ABB AX418, User Manual

Page 1: ...Single and Dual Input Analyzers for Dissolved Oxygen AX418 AX438 AX480 AX468 and AX488 User Guide IM AX4DO_5 ...

Page 2: ... these instructions must be read carefully before proceeding 2 Warning labels on containers and packages must be observed 3 Installation operation maintenance and servicing must only be carried out by suitably trained personnel and in accordance with the information given 4 Normal safety precautions must be taken to avoid the possibility of an accident occurring when operating in conditions of hig...

Page 3: ... 5 10 Test Outputs and Maintenance 37 Section Page 6 INSTALLATION 39 6 1 Siting Requirements 39 6 2 Mounting 40 6 2 1 Wall Pipe mount Analyzers 40 6 2 2 Panel mount Analyzers 41 6 3 Electrical Connections 42 6 3 1 Relay Contact Protection and Interference Suppression 43 6 3 2 Cable Entry Knockouts Wall Pipe mount Analyzer 44 6 4 Wall Pipe mount Analyzer Connections 45 6 4 1 Access to Terminals 45 ...

Page 4: ...n I e l g n i S P R O x o d e R H p e l b a c i l p p A t o N 6 6 4 X A P R O x o d e R H p t u p n I l a u D P R O x o d e R H p P R O x o d e R H p 8 6 4 X A n e g y x O d e v l o s s i D d n a P R O x o d e R H p t u p n I l a u D P R O x o d e R H p n e g y x O d e v l o s s i D 0 8 4 X A n e g y x O d e v l o s s i D t u p n I e l g n i S n e g y x O d e v l o s s i D e l b a c i l p p A t o ...

Page 5: ...e is automatically stored Menu 1 Menu 2 Advance to next menu 2 2 1 Membrane Key Functions Fig 2 2 2 OPERATION 2 1 Powering Up the Analyzer Warning Ensure all connections are made correctly especially to the earth stud see Section 6 3 1 Ensure the input sensor s is are connected correctly 2 Switch on the power supply to the analyzer A start up screen is displayed while internal checks are performed...

Page 6: ...ilsafe A2 Action A3 Assign A3 Failsafe A3 Action Config Alarm 3 A3 Type Section 5 4 Page 23 A1 Setpoint A2 Setpoint A2 Hysteresis A2 Delay A3 Setpoint A3 Hysteresis A3 Delay Wash Frequency Wash Duration Recovery Period Wash Mode Applicable only to Alarm 3 Config Alarm 4 A4 Type A4 Assign A4 Failsafe A4 Action Config Alarm 5 A5 Type A5 Assign A5 Failsafe A5 Action A4 Setpoint A4 Hysteresis A4 Delay...

Page 7: ...ault AO3 Default Val AO4 Default AO4 Default Val TEST MAINTENANCE Test Outputs Test Output 1 Test Output 2 Maintenance Hold Outputs Test Output 3 Test Output 4 Section 5 10 Page 37 Load Save Config Factory Config User Config Press To Abort Press To Set CONFIG CONTROL Controller Section 5 7 Page 31 PID Controller Control Action Prop Band Integral time Derivative time Output Type Pulses Minute Cycle...

Page 8: ...100 Control Set Point Dissolved Oxygen Control set point Use the and keys to adjust the control set point between 0 and 250 saturation if A Parameter set to Sat between 0 00 and 25 00 ppm if A Parameter set to ppm see Section 5 3 between 0 00 and 25 00 mg l if A Parameter set to mg l Sensor Output Current See Section 3 1 See Section 4 1 A3 Type set to Wash Section 5 4 see Section 2 3 3 A3 Type not...

Page 9: ... of the sample Sensor Output Current Sensor A Sensor B See Section 3 1 See Section 4 1 A3 Type set to Wash Section 5 4 see Section 2 3 3 A3 Type not set to Wash Section 5 4 return to top of page Temperature 20 0Deg C 20 0Deg C Dual D O 100 0 Sat 9 07ppm VIEW SETPOINTS SENSOR CAL Dual D O Wash Function Sensor Output uA uA 25 00 25 00 2 OPERATION 2 3 Operating Page 2 3 2 Dual Input Dissolved Oxygen ...

Page 10: ...Wash Function not set to Manual The display returns to the top of the Operating Page Press to Wash Manual Wash only Press to Wash and Press to Abort are shown alternately on the lower display line Press the key to initiate the wash cycle The display returns to the top of the Operating Page and the lower display line shows WASH IN PROGRESS until the wash cycle is completed The Wash Function selecti...

Page 11: ...ents set point values and relay LED actions are programmable see Section 5 4 Those shown in the following frames are examples only Sensor A Dissolved Oxygen Alarm 1 Set Point Sensor A Temperature Alarm 2 Set Point Sensor B Dissolved Oxygen Alarm 3 Set Point Dual input analyzers only Sensor B Temperature Alarm 4 Set Point Dual input analyzers only Note Alarm 4 available only if option board fitted ...

Page 12: ...ion board fitted and analog features enabled see Section 7 3 3 3 View Hardware Sensor A Module Shows the type of input board fitted to the analyzer for the Sensor A input D O Dissolved Oxygen Sensor B Module Dual input analyzers only Shows the type of input board fitted to the analyzer for the Sensor B input Option Board Note Displayed only if the option board is fitted Displays the optional featu...

Page 13: ... The logbook stores data entries for alarm events sensor errors power failures and sensor calibrations View Logbook Use the and keys to access the Alarms logbook Note If no entries are stored in the Alarms logbook the display shows No More Entries Alarms The Alarms logbook contains up to 10 entries entry 1 is the most recent each comprising an alarm number alarm state On or Off and the date time o...

Page 14: ...y shows No More Entries View Logbook Use the and keys to access the Power logbook Note If no entries are stored in the Power logbook the display shows No More Entries Power The Power logbook contains up to 2 entries entry 1 is the most recent each comprising the power state On or Off and the date time of the occurrence Option board fitted and analog features enabled Section 7 3 see Section 3 6 See...

Page 15: ...utomatic calibration frame 1 contains the entry number sensor letter and pass fail indication frame 2 contains the sensor efficiency value together with the date time of the calibration If an entry is generated by a manual calibration frame 1 contains the entry number sensor letter and User indication frame 2 contains the sensor zero and span slope values together with the date time of the calibra...

Page 16: ...age see Section 2 3 See Section 4 1 3 6 View Clock Note The View Clock function is available only if the option board is fitted and analog features enabled see Section 7 3 Date 05 03 04 VIEW CLOCK Time 08 54 Dissolved Oxygen SENSOR CAL VIEW CLOCK Dual D O 3 OPERATOR VIEWS ...

Page 17: ...set to zero Section 5 8 see Section 5 2 Continued below Calibration Type Manual manually adjust the analyzer s span reading and zero reading if required see next page to match those from a reference instrument Auto automatic calibration None display sensor efficiency calculated from the last successful calibration Note Manual calibration is normally used only in conditions of extreme cold when rem...

Page 18: ... value is adjusted to the maximum of its range 0 400 to 2 500 Adjustment outside this range is not possible see Table 8 1 page 55 Sensor B calibration dual input analyzers only is identical to Sensor A calibration Single input analyzers only return to main menu Alter Sec Code not set to zero Section 5 8 see Section 5 1 Alter Sec Code set to zero Section 5 8 see Section 5 2 Continued on next page C...

Page 19: ...e correction have been selected the analyzer functions at a default setting of 0m sea level and 760mm Hg Altitude Set the local altitude in metres above sea level 1m 3 28 ft Calibration Type Select the required calibration type Comm Commisioning calibration includes a zero calibration procedure using 5 sodium sulphite Recommended method following system installation or capsule change Std Standard ...

Page 20: ... detected the lower display line shows 100 for 2 seconds the display then advances automatically to the next frame Span Calibration Water Calibration Method Thoroughly rinse the sensor with demineralized water and carefully dry the sensor capsule with a soft tissue Immerse the sensor capsule in air saturated water Press the key to initiate calibration Note To abort calibration press the key again ...

Page 21: ...ng is detected the lower display line shows 100 for 2 seconds the display then advances automatically to the next frame Sensor Output Provides an indication of sensor performance When five bars are displayed the sensor has maximum life remaining When one bar is displayed and flashing the sensor is exhausted Order a replacement sensor when two bars are displayed Note If a calibration results in a s...

Page 22: ...Enter the required code number between 0000 and 19999 to gain access to the configuration pages If an incorrect value is entered access to the configuration pages is prevented and the display reverts to the Operating Page see Section 2 3 See Section 5 2 SECURITY CODE 0000 CONFIG DISPLAY 5 1 Security Code ...

Page 23: ...Display Backlight Backlight Use the and keys to select the required backlight option Auto Backlight comes on at each button press and switches off one minute after the last button press On Backlight is always on Return to main menu See Section 5 3 CONFIG DISPLAY Set Language Temp Units Off Set Temp Units Deg F Deg C LED Backlight Set Backlight Auto On CONFIG DISPLAY CONFIG SENSORS Set Backlight Se...

Page 24: ...stuarine waters see Appendix A2 Salinity Enter the salinity value of the process fluid in parts per thousand ppt see Appendix A2 Sensor B configuration dual input analyzers only is identical to Sensor A configuration See Section 5 4 Filter Time Set the required filter time between 1 and 60 seconds in 1 second increments Sensor B configuration dual input analyzers only is identical to Sensor A conf...

Page 25: ...ter see next page to generate an alarm in response to a specified sensor reading Status An alarm is generated if either a power failure or a condition occurs that causes any of the error messages in Table 8 1 page 55 to be displayed Wash Alarm 3 is configured to control the wash sequence Note The Wash alarm type can be assigned only to Alarm 3 and is displayed only when the lower display line show...

Page 26: ...ps below the value set in the Alarm 1 Set Point parameter depending on the type of Alarm 1 Action selected see next page A B The analyzer activates an alarm if the difference between the Sensor A and Sensor B readings exceeds or drops below the value set in the Alarm 1 Set Point parameter depending on the type of Alarm 1 Action selected see next page Note The Sen B Temp B and A B alarm assignment ...

Page 27: ...t the required hysteresis in 0 1 increments See also Figs 5 2 to 5 6 page 27 Alarm 1 Delay If an alarm condition occurs activation of the relays and LEDs can be delayed for a specified time period If the alarm clears within the period the alarm is not activated Set the required delay in the range 0 to 240 seconds in 1 second increments See also Figs 5 2 to 5 6 page 27 Alarms 2 and 3 configuration ...

Page 28: ...1 minute increments between 1 and 10 minutes Recovery Period Set the recovery period required between 0 5 and 5 0 minutes in 0 5 minute increments Option board fitted and analog features enabled Section 7 3 Alarm 4 configuation is identical to Alarm 1 Option board not fitted or option board fitted and analog features disabled Section 7 3 see Section 5 5 5 4 Configure Alarms 5 4 1 Wash Cycle Config...

Page 29: ...LED On Process Variable High Set Point Delay Hysteresis Relay Energized LED Off Relay De energized LED On Process Variable Hysteresis High Set Point Relay Energized LED Off Relay De energized LED On Process Variable High Set Point Delay Relay De energized LED Off Relay Energized LED On Process Variable High Set Point 5 PROGRAMMING 5 4 Configure Alarms Note The following examples illustrate High Al...

Page 30: ...ange Select the analog output current range for the selected output Span Value Sat or ppm or mg l and Adjust are shown alternately on the upper display line Use the and keys to adjust the displayed reading to the required span value Sat 20 0 to 250 0 Sat minimum differential 20 0 Sat ppm 2 00 to 25 00 ppm minimum differential 2 00 ppm mg l 2 00 to 25 00 mg l minimum differential 2 00 mg l Note The...

Page 31: ...el set in the Default Val frame below Off Ignore failure and continue operation Default Value The level to which the analog output is driven if a failure occurs Set the value between 0 00 and 22 00mA Output 2 configuration and Outputs 3 and 4 if option board fitted and analog features enabled see Section 7 3 is identical to Output 1 configuration Option board fitted and analog features enabled Sec...

Page 32: ...fields Use the and keys to adjust each field Time Set the time in the form hh mm Press to move between the hours and minutes fields Use the and keys to adjust each field Press to Wash and Press to Abort are shown alternately on the lower display line Press the appropriate key to set the clock or abort the changes 5 6 Configure Clock Note The Configure Clock function is available only if the option...

Page 33: ...ID controller Controller set to PID see Section 5 7 1 See Section 5 8 5 7 Configure Control Notes PID control is applicable only to single input analyzers Before configuring the PID controller refer to Appendix B for further information CONFIG CONTROL Controller PID Controller PID Off CONFIG SECURITY ...

Page 34: ...ents Integral Action Time Set the integral action time between 1 and 7200 seconds in 1 second increments Set to OFF to disable integral action time Derivative Action Time Set the derivative action time between 0 1 and 999 9 seconds in 0 1 second increments Set to OFF to disable derivative action time Output Type Set the required output type Time Time proportioning relay 1 Analog Analog output anal...

Page 35: ... the retention time of the vessel and the flow of the chemical reagent and is adjusted experimentally to ensure that the chemical reagent is adequate to control the dosing under maximum loading It is recommended that the Time Proportioning Output is adjusted in Manual Mode set to 100 valve output before setting up the PID parameters The time proportioning output value is calculated using the follo...

Page 36: ...ngth and the solution flow rate The chemical reagent flowrate and pulse frequency is adjusted experimentally to ensure that the chemical reagent is adequate to control the dosing under maximum loading Adjust the Pulse Frequency Output in Manual Mode and set to 100 valve output before setting up the PID parameters For example if the observed value on the display is 6 and the control point is 5 then...

Page 37: ...rol Mode is set to Manual irrespective of its setting prior to the power failure Control Output Section 2 3 is set to the level set in the Default Output frame below Last Control Mode and Control Output are set to the same state as that set prior to the power failure Default Output Set the default output required after Power Failure Recovery between 0 and 100 in 0 1 increments Note A setting of 0 ...

Page 38: ...ation Code Set the sensor calibration access code to a value between 0000 and 19999 Return to main menu Option board fitted and analog features enabled Section 7 3 see Section 5 9 5 9 Configure Logbook Note The Configure Logbook function is available only if the option board is fitted and analog features enabled see Section 7 3 Configure Logbook Use the and keys to to set the logbook On or Off If ...

Page 39: ...ee Section 7 3 Test remaining outputs Maintenance Hold Outputs Enables the relay action and analog outputs to be maintained Auto Changes in relay action and analog outputs are disabled during sensor calibration On Changes in relay action and analog outputs are disabled Off Changes in relay action and analog outputs are not disabled Note The LEDs flash while the analyzer is in Hold mode Continued o...

Page 40: ...borted the display returns to the Operating Page and CAL ABORTED is displayed Continued below See Section 7 3 Load Save Configuration Select whether a configuration is to be loaded or saved Note If No is selected pressing the key has no effect Return to main menu See Section 7 3 Load User Factory Configuration Note Applicable only if Load Save Config is set to Yes Factory Config resets all the par...

Page 41: ...w an unrestricted view of the front panel displays and controls Fig 6 1 Siting Requirements C Within Environmental Limits B Within Temperature Limits A Maximum Distance Between Analyzer and Sensor DO Sensor Maximum Distance 100m 275 ft IP66 NEMA 4X Dissolved Oxygen Dissolved Oxygen Dissolved Oxygen Dissolved Oxygen 65 C 149 F Max 20 C 4 F Min Dissolved Oxygen Dissolved Oxygen 6 INSTALLATION ...

Page 42: ... B Pipe mounting Position U bolts on pipe Position plate over U bolts Secure transmitter to mounting plate Secure plate A Wall mounting Mark fixing centres see Fig 6 2 Drill suitable holes 1 2 3 4 1 2 3 61 23 8 OD Vertical or Horizontal Post Secure instrument to wall using suitable fixings Fig 6 3 Wall Pipe mounting 6 2 Mounting 6 2 1 Wall Pipe mount Analyzers Figs 6 2 and 6 3 ...

Page 43: ...g screw on each panel clamp Remove the panel clamp and anchors from the instrument case Cut a hole in the panel see Fig 6 4 for dimensions Instruments may be close stacked to DIN 43835 1 2 3 4 5 6 Refit the panel clamps to the case ensuring that the panel clamp anchors are located correctly in their slots Fig 6 5 Panel mounting 6 2 Mounting 6 2 2 Panel mount Analyzers Figs 6 4 and 6 5 Note The cla...

Page 44: ...r use only with equipment with no accessible live parts The relay contacts are voltage free and must be appropriately connected in series with the power supply and the alarm control device which they are to actuate Ensure that the contact rating is not exceeded Refer also to Section 6 3 1 for relay contact protection details when the relays are to be used for switching loads Do not exceed the maxi...

Page 45: ... or diodes for DC applications These components must be connected across the load see Fig 6 6 For AC applications the value of the resistor capacitor network depends on the load current and inductance that is switched Initially fit a 100R 0 022 F RC suppressor unit part no B9303 as shown in Fig 6 6A If the analyzer malfunctions locks up display goes blank resets etc the value of the RC network is ...

Page 46: ...rom the outside Secure the cable gland with the nut 2 3 4 6 Cable entry knockouts Factory fitted cable gland 1 Release the four captive screws and remove the terminal cover plate Fig 6 7 Cable Entry Knockouts Wall Pipe mount Analyzer Note When removing knockouts take great care not to damage wiring and components within the analyzer 6 3 Electrical Connections 6 3 2 Cable Entry Knockouts Wall Pipe ...

Page 47: ...nnections 6 4 1 Access to Terminals Fig 6 8 Fig 6 8 Access to Terminals Wall Pipe mount Analyzer Terminal Block A Terminal Block B Terminal Block C Option Board Case Earth Ground Stud Release the four captive screws and remove the terminal cover plate ...

Page 48: ...0 B9 B8 B7 B6 B5 B4 B3 B2 B1 TC Link Common TC Link Common Temperature Compensator Connections Used for optional RS485 connection Refer to IM PROBUS Before making any electrical connections see Warnings on page 42 Earth Ground Stud on Case see Fig 6 8 85 to 265 V AC Power Supplies 12 to 24V DC or 24 V AC Line L Neutral N Connect supply earth ground to stud on case E C A4 Relay 1 NC A5 NO A6 C A7 R...

Page 49: ...LLATION 6 5 Panel mount Analyzer Connections 6 5 1 Access to Terminals Fig 6 10 Terminal Block C Option Board Terminal Block B Terminal Block A Earth Ground Stud Fig 6 10 Access to Terminals Panel mount Analyzers ...

Page 50: ... Power 24 V AC 24V DC Supplies Before making any electrical connections see Warnings on page 42 Terminal Block B Sensor Connections see Note 2 below Sensor B Sensor A B1 B9 Temperature Compensator Common Yellow B2 B10 Temperature Compensator Third Lead Green B3 B11 Temperature Compensator Black B4 B12 Sensor ve Red B5 B13 Sensor ve Blue B6 B14 Screen B7 B15 Not Used B8 B16 Not Used L Line N Neutra...

Page 51: ...current output measurement 0 to 20mA Note Decade resistance boxes have an inherent residual resistance that may range from a few m up to 1 This value must be taken into account when simulating input levels as should the overall tolerance of the resistors within the boxes 7 2 Preparation a Switch off the supply and disconnect the sensor s temperature compensator s and current output s from the anal...

Page 52: ...djust 4mA O4 Adjust 4mA O3 Adjust 20mA O4 Adjust 20mA Cal Output 2 O2 Adjust 4mA O2 Adjust 20mA Use the Sidescroll Key to scroll through the Pages within each Menu Use the Menu Key to scroll through the Menus Use the Downscroll Key to scroll through the Frames within each Page Section 7 3 Page 51 Calibrate I P Calibrate I P Alter Fact Code Option Board Available only if the option board is fitted ...

Page 53: ...mplete see next page Current Zero 0 A Set the sensor simulator reading to 0 A The display advances automatically to the next step once a stable and valid value is recorded Note The upper 6 segment display shows the measured value Once the signal is within range the lower 6 segment display shows the same value and Calib is displayed to indicate that calibration is in progress Span 100 A Set the sen...

Page 54: ...rns automatically to Cal Sensor A once a stable and valid value is recorded Abort Calibration Select Yes or No Yes selected before completion of A Span 100uA frame calibration advances to A T Zero 100R and continues after completion of A Span 100uA frame the display returns to the Calibrate Sensor A page No selected calibration continues from the point at which the key was pressed A Ref Checking 1...

Page 55: ...utput 2 Note Output 2 calibration is identical to Output 1 calibration Option board fitted and analog features enabled continued on next page Option board fitted additional features disabled continued on next page Option board not fitted continued on next page Option board fitted and analog features enabled continued on next page Option board fitted additional features disabled continued on next p...

Page 56: ...s if an option board is fitted but cannot detect the additional features available If an option board is fitted the correct selection must be made below to enable use of the available features If an incorrect selection is made the software menus and frames associated with that option are displayed in the Operating and Configuration pages but the features do not work Use the and keys to enable the ...

Page 57: ...f s a h A r o s n e S f o n o i t a r b i l a C e h t e c a l p e r s t s i s r e p t l u a f e h t f I n o i t a r b i l a c r o s n e s P O s n e S B e t o N g n i h s a l f e h t t a e p e R d e l i a f s a h B r o s n e S f o n o i t a r b i l a C e h t e c a l p e r s t s i s r e p t l u a f e h t f I n o i t a r b i l a c r o s n e s D E T I B I H N I H S A W n o i t c n u F h s a W o t t e ...

Page 58: ... F adjustable 0 05 to 0 02 C 0 02 to 0 009 F Temperature sensor Programmable Pt100 3 wire Pt1000 Balco 3k Calibration Ranges Check value zero point 0 to 14pH Slope Between 40 and 105 low limit user configurable Electrode Calibration Modes Calibration with auto stability checking Automatic one or two point calibration selectable from ABB DIN Merck NIST US Tech Two x user defined buffer tables for m...

Page 59: ... load resistance 7501 at 20mA Configuration Can be assigned to either measured variable or either sample temperature Digital Communications Communications Profibus DP with option board fitted Control Function AX480 Only Controller Type P PI PID Configurable Control Outputs Output Can be assigned a maximum of two relays two analog outputs or one of each Analog Current output control 0 to 100 Time p...

Page 60: ...nal Power consumption 10VA Insulation Mains to earth line to ground 2kV RMS Environmental Data Operating temperature limits 20 to 65 C 4 to 149 F Storage temperature limits 25 to 75 C 13 to 167 F Operating humidity limits Up to 95 RH non condensing EMC Emissions and immunity Meets requirements of EN61326 for an industrial environment EN50081 2 EN50082 2 Hazardous area approvals CENELEC ATEX IIG EE...

Page 61: ...appropriate oxygen solubility values experimentally e g by saturating aliquots of the water with air at various temperatures spanning the required measurement range and determining the resulting dissolved oxygen concentrations titrimetrically The analyzer can then be used to measure both saturation and temperature The required oxygen concentration can be calculated from concentration S ppm Saturat...

Page 62: ...e sensors can be suspended close within a few centimetres to the surface of a body of water The operation of the oxygen sensor is such that the output in air is slightly higher than in air saturated water at the same temperature This difference is reproducible allowing calibration in air by adjusting the instrument reading to 108 saturation or the equivalent concentration rather than 100 This adju...

Page 63: ...cting Process Variable Range B1 Single PID Controller Fig B1 The single PID controller is a basic feedback control system using three term PID control with a local set point Fig B2 Reverse Acting Single PID Control APPENDIX B B1 1 Reverse Acting Single PID Control Fig B2 Reverse acting control is used when the process DO is less than the required output DO ...

Page 64: ...s Variable Range B2 Ouput Assignment The output signal is assignable to either relay 1 Time or Pulse output type or analog output 1 Analog output type APPENDIX B B1 2 Direct Acting Single PID Control Fig B3 Direct acting control is used when the process DO is greater than the required output DO ...

Page 65: ... the following Proportional Band 100 Integral Time 0 off see Section 5 7 1 Derivative Time 0 off Notes If the system goes into oscillation with increasing amplitude Fig B4 Mode B reset the proportional band to 200 If oscillation continues as in Mode B increase the proportional band further until the system ceases to oscillate If the system oscillates as in Fig B4 Mode A or does not oscillate refer...

Page 66: ...64 NOTES ...

Page 67: ...ntation pH Conductivity and Dissolved Oxygen Transmitters and Sensors Ammonia Nitrate Phosphate Silica Sodium Chloride Fluoride Dissolved Oxygen and Hydrazine Analyzers Zirconia Oxygen Analyzers Katharometers Hydrogen Purity and Purge gas Monitors Thermal Conductivity Customer Support We provide a comprehensive after sales service via a Worldwide Service Organization Contact one of the following o...

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