TPS proCHEM-S Manual Download Page 1 | Manualshive

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TPS proCHEM-S Manual Download Page 1

Congratulations !

Your new

pro

CHEM

-S

controller is the latest in simple, reliable process

control instrumentation. With correct operation and maintenance, your

pro

CHEM

-S

will give you many years of reliable service.

The

pro

CHEM

-S

is a breeze to operate. This manual has been

designed to help you get started, and also contains some handy
application tips. If at any stage you require assistance, please contact
either your local TPS representative or the TPS factory in Brisbane.

The manual is divided into the following sections:

1.

Table of Contents

Each major section of the handbook is clearly listed. Sub-sections
have also been included to enable you to find the information you
need at a glance.

2.

Introduction

The introduction has a diagram and explanation of the display and
controls of the

pro

CHEM

-S

. It also contains a full listing of all of the

items that you should have received with the unit. Please take the
time to read this section, as it explains some of items that are
mentioned in subsequent sections.

3.

Main Section

The main section of the handbook provides complete details of the

pro

CHEM

-S

, including operating modes, calibration, troubleshooting,

specifications, and warranty terms.

4.

Appendices

Appendices containing background information and application notes
are provided at the back of this manual.

pro

CHEM

-S

Process Controller

Version

: 1.0

Date

: 05-Sep-2003

Author

: MS

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Summary of Contents for proCHEM-S

Page 1: ... listed Sub sections have also been included to enable you to find the information you need at a glance 2 Introduction The introduction has a diagram and explanation of the display and controls of the proCHEM S It also contains a full listing of all of the items that you should have received with the unit Please take the time to read this section as it explains some of items that are mentioned in ...

Page 2: ...ty Ltd ABN 30 009 773 371 4 Jamberoo Street Springwood Brisbane Australia 4127 Phone 07 32 900 400 International 61 7 32 900 400 Fax 07 3808 4871 International 61 7 3808 4871 Email tps tps com au Web www tps com au ...

Page 3: ...Output 19 3 8 Calibrating the 4 to 20mA Output 20 4 Calibration 21 4 1 Calibration Procedure 21 4 2 Calibration Notes 22 5 Process Monitoring 23 6 Automatic Control 23 7 Fuse Replacement 23 8 Troubleshooting 25 8 1 Instrument Function Troubleshooting 25 8 2 Salinity TDS Troubleshooting 26 9 Warranty 28 10 Appendices 30 10 1 Re setting the Display Range 30 10 2 Care Cleaning and Maintenance of Sali...

Page 4: ...Page 4 1 Introduction 1 1 proCHEM S Illustration ...

Page 5: ...ow LED provides visual indication of when the Lower Limit has been exceeded Factory set to light up when the reading is below the Lower Limit See section 3 5 Zero Calibrate Control Adjust this control to calibrate the proCHEM S with the sensor dry and in air See section 4 Span Calibrate Control Adjust this control to calibrate the proCHEM S in a Salinity TDS standard See section 4 Function Switch ...

Page 6: ...f Salinity TDS standard to suit specified range Options that may have been ordered with your proCHEM S Sensor options 1 k 0 1 GK Series Salinity TDS sensor 5m 112205 2 k 1 0 GK Series Salinity TDS sensor 5m 112206 3 k 10 GK Series Salinity TDS sensor 5m 112207 4 Extra cable for Salinity TDS sensors order by the metre 130040 Instrument options 1 4 20mA loop powered remote LCD 130080 2 12V DC Power ...

Page 7: ... 0 o C Zero Range 5 Span Range 70 to 130 Sensors Platinised Platinum k 0 1 k 1 0 or k 10 Enclosure Polycarbonate waterproof to IP65 Display 12 7 mm LCD optional remote 4 20mA loop powered display available Analogue Outputs 4 to 20mA 500 Ohms max loop resistance 0 to 1 V DC min load 1000 Ω 0 to 10 V DC optional min load 1000 Ω Control Outputs 2 x Clean contact changeover relays rated to 2A at 240V ...

Page 8: ...when setting the Salinity TDS value at which the Low LED and relay output are activated The relay output is not operational in this mode Factory set to activate when the reading is below the Lower Limit Can be user set to be a activate when the reading is above the Lower Limit See section 3 5 3 Calibrate Switch to Calibrate mode to place the proCHEM S into standby eg when calibrating This mode dis...

Page 9: ...n and Set up 3 1 Connection and Configuration Diagram The diagram below is provided as a reference for the terminal connections configuration jumpers and user adjustable trimmers that are discussed throughout this section ...

Page 10: ...cover and are positioned so that they do not affect the waterproofing of the enclosure The third mounting point is centrally located near the top of the rear of the enclosure and has been designed to hook over a screw head The dimensions for the mounting screw centres are provided on the rear of the enclosure and are also illustrated below ...

Page 11: ...tream Additionally the line must be run through a mixing chamber such as a large drum to ensure that the injected chemical has mixed in properly by the time the solution flows past the sensor There must always be adequate flow of fresh sample past the sensor for accurate monitoring The diagrams below show typical mounting arrangements for dip mounting and in line mounting Dip Mounting In line Moun...

Page 12: ... colour 5 Duplicate 240V AC Earth contact Green standard colour 6 Duplicate 240V AC Earth contact Green standard colour 7 220 240V AC Neutral input Blue standard colour 8 Duplicate 240V AC Neutral contact Blue standard colour 9 Duplicate 240V AC Neutral contact Blue standard colour 10 Normally Closed contact of Lower relay output Customer Defined 11 Common contact of Lower relay output Customer De...

Page 13: ...Page 13 18 ve of current or voltage output Customer Defined ...

Page 14: ...ay terminal block which is on the right hand side of the enclosure Terminal No Connection Colour 1 Salinity TDS Sensor ATC Blue 2 Salinity TDS Sensor ATC White 3 No Connection 4 Guard Shield Braid when fitted 5 Salinity TDS Sensor Cell Black 6 Salinity TDS Sensor Cell Red ...

Page 15: ...necessary See section 3 5 4 for an explanation of hysteresis 3 5 1 Setting the Upper Limit value 1 Switch the proCHEM S to Set Upper Limit The Upper Limit value is now displayed Note that the Alarm LED and output relays are now disabled The 4 20mA or 0 1V outputs are still active and proportional to displayed value 2 Adjust the Set Upper Limit control until the display reads the desired set point ...

Page 16: ...e first Limit as a control point eg to start a dosing pump and the second limit beyond that as an alarm point in case the control action was not effective The proCHEM S must be switched OFF before changing jumper settings To reverse the action of the Lower Limit and have two Limits that activate the High and Low LED s and relays when the reading rises above the Limits set the J3 and J4 jumpers as ...

Page 17: ...put is switched ON and OFF This feature can significantly increase the life of pumps and solenoid valves The factory set hysteresis is approximately 10 digits regardless of decimal point location as in the example above The hysteresis can be increased to as high as 40 digits with the relevant LOWER HYST RV2 or UPPER HYST RV4 trimmers in the terminal area Turning the trimmer clockwise increases the...

Page 18: ...CHEM S must be switched OFF before changing jumper settings The jumper settings for 4 to 20 mA output are C V C V C J5 The jumper settings for 0 to 1V DC output are C V C V C J5 Note that the spare jumper has been fitted to a spare Current Voltage Output jumper pin This is a safe place to keep it in case the proCHEM S needs to be reset to current output in the future ...

Page 19: ...ull scale of the readout If a custom 4 to 20 mA output eg 4 to 20 mA output for 700 to 1000 counts is supplied the user can still change between this custom output and the normal 4 to 20 mA output for full scale The jumper settings for the standard 4 to 20 mA output are The jumper settings for the custom 4 to 20 mA output are ...

Page 20: ...responds to 4 mA for a custom 4 to 20 mA output 4 Adjust the 4 20mA ZERO RV1 trimmer in the terminal area until the Digital Milliamp Meter reads 4 mA 5 Adjust the Set Upper Limit control until the display reads 1000 regardless of decimal point location for the standard 4 to 20mA output or the Salinity TDS that corresponds to 20 mA for a custom 4 to 20 mA output 6 Adjust the 4 20mA SPAN RV3 trimmer...

Page 21: ...n 6 Shake the Salinity TDS sensor dry and hang it in air DO NOT wipe the platinised platinum electrode surface as this will remove the platinum black layer 7 When the reading has stabilised adjust the Zero control until the display reads exactly zero Span Calibration 8 Place the Salinity TDS sensor into a small sample of Salinity TDS standard A suitable standard should be chosen for the display ra...

Page 22: ...ready for Salinity TDS measurements 4 2 Calibration Notes 1 The Zero calibration is quite stable long term and only needs to be performed monthly as a routine check In applications where the sensor can become dirty or coated with oils etc a Zero calibration may need to be done weekly 2 A Span calibration should be performed at least weekly Of course more frequent calibration will result in greater...

Page 23: ...rm LED s and the relay outputs These will be switched ON while the Salinity TDS exceeds the limit value and will switch OFF once the Salinity TDS is back within the limit 7 Fuse Replacement If the current drain from any device connected to the output relay exceeds 1 Amp the output protection fuse will blow To replace the fuse 1 SWITCH THE proCHEM S OFF 2 Remove the main front panel by unscrewing t...

Page 24: ...REPLACE THE FUSE WITH A 1 AMP 240V FUSE USING A FUSE WITH HIGHER CURRENT RATING MAY DAMAGE YOUR CONTROLLER VOIDING THE WARRANTY Before switching the proCHEM S back to Automatic Control mode ensure that the cause of the blown fuse has been eliminated If the current drain of the device connected to the relay output is greater than 1 Amp an external contactor should be used Please consult an electric...

Page 25: ...correctly see section 3 5 3 Check and adjust the Hysteresis trimmer see section 3 5 4 If in doubt set this to minimum level Check and replace fuse if necessary see section 7 Return to TPS for repair Incorrect analogue output signal 1 Current Voltage Output jumpers incorrectly set for required output 2 4 20mA loop resistance too high 3 Load on 0 1V DC output is too low 4 4 20mA output is not calibr...

Page 26: ...d solution is inaccurate 5 Electrode is faulty Immerse electrode at least to the vent hole in the white plastic cover Clean electrode as per the instructions detailed in section 10 2 2 Electrode requires replatinisation Return to the factory or see details in section 10 2 3 Replace standard solution Return electrode to factory for repair or replacement Standard calibration fails reading is too hig...

Page 27: ...e details in section 10 2 3 Readings drift 1 Electrode may have a build up of dirt or oily material on electrode wires Clean electrode as per the instructions detailed in section 10 2 2 Readings are low or near zero 1 Electrode may have a build up of dirt or oily material on electrode wires 2 Electrode is not immersed deeply enough 3 Electrode is faulty Clean electrode as per the instructions deta...

Page 28: ...he equipment Shipping damage is not covered by this warranty PLEASE NOTE A guarantee card is packed with the instrument or electrode This card must be completed at the time of purchase and the registration section returned to TPS Pty Ltd within 7 days No claims will be recognised without the original guarantee card or other proof of purchase This warranty becomes invalid if modifications or repair...

Page 29: ...ime phone number Your company name ORDER number and return street address A description of the fault Please be SPECIFIC Note Please Repair does NOT describe a fault Your equipment will be repaired and returned to you by air express where possible For out of warranty units a repair cost will be calculated from parts and labour costs If payment is not received for the additional charges within 30 da...

Page 30: ...the J3 and J4 jumper blocks The diagram below shows the location of the jumper blocks which set the decimal point position This is accessed by removing the front panel of the unit as described in section 7 Fuse Replacement The circuit board does not need to be separated from the panel as there is sufficient clearance to change the jumper settings Attach spare jumpers off single unused pins for saf...

Page 31: ...1000 ppM A B 1 2 1 2 3 4 Decimal Point A B 1 2 1 2 3 4 Decimal Point A B 1 2 1 2 3 4 Decimal Point 0 to 1 000 ppK This is the same range as above Only the decimal point jumper is changed A B 1 2 1 2 3 4 Decimal Point A B 1 2 1 2 3 4 Decimal Point A B 1 2 1 2 3 4 Decimal Point 0 to 10 00 ppK This range not available for k 0 1 sensor A B 1 2 1 2 3 4 Decimal Point A B 1 2 1 2 3 4 Decimal Point 0 to 1...

Page 32: ...distilled water Salinity TDS electrodes can be stored dry Ensure that the electrode is stored in a covered container to avoid dust and dirt build up 10 2 2 Cleaning of Salinity TDS of Electrodes Platinised platinum Salinity TDS electrodes can only be cleaned by rinsing in a suitable solvent DO NOT wipe the electrode wires as this will remove the platinum black layer 1 Rinsing in distilled water wi...

Page 33: ... Rinse the electrode well in distilled water 3 Immerse the electrode in platinising solution to the same level as for calibration see section 4 Platinising solution is available from TPS part no 122300 Alternatively platinising solution can be prepared by dissolving 1g of Hydrogen Chloroplatinate H2PtCl16 in 30mL of distilled water and including about 0 01g of Lead Acetate CH3COO 2Pb and a drop or...

Page 34: ... for 12V DC version 7 Positive of 12V DC Input 8 No connection for 12V DC version 9 No connection for 12V DC version 10 Normally Closed contact of Lower relay output 11 Common contact of Lower relay output 12 Normally Open contact of Lower relay output 13 Normally Closed contact of Upper relay output 14 Common contact of Upper relay output 15 Normally Open contact of Upper relay output 16 No Conne...

Page 35: ...Page 35 10 4 Relay Output Wiring Examples for mains powered units The diagrams below provide some examples of wiring the relay outputs for standard mains powered proCHEM S units ...

Page 36: ...Page 36 10 5 Relay Output Wiring Examples for 12V DC powered units The diagrams below provide some examples of wiring the relay output for proCHEM S units with the 12V DC power option ...

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