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User Manual - IC Controls

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1. 37 Calibration of 4 to 20 mA Outputs 39 Testing of Relay Outputs 39 Display Prompts 40 Glossary 41 Installation 42 WING 2 dace Ross 42 Configuration of Program 43 Appendix A Installation Summary 46 Appendix B Enabling Security 47 Appendix C Unit Conversion 48 Appendix D Saturated DO Values 49 Appendix E Default Settings 50 Appendix F Data Capture 51 Appendix G Ordering Information Parts List 53 Appendix H Dissolved Oxygen Solutions 54 Drawings 4 RR Ro ERU 55 Display Schematic 55 Microprocessor Board Schematic 56 Microprocessor Board Component Location 57 D O and Temperature Input Schematic 58 Current Output and Alarms Schematic 59 Power Supply Schematic 60 Wiring and Component Location 61 800 Interface 62 Mounting Dimensions 63 2 Pipe Wall Mounting Kit 64 Panel Mounting Kit 65 Index vus UR Eun 66 Industrial Products Warranty 68 Page 3 856 Menu Figure 1 Main menu Page 4 display home base SAMPLE IC CONTROLS CALIBRATE 1 ppm DO main menu set 25 0 e Laut
2. Tip Retainer Figure 20 Step 3 Inserting Membrane Module 4 Flush the coils of the electrode with electrolyte solution Then holding the electrode cap with membrane module installed in an upright position fill with electrolyte until the center cavity is full Tilt at about 30 and add an extra 1 8 inch of electrolyte observing that the crack around the membrane module fills with electrolyte 5 Next hold the cap like a cup Figure 21 and slowly lower the electrode coils vertically down into the cap until the threads touch Rotate the sensor body untill you can see the flat area through the threads Slowly rotate the cap on allowing the excess electrolyte and bubbles to overflow up the flat Continue to slowly rotate the cap until a firm stop is reached CAUTION donot force the cap beyond the stop The parts are plastic and can break 6 Dry the D O sensor and blot the tip Examine the tip the membrane should be smooth with no wrinkles or cuts and the surface contours of the gold electrode should be clear There should be no lines from trapped bubbles between the membrane and the silver electrode If there are no visible problems as described here then the D O sensor is ready to be put into service 856 Instructions Sensor Maintenance Inserting D O Sensor in the Twist Lock Fitting 1 Inspect the inside of the twist lock fitting for any foreign matter and wipe out any dirt which may be inside I
3. this is a global setting both the units used for temperature and for pressure will change Factory Defaults Re initalizing All Settings Oc casionally 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 and settings to factory defaults and then proceed with the normal startup display The initialization procedure is not to be used unless you are absolutely sure that you want to restore the analyzer to factory default configuration After the analyzer program 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 Select CONF init ALL from the menu The display will flash do Nothing will happen if at this point you press Cancel or Sample The analyzer will be re initialized when the user presses Enter 856 Instructions IC CONTROLS Installation Password Security As part of the installation procedure you need to decide whether password security is to be implemented or not The factory default is no security No password security should be necessary if you are the only user and no protection of settings is needed Password security should be implemented for critical
4. 20 mA output ASCII serial output log Baud rate for serial communications use metric units First temperature input in degrees Celsius Second temperature input in degrees Celsius Calibrate Membrane Compensation Factor Chip Is this analyzer equipped with a real time clock chip Clear the internal data log Normally closed alarm contact Configuration of program Continue internal data log when buffer full Signal output in mA or current Date Real time clock setting for day of the month 1 31 Day of the week Set default for main sample Deviation alarm First dissolved oxygen input Second dissolved oxygen input Reset clear action has been taken D O cell efficiency constant as efficiency Adjusted by calibration Error or warning number RAM checksum failed Some settings may be lost Temperature in degrees Farenheit use imperial units First temperature input in Farenheit Second temperature input in Farenheit Fast response membrane Fault alarm Frequency of internal data log updates in seconds Full What to do when internal data log is full continue logging or stop High alarm high limit 20 mA for 4 20 mA output window Output hold Page 40 kPa LO nodE NO NC OFF OFFS on ON OF onth OPEN out out 1 out 2 PAS 1 PAS 2 PASS PPb PrES PSI rANG rES rnG rNG n r
5. 810865 ewe 83ZA VMV 9S8 I1CLVI G000ScV 3lNI 008 ONISIA 311IL vopouoj 0 450 0 3 36 952 86 6I II 233 4p Wwe Vu C 988 008 Y CHS E CXIIV 9l 185 E ND2 Ea NJE v o E LHM CA El CA CX 192 CVI0 2 Ede CC 142 T GA dw3l 3 20 T dw3i 8 TOC 13 M43 I 3 3 MLI 1 0281 20281 Toeg1 0028 1 968 LNAWNALSNI ass39UusdDa23IWN BNISN ANIWA 135 ANY 21 TWANWW L 313 21 OLAV 3AVH LON S300 NOSN3S V ASN 3anifid ADA JAVYS 3ADN3S 9l AWWNG WHO OOTT HLIM G3ddIHS 3N3ZA WNV Y L000026V Nd SV STOSLNOD OI 3 18V IIVAV 9666 N31138 318V2 Q30N3AWOD233 03I1 s3W4nisno Y WHO 000 SI 21 V SALON e s G o I 3 LAdLNO LAdNI TI XOH ALONAY Sa 55 5 30151 0 NO G I3HS 338 NO 0 IC SIN3 318v2 NUSN3S U d I3NNI dOSNuUS 856 Instructions Page 62 IC CONTROLS Drawings Mounting Dimensions 7 8740 20 1700 2 0000 r 2 0000 20 8750 dote CONTROLS dr Orangeville Ontario Canada chk TTLE MOUNTING app DIMENSIONS Iscole Isheet of 856 Instructions Page 63 Drawings 2 Pipe Wall Mounting Kit IC CONTROLS Page 64 oy dote IC
6. CONTROLS sac 10 13 00 Orangeville Ontario Canada chk TITLE 2 PIPE WALL MOUNTING KIT 630 652 655 ETC d E CPOE mE scale sheet of 1 2 856 Instructions IC CONTROLS Drawings Panel Mounting Kit 9 5000 8 9000 BEZEL C 2 40 6 2500 LIO 4 N NOTES 1 PANEL CUTOUT 810W X 4 80H INCH 2 TWO SCREW HOLES APROX 015 DIA AT SIDES 2 40 FROM TOP OF CUTOUT CENTERED 8 90 INCH APART 3 MOUNTING SCREWS 6 32 fee pate C CONTROLS dr 9 01 95 Orangeville Ontario Canada ETE RENI aE CC PANEL MOUNTING KIT 655 455 ETC code dwg 44950054 scole Sheet CL 1 0 856 Instructions Page 65 Index Index 4 Err 6 sign 19 sign 19 37 option 32 4 20 SEE output signals Acknowledging error messages 19 Alarms 28 caution number 28 differential 28 fault alarm 28 function 28 indication of 28 30 on off switch 28 output hold 18 relays 39 sensitivity of 30 setpoint 28 two stage 30 units 29 use of contacts 26 wiring 30 ASCII 51 AUTO key 29 Automatic temperature compensation selecting 16 Calibration 49 D O 15 history log 35 output hold 18 retrieving history log 35 temperature input circuit 38 troubleshooting 37 zero oxygen standard 15 Calibration records SEE ALSO description Caution 7 x 21 29 Caution 8 x 21 29 Compensa
7. applications where program settings may only be changed by authorized personnel For minimal security IC CONTROLS advises that the user set a level 2 password Leaving the level 1 password at 000 gives the operator complete access to all areas of the program but does not allow him to change program settings in the configuration menu With minimal security in place you prevent unauthorized users from enabling password security Appendix B describes how to enable or disable security This appendix can be removed from the instruction manual before it is made available to the operator Real Time Clock The analyzer maintains an internal date time clock 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 Intelligence Access Program which is available as an option Analyzers purchased with a 34 option are equipped with a real time clock which will maintain the correct time and date even with the analyzer power turned off To 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 l
8. as an option with this analyzer With this program you can do real time recording access of analyzer internal datalog access analyzer calibration records and event tags and more The analyzer can be networked using the RS485 serial port built into the analyzer Refer to the IC Net documentation for further details The RS485 port can also be used as a data port to send conductivity temperature and auto range number default freqency is 60 seconds or as a two way communication port for remote operation if an interface format program is available 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 The 856 analyzer uses 8 data bits no parity 1 stop bit and 9600 baud Data transmitted by the analyzer is in simple ASCII format No special software is needed on the computer to receive the ASCII data The 856 continuous output consists of four data fields separated by commas Each line of data is terminated by a linefeed newline Comma separated fields are designed to make it easy to import the data into other programs for analysis for example into a spreadsheet see Appendix F You can also use the RS485 to send ASCII format serial D O temperature and auto range number Default frequency is 60 seconds 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 Interna
9. calibration errors that may cause all readings to be off by as much as 2 96 Atmospheric pressure is affected by altitude and weather conditions Refer to figure 18 as a guideline for adjusting pressure compensation for altitude Setting Manual Pressure Compensation Select d o Pr C from the menu The pressure setting to be used for manual pressure compensation will be displayed 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 key to display the desired pressure for manual pressure compensation Press ENTER to accept the displayed value When metric units are selected the default pressure is displayed in kPa When imperial units are selected PSI are used 856 Instructions Calibration Calibration Procedure When executing the calibration procedure the analyzer will adjust the efficiency constant for the D O cell Each D O input D O 1 and D O 2 is calibrated individually Before doing the calibration procedure take the D O sensor that needs to be calibrated and suspend it above water Select d o 1 CAL or d o 2 CAL from the menu The analyzer will show the D O reading using ppm units The display will be blinking to indicate that the analyzer is calibrating and testing for stability The calibration is automatic from here on As soon as the sensor reading has stabilized sufficie
10. data wires at other end P N A2500192 Installation 1 It is good practice to first turn off the analyzer before connecting a serial cable 2 Bring the RS485 cable into the analyzer through the centre hole Wire the RS485 cable into the terminal block TB1 located on the display board Connect the black to terminal B red to terminal A and the clear to EARTH 3 Connect the converter to a free COM port on your laptop computer 4 nsert the cable s RJ11 connector into the converter Making a Custom Cable A cable has been provided with the adapter If this cable is not long enough use the following information to create your own cable Connect shield at one end only Converter Signal RJ11 Pin Number DATA A 2 DATA B 5 Signal Ground 4 IC CONTROLS INTELLIGENT ANALYZER EARTH 1 pu Jack End Ru 11 Plug End Fut 96 Conductor Page 33 IC Net Features Internal Data Log The 856 analyzer will log more than 1000 data points in its internal memory storing readings at specified intervals by default once a minute The analyzer will log data and store the readings internally At once a minute the internal log will have the last 16 hour of measurement trend Later if there is an upset the logged readings can be downloaded using the Net Advanced Intelligence Access program for analysis ond or documentation record The user can select how frequently
11. pin2 to SERIAL O P in the analyzer Connect pin3 to SERIAL I P in the analyzer Connect pin 5 to SIGNAL COM in the analyzer Connect earth or shield at one end only 856 Instructions IC CONTROLS 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 is 9600 5 To enable serial transmission by the analyzer set the serial ON OFF switch to ON 6 Select the node number of the analyzer The default number is 1 If multiple analyzers are networked each analyzer needs a unique node number Figure 34 Port powered RS232 to RS485 converter Wut gt gt Zt 4 t A duree Si m UTI Figure 35 RS485 analyzer wiring 856 Instructions IC Net Features Portable Laptop Hookup RS232 to RS485 Converter The A7900015 is a port powered half duplex RS232 to RS485 converter The unit supports two wire RS485 communications The converter handles the enabling and disabling of the transmitter This works regardless of the operating system or program you are running The RS232 side has a 889 female connector The RS485 side has a six position RJ11 connector Material List RS232 to RS485 converter P N A7900015 10 foot cable with RJ11 connector at one end and
12. recall factors leading to upset conditions that require digital communication for access It keeps track of calibrations their date and results upset events such as power outages alarms and also logs into its memory a running history of 1000 plus D O or temperature readings Serial communications give the analyzer the ability to communicate with a computer running an IC Net Advanced Intelligence Access program The IC Net software is available as an option with this analyzer With this program you can do digital real time recording access the analyzer s internal sample trend history log access analyzer calibration records and event tags and more The analyzer can be networked using the RS485 serial port built into the analyzer Refer to the Net documentation for further details 1298 ov be ei eter 10 856 Instructions IC CONTROLS Security The 856 has a built in password protection system This security system is disabled by default If password protection is not enabled then you have unrestricted access to all analyzer settings available through the menu as described in this manual and you can safely ignore this section Having security disabled gives you the same access 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 righ
13. the trimpot to a reading of 3 00V at TP200 while inputing 0 160VDC through a 100 K 196 resistor 0 160 VDC simulates 8240 ppb D O at approx 100 96 efficiency under above conditions Alignment of Dissolved Oxygen Detection Circuit D O 2 1 Set up a precision multimeter Fluke 8051A or equivalent to read VDC Use the D O sensor connection TB202 4 and D O sensor TB202 2 as common See wiring diagram Set the D O efficiency constant to 10096 by selecting d o EFF from the menu and editing the value to read 100 0 Adjust the electronic standardize with blue trimpot VR201 located mid board above the D O terminal block Refer to drawing D5940109 Adjust the trimpot to a reading of 3 00V at TP200 while inputing 0 160VDC through a 100 K 196 resistor 0 160 VDC simulates 8240 ppb D O at approx 100 96 efficiency under above conditions Page 37 Troubleshooting Alignment of Temperature Input Circuit 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 below Adjusting Electronic Calibration First Temperature Input 1 Remove any offset calculated by a previous software calibration of the temperature input Select CONF in 1 OFFS from the menu and edit the offset to read 0 0 Set up a precision multimeter Fluke 8051A or equivalent to read VDC Us
14. to log and which input to log either D O or temperature At a rate of once an hour the internal log will have the last 40 days of history Internal logged data is date time stamped by the analyzer The data cannot be displayed directly from the analyzer but requires the IC Net Intelligence Access Program for digital connection Setup for Internal Data Logging 1 Select iLOG FrEq from the display This number is the logging frequency specified in seconds For 1 second intervals use 1 for internal data log menu when not logging StAr do d o 1 492 itor 1 II ia 1 available frequency of log update in seconds 9C2 10 __ cont continue logging overwriting oldest data StOP stop logging when buffer full cnt H o number of data points currently in buffer CLr do clear the buffer deleting all data points Simultaneous serial ASCII output of all inputs OFF No ASCII serial output internal data log menu while logging StOP do in L 3 9 1 input being logged FrEq 60 frequency of log update in seconds continue logging overwriting oldest data Cont Fuzz 5 0 stop logging when buffer full cnt 1 626 number of data points currently in buffer Simultaneous serial ASCII output of all inputs Figure 36 Internal data log menu No ASCII serial output Page 34 IC CONTROLS 1 minute intervals use
15. very little resolution See figure 24 The alternative of having an operator change the scale adjustment is impractical in most cases TYPICAL 4 20 mA OUTPUT WITHOUT AUTOMATIC RANGE SWITCHING 96 OUTPUT 0 TIME Figure 24 Output without range switching Automatic range switching will automatically expand the span adjustment by a factor of 10 each time the output level is within the bottom 10 per cent of the scale With automatic range switching in effect for outi the output will adjust automatically over 3 ranges moving from range 1 which is 100 of full scale to range 3 which is 1 96 of full scale For D O this means that with full scale setting of 20 ppm the output will automatically switch down to range 3 which represents 0 to 0 2 ppm or 0 to 200 ppb While automatic range switching is most practical for the D O input the concept will work for the temperature input as well A hysteresis is built into the output logic to avoid having the output switch between ranges too frequently thereby painting the chart recorder The output will stay on the current range if the output level is between 9 5 and 100 of the current scale The output will not switch downscale or to the next highest range number until the output reaches 9 5 of the current scale The output will switch upscale again when the output reaches 100 of the current scale Enabling Automatic Range Switching Only out1 has automatic range switchin
16. 0 LEVEL 1 LEVEL 2 VIEW ONLY VIEW ONLY OPERATOR COMPLETE DISPLAY DISPLAY DISPLAY DISPLAY RE 592 E 1 2 Figure 10 Entering a password Page 12 856 Instructions IC CONTROLS 856 Dissolved Oxygen Measurement 856 Dissolved Oxygen Measurement Introduction Voltmeter Dissolved oxygen is a measure of the amount of S oxygen usually thought of as a gas that is dissolved in a liquid such as water Oxygen is Oro Ded 1500 essential life even for fish and other aquatic forms plus is the most common element found Lead Anode taking part in corrosion reactions Pb Pb 2e Mechanically hard and porous metal oxide deposits have little strength and form rapidly in the presence Electrolyte Solution of water and oxygen Rapid corrosion will occur inside an industrial utility boiler system unless Figure 12 Basic galvanic cell dissolved oxygen can be virtually eliminated Corrosion results in expensive repairs or equipment The 856 uses a galvanic cell separated from the failures and subsequent replacement sample by an oxygen permeable PTFE membrane The cell has a gold cathode in close contact with the Galvanic Measuring Cell PTFE membrane where oxygen gains electrons is reduced to become hydroxyl ions and a lead anode that produces a fixed potential regardless of oxygen concentration to complete the circuit The 856 dissolved oxygen measuring se
17. 1 54 11 27 11 00 10 75 10 50 10 26 10 03 9 81 9 60 9 41 9 21 9 03 8 84 8 67 8 51 8 35 8 19 8 04 7 90 7 76 7 63 7 50 7 37 7 25 7 18 7 01 6 90 6 79 6 68 6 57 6 46 6 36 6 26 6 16 6 06 5 97 5 88 5 79 5 69 14 37 13 99 13 61 13 26 12 90 12 58 12 25 11 96 11 66 11 39 11 11 10 86 10 60 10 37 10 13 9 92 9 70 9 50 9 30 9 12 8 93 8 76 8 59 8 44 8 28 8 13 7 98 7 84 7 70 7 57 7 44 7 32 7 20 7 09 6 97 6 86 6 75 6 64 6 53 6 43 6 33 6 23 6 13 6 04 5 94 5 85 5 76 14 52 14 13 13 75 13 39 13 04 12 71 12 38 12 08 11 77 11 50 11 22 10 96 10 71 10 47 10 24 10 02 9 80 9 60 9 40 9 21 9 03 8 85 8 68 8 52 8 36 8 21 8 06 7 92 7 78 7 65 7 52 7 40 7 28 7 16 7 05 6 93 6 82 6 71 6 61 6 50 6 40 6 30 6 20 6 10 6 01 5 91 5 82 14 57 14 17 13 79 13 43 13 08 12 74 12 42 12 11 11 81 11 53 11 26 10 99 10 74 10 50 10 27 10 05 9 83 9 63 9 43 9 24 9 06 8 88 8 71 8 55 8 39 8 24 8 09 7 95 7 81 7 68 7 59 7 42 7 30 7 18 7 07 6 95 6 84 6 73 6 63 6 52 6 42 6 32 6 22 6 13 6 03 5 94 5 84 11 0 103 0 104 0 105 0 106 0 14 67 14 27 13 88 13 52 13 17 12 83 12 50 12 20 11 89 11 61 11 34 11 08 10 82 10 58 10 34 10 12 9 90 9 70 9 50 9 31 9 12 8 95 8 77 8 61 8 45 8 30 8 15 8 01 7 87 773 7 60 7 48 7 35 7 23 7 12 7 00 6 89 6 78
18. 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 outi LO from the menu The current value will display Press Enterto go into edit mode The analyzer will display PASS for 2 seconds because we need to enter a password first Level 1 security is needed to change this setting Select PASS from the main menu again Change the 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 the menu Press Enter with 0000 displayed Both passwords are set to 0000 again and password security is disabled 16 47 Appendix C Unit Convers
19. 5 Keypad arrow keys 8 LED 6 41 Main input 44 MANUAL key 29 Manual temperature compensation selecting 16 Measurement history internal log 35 Membrane compensation factor 16 44 Memory test 6 Menu 7 adaptive 7 19 30 edit settings 8 856 Instructions IC CONTROLS home base 7 Metric units 9 44 Output channel SEE output signal Output hold 18 timeout 7 Output signals 24 27 enabling auto ranging 25 hysteresis 25 output hold 18 range indication 26 reversing 24 settings 24 simulated 27 span 24 standby mode 36 units 27 Password 47 entering 11 Pressure 49 units 9 44 Pressure compensation 6 17 49 selecting type 17 setting 17 Prompts 40 Quattro Pro spreadsheet 52 Range indication 26 alarm contacts 25 26 output 2 25 26 Range switching D O measuring circuit 37 44 enabling 25 output signals 25 range indication 26 Real time clock 10 45 Relays 39 RS232 32 RS485 32 SAMPLE key 7 8 Sample menu 7 44 Security 11 45 47 access level 11 47 disabling 47 enabling 45 47 password 47 password 1 47 password 2 47 timeout 7 Simulated current output 27 Standby mode 36 856 Instructions Index Start up diagnostics 6 Startup display 7 Program Initialization 44 Temperature 49 error messages 21 measuring circuit 38 output signals 24 units 9 44 Temperature compensation 6 16 17 41 49 selecting type 16 Terminal program Windows 3 1 51 Windows 9x NT 51 Timer 15 minu
20. 6 68 6 57 6 47 6 37 6 27 6 17 6 08 5 98 5 89 14 81 14 41 14 02 13 66 13 29 12 96 12 62 12 32 12 01 11 73 11 45 11 19 10 93 10 68 10 44 10 22 10 00 9 79 9 59 9 40 9 21 9 04 8 86 8 70 8 53 8 38 8 23 8 09 7 95 7 81 7 68 7 55 7 43 7 31 7 19 7 07 6 96 6 85 6 74 6 64 6 53 6 43 6 33 6 24 6 14 6 05 5 95 14 95 14 56 14 16 13 79 13 42 13 09 12 75 12 44 12 13 11 85 11 56 11 30 11 03 10 79 10 54 10 32 10 10 9 89 9 68 9 49 9 30 9 13 8 95 8 79 8 62 8 47 8 31 8 17 8 02 7 89 7 76 7 63 7 50 7 38 7 26 7 15 7 03 6 92 6 81 6 71 6 60 6 50 6 40 6 30 6 20 6 11 6 01 15 10 14 70 14 30 13 93 13 56 13 21 12 87 12 56 12 25 11 96 11 67 11 40 11 14 10 89 10 65 10 42 10 20 9 99 9 78 9 58 9 39 9 21 9 03 8 87 8 70 8 55 8 39 8 25 8 10 7 97 7 84 7 71 7 58 7 46 7 34 7 22 7 11 7 00 6 89 6 78 6 68 6 57 6 47 6 37 6 27 6 17 6 08 15 25 14 84 14 43 14 06 13 69 13 34 13 00 12 68 12 37 12 08 11 79 11 52 11 24 11 00 10 75 10 52 10 28 10 08 9 87 9 67 9 47 9 30 9 12 8 96 8 79 8 64 8 48 8 33 8 18 8 05 7 91 7 78 7 65 7 58 7 41 7 30 7 18 7 07 6 95 6 85 6 74 6 64 6 53 6 43 6 33 6 24 6 14 Page 49 Appendix E Default Settings Appendix E Default Settings The following program settings are the default settings for the analyzer New analyz
21. 60 or for 1 hour intervals use 3600 Any interval from 1 to 9999 seconds can be specified 2 Select iLOG in from the menu Select the input to be logged Only one of the inputs can be logged a time Select 106 FULL from the menu This setting specifies what the analyzer should do when the logging buffer has been filled Set to cont to continue logging when the buffer is full In this case each new data point that is stored in the log will erase the oldest data point This is the factory default Set to StOP to stop logging when the buffer is full In this case the analyzer will fill up the data logging memory approximately 1000 data readings and then simply stop logging preserving all data points that have been taken 4 When you are ready to start logging select StAr from the menu Press Enter when the flashing do is displayed The analyzer will briefly display donE to indicate that it has completed the desired action starting the data log At this point the logging menu will change somewhat to indicate the options available while logging is in progress Displaying Logging Status From the menu select iLOG cnt This count number shows the number of data points that have been logged While the analyzer is logging you will be able to see this number incrementing The data point count will be 0 after the data log has been cleared from memory Also the cnt frame must sh
22. 65 13 29 12 93 12 59 12 25 11 95 11 64 11 36 11 07 10 81 10 55 10 31 10 07 9 84 9 62 9 41 9 21 9 02 8 83 8 66 8 48 8 32 8 15 8 00 7 85 7 71 7 57 7 44 7 31 7 18 7 06 6 94 6 83 6 71 6 60 6 49 6 39 6 28 6 18 6 09 5 99 5 90 5 80 5 71 5 61 5 53 5 44 856 Instructions Appendix D Saturated DO Values the 856 analyzer uses the table below to determine the efficiency of the cell 96 0 97 0 98 0 99 0 100 0 101 0 101 3 13 80 13 43 13 06 12 72 12 38 12 07 11 76 11 48 11 19 10 93 10 66 10 42 10 17 9 95 9 72 9 52 9 31 9 12 8 92 8 75 8 57 8 41 8 24 8 09 7 94 7 80 7 65 7 52 7 38 7 26 7 18 7 02 6 90 6 79 6 67 6 57 6 46 6 36 6 25 6 16 6 06 5 97 5 87 5 78 5 68 5 59 5 50 13 94 13 57 13 20 12 86 12 52 12 20 11 89 11 60 11 30 11 04 10 77 10 52 10 28 10 05 9 83 9 62 9 41 9 21 9 02 8 84 8 66 8 50 8 33 8 18 8 02 7 88 7 73 7 60 7 46 7 34 7 21 7 09 6 98 6 86 6 75 6 64 6 53 6 43 6 33 6 23 6 13 6 03 5 94 5 84 5 75 5 66 5 57 14 09 13 71 13 34 12 99 12 65 12 33 12 01 11 72 11 42 11 15 10 89 10 64 10 39 10 16 9 93 9 72 9 51 9 31 9 12 8 93 8 75 8 59 8 42 8 26 8 11 7 96 7 82 7 68 7 55 7 42 7 29 7 17 7 05 6 94 6 82 6 71 6 60 6 50 6 40 6 30 6 20 6 10 6 00 5 91 5 82 5 72 5 63 14 23 13 85 13 48 13 13 12 77 12 45 12 13 11 84 1
23. D O menu to inspect the new calibration value This value is used internally to determine the analyzer gain When leaving the calibration display the analyzer will again display D O using the units you were using before doing the calibration If you were using ppb then the analyzer will again display the D O reading as ppb when you press SAMPLE or leave the calibration display using the arrow keys Page 17 Calibration Output Hold The 856 allows the user to hold a D O output at its current level Output hold affects both 4 20 mA outputs and alarms which monitor the D O input which has been put on hold Enable output hold by changing the d o HOLd setting to YES Output hold has the following effect 4 20 mA output signals transmitting the D O input which is put on hold are frozen at their current levels alarms monitoring the D O input will maintain their existing on off condition The output hold remains in effect until the operator changes the d o 1 HOLd or d o 2 HOLd setting to or until no key has been pressed for 15 minutes The 15 minute timeout ensures that output hold will not remain in effect for longer than 15 minutes if the analyzer is left unattended 16 18 IC CONTROLS 856 Instructions IC CONTROLS Error Messages To display errors detected by the analyzer select Err from the main menu If there are no error messages
24. INSTRUCTION MANUAL MODEL 856 MICROPROCESSOR DUAL INPUT ppm DISSOLVED OXYGEN ANALYZER INST 856 210 ase INTELLIGEN Ee e CONTROLS IC CONTROLS CONTENTS Proprietary Information 2 856 Menu ev 4 Analyzer Operation 6 Startup Procedure ls 6 Start up Settings 6 Moving Around in the Menu 7 Remembers Where You Were 7 Home Base Press Sample 7 Display 7 Four Arrow 8 AUTO and MANUAL Keys 8 EditMode 8 Metric or Imperial Units 9 Input Damping 10 Real Time Clock 10 Internal Intelligence Access IC Net Features10 moe IR Rn 11 Entering a Password 11 856 Dissolved Oxygen Measurement 13 Introduction 13 Galvanic Measuring Cell 13 Display Units 14 Calibration 15 Saturated Air Calibration Technique 15 Zero Test Technique 15 Membrane Compensation Factor 16 Temperature Compensation 16 Selecting Manual Temperature Compensation 16 Barometric Pressure Compensation 17 Calibration Procedure 17 Output Hold 18 Error Mess
25. NONE will be displayed otherwise scroll through the error list using the Up and Down arrow keys Error messages are numbered Errors are identified as En e where n is the input number and e is the error number For example E1 1 is error 1 for the first dissolved oxygen input Refer to table 2 below input sample input for error messages D O 1 1 D O 2 2 C1 3 C2 4 Alarm A 7 Alarm B 8 Table 2 Input numbers for error messages Errors can be acknowledged but cannot be removed from this list directly each error caution will be removed automatically when appropriate e g errors associated with improper calibration will be cleared after a successful calibration The error LED will be on as long as there is an unacknowledged error message and as long as any input is off scale Each source of error must be removed or acknowledged before the error LED will go off If no electrode or sensor is attached to an input it may be most convenient to turn off the input For example if there is no temperature input the temperature display would consistently be off scale without a resistor across the input terminals causing the error LED to always remain lighted Refer to the Input On Off Switch heading in the Installation Configuration of Program section 856 Instructions Error Messages Acknowledging an Error Message To turn off the error LED and shut down the external fault
26. NTROLS Standby Mode Standby mode can be selected from the main menu In standby mode the alarms will not function and the 4 20 mA outputs will go to 4 00 mA When SAMPLE is pressed all the inputs will show StbY instead of the normal input measurement The analyzer will not resume normal operations until the analyzer is taken out of standby mode While in standby mode the entire menu and all settings are accessible to the operator as before None of the settings will take effect until the analyzer is returned to normal operation The standby feature is protected by security level 2 Figure 37 Standby menu Page 36 856 Instructions IC CONTROLS Troubleshooting Slow Response typically due to excessive sample line length and low flow thus producing long sample transport lags Resolve by adding a fast flow loop with the sensor in a short side stream or by shortening the line Slow response can also be caused by a buildup of dirt in the sample line In this case the problem may be aleviated by changing the take off point or by installing a knock out pot or sintered stainless steel filter Consult IC CONTROLS for specific solutions Readings consistently low or spike low characteristic of wiring problems between the analyzer and the sensor an open circuit in the field wiring will result in zero cell current and a very low reading Review the installation instructions Readings gradually falling the
27. able for D O input The percent saturation unit displayable by the analyzer displays the calculated 96 of maximum concentration of dissolved oxygen at the current temperature and pressure For example at 25 77 F and 101 3 kPa 1 atmosphere 14 69 PSI the maximum amount of oxygen that can be dissolved in water is 8 24 ppm If at this temperature and pressure the analyzer is measuring 2 0 ppm the 96 concentration would be IC CONTROLS 2 00 10095 24 39 8 24 Switch between display units by changing the setting in d o 1 unit or in d o 2 unit The options are 1E 3 for ppm 1E 3 is scientific notation for milli PPb for ppb and Pct for percent of saturation The conversion between ppm and ppb is as follows ppm 1000 ppb b m PPP 10007 The conversion between ppm or ppb to 96 saturation is somewhat more complicated because this conversion is not a simple multiplication factor but depends on the temperature and pressure of the solution Figure 13 shows the 96 saturation at various temperatures and pressures You need to know both the temperature and the atmospheric pressure in order to accurately calculate the 96 saturation of the solution cm Dissolved Oxygen ppm 0 10 20 94 kPa 98 kPa 102 kPa Temperature Figure 13 ppm DO at various temperatures pressures Page 14 856 Instructions IC CONTROLS Calibration Saturated Air Calibration Techniqu
28. ages 19 Sensor Maintenance 22 Monthly Maintenance 22 Yearly Maintenance 22 Chemical Cleaning Maintenance 22 Removal of the Dissolved Oxygen Sensor Flow and Insertion 22 Assembly of the Dissolved Oxygen Sensor 23 Inserting D O Sensor in the Twist Lock Fitting 23 0 24 Dual 4 to 20 mA Output Signals 24 Automatic Range Switching 25 Remote Indication of Range Number 26 Unit Selection 27 Simulated 4 to 20 mA Output 27 Alarms 2 Bare oem Re vem RE 28 Use of Relay Contacts 28 Alarm Indication 28 Manual Override 29 Delayed Activation 29 856 Instructions INST856 210 Unit Selection i sce a ees 29 Wiring and NO NC Contacts 30 Use of Alarm Contacts 30 High Low 30 Deviation Alarm 30 FaultAlarm 2 eat RES 31 Using Alarms for On Off Control 31 Net Features 32 Wiring and Enabling 32 Portable Laptop Hookup 33 Internal Data Log 34 Calibration amp Event History 35 Standby Mode 36 Troubleshooting 37 Electronic Hardware
29. alarm contact acknowledge the error Select Err from the main menu Use the Up or Down arrow key until the error message to be acknowledge is displayed Errors are displayed with either a ora sign in front The sign is used to indicate an active or unacknowledged error the sign indicates an inactive or acknowledged error Acknowledging the error will change the sign from to Press ENTER to go into edit mode The to sign will be flashing Use the Up or Down arrow key to change the sign then press ENTER again Page 19 Error Messages Error Messages for Dissolved Oxygen IC CONTROLS Error Description Causes Solutions E1 0 Reading off scale The internal A D The analyzer is at the limit of its measuring capability E2 0 Display shows Err converter is at the top Check the sensor setup to make sure that the sensor is of the scale The operating properly Service or replace the sensor if analyzer cannot necessary measure higher dissolved oxygen The analyzer needs electronic adjustments Arrange for values servicing E1 1 Electrode has Poor electrode Check electrode and setup until stable reading is E2 1 stabilized after 5 performance sample is achieved then redo calibration minutes of not stable interference calibration E1 2 Electrode efficiency Improper elect
30. alarm indication or for control functions The two alarms function independent of each other Either alarm can monitor the dissolved oxygen or the temperature input Each alarm features an adjustable setpoint 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 alarm Alarms can be set anywhere between 0 and 9999 ppb or ppm for the dissolved oxygen input or 5 C and 105 C for the temperature input 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 AL AL A FUNC to CONF AL AL A FUNC to AL I While another use is selected for the relay contacts then the alarm cannot simultaneously use the contact however the alarm function continues using the LED display messages and serial communication The alarm contacts can also be used for remote indication of the range number for the first 4 20 mA output In this case the alarms will continue to function An alarm is indicated using the alarm LED but not the alarm contact This usage of the alarm contacts is selected by setting AL AL A to on Remote range indication is described in the section describing the 4 20 mA o
31. am stored in memory The alarm A setpoint has now been changed from For practical reasons the temperature input is 10 to 20 Press the left arrow key to display SEt always identified as C throughout this instruction AL A etc 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 Since this is a global setting both the units used for temperature and for pressure will change 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 Adjusts blinking digit upward or selects the previous item from the list If a 9 is displayed then the digit will loop around to show 0 Adjusts blinking digit downward or selects the next item from the list If a 0 is displayed then the digit will loop around to show 9 Numeric Values only move to the right one digit If blinking is already at last digit display will loop to the sign on the left Numeric Values move left one digit If blinking is at the sign then blinking goes to the last character Settings restore the initial value if it was changed Otherwise leave edit mode without doing anything Figure 9 Summary of key functions in edit mode 856 Instructions Page 9 Analyzer Operatio
32. analyzer can no longer be calibrated properly This problem is typical of sludge slime deposits on the sensor face The sensor will need to be cleaned Refer to the annual maintenance procedure in this manual Readings trend where expected but spike high This problem is typical of air bubbles in the sample line If a bubble hangs up in the D O flow cell you may see a high surge that slowly falls over some hours Correct by finding air in leakage point and stopping leak Readings at maximum Err message under all conditions Usualy an indication that the D O sensor is in air but still set to display in ppb oxygen Caution 1 7 will appear in the error menu Select d o unit from the menu then set units to ppm 1E 6 frame With units as ppm we can display readings greater than 10 ppm or 9999 ppb Err message means off scale high 856 Instructions Troubleshooting Electronic Hardware Alignment of Dissolved Oxygen Detection Circuit D O 1 1 Set up a precision multimeter Fluke 8051A or equivalent to read VDC Use the D O sensor connection TB200 4 and D O sensor TB200 2 as common See wiring diagram Set the D O efficiency constant to 10096 by selecting d o EFF from the menu and editing the value to read 100 0 Adjust the electronic standardize with blue trimpot VR200 located mid board above the D O terminal block Refer to drawing D5940109 Adjust
33. 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 the alarm LEDs continue to indicate alarm 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 AUTO mode alarms OFF or analyzer in STAMDEB T mode MANLIAL made AUTO made Figure 27 Alarm override status 856 Instructions Alarms Delayed 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 dLAY from the alarm menu The default value of 0 seconds is for immediate contact activation The delay time can be set from 0 to 9999 seconds Unit Selection 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 in use for this alarm The unit setting affects the setpoint differential and deviation settings for the alarm The temperature input will use different units depending on whether metri
34. 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 do no no AL A CLSd Lar AL b AL rnG Membrane Compensation Factor NONE No membrane compensation FASt Fast response membrane Std Standard membrane no dash option rugg Ruggedized membrane LLL 5 input damping sec tc 9c2 d o 2 5VDC 0 17 D O input V ON OF is Em ON OF OFF 9C1 CALIBRATE 9C2 CAL 22 3 C OFFS 0 2 Offset C F dA A 5 Input damping sec 0 1 20 2 9C1 9C2 YES L 2o no YEAr 1997 onth 12 dAtE 31 dAY Fri rtc hour 23 in 59 SEC 59 hund 99 Lec metric or imperial unit Lr unit selection kd selectable only if PAS 000 security enabled Pas 2 0000 Figure 40 Configuration menu 856 Instructions 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 The normally open normally closed configuration selected here will remain in effect even when the alarm contacts are used to indicate the range number for the first 4 20 mA output Relay Contact Function Relay Contact Functi
35. ature high limit low limit and on off switch Set preference for metric imperial units in CONF unit Set the normally open normally closed configuration of the alarm contacts in CONF AL The program setting must reflect the actual NO NC wiring Default is normally open If desired install password security Page 46 IC CONTROLS 856 Instructions IC CONTROLS Appendix B Enabling Security Appendix B Enabling 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 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 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 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 require
36. ature input or CONF in C2 OFFS for the second temperature input Whenever the hardware alignment is correct the offset will be 0 0 The displayed offset can be edited 856 Instructions IC CONTROLS Calibration of 4 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 20 mA Output Self Calibration 1 Select cur from the output 1 menu to display the present output current in mA The display will be updated as the output current changes based on the input signal and the program settings 2 To simulate a different 4 20 mA output signal press ENTER to enter edit mode Use the arrow keys to display the desired output 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 to output different signal levels 3 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 4 Repeat the above steps for output 2 Approach 2 Use Voltage Source to Adjust Input This faster calibration approach requires a voltage source for the input 1 Tocalibrate output 1 set in C In
37. c or imperial units are selected For temperature the unit selection can be viewed only The choice between metric or imperial units is made in the configuration menu See the Installation Configuration of Program section for further details The D O inputs allow the user to select between ppm ppb and 96 saturation units Edit the unit setting to choose the desired units for alarm settings Page 29 Alarms 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 856 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 Figure 3 for the configuration menu Select CONF AL from the menu The normally open normally closed configuration selected will remain in effect even when the alarm contacts are used to indicate the range number for the first 4 20 mA output sample sample time Figure 29 High alarm Page 30 IC CONTROLS Use of Alarm Contacts By default the alarm contacts will be used to indicate alarm conditions If there is an alarm condition for either alarm then the alarm will be indicated using b
38. d A9160024 0 25 Amp microfuse A9160029 0 10 Amp microfuse A3200070 Hardware set M55 series front panel four each of standoff lock washer 4 40 nuts A2500201 Panel mounting kit M55 series A2500255 Pipe wall mounting kit M55 series D4950053 Interconnect Cable to 800 Interface A9200007 D O cable 6 conductor with shield per foot D5980187 800 D O Interface Pipe Top Explosion Proof Type A2500053 D O Preamp for 855 856 etc 05980187 9120098 Terminal strip 6 2101513 Explosion proof J box only 800 71 D O Interface Wall Mount Type A2500053 D O preamp for 855 856 etc D5980187 A2100049 Preamp holding bracket A9120050 Terminal block 6 CKT A2101514 Weather proof wall mount J box only Calibration Supplies A1100192 De ionized water rinse solution for cleaning sensor internals 500 mL bottle A1100192 6P Six pack of deionized water rinse solution for cleaning sensor internals six 500 mL bottles A1100193 Zero dissolved oxygen standard 500 mL bottle A1100193 6P Six pack of zero dissolved oxygen standard A1100194 Dissolved oxygen electrode renew solution 100 mL bottle 856 Instructions Page 53 Appendix H Dissolved Oxygen Solutions IC CONTROLS Appendix H Dissolved Oxygen Solutions Dissolved Oxygen is one industrial measurement that is difficult to zero and frequently operates with large errors Accurate calibration can be hard to achieve s
39. d to make changes in the configuration menu but all other settings are unprotected Effectively the user will always have at least level 1 access At this point password 1 is still 000 You may optionally enable operator access control or level 1 security by changing the level 1 password from 000 to a non zero value Change the password by selecting CONF PAS 1 from the menu then entering an appropriate 3 digit password 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 856 Instructions 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 Password Example a Quick Tour With security disabled select CONF PAS
40. e At any given temperature and barometric pressure the partial pressure of oxygen in water saturated air is exactly the same as it is in air saturated water Thus a sensor can be calibrated in water saturated air using the 20 9 oxygen available in air as the full scale standard and it will correctly read dissolved oxygen in water samples Both temperature and barometric pressure affect the partial pressure of oxygen in air saturated with water vapour Fortunately the 856 has microprocessor memory programmed with the required values as well as an automatic temperature sensor so it can automatically obtain the correct data look up the dissolved oxygen table compute the correct gain and calibrate the analyzer for each D O input The operator need only remove the cell and suspend it over a beaker of water This calibration technique will give a 100 96 saturation reading for the temperature and pressure which the 856 will display as ppm dissolved oxygen Actual dissolved oxygen table values are printed in appendix D To calibrate the D O sensor suspend the probe above water in a beaker or otherwise and let the analyzer auto calibrate Refer to figure 15 Beaker Keep about 1 4 to 1 2 inch above water Figure 15 D O sensor setup for calibration 856 Instructions Calibration Zero Test Technique The best way to zero check at the point of use in the plant is to use a a Zero Oxygen Standard ava
41. e Electronic calibration Follow procedure in Hardware Alignment section 5 E3 2 Temperature Temperature Attach temperature compensator E4 2 reading compensator not off scale attached Turn off temperature input Follow nput On Off Switch Temperature procedure in Software Configuration section Pe han Connect resistor to TC terminals to simulate a constant temperature Refer to Hardware Alignment section Temperature is Verify process and sensor location actually higher than 105 Electronic calibration Follow procedure in Hardware Alignment section necessary Caution Messages for Alarms Caution Number Description CA7 6 Alarm A HIGH alarm CA7 7 Alarm A LOW alarm CA7 8 Alarm A DEVIATION alarm CA7 9 Alarm A Fault alarm CA8 6 Alarm B HIGH alarm CA8 7 Alarm B LOW alarm CA8 8 Alarm B DEVIATION alarm CA8 9 Alarm B Fault alarm 856 Instructions Page 21 Sensor Maintenance Sensor Maintenance The dissolved oxygen sensors provided by IC CONTROLS are designed for simple maintenance The sensors are robust and will withstand difficult applications when properly applied and maintained Follow instructions in this section to promote proper operation Galvanic D O sensors need a continuous current drain Maintenance should be done with D O sensor wired to its analyzer or shorted coax centre to shield Monthly Maintena
42. e the TEMP sensor connection TB201 2 as common See wiring diagram Place a 1000 ohm 1 resistor across T and T Adjust blue trimpot VR202 located at the bottom left of the board for a reading of 0 200 V at TP202 Refer to wiring diagram for component locations Place a 1385 ohm 1 resistor across and T Adjust blue trimpot VR203 located at the top left of the board for a reading of 4 85 V at TP202 Refer to wiring diagram for component locations drawing D5940109 Close case and press Sample key followed by the Down key to display the temperature reading Re insert the 1000 ohm 1 96 resistor and adjust as in step 3 until the display reads 0 0 0 1 Re insert the 1385 ohm 1 96 resistor and adjust as in step 4 above until the display reads 100 0 0 1 C Adjusting Electronic Calibration Second Temperature Input 1 Remove any offset calculated by a previous software calibration of the temperature input Select CONF in 2 OFFS from the menu and edit the offset to read 0 0 Set up a precision multimeter Fluke 8051A or equivalent to read VDC Use the TEMP sensor connection TB203 2 as common See wiring diagram Place a 1000 ohm 1 resistor across T and T on the second level of the terminal block Adjust blue trimpot VR204 located at the bottom right of the D O terminal blocks for a reading of 0 200 V at TP203 Refer to wiring diagram for component locations Pa
43. eft off when it is powered down if it doesn t 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 A faster way to set the clock in the analyzer is to use the IC Net program to synchronize the analyzer with the connected computer 16 856 Instructions Page 45 Appendix A Installation Summary Appendix A Installation Summary More detailed instructions for setting up the analyzer are found in the nstallation section Electrical The analyzer requires 115 VAC power to be hooked up to TB400 found on drawing D5920101 Connect the two alarm contacts Alarm A contact TB300 Alarm B contact TB301 Connect the two isolated 4 20 mA outputs Output 1 TB303 Output 2 TB304 Connect the D O sensors as follows D O 1 at TB200 and TB201 D O 2 at TB202 and TB203 Program Refer to appendix E for default settings Before putting analyzer into operation verify your settings to ensure that they agree with the intended setup For a more detailed description of any program setting refer to the appropriate section of this instruction manual Change defaults for the alarms Set alarm function high low deviation fault input D O temperature differential setpoint and on off switch Change defaults for the 4 20 mA outputs Set input D O temper
44. ernal log The internal log is not written until the analyzer has not been used for 15 minutes then a single record is written the current calibration If for example two consecutive calibrations are done and then a number of manual changes to cell constant 856 Instructions IC Net Features these changes only create a single log entry rather than filling say 6 of the 12 available calibration event tag spaces For the D O input the following factors are logged efficiency temperature compensation method and setpoint pressure compensation setpoint For temperature the following factor is logged offset Internal date time Time Clock The analyzer maintains an internal date time clock 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 optional IC Net Intelligence Access Program Analyzers purchased with a 34 option are equipped with a real time clock which will maintain the correct time and date even with the analyzer power turned off To 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 internal time clock maintained by the analyzer but the time and date will need to be adjusted each time the analyzer loses power Page 35 Standby Mode IC CO
45. ers will have these settings unless the setup has already been customized for your application D O Inputs D O 1 units ppm TC method auto TC input C1 pressure comp kPa 101 3 ON OFF switch ON Outputs Output 1 Input to be transmitted 1 Low setting Oppm High setting 20ppm units ppm ON OFF switch ON Automatic range indication OFF Alarms Alarm A Input for alarm DO Alarm function High ON OFF switch OFF Setpoint 10 ppm Differential pressure in kPa auto 101 3 ON Output 2 D O 2 0 ppm 20 ppm ppm ON Alarm B DO Low OFF 1 0 ppm 0 05 ppm 0 05 ppm Global units metric units temperature in degrees Celsius Alarm Contacts Configured normally open Security not enabled Input on off configuration All inputs are on and will show up in the sample menu Page 50 IC CONTROLS 856 Instructions IC CONTROLS Appendix F Data Capture Example Windows 3 1 Terminal Program To illustrate the capturing of data on a computer following is the description for loading and setting up the TERMINAL program which is part of the standard Windows 3 1 operating system 1 Load Windows 3 1 then switch to the program manager 2 From the accessories group double click on the Terminal icon 3 From the menu select Settings Communications Set the communications settings as shown in figure 36 The Connector setting in the figure is set to COM1 match thi
46. etric and Farenheit units for imperial units The choice between metric or imperial units is made in the configuration menu See the configuration section elsewhere in this manual for further details The D O inputs allow the user to select between ppm ppb and saturation units Edit the unit setting to choose the desired units for the HI and LO settings 856 Instructions Outputs Simulated 4 to 20 mA Output Select cur from the output menu to display the signal currently transmitted by the output channel The signal is displayed in mA The display will be updated as the output signal changes based on the input signal and the output settings To simulate a different 4 to 20 mA output signal press ENTER to enter edit mode Use the Up or Down key to display the desired signal needed for testing the output signal Press ENTER to have the displayed value take effect The output signal will change to transmit the displayed value 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 Troubleshooting and Servicing See also the Troubleshooting Electronic Hardware Alignment section for troubleshooting and servicing procedures Page 27 Alarms Alarms Two alarms alarm A and alarm B are a standard feature for the 856 Each alarm has an alarm contact associated with it which can be used for remote
47. f 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 Figure 4 Internal Data Log Menu ON OF dirr 0 05 0 SEt I 10 00 1 00 Figure 2 Alarm menu 856 Instructions EF FREE o a m o a N V BE SAt Alarm function low high deviation fault list of available inputs ppb available units ppm depend on type of input selected 96 sat Differential Delayed alarm activation sec Setpoint Deviation x Accessible only when function is activated 856 Menu AL A AL b P ag o Bai INO NC rnG a 2 0 17 o gla 5 8 Membrane Compensatlon Factor No membrane compensation Fast response membrane Standard membrane no dash option Ruggedized membrane Input damping sec D O input V CALIBRATE YEAr onth 1 dAtE 31 dAY Fri rtc hour 23 in 59 SEC 59 hund 99 unit o rp metric or imperial unit selection selectable only if security enabled Figure 3 Configuration menu sez c Offset C F Input damping sec P on OFF w e fe NodE Figure 5 Serial comm
48. g available From the menu select out out1 ArnG then edit the setting to show YES A common setting for LO 1150 which is the lowest possible value for the 0 0 input Setthe value to the full scale value for range 1 The unit selection for D O should be 1E 6 which represents ppm With automatic range switching for output1 enabled you can tell at the analyzer which range output1 is 856 Instructions Outputs on by selecting out outi rnG from the menu This frame gives a live update of the range number The rnG frame can only be selected from the menu if ArnG is setto YES Example of Range Switching for D O input Figure 23 show the effect of adding range switching to the 4 20 mA output The first graph shows the D O level coming down after a calibration but has virtually no resolution at the operating level The second graph shows the 4 20 staying within 10 to 100 of scale by automatically switching between ranges Only on the last range range 5 is the output of the 4 20 allowed to go below 10 96 of scale To achieve results similar to those in figure 23 use the following settings for output 1 in d o 1 ON OF on unit 1E 6 I for ppm HI 220 LO 0 ArnG YES I For output2 in ON OF on LO j 1 HI 5 To use the alarm contacts for range indication set AL ArnG to on I Table 3 summarizes the results for these
49. ge 38 IC CONTROLS 4 Place a 1385 ohm 1 resistor across T and T Adjust blue trimpot VR205 located at the top right of U201 for a reading of 4 85 V at TP203 Refer to wiring diagram for component locations drawing D5940109 5 Close case and press Sample key followed by the Down key to display the temperature reading 6 Rerinsert the 1000 ohm 1 resistor and adjust as in step 3 until the display reads 0 0 0 1 7 Re insert the 1385 ohm 1 resistor and adjust as in step 4 above until the display reads 100 0 0 1 C Software Calibration First and Second Temperature Inputs To do a software calibration of the temperature input the correct temperature needs to be known From the menu select CONF in 1 CAL for the first temperature input or CONF II in C2 CAL for the second temperature input The actual temperature as measured by the temperature sensor will be shown Edit the displayed value to the known correct temperature Press ENTER to leave edit mode then SELECT to start the calibration 2 current temperature will be shown using a flashing display When it looks like the input is stable press ENTER to set the new temperature The software offset for the temperature input will be adjusted automatically 3 The calculated offset in degrees Celsius can be viewed by selecting CONF in C1 OFFS from the menu for the first temper
50. he EPROM chip holds the program which determines the functioning of 856 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 865 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 NO Normally Open Normally Closed Each of the alarm contacts can be wired and configured as normally open or normally closed A circuit which is wired normally closed will be closed i e the external device wired to it is turned on when the analyzer is not powered Normally Open A circuit which is wired normally open will be open i e the external device wired to it is turned off when the analyzer is not powered ppb Concentration as Parts Per Billion ppm Concentration as Parts Per Million 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 backu
51. ilable from IC CONTROLS as P N A1100193 in 500 mL bottles or in a 6 pack as P N A1100193 6P sodium sulfite O2 scrubber with a cobalt chloride catalyst CAUTION If zero standard gets on hands wash with running water Preparation of Zero Oxygen Standard To 1 liter of distilled water add 20 gram of Na2SO3 and 10 milligram of Co2Cl2 and mix thoroughly Make sure that the zero standard is used within 8 hours because the oxygen scavenger will be used up quickly with exposure to air Submerge the 856 sensor in a deep beaker so that it is 2 to 3 inches below the surface of the liquid Refer to figure 16 Provide slow gentle movement to ensure that the oxygen present is consumed The D O sensor should rapidly fall to 0 1 to 0 2 ppm levels thus confirming operation of the sensor beaker Keep about 2 to 3 inch below surface Figure 16 D O sensor setup for zero calibration Page 15 Calibration Membrane Compensation Factor The models 802 814 and 825 D O sensors can be ordered with a choice of membranes Standard membrane no dash option specified Fast response membrane thinner and less durable specified with 4 option Ruggedized membrane thicker and slower response specified with 5 option For more accurate response the anlyzer configuration should be adjusted to reflect the membrane used by the sensor To change the compensation factor select CONF in I d o 1 CF then select the approp
52. ince there are special cleaning requirements Air is available as a high end standard which makes it seem easy Biological growth film on the sensor lowers apparent oxygen in air as well as retains oxygen during low oxygen periods making low D O levels hard to confirm without a zero standard IC CONTROLS has produced the following standards from the highest quality raw materials to help solve these problems Description Part No Size 6 pack Zero D O Standard A1100193 500 mL A1100193 6P D O Sensor Cleaning Solution A1100194 500 mL A1100194 6P Deionized Water A1100192 500 mL A1100192 6P ppm Membrane Module amp Fill Solution for 802 and 825 for Normal Response A2103015 for Fast Response A2103013 Rugged Slow Response A2103017 Membrane Module amp Fill Solution for A2103009 869 for Standard Response A2103013 ppb Membrane Module amp Fill Solution for A2103001 865 for Normal Response A2103003 About Calibration When you buy from IC CONTROLS our commitment to you includes the standards to properly clean and calibrate the equipment Our commitment to you does not stop when we ship the equipment it continues until you have calibrated the analyzer system are satifsifed with the results and beyond To assist you in obtaining reliable results IC CONTROLS developed calibration and cleaning procedures and manufactures and packages the necessary standards buffers and supplies in convenient usage quantities If you need assi
53. ion Appendix C Unit Conversion Relation of ppb ppm mg L 96 Saturation for DO 1000 ppb 1 ppm 1 ppm 0 001 ppb 1 ppm is approximately 1 mg L The variation occurs because the weight of water varies slightly with temperature Percent saturation is directly related to the temperature and pressure of the system A given ppb will given different saturation depending on the variation in temperature and pressure See appendix D Temperature Units 5 32 50 F 32 F 2x C 32 Page 48 Pressure Units _ kPa 6 895 kPa PSIX6 895 1 atmosphere PSI 1 atmosphere 1 atmosphere 1 atmosphere 1 bar IC CONTROLS 1 01325 bar 760 mm Hg or Torr 14 70 psi 101 3 kPa 100 000 Pascals 856 Instructions IC CONTROLS Appendix D Saturated DO Values are reported as parts per million During calibration The table below lists shows the concentration of dissolved oxygen in water over a range of temperature and pressure Dissolved oxygen values C kPa 94 0 95 0 0 13 51 1 13 15 2 12 79 3 12 46 4 12 13 5 11 82 6 11 52 7 11 23 8 10 95 9 10 69 10 10 44 11 10 20 12 9 96 13 9 74 14 9 52 15 9 31 16 9 11 17 8 92 18 8 74 19 8 56 20 8 39 21 8 23 22 8 07 23 7 92 24 7 77 25 7 63 26 7 49 27 7 36 28 7 23 29 7 10 30 6 98 31 6 87 32 6 75 33 6 64 34 6 53 35 6 42 36 6 32 37 6 22 38 6 12 39 6 02 40 5 93 41 5 83 42 5 74 43 5 64 44 5 55 45 5 46 46 5 38 13
54. ions are performed Events such as power down power up and alarms are recorded in a separate log which tracks the last 20 events time date stamped When combined with the internal data logging capability this allows the operator to recall factors leading to alarm conditions Retrieving Calibrations and Events At any time the date time stamped events can be retrieved from the analyzer using a computer running the IC Net program The display limitations of the analyzer leave no way to view event records using only the analyzer There is no menu for events and logging is done without any user intervention Event Records Sample output of event records Thu Dec 18 14 50 47 1997 ANALYZER OFF Thu Dec 18 17 47 30 1997 ANALYZER ON Thu Dec 18 17 47 30 1997 E1 5 Thu Dec 18 17 47 31 1997 E2 2 Thu Dec 20 10 11 21 1997 CAT7 6 gt PN PR 3 The first number is sequential The next part of each line is the date time stamp The final part is the event record Different time date formats are available Calibration Records Each time a calibration for D O or temperature is changed the change is recorded in a date time stamped log The log is written both when a normal calibration is performed and when a calibration parameter such as cell constant or efficiency is manually adjusted Any change in any factor affecting the calibration is recorded Another feature is when the calibration is committed to the int
55. l Data Log menu both ASCII and serial must be on The data format uses 8 data bits no parity 1 stop bit and 9600 baud The output consists of three data fields separated by commas Each line of data is terminated by a linefeed newline Comma separated fields make it easy to import 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 2a RS485 wiring standard Wire the RS485 cable into the terminal block TB1 located on the display board Refer to figures 32 and 35 Connect pin1 RD A to pin 3 TD A and connect this to terminal A on TB1 in the analyzer Connect pin2 TD B to pin 9 RD B and connect this to terminal B in the Page 32 IC CONTROLS DB 9 Connector N 9 9 B BLK a ARED 5 OTE O L2 EARTH SHIELD TD B e Pin Assignments Pin 1 RD A NEA T RDA Pin 2 TD B A Pin 9 RD Figure 32 RS485 wiring DB 9 Connector f SERIAL RED SIGNAL GRN Q SERALIP EARTH SHIELD Figure 33 RS232 wiring analyzer Connect earth or shield at one end only 2b 5232 wiring 37 option Wire the RS232 cable into the terminal block TB1 located on the display board Refer to figure 33 Connect
56. larm types Editing a value is like picking an option from a list You can see only one item on the list at a time Example Turn alarm A off From the menu select AL AL A ON OF The analyzer will now display either ON or OFF which are the two choices To change the setting press ENTER to go into edit mode The display will start blinking Use the up or down arrow key to switch between the possible options which in this case are ON and OFF 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 setpoint are adjusted by going into edit mode and then adjusting each digit until the new value is displayed Use the left and right arrow keys to move between digits and use the up and down arrow keys to adjust each digit When you press ENTER 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 the up or down arrow key when the plus minus segment is blinking Press ENTER again to leave edit mode Now before the new value is changed the analyzer will check the new value to make sure that it is within
57. lect manual temperature compensation With SEt still displayed 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 key to display the desired temperature for manual temperature compensation Press ENTER to accept the displayed value TC Configuration Selection of Temperature Input The default configuration for the 856 is for input D O 1 to use C1 and for D O 2 to use C2 for temperature compensation This setup can be changed e g if you want both D O sensors to use the same TC Refer to the instructions in the nstallation section Configuration of Program 15 min timeout if no key pressed 856 Instructions IC CONTROLS Barometric Pressure Compensation 70 0 500 1000 1500 2000 2500 Altitude meters above sea level Figure 18 Effect of altitude on barometric pressure The 856 uses a manual pressure compensation method When the analyzer is calibrated the specified pressure is used to determine the concentration of dissolved oxygen The 100 96 saturation reading is affected both by temperature and by pressure While the barometric pressure only affects the 100 96 saturation reading at calibration its use eliminates
58. log box click on the Connect using list and select the COM port to which the 855 is connected e g select COM1 4 Inthe COM1 Properties dialog box use the following settings Bits per second 9600 baud rate Data bits 8 Parity None Stop bits 1 Flow control None Click on OK To return to this dialog box later for example to change the baud rate select File Properties from the menu then click on the Configure button 5 To capture data into a file select Transfers Capture text from the menu Specify the file name and location Example c logs log01 dat or use the Browse button to select an existing file to append to The hyperterminal program will now store any ASCII data sent out by the analyzer into the specified file 6 To pause or resume data collecting to the specified file select Transfers Capture text then Stop or Resume 7 finish the collecting of data select Transfers Capture text Stop from the menu 8 When exiting the program a dialog box will ask Do you want to save session 456 analyzer If you respond Yes the next time you select Hyperterminal from the Start menu you will be able to select the 456 analyzer settings Page 51 Appendix F Data Capture Example Load Log File in Excel The following example illustrates how to load a log file into Microsoft Excel 5 0 1 By default the Net Access program uses the DAT extension f
59. low and high span adjustments All output settings are selected from the out menu Output Span Adjustment To adjust the output span or output window 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 Practically any combination of output settings you can dream up can be set out2 ON OF m umi 0 0 12 02 SP HER IC CONTROLS Reversing the 4 to 20 mA Output The low scale setting will normally be lower than the high scale setting It is possible to reverse the output or flip the window by reversing the settings of the low and high scale Example Define an output window from 0 to 10 ppm D O with 10 ppm corresponding to 4 mA output and 0 ppm corresponding to 20 mA output Set LO to 10 and set HI to 0 list of available inputs ppb available units ppm depend on type Wwe of input selected mA zm o Qe Figure 22 Output menu Page 24 range number for automatic range switching 856 Instructions IC CONTROLS Automatic Range Switching Automatic range switching greatly enhances the resolution capability of the 4 20 mA output A typical application would track the D O input from 0 to 20 ppm As soon as the D O level drops below about 1 ppm a typical recorder would be able to show
60. m settings which can be changed by the user Menu areas shaded in light gray are read only menus G 856 Instructions IC CONTROLS Moving Around in the Menu The layout of the program is shown in the menus found on pages 4 and 5 Remembers Where You Were The analyzer remembers where home base is it remembers which areas of the menu you used last and it will loop around columns in the menu for you You can explore the menu with the arrow keys to find any capability and simply press SAMPLE to return to home base Then use the Right arrow key to return to exactly where you were Home Base Press Sample The SAMPLE key s function is to give you a known starting point displaying the home sample or home input The key is usable from anywhere in the menu ho The dissolved oxygen display is the default home base display for the analyzer The analyzer s inputs dissolved oxygen 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 Figure 8 Home base From anywhere in the menu the SAMPLE key can be used to return to the dissolved oxygen d o 1 or home sample display The program will safely abort whatever it was doing at the time and return to displaying the first dissolved oxygen sample t lt 4 m Figure 6 Keypad 856 Inst
61. mpty notebook or open an existing notebook to which the data log should be added Select Notebook Text Import from the menu Under Option select Only Commas Navigate to the log file You may want to change filename from TXT to to be able to see the log file Click on OK to import the log file into Quattro Pro The date time stamp will be loaded in column A and the input values will be loaded in columns B C etc The date time stamp will be treated as text while the input values will be treated as numeric values that can be graphed manipulated etc _ QuattroPro NOTEBKI WB2 File Edit View Block Notebook Graphics Tools Window Help De BS bec fla Arial 10 pt Normal General 980310 11 41 57 980910 11 41 57 T 41 57 980910 11 47 59 980910 11 48 00 980910 11 48 01 980910 11 48 02 980910 11 48 03 980910 11 48 04 980910 11 48 05 MI 7 1 2 3 4 5 7 8 Figure 43 Quattro Pro Spreadsheet 856 Instructions IC CONTROLS Appendix G Ordering Information Parts List Appendix G Ordering Information Parts List Part Reference Number Description Drawing 855 ppm Dissolved Oxygen Analyzer A9051023 Assembly 856 D O power PCB D5980184 A9051009 Assembly M55 micro display board D5980176 A9141007 Assembly M55 case complete D4830022 A9201014 16 wire interconnector cable two en
62. n Input Damping The D O and temperature measurements can be damped to provide the user with a means of dealing with rapidly varying or noisy signals Damping range is 3 to 99 seconds With 0 there would be no damping and each reading the analyzer makes is used to directly update the display and 4 20 mA output The factory default setting of 5 seconds adds the next four seconds of readings to the first and averages these thus giving a fast but more stable response Selecting 99 seconds adds the readings from the previous 99 seconds and averages 100 readings providing smooth damping out of turbulent readings Select CONF in from the menu Use the up and down arrow keys to select the input to adjust then select the dA frame Press Enter then change the input damping to the new number of seconds Press Enter again to leave edit mode Real Time Clock The analyzer clock 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 even with the analyzer power is turned off m LI IC CONTROLS Internal Intelligence Access Net Features The 856 Dissolved Oxygen Analyzer has advanced intelligence which allows the operator to
63. n low high deviation Func fault L EE Fekk list of r3 available C1 inputs AL A 9C2 AL b PPb b uc available units ppm depend on type of input selected DT SAt 96 sat ON OF OFF diFF 0 05 Differential dLAY 0 Delayed alarm activation sec SEt 10 00 Setpoint 1 00 Deviation x Accessible only when function is activated Figure 26 Alarm menu 856 Instructions IC CONTROLS Caution Number Description CA7 6 Alarm A HIGH alarm CA7 7 Alarm A LOW alarm CA7 8 Alarm A DEVIATION alarm CA7 9 Alarm A Fault alarm CA8 6 Alarm HIGH alarm CA8 7 Alarm B LOW alarm CA8 8 Alarm B DEVIATION alarm CA8 9 Alarm B Fault alarm Each alarm situation also causes an event tag to be written into an internal log which can be accessed using the IC Net Intelligent Access Program The IC Net program uses the analyzer s serial communication port to read and display this information Refer to the IC Net instruction manual for details Manual 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 attending to a problem the alarms can be switched to manual override using the MANUAL key In AUTO mode the green AUTO LED is and the analyzer alarms will activate and deactivate the relaycontact
64. nce Certain applications may require occasional sensor cleaning A monthly maintenance check is recommended by visual examination of the sensor cell area If needed a soft wipe can be used to blot plus detergent and water to remove any deposits Rinse thoroughly after cleaning with water Run a calibration and if sensor efficiency is above 50 percent return to service Black or red discoloration inside the sensor cap may not cause problems However if after calibration the electrode response is slow replace the electrolyte and wipe the coils and surface lightly using a soft wipe or a little more vigerous cleaning can be done using a toothbrush Recharge with fresh electrolyte Calibrate and return the sensor to service Yearly Maintenance Replace the membrane module and electrolyte Unscrew the electrode cap and dump the contents Flush the cell internals with demin water and rinse with electrolyte Examine the lead coils for black or red discoloration or heavy grey coating Such coatings should be removed for best performance caution the lead coils are soft metal never use force in cleaning Clean light fouling by wiping in the direction of the coils untill a shine appears Heavier foulings may come off with a toothbrush worked along the coils so the bristles get down in the cracks followed by rinse and wiping to achieve a dulll shine Remove the old membrane module from the cell and replace with new Re assemble
65. nded that the sensor be located as near as possible to the dissolved oxygen transmitter to minimize any effects of ambient electrical noise interference All long low level D O sensor signals should be run through a dedicated conduit Take care to route D O signal wiring away from AC power lines to minimize unwanted electrical interference TB200 0 V 00 V Figure 38 Sensor wiring direct connect D O 1 Page 42 SHD COM DO CTR D O TB201 RED 0 T HT O T IC CONTROLS When installing any instrument cable in conduit use caution to avoid scraping or cutting the cable insulation resulting exposure of the cable s internal shield wire will greatly increase the chances of system malfunction at any future time Avoid excessive twisting or coiling of all instrument cable to minimize possibilities for broken wire Make sure all connections are clean and tight Figure 39 Sensor wiring direct connect D O 2 856 Instructions IC CONTROLS Configuration of Program The 856 analyzer has been designed with ease of use in mind In most cases the analyzer factory configuration will handle the application and no configuration of the analyzer is necessary init Installation Relay Contacts NO NC The alarm contacts for alarms A and B may be wired as normally open or normally closed Refer to installation instructions and wiring diagrams for wiring instructions By default the 856 program
66. nsor is an electrochemical cell similar to a battery that produces a current when oxygen is present By using carefully selected electrodes in contact with The chemical reactions within the cell are an appropriate electrolyte a chemical reaction At the cathode O2 2 20 46 40H occurs that uses electrons gained from oxygen At the anode 2Pb 2Pb 4e molecules to produce a galvanic current directly Overall O2 2H20 2Pb 2Pb20H proportional to the concentration of oxygen present Figure 12 showshow such an electrode system works in a simple laboratory test Figure 11 shows how these scientific principles can be implemented into a working dissolved oxygen electrode Also unlike an electrolytic cell in which a flow of current produces the chemical reaction there is no zero current as galvanic current naturally is zero when zero oxygen is present Gold Cathode Lead Anode KOH LIII Solution Sensor Body Insulator Figure 11 Galvanic dissolved oxygen sensor 856 Instructions Page 13 Display Units Display Units By default the 856 analyzer will come up reading parts per million dissolved oxygen The unit setting allows the analyzer to display the dissolved oxygen reading using either ppm parts per million ppb parts per billion or saturation concentration units parts per million SAt parts per billion 96 saturation Figure 14 Display units avail
67. ntly the display will stop flashing and the new sensor efficiency constant will be calculated The calibration setting will be based on the temperature used for temperature compensation and the pressure used for pressure compensation The proper ppm D O reading is obtained from an internal table See appendix D for a table of values used by the analyzer As soon as the display stops flashing the calibration will be completed It is possible to override the automatic operation of the analyzer The ENTER key may be pressed before the electrode has stabilized forcing the analyzer to calibrate using the current D O reading Also the calibration may be redone or started over at any time Press CANCEL display the CAL frame then press SELECT to restart the calibration If the analyzer detects a problem during calibration an error message will appear If an error has been detected then the calibration was not successful and the previous calibration has been retained Press any key to acknowledge the error message Take corrective action and redo the calibration Consult the error table in the Error Messages section for details Press any key to resume normal operation after an error message has appeared When the reading stops blinking the calibration has been completed The reading will be displayed using the new calibration value After a successful calibration select EFF from the
68. o kPa PSI aor soz No ppb efficiency 15 min timeout if no key pressed ppm 96 saturation Err See list of error and caution Ei outl out messages for conductivity See Internal Data Log Menu 83 list of C1 available 902 inputs ArnG PPb ppb available units ppm depend on type of input selected A 96 sat on out2 ON OF rnG ar _ conr PASS 0000 YES no See Alarm Menu See Serial Menu StbY P FEE OFF 20 00 0 00 12 02 ma YES turn automatic range Switching on off no JE range number for automatic range switching See Configuration Menu X Accessible only when function is activated 856 Instructions IC CONTROLS internal data log menu when not logging StAr do 1 d o 2 Lin 2 FrEq 10 StOP cnt 9 CLr do on ASCI OFF frequency of log update in seconds continue logging overwriting oldest data stop logging when buffer full number of data points currently in buffer clear the buffer deleting all data points Simultaneous serial ASCII output of all inputs No ASCII serial output internal data log menu while logging StOP do Lin L 1 FrEq 60 Cont FULL StOP cnt 626 J n OFF ascz input being logged frequency o
69. o 000 when you have finished using the analyzer This is accomplished by selecting PASS from the main menu then pressing Enter with 0000 displayed Page 11 Security Passwords A Quick Tour Assuming that password 1 is defined and we are at access level 0 try changing the output 1 low setting Select out outi LO from the menu The current value will display Press Enterto go into edit mode The analyzer will display PASS for 2 seconds because we need to enter a password first Level 1 security is needed to change this setting Select PASS from the main Change the displayed value to the level 1 password then press Enter The analyzer will display good followed by ACC 1 indicating that the password is valid and that we now have level 1 access ENTER PASSWORD PASSWORD IC CONTROLS Try changing the output 1 low setting again You will find that this time we can go into edit mode unhindered Before walking away from the analyzer we should disable level 1 access to prevent unauthorized users from using the analyzer Select PASS from the menu again then press Enter with 0000 displayed The analyzer will display ACC O indicating that we have returned to the lowest access level 2 ENTERED NO YES PASSWORD 1 ENTERED 0000 ENTERED ACCESS ACCESS ACCESS ACCESS LEVEL O LEVEL
70. on The function of each relay contact can be switched between alarm contact and range number indicator Refer to the Alarms and 4 20 mA Outputs sections Page 43 Installation Input On Off Switch Each input has been provided with an on off switch The most common use of this feature is to turn off a temperature input if no temperature compensator or temperature sensor has been installed Turning off an 2 temperature input for example will make the temperature 2 display at the left side of the menu disappear as if it did not exist In addition an input that has been turned off will not show up in other selections such as the selection of an input for the output or alarm menus Membrane Correction Factor Select the type of membrane included in each sensor Refer to the Calibration section Temperature Compensation Input for D O Inputs For both D O 1 and D O 2 the operator can select which temperature input channel C1 or C2 is to be used for temperature compensation It is also possible for both D O 1 and D O 2 to simultaneously use the same temperature channel for temperature compensation The default setting is for D O 1 to use C1 and for D O 2 to use C2 for temperature compensation In case manual temperature compensation has been selected for a D O input the temperature channel selected here has no effect To select manual temperature compensation for either the D O 1 or the D O 2 inp
71. or its log files Excel prefers TXT PRN or CSV You can keep the DAT extension or use TXT or CSV 2 Open Excel then select File Open from the menu 3 Navigate to the log file If you used the PRN TXT or CSV extension for the log file you may want to change List Files of Type to Text Files otherwise use All Files Select the log file then click on OK 4 Text Import Wizard dialog box should open n Original Data Type select Delimited then click the Next gt button 5 Under Delimiters select Comma Click the Finish button to load the log file into Excel 7 The date time stamp will be loaded in column A and the input values will be loaded in columns B C etc The date time stamp will be treated as text while the input values will be treated as numeric values that can be graphed manipulated etc _ MicrosoftExcel LOG DAT File Edit View Insert Format Tools Data Window m t 0 0 0 0 0 0 5 0 0 Figure 42 Excel Spreadsheet Page 52 IC CONTROLS Example Load Log File in Quattro Pro The following example illustrates how to import a log file into Quattro Pro for Windows 1 By default the Net Access program uses the DAT extension for its log files Quattro Pro prefers TXT or PRN You can keep the DAT extension or use TXT 2 Open Quattro Pro and start with a new e
72. oth the alarm LED and the alarm contact This usage of the alarm contacts is selected by setting AL AmG to OFF The alarm contacts can also be used for remote indication of the range number for the first 4 20 mA output In this case the alarms will continue to function An alarm is indicated using the alarm LED but not the alarm contact This usage of the alarm contacts is selected by setting AL ArnG to on Remote range indication is described in Outputs section High or Low Alarm A high alarm is set when the dissolved oxygen rises above the setpoint and is cleared when the dissolved oxygen drops to below the setpoint minus the differential A low alarm is set when the dissolved oxygen drops below the setpoint and is cleared when the dissolved oxygen rises to above the setpoint plus the differential See figures 28 and 29 below The differential has the effect of setting the sensitivity of the alarm The differential provides a digital equivalent of a hysteresis 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 setpoint 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 dissolved oxygen is expected to stay between 2 0 and 4 0 ppm then we would set in
73. ow 0 before a new data log can be started The StAr frame won t be in the menu while the analyzer is actively logging data Ending a Data Log To end a data log e g to stop logging more points select StOP from the internal logging menu Press Enter when the analyzer displayed the blinking do The analyzer will briefly display donE to indicate that it has stopped the logging operation Data logging will stop automatically if the FULL setting is set to StOP and the entire logging buffer has been filled Clearing the Data Log from Memory The data log can be cleared erased from the analyzer memory The menu will not allow you to start a new log until the existing log has been explicitly erased This is a safety feature to ensure that you don t accidentally wipe out an existing log when starting the next log To erase the internal data log from memory 856 Instructions IC CONTROLS 1 Select iLOG CLr from the menu 2 With the display flashing do press Enter Note there is no way to recover a data log once memory is cleared Be very sure that you do want to clear the internal data log from memory before pressing Enter Calibration amp Event History The analyzer stores important information automatically tagged with a date time stamp The analyzer stores the last 12 calibration records for each input which is sufficient for a year s worth of calibration history when monthly calibrat
74. ow small interactions Recheck zero and span to confirm good calibration 6 If so desired all software settings can be returned to factory default condition by following the procedure in the nstallation Configuration of Program section Testing of Relay Outputs 1 Relay output operation can be verified by testing for contact closure or continuity at each relay To activate a relay select CONF NO NC AL A from the menu Press ENTER go into edit mode then press the Up or Down arrow key to change the normally open normally closed configuration from open to closed Press ENTER again to accept the new value A closed contact should open an open contact should close Repeat step 1 for the Alarm B contact To return all configurations and analyzer settings to factory default run InIt I in the nstallation Configuration of Program section Page 39 Display Prompts Display Prompts 16 61 ACC n AL AL A AL b ArnG ASCI BAud C 92C1 C2 CAL CF CHIP 1 CLI I CLSd CONF Cont cur dAtE dAY dFLt dEv d o 1 4 0 2 donE Err Er 94 L een F2 FASt FrEq FULL HI Hold Part per million D O unit selection in scientific notation Access level for security Alarms Alarm A Alarm B Automatic range switching for 4
75. p device which preserves the contents of the RAM chip for a considerable time even if the analyzer is turned off All settings are stored in RAM TC Temperature Compensator Temperature Compensation Correction for the influence of temperature on the sensing electrode The analyzer reads out concentration as if the process were at 25 or 77 regardless of actual solution temperature IC 856 Instructions Glossary Page 41 Installation Installation Wiring Nominal input power for the 856 microprocessor analyzer is 115 VAC 10 single phase 50 60 Hz Power connections are made at TB400 Three wire grounded power must be used with the third wire connected to a good earth ground If this ground connection is not made published instrument specifications may not be achieved There are three 0 5 inch conduit entrances in the bottom of the instrument enclosure Recommended use line power right hand entrance alarm wiring center entrance D O sensor wiring left entrance 4 to 20 mA wiring middle entrance All conduit connections should be gasketed and sealed to maintain environmental integrity within the instrument enclosure The basic wiring scheme for all IC CONTROLS D O sensors is shown in figures 38 and 39 This wiring scheme is intended for cable runs less than 3 meters 10 feet where electrical interference is expected not to be severe The D O sensor at 1 ppb D O produces less than 1 microamp It is recomme
76. put a low enough signal to cause analyzer to display Err and generate error 2 1 the analyzer will output 4 00 mA Reverse the polarity or input a high enough signal to cause the analyzer to display Err and generate error 2 2 analyzer will output 20 00 mA 2 Repeat step 1 for output 2 Tip both outputs can be simultaneously calibrated if you set in for both inputs 856 Instructions Troubleshooting Adjusting Electronic Calibration 1 Outputs are isolated from main circuit therefore measurements are made with common at the output 2 terminal TB304 2 Measure output 1 zero at TP301 pin 8 of U304 while output 1is outputting 4 00 mA Reading should be between 0 870 and 0 890V Adjust 2 voltage with VR300 3 Change analyzer output to 20 00 mA switch meter to mA and measure Terminal terminal of O P 1 and adjust VR301 so that the current reads 20 00 mA Return analyzer output to 4 00 mA and trim actual output to 4 00 mA using VR300 Check again at 20 00 mA and repeat adjustments until satisfied 4 Measure output 2 zero at TP300 pin 7 of U304 while output2 is outputting 4 00 mA The test point should read between 0 870 and 0 890V Adjust 2 zero voltage with VR302 5 Change output at output 2 to 20 00 mA switch meter to mA at TB304 terminal of output 2 and adjust VR303 span pot until the current reads 20 00 mA Note Zero and span are very wide range adjustments which sh
77. 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 value you entered Likewise if the new value you entered is higher than allowable then the highest allowable value is used instead The analyzer will display whatever value it has stored in memory 856 Instructions IC CONTROLS Analyzer Operation Metric or Imperial Units ange the alarm A setpoint from 10 to 20 From the menu select AL 1 AL A SEt The current By default the analyzer will use metric units This means that temperature will be displayed using setpoint e g 10 will be displayed Press ENTER degrees Celsius and that the prompt for the to enter edit mode The display will change to en ru temperature input will be Using metric units 0010 and the last digit will start blinking Press the pressure is displayed as kPa The analyzer can lt CANCEL to move left one digit The second digit also be made to use imperial units Using imperial from the end will now be blinking Press the up units temperature will be displayed using degrees arrow key to change the 1 to 2 Press ENTER Farenheit and the prompt for the first temperature again and the display will change from 0020 to input will be F instead of C Pressure will be 20 indicating that the new value has been displayed as PSI throughout the progr
78. riate membrane Temperature Compensation Almost all industrial applications encounter fluctuating temperature and need rapidly responding automatic compensation IC CONTROLS dissolved oxygen sensors normally have a TC built into the dissolved oxygen sensor The TC is wired to the analyzer allowing the 856 to provide digital temperature compensation If no automatic temperature compensator is available or needed manual temperature compensation can be used If the temperature of the sample is constant set the manual TC temperature to the process temperature If the process temperature varies or is unknown a default temperature of 25 or 77 is normally used 101 3 es es 100 96 efficiency YES Figure 17 D O menu Page 16 IC CONTROLS Selecting Manual Temperature Compensation To see the current temperature compensation method used by the 856 analyzer during calibration and for calculation of saturation select d o 1 tc or d o 2 t c from the menu Refer to figure 17 At this point either Auto for automatic temperature compensation or SEt for manual temperature compensation setpoint 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 I Press ENTER to se
79. rode Set up electrode then redo calibration Also refer to E2 2 would be less than setup or electrode Troubleshooting section 20 Previous failure setting retained E1 3 Sensor efficiency No DO signal or signal Check electrode connection then redo calibration Also E2 3 would be more from sensor is very refer to troubleshooting section than 300 96 weak Previous setting retained E1 5 Temperature Process outside of TC Use manual temperature compensation 2 5 compensator is operating range of 5 C off scale to 105 C TC not connected Check TC connections or install TC CA1 6 Display shows 0 00 Sensor reading is Sensor is not connected or there is a bad connection CA2 6 ppm dissolved below measuring Connect the D O sensor or check connections oxygen There is capability of analyzer no dissolved oxygen measurement CA1 7 Display shows Dissolved xxygen Display DO using ppm units Select d o 1 unit or CA2 7 Err reading is too displayed using ppb d o 2 unit from menu then set to 1E 6 to display high for display units and dissolved ppm dissolved oxygen oxygen 9999 ppb Page 20 856 Instructions IC CONTROLS Error Messages for Temperature Error Messages Error Description Causes Solutions E3 1 Temperature Temperature less Verify process and sensor location E4 1 reading than 5 off scale EE Temperatur
80. rts are warranted to be free from defects in material and workmanship for a period of three 3 months from the date of installation or eighteen 18 months from the date of shipment when used under normal operating conditions and in accordance with the operating limitations and maintenance procedures given in the instruction manual and when not having been subjected to accident alteration misuse abuse freezing scale coating or poisoning ions Chemical solutions standards or buffers carry an out of box warranty Should they be unusable when first out of box contact IC CONTROLS immediately for replacement To be considered for warranty the product shall have an RA Return Authorization number issued by IC CONTROLS customer service department for identification and shall be shipped prepaid to IC CONTROLS at the above address In the event of failure within the warranty period IC CONTROLS or its authorized dealer will at IC CONTROLS option repair or replace the product non conforming to the above warranty or will refund the purchase price of the unit The warranty described above is exclusive and in lieu of all other warranties whether statutory express or implied including but not limited to any implied warranty of merchantability or fitness for a particular purpose and all warranties arising from the course of dealing or usage of trade The buyer s sole and exclusive remedy is for repair or replacement of the non conforming produc
81. ructions Analyzer Operation Display Features 1 The analyzer has a built in timer which returns the program to displaying the home base if no key has been pressed for 15 minutes This time out has the same effect as pressing the SAMPLE key If security has been enabled as well the timeout will change the 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 If output hold for a D O input is in effect the same timer will release the output hold When displaying the home base you can press Left to show which of the samples is displayed Pressing Right displays the same sample again If an input does not show up in the menu and cannot be selected then it has been turned off in the configuration step Each input can be turned off and thereby effectively disappear from the menu if it is turned off in the configuration menu To change the configuration see under the nput On Off Switch heading in the nstallation Configuration of Program section The main sample i e the input that is displayed first when the Sample key is pressed can be changed By default the main input is d o 1 Change the default in CONF in dFLt Refer to the nstallation section Configuration of Program for further details Main Menu v n Figure 7 Main menu Page 7 Analy
82. s setting to reflect the connection on your computer 4 capture data into a file select Transfers Communications Baud Rate Oo 300 600 1200 2400 4800 9600 19200 Data Bits Stop Bits 8 eros O2 Flow Control Connector Xon Xoff Hardware None Parity None Odd Even Mark Space COMI COM2 L Parity Check LI Carrier Detect Figure 41 Terminal Communications Dialog Receive text file from the menu Specify the file name and location Example C logs log01 dat The terminal program will now store any ASCII data sent out by the analyzer into the specified file 5 To stop or pause data collecting use the buttons at the bottom left of the window 856 Instructions Appendix F Data Capture Example Windows 95 98 NT Hyperterminal To illustrate the capturing of data on a computer following is the description for loading and setting up the Hyperterminal program versions of which come with Windows 95 Windows 98 and Windows NT 1 From the Start menu select Programs Accessories Communications Hyperterminal Win95 98 or Programs Accessories Hypterterminal WinNT then click on the Hyperterminal program icon 2 For a new communications setup you will be prompted for the name of the connection Give the connection a descriptive name e g 456 analyzer then click on OK 3 the Connect To dia
83. settings TYPICAL 4 20 mA OUTPUT WITH AUTOMATIC RANGE SWITCHING 100 6 10 0 1 2 3 100 N 5 C 5 o 0 TIME contacts 0 0 0 1 1 0 Figure 23 Output with automatic range switching Page 25 Outputs Remote Indication of Range Number Once output 1 is set to switch between ranges automatically we still need to be able to indicate to a recorder or a digital control system which range number output 1 is on This task can be accomplished either by using the alarm contacts or by using the second 4 20 mA output The analyzer will also allow both methods to be used simultaneously Using the Alarm Contacts The alarm contact method uses the two alarm contacts to distinguish between ranges With two contacts there are four possible combinations The on off combinations for the A and B contacts are shown in table 3 Set up the alarm contacts for range indication by selecting AL ArnG from the menu then editing the setting to show While the alarm contacts are being used for remote range indication of output1 the alarms will continue to function as normal i e LED indication and alarm type display in SAMPLE frame will continue It is not possible to use an alarm contact for alarm indication and range indication at the same time Also note that while the alarm contacts are being used for range indication the normally open normally closed configuration will be observed Consul
84. stance with calibration techniques or any other matter our application development laboratory specialists are only a toll free phone call away for advice and or laboratory simulation of your probem Buy from IC CONTROLS because you get outstanding customer support as well as quality industrial equipment in short REAL SOLUTIONS Page 54 856 Instructions Microprocessor Board Component Location NOILVOO LN3JNOdNWOO 09V09 AV IdS Id SSW JALIL 0opouoj olaogug 8aj ebuod o VS CL s 933 4p SORANO I T AE ETE Lera C 20 LeSTL 198 8C02606V ELES WL MMS452N c c 0XV7 5IC V9 VIM D vOTOWIW O EZ AJY 6ZOLSSEWN AV1dSId SSW 1300M LTC1535 L9 0 0C CM0 5 0 HDIH Hd v 0d dW31 9 0d dW31 L 0d X019373S 39NV3M Page 57 856 Instructions Drawings IC CONTROLS Wiring and Component Location SENE 9009 A3B 81086SQswo pasn M0ILIV 0 LNANOdWOO 7 ONIMIM 9S8 aj aBuoup STOHLNOD 4j C0L IC0X9 0 E STOULNOD l 0401 S08CT 781200 dL E ji 8oscr L 9 0 d O 0024 ev 99 9VI31 dW31 HA BIS wai 0 515 wav Wavy Page 61 856 Instructions IC CONTROLS Drawings 800 Interface 9 0DS O T
85. t 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 856 Instructions
86. t should appear clean shiny and bright Insert the assembled and calibrated D O sensor in the twist lock fitting Rock the sensor back and forth to pass the O rings and align the locking pins with the slot in the fitting Press slowly all the way down until the D O sensor pins firmly contact the fitting bottom By hand turn the sensor until the pins are fully under the locking latch Then release pressure observing that the pins come back and engage the lock CAUTION do not use a large wrench to turn the sensor The plastic pins of the D O sensor could be broken or be deformed NOTE the twist lock fitting is not intended for use at high pressure flat for air bubble release 30 g gt Figure 21 Step 5 Membrane amp Cap Installation Page 23 Outputs Outputs Dual 4 to 20 mA Output Signals Two assignable 4 to 20 mA output channels are provided The user may configure the analyzer to determines which input signal will be transmitted by each 4 to 20 mA output channel Each output channel can be configured to transmit a dissolved oxygen or a temperature signal Out2 can also be used to transmit the range number for out1 The output channels function independent of each other Each output channel has a separate on off switch and adjustable low and high span adjustments It is normal for example to transmit two dissolved oxygen signals using both outi and out2 with each output using a different set of
87. t the nstallation Configuration of Program section for further details IC CONTROLS Using the Second 4 20 mA Output A more versatile method for indicating the range number for output remotely is to use output2 The following settings for output2 will transmit the range number in ArnG ON OF on I Also set the HI and LO parameters to indicate which values represent 4 00 and 20 00 mA Table 4 shows the relationship between the range number and some of the possible LO HI settings Range LO 0 LO 1 LO 5 LO 5 Number 5 HI 5 HI 21 HI 0 OUT2 400 400 400 4 00 OFF 1 7 20 4 00 20 00 20 00 2 10 40 8 00 16 00 16 80 3 13 60 12 00 12 00 13 60 Table 4 Using output 2 for range indication range output 1 output 1 output 2 number fullscale scaleppm D O relay contacts 1 100 20 0 4 00 A 0 0 2 10 2 0 8 00 0 1 3 1 0 0 2 12 00 A 1 0 Table 3 Example of range switching for D O input Page 26 856 Instructions IC CONTROLS Unit Selection The output module will be using different units for its high and low settings depending on the input selected Select unit from the output menu to display the units in use for this output The temperature input will use different units depending on whether metric or imperial units are selected Celsius units for m
88. te timeout 7 44 output hold timeout 7 security timeout 7 Troubleshooting 37 Twist lock fitting 23 Units 27 29 44 48 metric or imperial 9 pressure 9 44 temperature 9 44 Version 6 Warranty 68 Windows Hyperterminal 51 Wiring 42 Zero oxygen standard 15 Page 67 Industrial Products Warranty IC CONTROLS 0 CO NTRO LS LTD Head Office Manufacturing amp Research 29 Centennial Road Orangeville Ontario LOW 1R1 Canada Tel 519 941 8161 Fax 519 941 8164 Page 68 Industrial Products Warranty Industrial instruments are warranted to be free from defects in material and workmanship for a period of twelve 12 months from the date of installation or eighteen 18 months from the date of shipment from IC CONTROLS whichever is earlier when used under normal operating conditions and in accordance with the operating limitations and maintenance procedures in the instruction manual and when not having been subjected to accident alteration misuse or abuse This warranty is also conditioned upon calibration and consumable items electrodes and all solutions being stored at temperatures between 5 and 45 C 40 and 110 F in a non corrosive atmosphere IC CONTROLS consumables or approved reagents must be used or performance warranty is void Accessories not manufactured by IC CONTROLS are subject to the manufacturer s warranty terms and conditions Limitations and exclusions Industrial electrodes and replacement pa
89. the cell calibrate check efficiency and if above 50 percent place in service Chemical Cleaning Maintenance Recover of failing D O sensors can sometimes be achieved with p n A1100194 D O sensor cleaning solution This procedure should be done over a sink Wear plastic or rubber gloves as the solution is acidic Wash hands thoroughly with lots of water if the solution comes in contact with the skin Page 22 IC CONTROLS D O sensor beaker Keep coils below surface Figure 19 D O Sensor Cleaning 1 Remove the protective cap exposing the coils and gold tip 2 Immerse in cleaning solution as shown Figure 19 for 5 to 10 minutes or until deposits disappear 3 Remove and rinse in Distilled or Demin water use wiping or toothbrush to speed removal 4 Repeat 2 amp 3 untill coils and tip look clean and have a grey shine then re assemble D O sensor with new membrane and fill solution calibrate and check efficiency is above 50 96 5 Repeat 2 to 4 as necessary to get at least 50 percent efficiency If not possible D O sensor should be replaced Removal of the Dissolved Oxygen Sensor Flow and Insertion Type 1 Stop the sample flow to the dissolved oxygen sensor and vent the sample line to atmosphere 2 If installed by insertion directly into a tank wall ensure the level in the tank is below the sensor before removing sensor 3 Pressin to release the pins from the twist lock fit
90. ting and turn the sensor until the pins line up with the exit slot 4 Gently rock the dissolved oxygen sensor back and forth to ease the O ring seals back up the compression throat CAUTION Removal of the dissolved oxygen sensor from a sealed flowcell will vacuum stretch the thin dissolved oxygen sensing membrane Stretching the membrane will cause slow response and higher readings at low ppb levels Parting the membrane will cause dissolved oxygen sensor failure 5 When the dissolved oxygen sensor has been fully removed wipe the sensor clean and then proceed to the calibration procedure or monthly yearly maintenance as necessary 856 Instructions IC CONTROLS Assembly of the Dissolved Oxygen Sensor This procedure should be done over a sink Wear thin plastic or rubber gloves as the electrolyte is a caustic solution Wash hands thoroughly with lots of water if the electrolyte comes in contact with the skin Rinse until the slippery feel of the caustic disappears 1 Galvanic D O sensors need to have a current drain at all times Assemble sensor wired to analyzer or if not possible short the coax ctr to shd 2 Remove the protective cap exposing the coils and gold tip Inspect the electrode to ensure the coils are clean and the gold electrode is bright 3 Assemble a membrane module in the cap with the membrane facing down so that it covers the center hole in the cap Membrane Module O ring TON
91. tion factor membrane selection 16 44 Configuration 42 45 def aults 44 input on off switch 44 normally closed 41 normally open 41 Program 44 units 9 44 Current output Page 66 displaying 39 SEE output signals simulating 39 D O applications 13 calibration 15 49 introduction 13 measuring circuit 37 output hold 18 output signals 24 pressure compensation 49 temperature compensation 49 troubleshooting 37 D O sensor SEE Electrode Damping 10 44 Default settings 50 Diagnostics memory test 6 startup procedure 6 Differential SEE hysteresis Display schematic 55 Dissolved Oxygen SEE D O Edit mode change settings 8 numeric values 8 Electrode assembly 23 maintenance 22 Error codes 6 Error messages 19 sign 19 sign 19 acknowledging 19 CA 1 6 20 CA 1 7 20 CA 2 6 20 CA 2 7 20 E 1 0 20 E 1 1 20 E 1 2 20 E 1 3 20 E 1 5 20 E 2 0 20 2 1 20 E 2 3 20 2 5 20 E3 1 21 IC CONTROLS 3 2 21 E4 1 21 E 4 2 21 meaning of 40 remote indication 28 temperature 21 Event records SEE ALSO description Event tags SEE ALSO description Excel spreadsheet 52 Fault alarm 28 Home base 7 Hyperterminal 39 51 Hysteresis 41 IC Net 34 baud rate 33 caution messages 29 internal data log 34 node number 33 wiring and enabling 32 Imperial units 9 44 Input damping 10 44 on off switch 7 19 Installation 42 46 wiring 42 Internal data log 34 Internal date time clock 35 Real time clock 3
92. to d o Func to dEv SEt to 3 0 and dEv to 0 5 Effectively we simultaneously have a high alarm at 4 0 ppm and a low alarm at 2 0 ppm The differential setting will continue to function as for high and low alarms 856 Instructions IC CONTROLS Fault Alarm A fault alarm for an input will be set when anything goes wrong with that input Something is wrong with an input if the input is off scale or an unacknowledged error or caution message exists for that input To use an alarm as a fault alarm select FUNC from the alarm menu then select L IL To enable the alarm make sure the on off switch is set to on The setpoint and differential for the alarm have no effect when the alarm is used as a fault alarm Using Alarms for On Off Control The alarms can also be used for process control The alarms contacts will then function as on off signals for switches controlling a valve pump motor etc The setpoint determines the control point of the system and the setting of the differential controls the amount of corrective action before a controlled shut off occurs sample time Figure 31 Low control time Figure 30 High control 856 Instructions Alarms Page 31 IC Net Features IC Net Features Serial communications give the analyzer the ability to communicate with a computer running an Net Advanced Intelligence Access program The IC Net software is available
93. ts the program will display PASS for 2 seconds indicating that you must first enter a proper password before you are allowed to proceed access level description 0 View only access to all settings 1 Access to all settings except for configuration menu Usage operator access no changes can be made to configuration and passwords cannot be changed 2 Access to all settings This gives you the same access to the program as when password security is not enabled Passwords can be changed Usage installation management Table 1 Security access levels 856 Instructions Security 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 figure 10 to determine how the program validates a password You will now have level 1 or level 2 access for as long as you are working with the analyzer The access level will automatically be restored to level 0 after no key has been pressed for 15 minutes This 15 minute timeout will also redisplay the main sample It is good practice to return the analyzer to level 0 access or level 1 access if password 1 is set t
94. ttings and parameters can be viewed and or changed at any time using the keypad Refer to the menus starting with Figure 1 The areas shaded in dark gray indicate program settings which can be changed by the user Menu areas shaded in light gray are view only menus Page 6 IC CONTROLS Start up Settings The 856 dissolved oxygen analyzer uses sensors with a galvanic cell which has an electrochemical zero current output at 0 ppm disolved oxygen Full scale calibration is easily done using atmospheric air as the oxygen standard The 856 needs only to have the operator remove the cell expose it to air plus enter the calibrate command All stabilization temperature and pressure compensation plus calibration adjustments are automatic Temperature plays a major role in dissolved oxygen readings The 856 has stored temperature vs dissolved oxygen tables in memory A temperature detector is in close contact with the dissolved oxygen sensing tip in the sample The temperature sensor can be field calibrated but comes from the factory pre calibrated Pressure also plays a significant role during calibration The 856 also has pressure vs dissolved oxygen at saturation tables stored in memory See Appendix D for a table of saturated D O values at various temperatures and pressures Changing Settings Analyzer settings and parameters can be viewed and or changed at any time Refer to the menus the areas shaded in dark gray indicate progra
95. ugg SAt SEr SEt StAr StbY Std StOP LLC unit I YEAr 1 IC CONTROLS Hour Real time clock setting Hundredths of a second Real time clock display Input menu or setting OR Minute real time clock setting kPa units for pressure Low alarm low limit 4 mA for 4 20 mA output window Node number for IC Net communications Normally Open Normally Closed alarm contact off Offset i e offset in C F for temperature input calibration on On off setting Month Real time clock setting Normally open alarm contact output menu first 4 20 mA analog output channel second 4 20 mA analog output channel Set password 1 operator access Set password 2 complete access Enter password to change access level ppb parts per billion D O unit selection Pressure compensation setting Pressure PSI units for pressure Analyzer D O input range selection Reset calibration settings Range number generated by 4 20 mA output Range number for D O input Ruggedized membrane 96 saturation dissolved oxygen Serial communications menu Setpoint select manual temperature compensation Start internal data log Standby mode for analyzer Standard membrane Stop internal data log Temperature compensation setting Unit display or selection Year Real time clock setting 856 Instructions IC CONTROLS Glossary EPROM Erasable Programmable Read Only Memory T
96. unications menu Page 5 Analyzer Operation Analyzer Operation Startup Procedure 1 Install the Model 856 analyzer according to the instructions in nstallation and Appendix A Installation Summary Verify power supply has been wired for proper voltage and instrument is suitably grounded Turn on flow at sample inlet or insert sensor s in sample Power up the 856 analyzer The startup procedure will begin by alternately flashing tESt and while performing the memory tests The analyzer will display in sequence the analyzer model number in this case 856 and the program version number e g 2 10 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 If the analyzer passes all the tests then the hardware is functioning properly and the analyzer will proceed to display the dissolved oxygen reading d o 1 If the analyzer displays Err this indicates that the dissolved oxygen input is offscale The error LED will be lighted as long as either the dissolved oxygen or the temperature input is off scale An off scale error can indicate that a sensor is not in solution is off scale or is not connected properly If the error LED remains lighted then press the Error key to see what errors have been detected by the analyzer After completing the above steps the monitor is now in normal operational mode Analyzer se
97. ut consult the Temperature Compensation section for the procedure Input Damping Refer to the Analyzer Operation section Temperature Calibration Refer to the Troubleshooting section Default Sample Display The default setup is for the main input to be the first dissolved oxygen input D O 1 Whenever the Sample key is pressed or the 15 minute timer times out after the user has not pressed a key this is the input that will be displayed in the sample menu The main input can be changed to D O 2 C1 or C2 to fit your needs Select CONF in from the menu then edit the setting Page 44 IC CONTROLS 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 prompts for the temperature inputs will be 1 and C2 Using metric units the pressure is displayed as kPa The analyzer can also be made to use imperial units Using imperial units temperature will be displayed using degrees Farenheit and the prompt for the first temperature input will be F1 instead of 1 Pressure will be displayed as PSI throughout the program For practical reasons the temperature input is always 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 Since
98. utputs Alarm Indication The A and B LEDs on the front panel show the current state of each alarm and alarm contact Refer to figure 26 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 I or 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 An LED that is blinking or shows the alarm condition The status of the relay contact can also be determined at a glance as it is activated when the LED is on and is deactivated while the LED is only blinking or Page 28 IC CONTROLS off The alarm LED will blink while the alarm override is in MANUAL because this situation deactivates the alarm contacts Each alarm will simultaneously generate a caution number in the error menu The table below describes the meaning of each alarm caution The alarm cautions will not cause the error LED to come on because the error LED only comes on if there are any errors To view alarm caution s using the error menu select Err from the main menu then use OFF alarm condition J BLINK 9 alarm condition adn contact not activated alarm condition contact actvated ON e Figure 25 Alarm status indication the up or down arrow key to scroll through the list of errors and cautions if any Alarm functio
99. zer Operation Four Arrow Keys The four arrow keys on the keypad are used to move around in the menu The same keys can have other functions as well e g see under Edit Mode but when moving from frame to frame in the menu these keys work as expected Example Press SAMPLE to make sure that we are at home base Press the right arrow key One of the prompts in the main menu i e the column starting with d o 1 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 dissolved oxygen 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 Page 8 IC CONTROLS Edit Mode Edit mode is used to change a numeric value or to select between different options The values and settings which can be edited are identified by the darker shading in the menus Any frame which has a white background cannot be modified by going into edit mode but can be viewed Editing by Selecting a Setting Examples of selecting a value are on off settings and switching between different a

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