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Low and High Level

Dissolved Oxygen Monitor

9438

User Guide

IM/9438_6

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Summary of Contents for 9438

Page 1: ...Low and High Level Dissolved Oxygen Monitor 9438 User Guide IM 9438_6 ...

Page 2: ...s of high pressure and or temperature 5 Chemicals must be stored away from heat protected from temperature extremes and powders kept dry Normal safe handling procedures must be used 6 When disposing of chemicals ensure that no two chemicals are mixed Safety advice concerning the use of the equipment described in this manual or any relevant hazard data sheets where applicable may be obtained from t...

Page 3: ...D DISPLAYS 14 5 1 Displays 14 5 2 Switch Familiarization 14 6 START UP AND OPERATION 15 6 1 Instrument Start up 16 6 2 Operation Dissolved Oxygen Measurement Mode 16 6 2 1 Operation Page 16 6 2 2 Calibration Page 17 7 PROGRAMMING AND ELECTRICAL CALIBRATION 18 7 1 Access to Secure Parameters 18 7 2 Language Page 18 7 3 Set Up Parameters Page 18 7 4 Set Up Alarm Page 19 7 5 Set Up Retransmission Pag...

Page 4: ...er feed water steam condensate Calibration of the sensor can be manually initiated when required or set to automatic with the programmable frequencies 1 day 1 week and 4 weeks System status can be assessed remotely using programmable alarm and or current output diagnostic functions The 9438 500 transmitter is a wall mounted instrument and the 9438 501 model is a panel mounted 1 4 DIN sized instrum...

Page 5: ...00 mm all around for easy removal of the flowcell assembly for maintenance when not installed in the optional enclosure see Section 2 3 1 for overall dimensions of units Note To eliminate the risk of bubbles accumulating at the sensor and hence giving erroneous readings the flowcell assembly must be mounted vertically 2 2 Mounting the Instrument 2 2 1 Wall mounted Instrument Figs 2 2 to 2 4 Fig 2 ...

Page 6: ...se stacked to DIN 43835 Insert the instrument into the panel cut out Refit the panel clamps to the case ensuring that the panel clamp anchors are located correctly in their slot Secure the instrument by tightening the panel clamp retaining screws Loosen the retaining screw on each panel clamp Remove the panel clamp and anchors from the instrument case 4 5 6 1 3 2 3 2 2 2 Panel mounted Instrument F...

Page 7: ... Note Sample Outlet Sample inlet via shut off valve if required Sample drain during automatic calibration 2 3 Installing the Dissolved Oxygen Flowcell 2 3 1 Flowcell Dimensions Overall Fig 2 7 2 3 2 Enclosure Dimensions Optional Fig 2 8 2 3 3 Connecting the Sample Lines Fig 2 9 Mount the flowcell vertically with or without the enclosure as shown in Figs 2 7 and 2 8 Connect the sample inlet and out...

Page 8: ...h voltage operated control circuits and high common mode voltage are switched off Although certain instruments are fitted with internal fuse protection a suitably rated external protection device e g fuse or miniature circuit breaker m c b must also be fitted by the installer 3 1 Access to Terminals 3 1 1 Wall mounted Instruments Fig 3 1 3 1 2 Panel mounted Instruments Fig 3 2 Fig 3 1 Access to Te...

Page 9: ...ssion range see Section 7 Since the retransmission output is isolated the ve terminal must be connected to earth ground if connecting to the isolated input of another device 3 2 1 Relay Contact Protection and Interference Suppression Fig 3 3 If the relays are used to switch loads on and off the relay contacts can become eroded due to arcing Arcing also generates radio frequency interference RFI wh...

Page 10: ...e ve 3 2 2 System Wiring Schematic Fig 3 4 The wiring of a single solenoid sensor system from a user supplied 24 V DC supply is shown in Fig 3 4 If the 9438 080 power supply unit is employed refer to Appendix A for wiring details 3 3 Wall mounted Instrument Connections Fig 3 5 Note Refer to Fig 3 1 for access to terminals Caution Slacken terminal screws fully before making connections Warning The ...

Page 11: ... 8 9 E N L 1 2 3 4 5 6 7 8 9 10 11 12 Earth Stud Earth Stud on case Earth Stud on case Pt1000 Temperature compensator Braid Retrans 2 Output if fitted ve ve 4 5 3 4 Panel mounted Instrument Connections Fig 3 6 Note Refer to Fig 3 2 for Access to Terminals Caution Slacken terminal screws fully before making connections Warning The power supply earth ground must be connected to ensure safety to pers...

Page 12: ...ted Instrument Fig 3 7 3 5 2 Panel mounted Instrument Fig 3 8 Information Use a small flat blade screwdriver to remove the screw caps from the case Fig 3 7 Selecting the Mains Voltage Wall mounted Instrument Fig 3 8 Selecting the Mains Voltage Panel mounted Instrument Note Some versions are fitted with a switch in place of links The applied voltage should be as indicated on the switch when positio...

Page 13: ... the position indicated cathode to terminal 1 and anode to terminal 2 Fit the cover and tighten the cable gland Solenoid Valve 1 2 3 24 V DC via N O of relay in 9438 transmitter see Fig 3 4 0 V Cable Gland Diode See Appendix A if 9438 080 PSU is supplied Customer supplied cable to transmitter or PSU 2 1 3 3 2 1 3 6 Flowcell Solenoid Valve Connections Fig 3 9 Fig 3 9 Solenoid Connections Note Use 2...

Page 14: ... Sensor Connector Body O ring Clamping Screw Thrust Washer Connector Nut 6 4 1 Fitting the Dissolved Oxygen Sensor Fig 4 1 Caution Only install the oxygen sensor immediately prior to use otherwise leave it stored in its protective container The sensor has a limited shelf life and should NOT be stored longer than about 6 months Store under cool conditions Take special care to line up the two pins i...

Page 15: ...Fig 4 3 Note The plug is a latching type to prevent it s accidental removal To remove hold the plug at its widest point and pull out The plug is protected against spillage and corrosion by a sleeve which slides over it Fig 4 2 Electrical Connections at the Flowcell Fig 4 3 Sample Flow Schematic Check that the sample flows correctly in both normal operation and during a calibration or thermal overl...

Page 16: ... Storing a Parameter Choice Parameter X Y Z Select Parameter 1 Parameter 2 Parameter 3 Page X Parameter 4 Advance to next parameter or New value is automatically stored or 5 1 Displays Fig 5 1 The display comprises a 5 digit 7 segment digital upper display line and a 16 character dot matrix lower display line The upper display line shows numerical values of dissolved oxygen concentration temperatu...

Page 17: ...ear Linear Diagnostics YES NO SET UP RETRANS 2 Cal Time s 3 0 Fail M time s 3 0 Fail S time s 3 0 RTX Log Bi Linear Linear RTX O P Temp D O 2 0 0 RTX Span mg kg o C 2 0 RTX Zero mg kg o C RTX Type 4 20 0 20 0 10 B i L i n e a r B i L i n e a r L i n e a r 1 0 0 Enter Input 5 0 0 Enter Output Cal Time s 3 0 Fail M time s 3 0 Fail S time s 3 0 Test Retrans 0 0 Autocal Off 4Weeks 1Week 1Day Temperatu...

Page 18: ... known only to authorized operators in the Set Up Alarm page see Section 7 2 6 2 1 Operation Page Measured Dissolved Oxygen The measured dissolved oxygen is displayed in µg l mg l ppb ppm mg kg or µg kg Auto ranging 0 0 to 99 9 µg kg 1 100 to 999 µg kg 1 1 00 to 9 99 mg kg 1 10 0 to 20 0 mg kg 1 Press to advance to next parameter or press to advance to Calibration Page Section 6 2 2 Sample Tempera...

Page 19: ...y has been achieved the calibration valve closes allowing sample to flow past the sensor Abort Calibration Pressing during Calibrating in Air aborts the calibration and the Cal Aborted message is displayed for 2 seconds The calibration valve closes allowing the sample to flow past the sensor again Note that the A2 LED continues to indicate that a calibration is in progress and will do so for the d...

Page 20: ...e used to advance to all subsequent parameters and pages If a parameter is changed it is automatically stored on operation of either switch Display Units Select the required display units µg kg µg l or ppb Barometric Pressure Correction Set the local barometric pressure in mm Hg between 500 and 800 If the local barometric pressure is unknown the default value which is the standard sea level value ...

Page 21: ... no alarm is set and the alarm l e d is off and the relay de energized at all times Alarm Action For Fail safe alarm operation the relay s alarm state must be the same as the power down state i e the relay is de energized For High alarm operation the relay must be energized below the alarm set point For Low alarm operation the relay must be energized above the alarm set point The alarm LEDs are il...

Page 22: ...full measurement range with the units automatically changing The set point value is subject to hysteresis as detailed above Set the alarm set point to the required value Displayed only if Alarm Action is set to High or Hi Lo Alter Secure Parameters Security Code Set the secure parameters security code to a value between 00000 and 19999 IMPORTANT YOU MUST MEMORIZE THE NEWLY SET SECURITY CODE If it ...

Page 23: ...ansmission output scale required Log logarithmic see Fig 7 2 Bi Linear see Fig 7 1 Linear Note for Bi linear and log scales The accuracy specification of the instrument should always be given consideration when setting the scale limits to avoid impractical discrimination on the retransmission output Retransmission 1 Span The span current output can be set to any value between Linear 20 mg kg 1 and...

Page 24: ...e Appendix B Set Up Retransmission 2 see also Table 7 1 Note Available only on 9438 800 series instruments Retransmission 2 Output Range The retransmission 2 output can be selected from three mA current ranges to ensure compatibility with the peripheral device connected Select the current range required for retransmission 2 output Retransmission 2 Output Assignment Select the Retransmission output...

Page 25: ...ncrements This is point A on Fig 7 1 Enter Output Set the percentage output at which the breakpoint occurs 0 0 to 100 in 0 1 steps This is point B on Fig 7 1 Diagnostics Select whether the current output diagnostics are required See Appendix B Calibration Pulse Time Set the frequency of the calibration pulse signal Programmable frequency of 15 30 45 seconds 1 2 3 4 5 minutes See Appendix B Calibra...

Page 26: ...or 0 to 1k5 c Digital milliammeter current output measurement 0 to 20 mA Note Resistance boxes have an inherent residual resistance which may range from a few milliohms up to 1 ohm This value must be taken into account when simulating input levels as should the overall tolerance of the resistors within the boxes 7 6 2 Preparation a Switch off the supply and disconnect the sensor temperature compen...

Page 27: ...s entered access to subsequent parameters is prevented and the display reverts to the top of the page Select YES to access the electrical calibration sequence Select NO to advance to Cal Time 1 Caution Do not select YES unless instrument calibration is required Microamp Zero Set the current source to 0 µA and allow the instrument display to stabilize Microamp Span Set the current source to 100 µA ...

Page 28: ...djust Retransmission Zero 2 See Adjust Retransmission Zero Adjust Retransmission Span 2 See Adjust Retransmission Span Calibration Time 1 Wait period before the stability of the sensor is checked during the calibration sequence Programmable from 1 to 10 minutes default 2 minutes See Section 7 5 Calibration Time 2 Recovery period where the sample is allowed to flow and the instrument settles on rea...

Page 29: ...ay Span Retransmission Output 0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100 A B Dissolved Oxygen Measurement shown as of Display Span Retransmission Output 1 100 10 0 10 20 30 40 50 60 70 80 90 100 Fig 7 1 Bi Linear Scaling Fig 7 2 Logarithmic Scaling two decades example ...

Page 30: ...s clean refit the sensor as in 5 below If deposits are visible on the membrane remove by gently wiping the membrane with a moist paper tissue for oily or greasy deposits the tissue may be moistened with a mild detergent or if necessary with iso propyl alcohol propan 2 ol After cleaning dry the interior of the flowcell with a paper tissue or soft cloth ensure that the O ring is correctly positioned...

Page 31: ... e h t n i a r d d n a 0 3 r e t f A r o s n e s e h t o t e g a m a d e h t d n a s e s o l c e v l a v e h t s e t u n i m d e r u s a e m s i e r u t a r e p m e t e l p m a s l i t n u s e u n i t n o c s s e c o r p s i h T n i a g a 5 5 s i e r u t a r e p m e t e l p m a s e h t C t o n s i e r u t a r e p m e t e l p m a s f I 5 5 e r u t a r e p m e t e h t k c e h c C e e s r e t t i m s...

Page 32: ... be returned to the Company for repair d If the response in a is correct select the Operating Page and set the current source to a value which gives an on scale D O reading on the transmitter Make a note of the current source setting and the D O reading Reconnect the sensor cable and connect the current source to the sensor end of the cable Set the same current value on the source and check that t...

Page 33: ...ve power supply optional IP65 optional Transmitter Panel mounting IP66 NEMA4X Wall mounting IP66 NEMA4X front Power Requirements System Power consumption 21 VA Transmitter Power supply 100 to 130 V or 200 to 260 V 50 60 Hz Power consumption 10 VA Error due to power supply variations Less than 2 for 6 20 variation from nominal supply voltage Insulation mains to earth 2 kV r m s Solenoid valve Power...

Page 34: ...own in Fig 11 1 Strategic spares are listed below 11 1 Strategic Spares Part No Description Qty 9438 080 24V Power Supply Unit 1 0234 037 Solenoid Valve assembly 1 0216 574 Flow Gauge assembly 1 0216 575 Needle Valve Cartridge assembly 1 PCB Assemblies Wall Mounted 9438 070 Complete Main PCB assembly for single current o p 1 9438 071 Complete Main PCB assembly for single current o p Serial Modbus ...

Page 35: ...which includes Connector Body Sensor Connector Cable Assembly Connector Nut Thrust Washer Clamping Screw Plug Clamping Screw Thrust Washer Connector Nut Compression Coupling to suit 6 mm or 1 4 in o d stainles steel pipe Sensor Connector Cable Assembly 9437 029 031 032 034 1 m 5 m 10 m 30 m respectively Oxygen Sensor 9435 300 including O rings O ring 7 8 in I D x 0 070 in cord Note Ensure that the...

Page 36: ...on relay in the main 9438 transmitter Fig A 3 shows the connection details in the PSU Fig A 4 shows the interconnection between the PSU and a single 9438 transmitter A 2 PSU Dimensions Fig A 1 Warning Before making any connections ensure that the power supply any high voltage operated control circuits and high common mode voltage are switched off Although certain instruments are fitted with intern...

Page 37: ...id Valve Powered Via Optional PSU 9438 Transmitter Relay 2 C NO Solenoid Valve 90 264 V a c Mains supply Switch Mode PSU up to 4 D O Systems Switched Output to Solenoid Valve 0V 24V C N O A 4 PSU Connections Fig A 3 A 5 Wiring Schematic Fig A 4 A 6 Specification Overall dimensions 160 x 98 x 62 mm 6 3 x 3 86 x 2 44 in Output power 24 V 2 5 A 60 W maximum from all outputs Holdup time 6 ms at full l...

Page 38: ...ned during a calibration but the output will pulse from the maintained value to 0 depending upon a programmable Cal Pulse period The Calibration Pulse period can be programmed 15 30 45 seconds 1 2 3 4 5 minutes This will continue for the full duration of the calibration exposing the sensor to air and the recovery period At the end of the recovery period if the response is good the instrument will ...

Page 39: ...mentation 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...

Page 40: ...thout notice Printed in UK 05 05 ABB 2005 ABB Limited Oldends Lane Stonehouse Gloucestershire GL10 3TA UK Tel 44 0 1453 826 661 Fax 44 0 1453 829 671 ABB Inc Analytical Instruments 9716 S Virginia St Ste E Reno Nevada 89521 USA Tel 1 775 850 4800 Fax 1 775 850 4808 ABB has Sales Customer Support expertise in over 100 countries worldwide www abb com ...

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