OM84373b MAX Service Manual
Contents
1. milli K kilo or M mega Example Get the value of setpoint Command G002A02 Response G002A02 1 1125000m 2 9 Variables For Get and Set Parameter Command For the index number the maximum value depends upon the parameter type and may be 1 Channels 6 2 Circuits 7 3 Measurements 16 4 Analog outputs 8 5 Relays 4 6 Setpoints 16 7 Discrete Outputs 2 8 Discrete Inputs 2 Chapter 6 RS232 Communications 19 nie SmasterPassword SmasterPassword integer 08 08 Mode integer Measurements Measurement mode 09 09 Ranges integer Measurements Measurement range TT OB iOmerchan2 Integer Measurements 2 other channel needed 13 OD sName String Measurements Name of measurement o 29 i 3 44 gaz me Code 44 iSpRelay Setpoints Relay or output for setpoint 20 RS232 Communications Chapter 6 Bu BER lAoutSgna iAoutSignal fAoutWin Float_ Analogs SS CCS Dom Foa Aaos _ moment Leg Aaos _ _ RSC 3C_ TAoutWax2 Foa Ang JI e 3D iAMmiMut integer Anaos T 62 3E_ iAMidtMult Integer Analog _ e SF Dass Integer_ Analogs s ss sss C 64 40_ iAMin2Mult Integer mer J e a 1AMax2Mult I integer_ Analogs OOOO 66 42 Language Integer 1 Language D English e 44 Pany Integer2. 1 Type 2 point Page Down when set 4mA reads 4 0001mA METER CAL RESULTS SAVE VERIFY DATA Ch 1 Res 1 Chan1 Res 1 Cal Date 03 12 99 Enter Date01 02 00 Verified 03 12 99 erify Data is Saved CALIBRATE SENSOR CALIBRATE ANALOG CALIBRATE METER A reads 147 511S cm Channel 1 1 reads 3 9942 Mi Cal point 1 147 10 u 20mA reads 20 001mA Cal point 14 0000 M Page Down to do cal Page Down when set Page Down to do cal CALIBRATE SENSOR ANALOG CAL IS DONE CALIBRATE METER A reads 147 5 1S cm Before N A 1 reads 1 8029 Mi Cal point 2 147 10u After N A Cal point 24 8180 M Page Down to do cal Enter date 05 12 00 Press ENTER when set SENSOR CAL IS DONE METER CAL IS DONE Before 123 11uS cm After 121 9 uS cm Enter Date00 00 00 Enter Date00 00 00 Chapter 7 Menu Trees 31 ANALOG OUTPUTS SETPOINTS AND RELAYS MENUS Analog Outputs Setpoints Relays Types ANALOG 1 Normal linear SETPOINT RELAY Meas A DI Tank S cm 2 Bi linear Measure A DI Tank Delay 0005 sec Type Normal 3 Auto Range Value 18 123M Q cm Hysteresis 10 Low Value 4mA 4 Logarithmic Type High State Normal Normal Linear Bi Linear Auto Range SETPOINT 1 RELAY 1 Activate Relay 1 Ext Reset In 1 ANALOG ANALOG 1 ANALOG 1 If sensor error Off Type is SPDT Mech 4mA 10 000 m S cm 4mA 0 0000 u S cm Range 1 Settings Status Next Page Relay is now on 20mA 20 000 m S cm Mid 1 0000 u 4mA 0 0000 u S cm more 20mA 11 000 u
3. yyy is the model number aaaa aa is the unit name as programmed by the user zzz is the software revision number obbbbbbb is the serial number Example Command A or A00 Response A00 Thornton 775 LAO Lab Unit Ver 1 00 S N 000072358 2 4 Get Data Command Description This command will return the latest set of measurement data Command Format 16 RS232 Communications Chapter 6 Dxxab Where xx is the network address of a unit can be set to 00 for this unit a measurement channel A Z to get If this character is a then all measurements will be returned b optional F to request measurement data in floating point format otherwise data is returned in the real format Response Format Dxx bcd eeeeee ffffff ggf Where xx is the network address of the unit be ff is the data returned with the format described in section 2 2 Example 1 Command DOOB Response D00 A1 513 67 Ko cm C7 Example 2 Command D00 Response D00 A1 513 67 Ko cm C7 DOO B1 25 45 DegF DA D00 C2 18 18 Mo cm 32 D00 D2 25 45 DegC 91 Notes If the all of the data is requested by specifying the channel as then a number of responses will be sent out with the format described above Each response or line will be terminated with a CR character For example sending the command D00 may result in 8 responses for the 8 defined measurements in the meter 2
4. 1 Parity oO o 69 45 iDataOutputon Integer 1 sst Di 47 iNetworkAddress Integer 1 o 172 48_ iNetworkType Integer T _ _ L SSS 73 49_ iAutoScrollOn Integer 1S 74 4A DispayMode Integer 1 175 4 iisplayStart_ Integer 1S SSS 76 4C iDisplayOrder Integer Measurements o 80 50 fMeterCalSiope2 Float Oireuits Chamnes 81 51 fMeterCalSiope Float _ Circuits Channels nn s o 82 52 MeterCalofiset Long Cireuits Channels J 83 53 iMeterVerpaie Long Oireuits Chamnes J 84 54 iMeterVerpate Long Cirouits Channels 85 55 dCalMeasureLimit Float Gireuits Channels C 86 56 dCaMeasureBeforet Flat Circults AChannels x C 87 57 dCalMeasureAfteri Fat Oireuits Channels 88 58 dCalMeasureBefore2 Float Circuts Channels_ X 89 59 dCalMeasureAfter Fat Oireuits Channels 90 5A dCalMeasureBefore Float Cirouits AChannels x C 91 5B dCalMeasureAfters Fat Oireuits Channels 92 5C dCalValuet Foa Cicuts Channels 193 5D dCaiValue2 Float Cireuits Chanes SSS 94 5E dcalVallues reet Oireuits Channels 95 5F dCalVerifyinput Float Cirouits Chanes 96 60 dCalVerityinput Float Cicuts Chames 97 61 _ dcalverifyinputs Float Cireuits Chan
5. 20mA 10 000 u SETPOINT 1 Elapsed time since ANALOG 1 ANALOG 1 ANALOG 1 last activation is On failure set Min On failure set Min Range 2 Settings dd hh mm 01 52 45 Calibrated 03 17 97 Calibrated 03 17 97 4mA 0 0000 u S cm Current Out 14 24mA Current Out 14 24mA 20mA 100 00 u ANALOG 1 When using range 2 activate Relay 1 more ANALOG 1 On failure set Min Calibrated 03 17 97 Current Out 14 24mA 32 Menu Trees Chapter 7 DISPLAY SETUP SECURITY AND DIAGNOSTICS MENUS Display Setup DISPLAY MENU Scrolling Auto Backlite Always On Disp Order Custom DISPLAY SETUP Display Line 1A Display Line 2B Display Line 3 CHANGE PASSWORD Which password to change Master Master Pass DISPLAY SETUP Display Line 4H Display Line 5J Display Line 6K CHANGE PASSWORD Enter a new Master password New Password VERIFY PASSWORD Confirm new password Then press Enter key New Password Chapter 7 Change Password Security SECURITY MENU Select option using TL then press Enter Goto Change Password Menu Options 1 Change Password 2 Change Lockout 3 Lockout Status Change Lockout Lockout Statug LOCKOUT STATUS Lockout is Enabled User 1 Lockout All User 2 Open Cal Only LOCKOUT MENU To change lockout enter the Master Password LOCKOUT MENU Lockout Disabled Lockout All User2 Lock Cal Only LOCKOUT STATUS Time since last change in meter
6. 4 Recall Setup Data Smart Sensors SMART SENSORS Select a menu using T4 then press Enter Goto Save Sensor Data PRINT METER SETUP Press Enter when ready to print the meter setup PRINT METER SETUP Please wait Printing setup Press Menu to quit Edit Smart Data Clear Setup Data Recall Setup Data CLEAR SENSOR DATA Select a channel to RECALL SENSOR DATA Select a channel to read sensor data 1 Then press Enter clear sensor data 1 Then press Enter 35 CHAPTER 8 ACCESSORIES AND SPARE PARTS ACCESSORIES Description Part Number Patch cords have connectors at both ends for 770MAX and Smart Sensors not used with pulse input flow sensors Pressure and level sensors are limited to 150 ft 45 6 m maximum and 4 electrode conductivity sensors are limited to 50 ft 15 2 m maximum length 1 ft 0 3 m cord 1001 79 5 ft 1 5 m cord 1005 79 10 ft 3 m cord 1010 79 15 ft 4 5 m cord 1015 79 25 ft 7 6 m cord 1025 79 50 ft 15 2 m cord 1050 79 100 ft 30 5 m cord 1100 79 150 ft 45 6 m cord 1115 79 200 ft 61 m cord 1120 79 300 ft 91 m cord 1130 79 Rear cover for wall mounting and NEMA 4X IP65 sealing 1000 69 Cable Grip Kit for sealing 1 2 conduit hole entrances for 2 patch cords to rear cover 1000 80 or other enclosure with large grommets to pass modular connector of patch cord Pipe mounting bracket for 2 pipe 15540 Ferrite Suppressor Module 2 required on pow
7. Key 8 09 Key 9 OA Menus key OB Help key 0C Right Arrow key OD Left Arrow key OE Up Arrow key OF Down Arrow key 10 Help key 11 Page Up key 12 Page Down key 13 Next key 14 Decimal minus Key FF special code to make the unit exit the menu mode All other codes are not used Response Format If the key code is valid then the display message will be returned as Kxx a a bb Where xx is the network address of the unit 22 RS232 Communications Chapter 6 a a is the message displayed as a result of the key press bb is the cursor position Example Command K000A Response K00 This is the main menu Select a function then press NEXT 64 2 11 Display Message Command Description This command is used to display a message for a specified time period in seconds The display time is from 0 to 256 seconds specified as a hexadecimal number If the unit is in the menu mode then the menus will be terminated before the message is displayed Command Format Mxxaab ba Where xx is the network address of a unit can set to 00 for this unit aa is the display time in seconds from 00 to FF b b is the message to be displayed up to 80 characters Response Format Mxx OK Where xx is the network address of the unit Example Display This is a test for 10 seconds Command M000A This is a test Response M00 OK 2 12 Self Test Command Descriptio
8. Setup Pressure Sensor Tank Level Sensor MEASUREMENT A Sensor input Chan 1 Units Full Name DI Tank MEASUREMENT A Multiplier 1 23456 Adder 0 25413 Averaging High MEASUREMENT A Max PSI 15 00 Tank Height 15 25 ft Area 10 000 sq ft MEASUREMENT A Resolution 0 01 MEASUREMENT A Reading 70 39 Full Sensor S N 123456 Cal Date 07 23 97 MEASUREMENT A Raw reading from the sensor 0 00000000V Using chan 1 Chapter 7 15 Set Hold Time MESSAGES AND CALIBRATION MENUS Calibrate CALIBRATE MENU Select a calibration then press ENTER Calibrate Sensor Messages MESSAGES Meas A Chant Q cm No problems reported Calibration Types 1 Sensor 3 Analog 2 Meter 4 Meter Results 5 Meter Verify Sensor Analog Meter Meter Results Meter Verify CALIBRATE SENSOR CALIBRATE ANALOG CALIBRATE METER METER CAL RESULTS METER CAL VERIFY Hold outputs during Hold outputs during Hold outputs during Ch1 Res 1Point1 han 1 Res 1 cal Enter00for no cal Enter 00 for no cal Enter 00 for no Cal At 18 181 M Hold time 00 mins Hold time 00 mins Hold time 00 mins Error 0 51 Ok CALIBRATE SENSOR METER CAL RESULTS SAVE VERIFY DATA Ch 1 Res 1Point1 han1 Res 1 Before 18 185M2 Enter Date01 02 00 After 18 181M2 Page Down to Store CALIBRATE ANALOG Channel CALIBRATE METER Cond Type 2 point S cm Page Down when set Page Down when set Chan1 gt Res
9. The level of the input lines high or low will be displayed and updated every second Outputs Set the outputs low or high for testing Press 1 to set low or 2 to set high Self Tests An automated series of tests will check the operation of the following components Smart sensors Analog outputs Discrete outputs Discrete Inputs Chapter 5 Network e Display circuit board e Measurement circuit board e Options circuit board Other circuits ROM RAM etc The display shows how many tests have run the elapsed time and the number of errors found Press Menus to stop the test sequence Chapter 5 Troubleshooting 13 CHAPTER 6 RS232 COMMUNICATIONS Connections for the RS232 serial port are shown in Chapter 4 1 SERIAL PORT COMMUNICATIONS 1 1 General The Serial Port Communications command set provides the user with complete control and configuration of a meter All messages sent to and from the meter will consist of the printable set of ASCII characters Each message will be terminated with a carriage return lt cr gt character All messages sent to the 770Max will receive a response The response will consist of the requested data an OK message or an error message All commands must specify an identifier address same as the network address A command with an address different from that of the unit will be sent over the network The identifier address 00 can be used to indica
10. patch cord sockets Press it evenly into place with a thumb or finger 8 Plug the measurement board back into the front display board 9 Carefully align the entire circuit board assembly so each circuit board keys into its respective slot in the case and slide it in Some flexing may be necessary to assure complete installation 10 Plug the front cover keypad ribbon cable back onto the display circuit board pins 11 Replace the cover back onto the instrument and tighten the two cover screws 12 Reconnect input and output plugs in their original locations and re wire power to the meter OUTPUT UPGRADES Relays and additional analog outputs may be added with circuit boards to an existing 775 A0 Instrument which has no option board already installed Kit 1000 91 adds 4 SPDT relays to convert an instrument to model 775 _A1 Kit 1000 92 adds 4 SPDT relays and 4 additional analog outputs to convert an instrument to model 775 _A2 These options are UL and cUL recognized when installed in instruments manufactured since July 2000 These options are not CE rated CAUTION Adding operating conditions Kit 1000 91 lowers the maximum ambient temperature rating to 104 F 40 C when operating on 230 VAC power these outputs restricts Kit 1000 92 lowers the maximum ambient temperature rating to 104 F 40 C on 115 VAC power and cannot be used above 130 VAC This kit may only be installed in an instrument with main soft
11. than the limit of error of the standard or of the 770MAX specification 13 Press Enter to reach the parameter range field e g Res _ 14 Press up arrow to go to the next range and repeat steps 8 12 for the 3 remaining resistance verification points The meter will display Res 1 Res 2 Res 3 or Res 4 This is to accommodate a future feature All of these selections are equivalent the meter will auto range to the correct measuring circuit regardless of the number indicated Chapter 2 15 Repeat steps 8 13 for the other channels to be verified 16 For the temperature range repeat steps 2 14 but with the decade box connected to the temperature leads of the conductivity adapter 17 For the voltage range repeat steps 2 15 with a precision voltage source connected to Smart voltage adapter 1000 79 18 For the frequency range repeat steps 2 15 with a precision frequency generator producing a 0 3 V square wave connected to Smart frequency adapter 1000 83 19 For frequency verification of channels 5 and 6 connect the frequency generator directly to TB2 terminals 7 and 6 respectively and to common TB2 terminal 2 0 Repeat step 18 omitting the adapter 20 Press Menus twice to exit Recommended Verification Points Parameter Verification Range of amp Range Point Measurement 100 Q 0 700 Q 2000 Q 300 14 000 Q 50 000 Q 3750 175 000 Q The 770MAX automatically selects the appropriate m
12. 232 Communications Chapter 6 d optional multiplier u micro m milli K kilo or M mega 2 16 Get Set Output Line Command Description This command is used to set an output line to either a low or high level It is also used to read the state of the line without changing it Command Format Lxxaab Where xx is the network address of a unit can set to 00 for this unit aa output number b state O low 1 high If b is set to a character then the state will be returned not changed Response Format Lxxaa b Where xx is the network address of the unit aa output number b the state of the output O low 1 high Example Set output 1 high Command L00011 Response L0001 1 2 17 Read Input Line Command Description This command is used to read the state of an input line Command Format Ixxaa Where xx is the network address of a unit can set to 00 for this unit aa input line number Response Format Ixxaa b Where xx is the network address of the unit aa input number b the state of the output O low 1 high Example Read input 1 high Command 10001 Response 0001 1 2 18 Get Set Date Time Command Description This command is used to set or get the date and time Command Format Txxaa bbbbbbbb Where xx is the network address of a unit can set to 00 for this unit aa 01 for the
13. 5 Set Auto Data Output Command Description This command will enable or disable the automatic data output Command Format Bxxa Where xx is the network address of a unit can set to 00 for this unit a 1 to enable the data output 0 to disable the data output Response Format Bxx OK Where xx is the network address of the unit Example To enable the data output of this unit Command B001 Response B00 OK Notes If the data output is enabled on a unit over the network then the data will be sent out the serial port of that unit only the data will not be sent over the network Chapter 6 RS232 Communications 17 2 6 Reset Command Description This command will perform various types of resets either a system measurement total flow or total grains reset The reset parameter character can be 1 S performs a system reset 2 M performs a measurement reset Averaging buffers are cleared RTDs are re measured 3 T performs a total flow reset The next character in the command specifies the channel A sa Pi 4 G resets a total grains measurement The next character in the command specifies the channel A P Command Format Rxx ab Where xx is the network address of a unit set to 00 for this unit a is reset type either S M T or Z b is the optional information such as channel number for a total flow reset Response Format Rxx OK Where x
14. 770MAX Multiparameter Analyzer Transmitter Service Manual thornton IMPORTANT SAFETY INFORMATION This instrument is compliant with safety standards as outlined in the European Community low voltage directive EN61010 1 and with CSA Std C22 2 No 0M1982 General Requirements Canadian Electrical Code Part Il 0 4 M1982 Bonding and Grounding of Electrical Equipment and 142 M1987 Process Control Equipment Certification is pending Please read and observe the following INSTALLATION This instrument must be installed by trained instrumentation personnel in accordance with relevant local codes and instructions in this manual Observe all instrument specifications and ratings SHOCK HAZARD Make sure power to all wires is turned off before proceeding with installation or service of this instrument High voltage may be present on the input power and relay wires RELAY CONTROL ACTION 770MAX optional relays will always de energize on loss of power equivalent to normal state regardless of relay state setting for powered operation Configure any control system using these relays with fail safe logic accordingly PROCESS UPSETS Because process safety conditions may depend on consistent operation of this instrument take appropriate action to maintain conditions during sensor cleaning replacement or sensor or instrument calibration A timed Hold function may be selected which holds analog output signals and relays with their exi
15. MAX exploded view Chapter 1 which retains all setup configuration data plus calibration data for standard analog outputs 1 4 The power supply circuit board is located on the left side of the instrument It contains the universal 100 240 VAC power supply plus terminal connections for the 4 standard analog outputs RS232 communications discrete inputs and outputs and pulse flow input circuits The measurement circuit board is on the right side of the instrument and contains the measuring and communication interface circuits for smart sensors plus the NVRAM with measuring circuit calibration data The options circuit board if used is in the center and contains 4 relays and may contain 4 additional analog output circuits and their calibration data depending m the option specified The label on the rear of the case depends on which if any options board is installed An options board may be installed in the field using the appropriate kit of parts REAR LABEL MEASUREMENT PCB ASSEMBLY MAIN PCB ASSEMBLY Introduction 1 WIRING For full installation wiring instructions refer to manual 84372 Information here is for reference only CAUTION Route all sensor and output signal wiring away from power and switching circuits to minimize noise pickup and interference Rear panel terminal boards 2 Introduction AC Power Wiring Earth ground TB1 AC power neutral AC power hot CAUTION Power wire insu
16. at the diagonal corners of the chip Use extra care to prevent damage to the socket CAUTION This instrument and associated electronic parts are static sensitive All work Chapter 4 Upgrades must be done at an approved static free work station Personnel replacing static sensitive devices should be properly grounded to avoid component damage Installation Procedure 1 Disconnect power wiring and unplug all input and output connections from the unit noting the location of each plug in connector for use in re installation 2 Loosen the two front cover screws they are captive and will be retained in the cover 3 Lift the front cover off the instrument and unplug the keypad ribbon cable from the front circuit board 4 Carefully slide the entire assembly of circuit boards out of the case onto a static free surface 5 Unplug the measurement circuit board right most board which has the 4 Smart sensor patch cord sockets from the front circuit board 6 Locate the part no 43715 large integrated circuit in a socket position U6 of the measurement circuit board Note that the sloped edge of the integrated circuit faces the patch cord sockets Using the PLCC diagonal extraction tool or alternative tools noted above gently remove the integrated circuit from the socket CAUTION Excessive force or twisting could break the socket 7 Align the new integrated circuit over the socket with the sloped edge facing the
17. cation to determine if calibration is in fact necessary Verify at least one value for each internal range Recommended values are given in the table at the end of the verification procedure 4 Meter Calibration VERIFICATION PROCEDURE 1 If the 770MAX outputs are connected for alarm or control set a hold time per steps 3 6 of the calibration procedure in the next section Press Menus twice to exit 2 Connect the appropriate adapter to the patch cord of the channel to be verified 3 Connect the adapter leads to the test equipment The resistance adapter has four leads two for resistance and two for temperature 4 On the 770MAX front panel press Menus 5 Press the up arrow key until Go to Calibrate is displayed Press Enter 6 Press the down arrow key to display Go to Meter Verify 7 Press Enter The channel parameter and range identification are displayed 8 Select the channel and measurement type to be verified using Enter and up arrow Measurement types are Res_ Temp Volts and Freq 9 Enter the verification value from Table A at Input including any unit multiplier e g K M etc 10 Set the test equipment for exactly the same verification value from Table A 11 Allow the error value to fully stabilize and then confirm that the resulting Error in percent of reading except for voltage is acceptable 12 NOTE Calibration is unnecessary if the error is smaller
18. date 02 for the time bbbbbbbb the time hh mm ss or date mm dd yy If b is set to a character then the date and time will be returned Response Format Txx OK if setting the date or time or Txx mm dd yy hh mm ss Chapter 6 RS232 Communications 25 Where xx is the network address of the unit Example 1 Set the time Command T0002 13 45 00 Response T00 OK Example 2 Read the data and time Command T0000 Response T00 07 02 97 13 45 20 2 19 Print Error Status Command Description This command is used to get a summary of all of the error counters Command Format Qxx Where xx is the network address of a unit can set to 00 for this unit Response Format aaaaaaa Each error counter is returned as a string such as Qxx Messages sent 45781 Example Command Q3A Response T3A 08 31 98 10 54 59 Q3A Exceptions 0 Q3A Divide by 0 0 Q3A Messages sent 45781 Q3A Messages received 43259 Q3A Comm errors 1 Q3A Comm timeouts 2517 Q3A LSC Bus Busy 2 Q3A Buffer overflows 0 Q3A Wrong sender 0 Q3A Error responses 0 Q3A LSC Collisions 0 Q3A LSC Tx Timouts 0 Q3A LSC Resets 0 Q3A EEPROM Errors 0 Q3A Sensor Nvram Errors 0 26 RS232 Communications Chapter 6 2 20 Get Messages Command Description This command will return all of the messages for a measurement Command Format Fx
19. decades mmmmmmmm calibration date zz xor checksum of all preceding characters 28 RS232 Communications Chapter 6 CHAPTER 7 MENU TREES The following menu trees illustrate the general sequence of settings available in the 770MAX However some low level menu items are dependent on the type of sensor connected and on previous menu selections For example only a flow measurement with totalized flow units selected will show the menu field for setting External Reset Also the model of 770MAX will determine how many analog outputs and relays are present for configuration The screens below will appear after pressing Menu only if security has been enabled Otherwise pressing Menu accesses the Main Menu directly as shown on the following pages Menu key ENTER PASSWORD A password is needed MAIN MENU to enter the menus 3 Normal operation Password Wrong Password ENTER PASSWORD Invalid password You can view menus only Press Enter if OK Enter key MAIN MENU View Only Chapter 7 Menu Trees MEASUREMENTS MENUS Settings which can be changed are inBold Some menu displays depend on previous settings e g Fixed Temp appears only if Temp Source has been set to Fixed 30 Conductivity Sensor MEASUREMENT A Sensor input Chan 1 Units Q cm Auto Name DI Tank MEASUREMENT A Multiplier 0 12345 Adder 0 25413 Averaging High MEASUREMENT A Compensate Standard Te
20. e appropriate model number replace the final O in 775 _A0 with a 1 if using 1000 91 or with a 2 if using 1000 92 Obliterate the CE mark with a waterproof marker Reinstall in the existing wiring plugs to respective receptacles and add connections to the new outputs as required Chapter 4 CHAPTER 5 TROUBLESHOOTING ON LINE ERROR MESSAGES The following messages can appear in the Go to Messages menu to indicate error conditions or problems with reading sensors This menu area should always be checked first when an operating problem is encountered 1 Measure PCB failed hardware failure No sensor on chan 2 3 lnvalid sensor type 4 Sensor checksum err 5 Sensor const bad the sensor multiplier or adder factor may be wrong D Invalid pipe ID 7 Invalid tank height 8 Invalid channel the selected channel is wrong for the desired measurement i e Rejection ratio etc 9 Res sensor open patch cord or sensor cable may be bad 10 Res sensor shorted patch cord or sensor cable may be bad 11 Compensate error wrong compensation method selected or conductivity may be too high for this compensation method 12 Temp out of range 13 Unable to measure R unable to measure resistance of sensor air bubble dry cell etc 14 Invalid max PSI 15 Invalid tank area 16 Unknown measurement 17 Too big to display the mea
21. easuring range for the resistance it detects CALIBRATION PROCEDURE 1 Connect the appropriate adapter to the patch cord of the channel to be calibrated 2 Connect its leads to the test equipment The resistance adapter has four leads two for resistance and two for temperature 3 On the 770MAX front panel press Menus 4 Press the up arrow key until Go to Calibrate is displayed then press Enter 5 Press the up arrow key to display Go to Meter and press Enter 10 11 12 13 14 15 16 17 18 19 20 21 will be held at their current status for that period of time to prevent upset while offline Press Enter The channel parameter and range identification are displayed Select the channel and range to be calibrated using Enter and up arrow Select the calibration Type number of points It is recommended to do 3 point calibrations for resistance and 2 point calibrations for all other measurements including temperature Press Page Down to display the CALIBRATE METER screen with the reading and the recommended calibration value Set the test equipment for the exact calibration value Press Page Down and wait for the calibration to be performed Repeat steps 10 and 11 for additional calibration points On completion METER CAL IS DONE will be displayed Correct the date if necessary and page up twice to the main calibration screen Set the chan
22. ected the format is ERROR HK 01 invalid opcode 02 parameter error 03 checksum error 04 parity error 05 unit is not available 06 command failed 07 timeout error 0E data not available 2 COMMAND SET 2 1 Command Summary Command 1 Attention 2 Set Auto Data Output 3 Get Data 4 Reset 5 Set Parameter 6 Get Parameter 7 Key Press 8 Display Message 9 Self Test 10 Echo Command 11 Get Analog Output 12 Return All Setup 13 Get Set Output Line 14 Read Input Line 15 Get Set Date Time 16 Print Meter Setup 17 Print Error Status 18 Get Messages 19 Get Setup Information Function Opcode Returns the software revision level and serial number Enables or disables the data output Returns the latest set of measurement data Performs various types of resets use with caution Sets a parameter value Gets a parameter value Simulates a key press returns the menus displayed Displays a message Performs all of the self tests Echos the characters in the command for testing the port Sets the analog output current to a level for testing Returns all setup information Gets or sets the state of an output line Reads the state of an input line Gets or sets the date or time Sends the meter setup out serial port readable format Returns a summary of all error counters Returns all messages for a measurement Returns a block of data for measurements or relays etc All other opcodes will retu
23. el to be verified 7 Press Page Down 8 Measure the actual output on the milli ammeter record the value and compare it with 770MAX output specifications 9 Repeat steps 6 through 8 for 8 12 16 and 20mA 10 Press Menus twice to exit 12 Reactivate any system suspended in step 1 Analog Output Calibration 7 CHAPTER 4 UPGRADES There is software for various functions located in the 770MAX The need for field upgrade is likely to occur only with the Main Program and Measurement software Optional relays and additional analog outputs can be added in the field using the appropriate kits described later in this chapter MAIN PROGRAM SOFTWARE UPGRADE Over the life of the instrument it may become desirable to upgrade the main operating software of the 770MAX to a newer version The main operating software revision number can be displayed by stepping through the menus Other Menus Software Revs Main Program 770MAX to computer RS232 port wiring DB9 Connector to computer view of end 5 O O O O O of cable that plugs nto 9 O O O O computer Procedure 1 Record all the configuration settings and the serial number of the 770MAX unit being upgraded 2 Confirm that the 770MAX is configured for communications Press Menus and up arrow to display RS232 Setup Set Baud 38 4K Par Even Data Output Off if they are not already set this way 3 Connect the 770MAX to the computer RS232 port as sh
24. er line for CE compliance 95010 Patch cord extension 5 ft 1 5 m 1005 87 Patch cord extension 15 ft 4 5 m 1015 87 Connector for patch cord extension 25320 12 VDC Power Supply for 1 or 2 pulse input flow sensors powered by 85 265 VAC 1000 65 24 VDC Power Supply for 1 or 2 pulse input flow sensors powered by 85 265 VAC 1000 66 Pulse input flow sensor kit required for some pulse flow sensors 1000 67 Automatic Smart Calibrator Kit 1875 120VAC calibrator power supply used when not connected to 770MAX for downloading to PC 36151 Smart pH ORP BNC preamp for pH ORP electrode with BNC connector no temp comp 1000 78 Smart pH ORP K9 preamp for pH ORP electrode with K9 connector no temp comp 1000 84 Smart conductivity adapter cable allows decade box input for calibration 1000 82 Smart frequency adapter cable allows frequency input for pulse flowmeters 1000 83 770MAX Service Manual 84373 36 SPARE REPLACEMENT PARTS Description Part Number 10 Terminal pluggable connector 2 for models 775 __0 amp 775 __1 3 for model 775 __2 25302 6 Terminal pluggable connector 2 for models 775 __1 and 775 __2 25301 Fuse 0 5 A slo blo 5 x 20 mm Littlefuse 239 500 or equivalent 35092 Panel mounting screws 6 32 x 7 16 4 required 21800 Front panel assembly molded cover with gasket screws retaining washers and keypad 07331 Screws for front panel 2 required included in front panel assembly above 21674 Retaining washers for fr
25. es SS 98 62_ fMeterCalSlopetPrev_ Float Circuits Channels J 99 63 TMeterCalSlope2Prev Fat Circuits AChannels 100 64 IMeterCalOf setPrev Float Circuits Channels DD riot 65 iPoweSae mr L C S O1 O1 O1 O1 O1 O1 O1 O1 O1 Sea BE Sigg deng ge Code Chapter 6 RS232 Communications 21 3 58 IO 102 6 dTotaippmG Foa Chanes 1103 67 sUnitSeralNumber String to 104 68 dCel K Factor Float Channels 10 K factors for Vortex flow sensors 1105 69 dCell_F_Factor Poet Channels 10 F factors for Vortex flow sensors 106 107 6B dCalVerifyMeasured1 Float Circuits Channels j 108 6C dCalVerifyMeasured2 Float Circuits Channels_ 6D_ dCalVerifyMeasured3 Float Circuits Channels Setpoint Types Analog Output Types 0 No Setpoint 0 Normal 1 High 1 Bilinear 2 Low 2 Auto range 3 USP 3 Log 4 Reset 2 10 Keypress Command Description This command is used to simulate a key press from the front panel The response is a string of characters which is the message displayed as a result of the key press Also the cursor position is returned Command Format Kxxaa Where xx is the network address of a unit can set to 00 for this unit aa is the key code as follows 00 Key 0 01 Key 1 02 Key 2 03 Key 3 04 Key 4 05 Key 5 06 Key 6 07 Key 7 08
26. et Analog Output Command Description This command is used to set the analog output current to a value It is intended for testing purposes only When this command is received the analog outputs will be held at the set value until another command is received or a key is pressed Command Format Oxxa bbbbbbbb Where xx is the network address of a unit can set to 00 for this unit a is the analog output number 1 4 or 1 8 with optional outputs bbbbbbbb is the output current in mA Response Format Oxx OK Where xx is the network address of the unit Example Set the output of channel 3 to 12 125mA Command 000 312 125 Response O00 OK 2 15 Return All Setup Command Description This command will cause the entire meter setup to be returned Each setup parameter is sent with the same format as the Get Parameter command This command is equivalent to sending the Get Parameter command for every parameter Command Format Zxx Where xx is the network address of a unit can set to 00 for this unit Response Format The response will be multiple lines of data Each line will be terminated with a CR character and will have the following format same as the Get Parameter Command response Gxxaabb cccccccccca Where xx is the network address of the unit aa code of parameter 00 to FF bb channel or measurement number eccccccccc value up to 10 digits including a decimal point 24 RS
27. he exact output current on the milli ammeter and enter that precise value into the 4 mA reads 4 0000 screen and press Page Down 7 Read the exact output current on the milli ammeter and enter that precise value into the 20 mA reads 20 000 screen of the 770MAX and press Page Down Chapter 3 8 Enter the date and press Page Down to save it 9 Press page up twice and repeat steps 2 and 5 8 for the additional outputs 10 Press Menus twice to exit and resume normal measurement The 770MAX automatically computes any deviation from 4 and 20 mA and adjusts itself accordingly 11 Reactivate any system suspended in step 1 ANALOG OUTPUT VERIFICATION Analog outputs may be verified using the 77OMAX diagnostic menu and a milli ammeter The menu allows setting the analog outputs to specific mA values Verification Procedure 1 Disable or place in manual any control system using the analog output signals since they will be interrupted during verification 2 Connect a high precision milli ammeter in series with the analog output signal to be verified See Manual 84372 Chapter 4 for terminal connections 3 Press Menus and Down arrow to display Goto Diagnostic and press Enter 4 Use Up down arrows if needed to display Goto Analog Output and press Enter 5 Using up down arrows select the Analog Output to be verified and press Enter 6 Using Up down arrows set Output 4 00mA or another lev
28. her channel 2 kkkkkkkk multiplier 1 3 Chapter 6 RS232 Communications 27 WII additive 1 mmmmmmmm multiplier 2 nnnnnnnn additive 2 oo temperature source pppppppp temperature value qq compensation method rrrrrrrr Compensation value ssssssss maximum value 1 tttttttt maximum value 2 uuuuuuuu maximum value 3 vvvvvvvv sensor part number wwwwwwww sensor serial number XXXXXXXX sensor cal data yy smart sensor status zz xor checksum of all preceding characters For setpoints Vxx02zz aabbecddddddddeeffffffffzz aa setpoint measurement bb setpoint type cc setpoint relay dddddddd setpoint value ee ignore setpoint if error ffffffff time since last activation zz xor checksum of all preceding characters For relays Vxx03zz aabbccddeezz aa relay delay bb relay hysteresis cc relay state dd external reset enabled ee relay type zz xor checksum of all preceding characters For Analog Outputs aa measurement bb analog output type cc control dd output level on failure ee low end ouput 0 or 4mA ffffffff minimum value 1 99999999 mid value 1 hhhhhhhh max value 1 kkkkkkkk not used Il number of
29. is section describes calibration of the 0 4 20 mA output signals For startup information to scale the range that the signal represents in engineering units see main Instruction Manual 84372 Chapter 4 Analog output signals are factory calibrated within specifications but may be re calibrated if necessary The 770MAX analog output calibration is performed by measuring the output signal when it is set to its minimum 4 mA and maximum 20 mA limits and entering the exact mA value into the instruments display The 770MAX automatically computes any deviation from 4 and 20 mA and adjusts itself accordingly Verification of outputs is accomplished through a diagnostic menu It is desirable to calibrate and verify when the system receiving instrumentation is connected in the circuit to present the approximate operating load to the circuit Maximum load is 500 ohms Calibration Procedure 1 Disable or place in manual any control system using the analog output signals since they will be interrupted during calibration 2 Connect a high precision milli ammeter in series with the analog output signal to be calibrated See Manual 84372 Chapter 4 for terminal connections 3 Press Menus and Up arrow to display Goto Calibrate and press Enter 4 Press Up arrow to display Goto Analog and press Enter twice passing through the Hold Time screen 5 Select the output signal to be calibrated and press Enter 6 Read t
30. item is returned Items returned for credit or exchange must be in salable condition Items returned after 30 days from date of invoice will be subject to a 10 rehandling charge Note Substitution or modification of cables voids all warranties THE ABOVE WARRANTY IS THE ONLY WARRANTY MADE BY THORNTON INC AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE thornton Thornton Inc 1432 Main Street Waltham MA 02451 1623 781 839 6400 Smartline 800 642 4418 Faxline 781 890 5507 Email info thorntoninc com Part 84373 Rev B 6 00
31. l Grains Total Grains RESET TOTAL GRAINS Reset total on Ch2 Press Enter to reset other keys to quit he total on this hannel was reset Press the Enter key Chapter 7 TECH SUPPORT SET HOLD TIME AND OTHER MENUS TECH SUPPORT Time Date TIME DATE MENU Time 12 45 27 Date 07 23 00 Page Down key to set TECH SUPPORT Web Thorntoninc com Email Service Thorntoninc com Set Unit Name SET UNIT NAME Name or location of this unit is aaaaaaaaaaaaaaaaa Chapter 7 SET HOLD TIME Hold outputs Ente time or 00 for none Hold time 00 mins Software Revs SOFTWARE REVS Serial 012345 Main Program 1 50 Measurements 1 50 SOFTWARE REVS Display Rev 1 10 Option 1 Analog v1 00 Option 2 Not instal Lost Passwords Master RECOVER PASSWORDS ACEGI User 1 CFILO User 2 GKOSW Other Menus OTHER MENUS Select a menu using TL then press Enter Goto Software Revs Total Flow TOTAL FLOW Total Flow on Chan5 is 125134 2395 Gal Service Only Save Setup Data SAVE SENSOR DATA Select a channel to save sensor data Then press Enter Menu Trees PASSWORD NEEDED Please enter the service password Password 1 Other Menus Options 1 Set Time Date 2 Software Revs 3 View Total Flow 4 Print Config 5 Smart Sensors Smart Sensor Options 1 Save Setup Data 6 Set Unit Name 7 Lost Passwords 2 Clear Setup Data 8 Service Only 3 Edit Smart Data
32. lation must be stripped back 0 5 in 13 mm for reliable connection Sensor Wiring Smart sensor patch cords plug into jacks CH1 through CH4 To avoid confusion when unplugged label the channel at the end of each patch cord Extending or making a break in patch cords must be done only using extension cables 1005 87 5 ft 1 5 m or 1015 87 15 ft 3 m and union connector 25320 CAUTION Do not cut or shorten patch cords They use very fine gage shielded cable not suitable for screw terminals or splicing Do not extend patch cords using computer network cables since they provide only 8 of the 10 conductors needed by 770MAX and will damage the modular jacks Pulse input flow sensor wiring is shown in Appendix B of Instruction Manual 84372 Chapter 1 Other Connections Refer to rear panel figure for location Al modets Channel 6tow e Dita ground o Jee 10 RS232 transmit 14 Discrete out 1 E E 17 18 19 20 TB3 All models Analog output Analog output 2 2 Analog output 1 gt areas _ Ano ouput ar ca t 77 maoo t EC 25 26 z Chapter 1 Models 2 Relay 3 common ony 5 Relay 4 normaly cased TB6 Relay 1 normally open Models pn Relay 1 common 775 __18 amp BE Relay 1 normally closed 775 __2 Relay 2 normally open only Relay 2 common Relay 2 normally closed Introduction 3 CHAPTER 2 METER CALIBRATION The 770MAX has been fac
33. m NICatONS series nid 14 Reisen Tele RE 15 CHAPTER 7 MENU TREES uu un en 29 Meas uremente M enUuu u n L Kuu Susa Sa Bee ai ukuna 30 Messages and Calibrate Menus L L l SSS 31 Analog Outputs Setpoints and Relays Menus 32 Display Setup Security and Diagnostics Menus a a a 33 RS232 Network and Reset Menus sseeseeeseeesneesineeruneriesrrneernnernnnrrnnnrienrrnnernnernnnernnne 34 Tech Support Set Hold Time and Other Menus a 35 CHAPTER 8 ACCESSORIES amp SPARE REPLACEMENT PARTS 36 CHAPTER 1 INTRODUCTION See Instruction Manual 84372 supplied with the instrument for standard operating information for the 770MAX This service manual covers instrument calibration upgrades RS232 communications and other information for troubleshooting and training The 770MAX is provided with a Help key which provides supplementary information about the area of the menus being displayed It can be especially helpful in initial configuration INSTRUMENT OVERVIEW The 770MAX series utilizes 3 or 4 surface mount printed circuit boards plus a display module which slide into the molded case and are held in place by the front cover secured by two screws The main circuit board is located in the front of the instrument It contains the display module main processor operating firmware and flash memory OPTIONAL PCB ASSEMBLY POWER SUPPLY PCB ASSEMBLY DISPLAY ASSEMBLY FACEPLATE ASSEMBLY 770
34. mp Source Fixed Fixed Temp 25 000C MEASUREMENT A Resolution Auto TDS Factor 1 254 MEASUREMENT A Reading 18 18 Mo cm Sensor S N 123456 Cal Date 07 23 97 MEASUREMENT A Raw reading from the sensor 0 00000000Mo Ch 1 range 0 1M Name DI Tank MEASUREMENT A Multiplier 0 12345 Adder 0 25413 Averaging High MEASUREMENT A Reading 21 255 GPM Sensor S N 123456 Cal Date 07 23 97 MEASUREMENT A Raw reading from the sensor 0 00000000Hz Using chan 1 Flow Sensor Measurements pH ORP Sensor Name DI Tank MEASUREMENT A Multiplier 0 95345 Adder 0 25413 Averaging High MEASUREMENT A STC 0 0000 IP 7 000 Temp Source Fixed Fixed Temp 25 000C MEASUREMENT A Resolution 0 01 MEASUREMENT A Reading 8 123 pH Sensor S N 123456 Cal Date 07 23 97 MEASUREMENT A Raw reading from the sensor 0 00000000V Using chan 1 Menu Trees Main Menu Options 1 Measurements 6 Relays 11 Network 2 Messages 7 Display Setup 12 Reset 3 Calibrate 8 Security 13 Tech Support 4 Analog Outputs 9 Diagnostic 14 Other Menus 5 Setpoints MEASUREMENT A Sensor input Chan 1 Units PSI Auto Name DI Tank MEASUREMENT A Multiplier 1 23456 Adder 0 25413 Averaging High MEASUREMENT A Resolution 0 01 Max PSI 15 00 MEASUREMENT A Reading 20 34 PSI Sensor S N 123456 Cal Date 07 23 97 MEASUREMENT A Raw reading from the sensor 0 00000000V Using chan 1 10 RS232
35. n This command is used to perform the selftest diagnostic test Command Format Uxx Where xx is the network address of a unit can set to 00 for this unit Response Format Uxx OK if all of the tests pass Uxx FAILED aa if one or more tests fail Where xx is the network address of the unit aa code of test that failed If more than one test fails then multiple codes will be included in this response each separated by a comma The codes are 01 ROM test fails 02 RAM test fails 03 NVRAM test fails 04 Timer test fails 05 A D test fails 06 Serial port test fails 07 Network Test fails 08 Display test fails 09 Keypad test fails OA Analog output test fails Example Command U00 Response U00 FAILED 01 04 This response indicates that the ROM test and timer tests failed Chapter 6 RS232 Communications 23 2 13 Echo Command Description This command is used to test the serial port The characters in the command are sent back in the response Command Format Exxa a Where xx is the network address of a unit can set to 00 for this unit a a string of any ASCII characters used to test the port up to 128 Response Format Exxz a a Zz Where xx is the network address of the unit a a string of characters from the command DI zz OK if there is no communication problem Example Command E00123456789A Response E 00123456789A OK 2 14 S
36. nd observe Connected in the lower border of the window when communications are functioning 13 Click m the integrated circuit button Program Unit 4 from right on the tool bar 14 Select Units to Program One Unit and enter 0 zero in the box Leave Unit Type at Main 15 Click Read and locate the new 770MAX software file and click OK The new software version will be loaded into computer memory 16 Click Program Loading to the 770MAX will take several minutes Allow to run until 100 is displayed 17 Restore the serial number of the unit using the appropriate command in Chapter 6 18 Disconnect the RS 232 wiring from the 770MAX 19 If necessary reconfigure the unit with the settings recorded in step 1 MEASUREMENT SOFTWARE UPGRADE Over the life of the instrument it may become desirable to upgrade the measurement software of the 770MAX to a newer revision to add additional capabilities 770MAX measurement software is upgraded by installing a new part 43715 integrated circuit in a socket located on the measurement printed circuit board The following tools and equipment are needed 1 Static free work station 2 Small flat blade screwdriver 3 PLCC diagonal extraction tool to remove the integrated circuit Part number 126 453 available from Contact East Inc 1 978 682 2000 If the tool is not available the integrated circuit can be removed using two very small screwdrivers and prying
37. nel parameter range and type for the next calibration and page down Repeat steps 8 14 for the remaining ranges Repeat steps 1 and 8 15 for the other channels to be calibrated For the temperature range repeat steps 1 2 and 8 16 but with the decade box connected to the temperature leads of the conductivity adapter For the voltage range repeat steps 1 2 and 8 16 with a precision voltage source connected to Smart voltage adapter 1000 79 For the frequency range repeat steps 1 2 and 8 16 with a precision frequency generator producing a 0 3 V square wave connected to Smart frequency adapter 1000 83 For frequency calibration of channels 5 and 6 connect the frequency generator directly to TB2 terminals 7 and 6 respectively and to common TB2 terminal 2 Repeat step 19 omitting the adapter Press Menus twice to exit 6 In Hold time 00 mins if meter outputs are Chapter 2 connected for alarm or control enter a value greater than the time in minutes needed to complete calibration Analog and relay outputs Units manufactured prior to March 00 may give an erroneous default resistance on one range of 2Q which should be changed in the display and in the decade box setting to 2000 Meter Calibration 5 Calibration Values Pont Io Teo Tem too Is ee Ier rn ne Ins 6 Meter Calibration Chapter 2 CHAPTER 3 ANALOG OUTPUT CALIBRATION ANALOG OUTPUT CALIBRATION Th
38. ont panel 2 required included in front panel assembly above 21675 Vacuum fluorescent display module order connector and mounting standoffs separately 47048 Connector for vacuum florescent display module above 25300 Liquid crystal display module order mounting standoffs separately 47047 Display standoffs 4 required for either display above 21673 Relay option kit to convert model 775 __0 to 775 __1 not CE rated 1000 91 Analog output amp relay option kit to convert 775 _ Oto 775 __2 1000 92 not for 230 VAC power not CE rated Recommended Spare parts 37 WARRANTY Thornton Inc warrants products it manufactures against defects in materials or workmanship for one year from start up or 18 months from the date of shipment from Thornton whichever is sooner Warranties do not apply to limited life components such as batteries Some non Thornton manufactured resale items may have shorter warranties than one year Thornton honors only the warranty period of the original manufacturer Catalog descriptions although accurate should not be taken as a guarantee or warranty Thornton s obligation under the warranty shall be to repair at its facility or replace any products which Thornton finds to be defective Items returned for warranty must be properly packaged shipped prepaid and insured and must be accompanied by the Return Authorization Number described below Returned Goods Please contact us for a Return Authorization Number before any
39. own above 8 Upgrades The main program software is changed by downloading the new operating file using Thornton utility program Max95 exe It runs on computers using Windows95 or later and occupies about 0 7 MB of hard disk space NOTE Not all menus of the Max95 program are functional use only those needed for the upgrade as described in the procedure below A cable is required with connector for the computer s RS232 port Most computers use a DB9 connector as shown Tinned leads at the other end connect to the 770MAX screw terminals Because the memory chip containing operating software also contains extensive instrument calibration data it is not practical to upgrade software by replacing the memory chip 770MAX TB2 terminals Ground Receive Transmit 6 4 From email or floppy disk copy the program Max95 exe and the new 770MAX software file e g 43714 14 into a convenient folder or desktop of the computer 5 Run Max95 exe by double clicking it in Windows Explorer and ignore any small incidental windows that may open 6 Click to open Communication menu and RS 232 Functions and select Gateway Port Setup 7 Select Port COM 1 or other port if you are using another 8 Select Baud Rate 38400 Chapter 4 9 Select Data Bits 8 10 Select Parity Even 11 Uncheck Enable Polling Leave other settings as found Flow Control Xon Xoff Stop Bits 1 12 Click OK a
40. ration can be continued by changing the temperature source under the Measurements menu to a fixed value or to use the temperature signal from another channel that is also correct for this measurement In some cases using temperature from another channel may be desirable anyway to obtain a faster responding or more accurate temperature signal Raw Sensor Signals Direct reading of the sensor output is available from the Measurements menu It gives raw readings in base units e g Hz for flowrate It is not adjusted with calibration factors temperature compensation Troubleshooting 11 etc and is helpful in finding the cause of erroneous readings To view the raw reading press Menus and select the desired measurement Page down to the last normal screen indicated by disappearance of the down arrow in the lower right corner then page down one more to see Raw reading from the sensor XXXXX XX plus identification of channel and internal range for resistivity OFF LINE DIAGNOSTICS The Diagnostic Menu is used to run a series of off line automated diagnostic testing routines to verify the operation of system components including meter sensors analog output serial port network display keypad flow channels inputs and outputs NOTE Some diagnostic tests may interrupt normal operation such as analog outputs To access the Diagnostic Menu 1 Press Menus 2 Press the up arrow key un
41. rn an error message Chapter 6 RS232 Communications 15 lt noI 4t2MNOMCZAOVIUIUUD 2 2 Data Output Format If the data output feature is enabled then the measurement data will be transmitted with the following format Each defined measurement will be transmitted as a separate string Daa bcd eeeeeeee fffffff ggh PositionField Data 01 D This character always D 02 03 aa Unit address 00 to FF 04 te Always a character 05 b Measurement designator A Z 06 G Channel of measurement 1 6 07 d Setpoint condition no error gt high setpoint exceeded lt low setpoint exceeded 08 AN Always a space 09 17 eeeeeeee Measurement data 18 K Always a space 19 24 fffffff Units for measurement example Mo cm 25 Always a space 26 27 gg Exclusive or checksum of all preceding characters 28 h Carriage Return character 2 2 1 Data Output Example DO7 Al 286 2020 uS cm IC D07 B1 22 8267 C 03 2 3 Attention Command Description This command will return the software revision level meter configuration and serial number It is also used to determine if the meter is on line and able to communicate Command Format Axx Where xx is the network address of a unit leave blank or set to 00 for this unit Response Format Axx Thornton 775 yyy aaaaa aaa Ver zzzz S N bbbbbbbb Where xx is the network address of the unit 00
42. setup was 00 36 09 Lost Passwords Diagnostic DIAGNOSTIC MENU Select a test using 7 then press Enter Go to Meter Tests DIAGNOSTIC MENU Test Timers Result Passed ENTER for next test Diagnostic Tests Meter Tests Smart Sensors Serial Port Network Display Keypad Flow Channels Inputs Outputs 10 Self Tests 11 Analog Output OONDARWN RECOVER PASSWORDS Wrong Master Password Wrong password was entered Press the Enter key Menu Trees ACEGI User 1 CFILO User 2 GKOSW 33 RS232 NETWORK AND RESET MENUS RS232 Setup RS232 SETUP Baud 38 4K Par Even Data Output On Output time 120 sec RS232 SETUP Network Address 001 Status No Errors Messages 5987 34 Network NETWORK SETUP Network Address 001 Type None Status Not Install System RESET SYSTEM Press Page Down when ready to reset or other keys to quit he system has been reset Press the Enter key Reset System Measurements RESET MEASUREMEN Reset Channel1 Press Enter to reset or other keys to quit Total Flow RESET TOTAL FLOW Reset total on Ch2 Press Enter to reset other keys to quit This channel has been reset he total on this hannel was reset Press the Enter key Press the Enter key Menu Trees Reset RESET MENU Reset Options Select at A 1 System S ER a type si 2 Measurements T then press Enter 3 Total Flow 4 Tota
43. sting conditions for a set maintenance time interval This manual includes safety information with the following designations and formats WARNING POTENTIAL FOR PERSONAL INJURY CAUTION possible instrument damage or malfunction NOTE important operating information A On the instrument indicates Caution risk of electric shock A On the instrument indicates Caution refer to accompanying documents TABLE OF CONTENTS CHAPTER 1 INTRODUCTIOLN 1 INSITUMENL OVEM E 1 Ile EE 2 CHAPTER 2 METER CALIBRATIOLN 4 Verification Procedure ns ee I l nsn 4 Calibration ee E 5 CHAPTER 3 ANALOG OUTPUT CALIBRATIONN 7 Analog Output Calibration are eA aie abe aa iu 7 Analog Output Verification TS alle a 7 CHAPTER 4 UPGRADES U alates 8 Main Program Software Upgrade A 8 Measurement Software Upgrade 9 Output Upgrades L QS 10 CHAPTER 5 TROUBLESHOOTIMG 11 On Line Error e EE 11 sensor Troubleshooting une ee ee 11 Off Line Diagnostics meld meee een dteas esse 12 CHAPTER 6 RS232 COMMUNICATION S 14 Senal Port CommM
44. surement is too large to be displayed 18 Total flow over total flow has reached the upper limit 19 Temperature high 20 Voltage over range the voltage from the sensor pH pressure is too high bad sensor 21 Invalid max GPM 22 Check TDS factor Chapter 5 23 Range may be wrong measurement may have a wrong range i e set for S cm instead of uS cm 24 Invalid setpoint 25 Reference volts bad for pressure sensors this is a bad sensor 26 Flow rate is 0 the flow rate is zero gpm so the calculated measurement is zero or overrange 27 Bad meter calibrate a meter calibration factor is bad should recalibrate 28 A D over range the A D convert reported an error may be a defective measurement board 29 Unknown error xxxx LSC is Locked could appear in the startup screen and indicates that internal local serial channel communication has halted This could be caused by loose internal connections Re seat all circuit board and ribbon cable connectors and re power the instrument If the message persists factory service will be required SENSOR TROUBLESHOOTING Temp Compensated Measurements Temperature compensated measurements such as conductivity resistivity and pH require the temperature signal from the sensor to be within range or the compensated measurement will display asterisks If the temperature signal has failed or is not available ope
45. te that the command is designated for the device on the RS232 port not another unit on the network NOTE References to a network address are for future capability All floating point values use Intel standard format 1 2 Command Format The format of all commands is axxc c lt cr gt Where a is the opcode upper case letter from A to Z xx is the network address of the unit from 00 to FF hexadecimal This address can be specified as 00 which indicates the command is for this unit on the serial port c c is the command data lt cr gt is the ASCII carriage return character 1 3 Response Format The format of all responses is axx c c lt cr gt Where a is the opcode upper case letter from A to Z xx is the network address of the unit from 01 to FF hexadecimal c c is the response data lt cr gt is the ASCII carriage return character The response data will be one of the following types 1 Command Accepted if the command is accepted then the response data section will consist of the message OK 2 Command Data if the command requests data then that information will be returned The format of the data depends upon the command type 3 Command Rejected if the command is rejected then an error message will be returned with the format ERROR yy where vk is an error code 14 RS232 Communications Chapter 6 1 4 Error Codes The following error codes will be used when a command is rej
46. til the Diagnostic Menu is displayed then press Enter 3 Use the up down arrow keys to select a test then press Enter The indicated test will be performed and the results displayed 4 To test another component press Page Up to return to the Diagnostic Menu and select the next component 5 After completing the desired diagnostics press Menus twice to exit the menu system and return to display mode See the appropriate section below for information regarding the specific diagnostic tests Meter Tests Use to test the timers ROM checksum and RAM Tests are performed sequentially press Enter to perform next test Smart Sensors Select a channel to view the raw sensor data actual voltage ohms etc Analog Output 12 Troubleshooting Select an output to test then enter a current value milliamps to send out the analog output then press Page Down to set Repeat test with a second current value to verify range response Serial Port On back of meter use a jumper wire to connect TB2 terminals 9 and 10 then press Enter to begin test Network Diagnostic not currently available Display An automated sequence will test the display of all characters alpha numeric and symbol Press Enter to stop the test Keypad Press any key to test its response the correct name of the key should be displayed Press Menus twice to exit this test Flow Channels Diagnostic not currently available Inputs
47. tory calibrated to meet its specifications It is not normally necessary to re calibrate unless extreme conditions cause out of spec operation shown by verification Periodic verification or calibration may also be necessary to conform with QC requirements The 770MAX may be calibrated using high precision resistance decade boxes voltage source and frequency generator with the following procedures This is intended only for installations that have a policy of traceability to their own internal standards Standards equipment accuracies must exceed the 770MAX specifications as required by the applicable QC policy NOTE This is an extensive process requiring 72 calibration points to fully cover all measurement ranges of all parameters on all channels It is strongly recommended where possible to use the Thornton 1875 Automatic Smart Calibrator Kit which is supplied with a traceable certificate of accuracy It also enables printing out calibration certificates for instruments it has calibrated It is supplied with its own instruction manual It is necessary to verify and or calibrate only those measuring circuits actually being used in the installation The following Adapters are needed to interface with standards equipment 1000 82 resistance adapter for conductivity resistivity temperature 1000 79 voltage adapter for pH ORP pressure level 1000 83 frequency adapter for flow Before attempting calibration perform a verifi
48. ware revision 1 5 or higher Output Kit Installation Procedure 1 Disconnect power wiring and unplug all input and output connections from the unit labeling the location of each plug in connector for use in re installation 2 Peel off the rear face terminal identification label and replace it with the label supplied in the kit which will have additional cutout s 3 Loosen the two front cover screws they are captive and will be retained in the cover 4 Lift the front cover off the instrument and unplug the keypad ribbon cable from the front circuit board 5 Carefully slide the entire assembly of circuit boards out of the case onto a static free surface 6 As shown in the exploded view in Chapter 1 Introduction align the new output option circuit board with the large dual connector at the bottom back between the power supply and measurement boards Carefully plug it into the back of the main circuit board 10 Upgrades 10 11 Carefully align the entire circuit board assembly so each circuit board keys into its espective slot in the case and slide it in Some flexing may be necessary to assure complete installation The terminal blocks must fit into the cutouts to be flush with the back of the case Plug the front cover keypad ribbon cable back onto the display circuit board pins Replace the cover back onto the instrument and tighten the two cover screws Mark the instrument identification label with th
49. x is the network address of the unit Example Perform a system reset Command R00 S Response RO0 OK 2 7 Set Parameter Command Description This command will set a parameter value Command Format Sxxaabb ccccccccccd Where xx is the network address of a unit can set to 00 for this unit aa code of parameter to be changed 00 to FF see list below bb index number channel measurement number relay number etc eccccccccc value up to 10 digits including a decimal point d optional multiplier u micro m milli K kilo or M mega Response Format Sxx OK Where xx is the network address of the unit Example Set the value of setpoint 2 to 0 001125 Command S002A02 1 125000m Response S00 OK RS232 Communications Chapter 6 2 8 Get Parameter Command Description This command will get a parameter value Command Format Gxxaabb Where xx is the network address of a unit can set to 00 for this unit aa code of parameter to be changed 00 to FF see list below bb channel or measurement number index number Response Format Gxxaabb ccccccccccd Where xx is the network address of the unit aa code of parameter to be changed 00 to FF see list below bb index number channel measurement number relay number etc eccccccccc value up to 10 digits including a decimal point d optional multiplier u micro m
50. xa Where xx is the network address of a unit can set to 00 for this unit a the measurement designator A P Response Format FXX YYYYYYYYY Example Command F3AA Response F3AA Measure PCB failed F3AA Temp out of range F3AA Res sensor open 2 21 Print Setup Command Description This command will instruct the meter to print the entire meter setup same as the one from the menus Command Format Hxx Where xx is the network address of a unit can set to 00 for this unit Response Format aaaaaaa 2 22 Get Setup Information Command Description This command will return a block of data containing all of the setup data for a specific function such as measurements setpoints relays etc Command Format Vxxyyzz Where xx is the network address of a unit can set to 00 for this unit yy is the type of data to return 01 measurement 02 setpoint 03 relays 04 analog output zz the measurement number or setpoint number etc All data in the response is either hexadecimal floating point or ascii string Response Format For measurement Vxx01zz aabbccdd zz aa channel bb sensor type cc sensor sub type dd measurement type ee range ff averaging gf resolution hhhhhhh name i other channel 1 jj ot
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