Omega Engineering Oxygen Equipment Dissolved Oxygen System User's Manual
Contents
1. relative to the product OMEGA s policy is to make running changes not model changes whenever an improvement is possible This affords our customers the latest in technology and engineering OMEGA is a registered trademark of OMEGA ENGINEERING INC Copyright 2005 OMEGA ENGINEERING INC All rights reserved This document may not be copied photocopied reproduced translated or reduced to any electronic medium or machine readable form in whole or in part without the prior written consent of OMEGA ENGINEERING INC Where Do I Find Everything I Need for Process Measurement and Control OMEGA Of Course Shop online at omega com TEMPERATURE Thermocouple RTD amp Thermistor Probes Connectors Panels amp Assemblies 4 Wire Thermocouple RTD amp Thermistor A Calibrators amp Ice Point References A Recorders Controllers amp Process Monitors LF Infrared Pyrometers PRESSURE STRAIN AND FORCE 4 Transducers amp Strain Gages lt Load Cells amp Pressure Gages 4 Displacement Transducers A Instrumentation amp Accessories FLOW LEVEL 4 Rotameters Gas Mass Flowmeters amp Flow Computers WF Air Velocity Indicators A Turbine Paddlewheel Systems A Totalizers amp Batch Controllers pH CONDUCTIVITY A pH Electrodes Testers amp Accessories W Benchtop Laboratory Meters 4 Controllers Calibrators Simulators amp Pumps 4 Industrial pH amp Conductivity Equipment DATA ACQUISITION2. 6 1 3 Cleaning the sensor membrane before each calibration is recommended Use soft cloth and mild soap solution to remove material from the membrane When cleaning take care to avoid puncturing the sensor membrane Should this occur the complete sensor cartridge must be replaced 6 2 Calibration 6 2 1 Depending on the application system calibration should be performed periodically to maintain measurement accuracy Frequent checks are suggested until the operational history indicates the optimum period between checks Page 17 6 3 Reset 6 3 1 The instrument can be reset without losing calibration or any of the stored values by pressing and releasing the S9 reset button located at the bottom of the board near the center This action is equivalent to turning the power off and on 6 4 Output Hold 6 4 1 It may be useful during some system maintenance procedures to place the relay and analog outputs on hold To accomplish this simply press CALL To return to on line operation press RUN NOTE To safeguard against the operator forgetting to press RUN the instrument will automatically go back on line ten minutes after the last button was pressed provided this feature has been enabled by placing DIP switch No 7 Bank S1 in the ON position 7 0 UTILITY MENU 7 1 Utility Menu Functions 7 1 1 The Utility Menu enables authorized personnel to perform the following Adjust the temperature output range Adjust the offset and s
3. A single pole double throw relay is provided to give an output in the event of a perforated membrane This relay can be programmed to also signal memory loss See Section 4 8 When this relay is activated the contacts will close and the FAIL LED will be indicated on the panel Page 9 4 6 Analog Outputs 4 6 1 4 6 2 The analog output signals consist of a non isolated 0 1 mA 0 5 Vdc and isolated 4 20 mA signals From the factory all of the analog outputs have a linear range corresponding to the full range of the instrument The 4 20 mA output can be programmed to another linear range by entering two values Output High This is the value at which you wish to have 100 output e Output Low This is the value at which you wish to have 0 output When programming you must ensure that the output range has a span of at least 10 of the full range of the instrument For applications that require the output to decrease as the process value increases i e an inverted output the Output High value will be less than the Output Low See Section 5 4 The instrument may be used to measure the temperature of the process either in Celsius or in Fahrenheit The DOCN600 does not control temperature but the 0 5 Vdc and 0 1 mA analog outputs can be dedicated to follow the process temperature See Sections 5 6 4 7 Operation Menu 4 7 1 4 7 2 The operation menu allows the user to recall and to adjust the parameters r
4. 4 2 Calibration 4 2 1 The DOCN600 is calibrated at the factory with the sensor purchased with the instrument However the system should be field calibrated when installed and from time to time thereafter The calibration procedure is given in Section 5 3 4 3 Temperature Compensation 4 3 1 A temperature sensor in the DOE 601 sensor provides the means of continually compensating the D O reading for variation in the temperature of the process 4 4 Relay Outputs 4 4 1 4 42 4 4 3 4 4 4 Three SPDT relays are provided The normally open contacts are open when no alarm or control is active The two control relay can be programmed to close on either rising or falling D O They can be set to close at any point on the scale The deadband sometimes termed hysteresis defines the point at which the relays open See Sections 4 8 5 8 and 5 9 The third relay functions as a high low alarm It has two programmable setpoints high and low The deadband is fixed at 2 of full span This relay is also activated in the event of a perforated membrane See Section 4 5 The alarm contact can be programmed to also signal memory loss in the DOCN600 controller See Section 4 8 5 12 and 5 13 All relays can be programmed for fail safe operation which reverses the normal operation of the relay In this mode the relays will fail safe transfer in the event of power failure 4 5 Membrane Alarm Relay 4 5 1 4 5 2 4 5 3
5. 4 Data Acquisition amp Engineering Software 4 Communications Based Acquisition Systems 4 Plug in Cards for Apple IBM amp Compatibles 4 Datalogging Systems A Recorders Printers amp Plotters HEATERS Heating Cable l Cartridge amp Strip Heaters 4 Immersion amp Band Heaters 4 Flexible Heaters 4 Laboratory Heaters ENVIRONMENTAL MONITORING AND CONTROL 4 Metering amp Control Instrumentation 4 Refractometers 4 Pumps amp Tubing A Air Soil amp Water Monitors A Industrial Water amp Wastewater Treatment A pH Conductivity amp Dissolved Oxygen Instruments 4177 0805
6. DIP Switch 2 Bank S1 in the off position you must enter the password 6 when PASSWORD is indicated if you wish to change any stored value You do not need to enter the password to proceed to other items in the menu for recall of stored values If PASSWORD has not been enabled you do not need to enter the password to change stored values 5 2 Percent Saturation ppm 5 2 1 The instrument provides measurement of dissolved oxygen in either percent saturation or ppm In ppm measurement the reading is automatically compensated for temperature changes in the medium To select units of measurement enter the menu by pressing CALL to indicate sat ppm b Press the UP arrow button to select sat or the DOWN arrow button or select ppm c Press RUN to return to on line or press CALL for another menu selection 5 3 Calibration 5 3 1 To calibrate the instrument you will need a container of fresh clean water For best results a bubbler such as that used in a tropical fish tank should be in the container a Clean the sensor with a soft cloth and mild soap solution b Place the sensor over the water container for a few minutes There is no need to remove it from the float if so installed c Press CALL to enter the menu d Ifthe password function is enabled enter the password then press CALL to illuminate the sat ppm indicator If the password function is not enabled sat ppm will illuminate at the first press o
7. 5 Bank 51 is OFF 5 8 Relay A Setpoint 5 8 1 As shipped from the factory Relay A is configured to control decreasing D O However you may change the direction of control by changing the position of DIP switch 4 Bank 51 Please refer to Section 4 8 Page 15 The relay setpoint may be at any place on the scale To establish the setpoint proceed as follows a d Press CALL to enter the MENU If the PASSWORD function is enabled enter the password then press CALL to illuminate the sat ppm indicator If the PASSWORD function is not enabled Y sat ppm will illuminate at the first press of CALL Use the down arrow button to illuminate the PPM LED located to the right side of the display Press CALL the required number of times until RELAY A SETPOINT is indicated Now use the arrows to make the display read the desired value Press ENTER The display will flash until ENTER is pressed again to confirm entry ALED above the display indicates when Relay A is activated Press RUN to place the instrument on line or press CALL for another menu selection 5 9 Relay A Deadband 5 9 1 If you have configured the instrument with the DIP switch on the back of the panel for falling D O you will wish to have the deadband sometimes called hysteresis at a higher value than the setpoint If you have established a setpoint of 3 ppm you may wish the deadband to be between 6 ppm and 3 ppm Proceed as follows a d En
8. 7 1 5 7 2 Code 0 1 2 3 4 5 6 7 The temperature of the process can be read at any time by entering the menu and calling for TEMPERATURE Either C or F will be indicated depending on the position of DIP switch No 1 Bank S1 See Section 4 8 The 0 5 Vdc and 0 1 mA analog outputs can be dedicated to follow the process temperature by simply placing DIP switch No 8 in the off position The temperature span of the output is set to the utility menu See Section 4 8 and 7 4 The DOCN600 continuously checks the integrity of all stored data and monitors the condition of the measuring system If a fault is detected the FAIL LED above the display will turn red The STATUS in the operation menu will provide a numerical code giving a possible cause and a suggested remedy The following table shows the display codes causes and remedies Possible Cause Suggested Remedy Normal Condition No action required Reserved Temperature Sensor off Scale Verify process Check for open or short connections D O reading off Scale Verify process Check for open or short connections Memory Loss Call your OMEGA Rep Or OMEGA directly Reserved Sensor Fault Check probe membrane for perforation Factory Setting in force as a Perform procedure according to Section 9 2 result of the ESCAPE procedure NOTE Code 4 could be a serious failure so the alarm relay will energize in addition to the red illumination of the FAIL LED if DIP switch
9. ENTER is pressed again to confirm entry b Press CALL once to indicate OUTPUT LOW Now use the arrow buttons to make the meter read 5 ppm Press ENTER twice as above The analog output will now be at 4 mA when D O of the solution is 5 ppm and will increase to 20 mA when the D O of the solution is 10 ppm d Press RUN to place the instrument on line or press CALL for another menu selection e To invert the output i e decreasing output for increasing process value simply adjust for 4 mA on OUTPUT HIGH and for 20 mA on OUTPUT LOW NOTE A range expand of less than 10 of full scale is an invalid entry which will be indicated by the LED flashing when you return to RUN To correct return to the menu and correct the output settings To test your setup press CALL the number of times required to indicate TEST Now by using the arrow buttons you can sweep through the digital display With the instrument in TEST you can check the analog output at any desired reading with a meter connected to the appropriate output terminals Another use of this feature is to check the stability of the system When in TEST use the arrow buttons to select any value say 10 ppm Now return online by pressing RUN Return to the meter some hours or days later Press CALL to indicate TEST If the instrument is still in calibration and if no one has interfered the meter should read 10 ppm Page 14 5 6 Temperature 5 6 1 5 6 2 5 7 Status 5
10. Utility Menu 7 5 Adjust 4 20 mA Output 7 5 1 It may be desirable to fine tune the 4 20 mA isolated output to take into account the characteristics of your particular loop Before deciding that the adjustment is necessary be aware of the Output High and Output Low settings you may have programmed as described in Section 5 4 The following method involves a high and low calibration and requires the use of a Digital Multimeter DVM Proceed as follows ignoring the instrument display a Turn off the power to the instrument Connect your DVM to the 4 20 mA output terminals on the power supply board Page 19 8 0 e Turn on the power Enter the Utility Menu as described in 7 2 1 Press CALL to indicate CALIBRATION which is 4 20 mA Output adjust low in the Utility Menu See table in 7 2 2 Now use the arrow keys to make your DVM read 8 mA Press ENTER twice to confirm Press CALL to indicate TEMPERATURE which is 4 20 mA Output adjust high in the Utility Menu See table in 7 2 2 Now use the arrow keys to make your DVM read 16 mA Press ENTER twice to confirm Press RUN to return to on line or press CALL to proceed to another item in the Utility Menu 7 6 Altitude Compensation 7 6 1 The instrument can be compensated for the altitude at which it is located by the following procedure e DIAGNOSTICS 8 1 Description Go to the UTILITY MENU as described in 7 2 1 Press CALL to indicate STATUS which i
11. ACEMENT CARTRIDGE Part No DOE 601 SC Hermetically sealed MOUNTING HARDWARE FLOTATION MOUNTING Model DOE 600 BFMK consists of ball float extension pipe swivel bracket junction box and 50 feet of interconnect cable SUBMERSION MOUNTING Model DOE 600 SMK consists of 5 ft PVC pipe junction box and 50 feet of interconnect cable Page 3 3 0 INSTALLATION 3 1 Location 3 1 1 3 1 2 Locate the instrument within the reach of the cable provided for the DOE 601 sensor Select an installation site which is e free of mechanical vibrations reasonably clean and dry protected from falling corrosive fluids within the ambient temperature and humidity specifications e remote from high voltage relay and power switches 3 2 Type of Mounting 3 2 1 3 2 2 If the instrument is to be pipe or panel mounted a special hardware kit will be required For panel mount order part number DOCN600 PM For pipe mount order part number DOCN600 PIPE Instructions for both types of mounting will be included with the kits For surface mounting four feet brackets together with fastening screws are provided with the instrument These should be fastened to the back of the instrument and then it may be screwed or bolted in the selected location 3 3 Conduit Connections 3 3 1 Four 1 2 conduit holes are provided in the bottom of the enclosure One of these is fitted with an approved water tight plug To maintain NEMA 4 integrity appr
12. ER REQUIREMENTS 98 132 Vac 50 60 Hz less than 10 VA Optional 196 264 Vac 50 60 Hz AMBIENT CONDITIONS 30 to 50 C 22 to 122 F 0 to 90 R H non condensing ANALOG OUTPUTS Non isolated 0 1 mA 100 ohms maximum load Non isolated 0 5 Vdc 1000 ohms minimum load Isolated 4 20 mA 800 ohms maximum load The isolated output is isolated from the input ground line power and all other outputs Range Expand The 4 20 mA analog output can be made to represent any segment of the measuring scale Minimum segment is 10 of full scale Output Hold The analog outputs are automatically placed on hold during calibration or other setup operations Temperature Output The 0 5 Vdc output can be programmed to follow either the process temperature or dissolved oxygen TEMPERATURE COMPENSATION Automatic 0 to 100 C 32 to 212 F ALTITUDE COMPENSATION Automatic 0 to 40 C 32 to 104 F DIAGNOSTICS When system error is indicated call STATUS to obtain condition code On board simulated input to aid in troubleshooting to obtain condition code MEMBRANE ALARM A relay activates if membrane is perforated TEST Display value and analog outputs can be set manually to any value for testing and diagnostic purposes This feature allows the outputs to be tested independently of process value SAFETY amp SECURITY Non volatile memory EEPROM Passcode protected if selected Watch dog timer monitors microprocessor Instrument automatically
13. HE MENU WITH EACH PRESS The DOCN600 is a microprocessor based dissolved oxygen analyzers are designed for industrial applications They operate in conjunction with the DOE 601 sensor The software in the unit makes the instrument very easy to operate and maintain The outputs include voltage free relay contacts and industry standard analog transmission signals A relay to indicate a perforated membrane is provided The analog output signals transmit low power signals to peripherals such as data recorders or control systems The software is designed for ease of operation It uses a simple menu with all items indicated on the panel The user interface consists of six buttons on the front panel The buttons are scanned and responded continuously In addition an extensive system checking for values and parameters is performed by the software All of the operating parameters are stored in non volatile memory without the need of a battery The DOCN600 operates like a normal analog converter with a number of additional functions made possible by the microprocessor in the instrument Page 8 Some of these are Recall and easy adjustment of relay and output parameters Push button calibration A HOLD function for outputs Continuous sensor check during measurement Continuous self check and watch dog timer to ensure correct operation Password protection of stored values Temperature Output Simulated input for testing o
14. HOOTING AND SERVICE 13 17 18 20 21 1 0 MODEL DOCN600 DISSOLVED OXYGEN ANALYZERS AND MODEL DOE 601 DISSOLVED OXYGEN SENSOR INSTRUCTION MANUAL GENERAL INFORMATION The DOCN600 Dissolved oxygen analyzer is a versatile industrial microprocessor based instrument Outputs are programmed through the menu with push buttons on the face of the instrument Calibration is also accomplished through the front panel menu The instrument must be used in conjunction with the DOE 601 dissolved oxygen sensor The instrument provides non isolated 0 5 Vdc 0 1 mA and isolated 4 20 mA analog outputs The analog outputs may be programmed to represent any segment of the measuring scale A membrane perforation alarm is provided which gives early warning of a membrane failure The instrument can also be used to take a temperature reading and one of the non isolated analog outputs can be used to give a continuous temperature signal The integrity of the system is ensured with a watch dog timer and system alarm A password feature protects the stored values The instrument is housed in NEMA 4X enclosure The standard unit is provided with mounting hardware for surface mount applications Both panel and pipe mount kits can be ordered separately Page 1 2 0 SPECIFICATIONS DISPLAY 3 1 2 digit LED 1 2 high digits MEASURING RANGES D O 0 20 00 ppm and 0 100 saturation switch selectable Temperature 0 40 C 32 to 104 F POW
15. cordance with this labeling CAUTION Connecting the line voltage power supply to incorrect terminals may cause serious damage 3 7 Probe Connections 3 7 1 The interconnect cable as supplied will normally be connected to the sensor cable in the junction box If this is not the case connect the six wires and the shield of the extension cable to the numbered wires in the junction box as shown below Extension Cable Junction Box Blue Red Black Green White Yellow Shield Unnumbered OnahWN Green Yellow Connect the six wires of the interconnect cable to the terminal strip on the swing out board being sure to match colors as printed on the board Connect the shield to the terminal post located above the terminal strip Running the sensor and interconnect cable in 1 2 metal conduit for protection against moisture and mechanical damage is recommended Do not run power or control wiring in the same conduit electrical noise may interfere with sensor signal Page 7 4 0 DESCRIPTION OF FUNCTIONS 4 1 Overview 4 1 1 ARROWS ADJUST sat ppm O SETPOINT DISPLAY VALUE O TEST DEADBAND WHEN IN MENU O CALIBRATION O TEMPERATURE CONTROL RELAY B me SETPOINT oa DEADBAND RUN PLACES THE Sb EN TENT INSTRUMENT IN O ALARM HIGH THE RUN MODE O ALARM LOW O PASSWORD CONTROL RELAY A ENTER ACCEPTS THE DISPLAY VALUE WHEN MENU PLACES THE IN MENU MODE DOCN600 IN MENU MODE AND STEPS THROUGH T
16. d press CALL until ALARM HIGH is indicated With the arrow buttons make the display read the desired alarm value Press ENTER The display will flash until ENTER is pressed again to confirm the entry b Press RUN to place the instrument on line or press CALL for another menu selection 5 13 Alarm Low 5 13 1 a Press CALL until ALARM LOW is indicated With the arrows make the meter read the desired value Press ENTER The display will flash until ENTER is pressed a second time to confirm entry b Press RUN to place the instrument on line or press CALL for another menu selection NOTE A low alarm point higher than the high alarm point is an invalid entry which is indicated by the LED flashing when you return to RUN To correct return to the menu and reset the alarm points 6 0 OPERATING HINTS 6 1 Cell Care 6 1 1 If the sensor membrane is exposed to the atmosphere for more than 24 hours the electrolyte inside the membrane can dry out If this occurs the cartridge will need to be replaced To avoid membrane dry out place the sensor in a container of clean drinking water until it can be reinstalled into the aeration basin 6 1 2 Sensor cartridges can be stored for up to 5 years if the seal on its storage container is not broken and the temperature is between 70 F and 80 F with 50 to 80 humidity Do not store sensor cartridges at temperatures below freezing point 32 F The electrolyte solution will crystallize at 25 30 F
17. e controls which are frequently used the normal operation of the instrument all accessible on the control panel Some switches which are infrequently used are located on the back of the swing out board The DIP switches are scanned on RESET power up and every time the instrument is taken into the menu mode Therefore after changes to the DIP switch settings you must take the unit offline by pressing CALL in order for the instrument to scan the new DIP switch values The following table describes the use of the 16 DIP switches Switch Switch Description of Use OFF ON Selects temperature unit F C Enables use of Password Feature YES NO Fail Safe mode for Relay A NO YES Direction of Control Relay A Rising Falling Alarm Relay to Activate for Memory Loss YES NO Fail Safe mode for Alarm Relay NO YES Auto Return from menu if no button pressed NO YES 0 5 Vdc 0 1 mA selector Temperature D O Page 11 Dip Switch Bank S2 Fail safe for Relay NO YES Direction of Control for Relay B Rising Falling Reserved Reserved Reserved Reserved Reserved Reserved 4 9 Output Hold 4 9 1 Output hold is a function which freezes all output signals at the last value to prevent the occurrence of wild distortions during programming and maintenance 4 9 2 When the Operation Menu is entered by pressing CALL the alarm relays and the analog outputs are automatically placed on hold and remain on hold until the inst
18. ed on all mounting hardware and sensor threads to avoid leaks b Fasten adapter pipe with union to elbow c Insert adapter pipe with union into flotation ball and tighten union lock ring to secure float assembly Page 5 INTERCONNECT SWING OUT LIFT OFF MICROPROCESSOR BOARD DOCN600 JUNCTION BOX OFF ON SENSOR TEST D O aha ON LINE a TEMP 20 mm 10 25 2 um OFF ON 35 3 mm 542 OFF ON 543 BUTTON 107 118 59 RESET d The sensor may be attached to float assembly in one of two ways 1 With sensor EXTENDED FROM BOTTOM of flotation ball Insert 12 inch long extender pipe into the flotation ball and fasten it to the end of adapter pipe This will extend the sensor s membrane 12 inches below the flotation ball NOTE Extender pipe supplied only when ordered 2 With the sensor membrane FLUSH WITH BOTTOM of flotation ball Disregard using extender pipe and proceed with Step e e Route sensor cable through assembled pipe sections starting from bottom section and fasten sensor to pipe CAUTION Do not remove measuring cell cartridge from hermetically sealed package until it is to be used in step f Membrane will dry out and damage measuring cell f Install measuring cell cartridge Unfasten union nut from sensor and make sure to remove any moisture from cavity area and brass contact strips Insert cartridge in its correctly keyed posi
19. equired by the analyzer functions When the analyzer is powered up the program will display D O readings None of the LEDs in the operation menu will be illuminated Five buttons on the panel are used to operate the menu Use the CALL button to step through the items in the menu one at atime The red LEDs beside each item makes it very easy to follow the menu The function of the RUN button is to return to the on line D O display from anywhere in the menu The analyzer has a built in timer which when enabled by DIP Switch 7 Bank S1 Section 4 8 returns the program to RUN mode if no button has been pressed for 10 minutes This time out has the same effect as pressing the RUN button Page 10 When in the menu mode the display initially shows the current value of the parameters such as the Setpoint of the control relay while putting all of the outputs on hold The two arrow buttons are used to adjust the display value up or down To accept the new value press ENTER twice While the value on the display is being changed the relay outputs and the analog outputs remain on hold The items that appear in the operation menu are Password Sat ppm Test Calibration Temperature Status Output High Output Low Relay A Setpoint Relay A Deadband Relay B Setpoint Relay B Deadband Alarm Relay High Alarm Relay Low e eee 4 8 DIP Switches DIP Switch Bank S1 4 8 1 Th
20. f CALL e Use the UP arrow button to illuminate the sat LED located to the right of the display f Press CALL twice to illuminate the CALIBRATION indicator g Use the arrow buttons to make the display read 100 0 h Press ENTER as soon as the reading stabilizes The display will flash until ENTER is pressed again to confirm entry Page 13 If you wish to change the measuring unit to ppm press CALL a number of times to return to Yosat ppm and change ppm with the down button j Press RUN to return to on line measurement NOTE major change is necessary to make the display read 100 the display will flash when you press ENTER This is to warn that you may have made a mistake such as using stale water If you are confident your procedure was correct press ENTER a second time Otherwise repeat the calibration procedure by pressing CALL a sufficient number of times to go through the menu and return to CALIBRATION 5 4 Analog Output Range Expand 5 4 1 5 5 Test 5 5 1 5 5 2 5 5 3 The 4 20 mA isolated analog output may be spread over any section of the scale as long as that section is at least 10 of full scale The best way to describe this setup is by example Suppose you wish the 4 20mA output to span 5 ppm to 10 ppm Proceed as follows a Press CALL as many times as required until OUTPUT HIGH is indicated Now use the arrows to make the meter read 10 ppm Press ENTER The display will flash until
21. ide of OMEGA s control Components in which wear is not warranted include but are not limited to contact points fuses and triacs OMEGA is pleased to offer suggestions on the use of its various products However OMEGA neither assumes responsibility for any omissions or errors nor assumes liability for any damages that result from the use of its products in accordance with information provided by OMEGA either verbal or written OMEGA warrants only that the parts manufactured by the company will be as specified and free of defects OMEGA MAKES NO OTHER WARRANTIES OR REPRESENTATIONS OF ANY KIND WHATSOEVER EXPRESSED OR IMPLIED EXCEPT THAT OF TITLE AND ALL IMPLIED WARRANTIES INCLUDING ANY WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED LIMITATION OF LIABILITY The remedies of purchaser set forth herein are exclusive and the total liability of OMEGA with respect to this order whether based on contract warranty negligence indemnification strict liability or otherwise shall not exceed the purchase price of the component upon which liability is based In no event shall OMEGA be liable for consequential incidental or special damages CONDITIONS Equipment sold by OMEGA is not intended to be used nor shall it be used 1 as a Basic Component under 10 CFR 21 NRC used in or with any nuclear installation or activity or 2 in medical applications or used on humans Should any Product s be used in or w
22. inger will produce a drop of liquid The cartridge must be replaced See Section 9 4 3 With operating time silver oxide will build up on the anode silver wire When the anode becomes brown as a result of the deposit it is time to replace the sensor cartridge To replace the sensor cartridge unscrew the retaining nut remove and discard the spent cartridge and replace with a new cartridge Part No DOE 601 SC 9 5 Relay Replacement 9 5 1 The relays are plugged into the power supply board just above the terminals Be sure all the power including independent power to the relay is off Unplug the relay in question and replace with a new relay Contact OMEGA Engineering for assistance Page 23 STATEMENTS OF CONFORMITY FROM THE MANUFACTURER U S A WARNING This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions manual may cause interference to radio communications It has been tested and found to comply with the limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules which are designed to provide reasonable protection against such interference when operated in a commercial environment Canada This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the radio interference regulations of the Canadian Department of Communications Le pres nt appareil num r
23. instrument is set up for the available line voltage and make sure the line voltage is actually available at the terminals Now measure that sufficient voltage is available at all times it should be 98 Vac to 132 Vac or 187 Vac to 243 Vac respectively Shut line power off making sure it is off CAUTION Power to the relays may be supplied from a separate source shut it off too Check and if necessary replace the internal 0 25A fuse Push the connector of the ribbon cable firmly into its socket If these steps do not solve the problem it may be necessary to replace the power supply board See Section 9 3 1 below If the process value seems wrong clean the sensor as described in Section 6 1 3 Inspect the sensor wire terminal block connections and interconnections Calibrate and resume operation To find out whether the problem is in the sensor or in the analyzer use the self testing features Leave the instrument in RUN mode and proceed as follows a Move the slide switches S40 and S41 on the back of the swing out panel from position ON LINE to position TEST b Press CALL to enter the menu and go to sat ppm Set the D O simulation DIP switch Bank S42 switch No 1 On Switches No 2 3 and 4 Off The display should show 4 ppm 5 d Now proceed to turn each of the other S42 switches On with the remaining switches Off The display should read within 5 of 10 ppm with switch 2 On 16 ppm with switch 3 On and 20 ppm w
24. ique n met pas de bruits radio lectriques d passant les limites applicables aux appareils num riques de la classe A prescrites dans le R glement sur le brouillage radio lectrique dict par le minist re des Communications du Canada Page 24 WARRANTY DISCLAIMER OMEGA ENGINEERING INC warrants this unit to be free of defects in materials and workmanship for a period of 13 months from date of purchase OMEGA s WARRANTY adds an additional one 1 month grace period to the normal one 1 year product warranty to cover handling and shipping time This ensures that OMEGAS customers receive maximum coverage on each product If the unit malfunctions it must be returned to the factory for evaluation OMEGA s Customer Service Department will issue an Authorized Return AR number immediately upon phone or written request Upon examination by OMEGA if the unit is found to be defective it will be repaired or replaced at no charge OMEGA s WARRANTY does not apply to defects resulting from any action of the purchaser including but not limited to mishandling improper interfacing operation outside of design limits improper repair or unauthorized modification This WARRANTY is VOID if the unit shows evidence of having been tampered with or shows evidence of having been damaged as a result of excessive corrosion or current heat moisture or vibration improper specification misapplication misuse or other operating conditions outs
25. ith any nuclear installation or activity medical application used on humans or misused in any way OMEGA assumes no responsibility as set forth in our basic WARRANTY DISCLAIMER language and additionally purchaser will indemnify OMEGA and hold OMEGA harmless from any liability or damage whatsoever arising out of the use of the Product s in such a manner RETURN REQUESTS INQUIRIES Direct all warranty and repair requests inquiries to the OMEGA Customer Service Department BEFORE RETURNING ANY PRODUCT S TO OMEGA PURCHASER MUST OBTAIN AN AUTHORIZED RETURN AR NUMBER FROM OMEGA S CUSTOMER SERVICE DEPARTMENT IN ORDER TO AVOID PROCESSING DELAYS The assigned AR number should then be marked on the outside of the return package and on any correspondence The purchaser is responsible for shipping charges freight insurance and proper packaging to prevent breakage in transit FOR WARRANTY RETURNS please have the FOR NON WARRANTY REPAIRS consult OMEGA following information available BEFORE for current repair charges Have the following contacting OMEGA information available BEFORE contacting OMEGA 1 Purchase Order number under which the product 1 Purchase Order number to cover the COST was PURCHASED of the repair 2 Model and serial number of the product under 2 Model and serial number of the product and warranty and 3 Repair instructions and or specific problems 3 Repair instructions and or specific problems relative to the product
26. ith switch 4 On If this is the case the analyzer is in order and the problem is with the probe e Return S40 and S41 to On line and ensure that all S42 switches are Off check the temperature channel move the slide switches 540 and 541 from position On line to position TEST f Set the DIP switch 1 Bank 51 g Goto the TEMPERATURE menu item Set the temperature simulation DIP switch Bank S43 switch No 1 On switches No 2 and 3 Off The display should show 10 degrees Celsius 5 Page 21 9 2 Escape 9 2 1 9 2 2 9 2 3 9 2 4 9 2 5 e Now proceed to turn each of the other S43 switches On with the remaining switches Off The display should read within 5 of 25 C with Switch 2 On and 35 C with Switch 3 On If this is the case the analyzer is in order and the problem is in the sensor Otherwise the problem is in the analyzer f Return S40 and S41 to On line and ensure that all S43 switches are Off If the instrument appears to be DEAD for example not responding to the buttons or not performing on line measurement and control always try the reset feature first as described in 6 3 1 a The ESCAPE procedure is to be used normally at the factory only when the unit is powered with new MCU As a result the internal non volatile memory EEPROM is FORMATTED and the factory values are loaded into it b The ESCAPE procedure is to be used if a unit is serviced fo
27. ng nl Frystatska 184 733 01 Karvin Czech Republic TEL 420 0 59 6311899 FAX 420 0 59 6311114 Toll Free 0800 1 66342 e mail info omegashop cz 11 rue Jacques Cartier 78280 Guyancourt France TEL 33 0 1 61 37 2900 FAX 33 0 1 30 57 5427 Toll Free in France 0800 466 342 e mail sales omega fr Daimlerstrasse 26 D 75392 Deckenpfronn Germany TEL 49 0 7056 9398 0 FAX 49 0 7056 9398 29 Toll Free in Germany 0800 639 7678 e mail info omega de One Omega Drive River Bend Technology Centre Northbank Irlam Manchester M44 5BD United Kingdom TEL 44 0 161 777 6611 FAX 44 0 161 777 6622 Toll Free in United Kingdom 0800 488 488 e mail sales omega co uk It is the policy of OMEGA Engineering Inc to comply with all worldwide safety and regulations that apply OMEGA is constantly pursuing certification of its products to the European New Approach Directives OMEGA will add the CE mark to every appropriate device upon certification The information contained in this document is believed to be correct but OMEGA accepts no liability for any errors it contains and reserves the right to alter specifications without notice WARNING These products are not designed for use in and should not be used for human applications TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS INSTALLATION DESCRIPTION OF FUNCTIONS START UP AND OPERATION OPERATING HINTS UTILITY MENU DIAGNOSTICS TROUBLES
28. ns 5 12 and 5 13 Page 22 d After all the above operations are performed the FAIL LED will turn off and STATUS LED will turn green and Status 0 should be obtained e The unit may be tested now using the TEST menu item See Section 5 5 or the built in self testing feature See Section 9 1 4 f Bring the unit on line for measurement and control 9 3 Printed Circuit Board Replacement 9 3 1 a To replace printed circuit boards or relays shut off all power to the DOCN600 including any independent power to the relay contacts Make a record of the external wiring then disconnect the wires Unplug the ribbon cable connector b The power supply circuit board is fastened to the back of the enclosure by four screws remove the screws and the board is free Reverse the procedure to mount a replacement board c The microprocessor circuit board is located on the swing out assembly behind the door Swing the assembly out lift it up to unseat the lower hinge pin the upper hinge pin is spring loaded The assembly is now free The circuit board is fastened to the front panel by three screws Remove the screws to release the circuit board 9 4 Sensor Fault 9 4 1 9 4 2 9 4 3 If the membrane of the sensor cartridge is pierced the alarm relay contacts will close and the FAIL LED and STATUS LED will be illuminated However it may be difficult to see the leakage with the naked eye A slight pressure on the membrane with a f
29. ol YEAR WARRANTY Shop online at CEOMEGA omega com e mail info omega com For latest product manuals omegamanual info CERTIFIED CERTIFIED CORPORATE QUALITY CORPORATE QUALITY STAMFORD CT MANCHESTER UK TEMPERATURE STATUS OUTPUT HIGH OUTPUT Low DOCN600 Dissolved Oxygen System OMEGAnet Online Service Internet e mail omega com info omega com U S A ISO 9001 Certified Canada Servicing North America One Omega Drive P O Box 4047 Stamford CT 06907 0047 TEL 203 359 1660 FAX 203 359 7700 e mail info omega com 976 Bergar Laval Quebec H7L 5A1 Canada TEL 514 856 6928 FAX 514 856 6886 e mail info omega ca For immediate technical or application assistance U S A and Canada Mexico Benelux Czech Republic France Germany Austria United Kingdom ISO 9002 Certified Sales Service 1 800 826 6342 1 800 TC OMEGA Customer Service 1 800 622 2378 1 800 622 BEST Engineering Service 1 800 872 9436 1 800 USA WHEN TELEX 996404 EASYLINK 62968934 CABLE OMEGA En Espafiol 001 203 359 7803 e mail espanol omega com FAX 001 203 359 7807 info omega com mx Servicing Europe Postbus 8034 1180 LA Amstelveen The Netherlands TEL 31 0 20 3472121 FAX 31 0 20 6434643 Toll Free in Benelux 0800 0993344 e mail sales omegae
30. oved conduit hubs must be used to connect conduit The hubs must be connected to the conduit before being connected to the enclosure Any unused conduit holes must be closed with water tight plugs or connectors For convenience of internal connections the right conduit hole viewed from the front should be used for power connection the next hole to the left for relay outputs the next hole to the left for analog outputs and finally the fourth hole for sensor input 3 4 Electrical Connections CAUTION The instrument operates from line voltage This constitutes a possible shock hazard Ensure that line power is removed before attempting connections Note A separate source of line power may have been connected to the floating relay contacts 3 4 1 To access the terminal strips open the door of the instrument and then unscrew the captive retaining screw near the upper right hand corner of the panel Now swing open the panel to reveal the terminal strip on the power supply circuit board and the smaller terminal strip on the back of the swing out board Page 4 3 5 Sensor Installation Flotation Mounting 3 5 1 POWER SUPPLY BOARD CONTR RELAY B OUTPUTS Refer to diagram below and proceed as follows a Fasten elbow to 90 inch long pipe 0 ALM RLY Plug In RELAYS CONTR RELAY A VOLTAGE A107 118 NOTE Thread sealant Teflon tape is recommend
31. pan of the 0 1 mA 0 5 Vdc output Adjust the offset and span of the 4 20 mA output Perform the altitude compensation 7 2 Access to Utility Menu 7 2 1 7 2 2 Display LED Output High Output Low Sat ppm Test Calibration Temperature Status The Utility Menu is protected by password To access the Utility Menu press and hold both RUN and ENTER for five seconds until the PASSWORD LED illuminates The RUN LED will flash to warn that Utility Menu is in use Now with the arrow keys make the display read the password 7 Press ENTER The Utility Menu is entirely separate from the Operation Menu but uses the same LED display Press CALL to step through the menu items Below is the cross reference between menu items Meaning in Utility Menu Temperature Output 100 5 Vdc Temperature Output 0 0 Vdc 0 1 mA 0 5 Output Adjust Low 0 1 mA 0 5 Vde Output Adjust High 4 20 mA Output Adjust Low 4 20 mA Output Adjust High Altitude Compensation Page 18 7 3 Temperature Output 7 3 1 The 0 5 Vdc and 0 1 mA outputs may be programmed to track the temperature of the process The factory outputs have a linear range corresponding to 0 C to 40 C or 32 F to 104 F Suppose you wish the output to span 10 C to 45 C Proceed as follows a Enter the Utility Menu as described in 7 2 1 b Press CALL to indicate OUTPUT HIGH which is the Temperature output 100 point in the Utility Menu See table in 7 2 2 No
32. r a new MCU insertion in case where the MCU was not calibrated at OMEGA or in case of a memory loss problem when so advised by OMEGA service support Before performing the ESCAPE procedure it is important to know that this procedure provides the option to erase all programmed values and replace them with the factory set default values This is also true for the control setpoints and deadbands then alarm settings and the analog outputs scaling Also the temperature and the D O calibration points will be set to their initial values This means that the temperature and the D O calibration must be performed after an ESCAPE procedure After that all the control alarm and scaling parameters mentioned above must be set to the user values To perform the ESCAPE proceed as follows a Turn off the power b Press and hold the RUN button for about 3 seconds while turning on the power The FAIL LED will turn on and STATUS LED will become red and status code 7 will be obtained to show that the ESCAPE procedure was just performed After the ESCAPE procedure it is necessary to do the following a Tune the analog outputs and the temperature output span to suit your particular application and loop See Sections 7 3 7 4 and 7 5 b Calibrate the system as described in Section 5 3 c Setup the user values for Output High and Low See Section 5 4 e Control Relay See Sections 5 8 5 9 Alarm Relay See Sectio
33. returns to on line operation if accidentally left in menu mode This feature may be held disabled if desired ACCURACY Saturation 1 ppm 0 Temp 0 2 C STABILITY 0 1 of span per 24 hrs non cumulative RESOLUTION Saturation 0 1 ppm 0 01 Temp 0 1 C REPEATABILITY 0 1 of span or better RESPONSE TIME 20 seconds to 90 of value upon step change at 20 C ENCLOSURE NEMA 4X fiberglass reinforced polyester enclosure with four 1 2 conduit holes and mounting feet for surface mount MOUNTING CONFIGURATIONS Standard is surface mount Optional panel mount hardware Part No DOCN600 PM Optional pipe mount hardware Part No DOCN600 PIPE NET WEIGHT 3 1 2 1 6 kg Page 2 MODEL DOCN600 ADDITIONAL FEATURES CONTROL RELAYS Two relays can be independently set for operation in response to rising or falling value and for fail safe operation Deadband hysteresis independently adjustable Rating 5A 115 230 Vac 5A 30 Vdc SPDT ALARM RELAY High Low with fixed deadband of 2 of full scale Normal or fail safe operation Rating 5A 115 230 Vac 5A 30 Vdc SPDT RELAY INDICATORS Three LEDs indicate status or the three relays DOE 601 SENSOR TEMPERATURE RANGE 0 40 C 32 to 104 F WETTED MATERIALS PVC and Teflon F E P FAILURE ALARM 5A SPDF relay closes if membrane is punctured LED on panel is illuminated CABLE Integral 8 m 26 ft Maximum distance to analyzer 300 m 1000 ft REPL
34. rument returns to on line The output hold will remain for a maximum of 10 minutes after the last button was pressed if this feature has been enabled See Section 4 8 4 10 Parameter and Operation Checking 4 10 1 The instrument continuously checks all parameters in its memory while taking D O readings When it detects an invalid value it flashes the LEDs in the operation menu to indicate the parameter is at fault You must then access the operation menu to take corrective actions 4 11 Simulated Input for Testing 4 11 1 TEST is function for test and diagnostic purposes Values can be simulated internally and adjusted with the arrow buttons to set display reading and analog outputs to any desired value without disrupting instrument calibration 4 12 Utility Menu 4 12 1 The Utility Menu is provided to enable authorized personnel to change the range and fine tune the analog See Section 7 0 4 13 Watchdog Timer and Self Diagnostics 4 13 1 The DOCN600 continuously monitors the condition of all key components of the measuring system to ensure that the measurements are reliable Invalid entries and memory loss are indicated on the panel See Section 8 0 Page 12 5 0 START UP AND OPERATION 5 1 Password 5 1 1 To enter the menu press CALL then PASSWORD will be indicated With each press of CALL you will step through the menu When the last item is reached the menu wraps around to sat ppm If you have enabled PASSWORD by placing
35. s ALTITUDE COMPENSATION the Utility Menu Adjust the display to your altitude in thousands of feet For example 0 34 on display corresponds to an altitude of 340 feet Press ENTER The display will flash until ENTER is pressed again to confirm entry The supported altitude range is from 1 000 to 30 000 ft 305 to 9 144 m or 1 00 to 30 00 on the display As shipped from the factory the altitude is set to zero i e sea level Press RUN to go on line or CALL to proceed to another Utility Menu item 8 1 1 The DOCN600 has diagnostic features which alerts the operator to invalid entries and memory loss Invalid entries are indicated by the flashing of the appropriate menu LED The flashing will commence after RUN is pressed and will continue until the errors are corrected Memory loss is indicated by the flashing of TEST and by the alarm relay if enabled by DIP Switch No 5 of Bank 51 See Section 4 8 3 8 2 Invalid Output 8 2 1 Invalid output will be indicated if the expanded range is less than 10 of full scale To correct refer to Section 5 4 Page 20 9 0 TROUBLESHOOTING AND SERVICE 9 1 Isolate the cause 9 1 1 When a measurement problem occurs the first step is to try to isolate the cause If the DOCN600 is powered go through the menu and check your settings A convenient way to do this is to call TEST See Section 5 5 If your DOCN600 appears dead or intermittent check the breaker make sure that the
36. ter the menu and press CALL the required number of times to indicate RELAY A DEADBAND Use the arrow buttons to make the display read the desired value in this example 6 Press ENTER The display will flash until ENTER is pressed again to confirm the entry In this example after the instrument has been returned to RUN the relay will be energized when the D O falls to 3 ppm and will remain energized until the reading rises above 6 ppm When Relay A is activated a LED above the display will be illuminated Press RUN to place the instrument on line or press CALL for another menu selection 5 10 Relay B Setpoint 5 10 1 Relay Setpoint is configured the same way as Relay A Setpoint See Section 5 8 ALED above the display indicates when Relay B is activated 5 11 Relay B Deadband 5 11 1 Relay Deadband is configured in the same way as Relay A Deadband See Section 5 9 NOTE A deadband setting on the wrong side of the setpoint in an invalid entry which will be indicated by the LED flashing when you return to RUN To correct return to the menu and change the deadband setting or if the direction of control is the problem change the position of the relevant DIP switch See Sections 4 8 and 5 9 Page 16 5 12 Alarm High 5 12 1 The instrument is fitted with a relay which is set to activate on both high and low alarm conditions The deadband is factory set To set the ALARM HIGH proceed as follows a Enter the menu an
37. tion Fasten union not tightly so that O ring compresses to create an effective water tight seal g Calibrate system in accordance with the procedure described in Section 5 3 before placing sensor into operation Page 6 h Install pivot mounting bracket and mount junction box on the bracket Insert pipe sensor assembly through the bracket to the desired position Tighten pipe locking screw 3 6 Sensor Installation Submersion Mounting a Refer to diagram below and proceed as follows b Route sensor cable through pipe and fasten sensor to pipe The use of thread sealant Teflon tape on all mounting hardware and sensor threads is recommended to avoid leaks CAUTION Do not remove measuring cell cartridge from hermetically sealed package until it is to be used in step b Membrane will dry out and damage measuring cell c Install measuring cell cartridge Unfasten union nut from sensor and make sure to remove any moisture from cavity area and brass contact strips Insert cartridge in its correctly keyed position Fasten union tightly so the O ring compresses to create an effective water tight seal d Mount the junction box within reach of the sensor cable e Calibrate system in accordance with the procedure described in Section 5 3 before placing sensor into operation The terminal strip on the power supply board at the back of the instrument is labeled for power supply relay outputs and analog outputs Connect wiring in ac
38. w use the arrow button to show 45 0 on the display Press ENTER The display will flash until ENTER is pressed again to confirm entry c Press CALL to indicate OUTPUT LOW which is the Temperature output 0 point in the Utility Menu See table in 7 2 2 Now use the arrow buttons to show 10 0 on the display Press ENTER twice as above d Press RUN to return to on line or press CALL to proceed to another item in the Utility Menu 7 4 Adjust 0 1 mA 0 5 Output 7 4 1 It may desirable to fine tune the 0 1 mA 0 5 Vdc output to take into account the characteristics of your particular loop The following method involves a high and low calibration and requires the use of a digital multi meter DVM Proceed as follows ignoring the instrument display a Turn off the power to the instrument Connect your DVM to the 0 5 Vdc output terminals on the power supply board Turn on the power Enter the Utility Menu as described 7 2 1 Press CALL to indicate sat ppm which is 0 1 mA 0 5 Vdc output adjust low in the Utility Menu See table in 7 2 2 Use the arrow keys to make your DVM read 1 25V Press ENTER twice to confirm Press CALL to indicate TEST which is 0 1 mA 0 5 Vdc Output adjust high in the Utility Menu See table in 7 2 2 Use the arrow keys to make your DVM read 3 75V Press ENTER twice to confirm e Press RUN to return to on line or press CALL to proceed to another item in the
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