IC CONTROLS Repair and Service Field Service is dispatched in Canada from the home office of IC CONTROLS In North America call 1 800 265 9161 or call 519 941 8161 Outside of North America consult your authorized IC CONTROLS distributor or IC CONTROLS Ltd 29 Centennial Road Orangeville Ontario CANADA L9W 1R1 FAX 519 941 8164 email service iccontrols com www iccontrols com Page 42 www iccontrols com 875 Instructions Drawings IC CONTROLS Microprocessor Board D5980176 Component Loc 94108654 SG8 GG9 GGy u pasn NOILVOO LN3NOdNOO AV IdSId SSW JALIL opouoj 29400 STOHLNOD 4j ar 915197 vosas d 0 25 cu SOT REB 3 R67 wo Leva oF 3 QD M MMS452N 92 5 vIILZIWN 8S02E06W
11. Analyzer Industrial INTELLIGENT Free Available Chlorine analyzer controller input output isolated with NEMA 4X surface type housing Clear front window shows 4 digit display selects 0 20 ppm Chlorine temperature current output and program MODEL messages Future compatible Intelligent Analyzer logs in memory calibration records alarms and current measurement 875 trends or via RS485 two way communication in host real time log or sends its memory records on hosts request Precision greater of 1digit or 0 1 ppm 115 230 VAC with serial RS485 output plus dual 4 20 mA DC outputs fully program assignable span with 10 to 100 and 5 to 105 C 23 221 F Two fully assignable relays alarm or on off control or fault SPDT 10 Amp 115 VAC resistive fully programmable setpoint and deadband second relay may be used for intelligent problem alert Includes activateable security and one instruction manual Select 6 direct connect or 80 recommended over 30 ft See Option 35 IC Net Intelligence Access program for multi analyzer to networked computers via two way communication Requires one Chlorine Sensor Model 832 or 835 Sample Order ADD PROCESS CONTROL OUTPUT OPTIONS FOR FULL PID PROPORTIONAL PLUS INTEGRAL AND DERIVATIVE ACTIONS Single PID driving 4 20 mA output Single PID driving pump pulser output via relay 1 Single PID driving time proportional on off via relay 1 SENSOR OPTIONS and MOUNTING OPTIO
12. E2 2 Temperature Temperature Attach temperature compensator reading compensator not off scale attached Turn off temperature input Follow Input On Off Switch Temperature procedure in Software Configuration section Connect resistor to TC terminals to simulate a constant temperature Refer to Hardware Alignment section Temperature is actually higher than 105 C Verify process and sensor location Electronic calibration necessary Follow procedure in Hardware Alignment section Caution Messages for Alarms Caution Number Description CA7 5 Alarm A No Chlorine alarm CA7 6 Alarm A HIGH alarm CA7 7 Alarm A LOW alarm 7 8 Alarm DEVIATION alarm CA7 9 Alarm A Fault alarm CA8 5 Alarm B No Chlorine alarm CA8 6 Alarm B HIGH alarm CA8 7 Alarm B LOW alarm CA8 8 Alarm B DEVIATION alarm CA8 9 Alarm B Fault alarm Page 23 www iccontrols com 875 Instructions Sensor Instructions Sensor Instructions The Chlorine sensors provided by IC CONTROLS are designed for simple maintenance The sensors are robust and will withstand difficult applications when properly applied and maintained Follow instructions in this section to promote proper operation Assembly of the Chlorine Sensor This procedure should be done over a sink Thin plastic or rubber gloves are recommended when handling the electrolyte a salt so
13. HIGH alarm CA7 7 Alarm A LOW alarm CA7 8 Alarm A DEVIATION alarm CA7 9 Alarm A Fault alarm CA8 5 Alarm B No Chlorine alarm CA8 6 Alarm B HIGH alarm CA8 7 Alarm B LOW alarm CA8 8 Alarm B DEVIATION alarm CA8 9 Alarm B Fault alarm Each alarm also causes an event tag to be written into an internal log which can be accessed using the IC Net Intelligent Access Program The IC Net program uses the analyzer s serial communication port to read and display this information Refer to the IC Net instruction manual for details 875 Instructions Alarm Functions Manual Override In AUTO mode the green AUTO LED is lighted and the analyzer alarms will activate and deactivate the alarm contact as programmed Press the MANUAL key to temporarily deactivate the alarm contacts wanes OFF or OFF 7 tae Anales a STANDS moda BUNK 2 mode DON 2 ALITU maje Figure 23 LED flashes in Manual In MANUAL mode the green AUTO LED is blinking When no key is pressed for 15 minutes the 15 minute timeout will return the alarms to AUTO mode The alarm contacts are de activated but the alarm LEDs continue to indicate alarm condition s Press the AUTO key to return to AUTO mode immediately High or Low Alarm A high alarm is set when the value of the pH rises above the setpoint and is cleared when the pH drops to below the setpoint minus the differential A low alarm is set when the value of the pH dro
14. The analyzer digitizes the signal for maximum accuracy conditions it and then sends it out as a digital output and or on 4 20mA outputs Features The 875 CHLORINE Analyzer Features Intuitive user friendly program easy to use Grab sample calibration Single input range Self and sensor diagnostics Output hold during calibration Stores 12 calibration records Stores alarms caution and error messages Stores running 1000 minute Chlorine trend Two programmable 4 20mA outputs 10 Two programmable alarms 11 Serial digital output and for remote operation 12 Optional PID control 13 Three level security to protect your settings 14 Hidden alignment accessible when needed 15 Durable housing amp boards withstand fumes 6 Specifications Power Supply Measuring Range Temperature Range Compensation Display Outputs Serial Port Relays LED 4 20mA Operating Temperature Humidity Accuracy Chlorine Temperature Precision Response Time Damping Adjust Sample Conditions Dimensions Housing Weight Shipping Weight www iccontrols com IC CONTROLS 115 240 VAC 0 25A 50 60 Hz 0 to 2 ppm HOCL Chlorine 10 to 210 C 14 to 410 F Default 2 per C 4 5 LCD digits 1 5 cm high RS485 Bi directional Two 10 Amp SPDT Four Alarm A B Auto ERR Two programmable 6002 5 to 45 C 95 Maximum Standard Deviation 2 of Measured Range 0 1 C of Temperature 1
15. a flow The tilting of the probe tself acts as protection not allowing them to come in direct with the membrane Rotation spins them off and cleans he membrane Flow Oscillating Chlorine Electrode RPP DAES PERERA AN INA AG Page 62 Mid Basin Positionable Mounting N Pulleys and Cable or Rope by customer 800 Interface Remote or Local Analyzer 875 and Shroud Analyzer lt Membrane Cable AH 82 o S n E 832 Oscillating Chlorine Electrode INE IN oe INCL INIT AINE d NUI ANC IA LIN AS cf NS AN INC IN CI ILS INS IC INS If NC IN www iccontrols com 875 Instructions IC CONTROLS Appendix D 877 Spec Sheet Appendix D 877 Spec Sheet Model 877 pH ORP METHOD CHLORINE ANALYZER IC CONTROLS has incorporated intelligence into the microprocessor analyzers via the C Net Advanced Intelligence Access Program Measurements such as pH can be critical to your process and must be strictly monitored and maintained Analyzer Intelligence goes beyond measurement and control it provides the user with all necessary historical data including events such as calibration upsets diagnostics and more This information can be communicated for trending or advanced control even to remote locations Ultimately the user has superior control with a compe
16. grab sample cal reference reading Page 37 www iccontrols com Display Prompts HI alarm high limit 20 mA for 4 20 mA output window HOCI HOCI hypochlorous acid free available chlorine input Hold Output hold during calibration hour Hour Real time clock setting hund Hundredth of a second Real time clock display iLOG Internal data log in Input OR minute Real time clock setting LO Low alarm low limit 4 mA for 4 20 mA output window Node number for IC Net communications NO NC Normally Open Normally Closed OFF off OFFS Offset Old The grab sample cal old reading ON on ON OF On off switch onth Month Real time clock setting OPEN Normally open alarm contact out 4 20 mA analog output channel PH C pH compensation value for chlorine measurement rtc Real time clock SEC Second Real time clock setting SEr Serial menu SEt Setpoint select manual temperature compensation Set grab sample cal SLOP Slope Given as Nernstian response StAr Start internal data log StOP Stop Stop internal data log tc Temperature compensation tFCI Total Free Chlorine input hypochlorous acid hypochlorite ion unit Display of units used for analog outputs and alarms YEAr Year Real time clock setting 875 Instructions Glossary Glossary Electrode Both a sensing and a reference elect
17. iccontrols com The Free Chlorine instrument from IC CONTROLS the Model 875 gives you maximum flexibility reliability and ease of use Intuitive user friendly program just seems to do what you expect Auto calibration recognizes your buffers Self and sensor diagnostics Fault tolerant Output hold during calibration Two programmable 4 20 mA outputs Dual programmable alarms with self and sensor alert Optional PID control Frequent adjustments by keypad prompts Program remembers what you were doing No long key sequences Instant return to sample Operate without menu or manual LCD displays ppm Chlorine temperature alarm setpoints and calibration status EASY MAINTENANCE Reliable separately powered and optically isolated output circuit prevents computer interface problems Alignment controls hidden but accessible when needed 3 Level Security to protect settings Calculates Chlorine sensor Slope and Offset Durable housing withstands hosing down Survives acid and caustic fumes humidity etc USE ANY ELECTRODES Submersible Flow Insertion retractable USE ANY COMBINATION OF THE FOLLOWING Local digital indication 4 20 mA signals 4 20 mA Micro PID Control Adjustable alarms ON OFF control The Model 875 is 115 230 VAC operated 875 Instructions Appendix A 875 Spec Sheet M odel 875 SELECTION GUIDE ORDER BY FAX 519 941 8164 BASIC DESCRIPTION Free Available Chlorine HOCI
18. in the PH 7 51 menu ORP 700 The HOCI display is 25 0 the default home base display for Figure 9 Home base the analyzer Home Base can be changed in the Config menu The analyzer s inputs are arranged underneath each other at the left hand side of the menu Use the Up or Down arrow key to display each of the readings in turn From anywhere in the menu the SAMP key can be used to return to the HOCI or home sample display The program will safely abort whatever it was doing at the time and return to displaying the sample Features 1 15 minute time out The analyzer has a built in timer which returns the program to displaying chlorine if no key has been pressed for 15 minutes Security will change access level back to read only access The user will have to enter a password to go to a higher access level If the alarm override was activated the analyzer will return to auto and the contacts will be re activated The green AUTO LED will stop blinking and remain on steady EASY Menu main menu 2 When displaying the home base you can press Left to show which of Err the samples is displayed Pressing Right returns to sample again id 3 Each input can disappear from the out menu if it is turned off in the AL configuration menu 4 The input displayed when the SEr SAMPLE key is pressed can be CONF changed in CONF dF Lt Arrow Keys PASS The
19. into the terminal block TB1 located on the display board Connect the black to terminal B red to terminal A and the clear to EARTH 3 Connect the converter toa free COM port on your laptop computer 4 nsert the cable s RJ11 connector into the converter Making a Custom Cable A cable has been provided with the adapter If this cable is not long enough use the following information to create your own cable Connect shield at one end only Converter Signal RJ11 Pin Number DATA A 2 DATA B 5 Signal Ground 4 IC CONTROLS Data Upload Example Windows 3 1 Terminal Program These instructions are for loading and setting up the TERMINAL program which is part of the standard Windows 3 1 operating system 1 Win 3 1 then switch to the program manager 2 From accessories double click on the Terminal icon 3 Select Settings Communications Set as shown in figure below The Connector Port in the figure is set to COM1 change this setting to reflect the port your A7900015 serial port converter is on Commanications Daud Mats Qi Cao CBS ago my 2400 O gp C Sang Hara 97 ma sn MEE Mang C Odd C Even C Mak Ci Space C Paay Check 4 To capture data into a file from the menu select Transfers Receive text file Specify the file name and location Example C logs lo
20. its measuring Display shows Err is at the top of the scale The analyzer cannot measure higher chlorine values capability Check the sensor setup to make sure that the sensor is operating properly Service or replace the sensor if necessary The analyzer needs electronic adjustments Arrange for servicing E1 2 Electrode efficiency Improper electrode setup or Set up electrode then redo calibration Also refer would be less than electrode failure to Troubleshooting section 20 Previous setting retained E1 3 Sensor efficiency No Chlorine signal or signal Check electrode connection then redo calibration would be more from sensor is very weak Also refer to troubleshooting section than 300 96 Previous setting retained E1 5 Temperature Process outside of TC Use manual temperature compensation compensator is operating range of 5 C to off scale 105 C TC not connected Check TC connections or install TC Page 22 www iccontrols com 875 Instructions IC CONTROLS Caution and Error Messages Error Messages for Temperature greater than 105 C Error Description Causes Solutions 21 Temperature Temperature less Verify process and sensor location reading than 5 C off scale EM Temperature Electronic calibration Follow procedure in Hardware Alignment section less than 5 Necessary
21. menu 875 Instructions IC CONTROLS Alarm Functions Two alarms alarm A and alarm B are a standard feature for the 875 Each alarm has an alarm contact associated with it which can be used for remote alarm indication or for control functions The two alarms function independent of each other Either alarm can independently monitor any of the inputs Each alarm features an adjustable setpoint user selectable alarm type adjustable differential also called hysteresis The alarm types which are available are no chlorine high low deviation and fault alarm Alarms can be set anywhere between 0 and 20 ppm for chlorine or 5 C and 105 C for the temperature input SEt Func list of available inputs gt gt 5 5 9 gt rit c et m dEv 0 60 diFF 0 10 30 alarm activation delay sec Figure 22 Alarm menu Use of Relay Contacts By default the relay contacts will be used to indicate alarm conditions Alarm conditions are indicated using both the LED and the relay contact This usage of the relay contacts is selected by setting CONF AL AL A FUNC and CONF AL AL b FUNC to AL If some other use is selected for the relay contacts then the alarm cannot simultaneously use the contact however the alarm function continues using the LED display messages and serial c
22. of instruction manual x qty Priced x times each Short cable minimum 1 ft maximum 4 ft Long cable minimum 6 ft maximum 100 ft Priced length x times ft Stainless steel tag Zero Free Chlorine Standard 500 mL bottle P N A1100225 Free Chlorine Calibration Kit for colorimetric calibration and instructions P N A1100226 Chlorine Sensor Renew Solution P N A1100227 Deionized rinse water P N A1100192 Fast response Membrane Module and fill solution kit P N A2104013 Ruggedized slow response Membrane Module and fill solution kit P N A2104017 Special Contains small amounts of Hazardous Materials Page 60 835 21 26 93 Flowing sample line Free Chlorine electrode with zero standard Sample Order Insertion Sensor 835 3 28 93 Tank wall insertion CI electrode with 316 SS union insertion fitting and zero stand Sample Order Submersion Sensor 835 72 10 Fixed mount submersion Chlorine electrode with 10 ft lead 835 25 sample system 875 www iccontrols com 875 Instructions IC CONTROLS Appendix C 832 Spec Sheet Appendix C 832 Spec Sheet Model 832 Chlorine OSCILLATING SUSPENSION CHLORINE ELECTRODE The Survivor Buy the world s most accurate self cleaning rugged Free Chlorine electrode the IC CONTROLS Model 832 As a major supplier of rugged long life pH equipment to the waste water industry IC CONTROLS was repeatedly asked to develop a similar Free Chl
23. parts are warranted to be free from defects in material and workmanship for a period of three 3 months from the date of installation or eighteen 18 months from the date of shipment when used under normal operating conditions and in accordance with the operating limitations and maintenance procedures given in the instruction manual and when not having been subjected to accident alteration misuse abuse freezing scale coating or poisoning ions Chemical solutions standards or buffers carry an out of box warranty Should they be unusable when first out of box contact IC CONTROLS immediately for replacement To be considered for warranty the product shall have an RA Return Authorization number issued by IC CONTROLS customer service department for identification and shall be shipped prepaid to IC CONTROLS at the above address In the event of failure within the warranty period IC CONTROLS or its authorized dealer will at IC CONTROLS option repair or replace the product non conforming to the above warranty or will refund the purchase price of the unit The warranty described above is exclusive and in lieu of all other warranties whether statutory express or implied including but not limited to any implied warranty of merchantability or fitness for a particular purpose and all warranties arising from the course of dealing or usage of trade The buyer s sole and exclusive remedy is for repair or replacement of the non conforming
24. proportional to the concentration of Chlorine present Figure 14 shows how such an electrode System works in a simple laboratory test Figure 15 shows how these scientific principles can be implemented into a working Chlorine electrode Also unlike an electrolytic cell in which a flow of current produces the chemical reaction there is no zero current as galvanic current naturally is zero when zero Chlorine is present IC CONTROLS The 875 uses a galvanic cell separated from the sample by a Chlorine permeable PTFE membrane The cell has a gold cathode in close contact with the PTFE membrane where chlorine gains electrons is reduced to become chloride ions and a silver anode that produces a fixed potential and completes the reaction with the chloride to form silver chloride The chemical reactions within the cell are At the cathode Clo 2e 2 anode 2 2Ag 2e Overall 2Ag 2AgCl 100 0 Efficiency GEt ldo OLd 1 0 90 7 50 pH CAL set 1 00 O Auto Page 16 www iccontrols com set 2250 ccn 875 Instructions IC CONTROLS Chlorine Calibration Calibrating the Chlorine Measurement The 875 Chlorine reading is calibrated by grab sample an easy method of standardizing the chlorine measurement without taking the electrode out of the sample Grab sample standardization method requires the user to determine the actual
25. set the clock is to use the IC Net program to synchronize with the computer init ALL do ALA NONC re initialize only if you press Enter Lc 2 L4dFLt Hoc Metric or Imperial Units tFCI By default the analyzer uses metric units The Ioue HOCI dA B input damping sec temperature will be displayed using degrees Celsius dA 5 input damping sec and the prompt will be C The analyzer can also be made to use imperial units F car 22 3 For practical reasons the first temperature input is OFFS 0 0 Offset identified as C throughout this instruction manual and in the menu Input Damping The Chlorine and temperature measurements can Lunt Le metric or imperial F unit selection be damped to deal with rapidly varying or noisy 81997 onth L L 2 signals Damping range is 3 to 99 seconds With 0 dAtE 31 each reading is used to directly update the display rte f hour 23 and 4 20 mA output The factory default 5 adds the in 59 next four seconds readings to the first and divides SEC 59 by five this gives fast response Selecting 99 hund 99 provides a smooth damping out of turbulent PAS 1L 5 Selectable only if readings Any selection between 3 and 99 can be Y FEE DES made Figure 27 Configuration m
26. the display flashing do press Enter Note there is no way to recover once memory is cleared Be sure you do want to erase the internal log before pressing Enter Calibration amp Event History The analyzer automatically stores the last 12 calibration records for each input which is sufficient for a year s worth of history when monthly calibrations are performed Upset events records such as power down power up and alarms automatically are recorded in a separate log which tracks the last 20 events time date stamped When combined with the internal data logging capability this allows the operator to recall factors leading to alarm conditions Retrieving Intelligence Records At any time the date time stamped records can be retrieved from the analyzer using serial communication and a computer running the IC Net program The display does not have the volume capacity to view event records using only the analyzer There is no menu for intelligence records logging is done automatically The IC Net Advanced Intelligence Access program is available as option 35 To upload to your laptop Intelligence Records Calibration History Upset Events you require a part A7900015 serial port powered RS232 to RS485 converter and a part A2500192 serial cable Upset Event Printout Sample output of event records Thu Dec 18 14 50 47 1997 ANALYZER OFF Thu Dec 18 17 47 30 1997 ANALYZER ON y Thu Dec I8 17 47 30 1997 El 5
27. Calibration kit 17 41 Calibration records SEE ALSO description Page 54 Caution 7 x 23 29 Caution 8 x 23 Celsius 12 36 Chlorine calibration 17 chemistry 13 combined chlorine 14 disinfectant properties 14 free available chlorine 14 grab sample calibration 17 pH compensation 19 pH dependence of 13 14 species 19 TC 19 total free chlorine 14 total residual chlorine 14 Combined chlorine 14 Comparator high range 18 low range 18 Configuration 36 normally closed 38 normally open 38 Program 36 units 12 36 Consumables kit 17 Current output 28 displaying 40 output hold during calibration 20 reversing 28 simulating 28 40 standby mode 11 D O applications 16 introduction 16 measuring circuit 39 troubleshooting 39 42 D O sensor SEE Electrode Damping of inputs damp settings 12 36 Delayed alarm activation feature 30 Diagnostics memory test 10 startup procedure 10 Differential www iccontrols com IC CONTROLS SEE hysteresis Display prompts 37 Display schematic 43 Drawings 43 53 E coli 14 Edit mode 12 65 change settings 12 example 12 key functions 65 Electrode 38 assembly 24 maintenance 24 Error messages 21 sign 21 sign 21 acknowledging 21 caution 7 x 29 clearing 21 E1 0 22 E1 1 22 E1 2 22 E1 3 22 E1 4 22 E1 5 22 E 2 1 23 2 2 23 meaning of 37 remote indication 29 Event records SEE ALSO description Event tags SEE ALSO description Farenheit 12 36
28. ES cus PE Lum 2400 YEAr 1997 4800 onth 12 9600 dAtE 31 14 4 hour 23 59 19 2 SEC 59 28 8 hund 99 38 4 selectable only if PAS 1 000 security is enabled 2 0000 Figure 5 Serial menu Figure 3 Configuration menu Page 5 www iccontrols com 875 Instructions Introduction Introduction Model 875 is IC CONTROLS industrial quality remote operateable HOCI Chlorine Analyzer designed to give you maximum flexibility reliability and ease of use The model 875 as shipped from the factory is calibrated 0 to 2 ppm 4 to 20mA and should not require recalibration It has Chlorine and Temperature inputs two isolated 4 20mA outputs two 10Amp SPDT relays plus a serial communication port It s microprocessor intelligence recognizes your chlorine grab sample to calibrate holds output during calibration notifies you of diagnosed sensor or analyzer faults plus stores in memory the last 12 calibration records 1000 minute measurement trends alarms power outages and diagnostic messages all date time stamped General The 875 is one of a series of 115 240 VAC process analyzers supplied in a corrosion resistant IP65 NEMA 4X watertight dustite case These analyzers are also available for pH ORP Dissolved Oxygen and Conductivity plus two wire versions with optional explosion proof rating In the case of CHLORINE the analyzer specially measures the sensor signal corresponding to the actual Chlorine and temperature
29. INSTRUCTION MANUAL MODEL 875 INTELLIGENT CHLORINE ANALYZER FREE AVAILABLE M B75 INTELLIGENT ANALYZER CONTROLS IC CONTROLS CONTENTS Introduction General Features Specifications Installation Analyzer Analyzer Wiring Sensor Mounting Sensor Wiring Instrument Shop Test Startup Default Settings NOTICE OF COMPLIANCE Staup gu Analyzer Startup Tests Calibration Settings Retained EASY Menu Easy to Use Remembers Where You Were Home Base Press Sample Arrow Keys AUTO and MANUAL Keys Standby Mode Edit Mode Input Damping Real Time Application Information Chlorine Chemistry Chlorine and the effect of pH Terminology Disinfectant Properties of Chlorine 875 Chlorine Measurement Introduction Galvanic Measuring Cell Chlorine Calibration Calibrating the Chlorine Measurement pH and Temperature impact on Chlorine Manual Temperature Compensation Manual pH Compensation Zero Test Technique Output Hold Caution and Error Sensor Instructions Assembly of the Chlorine Sensor Inserting Chlorine Sensor in the Flow Fitting Removal of the Chlorine Sensor Flow and Insertion Type Monthly Maintenance Semi Annual Maintenance Chemical Cleaning Page 3 www iccontrols co
30. NS Internal AUDIBLE SONIC ALARM wired to relay A Direct connected must have electrode within 10 100 ft 80 recommended over 30 ft 2 pipe surface mounting kit P N A2500255 Panel mounting kit P N A2500201 supplied in a 1 2 Din metalic panel mount 144x144mm case 139x139 cutout OPTIONS 34 Real Time Clock for correct time with the power off 35 Advanced IC Net Intelligence Access window program for multiple analyzers over one RS485 two way link to multiple networked workstations See Computer section 36 communication documentation for user to write a custom Intelligence Access program 37 5232 Single Analyzer Communication replaces RS485 loop communication 38 Reserved for future Fieldbus replaces RS485 52 Back Lit Display uniform green P N A9130023 70 x Extra copies of instruction manual x Priced number required x times each 72 x Cable analyzer to preamp specify x ft P N A9200007 Price length x times ft 80 1800 preamp interface for up to 3000 ft sensor separation P N A2500053 82 Surface J Box amp terminals up to 100 ft sensor extension P N A2103023 Requires 83 to 88 83 Sub Assy 5 ft D O CI sensor extension cable with spade lugs P N 2103617 84 Sub Assy 10 ft D O Cl sensor extension cable with spade lugs P N A2103618 85 Assy 15 ft D O Cl sensor extension cable with spade lugs P N A2103619 86 Sub Assy 20 ft D O Cl sensor extension cable wit
31. Press Enter to go into edit mode The analyzer will display PASS for 2 seconds because we need to enter a password first Level 1 security is needed to change this setting 875 Instructions Appendix E Enabling Security Select PASS from the main Change the displayed value to the level 1 password then press Enter The analyzer will display good followed by ACC 1 indicating that the password is valid and that we now have level 1 access Try changing the output 1 low setting again You will find that this time we can go into edit mode unhindered Before walking away from the analyzer we should disable level 1 access to prevent unauthorized use ofthe analyzer Select PASS from the menu again then press Enter with 0000 displayed The analyzer will display ACC O indicating that we have returned to the lowest access level The analyzer has a built in password protection system This security system is disabled by default and does not need to be enabled if no password protection is necessary If you choose not to enable the password protection system then the user will have unrestricted access to all analyzer settings available through the menu as described in this manual ENTER PASSWORD PASSWORD 2 ENTERED NO PASSWORD 7 1 ENTERED E 0000 ENTERED YES Password Validation ACCESS ACCESS ACCESS ACCESS LE
32. Temperature 0 0 100 Alarm B Deviation 0 6 ppm 0 4 ppm 0 1 ppm 0 sec on No Chlorine 0 1 ppm 0 01 ppm 0 sec on Installation Global units metric units temperature in degrees Celsius Alarm contacts Configured normally open Security Not enabled pH and temperature compensation method for chlorine Automatic temperature compensation using input Manual pH Internal data logging Log Chlorine input Frequency once per 60 seconds Stop logging when log memory is full Serial communications Turned on 9600 baud node 1 NOTICE OF COMPLIANCE US This meter may generate radio frequency energy and if not installed and used properly that is in strict accordance with the manufacturer s instructions may cause interference to radio and television reception It has been type tested and found to comply with the limits for a Class A computing device in accordance with specifications in Part 15 of FCC Rules which are designed to provide reasonable protection against such interference in an industrial installation However there is no guarantee that interference will not occur in a particular installation If the meter does cause interference to radio or television reception which can be determined by turning the unit off and on the user is encouraged to try to correct the interference by one or more of the following measures Reorient the receiving antenna Relocate the meter with respect
33. Total Free Chlorine OCI APPLICATION TIPS Chlorine and Bromine work similarily Configuration can be changed in the field Free Residual refers to the buildup of HOCI after breakpoint chlorination of water containing ammonia which most do For automatic temperature compensation analyzer requires 33 TC option in pH sensor Free chlorine HOCI is taste free and aggressive against germs and organic compounds Maintaining 86 Free Chlorine minimum vs Total Residual Chlorine generally produces good organic destruction germ kill and where test is a factor of good tasting water Free Chlorine HOCI partly reacts in water to form H and OCI ions The reaction is reversible so Total Free Chlorine HOCI amp OCI is still available for reaction however the H ion introduces pH dependency so that pH is best kept low HOCI available at pH 6 97 pH 7 80 pH 7 5 50 pH 8 25 pH 9 3 Free Chlorine via the ORP method must be calibrated on site using the process water and colorimetric or titration method since most water has a background ORP unique to the balance of dissolved chemicals it contains Calibration using standards made up in a laboratory from distilled or deionized water will give radically different results from field performance because of the large ORP offset from the absence of dissolved chemicals except for chlorine Acid cleaning is recommended for the chlorine ORP sensing element since oils and organics in co
34. VELO LEVEL 0 LEVEL 1 LEVEL 2 VIEW ONLY VIEW ONLY OPERATOR COMPLETE DISPLAY DISPLAY DISPLAY DISPLAY bad good good acc o 1 2 Figure 28 Password Logic Page 66 www iccontrols com IC CONTROLS Disabling Password Security Password security can be disabled by setting the level 2 password to 0000 In order to change the password you must first have level 2 access to the program Select CONF PAS 2 from the menu then press ENT when the program displays 0000 Both passwords 1 and 2 are set to 0000 and security is now disabled The main menu will be changed to exclude the PASS frame and the configuration menu will no longer have the PAS 1 frame Password Example a Quick Tour With security disabled select CONF PAS 2 from the menu Set the level 2 password to 0002 Select CONF PAS 1 from the menu Set the level 1 password to 001 Security is now enabled Select PASS from the main menu Press Enter with 0000 displayed The analyzer will display ACC O to indicate we are now at access level 0 Try changing the output 1 low setting Select out out1 LO from the menu The current value will display Press Enterto go into edit mode The analyzer will display PASS for 2 seconds because we need to enter a password first Level 1 security is needed to change this setting Select PASS from the main menu again Change the disp
35. ampoule s tapered tip into one of the four depressions in the bottom of the sample cup Snap the tip by pressing the ampoule towards the side of the cup The sample will fill the ampoule and begin to mix with the reagent Note a small bubble of inert gas will remain in the ampoule to facilitate mixing Caution Do not break the tip of the ampoule unless it is completely immersed in your sample Accidentally breaking the tip in the atmosphere 875 Instructions Chlorine Calibration IC CONTROLS may produce a jack hammer effect 9 Install the Chlorine Calibration value determined shattering the ampoule in step 8 into the 875 Wear eye protection when working with Press SAMP then SELECT to tFCI then these ampoules SELECT to CAL then SELECT to Get then up arrow to SEt then SELECT again to numbers display then ENTER to get flashing numbers Edit the ppm total free chlorine value and change it to the new value from step 7 When flashing 7 Wipe all liquid from the exterior of the ampoule value is step 7 Chlorine Value that you and wait 1 minute determined Press ENTER to get analyzer to take value then SELECT to flashing DO then press ENTER again to get the 875 to install the Chlorine Calibration Done appears 10 Press SAMP to display HOCI or free chlorine residual in mg l or ppm Write down this value 6 Remove the fluid filled ampoule from the cup Mix the
36. an input if the input is off scale or an unacknowledged error or caution message exists for that input To use an alarm as a fault alarm select FUNC from the alarm menu then select Fit To enable the alarm make sure the on off switch is set to ON Delayed Alarm Activation Feature Alarm contact activation may be immediate or may be delayed Delayed alarm activation gives the operator a chance to correct alarm situations before the alarm contacts activate or will eliminate alarm activation based on a temporary The delay time is programmable by the operator To change or view the delay time select dLAY from the alarm menu The default value of 0 seconds is for immediate contact activation The delay time can be set from 0 to 9999 seconds Using Alarms for On Off Control The alarms can also be used for process control The alarms contacts will then function as on off signals for switches controlling a valve pump motor etc The setpoint determines the control point of the system and the setting of the differential controls the amount of corrective action before a controlled shut off occurs HIGH ALARM 7 differential Y sample 7 time 875 Instructions IC CONTROLS IC Features IC Net Features Intelligence Access Net Comma separated fields make it easy to import the data into other programs for analysi
37. analyzer stores the last 12 monthly calibration records for communication or download and even keeps upset records The last 20 upsets are recorded and datestamped ie out of spec alarm power interruptions etc Factors leading to alarm conditions are recalled and for measurement trend hundreds of data points can be accessed at user defined time intervals All of this communication is extremely fast up to 38k baud The optional C Intelligence Access Program runs your PC Window using RS485 RS232 and provides your networked PC s access to multiple analyzers C Net allows intelligent system performance that emulates human intelligence through reasoning manipulation of signals or advance process control and remote monitoring via computer network DCS phone Internet or satellite link This analyzer supports and communicates diagnostics Settings can be viewed functions tested calibration updated and remote operated from your computer terminal Note requires C Net Advanced Intelligence Access Program An optional Real Time clock allows accurate tagging of events and duration even through power outages Every IC CONTROLS microprocessor analyzer incorporates intelligence that enables advanced process control and the ability to communicate with ease and flexibility all in one analyzer Let IC CONTROLS provide you with REAL SOLUTIONS to your control needs buy IC CONTROLS Intelligent Analyzers Page 57 www
38. arrow keys to change the display to the desired password for level 2 You can press SAMP at any time to safely cancel password entry Press ENT to enter the password into memory and to enable password security The analyzer program automatically returns to the configuration menu With only password 2 set to a non zero value level 2 access is required to make changes in the configuration menu but all other settings are unprotected Effectively the user will always have at least level 1 access LEVEL 1 At this point password 1 is still 000 You may optionally enable operator access control or level 1 security by changing the level 1 password from 000 to a non zero value Change the password by selecting CONF PAS 1 from the menu then entering an appropriate 3 digit password RECORDING YOUR PASSWORDS You may want to write down the passwords you set and store them in a secure place Once a password has been set there is no way to redisplay it Since passwords are set in the configuration menu level 2 access is required to change either password If you have forgotten the level 2 password there is no simple way to regain access to the analyzer Contact the factory if you find yourself locked out of the analyzer Passwords A Quick Tour Assuming that password 1 is defined and we are at access level 0 try changing the output 1 low setting Select out out1 LO the menu The current value will display
39. as been pressed for 15 minutes Figure 16 Chlorine sensor setup for Zero check Page 20 www iccontrols com 875 Instructions IC CONTROLS Caution and Error Messages Detected errors and or cautions can be displayed by the analyzer From the main menu select Err If there are no error or caution messages NONE will be displayed otherwise scroll through the error list using the Up and Down arrow keys Errors and or cautions cannot be removed from this list directly each error caution will be removed automatically when appropriate e g errors associated with improper calibration will be cleared after a successful calibration Error messages are numbered Errors 1 through 5 are identified as where n is the input number and eis the error number Messages 6 through 9 are less serious and are identified as cautions instead e g CAn e Off scale errors for Chlorine are not numbered and are identified as Err and Err depending on whether the input is at the top or the bottom of the scale The off scale error is displayed instead of the sample reading and does not show up in the error menu with the numbered error messages if any input source input number for error caution messages Chlorine 1 C 3 Alarm A 7 Alarm B 8 Page 21 www iccontrols com Caution and Error Messages Error messages can be annoying when you have already been mad
40. can also be caused by growth of biologicals in the sample line In this case the problem may be alleviated by changing the take off point Readings consistently low or spike low characteristic of wiring problems between the analyzer and the sensor an open circuit in the field wiring will result in zero cell current and a very low reading Review the installation instructions Readings gradually falling the analyzer can no longer be calibrated properly This problem is typical of sludge slime deposits on the sensor face The sensor will need to be cleaned Refer to the annual maintenance procedure in this manual Readings trend higher This problem is typical of pressure gradually stretching the membrane which is getting thinner The membrane will soon fail Correct by lowering pressure at the sensor Electronic Hardware Alignment Devices referred to in the following descriptions are shown on component location drawings D5020260 and D5980176 Proper field wiring for hookup is shown on drawing D5020260 These instructions assume 115 230VAC power is hooked up the Calibration of Input electronic are operable and field wiring is in place Alignment of Chlorine Detection Circuit 1 Set up a precision multimeter Fluke 8051A or equivalent to read VDC 2 Use the D O sensor connection TB200 4 and sensor TB200 2 as common See wiring diagram 3 Set the Chlorine efficiency constant to 100 by sele
41. contents of the ampoule by inverting it several times allowing the bubble to travel from end to end each time 8 After waiting 1 minute use the appropriate comparator to determine the level of chlorine in the sample Write down the Chlorine Value Low range Comparator High range Comparator 0 1 ppm 1 5 ppm 11 Press down arrow to display HOCI OCI or total chlorine residual in mg l or ppm Write down this value The ampoule is placed The comparator should in the center tube flat illuminated by a end downward The top strong white light of the cylinder is then directly above the 12 Press SELECT then up arrow to tFCI then directed toward a comparator The filled SELECT plus up arrow to EFF then source of bright light ampoule should be SELECT to numbers efficiency Write while viewing from the placed between the down this value bottom Hold the color standards for Records will show how your unit trends over comparator in a nearly viewing It is very time horizontal position and important that the rotate it until the ampoule be compared standard below the by placing it on both Your 875 analyzer is now reading Chlorine and ampoule shows the sides of the standard tracking Chlorine changes in your water closest match tube before concluding that it is darker lighter or equal to the standard Using the high range comparator Page 18 www iccontrols com 875 I
42. cting tFCI EFF from the menu and editing the value to read 100 0 4 Adjust the electronic standardize with blue trimpot VR200 located mid board above the Page 39 www iccontrols com Troubleshooting terminal block marked D O see drawing D5020260 Adjust the trimpot to a reading of 2 50V at TP200 while inputting 0 250VDC through a 1Meg 1 resistor 0 250 VDC simulates 1 0 ppm HOCI Chlorine at approx 100 efficiency under above conditions Calibration of Temperature Input The temperature input can be adjusted both by making electronic adjustments and or by having the program compensate for differences in offset By default the analyzer is shipped with a 1 07K 1 resistor across the TC terminals This resistor should be left in place during normal operation if no TC is used in the sensor A 1 07K resistor across the TC terminals will simulate a temperature of approximately 18 C or 65 F Software Calibration To do a software calibration of the temperature input the correct temperature needs to be known 1 Select CONF in C CAL from the menu The actual temperature as measured by the temperature sensor will be shown Edit the displayed value to the known correct temperature Press Enter to leave edit mode then Select to start the calibration 2 current temperature will be shown using flashing display When it looks like the input is stable press Enterto set the new temperature T
43. ctronic Calibration 1 Outputs are isolated from main circuit therefore measurements are made with common at the output 2 terminal TB304 Measure output 1 zero at TP301 pin 8 of U304 while output 1 is outputting 4 00 mA Reading should be between 0 870 and 1 250V Adjust 2 voltage with VR300 Change analyzer output to 20 00 mA switch meter to mA and measure Terminal terminal of O P 1 and adjust VR301 so that the current reads 20 00 mA Return analyzer output to 4 00 mA and trim actual output to 4 00 mA using VR300 Check again at 20 00 mA and repeat adjustments until satisfied Measure output 2 zero at TP300 pin 7 of U304 while output2 is outputting 4 00 mA The test point should read between 0 870 and 1 250V Adjust 2 zero voltage with VR302 Change output at output 2 to 20 00 mA switch meter to mA at TB304 terminal of output 2 and adjust VR303 span pot until the current reads 20 00 mA Note Zero and span are very wide range adjustments which show small interactions Recheck zero and span to confirm good calibration If so desired all software settings can be returned to factory default condition by following the procedure in nstallation Factory Defaults He initializing All Settings Testing Relay Outputs 1 www iccontrols com Relay output operation can be verified by testing for contact closure or continuity at each relay To activate a relay select CONF NO NC
44. d Cathode 7 Teflon Membrane Silver Anode KCL Fill Solution Sensor Body Insulator www iccontrols com Application Information A X Sold Cathode Att zdwer Anode Ag LL solution sd Figure 14 Basic galvanic cell The OCI ion hypochlorite ion form of chlorine is a relatively poor disinfectant because of its inability to diffuse through the cell wall of microorganisms The obstacle is the negative electrical charge 875 Instructions 875 Chlorine Measurement 875 Chlorine Measurement Introduction Chlorine in water is a measure of the amount of chlorine usually thought of as a gas that is dissolved in the liquid Chlorine is widely respected as a leading chemical for the treatment of water to make it potable or safe to drink In addition Free Available Chlorine is often used to control biological agent growth in water filled industrial systems The 875 directly measures Free Available Chlorine using an 832 or 835 Galvanic Chlorine Sensor Galvanic Measuring Cell The 832 and 835 Chlorine measuring sensor are electrochemical cells similar to a battery that produces a current when Chlorine is present By using carefully selected electrodes in contact with an appropriate electrolyte a chemical reaction occurs that uses electrons gained from Chlorine molecules to produce a galvanic current directly
45. e aware of them A method has been provided to turn off the error LED and the fault alarm for a particular error message Refer to the heading Acknowledging an Error Message below for the exact procedure The error LED will be on as long as there is an unacknowledged error or caution message or as long as any input is off scale Each source of error must be removed or acknowledged before the error LED will go off Acknowledging an Error Message Select Err from the main menu Use the Up or Down arrow key until the error message to be acknowledge is displayed Errors are displayed with either a or a sign in front The sign is used to indicate an active or unacknowledged error the sign indicates an inactive or acknowledged error Acknowledging the error will change the sign from to Press ENT to go into edit mode The to sign will be flashing Use the Up or Down arrow key to change the sign then press ENT again An acknowledged error message is cleared for one occurrence of the error only If the error reappears the sign changes to and the error message must be acknowledged again 875 Instructions Caution and Error Messages Error and Caution Messages for IC CONTROLS Chlorine Error Description Causes Solutions E1 0 Reading off scale The internal A D converter The analyzer is at the limit of
46. e cap 3 Sensorin air the 875 Chlorine Analyzer should come up reading 0 0 0 05 4 Runa zero check use wires to be field installed and allow 30 minutes warm up time for the electronics to stabilize 5 Runa Std span check replace the Sensor with a 1 meg 196 resistor and input 0 250 VDC to simulate 1 0 ppm HOCL Chlorine With the Chlorine efficiency set at 100 the display should read approximately 1 0 5 6 To check for general performance place the Sensor running tap water chlorinated tap water should be between 0 2 and 1 0 ppm The display should read in that range 7 Before putting analyzer into operation verify your settings to ensure that they agree with intended setup Factory defaults are below For the 4 20 mA output set high limit and low limit 8 Set preference for temperature C F units in CONF unit 875 Instructions IC CONTROLS 9 Setdesired input signal damping if known normally 5 second 10 Unit is now ready for field installation Default Settings The following program settings are the default settings for the analyzer New analyzers will have these settings unless the setup has already been customized for your application Outputs Input to be transmitted Low setting High setting Alarms Input for alarm Alarm function Setpoint Deviation Differential delay on off switch Page 9 Output 1 Output 2 Chlorine 0 00 2 00 Alarm A
47. en select the dA frame Press Enter then change the input damping to the new number of seconds Press Enter again to leave edit mode Real Time Clock The analyzer has an internal clock used for date time stamping of calibrations events and a measurement log Both the system events and the internal log are accessed using the IC Net Intelligent Access Program which is available as option 35 Analyzers purchased with option 34 also have a real time clock which will maintain the correct time and date even with the analyzer power turned off 875 Instructions IC CONTROLS Application Information Chlorine Chemistry When chlorine gas is dissolved in water it hydrolyzes rapidly according to equation 1 This reaction occurs very rapidly in only a few tenths of a second at 18 C 1 Cl2 H20 gt HOCI Since HCI is a strong acid addition of gaseous chlorine to water results in a lowering of the pH from the acidic by product The important product of reaction 1 is HOCI or hypochlorous acid Hypochlorous acid is the killing form of chlorine in water Hypochlorous acid is unstable because the chlorine molecule is lightly bound and therefore will react quickly Free available chlorine or free chlorine is HOCI or hypochlorous acid Free chlorine HOCI is taste free and aggressive against germs and organic compounds Chlorine supplied as sodium hypochlorite calcium hypochlorite or bleach is in a basic
48. ent to ensure the Chlorine present is consumed The Chlorine sensor should rapidly fall below 0 1 ppm level thus confirming operation of the sensor Make sure that the zero check solution is used within 8 hours because the scavenger will be used up with exposure to air by also absorbing oxygen The remaining zero check solution should be stored tightly capped in its bottle The zero solution is single use so discard used zero solution beaker Keep about 2 to 3 inch below surface IC CONTROLS Output Hold The 875 features an automatic output hold Output hold goes into effect as soon as SELECT is pressed when CAL is displayed The output hold feature avoids false alarms and erratic signal output that would be caused by a routine calibration Output hold has the following effect 4 20 mA output signals for HOCI and TFCI are frozen at their current levels alarms for HOCI and TFCI disabled If the output signal for HOCI is not acceptable at the value found it can be changed for the duration of the calibration Select Hold from the menu to display the HOCI value used by the analyzer to determine the output signal Use the normal editing procedure to change the HOCI value used for output hold are temporarily The output hold remains in effect for the duration of the calibration thatis the output hold is disabled when the CAL prompt is displayed the SAMPLE key is pressed or after no key h
49. enu Page 36 www iccontrols com 875 Instructions IC CONTROLS Display Prompts 1E 6 Scientific notation for ppm parts per million AL Alarms AL A Alarm A AL b Alarm B bAud Baud rate for serial communications buF1 Buffer for standardizing or first buffer for calibration buF2 Second buffer for calibration C Temperature in degrees Celsius temperature input CHIP Chip Is this analyzer equipped with a real time clock chip CLr Clear the internal data log cnt Count of readings in internal data log dA Input damping time in seconds do Do press Enter to do reset clear action CAL Calibrate analyzer CLSd Normally closed alarm contact CONF Configuration of program to match hardware Cont Continue internal data log when buffer full cur Signal output in mA or current cuSt Custom buffer standard value for calibration dAtE Date Real time clock setting for day of the month 1 31 dEv Deviation alarm dFLt Default dLAY Alarm activation delay donE Done reset clear action has been taken Err Error 94 RAM checksum failed Some settings may be lost 95 EPROM checksum failed F Temperature in degrees Fahrenheit Fault alarm selectable function for alarm B FrEq Frequency of internal data log updates in seconds FULL Full What to do when internal data log is full continue or stop GEt Getthe
50. ers select Comma 6 Click the Finish button to load the log file into Excel Page 35 655 www iccontrols com IC Net Features INTELLIGENT ANALYZER Mehl Mene pH Cond 7 date time stamp will be loaded in column and the input values will be loaded in columns B C etc The date time stamp will be treated as text while the input values will be treated as numeric values that can be graphed manipulated etc __ MicrosoftExcel LOG DAT File Edit View Insert Format Tools Data Window S EH EFT NM eae 875 Instructions Configuration of Program Configuration of Program The 875 analyzer has been designed with ease of use in mind In most cases the analyzer has been configured to ordered specifications at the factory and no configuration of the analyzer is necessary Relays NO NC The 875 program assumes the alarm contacts are wired normally open A normally open alarm contact will be open if there is no alarm condition and will be closed when there is an alarm condition If the program configuration and the wiring for each alarm do not match then the incorrectly configured alarm contact will generate an alarm when there is no alarm condition and vice versa Re Initializing All Settings Occasionally it may be desirable to reinitialize all of the program s settings to bring them back to defaults Execut
51. form When a base is present a different reaction sequence occurs 2 NaOCI H20 gt 3 Ca OCl 2 2H20 gt 2HOCI 20H In any hypochlorite solution the active ingredient is always hypochlorous acid Then once HOCI and OH are formed an additional reaction occurs 4 HOCI lt gt OCI The proportion of chlorine hypochlorous acid and hypochlorite ion in solution depends on primarily on pH and somewhat on temperature The different forms of chlorine are named as follows Cle chlorine HOCI hypochlorous acid hypochlorite ion Page 13 www iccontrols com Application Information At atmospheric pressure and 20 C the maximum solubility of chlorine is about 7395 mg per liter or 7 395 ppm Chlorine and the effect of pH The most important reaction in the chlorination of an aqueous solution is the formation of hypochlorous acid The hypochlorous acid form of chlorine is very effective for killing germs Hypochlorous acid is a weak acid meaning that it tends to undergo partial dissociation to form a hydrogen ion and a hypochlorite ion Once in a water environment HOCI tends to dissociate into H and ions 5 HOCI lt gt H OCI X af Spectre 4 Iu i hi Soluis Percent of Chleeser Acid and ve 2 pH Figure 13 Chlorine species change vs pH 875 Instructio
52. four arrow keys on the keypad are StbY used to move around in the menu The Figure 10 same keys can have other functions ain menu well e g see under Edit Mode but when moving from frame to frame in the menu these keys work as expected Figure 11 Analyzer keypad 1 AUTO and MANUAL Keys The AUTO and MANUAL keys are used to implement the alarm override feature on analyzers that do not use the PID option See Alarm Override Standby Mode Standby can be selected from the main menu In standby the PID output will be 0 the alarms will not function the AUTO LED will be off and the 4 20 mA outputs will go to 4 00 mA When SAMP is pressed the inputs will show StbY The analyzer will not resume normal operations until the analyzer is taken out of standby mode While in standby mode the entire menu and all settings are accessible to the operator as before None of the settings will take effect until the analyzer is returned to normal operation The standby feature is protected by security level 2 Page 11 www iccontrols com 875 Instructions Edit Mode Edit Mode Edit mode is used to change a numeric value or to select between different options The values and settings which can be edited are identified by the darker shading in the menus Any frame which has a white background cannot be modified Enters edit mode The entire display or a single digit will blink to indicate t
53. g01 dat The terminal program will now store any ASCII data sent out by the analyzer into the specified file 5 To stop or pause data collecting use the buttons at the bottom left of the window Windows 98 Try Start Programs Accessories Communications Folder Hyper terminal Windows NT Try Start Programs Accessories Hyper terminal Folder Hyper terminal IC CONTROLS INTELLIGENT ANALYZER EARTH 8 W Jack End 11 Plug End RH11 Conducts Page 34 www iccontrols com 875 Instructions IC CONTROLS c och de EEL poapoeampoaeeoeac EZZENEML roni 2 398 Anairar n Phe amira nhh Example Load Log File in Excel The following example illustrates how to load a log file into Microsoft Excel 5 0 1 default the Net Access program uses the DAT extension for its log files Excel prefers TXT PRN or CSV You can keep the DAT extension or use TXT or CSV 2 Open Excel then select File Open from the menu 3 Navigate to the log file If you used the PRN TXT or CSV extension for the log file you may want to change List Files of Type to Text Files otherwise use All Files Select the log file then click on OK 4 Text Import Wizard dialog box should open In Original Data Type select Delimited then click the Next gt button 5 Under Delimit
54. gold cathode silver anode battery chemistry is Free Chlorine specific no need to compensate for non Chlorine gases Quick Union design for submersion screw in and flow through applications all with one sensor 875 Instructions Appendix B 835 Spec Sheet Model 835 IC CONTROLS Cl SELECTION GUIDE ORDER BY FAX 519 941 8164 MODEL 835 BASIC DESCRIPTION Quick Connect Free Available Chlorine Sensor Universal industrial union type submersible flow insertion Free Chlorine electrode with self cleaning tip 0 80 C 32 176 F at 0 60 PSIG Long life easy maintenance design with pop in pre tensioned Chlorine membrane module Body 8 CPVC Quick Union installation 172 MNPT fitting or submersion mount via 34 FNPT lead 5 ft ADD ELECTRODE OPTIONS 4 Fast response Membrane Module less durable Ruggedized Membrane Module slower response ELECTRODE INSERTION OPTIONS CPVC flow cell and insertion fitting 112 slip CPVC flow cell 1 FNPT P N A2300073 PVDF flow cell 172 FNPT P N A2300074 316 SS flow cell 1 FNPT P N A2300075 CPVC Union Insertion Fitting 172 MNPT to 60 PSIG at 90 C 194 F P N A2300086 PVDF Union Insertion Fitting 172 MNPT to 90 PSIG 90 C 194 F P N A2300087 SS Union Insertion Fitting 172 MNPT to 90 PSIG and 90 C 194 P N A2300088 Titanium Union Insertion Fitting 12 MNPT P N A2300089 Sample Order Flow Sensor OPTIONS Extra copies
55. h spade lugs P N A2103620 87 Assy 25 ft D O Cl sensor extension cable with spade lugs P N A2103621 88 x Sub Assy custom D O Cl sensor extension cable with spade lugs P N A2103622 minimum 25 ft Priced x ft ft Stainless steel tag Special ppM Free Available Chlorine analyzer with panel mounting kit 80 Free Available Chlorine analyzer with panel mount and preamp interface Page 58 www iccontrols com IC CONTROLS CL 875 Instructions IC CONTROLS Appendix B 835 Spec Sheet Appendix B 835 Spec Sheet Model 835 QUICK UNION CHLORINE ELECTRODE Buy the world s most accurate self cleaning rugged Free Chlorine electrode the IC CONTROLS Model 835 As a major supplier of rugged long life pH equipment to the waste water industry IC CONTROLS was repeatedly asked to develop a similar Free Chlorine Monitoring system that would withstand tough waste water applications and be easy to recharge and calibrate IC CONTROLS developed the Model 835 Quick Union Free Chlorine electrode with the following benefits Pop in membranes Factory pre tensioned membrane module works every time with no special operator skills needed No wrinkling or tearing of the membrane Self cleaning is achieved with a design that creates a rolling turbulence on the membrane The durable PVC body constructed from Schedule 80 PVC pipe is designed to withstand regula
56. hat the analyzer is in edit mode Adjusts blinking digit upward or selects the previous item from the list If a 9 is displayed then the digit will loop around to show 0 Adjusts blinking digit downward or selects the next item from the list If a 0 is displayed then the digit will loop around to show 9 Numeric Values only move to the right one digit If blinking is already at last digit display will loop to the sign on the left Numeric Values move left one digit If blinking is at the sign then blinking goes to the last character Press the Enter key again to leave edit mode and accept the new value Figure 12 Key Functions Editing by Selecting a Setting To change the setting press enter to go into edit mode The display will start blinking Editing a setting is like picking an option from a list You can see only one item on the list at a time Use the up or down arrow key to switch between the possible options press enter again to install the new setting and leave edit mode Select a Setting Example Turn alarm A off From the menu select AL AL A ON OF The analyzer will now display either on or OFF which are the two choices To change the setting press Enter to go into edit mode The display will start blinking Use the up or down arrow Page 12 www iccontrols com IC CONTROLS key to switch between the possible options which in this case
57. he 4 to 20 mA Output The low scale setting will normally be lower than the high scale setting It is possible to reverse the output or flip the window by reversing the settings of the low and high scale list of in available l inputs Con mn Al display units out2 unit used by output on ONOF org HI 14 00 LO 0 00 cur 12 02 mA Figure 20 Output menu Page 28 www iccontrols com IC CONTROLS Simulated 4 to 20 mA Output Select cur from the menu to display the output in mA that is presently being transmitted The display will be updated as the output signal changes based on the input signal and the program settings From here you can watch the output respond to the change in the input signal This is useful for verifying program settings and for testing the hardware calibration In addition you can use the 875 output to calibrate downstream receivers such as 4 to 20 mA recorders or data acquisition systems To simulate a different 4 to 20 mA output signal press ENTER to enter edit mode Edit the displayed mA value to display the desired output needed for testing the output signal Press ENTER to select the displayed value The output signal will be adjusted to put out the desired current This process can be repeated as often as necessary The output signal is held at the displayed level until the program leaves this part of the
58. he software offset for the temperature input will be adjusted automatically 3 calculated offset in degrees Celsius can be viewed by selecting CONF in C OFFS from the menu Whenever the hardware alignment is correct the offset will be 0 0 The displayed offset can be edited Adjusting Electronic Calibration 1 Remove any offset calculated by a previous software calibration of the temperature input Select CONF in C OFFS from the menu and edit the offset to read 0 0 2 Setup a precision multimeter Fluke 8051A or equivalent to read VDC 3 Use TB200 terminal 2 as common See wiring diagram Place a 1000 ohm 1 resistor across T and T Adjust blue trimpot VR202 located at the top right side of TB201 fora 875 Instructions Troubleshooting reading of 0 200 V at TP203 Refer to wiring diagram drawing D5920093 for component locations 4 Place a 1 74 kOhm 1 resistor across T and T Adjust blue trimpot VR203 located top right side of U203 for a reading of 4 80 V at TP203 Refer to wiring diagram for component locations 5 Close case and press Sample key followed by the Down key to display the temperature reading 6 the 1000 ohm 1 resistor and adjust VR202 until the display reads 0 0 0 1 C 7 the 1 74 kOhm 1 96 resistor and adjust VR203 until the display reads 195 0 0 2 C Calibration of 4 to 20 mA Outputs Use one of the fol
59. ille Ontario Canada TITLE on PIPE WALL MOUNTING KIT 658 655 ETC code no D4950053 RE V scole sheet of Page 52 www iccontrols com 875 Instructions IC CONTROLS Drawings Panel Mounting Kit D4950054 9 5000 8 9000 6 2500 L M NOTES 1 PANEL CUTOUT 8 10W X 4 80H INCH 2 TWO SCREW HOLES APROX 0 15 DIA EPK 16 CONTROLS Orangeville Ontario Canada TITLE AT SIDES 2 40 FROM TOP OF CUTOUT PANEL MOUNTING KIT CENTERED 8 90 INCH APART 633 4553 ETC 3 MOUNTING SCREWS 6 32 Page 53 www iccontrols com 875 Instructions Index Index INDEX 10 sign 21 Err 10 sign 21 37 option 31 1E 6 37 38 4 to 20 SEE Current output A7010001 17 41 Acknowledging error messages 21 Alarms 29 caution number 29 delayed activation 30 deviation alarm 30 differential 29 fault alarm 29 30 function 29 indication of 29 30 on off switch 29 relays 40 sensitivity of 30 setpoint 29 use of contacts 29 Ampoule 17 AUTO key 11 30 AUTOLED 11 30 Automatic temperature compensation selecting 19 Battery backup 10 Bleach 13 Calcium hypochlorite 13 Calibration chlorine 17 grab sample 17 history log 33 retrieving history log 33 settings 10 standardize 17 troubleshooting 39 zero oxygen standard 20
60. ing the initialization procedure will cause the analyzer to reset all the program variables and settings to factory defaults and then proceed with the normal startup display You will need to re enter the output signal settings alarm settings as well as the program configuration if it was different from the factory default settings Select CONF init ALL do from the menu The display will flash do Nothing will happen if you press Sample or Cancel The analyzer will IC CONTROLS Select CONF in up or down arrow key to the input then dA Press ENTER then edit to the new seconds Press ENTER to leave edit mode Real Time Clock All IC CONTROLS analyzers have an internal clock used for date time stamping of system events and the internal data log On power outage the clock stops then it continues where it left off when power returns When purchased with option 34 a real time clock will maintain the correct time and date even with the power turned off To check if your analyzer has a real time clock select CONF rtc CHIP from the menu If the display shows YES then there is a real time clock If the display shows no you can still set the date time clock but the time and date will need to be adjusted each time the analyzer loses power To set the real time clock select CONF rtc from the menu Set the year month day of the month hour minute and second The fastest way to
61. ion comes in contact with the skin 1 Remove the protective cap exposing the coils and gold tip 2 Immerse in cleaning solution as shown Figure 19 for 5 to 10 minutes or until deposits D O sensor beaker Keep coils below surface Figure 19 Chlorine Sensor Cleaning disappear 3 Remove and rinse in Distilled or Demin water use wiping in the direction of the coils or a toothbrush to speed removal 4 Repeat 2 amp 3 until coils and tip look clean and have a shine then re assemble Chlorine sensor with new membrane and fill solution calibrate and check efficiency is above 50 5 Repeat 2 to 4 as necessary to get at least 50 percent efficiency If not possible Chlorine sensor should be replaced Page 26 www iccontrols com IC CONTROLS Sensor Storage Short Term Immerse the sensor tip in tap water Wet storage is good for a week or two CAUTION If a wet sensor dries out in storage there may be none repairable damage Long Term Dis assemble the Chlorine sensor tip and pour out the fill solution Rinse the coils gold tip and membrane module with demin water and blot dry with a paper towel Re assemble the Chlorine sensor dry and store dry with the tip covered Dry storage can be used for a year or more 875 Instructions IC CONTROLS NEW CHLORINE SENSOR NEW CHLORINE SENSOR The 875 can be used with IC CONTROLS Galvanic Chlorine sensors IC CONTROLS sensors are available i
62. ion needs to be made Use the up and down arrow key to display SEt Press Enter to select manual temperature compensation With SEt as the current display press Select to display the temperature setting for manual temperature compensation If the current value needs to be changed press Enter to edit the current setting The display will start blinking Use the up and down arrow keys to display the desired temperature for manual temperature compensation Press Enter to accept the currently displayed value Manual pH Compensation From the menu select tFCI PH C At this point press Select to display the pH setting to be used with manual pH compensation If the current value needs to be changed press Enter to edit the current setting The display will start blinking Use the up and down arrow keys to display the desired pH for manual pH compensation Press Enter to accept the currently displayed value 875 Instructions Chlorine Calibration Zero Test Technique The best way to zero check atthe point of use where all water and even the air contains some chlorine is to use a Zero Chlorine Solution available from IC CONTROLS as p n A1100225 in 500 mL bottles or a 6 Pack as p n A1100225 6P CAUTION If Zero Standard gets on hands wash with running water Submerge the 832 or 835 sensor in a beaker so that itis 2 to 3 inches below the surface of the zero check liquid Refer to Figure 16 Provide slow gentle movem
63. ions IC Features analyzer Connect earth or shield at one end only Turn on the analyzer and the computer Configure the analyzer for the desired baud rate Select SEr baud from the menu Baud rates from 1200 to 38400 baud can be selected the default is 9600 baud For RS485 systems with automatic send data control the lowest baud rate that can be used is 9600 5 To enable serial transmission by the analyzer set the serial ON OFF switch to ON 6 Select the node number of the analyzer The default number is 1 If multiple analyzers are networked each analyzer needs a unique node number Internal Data Log The 875 analyzer will log more than 1000 data points in its internal memory storing readings by default at once a minute At once a minute the internal log will have the last 16 hours of history If there is an upset the logged readings can be downloaded using the Net Advanced Intelligence Access program for analysis and or documentation record internal data log menu when not logging list of available inputs 7 StAr FrE frequency of log update in seconds do 10 FULL Cont continue logging overwriting oldest data stop logging when buffer full cnt 0 number of data points currently in buffer CLr do clear the buffer deleting all data points on Send ASCII serial output when logging OFF No ASCII serial output internal data log me
64. is available through the use of the 835 factory integrated sample system option 25 14x26 inch SS sample panel with PRV flow setting valve atmospheric break constant head grab sample point drain plus mounting of the 835 and 875 The panel wall mounts on four 3 8 inch bolts at 12 25x24 25 centers Simple sample hookup is via a 1 4 FNPT connection and drain is via 3 4 FNPT for a hose fitting ib Figure 6 835 25 sample system It is recommended that the sensor be mounted within the sensor lead length as near as possible to the Chlorine analyzer When using a separate flowcell the sensor should be mounted on a 45 rising line with the sensors tip down at an angle anywhere from 15 875 Instructions Installation above horizontal to 15 below vertical 45 above horizontal is best because air bubbles will rise to the top and grit will sink both bypassing the sensor Max 90 9 159 Figure 7 sensor angle The 38mm 11 2 schedule 80 CPVC slip sensor flowcell P N A2300090 is supplied with a specially modified corrosion resistant mounting bracket and 2 stainless steel bolts for use on a metal panel The mounting bolts are 64mm 2 5 long and require two holes on 66mm 2 6 center drilled 7 6 9mm 0 276 and taped for a 1 4 20 thread Alternatively the manifold can be mounted to a wood surface using two 75mm 3 12 wood screws Best practice uses a ball valve and PRV pressure regulating va
65. l be closed i e the external device wired to it is turned on when the analyzer is not powered Normally Open A circuit which is wired normally open will be open i e the external device wired to it is turned off when the analyzer is not powered On off Control Control response in which the contact is either fully on or fully off ppm Parts Per Million 1 ppm 1 mg L Displayed in the analyzer as 1E 6 which is scientific notation for one millionth RAM Random Access Memory Memory ina RAM chip can be both written to and read from The contents of RAM will disappear as soon as the RAM chip loses power The RAM chip has a battery backup device which preserves the contents of the RAM chip for a considerable time even if the analyzer is turned off All settings are stored in RAM TC Temperature Compensator Temperature Compensation Correction for the influence of temperature on the sensing electrode The analyzer reads out concentration as if the process were at 25 degrees Celsius regardless of actual solution temperature Total Free Chlorine Sum of the hypochlorous acid HOCI and hypochlorite ion OCI forms of chlorine 875 Instructions IC CONTROLS Troubleshooting Hints Slow Response typically due to excessive sample line length and low flow thus producing long sample transport lags Resolve by adding a fast flow loop with the sensor in a short side stream or by shortening the line Slow response
66. layed value to 0001 which is the level 1 password Press Enter The analyzer will display good followed by ACC 1 indicating that the password is valid and that we now have level 1 access Try changing the output 1 low setting again You will find that this time we can go into edit mode unhindered Select PASS from the main menu again Enter the level 2 password which is 0002 We are going to set the level 2 password to 0000 again to disable password security Password 2 is found in the configuration menu and therefore requires level 2 access before it can be accessed Select CONF PAS 2 from the menu Press Enter with 0000 displayed Both passwords are set to 0000 again and password security is disabled 875 Instructions pH ORP 0 CONDUCTIVITY C R O LS DISSOLVED OXYGEN CHLORINE Quality Water Analysis Equipment STANDARDS 29 Centennial Road Orangeville ON LOW 181 Phone 519 941 8161 Fax 519 941 8164 Toll Free North America 1 800 265 9161 e mail sales iccontrols com website www iccontrols com IC CONTROLS PRODUCTS i CONDUCTIVITY TWO SENSOR CONDUCTIVITY TWO WIRE ANALYZERS ANALYZERS TRANSMITTER pH ORP pH ORP TWO WIRE ANALYZERS ANALYZERS TRANSMITTERS ppm DO TWO WIRE ppm DO TRANSMITTERS pH ORP BASED CHLORINE ppm CHLORINE ANALYZERS J CALIBRATORS
67. lowing two approaches to get the analyzer to output the desired current level and then make electronic adjustments to calibrate the output Approach 1 Simulated 4 20 mA Output Self Calibration 1 Select cur from the output 1 menu to display the present output current in mA The display will be updated as the output current 2 To simulate a different 4 20 mA output signal press Enter to enter edit mode Use the arrow keys to display the desired output signal Press Enter to select the displayed value The output signal will be adjusted to put out the desired current This process can be repeated as often as necessary to output different signal levels 3 output signal is held at the displayed level until the program leaves this menu selection Make calibration adjustments while the analyzer shows the output at 20 00 mA 4 Repeat the above steps for output 2 Approach 2 Use Voltage Source to Adjust Input This faster calibration approach requires a voltage source for the input 1 Tocalibrate output 1 set in C Input a low enough signal to cause analyzer to indicate Err the analyzer will output 4 00 mA Reverse the polarity or input a high enough signal to cause the analyzer to indicate Err analyzer will output 20 00 mA 2 Repeat step 1 for output 2 Page 40 IC CONTROLS Tip both outputs can be simultaneously calibrated if you set for both inputs Adjusting Ele
68. lution Wash hands with water if the electrolyte comes in contact with the skin 1 Galvanic Chlorine sensors should have a current drain at all times Assemble sensor with a short coax center to shield 2 Remove the protective cap exposing the coils and gold tip Inspect the electrode to ensure the coils are bright and clean and the gold electrode is bright 3 Assemble a membrane module in the cap with the membrane facing down so that it covers the center hole in the cap Membrane Module Ss O ring a v Y Tip Retainer Figure 18 Membrane Module Assembly 4 Flush the coils of the electrode with P N A1100233 electrolyte solution Then holding the electrode cap with membrane module installed in an upright position fill with electrolyte until the center cavity is full Tilt at about 30 from vertical and add an extra 1 8 inch of electrolyte observing that the crack around the membrane module fills with electrolyte 5 Next hold the cap like a cup Figure17 and slowly lower the electrode coils vertically down into the cap until the threads touch Page 24 www iccontrols com IC CONTROLS Flat for bubble release 60 degree angle Figure 17 Installing the membrane module Rotate the sensor body until you can see the flat area through the threads Slowly rotate the cap on allowing the excess electrolyte and bubbles to overflow up the flat Continue to slowly rotate the cap until a firm stop is
69. lve before the sensor for flow control and servicing followed by an atmospheric drain to collect representative samples without disturbing sample conditions and act as a vent for bubbles The drain line should be larger than the sample line to allow for purging of sediments bubbles biologicals etc Figure 8 recommended sensor piping Sensor Wiring The basic wiring scheme for IC CONTROLS Chlorine sensors is shown in drawing D5020261 This wiring scheme is intended for cable runs less Page 8 www iccontrols com IC CONTROLS than 20 meters 65 feet where electrical interference is low CTR D O T WHT T GND USED v SHLD COM NOT USED v SENSOR 5555 All low level sensor signals should be run through dedicated conduit Take care to route all signal wiring away from AC power lines to minimize unwanted electrical interference When installing sensor cable in conduit use caution to avoid scraping or cutting the cable insulation the resulting short of the cable s internal driven shield will cause conductivity errors Avoid twisting the sensor lead to minimize possibilities for broken wire Make sure the sensor connections are clean and tight Instrument Shop Test Startup 1 Apply 115 240 VAC power to the analyzer 2 Hook up your sensor via TB200 and remove orange protectiv
70. m INST875 110 Sensor 26 NEW CHLORINE SENSOR 27 4 to 20 mA Outputs 28 Alarm Functions 29 Use of Relay Contacts 29 Manual Override 30 Using Alarms for On Off Control 30 Features 31 Intelligence Access 31 Wiring Enabling 31 Internal Data 100 32 Calibration amp Event 33 Portable Laptop Hookup 34 Configuration of Program 36 Display Prompts 37 Glossary 38 Troubleshooting 39 Hints runs acd oe Sa cheek Emme eoa 39 Electronic Hardware Alignment 39 Calibration of 4 to 20 mA Outputs 40 Testing Relay Outputs 40 Parts Rata aoe ee e opus 41 Repair and Service 42 Drawings a 43 Display Schematic D5980178 Microprocessor Board Schematic D5980177 Microprocessor Board Component Loc D5980176 Input Schematic D5020259 Current Output and Alarms Schematic 05980186 Power Supply Schematic D5980185 Main Board Component Location D5020260 Wiring D5020261 Mounting Dimensions D4830022 2 Pipe Wall Mounting Kit D4950053 Panel Mounting Kit D4950054 Index ud B
71. mbination with HOCI tend to have poisoning effects on the sensing element making response sluggish Manual cleaning may be used with pure measured water If measured water is likely to have significant organics oils IC Controls recommends automatic acid cleaning option 51 Page 64 www iccontrols com 875 Instructions IC CONTROLS Appendix E Enabling Security Appendix E Enabling Security The analyzer has a built in password protection System This security system is disabled by default If password protection is not enabled then you have unrestricted access to all analyzer settings available through the menu as described in this manual and you can safely ignore this section Having security disabled gives you the same access tothe program as being at access level 2 at all times By default security is disabled To enable the security system first follow Enabling Security access level description 0 View only access to all settings 1 Access to all settings except for configuration menu Usage operator access no changes can be made to configuration and passwords cannot be changed 2 Access to all settings This gives you the same access to the program as when password security is not enabled Passwords can be changed Usage installation management With security enabled anyone can view settings anywhere in the program When you do not have proper access rights the prog
72. memory a running history of 1000 minutes of chlorine readings DB 9 Connector The analyzer s serial communication has the ability to communicate with a computer running Using IC Net you can do digital real time recording access the internal sample trend history eee log access analyzer calibration records upset event records remote operate it from your computer 95 SERIAL IP more Multiple analyzers can be networked together EARTH HED Refer to IC Net in IC Controls catalogue for TBI further details TN i d EARTH You can also use the RS485 to send ASCII format serial chlorine temperature and auto range number iri default frequency is 60 seconds No special gt software is needed on the computer to receive ASCII data The ASCII data port function can be turned 2b 5232 wiring 37 option on off and controlled from the Internal Data Log Wire the RS232 cable into the terminal block menu both ASCII and serial must be on The data TB1 located on the display board Refer to format uses 8 data bits no parity 1 stop bit and 9600 figure 25 Connect pin2 to SERIAL O P in the baud The output consists of three data fields analyzer Connect pin3 to SERIAL I P in the separated by commas Each line of data is analyzer Connect pin 5 to SIGNAL COM in the terminated by a linefeed newline Page 31 www iccontrols com 875 Instruct
73. n the following service types 1 submersion service 2 sample side stream service flow through 3 insertion through pipe tank wall installation 4 universal type flow submersion insertion Standard Sensors are for HOCL Chlorine SERVICE 832 Submersible 835 Quick Union Universal Industrial 1234 STANDARD 835 SENSOR Various other options may also be selected see IC CONTROLS Catalogue for full details or contact Customer Service at www ICCONTROLS COM Phone 1 519 941 8161 FAX 1 519 941 8164 832 submersible 875 835 25 sample system Page 27 www iccontrols com 875 Instructions 4 to 20 mA Outputs 4 to 20 mA Outputs Two assignable 4 to 20 mA output channels are provided The user may configure the analyzer to determine which input signal will be transmitted by each 4 to 20 mA output channel The output channels function independent of each other Each output channel has a separate on off switch and adjustable low and high span or scale adjustments This makes it possible for example to transmit both HOCL and Total Free Chlorine signals each using separate high and low adjustments To adjust the output span or output window for Chlorine or temperature signals set LO to correspond to the low end of the scale or 4 mA output and set HI to correspond to the high end of the scale or 20 mA output The analyzer will automatically scale the output according to the new settings Reversing t
74. nector IC CONTROLS recommends 100mm 4 inch minimum separation between rows columns Analyzer Wiring Reference dwg D5020261 four steps 1 The 875 requires 115 or 230 VAC power to be hooked up to TB400 Power consumed is less than 1 Amp so generally 16 gauge wire is OK For stable operation the microprocessor needs a good earth ground Caution Confirm that the 115 230 VAC switch is correctly set for your feed 2 required connect the two relay contacts As supplied they are not powered They are typically used as L1 HOT circuit ON OFF switches in NO normally open configuration to control the chlorine or acid pump valve Best practice uses a separate circuit to isolate the sensitive sensing circuits from any pump or solenoid inductive surges however as a convenience for light loads a 3Amp P N A9160035 circuit fuse can be installed at F402 to feed the 875 s L1 HOT to COM on Page 7 www iccontrols com Installation relay A Alarm A contact TB300 closest to AC lines Alarm B contact TB301 3 required connect the two isolated 4 20 mA outputs these are 24 VDC Output 1 TB303 closest to the relays Output 2 TB304 4 Connect the Chlorine inputs Chlorine signal Coax center TB201 D O Signal return Coax shield 201 COM Temperature Comp red TB201 T Temperature Comp white TB201 T Overall shield green Ground Sensor Mounting Optimum sensor performance with minimum user effort
75. ng no Cl list of Eune in HOCI available dEv tFCI inputs FLt StAr do C list of ALA i In available FrE 10 frequency of log update in seconds ALb inputs FULL Cont continue logging overwriting oldest data Ec StOP stop logging when buffer full i displ it d by al unit cnt number of data points currently in buffer on CLr do clear the buffer deleting all data points ONOF OFF ASCI Send ASCII serial output when logging 0 60 Lasa OFF No ASCII serial output diFF 0 10 alarm activation delay sec i r y internal data log menu while logging In input being logged StOP do 10 frequency of log update in seconds L init _ ALL _do_ FULL Cont continue logging overwriting oldest data Lstop stop logging when buffer full ALA OPEN AL LALA nowo CLSd cnt 626 number of data points currently in buffer AL b on en serial output when logging asa Send ASCII serial hen default sample OFF ASCII serial output display Figure 4 Internal data log menu dA 5 input damping sec dA 5 input damping sec CALIBRATE 122 3 1 0 0 Oftset c c metric or imperial a oF unit selection ser Y
76. nner and less durable Change to Ruggedized Membrane Module thicker and slower response Sample Order OPTIONS Extra copies of instruction sheet EA Short cable x ft minimum 1 ft maximum 9 ft Long cable x ft minimum 11ft maximum 100ft Length x times per ft Stainless Steel tag Zero Free Chlorine Standard 500 mL bottle P N A1100225 Free Chlorine Calibration Kit for colorimetric calibration and instructions P N A1100226 Chlorine Sensor Renew Solution P N A1100227 Deionized water rinse solution P N A1100192 Fast response Membrane Module and fill solution kit P N A2104013 Ruggedized slow response Membrane Module and fill solution kit P N A2104017 Special Contains small amounts of Hazardous Materials 832 93 94 Chlorine Electrode with zero standard and spares RECOMMENDATION FOR CALIBRATION AND SERVICE SUPPLIES Minimum Normally Zero Free Chlorine Standard P N A1100225 Zero Free Chlorine Standard P N A1100225 Membrane Module and fill solution kit Fast Response P N A2104013 Ruggedized P N A2104017 Free Chlorine Sensor Renew Solution P N A1100227 Deionized water rinse solution P N A1100192 Channel Tank Side Mounting Remote 800 Interface 875 or Local Analyzer Analyzer and Rain Shroud Support Hanging Chain 832 Side View Biologicals will not hit he membrane surface f the probe is in
77. ns Application Information IC CONTROLS 99 7 chlorine This pH change has been known to RI cause surprise downstream fish kills Note is total free chlorine Terminology In the industry there are a number of terms used to indicate the various forms of chlorine that are of interest These terms tend to be used rather loosely and not necessarily consistently For that reason we will define the following terms for purposes of this instruction manual and the 875 analyzer Free Available Chlorine refers to the hypochlorous acid HOCI form of chlorine only It is said to be free available because it is the free uncombined form of chlorine that is effective for killing concentration 1 Total Free Chlorine refers to the sum of hypochlorous acid HOCI and hypochlorite ion OCI The x hypochlorite ion is not effective for killing but it is in a 4 free form All of the total free chlorine would be in the form of hypochlorous acid if the pH is low enough 0 3 i 1 1 5 00 6 00 7 00 8 00 900 10 00 A pH Combined Chlorine refers to chlorine which is not readily available for example chlorine combined as chloramines or organic nitrogen is not an effective disinfectant and will not readily convert to 5 pH th tion i PAG Re Ween cde She ne hypochlorous acid or hypochlorite ion incomplete and both species are present to some degree Since H is one of the io
78. ns that is formed Total Residual Chlorine refers to the sum of total free and its concentration is expressed as pH it follows chlorine and combined chlorine In environmental that changing pH levels will influence the balance of studies low total residual chlorine is of particular this reaction and with it the availability of interest to ensure no downstream consequences for hypochlorous acid for reaction aquatic life In a water environment the water pH will therefore Disinfectant Properties of Chlorine affect the chemistry of chlorine through its pH sensitivity As pH rises this is important Chlorine is known to be a good disinfectant it is able to kill living matter in water such as bacteria cysts and spores Exactly how chlorine works to kill is not 6 H20 lt H OH preference is right to left known Studies do agree however that certain forms of chlorine are more effective than others Whatever the chemical reaction it is also generally agreed that Three things follow from this form of ionization the relative efficiency of various disinfecting 1 Since the tendency of these two ions to react compounds is a function of the rate of diffusion of the and form H20 is much stronger than the active agent through the cell wall Factors which affect tendency of water to break down into the the efficiency of destruction are ions it follows that as the pH rises there are Nature of disinfectant kind of chlorine residual fewer H ions and m
79. nstructions IC CONTROLS pH and Temperature impact on Chlorine The measurement of the chlorine concentration is done by the Galvanic HOCI sensing electrode However the Chlorine chemistry of the sample will change both with temperature and with pH The figure on page 14 shows how the relative concentrations of hypochlorous acid and hypochlorite ion shift with a change in the pH This same relationship is also dependent on the temperature of the solution as the curves will shift with changes in the temperature The 875 has been designed for relatively steady pH and compensates pH by manual input of the sample pH Temperature compensation uses the temperature sensor in the chlorine electrode A method has been provided in the analyzer program to change the compensation method for temperature compensation from automatic to manual Providing a method of manual temperature compensation allows the analyzer to continue measuring free available chlorine and total free chlorine in case the temperature is malfunctioning or absent Page 19 www iccontrols com Chlorine Calibration Manual Temperature Compensation From the menu select tFCI At this point either Auto for automatic temperature compensation or SEt for manual temperature compensation setpoint will be displayed To change the setting from Auto to SEt press Enterto edit the current setting The display will start blinking indicating that a select
80. nu while logging In tFCI input being logged StOP do FrE 10 frequency of log update in seconds FULL Cont continue logging overwriting oldest data stop logging when buffer full cnt 626 number of data points currently in buffer on Send ASCII serial output when logging OFF No ASCII serial output Figure 26 Internal data log menu Page 32 www iccontrols com IC CONTROLS The user can select how frequently to log and which input to log either chlorine or temperature At once an hour the internal log will have the last 41 days of history Internal logged data is date time stamped by the analyzer The data cannot be viewed directly from the analyzer it requires IC Net for digital download to a computer for viewing Setup for Internal Data Logging 1 Select iLOG FrEq from the display This number is the logging frequency specified in seconds For 1 second intervals use 1 for 1 minute intervals use 60 or for 1 hour intervals use 3600 Any interval from 1 to 9999 seconds can be specified 2 Select iLOG in from the menu Select either chlorine or temperature as the input to be logged Only one of the inputs can be logged at a time 3 Select iLOG FULL from the menu The FULL setting specifies what the analyzer should do when the memory is full Continuous logging cont each new data point will erase the oldest data point This is the factory default To
81. of Measured Range or 2 digits whichever is greater 90 50 seconds Flow Temp 3 to 99 seconds Sensor Dependent 20 x 12 x 7 5 cm w h d 7 87 x 4 72 x 2 75 inch IP65 NEMA 4X 2 5 168 1 1 Kg 4 0 Ibs 1 8 Kg 875 Instructions IC CONTROLS Installation Analyzer Mounting The analyzer can be neatly surface mounted using hidden mounting holes and 19mm 75 No 8 Screws see dwg D4830022 Dimensions are case 8 0 x4 75 x3 0 with group spacing on horizontal 225mm 9 0 centers and vertical 200mm 8 0 centers Optional pipe wall mounting kit is available see dwg D4950053 or panel kit see dwg D4950054 The sensors are supplied with 5 foot leads as standard The analyzer should be kept within this distance The analyzer should be positioned to allow the sensor still connected up to be removed and the electrode tip placed in a beaker on the floor for cleaning or calibration Assume the safest place for the beaker is on the floor the service person stands A good arrangement has the analyzer on a wall at about eye level 1 5m 5 feet the sensor manifold horizontally below it at about 0 6m 2 feet with the floor clear The electrical connector and relays are on the right bottom the 24 VDC signal output connectors in the middle and the electrode connectors are on the left bottom Vertical separation between rows of analyzers should allow for electrode leads which need periodic replacement and the electrical con
82. ommunication The relay contacts can also be used for PID pump pulse outputs PID time proportional control etc Alarm Indication The A and B LEDs on the front panel show the current state of each alarm and alarm contact In Page 29 display units used by alarm www iccontrols com Alarm Functions addition an alarm will cause the sample display for that input to alternate with the alarm function no CI LO HI dEv or FLt An LED that is blinking or on shows that the alarm has an alarm condition The status of the alarm contact can also be determined at a glance the corresponding alarm contact is activated when the LED is on and is deactivated 5 See while the LED is g maion blinking or off 77 Note that the alarm caraiitz ri alarm LED will ae C blink while the Figure 21 Alarm status alarm is in MANUAL because this also deactivates the alarm contacts Each alarm will generate a caution number in the error menu The table below describes the meaning of each alarm caution The alarm cautions will not cause the error LED to come on because the error LED only comes on if there are errors To view alarm caution s using the error menu select Err from the main menu then use the up or down arrow key to scroll through the list of errors and cautions if any Caution Description CA7 5 Alarm A No Chlorine alarm CA7 6 Alarm A
83. or could be broken or be deformed Removal of the Chlorine Sensor Flow and Insertion Type 1 Stop the sample flow and vent the sample line to atmosphere CAUTION Removal of the Chlorine sensor from a sealed flowcell will vacuum stretch the thin sensing membrane Stretching the membrane will cause slow response and higher readings at low levels Parting the membrane will cause Chlorine sensor failure 2 If installed by insertion directly into a tank wall ensure the level in the tank is below the sensor before removing sensor 3 Byhand turn the Union nut until free For higher pressures it may be necessary to use a wrench to start turning the nut 4 Gently rock and pull the Chlorine sensor back and forth to ease the O ring seals back up the compression throat 5 When the Chlorine sensor has been fully removed wipe the sensor clean and then Page 25 www iccontrols com Sensor Instructions proceed to the calibration procedure or monthly yearly maintenance as necessary Monthly Maintenance Certain applications may require occasional sensor cleaning A monthly maintenance check is recommended by visual examination of the sensor cell area If needed a soft wipe can be used to blot plus detergent and water to remove any deposits Rinse thoroughly after cleaning with water Run a calibration and if sensor efficiency is above 50 percent return to service White silt inside the sensor cap may not cause problems
84. ore OH ions fraction 2 released by the breakdown of HOCI Concentration of disinfectant equation 5 react to form water equation 6 ier and leave behind residual OCI Length of contact time with disinfectant hypochlorite ions Hypochlorite does not Temperature react readily so the chlorine is weaker Type and concentration of organisms 3 However if the pH goes down and H ions e become readily available again the OCI ions P revert to HOCI which is the killing form of Page 14 www iccontrols com 875 Instructions IC CONTROLS Hypochlorous acid HOCI free available chlorine is the most effective of all the chlorine forms Hypochlorous acid is similar in structure to water The germicidal efficiency of HOCI is due to the relative ease with which it can penetrate cell walls This penetration is comparable to that of water and can be attributed to both its modest size and to its electrical neutrality The concentration of hypochlorous acid is dependent on the pH which establishes the amount of dissociation of HOCI to H and OCI ions Lowering the temperature of the reacting solution suppresses the dissociation conversely raising the temperature increases the amount of dissociation The rate of dissociation of HOCI is so rapid that equilibrium between HOCI and the OCI ion is maintained even though the HOCI is being continuously used up Figure 15 Galvanic Chlorine Sensor Page 15 im e Gol
85. orine Monitoring system that would withstand tough waste water applications and be easy to recharge and calibrate IC CONTROLS developed the Model 832 Suspension mounted oscillating Free Chlorine electrode with the following benefits Pop in membranes Factory pre tensioned membrane module works every time with no special operator skills needed No wrinkling or tearing of the membrane Self cleaning is achieved with a design that creates a rolling turbulence on the membrane The suspension design of the Model 832 allows the electrode to oscillate in the flow Combined with the turbulence created on the electrode membrane self cleaning is achieved Plus the free oscillating rotating action encourages rags to spin off the electrode The durable PVC body constructed from Schedule 80 PVC pipe is designed to withstand regular impacts typical in waste water processes Even after months on line the 832 comes out of the effluent with a perfectly clean tip and membrane Air is purged from the cell as the membrane module cap is threaded on resulting in very fast stabilization Self regenerating electrolyte maintains consistent Free Chlorine readings during long operating runs without the need for re charging Galvanic technology provides an absolute zero zero current equals zero Free Chlorine which provides excellent ppm accuracy even at very low levels The gold cathode tip is unaffected by Sulfides etc in the waste water treatment proce
86. product or part thereof or refund of the purchase price but in no event shall IC CONTROLS its contractors and suppliers of any tier be liable to the buyer or any person for any special indirect incidental or consequential damages whether the claims are based in contract in tort including negligence or otherwise with respect to or arising out of the product furnished hereunder Representations and warranties made by any person including its authorized dealers distributors representatives and employees of IC CONTROLS which are inconsistent or in addition to the terms of this warranty shall not be binding upon IC CONTROLS unless in writing and signed by one of its officers Page 56 www iccontrols com 875 Instructions IC CONTROLS Appendix A 875 Spec Sheet Appendix A 875 Spec Sheet Mod el 875 INTELLIGENT CHLORINE ANALYZER IC CONTROLS has incorporated intelligence into the microprocessor analyzers via the C Net Advanced Intelligence Access Program Measurements such as Free Chlorine can be critical to your process and must be strictly monitored and maintained Analyzer Intelligence goes beyond measurement and control it provides the user with all necessary historical data including events such as calibration upsets diagnostics and more This information can be communicated for trending or advanced control even to remote locations Ultimately the user has superior control with a competitive advantage The
87. ps below the setpoint and is cleared when the pH rises to above the setpoint plus the differential see figures The differential has the effect of setting the sensitivity of the alarm The differential provides a digital equivalent of a hysteresis A two stage alarm can be implemented by choosing the same alarm function i e high or low alarm for both alarms but selecting different setpoints Deviation Alarm A deviation alarm is practical when the process is expected to stay within a certain range An alarm condition will be set if the input deviates too far from the setpoint Please note that the dEv frame only shows up in the menu after the alarm function has LOW ALARM 1 J A differential iss y S TEES e annes al el Lt ail time sample Page 30 www iccontrols com IC CONTROLS been changed to deviation alarm since it would have no effect for a high low or fault alarm Example if the total free chlorine concentration is expected to stay between 0 2 and 1 0 ppm the deviation setting would be 0 6 ppm 0 4 In the alarm menu set in to TFCI FUNC to dEv to 0 6 and dEv to 0 4 Effectively we simultaneously have a high alarm at 1 0 ppm and a low alarm at 0 2 ppm The differential setting will continue to function as for high and low alarms Fault Alarm A fault alarm for an input will be set when anything goes wrong with that input Something is wrong with
88. r impacts Air is purged from the cell as membrane module cap is threaded on resulting in very fast stabilization Self regenerating electrolyte maintains consistent Free Chlorine readings during long operating runs without the need for re charging Galvanic technology provides an absolute zero zero current equals zero Free Chlorine which provides excellent ppm accuracy even at very low levels The gold cathode tip is unaffected by Sulfides etc in the waste water treatment process Page 59 www iccontrols com The Model 835 Quick Union Chlorine electrode is a universal version offered in an easy to install configuration for insertion or submersion applications The Union style threaded fitting locks in the electrode for extra safety and very easy removal Recommended for applications where frequent removal in tough applications for calibration cleaning or Q C checks is required RELIABLE MEASUREMENT Free Available Chlorine HOCI Submersion Insertion or Flow Environmental Monitoring Process Liquids FEATURES Only one sensor needed for all uses Easy to lock in or remove for calibration Rugged body constructed from 1 schedule 80 pipe Fast accurate and stable response Smooth broad surface tip resists fouling of the membrane tip Open electrode tip has protective lugs to prevent handling damage Factory mounted membrane easy to replace in only two minutes Gold cathode is impervious to Sulfides etc Galvanic
89. ram will display PASS for 2 seconds indicating that you must first enter a proper password before you are allowed to proceed Entering a Password Security must be already enabled from the configuration menu With security enabled select PASS from the main menu The analyzer will display 0000 Use the arrow keys to display your level 1 or level 2 password then press ENT The program will display good followed by your access level before returning to the main menu If an incorrect password was entered the program displays bAd instead Refer to the chart at left to determine how the program validates a password You will now have level 1 or level 2 access for as long as you are working with the analyzer The access level will automatically be restored to level 0 after no key has been pressed for 15 minutes This Page 65 www iccontrols com 15 minute timeout will also redisplay the main sample It is good practice to return the analyzer to level 0 access or level 1 access if password 1 is set to 000 when you have finished using the analyzer This is accomplished by selecting PASS from the main menu then pressing Enter with 0000 displayed Enabling Security When security is disabled both password 1 and password 2 are set to 0000 Security is enabled by setting password 2 to a non zero value LEVEL 2 Select CONF PAS 2 from the menu The analyzer will display 0000 Use the
90. ree chlorine 14 total residual chlorine 14 Timer 15 minute timeout 11 30 security timeout 11 Timers 20 Total free chlorine 14 17 38 Total residual chlorine 14 Troubleshooting 39 42 Twist lock fitting 24 Units 12 36 Version 10 3 option 10 Warranty 56 Zero oxygen standard 20 875 Instructions Industrial Products Warranty IC CONTROLS CONTROLS 29 Centennial Road Orangeville Ontario LOW 1R1 Canada Tel 519 941 8161 Fax 519 941 8164 Industrial Products Warranty Industrial instruments are warranted to be free from defects in material and workmanship for a period of twelve 12 months from the date of installation or eighteen 18 months from the date of shipment from IC CONTROLS whichever is earlier when used under normal operating conditions and in accordance with the operating limitations and maintenance procedures in the instruction manual and when not having been subjected to accident alteration misuse or abuse This warranty is also conditioned upon calibration and consumable items electrodes and all solutions being stored at temperatures between 5 C and 45 C 40 F and 110 F in a non corrosive atmosphere IC CONTROLS consumables or approved reagents must be used or performance warranty is void Accessories not manufactured by IC CONTROLS are subject to the manufacturer s warranty terms and conditions Limitations and exclusions Industrial electrodes and replacement
91. rode are needed for the analyzer to measure the process Commonly these are combined into one and referred to as a combination electrode The temperature sensor may be built into the electrode as well EPROM Erasable Programmable Read Only Memory The EPROM chip holds the program which determines the functioning of 875 analyzer Replacing the EPROM chip with a chip containing a new or an updated program changes the way the analyzer functions The EPROM chip is programmed by the manufacturer Free Available Chlorine The hypochlorous acid form of chlorine HOCI Hysteresis The reading at which an alarm is turned on is not the same reading at which the alarm is turned off again This phenomenon is referred to as the hysteresis LED Light Emitting Diode LEDs are used as on off indicators on the front panel of the 875 Menu The series of prompts which determine the layout of the program used by the analyzer Microprocessor An integrated circuit chip which executes the program on the EPROM chip and controls all the input output functions Nernst Equation Equation which relates the voltage signal produced by the electrodes to the pH of the sample The equation is temperature dependent NC Normally Closed Page 38 www iccontrols com IC CONTROLS NO Normally Open Normally Closed Each of the alarm contacts can be wired and configured as normally open or normally closed A circuit which is wired normally closed wil
92. s for example into With this analyzer you can do real time recording a 2 d access the analyzer internal digital history log access the last 12 calibration records 20 upset Wiring and Enabling events and more It can be networked with other 1 analyzers using the RS485 serial port built into the analyzer Serial communications give the analyzer the ability to communicate with a computer running the IC Net Advanced Intelligence Access It is good practice to first turn off the analyzer and the computer before connecting a serial cable DB 9 Connector program available as option 35 N COM eL INTELLIGENT ANALYZER m 3 GND WHT O TD A EARTH SHIELD Q Pin Assignments QH TB1 AC wor 1 Pin 3 TD A Ping RD B Figure 24 RS485 wiring 2a RS485 wiring standard Wire the RS485 cable into the terminal block TB1 located on the display board Refer to figure 24 Connect pin1 RD A to pin 3 TD A and connect this to terminal A on TB1 in the analyzer Connect pin2 TD B to pin 9 RD B and connect this to terminal B in the analyzer Connect earth or shield at one end only The 875 advanced intelligence allows the operator to recall factors leading to upset conditions It keeps track of calibrations their date and results upset events such as power outages alarms and also logs into its
93. ss Page 61 www iccontrols com RELIABLE MEASUREMENT Free Available Chlorine HOCI Sewage Heavy organic growth environments FEATURES Self cleaning oscillating action in turbulence Fast accurate and stable response down to sub ppm levels Rugged PVC electrode body Smooth broad surface tip resists biological growth from accumulating on the membrane Factory mounted membrane easy to replace in only two minutes Gold cathode is impervious to Sulfides etc Galvanic gold silver battery chemistry is Free Chlorine specific no need to compensate for non Chlorine gases 875 Instructions Appendix C 832 Spec Sheet Model 832 SELECTION GUIDE IC CONTROLS Chlorine ORDER BY FAX 519 941 8164 BASIC DESCRIPTION Self Cleaning Oscillating Free Available Chlorine Electrode Oscillating Free Chlorine electrode with protected self cleaning long life tip for heavy biological growths Body material CPVC 0 80 C 32 176 F 10 ft lead length standard completely encapsulated Long life easy maintenance design with pop in pretensioned membrane module Mounts suspended from a chain for sumbersion or open channel flow installations Includes one instruction manual ELECTRODE OPTIONS SS Chlorine Sensor hanging chain x ft Priced length x times ft Swing arm with freestanding base for Chlorine Analyzer includes 9 ft chain for 832 Chlorine Sensor Change to Fast Response Membrane Module thi
94. stic fumes humidity etc INCLUDES ELECTRODES AND CALIBRATION KIT 1 CPVC Flow cell with 1 pH and 1 ORP electrode Field colorimetric Free Total chlorine calibration kit A pH calibration kit with 3 color coded buffers USE ANY COMBINATION OF THE FOLLOWING Local digital indication 4 20 mA signals Adjustable alarms ON OFF control The Model 877 is 115 230 VAC operated 875 Instructions Appendix D 877 Spec Sheet IC CONTROLS Model 877 Cl SELECTION GUIDE ORDER BY FAX 519 941 8164 Free Chlorine or Total Free Chlorine System ORP amp pH Sensors and Analyzer Free Available Chlorine Bromine Analyzer ORP method Input output isolated INTELLIGENT with NEMA 4X surface type housing Also field selects to read Total Free Chlorine Bromine Clear front window 412 digit display selects Free Br HOBr pH mV ORP temperature mA output and program messages Precision 0 1 ppm chlorine 0 1 pH 1 mV stability 1 digit 0 2 per month Future compatible Intelligent Analyzer logs in memory calibration records alarms and current measurement trends or via RS485 two way communication in host real time log or sends its memory records on hosts request 115 230 VAC line operated with Serial RS485 output plus two 4 20 mA outputs fully program configurable span within 0 10 ppm chlorine 0 1000 mV 0 12 pH and 5 to 105 C 23 221 F Two relays alarm on off control SPDT 10 Amp 115 VAC resisti
95. stop logging when the buffer is full set to StOP The analyzer will fill up the memory and then simply stop logging preserving all data points that have been taken 4 start logging select LOG StAr from the menu Press Enter when the flashing do is displayed The analyzer will briefly display donE to indicate that it has started the data log Logging Status From the menu select iLOG cnt This count shows the number of data points that have been logged While logging is active you will see this number incrementing The count will be 0 after the data log has been cleared Also the cnt frame must show 0 before a new data log can be started Ending Saving a Data Log To save or end a data log e g to stop logging more points select StOP from the internal logging menu Press Enter when the analyzer displays the blinking do The analyzer will briefly display donE to indicate that it has stopped logging Data logging will stop automatically if the FULL setting is set to StOP and the entire logging buffer has been filled Clearing the Data Log The data log can be erased from analyzer memory You can not start a new log until the existing log has 875 Instructions IC CONTROLS been erased This is a safety feature to ensure that you don t accidentally write over an existing log To erase the internal data log from memory 1 Select iLOG CLr from the menu 2 With
96. tc CHIP from the menu If the display shows YES then there is a real time clock If the display shows no then you can still set the internal time clock maintained by the analyzer but the time and date will need to be adjusted each time the analyzer loses power Analyzers purchased with a 34 option are equipped with a real time clock which will maintain the correct time and date even with the analyzer power turned off Real Time Clock To set the real time clock select CONF rtc from the menu Set the year month date day of the month hour minute and second The hund frame displays hundreds of a second but cannot be edited 875 Instructions IC Net Features Portable Laptop Hookup RS232 to RS485 Converter The A7900015 is a port powered half duplex RS232 to RS485 converter The unit supports two wire RS485 communications The converter handles the enabling and disabling of the transmitter This works regardless of the operating system or program you are running The RS232 side has a DB9 female connector The RS485 side has a six position RJ11 connector Material List RS232 to RS485 converter P N A7900015 10 foot cable with RJ11 connector at one end and data wires at other end P N A2500192 Installation 1 It is good practice to first turn off the analyzer before connecting a serial cable 2 Bringthe RS485 cable into the analyzer through the centre hole Wire the RS485 cable
97. ted go to the error display section select Err from main menu to see what errors have been detected by the analyzer Calibration Settings Retained If the analyzer was calibrated previously then the analyzer will use the calibration settings from the last successful calibration otherwise default settings are used Error and caution messages generated during the last calibration will remain in effect IC CONTROLS recommends a full chemical calibration of chlorine after initial startup See calibration section Analyzer settings and parameters can be viewed and or changed at any time Refer to the menu the areas shaded in dark gray indicate program settings 875 Instructions IC CONTROLS EASY Menu The layout of the program is shown in the menu found on pages 4 and 5 The menu can be used as a quick reference guide to all the analyzer functions Easy to Use Remembers Where You Were The analyzer remembers where SAMPLE is home base for the program it remembers which area of the menu you used last It loops around columns in the menu You can explore the menu with the arrow keys to find any capability then press SAMP to return Then use only the Right arrow key to return to exactly where you were Home Base Press Sample The SAMP key s function is to give you a known starting point displaying the home base home sample or 1 input The SAMP 06 key is usable from anywhere
98. titive advantage The analyzer stores the last 12 monthly calibration records for communication or download and even keeps upset records The last 20 upsets are recorded and datestamped ie out of spec alarm power interruptions etc Factors leading to alarm conditions are recalled and for measurement trend hundreds of data points can be accessed at user defined time intervals All of this communication is extremely fast up to 38k baud The optional C Net Intelligence Access Program runs in your PC Window using RS485 RS232 and provides your networked PC s access to multiple analyzers C Net allows intelligent system performance that emulates human intelligence through reasoning manipulation of signals or advance process control and remote monitoring via computer network DCS phone Internet or satellite link This analyzer supports and communicates diagnostics Settings can be viewed functions tested calibration updated and remote operated from your computer terminal Note requires C Advanced Intelligence Access Program An optional Real Time clock allows accurate tagging of events and duration even through power outages Every IC CONTROLS microprocessor analyzer incorporates intelligence that enables advanced process control and the ability to communicate with ease and flexibility all in one analyzer Let IC CONTROLS provide you with REAL SOLUTIONS to your control needs buy IC CONTROLS Intelligent Anal
99. to the receiver Move the meter away from the receiver Plug the meter into a different outlet so that the meter and receiver are on different branch circuits If necessary the user should consult the dealer or an experienced radio television technician for additional suggestions The user may find the following booklet prepared by the Federal Communications Commission helpful How to Identify and Resolve Radio TV Interference Problems This booklet is available form the U S Government Printing Office Washington D C 20402 Stock No 004 000 00345 4 CANADA This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications Le present appareil num rique n met pas de bruits radio lectriques depassant les limites applicables aux appareils num riques de la class A prescrites dans le R glement sur le brouillage radio lectrique dict par le minist re des Communications du Canada www iccontrols com 875 Instructions Startup Startup If the analyzer is new and has not been installed follow the procedures described in nstallation Electronic Hardware Alignment and Configuration of Program before mounting Mounting and wiring procedures for new installations vary with equipment options see drawing section for instructions If the analyzer has been previously installed all that is req
100. uired is to attach the electrode to the analyzer and then to turn on the power The analyzer will go through its automatic startup procedure any time power to the analyzer was lost for more than a few seconds The startup procedure initializes the analyzer program performs error checking and then proceeds to display the chlorine and operate the analyzer normally All program settings calibration settings and defaults will have been remembered by the analyzer as the memory is none volatile Analyzer Startup Tests The startup procedure will begin by alternately flashing tESt and and blinking the top LED while performing the memory tests The analyzer will then display in sequence the analyzer number in this case 875 any software option numbers and the program version number e g 1 01 The Page 10 www iccontrols com IC CONTROLS program then proceeds to the display test which will light each of the implemented display segments in turn Atthe same time each of the LEDs will be lighted If the analyzer passes all the tests then the hardware is functioning properly and the analyzer will proceed to display free chlorine If the analyzer displays Err or Err this indicates that the input is offscale The error LED will be lighted as long as any input is offscale An offscale error can indicate that the electrode is not in solution is off scale or is not connected properly If the error LED remains ligh
101. und woo e re e e eo 54 Industrial Products Warranty 56 Appendix A 875 Spec Sheet 57 Appendix 835 Spec Sheet 59 Appendix C 832 Spec Sheet 61 Appendix D 877 Spec Sheet 63 Appendix E Enabling Security 65 Entering a Password 65 IC CONTROLS PRODUCTS 67 875 Instructions IC CONTROLS 875 Menu main menu 100 0 Efficiency OLd 0 90 ppm display 4 home base E rm nc A 4 25 0 c Auto See list of d 0 35 udi and caution Le See Internal Data Log Menu cum available tFci inputs ETE outi Cunn HE display units 212 used by output on ONOF OFF HI 14 00 CHANGES LO cur 1202 mA Areas shaded in dark gray indicate program settings which can be changed by the user Menu areas shaded in light gray indicate view only Page 4 AL See Alarm Menu E CONF PAS See Serial Menu ERI 8688 ves StbY www iccontrols com See Configuration Menu Menus are context sensitive Accessible only when function is activated 875 Instructions IC CONTROLS 875 Menu SEt 0 10 internal data log menu when not loggi
102. ve fully programmable setpoint and deadband second relay may be used for intelligent problem alert Includes one ORP electrode and one pH electrode in 1 CPVC flow cell Includes calibration equipment kit for field colorimetric calibration and one instruction manual See Option 35 IC Net Intelligence Access program for multi analyzer to networked computers via two way communication ADD OPTIONS Integral AUDIBLE SONIC ALARM wired to relay A 2 pipe surface mounting kit P N A2500255 Panel mounting kit P N A2500201 supplied in a 1 2 Din metalic panel mount 144x144mm case 139x139 cutout Real Time Clock for correct time with the power off Advanced IC Net Intelligence Access window program for multiple analyzers over RS485 two way link to multiple networked workstations See Computer section Binary communication documentation for user to write a custom Intelligence Access program RS232 Single Analyzer Communication replaces RS485 loop communication Reserved for future Fieldbus replaces RS485 Cleaner override timer option and chemical cleaner accessories Pump nozzle etc P N A2100020 Tip end for chemical cleaner Calibration kit refill Extra instruction manuals Priced x times each 600 Interface cable P N A9200006 Price length x ft times ft Stainless Steel tag ECONOMICAL FREE AVAILABLE CHLORINE ANALYZER TWO electrode ANALYZER CONTROLLER chlorine ORP and pH in flowcell Reads Free Chlorine HOCI or
103. yzers Page 63 www iccontrols com The two sensor pH ORP Chlorine instrument from IC CONTROLS the Model 877 gives you maximum flexibility reliability and ease of use Intuitive user friendly program just seems to do what you expect Auto calibration recognizes your buffers Self and sensor diagnostics Fault tolerant Output hold during calibration Two programmable 4 20 outputs with optional PID control Dual programmable alarms with self and sensor alert Frequent adjustments by keypad prompts Program remembers what you were doing No long key sequences and instant return to sample Operate without menu or manual LCD displays Free Chlorine Total free Chlorine pH ORP temperature alarm setpoints and calibration status USE YOUR pH ORP ELECTRODES FOR Free available Chlorine measurement the micro measures ORP adjusts for pH effect and temperature with a polynomial formula and reads out Free Available Chlorine HOCI Total Free Chlorine measurement from the same pH and ORP signals the micro adds the OCI reaction to the polynomial formula and reads out Total Free Chlorine HOCI OCI EASY MAINTENANCE Reliable separately powered and optically isolated output circuit prevents computer interface problems Alignment controls hidden but accessible when needed 3 Level Security to protect settings Calculates pH and ORP sensor Slope and Offset Durable housing withstands hosing down Survives acid and cau

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