Home

USER MANUAL MODEL 654 MICROPROCESSOR

1. e O EARTH SHIELD RJ 11 CONNECTOR ANALYZE WITH RS 485 fj m EARTH Page 52 www iccontrols com um 654 202 1 Controls Appendix E Parts List Appendix E Parts List Part Number 9051008 9051009 9141007 9201014 9160024 3200070 2500201 2500255 9200006 2500033 9120098 2101513 2500033 2100049 9120050 2101514 1100083 1100084 1100187 1600061 1100192 1100090 1100091 1100094 um 654 202 Description Reference Drawing Number 654 ORP Analyzer Assembly 654 ORP power PCB D5900081 Assembly M55 micro display board D5980176 Assembly M55 case complete D4830022 16 wire interconnector cable two end 0 25 A microfuse Hardware set 55 series front panel 4 each of standoff lock washer 4 40 nuts Panel mounting kit 55 series D4950054 Pipe wall mounting kit 55 series D4950053 Interconnect Cable to 600 Interface ORP cable 5 conductor with shield per foot D5900080 600 ORP Interface Pipe Top Explosion Proof Type ORP preamp D5900080 Terminal strip 6 CKT Explosion proof J box only 600 71 ORP Interface Wall Mount Type ORP preamp D5900080 Preamp holding bracket Terminal block 6 CKT Weather proof wall mount J box only Consumable Supplies 263 mV ORP standard does 6 calibrations 66 mV ORP standard does 6 calibrations 476 mV ORP standard does 6 calibrations ORP calibration kit 1 year supply De
2. The 654 is one of a series of 115 230 VAC process analyzers supplied in a corrosion resistant IP65 NEMA 4X water and dust tight case These analyzers are also available for pH conductivity dissolved oxygen and chlorine plus as two wire versions with an optional explosion proof rating In the case of ORP the analyzer measures the sensor signal corresponding to the actual ORP The analyzer conditions and digitizes the signal for maximum accuracy and then sends it out as a digital output and or on 4 mA to 20 mA outputs Features The 654 ORP analyzer features Intuitive user friendly program easy to use Auto calibration recognizes specific ORP standards Self and sensor diagnostics Output hold during calibration Stores 12 calibration records Stores alarms caution and error messages Stores running 1 000 minute ORP trend Two programmable 4 to 20 mA outputs e kan Two programmable alarms 10 Serial digital output and for remote operation 11 Optional PID control 12 Three level security to protect settings 13 Durable housing IP65 NEMA 4X Page 6 www iccontrols com um 654 202 IC Controls Specifications PROPERTY Display Display Ranges Keypad LED s Case Dimensions Weight Shipping Weight Shipping Dimensions PROPERTY Temperature Environment Ratings Electrical Ratings Electrical Requirements um 654 202 INTRODUCTION Physical Data CHARACTERISTIC Fo
3. 58 www iccontrols com um 654 202 1 Controls DRAWINGS D4950053 Pipe wall Mounting 7 lil 1 0000 9 o fo 9 8 5000 S MINES t 2 lo Ss CS CONTROLS Orangeville Ontario Canada TITLE 2 PIPE WALL MDUNTING KIT 650 652 655 ETC code 9 04950053 scole sheet of 1 2 um 654 202 Page 59 DRAWINGS 1 Controls D4950054 Panel Mountin 9 5000 e 8 9000 BELEL 6 2500 20 8750 NOTES joy date CONTROLS 1 PANEL CUTOUT 810W X 4 80H INCH 19 01 95 Orangeville Ontario Canada 2 TWO SCREW HOLES APROX 0 15 DIA ED TITLE AT SIDES 2 40 FROM TOP OF CUTOUT OPP PANEL MOUNTING KIT CENTERED 8 90 INCH APART 655 455 ETC 3 MOUNTING SCREWS 6 32 SR Kei 44950054 IRE V scole sheet of 10 60 www iccontrols com um 654 202 IC Controls INDUSTRIAL PRODUCTS WARRANTY 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 w
4. NONE will be displayed otherwise scroll through the error list using the Up and Down arrow keys Errors and cautions cannot be removed from this list directly each error or caution will be removed automatically when appropriate eg errors associated with improper calibration will be cleared after a successful calibration Error messages are numbered Errors 1 through 5 are identified as En e where n is the input number and e is the error number Messages 7 through 9 are less serious and are ORP 1 identified as cautions instead eg CAn e Input Source Input Number for Error and Caution Messages Temperature 2 Off scale errors for ORP are not numbered and Alarm 7 are identified as Err and Err depending on whether the input is at the top or the bottom 8 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 Alarm B Table 1 Input values for error caution messages Error message indicators can be annoying when one has already been made 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 remain 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 be
5. S SHOSN3S N04 SOZhvOZh 103135 21 OXON ONIMIM SS9 Jii 2 123135 1031345 4 S10H1NO2 gi 080 S310H ONILNNOW 90 22 6 243 Ap 330p lt lt lt e lt ion amp Component Locat iring Wi SALON 202 202 d A Oe 3 e i mo So5 25 O SEG ogo m to m t sg hajas TAS Le ve al 00241 ee O m 6 Hd V d 8 tr ECO sa a EB E ed sont 1 Q Hd 915 d U 015 g ve LJ 5 x AL E eg 48 B O A8 2 y 00t0 gor 30019851 O oov aL H1 IC Controls D5900081 Page 55 um 654 202 Controls DRAWINGS 600 Interface irin Wi D5900080 p em mE pem E 007 TIM LNDHS ND 593 38 08000680 sap 009 ONS 71991849373 ANY
6. Supply voltages at 5 and 95 of scale for better results Supply voltages at 5 and 95 of scale for better results Connect TC connections or use manual TC Redo calibration within TC operating range um 654 202 1 Controls Error 1 7 Standardize caution The offset is more than 50 mV higher or lower than the offset for the previous calibration Description CAI 8 30 days have passed since last calibration 1 9 12 months have passed since electrodes were replaced Causes Large offset in reference electrode or electrode depleted Incorrect standard used for calibration or standard not specified correctly No calibration performed in the last 30 days More than 12 months have passed since the electrodes were replaced Messages for Temperature Input Error E2 1 Description Temperature reading is off scale Temperature is less than 5 C E2 2 Temperature reading is off scale Temperature is greater than 105 C um 654 202 Causes Temperature is low Electronic temperature calibration necessary Temperature compensator is not attached Temperature is high Electronic temperature calibration necessary ERROR MESSAGES Solutions Check electrode service or replace as necessary Use fresh standard and redo the calibration ensuring that the correct custom mV value is specified Repeating the calibration should clear the caution message Perform a cali
7. Alarms 30 caution messages 23 default settings 50 deviation 30 32 differential 30 33 fault 30 32 function 30 high 32 indication of 30 low 32 manual override 31 on off switch 30 relay outputs 42 sensitivity of 32 set point 30 two stage 32 AUTO key 15 31 Battery backup 13 Calibration 19 error checking 20 error messages 19 offset 19 output hold 22 overriding analyzer 19 standards 20 temperature compensation 21 temperature input 41 Calibrator 38 Celsius 16 Characterization example 27 output signal 27 Configuration normally closed 34 normally open 34 ORP input 39 program 34 temperature calibration 41 Current output 26 Current output characterization 27 output hold 22 reversing 26 settings 26 simulating 26 specifications 26 Page 62 standby mode 15 units 26 Default settings 50 Deviation alarm 32 Diagnostics memory test 13 startup procedure 13 Edit mode change settings 17 numeric values 17 Edit Mode change settings 17 example 17 key functions 18 numeric values 17 Electrode maintenance 22 replacing 22 troubleshooting 37 Electronic alignment 39 ORP Input 39 Error messages 23 sign 23 sign 23 acknowledging 20 23 alarms 23 1 7 25 1 8 25 1 9 25 calibration 19 clearing 23 E1 0 24 1 1 24 1 2 24 E1 3 24 E1 4 24 E1 5 24 2 1 25 E2 2 25 Fahrenheit 16 Fault alarm 32 Hardware alignment 39 electronic calibration 39 span adjustment 39 zero adjustment 3
8. 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 654 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 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 654 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 NC Normally Closed 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 will be closed ie the external device wired to it is turned on when the analyzer is not powered NO Normally Open Normally Open A circuit which is wired normally open will be open ie 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
9. J205 closed Refer to drawing 25900081 for jumper settings Adjusting Electronic Calibration 1 To make the electronic calibration read correctly first remove any offset in the software Select CONF in C OFFS from the menu and set the offset to 0 0 2 Disconnect any field wiring from TB201 terminals 5 and 6 identified as T and T If no is present remove the 25 resistor before starting the electronic calibration procedure 3 Input for temperature circuit zero by supplying 0 273 V representing 0 at TB201 T terminal with common at TB200 REF terminal Adjust the trimpot VR202 for a reading of 0 227 VDC at TP201 4 Input for temperature circuit span by supplying 0 373 V representing 100 C at TB201 T terminal with common at TB200 REF terminal Adjust the trimpot VR203 for a reading of 4 733 VDC at TP201 5 Close the case and press SAMPLE followed by the Down arrow key to display the temperature reading 6 Re apply 0 273 V and adjust VR202 until the display reads 0 0 C 0 1 C 7 Re apply 0 373 and adjust VR203 until the display reads 100 0 C 0 1 8 Re install the TC field wiring or the 25 resistor if there is no TC in the sensor The 25 resistor simulates a TC value close to 25 C Software Calibration The current temperature as measured by the temperature sensor needs to be known If the sensor is in the process the known temperature of the process ca
10. N 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 Illustration 32 Port powered RS232 to RS485 converter Material List P N A7900015 RS232 to RS485 converter P N A2500192 10 foot cable with RJ11 connector at one end data wires at other end Installation 1 It is good practice to first turn off the analyzer before connecting a serial cable 2 Bring the RS485 cable into the analyzer through the center hole Wire the RS485 cable into the terminal block TBI located on the display board Connect the black to terminal B red to terminal A and the clear to EARTH 3 Connect the converter to a free COM port on your laptop computer Illustration 33 Wiring RS485 cable 4 Insert 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 Lo Data A 2 B Data B 4 5 Signal Ground 4 N Jack End RJ 11 Plug End RJ 11 6 Conductor TB1 B BLK E 2 EE H EU RED
11. N33 L38 NOILISNNOI ON SI 3N3Hl INSNI Y cgooocgy 191 7VNN3INI zen Hd JI I L HLIM Q3ddIHS NJZATINNV V 3239 JN31NI 009 9000026 Nd SV SCHSIMD OI N31138 37895 317 4 s3wDisno JALIL UD STOYULNOD 1 90 L2 6 2434 ap OU Hi lt gt NI 215 AJISV3 LON LNG 2141234 SI 21 anss33 3dD32IN 9 ANIWA LAS ANY 91 1293138 OL LON 309 0 3I ERR EE 319894352 238 C1 V 1 PERI A gt LHM IC oe 43 133b dWwv3sld Nazz TE SSV 19 5 3D 3194935 3018110 NO 3 A0 433 381N39 88 9 IN ivo 9 9 ES e JE e LHM mw viv CA E ona AT ELE 438 2 133 A NAD d CA 1 1 10281 00281 Lngino anani VSI SG9 dl DNANNaULSNI XOH ALON dOSNHS V um 654 202 www iccontrols com Page 56 1 Controls DRAWINGS D4850015 600 Installation MODEL 600 ALTERNATE INSTALLAT
12. 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 menu selection Make calibration adjustments while the analyzer shows the output at 20 00 mA Repeat the procedure for output 2 Approach 2 Use Voltage Source to Adjust Input A faster calibration approach requires a voltage source for the ORP input To calibrate output 1 set in ORP Input a low enough signal to cause the 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 the analyzer will output 20 00 mA Outputs are isolated from main circuit therefore measurements are made with common at the output 2 terminal TB304 Tip Both outputs can be simultaneously calibrated if you set in ORP for both inputs Adjusting Electronic Calibration Measure output 1 zero at TP301 pin 8 of 0304 while output 1 is outputting 4 00 mA The test point should be between 0 870 V and 0 890 V 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 s
13. available from IC CONTROLS are quinhydrone standards buffered at 4 0 pH or 7 4 pH with an ORP of 263 mV and 66 mV at 25 C respectively If one of these standards is used select 263 or 66 from the calibration menu directly If automatic temperature compensation has been selected the temperature compensated values of these standards will be used automatically Illustrations 16 and 17 show how these standards change with temperature Temperature Compensation for 263 mV ORP Standard Temperature Compensation for 66 mV ORP Standard 268 m 266 7 70 eat 2 a 667 ot eck 260 et E L d 1 1 1 1 iT 20 22 24 26 28 30 20 22 24 26 28 30 Temperature C Temperature C Illustration 16 263 mV ORP standard Illustration 17 66 mV ORP standard ORP standards automatically recognized by the 654 are 263 mV ORP standard part number A1100083 66 mV ORP standard part number A1100084 These part numbers supply 6 calibrations Refer to Appendix E for ordering information Page 20 www iccontrols com um 654 202 IC Controls CALIBRATION Temperature Compensation for Quinhydrone Standards The ORP measurement does not require temperature compensation during normal operation Nevertheless it can be important to know the process temperature since redox potentials can have a high temperature coefficient The process temperature can be displayed by the analyzer if the ORP sens
14. calibration select orP CAL from the menu The user now needs to select a standard with which to calibrate the analyzer Select either a custom value or one of the quinhydrone standards supplied by IC CONTROLS Refer to the heading Selecting a Standard for further information on selecting a standard For this example a 200 mV ORP standard will be used Select CUSt from the menu If the display does not show 200 then edit the value to read 200 Place the electrode in the standard solution then press SELECT to start the calibration process The display will show a flashing ORP reading to indicate that the analyzer is reading ORP and is testing for stability The calibration procedure is fully automatic from here on As soon as the electrode has stabilized the display will stop flashing the electrode offset will be calculated and the new offset will be entered in memory It is however possible to override the analyzer The ENTER key may be pressed before the electrode has stabilized forcing the analyzer to calibrate using the current ORP reading Also the calibration may be redone or started over at any time Press CANCEL to display the selected buffer e g CUSt then SELECT to restart the calibration um 654 202 Page 19 CALIBRATION Controls If the analyzer detects or suspects any problems during calibration an error caution message will appear Caution messages for the ORP input are those with a number
15. case the alarms will continue to function An alarm is indicated using the alarm LED Illustration 20 Alarm menu but not the alarm contact Deviation dEv Alarm Indication The A and B LEDs on the front panel show the current state of each alarm and alarm contact In addition an alarm condition for an input will cause the sample display for that input to alternate with the alarm function either LO HI dEv FLt This way the operator can quickly determine which alarm caused the alarm condition alarm A or alarm B LED lighted and the type of alarm Each alarm will simultaneously generate a caution number in the error menu Refer to Error Messages section for the meaning of each alarm caution The alarm cautions will not OFF Q no alarm condition 47m alarm condition cause the error LED to come on because the O i LED onl if contact not activated error only comes on if there are any errors To view alarm caution s using the error menu alarm condition select Err from the main menu then use the ON Up or Down arrow key to scroll through the list contact activated 4 of errors and cautions if Illustration 21 Alarm status indication alarm LEDs Page 30 www iccontrols com um 654 202 1 Controls ALARM FUNCTIONS Alarm Override For normal alarm operation the alarms are said to operate in auto mode If the operator wishes to intervene and switch off the alarm contacts temporarily while at
16. electronics Send the analyzer to a service shop for electronic alignment or repair um 654 202 Page 37 TROUBLESHOOTING 1 Controls ORP Sensor Troubleshooting In order to troubleshoot an ORP sensor it is very important to have no doubt that the analyzer used to get readings is functioning correctly IC Controls manufactures a portable pH ORP analyzer and calibrator for troubleshooting purposes the model 659 The calibrator can be used to prove the analyzer before use or it can be used to prove the analyzer in an ORP loop after a problem has appeared CAUTION Before testing your ORP sensors be sure your test analyzer is known to be good 1 Inspect the sensor If the sensor is dirty or scaled a Clean with a soft cloth b Acid clean to remove scale IC Controls recommends using gentle scale remover P N A1100094 2 Test sensor response without adjusting analyzer calibration Test the sensor response both mV reading and response time in two different standards Record both the mV reading and the response time Use the following standards a 66 mV quinhydrone standard b 263 mV quinhydrone standard If the sensor response 15 slow clean the sensor again with a soft cloth or acid clean overnight with electrode wash solution P N 1100091 If the readings in the two standards do not differ by about 263 mV 66 mV 200 mV then there is a problem with the sensor Lack of response can be due to coating of
17. for 4 mA to 20 mA output window Hold Output hold during calibration hour Hour Real time clock setting hund Hundredth of a second Real time clock display Internal data log in Input OR Minute Real time clock setting um 654 202 Page 43 DISPLAY PROMPTS 1 Controls PROMPTS CON T init LO NodE NO NC OFF OFFS ON ON OF onth OPEN orP out out 1 out 2 PAS 1 PAS 2 PASS rEPL rtc SEC SEr SEt StAr StOP tbL tc unit YEAr Page 44 Initialize all program settings to factory defaults Low alarm low limit 4 mA for 4 mA to 20 mA output window Node number for IC Net communications Normally open Normally closed Off Offset On On off switch Month Real time clock setting Normally open alarm contact ORP input Output menu First 4 mA to 20 mA analog output channel Second 4 mA to 20 mA analog output channel Set password 1 operator access Set password 2 complete access Enter password to change access level Replace electrode Real time clock Seconds Real time clock setting Serial communications menu Set point Start internal data log Stop internal data log Characterization table Temperature compensation Display setting of units Year Real time clock setting www iccontrols com um 654 202 1 Controls GLOSSARY GLOSSARY Electrode Both a sensing and a reference electrode are needed for the analyzer to measure the process
18. 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 ie high or low alarm for both alarms but selecting different set points HIGH ALARM LARM alarm off 7 alarm on SETPOINT differential differential alarm off sample sample time Illustration 24 High alarm time Illustration 23 Low alarm Example The of a critical process may not drop to below 200 mV Use alarm A as a low alarm set at 200 mV and use alarm B as an advance warning device by configuring it as a low alarm set at 250 mV When alarm B is activated there is still time left to take corrective action Deviation Alarm A deviation alarm is practical when the process is expected to stay within a certain range An alarm will be set if the input deviates too far from a set point Please note that the dEv frame only shows up in the menu after the alarm function has been changed to deviation alarm since it would have no effect for a high low or fault alarm Example If the ORP is expected to stay between 100 mV and 300 mV then we would set in to orP Func to dEv SEt to 200 and dEv to 100 Effectively a high alarm at 300 mV and a low alarm at 100 mV has been set The differential setting will continue to function as for high and low alarms Fault Alarm A fault alarm for an input will be se
19. serial output log BAud Baud rate for serial communications C Temperature in degrees Celsius use metric units CAL Calibrate analyzer CHAr Output characterization on off CHIP Chip Is this analyzer equipped with a real time clock chip CLr Clear the internal data log CLSd Normally closed alarm contact cnt Count of number of readings in internal data log CONF Configuration of program menu Cont Continue internal data log when buffer full Ctr Center of scale setting for ORP input cur Signal output in mA or current cuSt Custom ORP standard value for calibration dA Damping setting for inputs dAtE Date Real time clock setting for day of the month 1 31 dEv Deviation alarm dFLt Default input to display when SAMPLE pressed dLAY Alarm activation delay do Do press ENTER to execute the reset clear action donE Done Reset clear action has been taken ELEC Electrode Err Error or warning number Er 91 RAM chip not detected or not functioning Er 92 RAM chip only partially functioning Er 93 RAM chip noise or address data line open Er 94 RAM checksum failed Some settings may be lost Er 95 EPROM checksum failed F Temperature in degrees Fahrenheit use imperial units FLt Fault alarm FrEq Frequency of internal data log updates in seconds FULL Full What to do when internal data log is full continue or stop Grab Grab sample calibration HI High alarm high limit 20 mA
20. the data into other programs for analysis for example into a spreadsheet Wiring and Enabling 1 It is good practice to first turn off the analyzer and the computer before connecting a serial cable 2 Wire the RS485 cable into the terminal block TB1 located on the display board Refer to illustration 31 Connect 1 RD A to pin TD A and connect this to terminal A on TBI 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 3 Turn on the analyzer and the computer 4 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 1s 9600 5 To enable serial transmission by the analyzer set the serial ON OFF switch to ON select SEr ON OF and edit to display on 6 Turn on ASCII output select iLOG ASCII and edit to display on DB 9 Connector C 5 1 5 9 BLACK RED REDI s 3 O CN EARTH SHIELD Pin Assignments Pin 1 RD A Analyzer Pin 2 TD B Pin 3 TD A E Pin 5 COM Pin 9 RD B Illustration 31 RS485 wiring um 654 202 Page 51 Appendix D Serial Output IC Controls Portable Laptop Hookup RS232 to RS485 Converter The P
21. the input damping to the selected seconds Press ENTER to leave edit mode um 654 202 Page 35 TROUBLESHOOTING 1 Controls TROUBLESHOOTING When trying to determine what the problem is with an ORP loop there are a few simple steps to follow First the problem is isolated to determine whether the problem is with the sensor or the equipment The equipment consists of the analyzer wiring and preamp Isolating the Problem 1 Write down the symptoms a ORP reading A b Temperature reading c ORP offset Illustration 28 BNC fitting Separate the sensor from the analyzer Disconnect the sensor from the analyzer at the BNC fitting This way the sensor and the equipment can be tested separately See if the analyzer reads correctly by inputting 0 mV a Take a paper clip and bend it into a U shape or use a shorting strap if one is available b Insert the paper clip in the analyzer input BNC connector shorting between the center pin and the outside ring This will give a 0 mV input If using a BNC shorting strap simply attach it to the input BNC connector c Note the ORP reading If the ORP is close to 0 mV e e then the analyzer is OK If the reading is far from 0 mV then do a calibration and not
22. 23 to 220 span adjustment 1 mV 0 1 0 1 output resolution 1 mV 0 2 0 4 Table 3 Output specifications Page 26 www iccontrols com um 654 202 1 Controls OUTPUT SIGNALS Output Characterization The analyzer has a user programmable output characterization capability Output characterization could be used to provide more accurate control over an output device such as a non linear ball valve or recorder output could be customized to meet your specific application needs The 21 point output table allows the user to specify the behavior of the output in increments of 596 of the uncharacterized output signal The table links uncharacterized output values to specific output values allowing a wide variety of linear and non linear behaviors to be described with high resolution By default the output module does not characterize its 100 output Whenever the CHAr setting in the output menu is set to OFF the characterization table tbl is bypassed so that the 4 mA to 20 mA output is linear With linear output selected an input value equal to the LO setting will produce an output of 4 mA and an input value equal to the HI setting produces an output of 20 mA If the CHAr setting in the output menu is set to on output is characterized according to the curve defined in the characterization table For output values which do not fall exactly on a 5 boundary the table output is extrapolated s
23. 34 TROUBLESHOOTING eere ene enenntn 36 Isolating the Problem sss 36 Equipment Problem Troubleshooting 37 ORP Sensor Troubleshooting 38 ELECTRONIC HARDWARE ALIGNMENT 39 Calibration of ORP 39 Calibration of Temperature Input 41 Calibration of 4 mA to 20 mA Outputs 41 DISPLAY PROMPT ccsscsssssssssssssssssesssnees 43 EZ A KKEN TA 45 Appendix Security eere 46 Appendix B Output Characterization 49 Appendix C Default Settings 50 Appendix D Serial Output 51 Appendix E Parts List esee 53 DRAWINGS e eeeeeeeeeeee enses entes tne tn tna tn sensn 54 D5980176 Display Component Location 54 D5900081 Wiring amp Component Location 55 05900080 Wiring 600 Interface 56 04850015 600 Installation 57 D4830022 Mounting Dimensions 58 04950053 Pipe wall Mounting 59 04950054 Panel 60 INDUSTRIAL PRODUCTS WARRANTY 61 NIK 62 Copyright 2007 IC Controls Ltd rights reserved Page 2 www iccontrols com um 654 202 IC Controls 654 MENUS 654 MENUS mV St CALIBR
24. 6 Input The 6 option for the 654 analyzer is an integral high impedance input No preamp needs to be wired This option requires either an electrode without a TC temperature compensator or with a 33P TC option pin jack connectors Connect the electrode BNC to the analyzer as shown in illustration 9 If the electrode has a TC insert the pin jacks into the pin jack receptacles matching the red wire with the red pin jack hole and the white wire with the white pin jack hole low level sensor signals should be run through a dedicated conduit Take care to route all signal wiring away from AC power lines in order 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 drive shield will cause ORP errors Avoid twisting the sensor lead to minimize potential for broken wires Ensure the sensor connections are clean and tight E uus TE LIES MEC Illustration 9 6 electrode connection Instrument Shop Test Startup 1 Apply 115 230 VAC power to the analyzer 2 Hook up the sensor and remove orange protective cap Keep for future use 3 Rinse the sensor in deionized water and place in 263 mV standard 4 654 should come up reading close to 263 mV 5 Perform a calibration for an ORP reading of 263 mV Allow 30 minutes warm up time for electronics to stabilize 6 To check f
25. 9 Home base 14 www iccontrols com IC Controls um 654 202 1 Controls Hysteresis 45 Input damping 16 35 Installation 9p 13 jumper 41 Keypad arrow keys 15 AUTO key 15 CANCEL key 18 DOWN key 17 ENTER key 17 MANUAL key 15 SELECT key 18 UP key 17 LED 13 45 MANUAL key 15 31 Memory test 13 Menu 3p 14 45 Offset manual adjustment 21 ORP 19 of scale 40 current output 26 electronic offset 40 electronic slope 40 inputrange 39 offset 19 Output hold 22 Password 46pp pH calibrating 19 Portable calibrator 38 Process control 33 Prompts 43 Quinhydrone standards 19pp Real time clock 16 Redox electrodes 19 Relay outputs 42 SAMPLE key 14 Security um 654 202 INDEX access level 46 disabling 47 enabling 46 password 46pp password 1 46 password 2 46 time out 14 Span electronic 39 Specifications 7 Standards 19 Standby mode 15 Start up display 13 error checking 13 initial startup 13 program initialization 34 Temperature 16 calibration 35 current output 26 default settings 50 electronic alignment 41 software calibration 41 units 16 35 Temperature compensation 21 definition 45 Timer 12 month timer 22 12 month timer 22 15 minute time out 14 30 day timer 22 security time out 14 Troubleshooting analyzer 36 isolating the problem 36 preamp 37 sensor 38 wiring 37 Version 13 Wiring 9 Zero electronic 39 Page 63
26. ATE E See list of error and cautio messages for conductivity list of available SAMPLE inputs display units used by output o B o 5 CHANGES Areas shaded in dark orange indicate program settings which can be changed by the user Menu areas shaded in light blue indicate view only See Alarm Menu CONF CONF See Serial Menu See Configuration Menu Accessible only when function is activated Illustration 1 Menu overview um 654 202 Page 3 654 MENUS alarm contact PP pump pulser PID AL A contact only time proportional PID AL A contact only input damping sec 200 MEN input damping sec CALIBRATE CAL 5 Offset metric or imperial unit selection YES 0 selectable only if security enabled 0000 E E Illustration 2 Configuration menu Illustration 3 Alarm menu Page 4 www iccontrols com 1 Controls list of available inputs display units used by output based on input Differential Delayed alarm activation sec Setpoint Deviation um 654 202 IC Controls 654 MENUS internal data log menu when not logging list of available inputs frequency of log update in seconds continue logging overwriting oldest data stop logging
27. ION RECOMMENDED INSTALLATION WEATHERPROOF SURFACE TYPE J BOX WEATHERPROOF EXPLOSION PROOF J BOX MODEL 600 71 4 5000 6 8900 1 ae 600 600 71 4 9200 p 3 4 fe A A RECDMMEND DUAL TU SUPPORT PLATE A I 31 FOR SUBMERSIBLE m APPLICATIDNS L N CONDUIT TD dias pop LJ ANALYZER SUBMERSIUN SUPPORT PIPE UR SENSOR BODY gt RECOMMENDED 3 74 LIQUID TIGHT FLEX CONDUIT AND FITTINGS RECOMMEND 90 ELBOW GRIP TOP OF LIQUID LEVEL PIPE TO HELP LIFT SUBMERSION SENSOR FOR 600 71 RECOMMENDATION FOR EASY SENSOR REMOVAL AND CALIBRATION FLEX CONDUIT TO SENSOR SHOULD BE 4 LONGER TYPICAL SENSORS THAN SENSOR PLUS SUPPORT PIPE SENSOR LEAD LENGTH RECOMMENDATIONS 643 NO 22 FOR 600 LENGTH OF SUPPORT PIPE PLUS 0 3 METER IFT 605 ND g FOR 600 71 2X LENGTH DF SUPPORT PIPE PLUS 15 METER 607 617 22 CONTROLS Orangeville Ontario Canada TITLE INSTALLATION INDUSTRIAL pH INTERFACE DEL 600 dr chk um 654 202 Page 57 DRAWINGS 1 Controls D4830022 Mounting Dimensions 2 0000 20 8750 by date 2 CONTROLS JEF C 90 Orangeville Ontario Canada TITLE MOUNTING DIMENSIONS code dwe sheet of 10
28. SPLAY Illustration 30 Password validation um 654 202 Page 47 Appendix A Security IC Controls PASSWORD EXAMPLE 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 0 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 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 Select PASS from the main menu again Change the displayed 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 th
29. USER MANUAL MODEL 654 MICROPROCESSOR ORP ANALYZER um 654 202 CONTROLS CONTENTS um 654 202 2 654 MENUSS 3 6 eat Eege 6 Specifications 7 tentato enata 9 Analyzer Mounting 9 Ke EET 9 Sensor 10 Sensor Wit ener 10 Instrument Shop Test Startup 11 KOCHT ME 13 Analyzer Startup Test 13 Start up 13 Changing Settings sse 13 EASY 14 Remembers Where You 14 Home Base Press 14 Display Features esee 14 AOW Keys c et e 15 AUTO and MANUAL 15 Standby Mode 15 Temperature C E onte 16 Real Time Clock eee 16 Input 16 EDIT 17 Editing by Selecting a Setting 17 Editing a Numeric Value sss 17 Summary of Key Functions in Edit Mode 18 CALIBRATION eeeeee eese enn stnann 19 Calibration Procedure sess 19 Selecting a Standard for Calibration 20 Temperature Compensation for Quinhyd
30. al temperature compensation will be displayed depending on the current setting To change the setting from Auto to SEt press ENTER to edit the current setting The display will start blinking indicating that a selection needs to be made Use the Up or Down arrow key to display SEt set temperature Press ENTER to select manual temperature compensation Refer to the section entitled Edit Mode for further information on changing settings and numeric values With SEt as the current display press SELECT to display and or adjust the temperature setting to be used with 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 or Down arrow keys to display the desired temperature for manual temperature compensation Press ENTER to accept the currently displayed value Note that even with manual temperature compensation selected for ORP the sample frame for temperature at the left hand side of the menu will continue to read the temperature from the temperature sensor The temperature value displayed is that of the sensor and not the manual temperature compensation value for ORP Manual Adjustment of Offset It is possible to bypass the regular calibration procedures and edit the offset directly The offset is protected by level 1 security which is the same security as the calibration procedure When the offset or slope are adjusted directl
31. atisfied Measure output 2 zero at TP300 pin 7 of U304 while output 2 is outputting 4 00 mA The test point should read between 0 870 V and 0 890 V 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 spanpot 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 To return all configurations and analyzer settings to default run init in the configuration menu Testing Relay Outputs No calibration is necessary beyond checking for actual operation To check actual operation check for contact closure continuity at each relay To activate relay go into configuration section and select CONF NO NC ALA from the menu Press ENTER press press ENTER to change OPEN to CLSd A closed contact should open or an open contact should close Repeat the same check for Alarm B To return all configurations and analyzer settings to default run init in the configuration menu Page 42 www iccontrols com um 654 202 1 Controls DISPLAY PROMPTS DISPLAY PROMPTS 4 20 4 mA to 20 mA analogue output signals 66 66 mV quinhydrone standard 263 263 mV quinhydrone standard ACC n Access level for security Displayed after password entered by user AL Alarms AL A AlarmA AL b Alarm B AUto Automatic ASCI ASCII
32. ay 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 from 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 Page 12 www iccontrols com um 654 202 1 Controls STARTUP STARTUP If the analyzer is new and has not been installed then follow the procedures described in Installation Electronic Hardware Alignment and Configuration of Program before mounting Mounting and wiring procedures for new installations vary with equipment options refer to drawing section for instructions If the analyzer has been previously installed all that is required is to attach
33. ble will now automatically characterize the output so that 0 1000 mV 100 1000 mV 2 It is probably easiest to draw or sketch the characterization curve before entering any table values A blank worksheet has been provided in Appendix B This worksheet can be copied and can serve as documentation for analyzer setup um 654 202 Page 27 OUTPUT SIGNALS 1 Controls 3 The characterization curve for this example is shown in illustration 19 For reference the ORP values corresponding to the uncharacterized output are shown at the top of the diagram There are four points on the graph that are of most interest a Normal 0 output corresponds to the LO setting of 1000 mV and 4 00 mA output b Normal 100 output corresponds to the HI setting of 1000 mV and 20 00 mA output c At 200 mV one requires 1046 output 200 mV corresponds to 40 of the horizontal scale d At 200 mV 90 output is required 200 mV corresponds to 60 of the horizontal scale 4 Once the points of interest are identified plot them on the graph and connect them with straight lines 5 The shaded column marked 46 characterized output can now be filled in by reading the coordinates off the graph For example to find the required table value for 45 find 45 on the horizontal scale follow the line up until it hits the curve The table value is the value on the vertical axis in this case 30 Refer to arrows in illustration 19 6 Once the shaded c
34. bration Verify electrode operation Follow Replacing Electrodes procedure if replacement required Solutions Verify process and sensor location Follow procedure in Hardware Alignment section Attach temperature compensator Connect resistor to TC terminals to simulate a constant temperature Refer to Hardware Alignment section Verify process and sensor location Follow procedure in Hardware Alignment section Page 25 OUTPUT SIGNALS 1 Controls OUTPUT SIGNALS Two assignable 4 mA to 20 mA output channels are provided The user may configure the analyzer to determine which input signal will be transmitted by each 4 mA to 20 mA output channel Each output channel can be independently configured to transmit an ORP or a temperature signal 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 two ORP signals each using separate high and low adjustments To adjust the output span or output window for ORP 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 the 4 mA to 20 mA Output The low scale setting will normally be lower than the high scale setting It is poss
35. curity enabled The initialization procedure is not to be Illustration 27 Configuration menu used unless you are absolutely sure that you want to restore the analyzer to factory default configuration After the analyzer program has been initialized 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 For your convenience the analyzer will remember your most recent menu selections From the menu select CONF init ALL do The do will be flashing you must press ENTER to proceed with initialization When ENTER is pressed the analyzer will go though its start up sequence Input On Off Switch Each of the inputs has been provided with an on off switch The most common use of this feature is to turn off the temperature input if no temperature compensator or temperature sensor has been installed Turning off an input will make the sample display at the left side of the menu disappear as if the input did not exist Page 34 www iccontrols com um 654 202 IC Controls CONFIGURATION OF PROGRAM Temperature Calibration The temperature compensator in the ORP sensors will sometimes show some variance in their offset To make the sensor read correctly without adjusting the electronic calibration of the analyzer use the following procedure The current temperature as measured by the temperature sensor needs to be known If th
36. e entered Likewise if the new value entered is higher than allowable then the highest allowable value is used instead The analyzer will display whatever value it has stored in memory Example Change the low output setting from 0 mV to 200 mV From the menu select out LO The current set point e g 000 0 will be displayed Press ENTER to select edit mode The display will change to 000 0 and the last digit will start blinking Press three times to move left three digits The last digit from the end will now be blinking Press the 7 key to change 0 to 2 Press ENTER again and the display will change from 000 0 to 200 0 indicating that the new value has been stored in memory The 4 mA to 20 mA low set point has now been changed from 0 0 mV to 200 0 mV Press the lt key to display LO out etc um 654 202 Page 17 EDIT MODE 1 Controls Summary of Key Functions in Edit Mode ENTER SELECT lt lt CANCEL Illustration 14 Page 18 Enters edit mode The entire display or a single digit will blink to indicate that the analyzer is in edit mode Press the ENTER key again to leave edit mode and accept the new value 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 the
37. e menu Press ENTER with 0000 displayed Both passwords are set to 0000 again and password security is disabled Page 48 www iccontrols com um 654 202 IC Controls Appendix B Output Characterization Appendix B Output Characterization 100 100 90 90 80 80 8 70 5 70 60 8 60 i 50 40 2 40 5 30 5 30 x 20 20 10 10 0 0 0 10 20 30 40 50 60 70 80 90 100 10 20 30 40 50 60 70 80 90 100 characterized output 96 characterized output Uncharacterized Characterized Input units 4 20 mA Output Output eg mV output 0 LO 4 00 5 4 80 10 5 60 15 6 40 20 7 20 25 8 00 30 8 80 35 9 60 40 10 40 45 11 20 50 12 00 55 12 80 60 13 60 65 14 40 70 15 20 75 16 00 80 16 80 85 17 60 90 18 40 95 19 20 100 HI 20 00 um 654 202 Page 49 Appendix C Default Settings IC Controls Appendix C 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 Output 1 Output 2 Input to be transmitted ORP Temperature Low setting 1000 mV 0 0 C High setting 1000mV 100 0 C ON OFF switch ON ON Characterizat
38. e sensor is in the process the known temperature of the process can be used Select CONF in CAL from the menu frame showing the current temperature will be displayed Press ENTER then change the displayed temperature to what the temperature should be Press ENTER again to leave edit mode Press SELECT to go to the calibration frame The current temperature will flash When the input is stable press ENTER to set the new temperature The displayed temperature will be adjusted to the specified temperature and the temperature calibration is completed Metric or Imperial Units By default the analyzer will use metric units This means that temperature will be displayed using degrees Celsius and that the prompt for the temperature input will be The analyzer can also be made to use imperial units as the preferred unit Using imperial units temperature will be displayed using degrees Fahrenheit in the sample menu 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 throughout this instruction manual and in the menus To select imperial units for the analyzer select unit from the configuration menu then go into edit mode and change the C prompt to F Real Time Clock 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 po
39. e sensor is not in solution is off scale or is not connected properly If the error LED remains lighted go to the error display section by selecting Err from the main menu to see what errors have been detected by the analyzer 9 After completing the above steps the analyzer is now in normal operational mode Analyzer settings and parameters can be viewed and or changed at any time using the keypad Start up Settings The 654 analyzer default assumes a properly functioning sensor with no offset Refer to Appendix C for a list of all analyzer default settings IC Controls recommends a full chemical calibration after initial startup Changing Settings Analyzer settings and parameters can be viewed and or changed at any time Refer to the menus starting with illustration 1 on page 3 The areas shaded in dark orange indicate program settings which can be changed by the user Menu areas shaded in light blue indicate view only menus um 654 202 Page 13 EASY MENU 1 Controls EASY MENU The layout of the program is shown in the menus starting on page 3 Remembers Where You Were The analyzer remembers where SAMPLE is The sample display is home base for the program The program also remembers which menu selections were used last and loops around the columns The menu can be accessed using the arrow keys to find any parameter then press SAMPLE to return to the displayed reading Then using the Right arrow key return to exactly where you
40. e the ORP reading and the offset Illustration 29 Paper clip short Problem Isolated ORP offset action EE less than 20 mV The equipment is good The problem is in the sensor Continue with Sensor Troubleshooting greater than 20 mV The equipment is likely at fault Continue with Equipment Troubleshooting to determine if the problem is with the wiring analyzer or preamp Page 36 www iccontrols com um 654 202 1 Controls TROUBLESHOOTING Equipment Problem Troubleshooting Check the wiring If the offset determined in the third step of the isolation procedure is greater than 20 mV check the wiring between the preamp and its terminal block and see if there are any loose or faulty connections Frayed corroded or broken wires here are the most common cause of equipment problems 2 Check the analyzer If the wiring looks good and after recalibration the large offset is still there a Use the paper clip U at the analyzer terminal block and short directly between the reference REF and the signal SIG to bypass the preamp and wiring b A new single point calibration can be done to see if there is any problem in the analyzer alone independent of the preamp and field wiring 3 Problem identified less than x20 mV The analyzer is good The problem is in the wiring or the preamp Further check the wiring A bad preamp would need to be replaced greater than 20 mV The problem is in the analyzer
41. een the possible options and then press ENTER again to accept the new setting and leave edit mode Example Turn alarm A off From the menu select AI ALA 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 key to switch between the possible options When ON is displayed press ENTER again to accept the new setting and leave edit mode Editing a Numeric Value Numeric values such as an alarm set point are adjusted by going into edit mode and then adjusting each digit until the new value is displayed Use the lt and keys to move between digits and use the and keys to adjust each digit When ENTER is pressed to go into edit mode two things will happen First the last digit will start blinking to show that this digit can be changed Second any blank spaces will change to zeros and a plus or minus sign will appear Now each digit can be accessed Change between positive and negative numbers by switching between plus and minus sign using or key when plus minus segment is blinking Press ENTER again to leave edit mode Before the new value is changed the analyzer will check the new value to make sure that it is within range If the new value is lower than the lowest value allowed for that frame then the analyzer will use the lowest allowable value instead of the new valu
42. en when the analyzer power is turned off Input Damping The ORP and temperature measurements can be damped to provide the user with a means to alleviate rapidly varying or noisy signals The available damping range is 3 s to 99 s with 0 there would be no damping and each reading the analyzer made would be used to directly update the display and 4 mA to 20 mA output The factory default of 5 s adds the next four seconds worth of readings to the first and divides by five this provides a fast response Selecting 99 s adds the readings for 99 s and divides by 99 providing smooth damping out of turbulent readings Any selection between 3 s and 99 s can be made Select CONF in from the menu Use the up or down arrow key to select the input to be adjusted then select the dA frame Press ENTER to edit the input damping to the selected seconds Press ENTER to leave edit mode Page 16 www iccontrols com um 654 202 1 Controls EDIT MODE EDIT MODE Edit mode is used to change a numeric value or to select between different options Values and settings which can be edited are identified by the darker shading in the menu Any frame which has a white background cannot be modified Editing by Selecting a Setting Editing a value is like picking an option from a list only one item on the list can be seen at a time To change the setting press ENTER to go into edit mode The display will start blinking Use the Up or Down arrow key to switch betw
43. ent 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 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 um 654 202 Page 61 INDEX INDEX Acknowledging error messages 23
44. ent span of the analyzer 3 Adjust the voltage using blue trimpot VR200 until the analyzer display matches the supplied voltage signal ie until the analyzer displays 1020 mV Adjusting Electronic Calibration The analyzer can be adjusted if the electronic zero is not correct To align the electronics properly to factory defaults with measurement span of 1020 mV 1 Select CONF in orP Ctr from the menu The center value should be 0 0 If not change the setting to 0 which represents the new center of the measurement span of the analyzer Press SAMPLE to display the ORP readout 2 Zero the input at the high impedance BNC connector normally found on the preamp Refer to drawing D5000080 The measured voltage at TP200 pin 8 of U200 should be at 2 50 VDC um 654 202 Page 39 ELECTRONIC HARDWARE ALIGNMENT IC Controls 3 Adjust the voltage using blue trimpot VR200 until the analyzer display reads mV NOTE There is no electronic span adjustment The input window for ORP is fixed Software Calibration The electronic calibration of the ORP input both the span slope and the offset can be fine tuned using program settings Although the offset can be adjusted electronically it may be easier to adjust the hardware alignment without having to open the case By doing the SLP 1 calibration you can adjust the slope span of the ORP input By doing both the SLP 1 and the SLP 2 calibration you adjust the slope span and a
45. fore 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 acknowledged is displayed Errors are displayed with either a positive sign or a negative sign in front The sign is used to Caution Messages for Alarms indicate an active or unacknowledged error the sign indicates an inactive or acknowledged error Acknowledging the error will change the sign from CA7 6 Alarm A HIGH alarm 7 7 Alarm A LOW alarm Press ENTER to go into edit mode The or sign CA78 Al A DEVIATION al will be flashing Use the Up or Down arrow key to DEAS Error Description change the sign then press ENTER again CA7 9 Alarm A FAULT alarm An acknowledged error message is cleared for one CA8 6 Alarm B HIGH alarm occurrence of the error only If the error reappears CA8 7 Alarm B LOW alarm the sign changes from to and the error message must be acknowledged again CARS Alarm B DEVIATION alarm CAS8 9 Alarm B FAULT alarm Table 2 Messages for Alarms um 654 202 Page 23 ERROR MESSAGES Error and Caution Messages for ORP Error E1 0 E1 2 E1 3 E1 4 E1 5 Page 24 Description ORP measurement is off scale Display shows Err or Err Electrode has not stabilized after 5 minutes of calibration Electrode has stabilized but offset gt 1000 mV The previous offset has been retained Electr
46. greater than or equal to 7 i e CA1 7 through CA1 9 Refer to the Error Messages section for a description of each message If an error has occurred the standardization was not successful the analyzer has kept the values from the last successful calibration Press ENTER to acknowledge the error The analyzer will return to the calibration menu and display the selected standard e g CUSt or 66 Take corrective action and retry the calibration If a potential problem has been detected eg there is a large change in the offset then the analyzer has successfully completed calibration The caution message simply informs the user that poor performance is suspected Press any key to resume normal operation after a warning or error message has appeared To check the new offset that has been calculated press SAMPLE then select orP OFFS from the menu to display the offset in mV for the ORP electrode Selecting a Standard for Calibration For any calibration standard selected the analyzer can be calibrated by selecting CUSt from the calibration menu then entering the ORP in mV of the standard The oxidation reduction potential of most standard solutions is at least somewhat dependent on temperature If the highest accuracy is required the temperature compensated value of the standard should be used The most common ORP standards are buffered pH solutions saturated with quinhydrone and ferrous ferric solutions Two quinhydrone standards
47. he analyzer is necessary However several hardware options are available and if they are changed the program configuration settings need to be set accordingly for the program to function properly Other program adjustments which are normally made infrequently or when installing the analyzer are located in the configuration menu Normally Open or Normally Closed Alarm Contacts The alarm contacts for alarms A and B may be wired as normally open or normally closed default 654 program assumes the alarm contacts are wired normally open normally open alarm contact pump pulser PID AL A contact only time proportional PID AL A contact only input damping sec alarm contact will be inactive if there is no alarm condition and will be active 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 input damping sec CALIBRATE Offset C F Initializing Program Settings Occasionally it may be desirable to reinitialize all of the program s settings to bring them back to defaults Executing the initialization procedure will cause the analyzer to reset all the program variables settings preferences and input calibrations to factory defaults and then proceed with the normal startup display selectable only if se
48. hichever 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 and 45 40 F and 110 F in a non corrosive atmosORPere 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 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 service departm
49. ible to reverse the output or flip the window by reversing the settings of the low and high scale Example Define an output window from 500 mV to 0 mV with 500 mV corresponding to 4 mA output and 0 mV corresponding to 20 mA output Set LO to 500 and set HI to 0 Simulated 4 mA to 20 mA Output Select cur from the menu to display the output current in mA that is presently being transmitted by this output signal The display will be updated as the output signal changes based on the input signal and the program settings From here one 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 To simulate a different 4 mA to 20 mA output signal press ENTER to access 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 menu Units for Outputs The output menu will be using different units for its settings depending on the input selected Select unit from the output menu to display the units in use for this output Output Specifications ORP Temperature Temperature F maximum span 2040 mV default 1000 mV to 1000 mV 5 to 105
50. ibrated This 30 day timer is reset automatically when the analyzer is calibrated Depending on the process the analyzer will need to be calibrated more frequently eg weekly or daily Frequent calibration is especially important if an accurate ORP measurement is required Over time electrode performance will degrade The sensing electrode can become contaminated and dirty and the reference electrode becomes depleted Depending on the harshness of the process the electrodes will need to be replaced after a few months or after several years of use An internal timer has been provided which causes a caution message 1 9 to appear after 12 months of continuous operation The caution messages are removed by following the Replacing Electrodes procedure below Replacing Electrodes When the electrodes have been replaced or serviced perform the following procedure to reset the 30 day and 12 month timers and to return the calibration settings to their default values The offset will be set to 0 0 mV Select orP ELEC rEPL from the menu Press SELECT The display will flash do Press CANCEL to abort the operation or ENTER to reset the timers and to reset the calibration settings the display will change to donE Page 22 www iccontrols com um 654 202 1 Controls ERROR MESSAGES 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
51. in ORP sensor to read temperature select 33P if using option 6 3 access level security partial and or all settings may be protected via 3 and or 4 digit security code Two independent assignable programmable configurable failsafe NO NC alarm relays SPDT Form C rated 10 A 115 V 5 A 230 V PID optional standard pump pulser or time proportional Two continuous assignable programmable 4 mA to 20 mA or 0 mA to 20 mA outputs isolated max load 600 Q Convertible from 1 VDC to 5 VDC or 0 VDC to 5 VDC Via RS485 bidirectional serial data port require IC Net 2000 software es 654 1 3 www iccontrols com um 654 202 IC Controls INSTALLATION INSTALLATION Analyzer Mounting The ORP sensor is typically supplied with at least a 1 5 m 5 foot lead as standard The 654 analyzer should be kept within the sensor lead length and mounted on a wall ideally at eye level Position the analyzer to allow the sensor still connected to the analyzer 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 on Horizontal separation between rows of analyzers should allow for electrode leads which need periodic replacement and the electrical conduit IC Controls recommends a minimum separation of 10 cm 4 in between rows columns As standard the 654 comes with four internal 0 43 cm 0 17 in holes for surface m
52. in sample ie the input that is displayed first when SAMPLE key is pressed can be changed By default the main input is ORP Change the default in CONF in dFLt Refer to the Configuration of Program section for further details StbY Illustration 11 Main menu Page 14 www iccontrols com um 654 202 IC Controls EASY MENU Arrow Keys The four arrow keys on the keypad are used to move around in the menu Example Press SAMPLE to make sure that display is at home base Press the Right arrow key One of the prompts in the column starting with out will be displayed Use the Up or Down arrow keys to display the prompt above or below If the prompt at the top or the bottom is displayed the program will loop around Press the Up or Down key until AL is displayed Press the Left key to return to the sample display Press the Right key again and AL will be displayed 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 Refer to the Alarm Override heading in the Alarm Functions section for a description of these key functions MANUAL ENTER SAMPLE 44 _ AUTO CANCEL SELECT Illustration 12 Analyzer keypad Standby Mode In standby the alarms will not function and the 4 mA to 20 mA outputs will go to 4 00 mA When SAMPLE is pressed the inputs will
53. ion switch OFF OFF Alarms Alarm A Alarm B Input for alarm ORP ORP Alarm function High Low ON OFF switch ON ON Set point 400mV 400 mV Differential 2mV 2mV Global units Metric units temperature in degrees Celsius Alarm contacts Configured normally open Security Not enabled Temperature compensation method for ORP calibration with quinhydrone standards Automatic TC using temperature input Input on off configuration Both the ORP and the temperature inputs are on and will show up in the sample menu Page 50 www iccontrols com um 654 202 IC Controls Appendix D Serial Output Appendix D Serial Output RS485 can be used to send ASCII format serial and temperature default frequency is 60 seconds as a two way communication port for remote operation if an interface format program is available No special software is needed on the computer to receive ASCII data The ASCII data port function can be turned on off and controlled from the internal data log menu both ASCII and serial must be on Data transmitted by the analyzer is in simple ASCII format No special software is needed on the computer to receive the ASCII data only an ASCII terminal program such as Hyperterminal on MS Windows systems The 654 continuous output consists of two data fields containing input values separated by commas Each line of data is terminated by a linefeed newline Comma separated fields make it easy to import
54. ionized rinse water 500 mL A11000192 6P for 6 pack Electrode storage solution 500 mL A1100090 6P for 6 pack Electrode wash solution 500 mL A1100091 6P for 6 pack Gentle scale remover 500 mL A1100094 6P for 6 pack Page 53 Controls DRAWINGS DRAWINGS D5980176 po TL Adel 91108659 5 ul pasn NOILVOO1 LN3NOdNWOO AV 14518 SSW ado JILIL 142 0pouoj 0119490 apnm e8uoag 90 876 933 Ap STOYLNOD 9 aroe 14 E ao Ed a ni m 65 NI ol R68 E en ik 867 oor E 5452 9074514 5 Ka Ca D SSW md 6ZOLSSEN B 8S02E06W en VOTOWIW LTC1535 9en x E o 85 Hd v 0d dW31 9 0d 1 04 40193735 8 40193135 Hd 4 0 91 4 0 SIS 8 wav A8 GDAS EK DAS OWDI 19 um 654 202 www iccontrols com Page 54 261 JO 19945 91055 18000650 um M3AV1 NO 0319001 33V 8074 OL DRAWINGS MO t SNOSN3S 0zf 90Z 193135 GLY WHO 0001 NOILWOOT EN3NOdWOOD 79 gg dE
55. le to the ORP analyzer to minimize any effects of ambient electrical noise interference Flow sensors can be in any orientation but should be mounted tip down at an angle anywhere from 15 degrees above horizontal to vertical 15 degrees above horizontal is best because air bubbles will rise to the top and debris will sink both bypassing the sensor Submersion sensors should not be mounted where a lot of air bubbles rise in the tank they will cause spikes in the ORP readout If an air bubble is allowed to lodge in the sensing tip electrical continuity between the sensitive glass and the silver silver chloride element may be disrupted Sensor Wiring The analyzer requires a model 600 interface or a 6 integral high impedance input some ORP sensors have option 22 a 600 interface on the sensor Illustration 7 shows an analyzer with a 6 integral preamp installed and illustration 8 shows a model 600 interface oye Illustration 7 6 integral high impedance input Illustration 8 Model 600 interface Page 10 www iccontrols com um 654 202 1 Controls INSTALLATION Installation of Model 600 Interface The model 654 requires a remote preamp model 600 interface Refer to drawing D5060286 for interface wiring This drawing provides all the markings and colour codes needed for proper connections to the preamplifier ORP sensor and temperature compensator At the analyzer connect the inputs TB200 ORP TB201 temperature Connecting a
56. lso fine tune the offset by adjusting the value for the center of the input window The factory default is a slope of 10096 which gives an input span or window of 2 x 1020 mV or 2040 mV To calibrate the ORP input by adjusting the slope 1 Connect a voltage supply at the high impedance BNC connector normally found on the preamp Refer to drawing D5900080 2 Select CONF in orP CAL SLP 1 from the menu The displayed value is the required voltage for the first test point You achieve best results by calibrating close to the bottom or top 596 of the scale eg at 900 mV or 900 mV for a 2040 mV span with center point of 0 mV The default value for SLP 1 is 900 mV This value can be changed as needed 3 Supply the specified voltage signal eg 900 mV to the ORP input 4 Press SELECT to display the flashing 40 When the input signal is stable press ENTER to do calibration The analyzer will calculate the slope 5 The slope can be displayed by selecting CONF in orP CAL SLOP from the menu This value can be manually adjusted by going into edit mode The slope can be more accurately calculated and the offset can be adjusted by supplying a second reference voltage In addition to the procedure above 1 Select CONF in orP CAL SLP 2 from the menu The displayed value is the required voltage for the second test point Choose a test point close to the other end of the scale eg at 900 mV if the first te
57. n be used Select CONF in C CAL from the menu A frame showing the current temperature will be displayed Press ENTER then change the displayed temperature to what the temperature should be Press ENTER again to leave edit mode Press SELECT to go to the calibration frame The current temperature will flash When the input is stable press ENTER to set the new temperature The displayed temperature will be adjusted to the specified temperature and the temperature calibration is completed The calculated offset in degrees Celsius or Fahrenheit can be viewed by selecting CONF in C OFFS from the menu By default and whenever the hardware alignment is correct the offset will be 0 0 The offset can also be manually adjusted by editing the offset Calibration of 4 mA to 20 mA Outputs Use one of the following 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 mA to 20 mA Output Self Calibration um 654 202 Page 41 ELECTRONIC HARDWARE ALIGNMENT IC Controls Select cur from the output 1 menu to display the present output current in mA The display will be updated as the output current changes based on the input signal and the program settings To simulate a different 4 mA to 20 mA output signal press ENTER to enter edit mode Use the arrow keys to display the desired output needed for testing the output signal
58. n the digit will loop around to show 9 Numeric values only move to the right one digit If blinking is already at last digit the 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 last character Settings restore the initial value if it was changed Otherwise leaves edit mode without doing anything Edit keys www iccontrols com um 654 202 1 Controls CALIBRATION CALIBRATION Redox electrodes sensing electrode theoretically do not undergo changes of zero point nor of characteristic slope as do glass electrodes used to measure pH Nevertheless incorrect redox potentials can be measured usually caused by contamination or poisoning of the electrode surface or by a change in the reference electrode Calibration is easily accomplished by selecting the proper standard placing the electrode in the standard solution and letting the analyzer do the rest The analyzer tests for electrode stability and performs diagnostic tests during calibration Automatic stability testing takes most of the guesswork out of deciding when a reading is acceptable or not The internal diagnostic tests will activate warning and or error messages if faulty operation is suspected or detected Illustration 15 ORP menu Calibration Procedure Performing a calibration or standardization causes the analyzer to calculate a new offset To start the
59. n use for this alarm The temperature input will use different units depending on whether metric or imperial units are selected for the analyzer The choice between metric or imperial units is made in the configuration menu Refer to the Configuration of Program section in this manual for details The input only uses mV units Wiring and NO NC Contacts The alarm contacts for alarms A and B may be wired as normally open or normally closed By default the analyzer assumes the alarm contacts are wired normally open A normally open alarm contact will be inactive if there is no alarm condition and will be active 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 Refer to illustration 2 for the configuration menu Select CONF from the menu um 654 202 Page 31 ALARM FUNCTIONS IC Controls High or Low Alarm A high alarm is set when the value of the ORP or temperature rises above the set point and is cleared when the ORP or temperature drops to below the set point minus the differential refer to illustration 24 A low alarm is set when the value of the ORP or temperature drops below the set point and is cleared when the ORP or temperature rises to above the set point plus the differential refer to illustration 23 The differential has the effect of setting the
60. nd connection is not made published specifications may not be achieved Supply wiring terminals are designed for 14 AWG conductors Supply should be protected by an external 15 A branch circuit CSA certified 12 inch liquid Illustration 6 Power wiring tight fittings should be used to maintain the IP65 rating Caution Bonding between conduit connections is not automatic and must be provided as part of the installation Caution Signal wiring connected in this box must be rated at least 300 V The basic wiring scheme for all IC Controls sensors is shown in drawing D5900081 For alarm RS485 or output wiring refer to the alarm serial communications or output section um 654 202 Page 9 INSTALLATION 1 Controls There are three 2 0 cm 0 875 in holes for 0 5 inch conduit in the bottom of the enclosure IC Controls recommends that AC be brought in through the right hand entrance for power and alarms 4 mA to 20 mA and digital low voltage wiring be brought in through the center entrance and sensor leads be passed through the left hand entrance Conduit should be flexible watertight and sealed using a gasket to maintain environmental integrity within the enclosure Connect the two relay alarm contacts Alarm A contact TB300 Alarm B contact TB301 Connect the two isolated 4 mA to 20 mA outputs Output 1 contact TB303 Output 2 contact TB304 Sensor Mounting It is recommended that the sensor be located as near as possib
61. o that the characterization is continuous 96 characterized output B 8 8 8 of the two outputs has its own independent EE characterization capability This makes it possible to uncharacterized output define a different behavior for each output Illustration 18 Characterization of ball valve Characterization Example Tri linear output The basic functionality of the output characterization can best be described by way of an example Goal to record the ORP input between 1000 mV and 1000 mV but give 80 of the scale to the area between 200 mV and 200 mV The purpose of this arrangement is to give maximum recorder resolution to the main area of interest which is 200 mV to 200 mV yet still maintain a record of the times that the ORP would go out of this region If output characterization were not available one could still set LO and HI to 1000 mV and 1000 mV respectively but the area of interest from 200 mV to 200 mV would occupy only 20 at the center of the scale To correct this problem the center of the scale will be expanded and the outside areas will be shrunk To achieve the desired output characterization the 21 point characterization table and the high and low settings need to be defined as follows 1 Set the boundaries for ORP output which are LO 1000 mV HI 2 1000 mV The characterization ta
62. off ORP Oxidation Reduction Potential The potential developed by a metallic electrode when placed in a solution containing a species in two different oxidation states Oxidation The loss of electrons by a molecule or ion RAM Random Access Memory Memory in a 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 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 C regardless of actual solution temperature Redox Reaction A chemical reaction involving transfer of electrons from one element to another One element is being oxidized another 15 being reduced Reduction The gain of electrons by a molecule or ion um 654 202 Page 45 Appendix A Security IC Controls Appendix A Security 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 Having sec
63. olumn in the table has been completed enter the table values in the program Select tbL from the output menu then enter each output value 21 points must be entered it is not possible to skip values The completed table for the example is shown in Table 4 7 activate output characterization set CHAr in the output menu to on Tri linear Output Characterization uncharacterized ORP mV 1000 LO 200 0 200 1000 HI 100 1000 90 200 80 70 60 50 0 40 30 E characterized output out Aw 20 10 0 10 20 30 40 50 60 70 80 90 100 uncharacterized output in Illustration 19 Tri linear output characterization 200 Page 28 www iccontrols com um 654 202 IC Controls 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 654 202 4 00 4 80 5 60 6 40 7 20 8 00 8 80 9 60 10 40 11 20 12 00 12 80 13 60 14 40 15 20 16 00 16 80 17 60 18 40 19 20 20 00 1000 900 800 700 600 500 400 300 200 100 0 100 200 300 400 500 600 700 800 900 b 1000 OUTPUT SIGNALS 4 00 4 20 4 40 4 60 4 80 5 00 5 20 5 40 5 60 8 80 12 00 15 20 18 40 18 60 18 80 19 00 19 20 19 40 19 60 19 80 20 00 Table 4 Analyzer table values for tri linear o
64. onic calibration error offset Electronic calibration error gain Temperature compensator is off scale when calibrating using temperature compensated quinhydrone standards Causes ORP measurement is too low or too high and is outside of analyzer measuring range Input window for ORP input needs to be shifted Default input range is 1000 mV to 1000 mV Sensing element is dirty Wrong reference electrode Large offset in electrode pair Wrong standard specified for calibration Electrode not connected Calibration points are too close to calculate accurate gain Previous settings retained Calculated gain is outside of 70 to 130 range Previous gain retained TC is not connected Standard is outside of TC operating range of 5 to 105 www iccontrols com IC Controls Solutions Verify the process and check connections Service or replace electrode if necessary Shift the ORP input window up or down by making electronic alignment and program adjustments Refer to the Program Configuration section Polish sensing element Refer to the electrode instruction manual or to the setup procedures in this manual Check electrode connections Perform electrode maintenance Refer to the electrode manual Use a different ORP standard Specify the correct ORP value for the standard and redo the calibration Check electrode connections and redo the calibration
65. or general performance place the sensor in 66 mV standard The display should read approximately 66 mV 7 Before placing the analyzer into operation verify settings to ensure that they coincide with the intended setup Refer to Appendix C Default Settings section 8 For the 4 mA to 20 mA output set high limit and low limit 9 Set preference for temperature units as or F in CONF unit 10 Install password security if desired 11 The unit is now ready for field installation um 654 202 Page 11 INSTALLATION 1 Controls 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 to the receiver Move the meter aw
66. or has an installed TC The measurement itself however is not temperature compensated During normal measurement the temperature reading has no effect on the ORP reading displayed by the analyzer Temperature correction of the ORP reading is used only when a calibration is performed with one of the quinhydrone ORP standards If a TC is in the sensor the microprocessor looks up the temperature corrected mV from an internal table The temperature probe can read temperatures from 5 to 105 The process temperature can be displayed directly by displaying the temperature input in the sample menu at the left hand side of the menu refer to page 3 Note that the sample menu always shows the temperature of the process regardless of whether manual or automatic temperature compensation has been set for calibrations To determine the current setting of the temperature compensator select orP CAL tc from the menu If Auto is displayed automatic temperature compensation is used for calibrations if SEt is displayed a manual set point is used for calibrations using 66 mV or 263 mV quinhydrone standards The TC setting is located within the CAL menu because temperature compensation is not used except during calibrations Selecting Manual Temperature Compensation Press SAMPLE to display the ORP reading then select ORP CAL tc from the menu At this point either Auto automatic temperature compensation or SEt manu
67. ou 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 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 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 ENTER 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 ENTER PASSWORD PASSWORD YES 2 ENTERED PASSWORD YES 1 ENTERED 0000 55 ACCESS ACCESS ACCESS LEVEL 0 LEVEL 0 LEVEL 1 LEVEL VIEW ONLY VIEW ONLY OPERATOR COMPLETE DISPLAY DISPLAY DISPLAY DI
68. ounting screws spaced 18 8 cm 7 41 in wide and 8 8 cm 3 47 in high Case dimensions are 20 cm x 12 cm x 7 5 cm w h d or 7 87 in x 4 72 in x 2 75 in w h d as shown on drawing D4830022 Pipe mounting kit option 8 for 5 cm 2 in pipe P N A2500255 is shown on drawing D4950053 It may also be used to surface mount the analyzer by removing the 2 inch U bolts and using the holes in the mounting plate for wall studs using customer supplied studs The mounting plate dimensions are 20 3 cm x 21 6 cm 8 in x 8 5 in with elongated U bolt holes Panel mounting kit option 9 P N A2500201 is shown on drawing D4950054 It requires a customer supplied panel cut out 20 6 cm 8 1 in wide x 12 2 cm 4 8 in high with two 0 4 cm 0 15 in screw holes centered 22 6 cm 8 9 in apart and 6 1 cm 2 4 in below top of cutout The panel bezel dimensions are 24 1 cm x 15 9 cm 9 5 in x 6 25 in Wiring Power for the 654 analyzer is 115 230 VAC x 10 single phase 50 60 Hz and 0 25 A Caution Line voltage selector switch must be set prior to applying power for either 115 VAC or 230 VAC Power connections are made at 400 inside the instrument enclosure refer to illustration 6 and drawing D5900081 The microprocessor requires a suitable ground to ensure stable operation power line with the third wire s connected to earth ground should be adequate however a EE ud local earth rod may prove more fitting If this grou
69. re operable and field wiring is in place Calibration of ORP Input Both the ORP and the temperature inputs can be calibrated both by making electronic adjustments and or by having the program compensate for differences in span or offset Both procedures are described here Before calibrating the ORP input the quality of the electronic calibration can easily be determined by supplying the ORP input with a known voltage and comparing this voltage with the displayed mV value Input Range Adjustment for ORP The voltage range the analyzer is capable of measuring is fixed at about 2040 mV This is adequate for measuring between 1020 mV and 1020 mV with about a 1 mV resolution Although the span is fixed the center of the input range or input window which is normally at 0 0 mV can be shifted up or down up to 1000 mV if so desired Both the electronics and the program setting for the center of the input window need to be adjusted for the analyzer to read correctly Example Change the input window to have the analyzer read from 0 mV to 2040 mV 1 Select CONF in orP Ctr from the menu Go into edit mode and change the setting to 1020 which represents the new center of the measurement span of the analyzer Press SAMPLE to display the ORP readout 2 Connect a voltage supply at the high impedance BNC connector normally found on the preamp Refer to drawing D5900080 Supply a signal of 1020 mV to match the new center of the measurem
70. rone e EE 21 Selecting Manual Temperature Compensation 21 Manual Adjustment of 21 Output Hold During Calibration 22 Electrode Mamtenanee 22 Replacing 22 ERROR MESSAQGES eere tenente 23 Acknowledging an Error 23 Error and Caution Messages for ORP 24 Messages for Temperature Input 25 1 Controls OUTPUT SIGNALS e eeeeeeeeee tenente enata 26 Reversing the 4 mA to 20 mA Output 26 Simulated 4 mA to 20 mA Output 26 Units for 26 Output Specifications 26 Output Characterization esses 21 Characterization Example Tri linear output 27 ALARM FUNCTIONS e eeeeeeee eene tnt tnen 30 Use of Relay 30 Alarm Indication esee 30 Alarm Overde 31 Delayed Relay 31 Units for Alarms esee 31 Wiring and NO NC Contacts 31 High or Low Alarm eee 32 Deviation 32 Fault nte 32 Using Alarms for On Off Control 33 CONFIGURATION OF PROGRAM
71. show StbY The analyzer will not resume normal operations until the analyzer is taken out of standby While in standby the entire menu and all of the 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 YES StbY Illustration 13 Standby menu um 654 202 Page 15 MENU Controls Temperature or F By default analyzer will use metric units This means that temperature will be displayed using degrees Celsius and that the prompt for the temperature input will be The analyzer can also use imperial units For imperial units temperature will be displayed using degrees Fahrenheit and the prompt for the first temperature input will be F instead of In this instruction manual the temperature input is always identified as C throughout the menus To select imperial units for the analyzer select unit from the configuration menu then go into edit mode and change the C setting to F Real Time Clock The analyzer clock is used for internal date time stamping of system events and the internal data log Both the system events and the internal data log are accessed using the IC Net Intelligent Access Program which is available as option 35 Analyzers purchased with option 34 have a real time clock which will maintain the correct time and date ev
72. st point was at 900 mV The default value for SLP 2 is 900 mV This value can be changed as needed 2 Supply the specified voltage signal eg 900 mV to the ORP input 3 Press SELECT to display the flashing do When the input signal is stable press ENTER to do the calibration The analyzer will calculate the slope using both test points and also adjusts the center of scale value 4 The calculated center of scale value can be displayed by selecting CONF in orP ctr from the menu This value can be manually adjusted by going into edit mode 5 The calculated slope can be displayed by selecting CONF in orP CAL SLOP from the menu This value can be manually adjusted by going into edit mode Page 40 www iccontrols com um 654 202 IC Controls ELECTRONIC HARDWARE ALIGNMENT 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 Both procedures are described here Before calibrating the temperature input the quality of the calibration can easily be determined by supplying the temperature input with a known temperature and comparing this temperature with the temperature display The temperature input of the 654 microprocessor analyzer requires option 33 or 33P in the sensor The 654 analyzer is configured at the factory for use with 33 TC option by selecting J204 to J207 for micro TC operation J204
73. t when anything goes wrong with that input Something is wrong with an input if the input is off scale or an unacknowledged error message exists for that input Caution messages do not cause a fault alarm To use an alarm as a fault alarm select FUNC from the alarm menu then select Flt To enable the alarm make sure the on off switch is set to on Also set the input in the alarm menu to the desired input either ORP or temperature The set point and differential for the alarm have no effect when the alarm is used as a fault alarm Page 32 www iccontrols com um 654 202 IC Controls ALARM FUNCTIONS Using Alarms for On Off Control The alarms can also be used for process control the alarm contacts will then function as on off signals for switches controlling a valve pump motor etc The set point 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 Examples of high and low control using the alarms are shown in the illustrations below HIGH CONTROL 1 2 A 2 1 differential 8 8 time time Illustration 25 High control Illustration 26 Low control um 654 202 Page 33 CONFIGURATION OF PROGRAM IC Controls CONFIGURATION OF PROGRAM The 654 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 t
74. tending to a problem the alarms can be switched to manual override using the MANUAL key In AUTO mode the green AUTO LED is on and the analyzer alarms will activate and deactivate the relay contact as programmed Press the MANUAL key to temporarily deactivate the alarm contacts In MANUAL mode the green AUTO LED will blink The relay contacts are deactivated but OFF Q alarms OFF or the alarm LEDs continue to indicate alarm author T STANDBY mode condition s Press the AUTO key to return to AUTO mode immediately and reactivate the relays If no key is pressed for 15 minutes the 15 minute timeout will return the alarms to ON AUTO mode AUTO mode BLINK mode z Illustration 22 Alarm override status AUTO LED Delayed Relay Activation Alarm relay activation by default is immediate upon alarm condition Alarm relay activation may be delayed Activation delay gives the operator a chance to correct alarm situations before the relay contacts activate or can eliminate alarms based on temporary or spurious changes in the process The delay time is programmable by the operator To change or view the delay time select ALAY from the alarm menu The default value of 0 seconds is for immediate contact activation The delay time can be set from 0 s to 9999 s Units for Alarms The alarm module will be using different units for its settings depending on the input selected Select unit from the alarm menu to display the units i
75. the electrode pair the ORP and or the reference electrode Lack of response can also be caused by a failed or poorly functioning reference electrode due to drying out or depletion 3 If the sensor passes the tests The sensor is good Place the sensor back in the loop and then calibrate following the calibration instructions in this manual 4 If the sensor fails the tests a Replace the ORP sensor b Consider returning the sensor to IC Controls for failure analysis if you think that electrode life was short IC Controls offers a free cause of failure and application analysis that may help you get longer sensor life Page 38 www iccontrols com um 654 202 IC Controls ELECTRONIC HARDWARE ALIGNMENT ELECTRONIC HARDWARE ALIGNMENT The electronics goes through factory alignment to set up default condition It should not normally be necessary to make any field adjustments make things easy for the instrument maintenance mechanic however IC CONTROLS designed electronic zero and span adjustments This allows the user the final say on setting and or the ability to re range the instrument to his particular requirements Devices referred to in the following descriptions are shown on component location drawings D5900081 Proper field wiring for hookup is shown on drawing D5900080 These instructions assume 115 VAC or 230 VAC power is hooked up that the voltage select switch is set to 115 V or 230 V operation the analyzer electronics a
76. the sensor to the analyzer and then turn on the power The analyzer will go through its automatic startup procedure any time power to the analyzer is lost for more than a few seconds The startup procedure will initialize the analyzer program perform error checks and then proceeds to display the ORP reading and function normally program settings calibration settings and default values will have been retained by the analyzer as the memory has battery backup Analyzer Startup Test 1 Install the analyzer according to the instructions in the Installation section Verify power supply has been wired for proper voltage and instrument is suitably grounded 2 Turn on flow at sample inlet or insert sensor in sample 3 Power up the analyzer 4 The startup procedure will begin by alternately flashing tESt and while performing memory tests 5 The analyzer will display in sequence the analyzer model number in this case 654 and the program version number eg 2 02 6 The display test lights each of the implemented display segments in turn At the same time each of the LEDs will be lighted in turn 7 If the analyzer passes all the tests then the hardware is functioning properly and the analyzer will proceed to display the ORP reading 8 If the analyzer displays Err this indicates that the input is off scale The error LED will be lighted as long as an input is off scale An off scale error can indicate that th
77. ur and one half LCD digits 1 5 cm 0 6 in displays for ORP temperature error codes prompts and diagnostic information back lit display optional ORP 2 020 mV to 42 020 mV Temperature 5 0 to 105 23 0 to 221 F 8 pushbutton entry keys 2 alarms A and B 1 auto 1 error 12 0 x 20 0 W x 7 5 cm D 4 7 in H x 7 9 in W x 3 0 in D 1 1 kg 2 5 Ib 2 3 kg 5 0 Ib 30cm x 23 cm x 23 cm 12 in x 9 in x 9 in Environmental Data CHARACTERISTIC Operational 5 0 to 45 41 0 F to 113 F Storage 10 0 C to 55 14 0 F to 131 F Relative Humidity 95 maximum non condensing Housing IP65 Nema 4X Pollution Degree 2 Installation Category II 115 230 VAC 0 25 A 50 60 Hz 115 230 VAC 10 50 W es 654 1 3 Page 7 INTRODUCTION Specifications PROPERTY Accuracy Precision Response Time Temperature Compensation Preamplifier Security Alarms Controls Outputs Communication Page 8 IC Controls Operational Data CHARACTERISTIC ORP 0 5 of ORP range Temperature 0 1 ORP 1 digit 1 0 mV Temperature 1 digit 0 1 C 9090 within 5 s default function of flow and temperature Damping adjustment 3 s to 99 s Auto 5 0 C to 105 C 23 0 F to 221 F Manual 5 0 C to 105 C 23 0 F to 221 F Require model 600 interface OR integral preamp option 6 within 100 ft maximum Require TC option 33
78. urity disabled gives the user the same access to the program as being at access level 2 at all times With security enabled anyone can view settings anywhere in the program When you do not have proper access rights the program will display 0 View only access to all settings PASS for 2 seconds indicating that a proper 1 Access to all settings except for password must be entered before being allowed to configuration menu Usage operator access no changes can be made to proceed configuration and passwords cannot This appendix contains instructions for setting be changed passwords in the configuration section of the menu 2 Access to all settings This gives the Daily usage of the analyzer by the operator does not same program access as when password security is not enabled Passwords can be changed Usage installation management require knowledge of setting passwords in the configuration section since all passwords are entered by selecting PASS directly from the main menu Table 5 Security access levels ENTERING A PASSWORD 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 ENTER 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 illustration 30 to determine ho
79. utput characterization example Page 29 ALARM FUNCTIONS IC Controls ALARM FUNCTIONS Two alarms alarm and alarm B are a standard feature 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 independently of each other Either alarm can monitor the ORP or the temperature input Each alarm features an adjustable set point user selectable alarm type adjustable differential also called hysteresis and an on off switch The alarm types which are available are high low deviation and fault Use of Relay Contacts By default the relay contacts will be used to indicate alarm conditions If there is an alarm condition for either alarm then the alarm will be indicated using both the alarm LED and the alarm contact This usage of the alarm contacts is selected by setting CONF list ae AL AL A FUNC to AL While nue another use is selected for the relay LALA display units used by unit contacts alarm cannot AL b mm output based Input simultaneously use the contact however the alarm function continues using the LED display messages and serial communication ON OF arc p GA Differential j Delayed alarm activation sec SE ki Setpoint kk Analyzers with PID option can also use the relay contacts for pump pulser or time proportional control In this
80. w 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 15 minute timeout will also return to display 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 main menu then pressing ENTER with 0000 displayed ENABLING PASSWORD 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 arrow keys to change the display to the desired password for level 2 You can press SAMPLE at any time to safely cancel password entry Press ENTER 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 Page 46 www iccontrols com um 654 202 IC Controls Appendix A Security Level 1 At this point password 1 is still 000 Y
81. wer turned off check if your analyzer has a real time clock chip select CONF rtc 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 real time clock maintained by the analyzer but the time and date will need to be adjusted each time the analyzer loses power Effectively the analyzer date time clock stops and continues where it left off when it is powered down if it does not have the 34 option 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 Input Damping The ORP and temperature measurements can be damped to provide the user with a means to alleviate rapidly varying or noisy signals The available damping range is 3 s to 99 s with 0 there would be no damping and each reading the analyzer made would be used to directly update the display and 4 mA to 20 mA output The factory default of 5 s adds the next four seconds worth of readings to the first and divides by five this provides a fast response Selecting 99 s adds the readings for 99 s and divides by 99 providing smooth damping out of turbulent readings Any selection between 3 s and 99 s can be made Select CONF in from the menu Use the up or down arrow key to select the input to be adjusted then select the dA frame Press ENTER to edit
82. were Home Base Press Sample From anywhere in the menu the SAMPLE key can be used to return to displaying ORP The program will safely abort whatever it was doing at the time and return to displaying the ORP reading SAMPLE The ORP display is the default sample display for the analyzer The analyzer s inputs and temperature 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 Illustration 10 Home base Main Menu Display Features a 2 1 The analyzer has a builtin timer which returns program to orP displaying ORP if no key is pressed for 15 minutes This time out has e same effect as pressing SAMPLE key If security has been Err enabled then time out will change access level back to 0 or 1 automatically which gives the user read only access The user will have to enter an appropriate password to go to a higher access level When the sample value is displayed pressing the Left arrow key will show which of ORP or temperature is displayed Pressing Right arrow key displays the sample reading again gt n N SEr 3 Each input can be turned off and thereby effectively disappear from CONF menu if it is turned off in configuration menu To change configuration refer to the Configuration of Program section PASS 4 The ma
83. when buffer full number of data points currently in buffer clear the buffer deleting all data points p Simultaneous serial ASCII output of all inputs No ASCII serial output internal data log menu while logging orP input being logged 60 frequency of log update in seconds continue logging overwriting oldest data stop logging when buffer full number of data points currently in buffer Simultaneous serial ASCII output of all inputs No ASCII serial output Illustration 4 Internal data log menu Ed d 1200 2400 4800 r4 E A m wo N N w 2 P Illustration 5 Serial menu um 654 202 Page 5 INTRODUCTION 1 Controls INTRODUCTION The model 654 is IC Controls industrial quality remote operational ORP analyzer designed to give maximum flexibility reliability and ease of use The model 654 is shipped from the factory with the input calibrated for measuring 1 000 mV to 1 000 mV and the output for 4 mA to 20 mA Calibration should not be required It has two isolated 4 mA to 20 mA outputs two 10 A SPDT relays plus a serial communication port The analyzer recognizes specific ORP standards to auto calibrate holds output during calibration notifies user of diagnosed sensor or analyzer faults plus stores in memory the last 12 calibration records 1 000 minute measurement trend alarms power outages and diagnostic messages all date and time stamped
84. y there is no way for the analyzer to verify the accuracy of the adjustments made IC Controls advises that the operator use the regular calibration procedures whenever possible um 654 202 Page 21 CALIBRATION Controls Output Hold During Calibration The analyzer features an automatic output hold During calibration ie as soon as SELECT is pressed when CAL is displayed both 4 mA to 20 mA output signals are frozen at their current levels and the alarms are temporarily disabled The output hold feature avoids false alarms and erratic signal output caused by a routine calibration If the output signal for ORP is not acceptable at the value found it can be changed for the duration of the calibration Select Hold from the calibration menu to display the ORP value used by the analyzer to determine the output signal Use the normal editing procedure to change the ORP value used for output hold The output hold remains in effect for the duration of the calibration that is the output hold is disabled when the CAL prompt is displayed the SAMPLE key is pressed or after no key has been pressed for 15 minutes Electrode Maintenance The electrodes need to be calibrated periodically to maintain an accurate ORP measurement An internal timer keeps track of the time since the electrodes were last standardized or calibrated After 30days a warning message 1 8 will appear warning the user that the electrodes need to cal

USER MANUAL MODEL 654 MICROPROCESSOR

Contents

Download Pdf Manuals

Related Search

Related Contents