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Op. Maintenance Manual 2 of 4 CiTY OF SANDY ELECTRONIC DOCS%lENT A2~CIx'TVING COYER SHEET FOLDER STRUCTURE DOCUMENT NAME: DATE R.&NGE: J(/ I995-20¢0 1990-1995 1985-1990 1980-1985 I975 1980 1970-1975 Before 1970 RETENTION: None J. 0 years I year /](/ .20 years 2 years Permanent -__ 5 years _ DISPOSITION OF DOCUMENT AFTER SCANNING: __ P*em.rn to Depm h~ent Store at ~ Recycle City of Sandy Water Treatment Facility Expansion OPERATIONS & MAINTENANCE MANUAL Volume 2 of 4 Instrumentation & Control System Equipment Engineer: Curran-McLeod, Inc. 6655 SW Hampton, Suite 210 Portland, OR 97223 Contractor: Slayden Constmction, Inc. PO Box 625 Stayton, OR 97383 City of Sandy Water Treatment Facility Expansion Engineer: Curran-McLeod, Inc. 6655 SW Hampton, Suite 210 Portland, OR 97223 Contractor: Slayden Construction, ]~nc. PO Box 625 Stayton, OR 97383 OPERATZONS & MA]~NTENANCE MANUAL TABLE OF CONTENTS Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Book ! of 4 Equipment & Electrical Vertical Split Case Pump Water Treatment Equipment Chemical Feed System Mixer Flap and Misc Valves Plumbing Fixtures Finishes Electrical Book 2 of 4 [nstrumentation& Control System Equipment Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Drawings Enclosures Annunciator & Panel Indicators Electrical Devices Level Gauges & Pressure Transmitters Propeller Flow Meter Streaming Current Controller Chlorine Residual Analyzer PLC Hardware & Modems Section I Book 3 of 4 PLC Programs PLC Programs Panel 800 Panel 803 Panel 804 Panel 805 Panel 806 Section 1 Section 2 Section 3 Section 4 Section 5 Book 4 of 4 Instrumentation & Control System O&M Manual HM! General Description HMI Licenses HM! Screens HM! Cross References HMI TAG Databases TABLE OFCONTENTS DWG. NO. TITLE PN-800-1 PANEL PN-800~ LAYOUT & DETAILS ~IATERIAL LIST ~AMEPLATE / DEVICE SCHEDULE PN-800-2 PANEL pN-800, POWER DISTRIBUTION & DETAILS PN-800-3 PANEL PN-800, PLC-I, DISCRE~E 1NPU~S? 120 V __ PN-800-4 PANEL PN-800, PLC-I, DISCRETE IN1 uTS, 120 V ~N-800-5 PANEL PN-800, PLC-I, DISC~RETE INPUTS, 120 V PN-800-6 PANEL PN-800, PLC-1, DISCRETE IN~UTS, 120 V PN-800-7 PANEL PN-800, PLC-I~ DISCRETE OUTPlYI~S, 120 V PN-800-8 PANEL pN-800, ~LC-I, ANALOG INPUTS PN-800-9 ~ANEL pN-800, PLC-I, ANALOG I~PUTS PN-800-10 PANEL pN-800, PLC-I, ANALOG INPUTS PN-800-11 PANEL PN-800~ pL~-I,~ANALOG OUTPUTS pN-800-12 PANEL PN-800, PLC-I, ANALOG OUT~UTS pN-800-13 PANEL PN-800, PI~-I, ANALOG OUTPUTS pN-800-14 PANEL PN-8O0, PLC-I? ANALOG OUTPUTS PN-800-15 pANEL PN-800, PLC-1 DISCRETE OUTPUTS, ANNUNCIATOR IPN-800-16 ,ANEL PN-800,~PLC-I DISCRETE OUTPUTS, ANNUNCIATOR ~ PANEL pN.$00, pLC-I DISCRETE OUTPUTS, ANNUNCIATO~ pN-800-18 PANEL pN-800~ pLC-1 DISCRET~ OUTrUTS? ANNUNCIATOR~ pN-800-~I9 PANEL pN-800~ p~--1 LAYOUT & MODULE ADDRESSING SBD-100 SYSTEM BLOCK DIAGRAM SBD-101 COMMUNICA~ON DETAILS p~N-803-1 TERRA FERN RESERVOIR, PANi~L DETA[LS~ MATERIAL LIST PN-803-2 TERRA FERN RESERV(~IR, WIRING DETAILS .. ' PN-804-1 SAN~)ERCOCK RESERVOIR, PANEL DETAILS MATERIAL LIST pN-804-2 SANDERC0~K RESERVOIR, WIRIN~ DETAILS -- MATERIAL LIST tN;805-1 VISTA LOOP RESERVOIR. PANEL OETAILS MATERIAL LIST pN-80~2 ' VISTA LOOP P~SERVOI~, WIRING DETAILS PN-806-1 BROWNELL SPRINGS WATER sOURCE, pANEL DETAILS MATERIAL LIST PN-806-2 BROWNELL SPRIN~S WATER SOURCE, WIRING DETAILS BILL OF MATERIALS PANEL PN-800 ~TEM QUAN DESCRIPTION CAT. MODEL # MANUFACTURER I I ENCLOSIYRE A-903624FS HOFFMAN 2 I BACKPAN A-72P36 HOFFMAN 3 I FLUORECENT LIGHT A-LF16024 HOFFMAN 4 I DOOR LATCH L-36 HOFFMAN 5 I LIGHT SWITCH 3031-2I LEV[TON 6 I GFIC RECEPTACLE 6598-HGI LEV1TON 7 I UPS 5119-2000 POWERWARE $ I CIRCUIT BREAKER 1492-CBIG150 ALLL~4-BKADI~Y 9 2 C1RCLrr~ BREAKER 1492-CBI0100 ALLEN-BRADLEY 10 2 CIRCUIT BREAKER 1492-CBIG050 ALLEN-BRADLEY 11 2 CIRCUIT BREAKER 1492-CBIGOI0 ALLEN-BRADLEY 12 1 POWER SUPPLY HD244 gA+ CONDOR 13 I0 RELAYS RH2B-ULC [DEC 14 10 RELAY SCOCKETS SH2B-05 1DEC 15 AR WIREWAY 2"X 2" O2X2WH6 PAUDUIT 16 AR W1REWAY I'X 2~ GIX2Wlt6 PAUDUIT 17 I AIqlqiJNC [ATOR LI Grit P, OX 94LBX0104XX PANALARM 18 I LOT NAMEPLATES SEE SCHEDULE 19 15 PANEL FNDICATOKS pAXP SERIES RED/LION 20 10 SELECTOR SW, 3-POS g0OT-II 7B ~.11 VN- BRADLEY 23 35 TERMINALS OR3.NGE i05-004 22 ENTRELEC 24 85 TEKMLNALS BE1GE 195-118.12 ENTRFLFC 25 90 I~KM1NALS YELLOW 10%118 20 ENTRELEC 26 25 TERMTNALS YELLOWKiREEN 165-114 17 EN'rF..P&.EC 27 40 TERMrNALS DISCONNECT ~ 115-434.06 ENTERLEC 28 12 TERME~ALS FUSED/IND 115-222.11 ~C 29 2 DR, I RAIL DIN-3 ENTERLEC 30 I MODEM LLM-I100/2 DATA LINC 31 l UPS RECEPTACLE 5262 I LEVITON 32 I PLC 10 SLOT RACK 1C693CHS391 GE 33 2 PROCESSOR IC693CPU363 GE 34 4 ANALOG I~PUT MODULE IC693ALG221 GE 35 5 ANALOG OUTPLr~ MODULE IC696ALG391 GE 36 I PLC EXPANSION RACK 1 C693CHS392 GE 37 2 ETHERNET UqTERFACE IC693CMM321 GE 38 5 DISCRETE INPUT MODULE IC693MDL240 GE 39 2 DISCRETE OUTPLr~ MODULE [C693MDL340 GE 40 5 12J24 VDC OUTPDT MODULE IC693MDL741 GE 41 3 POWER SUPPLY IC693PWR321 GE 42 1 EX?ANSION CABLE 1C693CBL300 GE 43 I MODEM CM RI g MDLCABLE GE 44 I ETHERNET MODULE TRANS DET 113 GE 45 2 L IOI~rFNIiqG pROTECTOR MOD PTEL-2 ATC February 2000 GFK 1797A Field Wiring Each ler/~ina] can accepl soli~ ot stranded wires. However. the wires into any given terminal should be ol the same type and size. 2 I "II e II ~ II m I1__ I 2. II ~e II ~ II ~ I1__ , ANNUmtCIATOR/UGHTBOX LAYOUT PN-800 PANEL INTERIOR ALS CJD ALS ENGINEER. CDRP,~N-McLEOO, INC. Sim/den PANEL PN-800 LAYOUT AND DETAILS 120 VAC TB-D1 1¢ TB-D1 IN CB-1 ~ GFIC CONV. CB-~_~2 OUTLET °10° L1A L2 N1 ODOR sw. .,,...%F,UOR. L,G T ,3 OFF '~ [([~ PANEL GND. LUG CB-3 L1A "10° 1 CB-4 1 5 CB 5 1 5 L5 CB-6 L6 CB-7 1 L3 L4 NTERRUPTIB LE~L~ POWER SUPPLY 1+24 VDC POWER SUPPLY TO 120 VA¢ PLO INPUT/OUTPUT MODULES AND DIGITAL DISPLAYS L7 POWER DISTRIBUTION PLC 1, RACi 1 DIAGRAM N1 2 2 2 DC 1 (-) DC 1 (+) CONT. ON DWG. PN-800-3 DC 1 (-) TB-D3 (GREY) DC1(+) TB-D1 TB-D2 TB-D3 TB-A1 TB-A2 TO ANNUNCIATOR LAMP CABINET AND 24 VDC OUTPUT MODULES t TO ANALOG OUTPUT MODULES t TO ANALOG SIGNAL CONDITIONERS TERMINAL BLOCK NUMBERS 120 VAC POWER AND DISCRETE INPUTS (BLUE & GREY) 120 VAC DISCRETE OUTPUTS (BLUE, GREY & ORANGE) 24 VDC POWER AND DISCRETE OUTPUTS (BEIGE) (DISCONNECT TYPE, GREY) ANALOG INPUTS (YELLOW) ANALOG OUTPUTS (YELLOW) PANEL PN-800 POWER DISTRIBUTION WIRING AND DETNLS PN-800-2 120 VAC FROM DWG. PN-80O-2 '2 lA TB-DI(GREY) 120 VAC CONTINUED ON DWC. PN-BO0-4 HS-2 HS-3 °StE°O~O. PN-"OO-F FOR CR210B T -- XO0 FILTER UNIT 2 CALL PN-800-7 FOR CR211B AODITIONAL CONTACTS FILleR UNIT 2 ON -r?~- ..... ~[ ..... D ........................................... ~ CR2OgB ¢ CR214B L_ __ ..... J k ..... ~-F~L]~--R-U-NjT--2-H~LGH--~-R-D-DI?- ...................... ~ RLTER UNIT .~ CALL o DWO. PN-800-7 FOR PN-802 L CRBO2-2A RLTER UNIT 3 BACK~A~H .NT-505-1 ~ DISCONNEDT IYPE TERMINAL PLC~I, RACK/, SLOT ~5 IC§95MDL240 16 PT. 120 VAC INPUT A12545678 B1 2 3 4-5 6 7 B ~- ........ X[0033 ~ .... X[0036 X[0038 %I004-2 ~- ........ XI004-5 ] NEUTRAL Slayd e n. PN-SOO-3 PANEL PN-E*OO PLC-1 DISCRETE INPUT MODULE~ 120 VAC FROM DWG. PN-RO0- .3 AUG 2001 /~ L N 120VAC CONTINUED ON DWG. PN 800 5 (GR~) DISCONNECT I'FPE (GREY) ~ TERMINAL ~ CRIH56W ~ BOOSTER PUMP/¥FD 1 ON ~ - I~r ISP^REi ,r- ....................... [~ r .... ~r ..... 1 r ................................ ~,-o-, . ~ ...... ~:~___~____~__~_~o~_~?~?_~_ L?~_ .................................. ~ ~ CR157W C ............................. :~ ~ _ _ _ !~_w_ _ _ _ ~ _ _~_~_ _w~_~_ _._~_~_~_ ,~_ _~_?_ _~_~ ..................................... :~.E]_ _ __ _~_~_w_ _ _ _ ~ _ _~_,_ _w~_~_ _~_~_~_~__~_o_o_~_ ~_~ ..................................... .... _t~t'___~__~_?_~__?_~__?__~_~_~_~_~_ .............................. NT-O06 M4 M4 I ~--IN ANNUNCIATOR UGHT CABINET PLC..~I, RACK~I, SLOT~6 ICBg3MOL240 16 PT, 120 VAC INPUT A123¢5§7R B12345678 PANEL PN-BO0 PLC-1 OISCREFE INPUT IWO~ULES WIRING 9ET. NLS o2/08/m No. PN-800-¢ 120 VAC FROM PN-800-4 "1 L N 120 VAC CONTINUED ON DWG. PN-SDO- 6 (GR£Y) DISCONNECT 1YPE ITRMINAL M5 FILTER EFFLUENT PUMP 5 ON ~ FILTER EFFLUENT PUMP 6 ON~l§ OOX HS-6 TERRA FERN PUMP 7 HOA HS-7 ~ OOX TERRA FERN PUMP 8 i oXDO , l~H°A HS-8~__~oOOX ltRRA FERN PUMP 9 [ m Lo o x00 HOA HS-9~.OOX TERRA FERN PUMP 10 ) o XO0 :~_~ A Oo~OX ~RRA FERN PUMP 11 SPARE POWER FNLURE'/~ SPARE PLC~I, R~CK~I, SLOT~7 IC693MDL240 16 PT. 120 VAC INPUT A1234567§ B12345678 --~ 1 ~- ........ ~065 ..... ~10066 ..... %Z0068 ~- .... )~iO070 2001 Siayden PANEL PN-8OO PLC-1 DISCRETE INPUT MOOULES WIRING DETNLS 02/OS/al PN-800-5 120 VAC FROM DWG. PN-800-5 L 120 VAC CONTINUED ON DWG. PN 800 7 HOA I XO0 R~W WATER BOOSTER PUMP 1 H u A FOR ADDITIONAL CONTACTS, H$-5 ~ OOX ~$[E OW(;. PN-800-7 (OR~) TB-D1 [~ SPA~E ~ I~ sPA~ ~ I~ sP~E ~ I-~ $~'~ ~ FLC_}, RACK~I, SLOT~ IC693MDL2.4¢ 16 PT. 120 VAC INPUT A1 2545678 B1234567B [~- ........ ~0087 ~ ........ ~0989 [~- ........ ~0093 r~- ........ ~oo95 r~- .... ~ NEUTRAL o2/oe/ol PANEL PN-800 PLC-1 DI$CRET~ iNPUT MODULES 120 VAC ; 1 FROM DWG. PN-80(~-B , '2 PLC_~ RACK ~. SLOT ~ IC693MDL340 16 PT. 120 VAC OUTPUT A12345§7B B12345678 xGo~oT ........ q~ 3}-- oo,o§ .... ~QO111 ~q0112 1 __OOX AHS-~ CR-800-2 ~(~ CR-800 J-.o~o CR-800-5 o(~o CR-800-7<(~o . CR-800-10 2 2 2 2 2 2 2 2 2 (ORANGE) (ORANGE) ECRaOO-1A ] I] CR~-O0-1S 1 CR-BO0-2 ECR.OO-2* ~ I Fc.,oo-2.1 CR-8OO-J CR-800-4 CR-800-5 CE-800 6 CR-800-7 ~1 [CRSOO~B I EceBO0-"C ] CR-800-10 RW BOOSTER PUMP 1, RUN CALL R~ BOOSTER PUMP 2, RUN CALL FILTER UNIT 1, RUN CALL RLTER UNIT 2, RUN CAL~ F1LTER UNIT 3, RUN CALL BACKWASH RESERVE FILTERS 1 & 2 REVISION PER ENCINEER CaD ck. PANEL PN-800 PLC-1 DISCREIE OUTPUT MODULES WIRING DETNLS 120 V^C L N FINISHED WAlleR TURBIDITY (0.0 - 1.0 NTU 1213141516171819202122232425 oooooo ?oooooo 1 2 3 ¢ 5 6 7 8 91011 TB-A1 (YELLDV) AlT 007 F1LTER UNIT l, EFFLUENT TURRIDll7 (O.O - 1.0 ITU) oooooo oooooo 000000 0 TB-A1 {YELLOW/) FLLTER 1 {__~- PLC~I, PACK~, SLOT~5 1¢693ALG221 AN~LOC INPUT O OK (YELLDW) TO OTHER A[-2 FLLTER UNIT 2 EFFLUENT T'dRBID~P( (0,0 - 1.0 NTU) 1213141516171819202122232425 oooooo? oooooo 234567891011 z~ ~ ~ . T~-~ TURBID~ TF 1 2 5 4 5 6 7 8 gl011 ~RB~Dm~~__TF PANEL PN-800 PLC 1 ANALOG INPUT MODULES Dwg, No, E)IGINEER: CURRAN-WcLEO0, INC. WIRING DETAILS PN-SOO-B FILTER UNIT ] INFLUENT FLOW (0-400 GPM) 121314151617181920 2122232425 oooooo??oooooo 1234567891011 TB-AI (YELLOW) FILTER UNIT 2 INFLUENT FLBW (0-400 GPM) 1213141516171819202122232425 oooooo? oooooo 1 2 3 4 5 6 7 8 91011 TD PN-801 FIC2 INPUT FROM FLOVMETER FT-864 TB-A1 (YELLOW) (YELLOW) PLC_!, RACK__2, SLOT__GA IC693AL6221 ANALOG INPUT O OK (YELLBW) FILTER UNIT 3 INFLUENT FLOW (0-1200 GPM) 1213141516171819202122232425 oooooo? oooooo )00000 2 3 4 5 6 7 6 91011 T]]-AI (YELLOW) FILTER UNIT 3 FROM FLOWMETER FT-80I AI-3~ FILTER UNIT 3~ ~AY 8 EFFLUENT TUR~I~ITY (0,0-1,0 1213141516171819202122232425 __ oooooo??oooooo -- o; oooooo 1 2 3 4 5 6 7 8 91011 NTU) REVISION PER ENGINEER Slayden PANEL PN-800 PLC-1 ANALOG INPUT MODULES WIRING DETAILS 2/~8/Ol PN-800-9 120 VAC N; AI-7 FINISHED ~ATER CL~ RESIDUAL (0,0-1,0 PPM) FROM F)NISHED WATER FLOWMETER FT-OlO (¥EU_OW) PLC~I, RACK~2, SLOT~7 ~ IC693ALG221 ANALOG INPUT (YELLOW) m-A1 RAW WATER llJRBIDI1Y AFr-O06 Slay de nn. PN-8OO-1D PANEL PN-800 PLC-I ANALOG INPUT UODULE~ WIRING DETN~ BROWNELL SPRINOS FLOW (0-500 OPM) 12131¢ 1516171819202122232425 00000000000000 -~o~6oooooo 1 2 3 4 5 6 7 8 91011 TERRA FERN RESERVOIR LEVEL (0-32 1213141516171819202122232425 O000000OO00000 I 6 o oooooo 1254567891011 TB -A2 2-9-5 +2¢ VDC -24 PLC~I, RACK~I, SLOT~B '~- IC693ALG391 O OK ADDRESS + ~ Slayden. 2/19/0t PANEL PN-800 ANALOG OU~UT MODULES ]].g, No, WIRING DL-CNLS PN - BOO- LI-2 SA~DERCOCK RESERVOIR LEVEL ((~-15 FT) 00000000000000 ~o&oooooo VISTA LOOP RESERVOIRS LEVEL (0-30 FO 00000000000000 6~o~6oooooo (YELLOW) TB-A2 +24- ',/DC -24 VBC PLC_]_I, RACK_i, SLOT I_...D z~ IC693ALG391 ANALOG OUTPUT 0 oK PER ENGINEER Sla_y~l~e~ R PANEL PN--BOO PLC-1 ANALO~ OU~UT UODULES WIRING O~LS 2/19/01 PN-800-12 OROWNELL SPRINGS TURBIOFF~ (O,O-1O,O NTU 1213141516171819202122232425 00000000000000 00000000000000 ,o , oooooo ELL SPRINGS CHLORINE RESIDUAL (0.0-1.0 PPkl) (YELLOW) +24 VDC -24 YDC PLC1, RAGK~2, SLOT_~8 IC695ALG391 ANALOG OUTPUT J~ 0 oK ~-~ ADDRESS + pANEL PN-800 PLC-1 ANALOG OUTPUT MODULES ~wo, No, ANALOG OUTPUT TO CHLORINATOR NC-OOg SPARE (YELLOW) +24 VDC -24 VDC PLC~I, RACK2_., SLOT~9 IC693ALC391 ANALO¢ OUTPUT AS BUILT Slayden pANEL PN-800 PLC-1 ANALOC OUll~UT MODULES WIRING DETAILS 2/19/01 PN-800-14 PLC 1_~ RACK 1, SLOT ' IO§gSMDL741 16 PT. 12/24- VDC OUTPUT A12345678 B1234- 5 6 78 L.~4P CABINET (ANNUNCIATOR) ~ TB-D3 POINT NO. INSCRIP~ON PUMP 1 ON [] I Pl PUMP STA. LOW SUCTION lED ON 6 NOTES: 1. ANNUNCIATOR POINT NUMBERS INDICATE ROW AND COLUMN. AH ENGRAVED WHF'E MNDOWS SHALL HAVE BLACK CHARACTERS. ALL OLUE WINDOWS SHALL ~VE BL,~:K CHARACTERS AND ALL RED WINDOWS SHALL HAVE WHflI: CHARACTERS. AUG 2001 Slayd en. PN-DCO- 15 pANEL PN-8,00 PLC-1, DC OUTPUT MODULES ANNUNCIATOR WIRING DETAILS CONT. FROM .~. OWG. PN-80( PLC l, RACK 1, SLOT ~4 IC69~DL741 16 PP. 12/2~- VOC OUTPUT A12345§7§ B1 2 3 ¢ 5 6 7 8 ~P CABIN~ (ANNUNCIATOR) P~MP 5 ON PUMP 5 M~NCTION HIGH ~RBIDI~ ~0~8 ~ ~ ~ 8-1 ~LTER UN. 3, ~Y2 HIOH ~RBIDI~ DWG. NO, PN-BO0-15 :D ON 7 Slayden.. 2/19/01 pANEL PN-BO0 PLC-1, DC OUTPUT MOOULES I]wO, No, $'~v'~, ~"~" e'.'3e3 ANNUNCIATOR ~RSNG DETNLS PN-BOO-16 A~ 1+24V ' 24 V~C CON' PLC ~ RACK ~. SLOT 1 IC695MDL7~l B1 2 3 ~ 5 8 7 8 ~P CABIN~ (ANNUNCIATOR) B Sla_yd e 2/19/01 pANEL PN-800 PLC-1, DC OUTPUT blODUL~ z~g, Ne, ANNUNCIATOR WIRING DETAILS PN-800-17 CONT. FROM OWG. NO. PLC ~ RACK j[ SLOT ICBR3MDL741 16 PT. ~2/24 VOC OU~UT A123¢5678 B123¢567§ %(]0146 ~Q0148 %qOlCg ~ ~Q0153 ~ %O015§ %00157 ] ~Q0160 ~ (~EIOE) 1+24V LAMP CABINET (ANNUNCIATOR) POINT NO. INSCRIFTION g I BROWNELL SPRINGS HIGH TURBIDll'¢ 1 O- 1 BROWNELL SPRINGS LOW CHLORINE RESIDUAL 1 ! - 1 BROWNELL SPRINGS CHLORINE LEAK 12-1 WTP LOW CHLORINE RESIDUAL 9-2 ~TP INTRUSION 10-2 WTP SMOKE AL~EM 112 VFFP CHLORINE LEAK 12-2 FINISHED WATER HIGH TURBIDIT~ 9-3 HIGH TURBIDrlY 11 - 3 (BLANK) 12-3 (BI~NK) 9-4 (eLANN) lO-~ (eLANR) 11 -¢ (BLANK) ~2-4 (BL~) pANEL PN-800 PLC-1, DC OUTPUT MODULES ANNUNCIATOR WIRING DETNLS No, HARDWlRED OUTPU1S TO ANNUNCIATOR UGRTBOX, ! 64 CONDUDTORS POWER SUPPLY PLC-CPU MODULE IC693CPU$63 IC693PWR321 ETHERNET C~D IC693CMM521 SLOT 2 BASE 2 TO WORKSTATION ~ DISCRETE DISCRETE OUTPUT OUTPUT 24 VDC 24 VDC ICSg3MDL741 ICSgSMDL7¢I I/O ADDRESS I/0 ADDRESS ~O00(D1- ~QO017- DISCRETE INPUT 120 VAD IC695MDL240 /0 ADDRESS XTOO3J- ×[0048 SLOT 5 120 VAC IC69JMDL240 ADDRESS ZlOOS4 SLOT 6 DISCRETE INPUT 120 VAC IC693MDL2¢O I/0 ADDRESS ZIS065- ×IQ080 SLOT 7 DISCRETE INPUT 120 VAD IC093MDL240 ADDRESS Y. I0096 SLOT 8 A~OG OUTPUT IC6@3ALG3g 1 VD ADDRESS SLOT 9 OUI~UT IC693ALC391 VD ADDRESS SLOT 10 PLC 1, RACK 1 EXPANSION CABLE POWER SUPPLY MODULE rC693PWR521 DISCRETE OUTPUT 2¢ VDC IC695MDL7¢l SLOT DISCRETE OUTPUT 24 VDC IC693MDL741 /0 ADDRESS SLOT 2 DISCRETE OUTPUT 120 VAD ICS93MDLJ¢O I/OADDRESS BLANK ANALOG COVER INPUT Icsg3ALG221 i/o ADDRESS SLOT 5 A~OG INPUT ~C693ALG221 I/O ADDRESS 7.AIO1 65- INPUT IC693AL0221 /0 ADDRESS ZATD169- 7.ATO172 SLOT 7 ANALOG OUTPUT IC693ALG391 I/O ADDRESS ~q0177- SLOT 8 A~OG OUTPUT ICS93ALG391 ADDRESS SLOT 9 C~R SLOT 10 PLC-1, RACK 2 PANEL PN-800 PLC-1 LAYOUT N~ID ~. N~. MODULE ADDRESSING PN-BO0-1g BILL OF MATERIALS PANEL PN-803 February 2000 GFK ;797A 23 Point Analog Micro PLC Au!ornate Pfogrammahl~ Induslriel Speicher~rogr ammierbare Steuerung Control/ore Logico P[ogrammabfle Automata Programable Oui Ja Si Nein No No 30" GFI CONVENIENCE TRANSIENT SLJRGE OLJ T1LET / PROTECTOR / // PROGRAMMABLE LOGIC CON]ROLLER MODEM ISOLA~ON J TR~SFORMER TB-A1 (ANALOG) l~-Ol (CISORETE] MARINE GRADE ALUMINUM MOUN~NG PLATE, 1/4' X 1/8" X 12" ACID ETCH TO SAllN FINISH CIRCUIT S NOSHOK SERIES 700 PRESSURE 1RANSN 0-30 PSi 1/2' CONDUIT TO --_ __ ll]LEM ETRy PANEL PANEL HEATER 1/2" X 1/4" BRASS W/THERMOSTAT THREADED REDUCER TERMINAL 1/4" COPPER 11JBING TO PROCESS, USE ADAPTERS AS REQUIRED AT PROCESS TAP & VALVE GAUGE COCK, TYP. MOUNT GAUGE & 1RANSMITTER TO ALUMINUM PLATE W~TH S.S. FASTENERS 18' ±~0" 1/2' THREADE[ PLUG COPPER TUBING llJBING ADAPTERS PRESSURE TRANSMITTER/GAUGE INSTALLATION DETAIL SCALE: 3/16" = 1" 6" DIAMETER ALTITUDE GAUGE 0-70 FT. USE 1/2' S,S. SPACERS BETWEEN WALL & MOUN~NG PLATE. PLATE TO WALL ~Tiq S.S. FASTENERS · 3/8' DIA. MOUNI~NG HOLES, (~-) PLACES LIGHTNING ARRESIER TELEMETRY PANEL INTERIOR SCALE: 3/16' = 1' AU(; 2861 Slayden PANEL pNi803 TERRA FERN RESERVOIR PANEL DETAILS 2/2O/Ol PN-80~-I ~ ~< ~m~ ~= I/0 ADDRESSING ~J. L~_ DISCRE[E INPUTS DISCRETE OU1PIJTS m PROGRAmmABLE LOGIC CONTROLLER WIRING DETAIL BILL OF MATERLALS PANEL PN-.804 W w Z I BILL OF MATERIALS ~rr~s~ PANEL PN-80$ QUAN DESCRB~TION CAT. MODEL # MANUFACTURER I I ENCLOSURE POOH2408S~LP HOFFMAN 2 I BACKPAN A-30P24 HOFYMAN 3 I PANEL HEATER D-AHI001A HOFFMAN 4 I 2 CIRCUIT BREAKER 1492-CB[Gl 50 ALLEN BRADLEy 5 ~ I ISO~T~O~ IRANSFORMER XCL025ES-16VI3H115 TIERNEy 6 6 RELAy, 2 POLE RH2B-ULC [DEC 7 6 KELAY SOCKET SH2B~5 IDEC 8 I TRANSIENT PROTECTOR 51020-W3~ LEV[TON 9 I MODEM LLM-1100/2 DATA-LINC I 0 I GFIC RECEPTACLE 6598-HG1 LEVITON 11 AR 9~/RE DUCT, 1" X 2" G 1X2'WH6 PANDLqT 12 I LIGHTNING ARRESTER PTEL-2 APC 13 30 TERMINALS~ GREY I1511811 ENTRELEC 14 10 TERMINALS, BLLYE 125 118 13 ENTRELEC 15 10 TERMI~ALS~ YELLOW 105 11820 ENTRELEC 17 4 '1 ~d RJtv~A/,S, YE LLO WK5~ R E EN 165 114.17 ENTRELEC 17 6 TERMINALS, FUSED I 15 222 11 ENTRELEC 18 AR DIN RAIL DIN-3 ENTRELE C 19 I PROGRAMMABLE CONT ~ IC200UAL006 GE 20 I PRESSURE GAUGE 6' SERIES 1010.0-701q20 ASHCROFT 21 I PRESSURE TRANSMITTER SERIES 1010 705-15.1.3 NOSHOK GFI CONVENIENCE TRANSIENT SURGE OUTLET / PROTECTOR / / FUSES B B PROgRAMmABLE CON~ RELAYS LOGIC CR~ CR CR CR CR FUSES B B PROGRAMMABLE CONII~OL RELAYS LOGIC CRI CR CR CR CR LIGHTNING ARRESTER TELEMETRY PANEL INTERIOR CIRCUIT /BREAKERS MARINE GRADE ALUMINUM MOUNRNC PLATE, 1/4' X 1/8' X 12' ACID ETCH TO SA~IN FINISH NOSHOK SERIES 700 PRESSURE PANEL HEATER 0-30 PSI W/THERMOSTAT 1/2" CONDUIT TO TELEMETRY PANEL 1/2" x 1/¢' BRASS TERMINAL mREADED BLOCKS 1/¢' COPPER TUBING TO PROCESS.' USE ADAPTERS AS REQUIRED AT PROCESS TAP & VALVE 1/~' BRASS GAUGE COCK, T'~. MOUNT GAUGE & TRANSMITTER TO ALUMINUM PLATE ~TH S.S. FASTENERS 18" 1/2' PLUG COPPER TUBING ~JBING ADAP~RS PRESSURE TRANSMITTER/GAUGE INSTALLATION DETAIL SC.~L~ 3/16' = 1" §" DIAMETER AL~TUDE GAUGE 0-70 FT. USE 1/2' S.S. SPACERS BETWEEN WALL ~ MOUN~NG PLATE. PLATE TO WALL ~ S.S. FASTENERS .3/B' DIA. MOUNllNG HOLES, (4) PLACES Slayd e . PANEL PN-805 VISTA LOOP RESERVOIR PANEL DETAILS 2/2O/Ol ]3wg. No, ~ ~ ~ s~ I/0 ADDRESSING ~m~] ~F~ u DISCRETE INPUTS DISCRE1E OUTPmj~rs m o SURGE o m PROGRAmmABLE LOGIC CONTROLLER WIRING DET&IL I PANEL PN-806 ITEM QUAN DESCRIPTION CAT. MODEL # MANUFACTUREI~ I l ENCLOSURE A30H2408SSLP HOFFMAN 2 I BACKPAN A-30P24 HOFFMAN 3 I PANEL HEATER D-AHI001A HOFFMAN 4 2 CIRCUIT BREAKER 1492-CBIG150 ALLEN BRADLEY 5 I ~:~OLATION TP. ANSFC~ XCL025ES-16VI3H115 TIeRNEy 6 6 KELAY~ 2 POLE KH2B-ULC IDEC 7 6 RELAY SOCKET SH2B-05 [DEC 8 I TRANSIENT PROTECTOR 51020-WM LEV[TON 9 I MODEM LLM- 110Of2 DATA-LINC I 0 I GFIC RECEPTACLE 6598-HG1 LEVITON 11 AR WIRE DUCT~ 1" X 2" G 1X2WH6 PANDUIT 12 I LIGHTNING ARRESTER PTEL-2 APC 13 30 TERMINALS. GREy 115 118 II ENTRELEC 14 10 TERM/NALS, BLUE 125 118.13 ENTRELEC 15 10 TERMINALS~ YELLOW 105 11820 ENTRELEC GR CONVENIENCE 1RANSIENT SURGE OUI~ET PROTECTOR o C LOGIC ~ CR CR CR C~ CR CR ~ CON~OL~R 1 2 3 ~ ~ 6 30" UODEM ~m 0 CIRCUIT PANEL HEAleR W/IHERMOSTAT TERMINAL BLOCK UGHTNING ARRESTER TELEMETRY PANEL INTERIOR Slayde_n. PANEL PN-806 BROWNELL SPRINGS WATER SOURCE PANEL DE-rAILS PN-806-1 L ] ENCLOSURE CB H~TER ~ o IOOW CB SURGE pLC PROGRAMMABLE LOGIC CONTROLLER WIRING DETAIL L~ChT£ I/0 ADDRESSING DISCRETE INPU~ DISCRETE OUTPUTS TERM. ADDRESS ~M. ADDRESS [-3 %I0503 g-I %QD514 [-4 ZIOS04 G-~ %Q0515 I-5 Z]0505 Q-3 XQD5[6 [-6 ZIOS06 G-4 ZQOS[7 [-7 X]OSO7 Q-5 XQDSI8 Slayd e n pANE]_ PN- 806 BROWN£LL SPRINGS WATER SOURCE WIRING DETAILS 2/2~/01 DwG, No, PN-806-2 GE IC200UALO0§ MICRO PLC // COMM. PLC,/MODEM C~BLE CE ~$MDL CABLE / 422/485) POWER GE 90-30 SUPPLT CPU IC693CPU363 /' POE .~ (RS 4 POWER CPU ETHERNET SUPPLY MODULE lC693(::M M521 COIL D<CESS ~ C~BLE AND SECURE TO ETHERNET MODULE BACKPAN GE ~DET-113 TO WORKSTATION COMPUTER i i i i DATA-LINC INDUSTRIAL LE/,S ED LINE MODEM i i ] i DATA-nNC INDUSTRIAL LEASED UNE MODEM DETAIL "C" PLC COMMUNICATION CONNECTIONS DETAIL "A" PLC COMMUNICATION CONNECTIONS DETAIL "B" PLC COMMUNICATION CONNECTIONS SYSTEM BLOCK DIAGRAM COMMUNICATION DETAILS SBD-101 TREATMENT CONTROL PANEL PN-801 (E-xm'nNc) TREATMENT CONI~OL PANEL PN-B02 (NDN PANEL) HARD WIRED SIGNALS: ~- DISCRETE INPUTS 3 DISCRETE OUTPUTS 4 ANALOG INPUTS BOOSTER PUMP STATION CONTROLS ................... J L ................ J SEE D~. SBD-IO1, DETAJL "A" CONNECTION DETN LS OYPICAL OF 5) HARD WIRED SIGNALS: 4 DISCR~I~ INPUTS 2 DISCRETE OUTPUTS 3 ANALOG INPUTS HARD WIRED PLC (2 RACKS) 2 DISCRETE OUTPUTS ANNUNC~TOR UGHTBOX 10 BASE 2 COAX ~_ SEE DWO. ~SBD-101, DETAIL "C" FOR CONNECT)ON DETNLS DWG. )~SBD-101, DETAIL "B' FOR CONNECTION DETAILS LEASED PHONE UNE E~(ISTING PHONE LINE (LEASED) COLOR PRINTER 120 V~m~ ~ EXISTING Sr-.~kDA NETWORK WORKSTATION 7- GE MICRO ERRA FERN RESERVOIR PANEL PN-803 GE MICRO PLC - 4 SANDERCOCK RESERVOIR PANEL § EACH PUMP "ON' STAllJS AND 'RUN" COMMAND TRANSMIHER PN-BO4 RESERVOIRS LEVEL GE MICRO PLC-5 ~ISTA LOOP RESERVOIRS PANEL PN-BD5 GE MICRO PLC-8 BROWNELL SPRINGS WATER SOURCE PANEL CHLORINE LEAK ALARM , ' - TURBIDIMETER - - FLO~,IETER ND~V CL2 R~ID~ AhtALYZER Slayd e,n,: PN-806 r i EXIST1NG I GE--g0-30 I PLC 2/2Vol SBD-lOO COMMUNICATION SYSTEM BLOCK DIAGRAM Free-StandingType 1 2 Enclosures Application 4.$6 Free-StandingType 12 Enclosures I Single-Door Single Acce$$ Inch Millimeter Standard Sizes Single-Door Single Access Free-StandingType 12 Enclosures Stainless Steel Type 4X Enclosures Standard Sizes Stainless Steel Type 4X Encrosure, Electric Heaters Applicatlon Sizing and Selection Lighting Packages ~-~ Q 9.16 red Tel +t (717) 767-6511 MODEL PAXP - I/8 DIN PROCESS INPUT PANEL METER GENERAL DESCRIPTION 88888 v :~_: ~800 100 -- SAFETY SUMMARY SPECIFICATIONS ELECTROMAGNETIC COMPATIBILI'r Y [mmunit) to EN 50082 Z Emissions to EN 501}81-2 R~ mterlerence EN 55011 ORDERZNG ZNFORHATION OPTZONAL PLUG-IN CARDS AND ACCESSORIES SETPOINT ALARMS PLUG-IN CARDS (PAXCDS) SERIAL RS485 PLUG-IN CARD (PAXCDC) SERIAL RS232 PLUG-IN CARD (PAXCDC) DEVICENET PLUG-IN CARD (PAXCDC) ANALOG OUTPUT PLUG-IN CARD (PAXCDL) UNITS LABEL KIT (PAXLBK) PC SOFTWARE (SFPAX) EXTERNAL CURRENT SHUNTS (APSCM) 1.0 ZNSTALLffNG THE METER Installation Installation Environment 3 62 *" f- i 1 77_'~ , ~.0 SETTXNG THE User Input Logic Jumper JUMPER SELECTIONS USER INPUT LO~IC JUMPER REAR TERMINALS [3.0 WXR_rNG THE METER WIRING OVERVIEW EMC INSTALLATION GUIDELINES OPTZONAL PLUG-ZN CARDS AND ACCESSOR_TES SETPOINT ALARMS PLUG-IN CARDS (PAXCDS) SERIAL RS485 PLUG-IN CARD (PAXCDC) SERIAL RS232 PLUG-IN CARD (PAXCDC) DEVlCENET PLUG-IN CARD (PAXCDC) ANALOG OUTPUT PLUG-IN CARD (PAXCDL) UNITS LABEL KIT (PAXLBK) PC SOFTWARE (SFPAX) EXTERNAL CURRENT SHUNTS (APSCM) METER 1.0 ZNSTALLZNG THE Installation Installation Environment the keypad of the unit 5 62 *~g Custom Un[ts Overlay Setpoird. Alarm Annunciators KEY DISPLAY MODE OPERATION OVERVIEW PROGRAMMING MENU PROGRAMMING MODE ENTRY (PAR KEY) PARAMETER MODULE ENTRY (ARROW & PAR KEYS) PARAMETER MENU MOVEMENT (PAR KEY) SELECTION/VALUE ENTRY (ARROW & PAR KEYS) PROGRAMMING MOOE EXIT (DSP KL=Y0r a~ .% o nD PAR KEY) PROGRAMMING TIPS FACTORY SETrlNGS ALTERNATING SELECTION DISPLAY PARAMETER MENU INPUT RANGE DISPLAY DECIMAL POINT DISPLAY ROUNDING* FILTER SETTING* ~ to ~S.~ seconds FILTER BAND* ~.~ to ~S~ display units SCALING POINTS* Linear - Scaling Points (2) Nonlinear - Scaling Points (Greater than 2) SCALING STYLE ~ q kEY keydn data i~> ~ ,q~t~ apply signal INPUT VALUE FOR SCALING POINT t the same for ~[~ and lpg ff scaling sbqes ~e decimal point follows the J[[~t INPUT VALUE FOR SCALING POINT ~ DISPLAY VALUE FOR SCALING POINT 2 General Notes on Scaling ~ PARAMETER MENU PAR b usER INPUTS FUNCTION KEYS NO FUNCTION PROGRAMMING MODE LOCK-OUT ZERO (TARE) DISPLAY RELATIVE/ABSOLUTE DISPLAY HOLD DISPLAY HOLD ALL FUNCTIONS SYNCHRONIZE METER READING STORE BATCH READING IN TOTALIZER SELECT TOTALIZER DISPLAY RESET TOTALIZER R[aSET AND ENABLE IOTALIZER display ENAEILE TOTALIZER SELECT MAXIMUM DISPLAY RESET MAXIMUM RESET, SELECT, ENABLE MAXIMUM DISPLAY SELECT MINIMUM DISPLAY RESET MINIMUM RESET, SELECT, ENABLE MINIMUM DISPLAY ~I cominues ~om thai x atue iHfi/e active {maintalned a¢Iion). RESET MAXIMUM AND MINIMUM SETPOINT SELECTIONS · - I - Reset Setpoint 1 (Alarm 1) · -~ - Reset Setpoint 2 (Alarm 2) Setpoint · -J - Reset Setpoint 3 (Alarm 3) Card · - ~ - Reset Setpoint 4 (Alarm 4) Only r - ~t - Reset Setpoint $ & 4 (Alarm 3 & 4) r -EJ~ - Reset Setpoint 2, 3 & 4 (Alarm 2, 3&4} r - RL L - Reset Setpolnt All (Alarm All) PRINT REQUEST PARAMETEFI MENU MAXIMUM DISPLAY LOCK-OUT' MINIMUM DISPLAY LOCK-OUT* TOTALIZER DISPLAY LOCK-OUT' These displays curt be pmgrammeO Io~ lO[ or rid When programmed for SP-1 SP-2 SP-3 SP-4 SETPOINT ACCESS* PROGRAM MOCE SECURITY CODE* By enlering any aon-zero value. [he prompl £~dE O will api~ ar when irving access the Program Mode Access will only he allowed after entering a MAX CAPTURE CELAY TIME* MIN CAPTURE DELAY TIME* UNITS LABEL BACKLIGHT' DISPLAY OFFSET VALUE* ;,5 MODULE S ~o...talizer,,¢~t~gra Parameters PARAMETER MENU TOTAUZER OEC,MAL EOINT* TO/ALIZER TIME SASE ~ ~£ seconds(+1) h.~r-hours(+3600) ~;> ~ _ I~] - minutes (+ 60) dR~I - days (+ 86400) TOTALIZER SCALE FACTOR' TOTALIZER BATCHING TOTALIZER USING TiME BASE TOTALIZER SCALE FACTOR CALCULATION EXAMPLES Modules 6, 7, and 8 are accessible only with the appropriate plug in cards installed A quick overview of each Module is listed below Refer to the corresponding plug-in card bulletin for a more detailed explanation of each parameter selection (Alarm) paramet~'~.rs PARAMETER MENU Rc ~' - n - SETPOINT ACTION I:(]rJ-n - ON TIME DELAY ~ to ~¢~.~ sec [(~F-n - OFFTIME DELAY ~,~ to 3~]5~ sec au~: -n - OUTPUT LOGIC r S~-n- RESET ACTION $.7 MODULE ;7. Serial Communications Parameters [~ ~"~ ~ [~--~PARAMETER MENU This module Is for RS232 and RS485. bR~d- BAUD RATE dR~R-DATA BITS PAAR~ R5 I' ~PE - ANALOG TYPE RS tE - ANALOG ASSIGNMENT PARAMETER MENU CALIBRATION input Calibration Analog Output Card Calibration RESTORE FACTORY DEFAULTS TROUBLESHOOTING PARAMETER VALUE CHART PAXP Process Input Meter I- I/~P Signal Input Parameters User Input and Function Key Parameters g-~P~: Se~fint(Almm)Paramet~s Programmer Date Meter# Security Code 3- L O~ Display and Program Lockout Parameters MIN DISPLAY LOCKOUT .'Ed TOTAL DISpLAy LOCKOUT r~d SETPOINT 1 ACCESS t~ SETPOINT 4 ACCESS L ~ Secondary Function Parameters S-I:I]~: Totalizer (Integrator) Parameters 7-5~[ Serial Communication Parameters B- BuJ: Analog Output Parameters PAXP PROGRAMMi'NG (~UI'CK OVERVZEW RED LION CONTROLS MODEL PAXCDL -ANALOG OUTPUT PLUG-IN OPTION CARD DESCRIPTION INSTALLING AN OPTION CARD SPECIFICATIONS Analog Output Card disabbdl ORDERING INFORMATION MODULE 8 -Analog Output Parameters PARAMETER MENU RS ~nl ~ ANALOG TYPE ANALOG ASSIGNMENT ANALOG LOW SCALE VALUE ANALOG HIGH SCALE VALUE PROBE .URN-OUT ACTION (PAXT ONLY) LIMITED WARRANTY RED UON CONTROLS INTERNATIONAL HEADQUARTERS ×~ MODEL 90PDL* INTEGRAL HORN MOUNTED IN LAMP CABINET ~..~ O R N MODULE REAR VIEW %.~LEF[ MAIN BUS 20DED WHITE) FO AK P2 P3 0V CUSTOMER WIRING FLASHER POSITION ~CODED RED) MODEL 90PDA* rNTEGRAL HORN MOUNTED IN ANNUNCIATOR CABINET HORN POSITION (CODED BLACK A REAR VIEW o FLASHER POSITION DED RED) CUSTOMER WIRING ',IOTES: ~ FOR RINGBACK AUDIBLE, gOPD** TERMINAL 6. 2. WAI~AGE 0.4, 12mA AT 24VDC, UNFILTERED. $. SOUND LEVEL AT TWO FEET. MIN. 68db, MAX. ~IWarning: Uaed on FM opproved equipment. WIRE FLASHER TERMINAL 6 TO SECOND 80db. ECN NO. 8700-68 8900-12 8980 7700-83 11872 / / 1725 WESTERN DRIVE, WEST CHICAGO, IL., 60185, U.S.A. PHONE: 1-630-251-5900 FAX: 1-630-231-¢502 SCALE NONE DATE o~/21/83 WIRING DIAGRAM, INTEGRAL HORN, FAST PULSE (90PS*3 OR CONTINUOUS TONE (90PS"1) DWG. NO. 90450-PB**-1 z POWERWARE® 5119 User's Guide 1000-3000 VA www,powerware,com Requesting a Declaration of Conformity EMC Statement Class A Statement for FCC and ICES (ZOO0 VA- 3000 VA) Fo~ Users in the United States Only For Users in Canada Self. Certified Class B Statement for FCC and ICES (1000 VA - 1~00 VA) For Users in the United Slates Only For Users in Canada Special Symbols This s)~nbol indicates that you should not discard the UPS or the UPS batteries in the trash. The UPS may contain sealed, lead-acid bakeries. Batteries must be recycled. TABLE OF CONTENTS Powerware 5119 -One of~he Best! .................................. 1 Installation ..................................................... 3 Inspecting the Equipment Safer7 Precautions 3 Installing the UPS 4 UPS Rear Panels ? Operation ...................................................... 11 Turning the UPS On 11 Starting the UPS on Battery Turning the UPS Off 11 Standby Mode 11 UPS Front Panel 12 AC input LEDs 13 Battery Charge LEDs 13 Load Level LEDs 14 Initiating the Self-Test 14 Configuration ................................................... 15 Why Change Factory Defaults? 15 Nominal input Voltage 15 Other Settings 15 Configuration Mode 15 UPS Maintenance ............................................... 19 UPS and Batte~j Care 19 Storing the UPS and Batteries 19 When to Replace Batteries 19 Replacing Batteries 20 How to Replace External Batteries 21 Howto Replace internal Batteries 22 Testing New Batteries 23 Recycling t he U~d Bat~e[7 24 Additional UPS Features .......................................... Communication Port Configurations ....................... 25 Communication Indicator ..................... 25 Pin Out ............................... 26 Network Transient Protector 27 Load Segments 27 Option Modules 27 Specifioatio~s .................................................. 29 Troubleshooting ................................................. Audible Alarms and UPS Conditions 33 Silencing an Audible Alarm 33 Service and Support 35 CHAPTER 1 POWERWARE 5119 - ONE OF THE BEST! The Powerwaree 5119 uninterruptible power system (UPS) protects your sensttive electtx)l~ic equipment from basic power problems such as power failures, power sags, power surges, brownouts, and line noise. Power outages can occur when you least expect it and power quality can be erratic. These power problems have the potential to corrupt critical data, destroy unsaved work sessions, and damage hardware -- caushug hours of lost productivity and expensive repairs. With the Powerware 5119, you can safely eliminate the effects of power disturbances and guard the integrity of your equipment. The Powerware 5119's flexibilit2? to handle an army of network devices nmkes it the perfect choice to protect your LANs, servers, and workstations. Figure 1. Powerware 5119 and External Battery Cabinet software, thc Powerware 5119 comes fully equipped with a Providing oumtanding performance and reliability, the PoweI waI~ S119's unique benefits include the roll.ring: Advanced Battery Management (ABMTM) doubles battery sel~ice life, optimizes recharge time, and provides a warning up to fi0 days before the end of useful battery life, Buck and Double Boost regulation ensures consistent voltage to your load by correctitz voltage fluctuations without using battery power. Hot swappable batteries simplify manitenance by allowing you to replace batteries safely without powering dc~vn the crincal load, Network Transient Protector guards your modem, fax maclnim, and ocher network conununications equipment from surRes. Stare on battery compatibility allows you to power up the UPS even if utility power is not available. · Optional power communication cards provide enhanced conm~utfication capabilities for increased power protection and longer battery backup times. · The Powerware 5119 is backed by worldwide agency approvals. CHAPTER 2 INSTALLATION This section explains; Equipment inspection Safety precautiorm UPS installation UPS rear panels Inspecting the Equipment If any equipment has been damaged during shipment, keep the shipping cartons and packtng materials for the carrier or place of purchase and ~e a claim for stripping damage, if you discover damage after acceptance, file a claim for concealed damage. To file a claim for shipping damage or concealed damage: 1) File with the carder within 15 days of receipt of the equipment; 2) Send a copy of the damage claim within 15 days to your service representative. Safety Precautions Read the following before you install the UPS. · This UPS contains its own energy source (batteries) The output receptacles may camj live voltage even when the UPS is not connected to an AC supply. Do not remove or unplug the input cord when the UPS is turned on This removes the saiety ground from the UPS and the equipment connected to the UPS · To reduce the risk of fire or electric shock, install this UPS in a temperature a~d humidity controlled, indoor environment, free of conductive contaminants Ambienl temperature must not exceed 40~£ (104°~} Do not operate near water or excessive humidity (95% nax). · The sum of earth leakage current trom the load cunnected to the UPS must not exceed 1 5 mA Installing the UPS The followk~ steps explain how to install the UPS. Figure 3 on page 6 shows a typical ~mLallation ot~l)~ See "UPS Rear Panels' on page 7 for the rear panel of each model. ]:lllll*l~ A small amount of arcin§ may occur wl~on connecting an extemal battery to the UPS insert the battery cable into the UPS batter7 connector quickly and firmly to your equipment and void your warranty Figure 2. Fault Indicators On 230V models, plug the UPS power cont into the thput coImector on the UPS rem pancl, Customer-supplied power cords must con'cctly rated for the UPS (see "Specificatioz~s' on page 29). You can also use the powe~ cord from the largest load if it is con-ectly rated. Plug the UPS power cord into a wall outlet or power source. The UPS conducts a self-test and enters Standby mode. If a red Site Wiring Fault or Battery Service indicator stays on, see Table 11 on page NOTE Low ¥oitage models may not recognize 50-Hz out lets Lf the UPS does not start when connected to a 50-Hz outlet, unplug the UPS. Press and hold the On I button for 3 seconds to star[ the UPS ow battery and reconfigure the nominal input voltage to either 100V or 110V (see rrgonfiguration Mo~e" on page 15}, [urn the UPS off. Wait for 30 seconds, Then plug the UPS into the outlet. Plug the equipment to be protected into the UPS output receptacles. DO NOT protect laser printers with the UPS because oP the exceptionally I~igh power requirements of the heating elements. StarL the UPS by pressing the On [ button as shown in Figure 3. The Power On indicator Illuminates indicating that power is available from the rear receptacles. The ip~stalladon is complete To learn how to operate the UPS, see "Operatmn" on page 11, To change the factory set defaull~, see "Conllguration~ on page 1S. NOTE The UPS charges to 90% in approximately 4 hours, However, it is recommended that the UPS charge for 24 hours after installation or long storage Load 0 quipment Figure 3. T)l)ical UPS Installation (120V Model Shown) UPS Rear Panels This section M~ows thc real' paz~cls of all Powerware 5119 models. Figure 4.1000-1500 VA, 120V Rear Panel with 5 15 Plug Option Slot Figure 5. 2~0 VA, 120V Rear Panel I1'; I©1'; Il-.. 1112111 I1,'11 I~.IjL ~l~.lj. Figure 6.2400-3000 VA, 12gv Rear Panel Option Slot Input Circuit IEC 320 input Connector Figure 7.1000-15~ VA, 230V Rear Panel T T - · Option Slot 0 0 (Three IEC-320 Receptacles) Figure 9.3000 VA, Z30V Rear Panel CHAPTER 3 OPERATION This section describes: TuIxfing the UPS on and off Startfing tho UPS on batiery Standby mode The UPS front panel and LEDs Tuming the UPS On After the UPS is connected to a power soLtrce, it conducts a self tes: and enters Standby mode. To turn on the UPS, press the On ] butlon on the front panel (shown itl Figure 10). The Power On indicator illuminates indicating that power is available from the mar receptacles. Starling the UPS on Battery To turn on the UPS without using utility power, press and hold the On ] button for three seconds, When the UPS starts on batter3~, it does Turning the UPS Off To turn off the UPS, press the Off ~ button on the front panel and then unplug the UPS from the power source. If you do not unplug the UPS, it remairm ha Standby mode. Standb]f Mode V~nen the UPS is turned off and plugged into a wall outlet or other power source, the UPS is in Standby mode. The battery recharges when necessary and the Power On indicator is off, indicating that power is not available from the rear receptacles. UPS Front Panel The UPS front panel LEDs ~ndlcate how the UPS is operating and also ale~t you of potential power problems. Figure 10 shows the UPS front panel indicators and controls. [~j Batle~ Charge LEDs 0 0 3 ,3 [: O, · .,e PowerOnlndicat~ OffBu~on Figure 10. UPS Front Panel The following sections describe the LED functions dur/ng normal operation. If any LEDs am red, see Table 11 on page 33 to identify and correct the problem, ~ AC Input LEDs The AC Input LEDs show information about :he utility power coming into the UPS (see Figure 11). ~ Normal Utili~ Input (Buck ~rld Sin§In Boa~) ~ Double BODS~ is Dn 0 The second LED indicates that the UPS is operating normally frown uOlity power. The UPS is providing consistent voltage with the Buck and Single Boos~ feature. The third LED indicates that the UPS is using the Double Boost feat~-e to automatically correct voltage fluctuations. If any AC Input LEDs are red, see page 34 for more information. ~ Batte~ ~harge LEDs The Battery Charge LEDs show ifd'ormation about the UPS batteries (see Figure 1 r~ Lead Level LEDs The front panel displays the total load current or watts plugged into the UPS (see Figure 13). 0 0 I 3 ! I Figure 13. Load Level LEDs (Normal Mode) Each LED represents 1/3 of a full load rating. When the UPS is approximately fully loaded (66 100%), all three LEDs Illuminate. If the load is 33 66% of UPS capactt3c the third and fourth LED illuminate. If any Load Level LEDs are md, see page 35 for mm,e information. Initiating the Self-Test Press and hold the ~ button for three seconds to lrdtiate the self-test. During the test, individual LEDs illuminate as various parts of the UPS are checked. If the UPS finds a pi~oblem, an LED indicates where the problem is. For more information, see. "Troubleshooting' on page 33. NOlt All three Battery Charge LEDs should be lit and the UPS must not be in Batter7 mode to pedorm the self-test. CHAPTER 4 CONFIGURATION Why Change Factory Defaults? Nominal Input Voltage When the utility power consistently fluctuates, thc UPS repeatedly corrects the input voltage by switching to battery power when the nominal input range is: Higher than 420% of 120V or 230V nominal Lowerthan 30%of120Vor230VnomJnal Higher than +20% and fower then -30% of 1 ~0V or 230V nominal You can configure the UPS to more closely match the nominal input vohagc by selecting a different input voltage or extending the input voltage range. See Table 1 on page 17 for a list of available options. Other Settings You can change the UPS defauh cm~figurations for alarms a~d shutdown parameters, including: timing for the low battery alarm, the time delay for an unconditional shutdown, alarms for loss of utility power or site fault, and controlling loads that use less than 5% of the current when the UPS is on battery See Table 1 on page 1 ? for a list of avaLlabla opOons. Configuration Mode When the UPS is in Col~figuration mode, the LEDs represent the co~ffigm-ation options. The control buttons (On ] button and ~ button) are used to modify the UPS corffiguration. Figure 14 shows the LEDs and Table 1 explains the corresponding optior~s. DO NOT press the Off ~ button while the UPS is in Configuration mode: pressing the Off ~) bu~ton removes all I~wer to your eqmpment 1. press and hold the On [ buuon and the ~ button simultaneously tbr one beep. The UPS switches to Configuration mode. 2. press the On 1 button to scroll through the options. Each time you press the button, the UPS beeps. The LED for the selected option blinks (see Figure 14 and Table 1). lfyou press the On [ button and nothing happens, the UPS is still in Operation mode. Repeat Step 1 for one beep ONLY to enter Configuration mode, and then perfom~ Step 2. 3. Press the ~ burton ONCE to toggle the selected option on or off. The Power On indicator corresponds with the current setting. Repeat Steps 2 and 3 for each option. 4. Press the On [ button and the ~ button $imtfltan~ously to return to Operation mode at any time. Scrolling past the last LED also returns the UPS to Operation mode. ] c o Figure 14. Using the C~nfiguratimt Mode Table 1. Configuration Mode LEDs and Options 0 I 0 0 0 I 0 I Vobage Mode © I © C C 3 ! 0 0 I 0 0 OFF ON OFF Sleep Mode 100/208V Nominal OFF ON' OFF (default) ON OFF (default) ON [detault} OFF CHAPTER 5 UPS MAINTENANCE Cax~e for the UPS and batteries Replace the batteries Recycle used batteries UPS and Batte~J Care For the best preventive maintenance, ke~p the area around the UPS clean and dust-free. If the atmosphere is very dusty, clean the outside of For full battery life, keep the UPS at ~t~ ambient temperature of Storing the UPS and Batteries If you store the UPS for a long period, recharge the battery every 1 g months by plugging the UPS into a power outlet. The UPS charges to 90% in approximately 4 hours. However, it ks recommended that the UPS charge for 24 hours after long storage When to Replace Batteries When the Battery Service indicator illuminates, the batteries may need replacing (see Figure 10 on page 12). Conduct a serf test by pressing the ~ button. If the indicator stays on, contact your service repmsentarive to order new batteries. Replacing Batteries Thc hot swappable barlery feature allows you to replace the UPS batteries easily without turning the UPS off or disconnecting the load. If you prefer to remove input power to change the battery: 1) Press the Off ~ but[on and then unplug the UPS; 2) Wait 60 seconds while the internal processor shuts down before you disconnect the hatter~ Cot~sider all warnings, cautions, and notes before replacing bat[eries. A How to Replace External Batteries battery See "Recy~:lk,g the Batteries" on page 24 for proper disposal. Figure 15. Figure 15, External Barry Connections (120V Model Sl'~wn) How to Replace Internal Batteries 4. Removc the old battery See "Recycling the Batterles' on page 24 for proper disposal 5. Coimect the new batteries to the UPS as shown in Figure and reinstall. 1500 VA Models Figure 16. Internal Batter,j Connections Testing New Batteries Press and hold the ~ button for three seconds to imtiate a self-test. After the test is finished, the red Barter3, Service indicator should turn off and the Battery Charge LEDs should show a chaqge. If the Batiery Service indicator stays on, check the battery connections. See the u~ubleshoniing guide on page 33 or call your service representative if the problem pemists. Recycling the Used Batte~j ~llllll Do not discard the UPS or the UPS batteries in the trash. This product contains sealed, lead acid batteries and must be disposed of properly. For more information, contact your local recycling or hazardous waste center. CHAPTER 6 ADDITIONAL UPS FEATURES This section describcs: · UPS communication capabilities Communication Port Configurations cable built to factor7 specifications {see Table 2} to the communication port A soffwm-e can exchange data with the UPS. The software polls the UPS and an orderly shutdown of the equipment. Communication Indicator When the UPS receives a command from the computer to establish commumcation, the Commurdcation h~dicator on the UPS front panel illuminates (see Figure 10 on page 12). When data is tral~fcrring, the Cornrntmication indicator flashes. Pin Out As shown ~n Table 2, Pins 1 and 2 operate in two modes: Basic Alarms mode mhd Serial Data mode. Basic Alarms mode has AC fail alarm and output shutdown. Serial Data mode is UPS Code II compliant. The system always starts In Basic Alarms mode. When serial data is received at Pin 1, the function ofPha 1 and Pin 2 clmnges to Serial Data mode. If serial data has not been received before going to battery power, sertal communication is disabled u~til AC input power reVarns. Figure 17. Communication port Table Z. Cemfnunication Port Configuration 9 Chassis Network Transient Protector The Network Transient Protector, shown in Figure 18, is located on the rear panel and has jacks labeled IN and OUT. This feature accommodates a single RJ 45 (10BeseT) network connecton Low voltage models can also accommodate an RJ - 11 telephone connector that provides p~x)tection for modems, fax machines, or other teleconununtcatlons equipment. As wi[}l lllOSt modem equipment, it is not advisable to use this jack in digital PBX (Private Branch Exchange) en¥iBolM nenT$. Cotmect tJ~e Lnput connector of the equlpmeui you are protecting to the jack labeled IN Connect the output connector to theJack labeled OUT. IN OUT Figure 18, Network Transient Protector Load Segments Option Modules Option modules help your UPS communicate in a variety of networking envlronments and are irtstalled in the UPS option slot. See the manual that accomparfies each module for more information, or contact your CHAPTER 7 SPECIFICATIONS Table 3. h/'~lel List 5119 models: 120V Models 230V Models Table 4. Electrical Input Z30V default. 208, 220, 230, 240V selectable Table 5. Eleclrical Oul~ut 120V Models 230V Models Table 6. Weights and Dimensions 120V Models 230¥ Models Table 7, Environrn~lal and Safety 230V Models sto~a~ Tem~re 0 C to 40 C [32 F to 104 FI: U[ tested 25 C (77 F) -20C to 60 C ( 4 Ftc 140 F) 5 95% noncondensing IEEE 587/ANSI C§241 Category B UL 1778; CAN/CSA C222, NO 1071 UL 1778; CAN/CSA C22.2, NO 1071; EN 5~O91-1 and IEC 60950 UL, CSA UL CSA, CE FCC V££1 EN 50091 2 Table 8. Indicatm's and C~llXOls ; Bar Graphs: [nput LoveL B att e~J Charge levi, % Load ~ ~losure~ AC Inp~ rail~re, I ~ .a.e~ Table 9, Ba~e~ 2000-30(]0 VA: externalPW5119 1048BP 200(~3C~VA~ extemaIPWSl191748BP Sealed maintenance free, valv~regulated, lead-acid Aovanced charging for faster recover'; approximately 4 hours to 90% usable capadt7 ~t nominal Table 10. Battery Run 1~mes (in Minutes) 43 43 23 23 2000 2400 Battery times are approximate and va~ depending on the lead configuration and batter)' charge. CHAPTER 8 TROUBLESHOOTING Audible Alarms and UPS Conditions The UPS has an audible alarm feature to alert you of potential power problems. Use Table 11 to determine and resolve the UPS alarms and conditions. Silencing an Audible Alarm To silence the alarm for an existing faulL, pless the (~ button. If UPS status changes, the alarm beeps, overriding the previous alarm silencing. Table 11. Troubleshooting Guide The UPS switches trequer~Uy between battery and AC input 3 I Site Wiring Fault 0 0 II 1.ow Batter~ Char§e page 1 g) U~S capacity or tho toad is delecuve Service and Support If you have any questions or problems with the UPS, call your Local Distributor or the Help Desk at one of the following telephone munbers and ask tbr a UPS technical representative. If repal~ is requl~ed, you will be given a Returned Material Authorization (RMA) Number. This number must appear on the outside of the package and un the Bill Of Lading (ff applicable). Use the original packaging or request packaging from the Help Desk or distributor. Units damaged i~a shipment as a result of improper packaging are not covered under warranty. A ~eplacement or lepah- unit will be shipped, freight prepaid for afl warrantied units. NOTE For critical applications, immediate replacement may ~e available. Call the Help Desk for the dealer or distributor nearest you Bulletin 1492 Circuit Protection Circuit Breakers Oescription Bulletin 1492 'Energy Limiting" circuit breakers am thermal magnetic type supplementary overcurrent protective device~ Bulletin t492 CB circuit breakers are available in one, bwo anb ~hree pole units ra~ed from 05 to 59 Energy Limitations 1492~:;B rs, Conventional Breakers The 1492~B line features the unique ability to achieve short circuit interruptions far more e~fectively than conventional a. pproximately one or two half cycles of (le~through-energy) of the fault current applications and sides) Sho~ Circuit Interruption 10 kA - 120 Volts AC Instant of initiation: 15° a~er voltage zero CONVENTIONAL BREAKERS ALLEN-BRADLEY 1492-CB LU LU MA~ ARC VOLTAGE \ 12-92 Allen-BradleY i'he Benefits of Limiting Let-Through-Energy (cont'd) interruptions Applications Bulletin 1492 CB ~Energy Limiting" applications Auxiliary Contacts: Refer to Specifications on page 12-96 for ratings. Each auxiliar~ contact module contains one (1) contact, either Normally Open or Normally Closed. Actuation of the contact is determined by the handle ~;len-Bradley Signal Contacts Relay Trip (Shunt-Trip): Refer to the table at the top of the next BulleUn 1492 Circuit Protection Circuit Breakers witched Neutral Module not field mountable) Switched Neutral Module (not field mountable): Reter to Specificabons on page 12-96 lot ratings This module is used to open the neutral line of the circuit as ~ result of the condition of the protected poles ~t is used as a safety measure (required by some standards) for the protection of networks with a grounded neutral system The switched neutral pole opens a~er and closes before the adjacent protected pole (i.e. early make, late breakl Automatic actuation is a result of the adjacent pole trip mechanism and manual actuation is by the linked hand,es 12-93 Bulletin 1492 Circuit Protection Circuit I~reakers How to Order 1492-CB The following information must be known to select the proper circuit breaker: What is the fulHoad amperage thai Wll~ be available in the systerrl? · Is it a 1.2, or 3 phase syslem? · What are the stad up or inrush proper ties of the load? · Will the system require additional "shaping" options? Auxiliary contacts, s~gnal contacts, etc. Afler defining these few parameters, the selection can be done by following the chad below, All options are field mountable except the Neutral switch, which come$ installed from the factory 1492 Bulletin Number Energy Limiting Circuit Breaker - CB 3 G 200 Selection Information You can order a basic one, two, or three pole circuit breaker from the following tables and add an accessory module to meet your specific application requirements _ NOO Rate6 Voltage · By Number of Trip Characteristic Poles DF, F, G, H DG, DH 480~ AC 3YIp Characteristic Code Magnetic Trip Range Switched Neutral Module Trip Current Rating Code (Standard Trip Characteristic is Typ~ G) Char. 12-94 * Prices Consult Sales office or price list Allen-BradleY Bulletin 800T NEMA Style Push Buttons 30.5mm NEMA Type 4/13. WatertlghtJOlltight 3 Position Selector Switch Units, Non-Illuminated Accessories - Page 11 Legend Plates- Page 11-46 Oimensions - Page 11-49 Operator Ogerator Standard Knob Knob Lever Metal Wing Lever Contact Position Type Note: X=Cl<~sed/O=Open Operator Operator Cylinder Lock Co~ltact Posftlon Type Lock tn Left O Lock In Center O Lock In All ~ 11-22 ~ Prices - Consult Sales Office or price list NEMA Style Push Buttons 30.gram NEMA Type 4/4X, Corrosion-Resistant Pilot Light Units Accessories - Page 11-81 Lamp Information - Page 11-90 Legend Plates - Page 11-91 Dimensions - Page tl-94 Lamp Typ~ Volts Color PI]or Light Push-To-Test Dual Input Typical Pilot Light Wiring Diagrams See applicable Co<~es and Laws Dual Input Pilot Light Typical Application Wiring Diagram 11-78 Dual Input Diode Pilot Light Device Schematic A/len-Bradley Fuse-holder M 4/8,SFLT M 4/8,SN1 M 4/8,SN terminal blocks M 4/8.SFDT M 4/8.SN2 M 4/8.SNT ~'~r 5x20GMA .t 5 x 25 fuses M 4/8.SFDT1 H~eav;~dut¥ switch I ~errninal blocks [ ~ith long blades and I removable plug Characteristics =DC Jther characteristics [ccessories M 4/6 SNB M 6/8.$NB Type Part number M 4/6,SNBTA M 6/8 UL CSA NFC-UTI M 618 color coded DIN-VDE UL CSA NFC-UTE M 6/SRTS 44 5 CSA NFC*UTE M 4/8 Terminal block compatible with fuse block M 4/8.SF DIN-VDE UL CSA id--c RH SERIES ~ [~ I~1 ~ General Purpose Relays General Purpose "Midget" Relays IOA Contact Rating *~ 1, 2, 3, & 4 Form C Contact RH Series Part List · Compact "M~dget' s~ze package saves space · Large switching capac~b/, (10A) · Choice of blade or PCB style terminals · Relay options include indicator light, check button, and top mounting bracket · DIN rail, surface panel and PCB type socAets available for a w~de range of mour~Iing applications RH2B-U RH2B-UL RH2B-ULC RH2B.UT RH4B-U SPDT RHiV2-U RH30-ULC RH3B,UT RH4B-ULC V2 OpoT i RH2V2-U (PC80078" (2mm) wide} 3PDT RH3V2-U Coil Ratings RH2V2-UL RH2V2L~ RH2V2.ULC · For RH2 relays = AC110/120V AC Ordering information Operational CharacterisUcs Contact Ratings Minimum operating voltage (A C,'OC) 0 2O=C Motor LOad Orop~out voltage (AC) 12OV AC Drop~out voltage (DC) 240V AC ~ 10% of r ate[~ vOltage UL Ratings SPDT, OPOTL 3PDT 02-3 DIN Rail Sna~Mount Seckets I~T~ ® s..~,,~ id.-.. SHIB~5 Terminal Arrangements SH1B-05C Fingersafe Style: Blade Snap-mounb'sudace mount Terminal: (Coil) M3 screws/ (Contact) M3,5 screws w/captive wire clamp, finger-safe Wire Size: Max up to 2-#12AWG Electrical Rating: 300V, IOA Compatible Relay: RH1 B, RAHB RBHB Hold-Down Spring: SY2$-02F 1 Hold-Down Clip: SFA-I01, SFA-202 -- RAIL Wire Size: Max up to 2 #12AWG Electrical Rating: 300V. 10A Hold-Down Spring: SY4S-02F1 SH2B-O5C Fingersafe Style: Blade. Snap-mount/sudace mount Wire Size: Max up to 2-#12AWG Electrical Rating: 300V, 1CA Compatible Relay: RH2B, RAMB, RBMB Hold-DOwn Sprln · SY4S-O2F1 United States: (800) 262-4332 or 1408l 747-0550, Canada: (9051890-8561 or (604) 946-1271 AC QUIET WALL SWITCHES (continued) 20/; ~gHPat 120V, 2 HP at 240V 120/277V AC BACK AND SIDE WIRED Brown Ivory White 3031-2 3031-21 3031-2W 3031-2L 3032-2 3032 gl 3032~2w 3032-2L -- 3033-2 3033-21 3033-2W 3033-2L PILOT LIGHT SWITCHES Description Single Pote Toggle Single Pole Locking Double Pole Toggle Double Pole Locking 3-Way Toggle 3-Way Locking LIGHTED HANDLE SWITCHES Clear Red Green Description 3031-PLC 3031-PLR 3031 PLG Single Pole,120v 3032-PLC 3032-PLR 3032-PLG Double Pole,120~ Ivory Clear Description 3031-LHI 3031-LHC Single Pole,120v HIGH-QUALITY, LONG-LIFE SWITCHES · Quiet, reliable mechanical action · Captive mounting screws for fast installation · Large-head terminal screws backed out and staked for fast wiring of up to No 10 copper/copper-clad wire · Grounding screw available (except where noted) · Heaw gauge ~st-resistant steel mounting strap gomnTE/ff. L · Back wiring clamps accept up to NO,10 copper or copper-clad wire · Convenient break off plaster ears for besl alignment · Large silver-cadmium oxide contacts for maximum conductivity · 12 AWG pigtail leads on selected redders speed installation in many applications · Backed by & Limited Ten-Year Warranty 120/277V AC ~'~ 1/2HP at 120V, 2 HP at 240V BACK AND SIDE WIRED Brown Ivory White CSB2-15 CSB2-151 CSB2-15W CSB3-15 CSB3-151 CSB3-15W CSB4-15 CSB4 15i CSB4 15W Description Former Cat. No. Single Pole Toggle 53501 Double Pole Toggle 53502 3 Way Toggle 53503 4oWay Toggle 53504 CSB%15 Pigtail devices appear on page C4 Cat No CS115-2 GFCI PERSONNEL PROTECTION DEVICES All devices are UL Listed Aisc CSA Certified except where indicated by HOSPITAL GRADE GFCI RECEPTACLES - Back and Side Wired 15A 125V at receptacle; 20A 125V feed*through Brown Ivory White Gray Red Description 6598-HG 6598 HGI 6598 HGW 6598-HGG 6598 HGR Duplex Receplacle with LED Indicalor Ught 20A 125V AC at receptacle and teed-through 6898-HG 6898-HG~ 6898 HGW 6898-H60 6898-HGR Duplex Receptacle with LED Indicator Light COMMERCIAL GRADE GFCI RECEPTACLES - Back and Side Wired 15A 125V Brown Ivory White Gray Red Black Almond Description 6598 6598 I B598-W Duplex Receptacle with Indicator LJghl 6599 6599 I 6599 W 6599 GY 6599 R 6599E 6599 A No Indicator Light 8599 L 8599-LI 6599-LW -- -- With 4 1/2 in. Leads g0A 125V AC at receptacle and feed-through NEMA S-gOR (r~DO[~ 6898 6898-1 6898-W -- Duplex Receptacle with LED Indicator * Light 6899 6899-1 6899 W 6899-GY -- -- No Indicator L~ght * SWITCH-RATED GFCI - Sack and Side-Wired 20A 125V AC Switch-Rated: Switch Rating 1.5 H,P, @ 120V Brown Ivory White Gray alack Description 6490-1 6490 W 6490-E Blank Face GFCI, no Indicator bght HIGH CURRENT GFCI - Back and Side Wired · Adds ground f~u~t protection to heavy · Test and Reset buttons confi(m proper operation equipment powered through 3 and 4 wire · Ideal for use with spas heater packs, high circuits with grounded neutral pressure washers industriar mixers and Other · Contact rating at GF. CI: 20A 125V;Joad capability equipment with three-phase motors with 125V control relay 50A L~2ziOV max. · UL Recognized Component File No E-48380' All devices are UL Listed and GSA Certified Ivory White Black Description 6895 I 6895-W 6895 E High Current G?CI Cat No 6599 Cat No 6895 INTERNATIONAL+ LINEARS FEATURES: DC Output: Line Regulation: L~ad Regulation: Output Ripple: SPECIFICATIONS: AC I~lput: 10(~, 120 and 240 V,a~: + 10%. 13%; 215 V~: Ove~oltage LOgic Inhibit: Automatic current limit / foldback 2311 StathamParkwa¥,Oxnard, CA93~33 * (8051486~565 * 1800)235'59L~ ' FA.X:(805) 487-8911 · ht~p#w~wcondorpov~rcorW~condordc 24 INTERNATIONAL + LINEARS SINGLE OUTPUT , DUAL OUTPUT ~O/~I~Ot~ OC Power Su~plies I~ CONDOR INTERNATIONAL + SERIES INSTALLATION INSTRUCTIONS RATINGS CPI97-A+ .... ~4~---15VSOAcderatet°44AatSo°c) 135~t'm J 5 1,3,s I ~e ~&, (deratc to 10A at 50oC) or 28V 10A (derate to 8 6A at 50oC) IF48-6-A -- ~48\ 6A (derate ~o 5A at 50°C/ 14 cf rtl 14 cfi= SAFETY DECLARATION: Condor DC ?~wcr Supplies, Inc. declares under our sole responsibflit,/mat ali AC INPUT HOOKUP INSTRUCTIONS o Catalog Nos. 51020 and 51240 Wired-Module Surge Protective Devices diagnostics for visual display of These sedes operated devices will LE~TTZTn General Data Cat NO. Rated Line Voltage (VRMS) MCOV 51020-WM 120V AC f2O Amps max Io~d/ $35V 51020 DIN 5!2,10 WM 240v A(i 120 Amps max Imadl 270V Performance Specifications i Specification 51020-WM 51240-WM Range 5102(~DIN 51240-DIN L-N 26kA L L 26kA L G: 26kA L-G: 26k~ L N 300J LL $40J I -O 320J L-G: 5603 40 Ia 50 Normal ano Common Mode 50 60Hz 50,60Hz Dimensional Drawings 51240-WM L L:565V L G:600V L-L:600V L G600V Clamping Performance Specification 51020-WM 51020-0~N Cat B3 combination L N: 300V wave (8x20ps) peak L-G: 350V Camping voltage UL 1449 ratings L N: 330V L-G: 400V Fault current rating Physical Specifications Agency Approvals Nos 5i02G C/M, 5~240 WM, 51020-DIN and 51240 DIN Cat NOS 51020-DIN and 51240-DIN Orl~y Isolating Transformers With Electrostatic Shield Single Phase Type GP-I 60 Hertz No Taps 115° C. Ri~e Class 180 Catalog Number Suffix for Voltages Rating of Basic 120x240V 208V 277V 480V 600V KVA Catalog to to to to to List Rating Number 120/240V 120/240V 120/240V 170/240V 120/240V Price TO [ ×C-I I I OES [J J 1,080 Isolating Transformers With Electrostatic Shield Single Phase Type GP-I 60 Hertz IS0 C, Rise Class 220 UVith 2-2Vz% FCAN and 4-2'/~% FCBN Taps Catalog Number Suffix for Voltages Rating of Basic 208V 2¢0V 277V 480V 600V KVA Catalog to to to to to List Rating Number 120/240V 120/240V 120/240V 120/240V 120/240V Price TIERNI~:y ELECTRICAL MANUFACTURING CO ~oI~ oP GENERAL PURPOSE 600V and Below Dimensions and Weights for Type GP-1 Indoor Single Phase Transformers 60 Hertz 115~ C. Rise Mounting Enclosure Features ! Phase I AI0proxin~ate Overall I Mounting Dimensions I ~oprox. Rating Height ~dth Depth A B C i in lbs. SERIES INDUSTRIAL TRANSMITTERS DESCRIPTION Noshok 700 Series Industrial Transmitters are the ideal choice for process industries and applications where high reliability and high performance are required These transmitters ~Jt~lize ceramic cagactiive sensor technology that provides extremely tow hysteresis and high repeatability. The ceramic sensors also give the ?00 Sedes the ability to achieve this high degree of performance over a ve~/broad temperature range. These features, combined with 5 to 1 Turndown Capabiliiy and RFI protection, make the 700 Sedes, Model 705 Industnal Transmitter an excellent value. MODEL 705 SPECIFICATIONS DIMENSIONS INDUSTRIAL TRANSMITTERS SERIES 700 WIRING DIAGRAMS AND ELECTRICAL CONNECTIONS ORDERING INFORMATION $~RIES 700 - MODEL ;'05 EXAMPLE ?05 30 1 0 Pressure Range 0-30 PSi Seal Material VITON(I/ ~ OASHCROFT · O~en-front case style, black epoxy- The Ashcrof~ Type 1010 g&uge is Ihe mo51 economical of the general sewce industrial gauges having 1% accuracy T~e 1010 also is the only Ashcroft gauge available in sizes up to 12- in diameter. General Service Gauge Type 1010, Grade lA (1.0% F.S.) 2"-20" ELECTRONIC MAIN LINE METERS MODELS ML-O4-D, ML-OG-D, ML-12-D, ML-16-D, ML-20-D, ML-22-D, ML-I1-D OPERATION AND MAINTENANCE MANUAL PARTS LIST FEATURING: *MODEL CN-OG-2 DIGITAL INDICATOR-TOTALIZER 'CERANIlC REARING CARTRIDGE PROPELLER ONE PIECE GEPARATORISPINDLE AND THREADED REVERSE THRUST SEARING CARTRIDGE 3255 WEST STETSON AVENUE HEMET, CALIFORNIA 92545 7799 U.S.A. PHONE: 909-652-6811 FAX: 909-662-3078 VISIT OUR WEB$ITE: ww~v.mccr ometer.com E-MAIL: infoL~mccrometer, com WARRANTY This Warranty shall apply to and he limited te the original purchaser consumer of any McCrometer produot. Meters or instruments defective because of faulty material or workmanship will be repaired or replaced, at the option of McCremeter, free of charge, FOB the factory in Homer, California, within a period of one (1} year from the date of delivery. Repairs or modifications by others than McCrometer or their authorized representatives shall render this Warranty null and void in the event that factory examination reveals that suoh repair or medifioation was detrimental to the meter ar instrument. Any deviations from the factory calibration require notification in writing to McCrometer of such recalibrations or this Warranty shag be voided. In case of a claim under this Warranty, the claimant is instructed to contact McCrometer, 3255 W. Stetson Ave., Hornet, California 92545, and to provide an identification or description of the meter or instrument, the date of delivery, and the nature of the problem. The Warranty provided above is the only Warranty made by McCrometer with respect to its products or any parts thereof and is made expressly in lieu of any other warranties, by course of dealing, usages of trade or otherwise, expressed or implied, including hut not limited to any implied warranties of fitness for any particular purpose or of merchantability under tho uniform commercial code. It is agreed this Warranty is in lieu of and buyer hereby waives all other warranties, guarantees or liabilities arising by law or otherwise. Seller shall not incur any other obligations or liabilities or be liable to buyer, or any customer of buyer for any anticipated or lost profits, incidental or consequential damages, or any other losses or expenses incurred by reason of the purchase, installation, repair, use or misuse by buyer or third parties of its products (includ- ing any parts repaired or replaced); and seller does not authorize any person to assume for seller any other liability in connection with the produots or parts thereof. This Warranty cannot be extended, altered or varied except by a written instrument signed by seller and buyer. This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state. McCrometer reserves the right to make improvements and repairs on product components which are beyond the Warranty period at the manufacturer's option and expanse, without obligation to renew the expired Warranty on the components or on the entire unit. Due to the rapid advance- ment of meter design technology, McCrometer reserves the right to make improvements in design and material without prior notice to the trade. All sales and all agreements in relation to sales shall be deemed made at the manufacturer's place of business in Hamer, California and any dispute arising from any sale or agreement shall be interpreted undar the laws of the State of California. ELECTRONIC MAIN LINE METER INDEX I. UNCRATING II. INSTALLATION 1. Flanged Tube Meters 2. Plain End Tube Meters 3. Welding Saddle Meters A. Align B. Scribe C. Cut Out D, Straightening Vanes aJ Hold b.} Mark c.) Insert E. Welding Saddle TO Pipe F. Meter Assembly III. OPERATION AND MAINTENANCE MANUAL IV. METER HEAD ASSEMBLY V. WORKING AREA VI. DISASSEMBLY & INSPECTION 1. Propeger Removal ReverseThrust Bearing Cartridge 3. Water Lubrication 4. Ceramic Gearing Cartridge 5. Spindle Ceramic Sleeve 6. SeparaterIGupport Sp[ndleAssembly VII. REASSEMBLING METER 1. Propeller Installation Z. Thrust Bearing CartridgeAssembly 3. Propeller Gearing VIII. SENSOR & CN-Ge-2 DIGITAL INDICATOR- TOTALIZER Y. CN-Be-2 I]igitatlndicator 2. CN.08.2 3, Sensor Housing METER 2. CN.08.2 ELECTRONIC MAIN LINE METER INSTALLATION UNCRATING. When uncrating the meter, any damage du to rough er improger bundling should he reported tn the transportation firm and McCrnmeter. Il for any reason, it is determined that the unit or parts of the unit should be re- turned to the factory, please contact McCrometer for clear- ance prior to shipment. Each unit must be properly orated to prevent any further damage. The factory assumes no responsibility for equipment damage in return shipment due to improper packaging. The shipping crate contains the following items: Main Line Meter Assembly with CN082 .................................................................... 1 Mounting Equipment as required ............................. - Operation and Maintenance Manual ....................... 1 Tool T-Z402X 1 ........................................................ 1 INSTALLATION of McCrometer Main Line Meters varies depending upon the type and model of meter selected for each application. The meter must hera a full flow of liquid for proper accuracy. The meter installations fall into three basic categories: 1. FLANGED TUBE METERS can he installed exactly as you would install any short length of flanged pipe. Flanged ends are staodard pattern and drilling for any meter size. Fully opened gate valves, fittings or other obstructions that tend to set up flow disturbances should be a minimum of five pipe diameters upstream and one pipe diameter down- stream from the meter. 2. PLAIN END TUBE METERS can be installed similar to replacing a short length of plain end pipe in the line by either welding, or by using one of a variety of pipe couplings avagable. NOTE: Meter head assembly 1#13) should be removed before welding (see step IV). Fully opened gate valves, Ettings or ether obstructions that tend to set up flow disturbances should be a minimum of five pipe diameters upstream and one pipe diameter downstream from the meter. 3. WELDING SADDLE METERS can be installed on an existing pipeline by cutting a hole of proper size and welding e meter saddle )furnished with the meter) tn the pipe The installation steps outlined below should be followed care- fully to achieve proper mounting of the meter: A. ALIGN the cutout template in the desired position for the meter on the pipe, Make certain that the center line of the piqe and the center line marked on the template are parallel with each other. Some people prefer to use the saddle as the template. B. SCRIBE the pipe along the line specified for your meter size cutoul. C. CUT OUT the section of pipe within the scribed line and remove all burrs, slag, and rough edges from the inside and outside of the cutout section. STRAIGHTENING VANES are recommended when there is less than ten pipe diameters of straight prpe (rio fllRegs ar head assembly (#131 should he removed before welding III. MCCROMETER products have been carefully designed to de as maintenance free as possible, Periodic preventive main tenance, however, is highly recommended and should be NOTE: METER DISPLAY WILL SHUT OFF AFTER A FEW MINUTES WITH THE LID OPEN. TO READ METER, CLOSE LID AND OPEN IT AGAIN. all meters, which includes: Cleaning and an inspection of the propeller and its bearing, The intervals between inspections depends on the water quality and the usage of the meter. The initial inspection should be performed after between future inspections. After five to ten years, the IV. METER HEAD ASSEMBLY ~13) should be removed from the gervice line by removing the meter head bolts (#44) and liftio9 up the rear (downstream) portion of the meter head (#13) carefully pulling the assembly back (downstream) and up at the same time to allow the propeller 1#31) to clear the inside of the meter saddle and be lifted free. inspect the meter head O-ring (#43) for any sign of damage and replace if necessary. Replace the meter assembly (#13) with a dummy cover plate if the service line is to remain in opera- the meter head belts 1#44). b) Lift the meter assembly and tgt it forward, cl Slide the assembly back out of the saddle opening. The propeller may have to be rotated in order to fit through the saddle opening. V. WORKING AREA chosen for disassembly and reassembly of of dust or dirt particles being introduced into the propeller VI. DISASSEMBLY AND INSPECTION OF METES includes cleaning the propeller assembly 1#30), ceramic sleeve hear- ing I#g21, separator assembly (#181, and drive magnet 1#34). 1. PROPELLER REMOVAL can be accomplishee by first removing the thrust bearing cartridge assembly (#41). Loosen the set screw (#4H) in the side of the nDSe gl the propeller. Remove the thrust bearing carlridga {#41) hy turnlfig it ceunterclochw[se while holding the propeller in place. 2. REVERSE THRUST BEARING CARTRIDGE i~'37) must now be removed. Tu[n the propeger {#30) so that the allen wrench clearance hole is lined up with the set screw q#3g) in the side of the reverse thrust bearing cartridge (#37), The 5/64 inch allen wrench, loosen the set sc[ew 1#38) in the bearing cartridge {//371 from the spindle (#181. The propeller 4. CERAMIC BEARING CARTRIDGE ~32) and drive mag- net {//34) should be cleaned df any foreign mater~al and in ceramic bearing surface (//32) and lbe magnet inside diameter separator/support spindle assembly (//18) can then be re- tighten the four mounting screws {#21). 30119-05 IM-MUlD-3A-0501 the thread+ Be careful not to cross thread the reverse thru~ gearbox (#17). adjust the amount of longitudinal end play of the propeller inch. End play can be agjusted after the set screw (//40) in gearbox 4#171. The clearance should be minimal and the 3. PROPELLER BEARING ~32) can be checked for ex- 3. SENSOR ROUSING should he removed only if replace 30119-05 ~.. BEFORE REPLACING THE SENSOR be sure the separator is dry. Slide sensor housing and wire assembly into the separator until it stops against the inside positioned toward back Iopen endl of separator. Tighten the in place. DO NOT OVERTIGHTEN. Feed the sensor wire up S. 3-VOLT LITHIUM BATTERY (~6} should offer an battery display that comes on when approximately six months should test between 2.5 and 3 volts to be considered good. a} Remove bonnet base cup (#8} from bonnet by prying up bonnet (#1) and lifting out the ON-OS 2 assembly (#4). les with positive (+) and negative (.) positioned as noted on circuit card. e) Reinsert CN 08 2 assembly (#4l fntn bonnet assembly (#1) with top of dial aligned with hinge side of bonnet. f) Install bonnet O-ring 1#21 in bonnet with coating of IX. PRIOR TO INSTALLING METER 1. PRDPELLER ASSEMBLY (#30) should be dipped in water to lubricate the propeller ceramic sleeve bearing (#32). Spin the propeller t#S1) gently te make certain the meter 2. CN-08-2 b~4) and sensor (#26) should be checked to be ORDERING PARTS OR RETURN TO FACTORY Inspection of all meter components that may be replaced in the field has been accomplished at this point. Should any of the meter parts, upon inspection, appear to be damaged or excessively worn they must be replaced to assure proper meter operation and prevent further damage. Cost tot re placement paris not covered by warranty are available by contacting the factory. If it is determined that the meter should be returned for repair, please notit¥ McCrometer prior to shipment, Each meter must be properly packaged to prevent damage to the meter in shipment. MAIN LINE METER INSTALLATION INSTRUCTIONS FLOW Set meter assembly on saddle as shown with one propeller blade pointing down. Propeller should point opposite the direction of flow. FLOW 2. TilUhe meter head assembly forward allowing the propeller to move through the opening. 3. Slide the assembly forward and down. The propel- ler may have 1o be rotated in order to fit through the saddle opening. Allow the meter head assembly to come to rest on the saddle. Install bolts and tighten to proper "~orque. ~119-05 IM-MLIID'3A'0501 2"-20" ELECTRONIC MAIN LINE METERS MODELS ML-O4-D, ML.OS-D, ML-12-D, ML-16-D, ML-20-D, ML-22-D, ML.II-D PARTS LIST No. QTY Part Number Description none I 7-CN08-2-R ~d~~.9) I I 3-4317-2-D Digital Indlcator-Totallzer Bonnet Lid (with pin) 8 I 1-4318-5 17 I 2-2238-* Gearbox 26 1 32 I 2-2426-P-1 Ceramic Bearing Cartridge 34 I 2-1601.2 - 38 I 1-1101-8-5 SetScrew Reverse Thrust Bearin 40 I 1-1125-6 Set Screw N ion Point 42 2 1-1510-1 Ceramic Thrust Bearing, 1/4" Diameter (each) 44 8 1-1251-8-24 Bolt Meter Head (each) none I 1-1607-6 Desiccant Bag * INSERT METER SIZE TO COMPLETE PART NUMBER- FOR EXAMPLE: ** USE 4" WHEN ORDERING SIZES 2" THRU 4" ~ CONSULT FACTORY TO COMPLETE PART NUMBER CONSULT FACTORY FOR PRICES 2"-20" ELECTRONIC MAIN LINE METERS MODELS ML-O4-D, ML-OB-D, ML-12-D, ML-16-D, ML-20-D, ML*22-D, ML-I1-D *MODEL CN-DB-2 DIGITAL INDICATOR-TOTALIZER ASSEMBLY *CERAMIC BEARING CARTRIDGE PROPELLER *ONE PIECE SEPARATOR/SPINDLE AND THREADED REVERSE THRUST BEARING CARTRIDGE 30119-41 IM-TR28-2-1 C-0801 DIGITAL INDICATOR-TOTALIZER TRANSMITTER MODEL TR-28-2 OPERATION AND MAINTENANCE MANUAL PARTS LIST FEATURING: 'MODEL CN-08-2 DIGITAL INDICATOR-TOTALIZEO 'ENCAPSULATED ELECTRONICS "SOLID STATE CONSTRUCTION 'CURRENT OUTPUT SIGNAL *PULSE OUTPUT SIGNAL *SEALED DOUSING 3255 WEST STETSON AVENUE NEMET, CALIFORNIA 92545-7799 U.S.~. PHONE: 909-66Z-6811 FAX: 909-652-3978 VISIT OOS WEBS]TE: www. mccrometer.core E.MAIL: info~mcel~meter.eom WARRANTY This Warranty shall apply to and be limited to the original purchaser consumer of any McCrometer product. Meters or instruments defective because of faulty material or workmanship will be repaired or replaced, at the option of McCrometer, free of charge, FOB the factory in Hornet, California, within a period of one {1) year from the date of delivery. Repairs or modifications by ethers than McCrometer or their authorized representatives shall render this Warranty null and void in the event that factory examination reveals that such repair or modification was detrimental to the meter or instrument. Any deviations from the factory calibration require notification in writing to McCrometer of such recalibrations or this Warranty shall be voided. In case of a claim under this Warranty, the claimant is instructed to contact McCrometer, 3255 W. Stetson Ave., Hornet, California 92545, and to provide an identification or description of the meter or instrument, the date of delivery, and the nature of the problem. The Warranty provided above is the only Warranty made by McCrometer with respect to its products or any parts thereof and is made expressly in lieu of any other warranties, by course of dealing, usages of trade or otherwise, expressed or implied, including but not limited to any implied warranties of fitness for any particular purpose or of merchantability under the uniform commercial code. It is agreed this Warranty is in lieu of and buyer hereby waives all other warranties, guarantees or liabilities arising by law or otherwise. Seller shall not incur any other obligations or liabilities or be liable to buyer, or any customer of buyer for any anticipated or lost profits, incidental or consequential damages, or any other losses or expenses incurred by reason of the purchase, installation, repair, use or misuse by buyer or third parties of its products (includ- ing any parts repaired or replaced); and seller does not authorize any person to assume for seller any other liability in connection with the products or parts thereof. This Warranty cannot be extended, altered or varied except by a written instrument signed by seller and buyer. This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state. McCrometer reserves the right to make improvements and repairs on product components which are beyond the Warranty period at the manufacturer's option and expense, without obligation to renew the expired Warranty on the components or on the entire unit. Due to the rapid advance- ment of meter design technology, McCrometer reserves the right to make improvements in design and material without prior notice to the trade. All sales and all agreements in relation to sales shall be deemed made at the manufacturer's place ef business Jn Hemet, California and any dispute arising from any sale or agreement shell be interpreted under the laws of the State of California. INDEX I. DESCRIPTION II. SPECIFICATIONS IlL UNPACKING IV. INSTALLATION V. METERS Z, Clean Meter Head VII. PRINCIPALS OF OPERATION VIII, SENSOR and TR-26-2 DIGITAL INDICATOR-TOTALIZER.TRANSMITFER 3. Sensor Assembly IX, TROUBLE-RHOOTING 3. TR.28.2 Oigitbl Transmitter X. iNSPECTION 2. Check Your Instrument 7. Separation of Signal and Power I. DESCRIPTION: The Model TR-28-2 Digital Indicator Totalizer Transmitter provides flow rate indication, totalization of flow volume and a current output blgnai proportional to the rate of flow when mounted on our meters. The TH-28-2 is for installation on propeller meters. II. SPECIFICATIONS: ]0. UNPACKING. When unpeshin9 the transmitter, any damage due to rough or improper handling shenld be reported to the transportation firm and McCrometer. If for any reason, it is determined that the unit or Model TS-28.2 1 Mounting Sase O-ring 1 Meunfing Sase (wlhardwme) 1 3. TRANSMITTER MOUNTING BASE (//10) and 4. POSITION OF INDICATOR-TOTALIZER 30119-41 IM-TR28-2-1C-0801 5. TRANSMITTER WIRING can be accompilohed by following the wiring diagram on page 8, 1 § or I T. TRANSMITTER OPERATION AND MAIUTEUAUCE MANUAL VI. MCCROMETER products have been carelully de. signed to be as maintenance tree as possible. Pe- riodic preventive maintenance, however, is highly rec- ommended and should be practiced according fo and inspection procedure can also ge used as a gulge NOTE: METER DISPLAY WILL SHUT OFF AFTER A FEW MINUTES WiTH THE LID OPEN. TO READ METER, CLOSE LID AND OPEN IT AGAIN. VII, PRINCIPALS OF OPERATION 1. The Model TR-28-2 hes four separate functions: 1. A 4-20 mA output signal operated through the 24 VDC loop power from the instrument. 2. Digital display rate of flow going through the meter. 3. D[gGal display of total Sow that has gone through the nmter from when first installed. 4. Scaled Pulse output of one pulse per total- 2. A bauer./al built into the Model TR.28.2 as a back up for the rate and totather only in case of a power failure. It should he understood how this back up battery operates when the 24 VDC loop power is off: 1. The 4-20 mA signal stops. 2. The diE'tat rate and totalizer dispJay stays on until it goes into pmgrmnmed sleep mede. (See PrograrmT~g Guide literature #1C.CR08.2.) 3. Because the unit bas a built in EEPROM memory, the tot alizer will still be storing total- $. When the power comes back on, the Model TR. 28-2 will: 2. It will display flow fate on the Model TR- 28 2 when lld is opened. 3. It has been storing all quantity going through the meter and wilt dloplay ~otalizer by opening lid. VIII. SENSOR AND TR.28-2 DIGITAL INDICATOR. TOTALIZER-TRANSMITTER 1, TR-28,2 DIGITAL TRANSMITTER ~4) should not he removed from the meter unless battery or sensor replacement is required or if the unit is to be reprogrammed. If the unit must be removed, pro coed as follows: Z. TR-ZS-Z {~4) can be removed from the trans- mitter mounting base (#10~ by removing the four bonnet mounting screws (#3). 30119-41 IM-TR2R~2-1C-0801 REPROGRAMMING: The bonnet can be lifted enough to slide the base cup and digital transmitter out of the bonnet allowing access to the grngram- ming buttons. Ieee Programming Guide literature #1C.CN08-2.) 3. SENSOR ASSEMBLY in fBe meter can be replaced by fogowing the meter instruction manual. 4. GATPERY REPLACEMERT ~/g}: Tim 3 Ynll Lithium Battery is used as a backup fo the 24 VDC loop power. In the event of a power loss, the battery will continue to operate tim rate and total functions of the TR.28.2. The 'low battery' in,ica. finn wig show approximately $ months prior to expi- ration. A. The banner (#1) can be lifted meugh fo access the terminahi connected tn sensor input and transmitter pulse/mA output. B. Garefully disconnect the wires from the transmittw. The unit can then be turned over and the batter/can be accessed through tim opening in the bottom of the base cup. Be sma to install the new batter/with the posilive ~+) and negctive (-) tenninahi positioned properly. C. Reconnect tim wires fo the transmitter. ~Bee ppge 9.) O. Reinsert the TR28-2 {#41 into the bonnet assembly 1#1) with tim top of dial aRgned with the hinge side of the bonnaL E. install the bonnet Q.ring (~2) into bonnet with a coating of silicone grease. NOTE: Batteries should be disposed of in an environmentally sound manner. IX. TROUBLE-GROOTINR the fransmitter is necessary if it is apparent that the instrument being controlled by the transmitter is not receiving a proper sloual from the transmitte~, andlor the tctsiiser or indica- tor-totagzer is nut functioning. Before beginning, it is important to be sure that the probben is with the transmitter. Tim thlinwing checbs should be made: 1} Check to be sure that water is finwing through the meter at flows above the minimum flow rate for the given size meter. 2) Check the instrument to be sure it has the re- quired power being supplied to it. 3) Check the junction box lo be sure the commu- nication lines from the transmitter to tim instrument wired properly to the instrument {see wiring diagrams on page 8, 10 or I1). 1. THE TROUBLE-SHOOTING GUIDEis proinded to help isohite any problem that may occur with the dures gered for each problem. meter}. receiving proper signal), and if the 24 VDC loop power to the Model TR-28-2. is now on, then use trouble-shooting procedures 2. 3, 5, 6, X, xr and Xll. 9, If the meter indicator-totagzef and remnle instrument do not operate, check the TR 28-2 by opening and closing the lid twice. If ne response, then follow all procedures. 2. WORKING AREA chosen for testing and in- spection of the internal components should be clean to reduce the chance of dust or dirt particles being introduced into the transmitter mechanism. 3. TR-28-2 DIGITAL TRANSMITTER must be removed from the mounting base (#10) to pain ac- cess to the transmitter terminals and to check con. n~ctions. Remove the unit from the mounting base following instructions in section VIII. Check the connection from the sensor in the mater to the ter- minals in the bottom of the TR-ZG-G. Check the connection Irom the pulse and mA terminals on tbe TR.28-2 to the instrument. Make sure the connec. tion is clean, tight, and the terminal is secure. 4. MOISTURE simukl not be apparent within the transmitter bonnet (#1). All O.rings should be in- spected for breaks or presence of foreign materials lhat allow leakage to occur. Check to be sure water is not coming up through the meter head. If water is coming up through the meter head then the meter should be checked (see meter service manual}. 5. TRANSMITTER COMMUNICATION LINES (//13) should be checked to detennirw the current level flowing in the loop. The method al measure. ment is to insert a multlmeter into the 4-20 mA loop by disconnecting one of the ~ signal wires, clip* ping one side of multimeter to disconnected wire and A. ]f the current level in the loop is 0.0 mA, supply level (± 1.0 VDCL B. If the level of current is greater than 2D mA, there are two possibilities. The TR-28-2 may be starting to loll, but unless there has been some major damage done to the unit (physical impact or voltage levels above 50 VUC applied(, it should not exceed 21.00 mA. High loop current can a~so be caused by a short in the transmitter hookup cable. A zero Ohm short will cause power supply fuse tn blow. However, it is possible to have a shunt of about 0.SW 1o Connecting transmitter lines, which will CaUSe exces sire loop current with transmitter in system (from 70.0 · 350 mA or more} but when TR-28-2 is tested separately it works fine. These shorts are difficult to find. They can be caused by incorrect wiring insthNatiofl or damage to wiring. Damage can be caused by physical contact (hack hoe, etc.) or from environmental effects (water in the raceways(. C. If transmitter output remains at 4.0 mA even when the meter and sensor are operating prod- eHy, the TR.28-2 must be replaced. If the loop current is within a satisfactory range, 3.90 mA te 21.00 mA, and varies with a the unit can be programmed with different thtalizeL rate sca~e, zero mA value and full scale mA value. ISee Programming Guide IGerature #1C-CH08-2.) X. INSPECTION and field testing has been accom plished at this point. Should any of the parts upon inspection appear to be damaged, they must be re. placed to assure proper operation and prevent fur- ther damage. XL REASSEMDLY ni necessary at this point. Before reassml~ling, make certain that the unit is cleaned of any dust or dirt. Cost for replacement parts not factory. BEFORE RETURHING TRANSMITTER TO FAC- TORY please notify McCrometer. Each unit must be properly packaged to prevent damage to the product during shipment. Should any of the unit*s pa~ts, further damage. Cost for replacement parts not and price list. Should the unit require further inspec- tion, it must he reassembled and returned tn the factory. XIL PROCEDURES FOR CHECKING OUT INOPERATIVE INSTRUMENT SYSTEMS: ter that wig be operating it. When an instrtmlent I. CHECK ALL INSTRUMENTS ANO TRANS- MITTERS for obvious visual damage. Mahe certain 3011941 IM-TR28-2~1C-0801 any necessary grounding has been made. g. CHECK YOUR INSTRUMENT tu be sure it is 3,00g OPM. from 20 mA. 30119-41 IM-TR28-2-1c-oeu1 by using a digital multimeter. Have lhe mutiJmeter set 1o measure milliamps. With no water flnwing through the meter the ammeter should measure 4.0 mA. If water is flowing through the meter the current level should he between 4 to 20 mA, NOTE: A.C. power should be removed from circuit hefore inserting the mulUmete[. The mul§meter must be connected in series with circuit being lesled. 5. TRANSMITTER COMMONICATIOIM LIOES (//13) should be checked to determine if the pulse output is preset. WARNING: A.C. power should be disconnected to the instrm~ent prior to any work taking place on the A. The preferred method of checking the pulse output is to use a McCrometer Model IN-15 attached to the pulse output of the TR-28-2. The McCrometer IN-16 will count each time the transmitter sends a B. A voltmeter can also be used to check the pulse output. Using a voltmeter, on 0 to 5 VOC scale, measure vohage between the two puine out- put wires when the totatlzer count changes. It will display a pulse votiape every time the tot altier counts Ithe voltaOe displayed will depend on how quickly at the junction box, then the problem is with the radio frequency inteHerence {RFI) on the operation of the instrument. Otherwise, if high level, short guratinn, heine spikes are permitted to enter the gigital equipmmlt, the noise can be transferred into the systems ingle networks and can be misinter- preted as signal data, resulting in erroneous system operation and other unpredictable responses. Poten Solenoids AC power wires 30119-41 IM-TR28-2-1C~801 PULSE OUTPUT WIRING WHEN USED WITH MODEL IN-16 MODELIN-1D REMOTE TOTALIZER WHITE(+) BLACK~-) JUNCTION BOX RESET WIRE (IF DESIRED) (SEE IN.16 DATA SHEET) WHITE)+) 8LAC K (q Isolated Pulse Output L~ft Pin ~ht I~ White (+) MODEL TR-28-2 PULSE OUTPUT WIRING WHEN USED WITH AUXILIARY EOUIPMENT AUXILIANY EOUIPMENT WHITE(+) BLACK(-) JUNCTION BOX Isolated Pulse Output L~ Pin Right Pin Black (-) White (+) MODEL TR-28-2 30119-41 IM-TR28-2-1 C-0801 MODEL TR-28-2 INDICATOR - TOTALIZER - TRANSMIttER · SOLID STATE CONSTRUCTION · CURRENT OUTPUT · PULSE OUTPUT SIGNAL · ONE PULSE PER TOTALIZER COUNT · DIGITAL DISPLAYS TR-2~-2 SIDE VIEW BLACK (-) AND WHITE (:) FOR PULSE OUTPUT (ONE CONTACT PER TOTALET. ER COUNT) NOTES: 4-20mA Output Left Pin Right Pin Green(-) Red{+) Left Pin Right Pin Red(+) Black(.) IsolatEd Pulse Output Left Pin Right Pin Black(-) White(+) (not used) 30119-41 IM-TR28-2-1C-0801 TR-28.2 TRANSMITTER (4-20 mA OUTPUll WIRED TO A MODEL IN-80 ANALOG OUT INPUT RESET INPUT GROUND 1Z VOLT OUT DC POWER IN Left Pin IOTE: TRANSMITTER CABLE SHIELD TO GROUND. TERMINAL STRIP 110VAC160 HZ TO INSTRUMENT GREEN TGANDMITI'ER POWER [24 VDC) 4~20 mA Output Left Pin Green(.) Red(+) IN-48 TERMINAL STRIP 4~2o~ JUMPER ~y~- 250 OHM RESISTOR NOTE: TRANSMITTER CABLE GREEN SHIELD TO GROUND1 TD-28-2 TRAHSMITTER 14-20 mA OUTPUT) WIRED TO A MODEL IH 41 10" CHART RECORDER RECORDER TB-Z 24 '/DC POWER SUPPLY V+ V- ' I 4-20 mA Output Left Pin Bt Pin GREEN RED TRANSMITTER POWER (24 VDC) Isolated Pulse Output Left Pin Right Pin Black (-) White (+) NOTE TRAHSMII'rER CABI SHIELD TO GROUND. J2 PLUG 4-20 mA Output Left Pin Right Pin Green(.) Red(+) Isolated Pulse Output SHIELD '~O GROUND. 30119-41 IM-TR28-2-1C-0801 DIGITAL INDICATOR- TOTALIZER - TRANSMI"I-I'ER MODEL TR-28-2 PARTS LIST No. QTY Part Number Description 2 I 1-1551-38 O-ring, Digital Indlcator-Totalizer Bonnet 4 I 5-TR28-2 Digital Indicator-Totalizer Assembly (Items 5 to 9) 6 4 1-1783-8 Battery (each) 9 I 1-1551-17 O-rin~, Base Cup 11 4 1-1115-10-10B Screw, Bonnet Mounting(each) 13 I 3-1701-4 Cable Assembly, 4 lead When ordering replacement parts, please specify: * Meter Size * Meter Model · Meter Serial Number Contact Factory For Pricing. 30119-41 IM-TR28-2-1C~801 DIGITAL INDICATOR- TOTALIZER - TRANSMITTER MODEL TR-28-2 FOR ELECTRONIC PROPELLER METERS EMTRAC® OPERATIONS MANUAL Streaming Current Controller with DuraTracTM Remote Sensor SCC 3000 XR Revised 1/01 Chemtrac® Systems, Inc. 6991 Peachtree Industrial Blvd. · Bldg 600 Norcross, GA 30092 (800) 442-8722 PII (770) 449-6233 FX (770) 447-{)889 chemtrac(~.~chemtrac.com o www.chemtrac.com TABLE OF CONTENTS I SAFETY PRECAUTIONS & WARRANTY INFORMATION Page 03 1.0 GENERAL INFORMATION Page 04 l.l Description o f Operation ......................................... 04 1.2 Selecting Proper Sample Point .........................................05 Figure 1 .............................................................. 06 1.3 Process Control Procedures ......................................... 07 1.4 General Specifications .................................................. 08 2.0 INSTALLATION Page 09 2.1 Sensor .................................................................... 09 2.1.[ Location .................................................. 09 2.1.2 Power Requirements ......................................... 09 2.1.3 Signal Transmission Wil4ng ................................ 09 2,2 Control Module ........................................................... 10 2.2.1 Control Module RS422/485/Modbus Communications ............ 11 2.3 System Start-Up ........................................................... 12 2.3.1 Initial Monitor Settings ................................ 12 2.3.2 Water Connections ......................................... 12 2.4 Sensor Mounting Instmcfions ............................................ 12 Diagram: Mounting Outline and Dimensions ....................... 13 Diagram: Mounting Dimensions for DuraTrac ....................... 14 Diagram: External Wiring Diagram ............................... 15 3.0 OPERATION Page 16 3.1 System Operation .................................................. 16 3.2 Treatment Optimization Procedure ................................ 16 3.3 Manual Control Using Controller ................................ 17 3.4 Automatic Control .................................................. 18 Figures 2 & 3 ........................................................... 20 3.5 Automatic Control Set-Up ................................ 21 3.6 General Operating Guidelines ........................................ 22 3.6,/ Tuning Constant Specifications ....................... 22 3.&2 Automatic Control Ttming Procedures .............. 22 4.0 TROUBLESIIOOTING GUIDE Diagram: Internal Wiring Diagram Diagram: Parts Identification Page 24 5.0 PROBE REPLACEMENT AND CLEANING PROCEDURES Page 27 5.1 Replacement Procedure ............................................... 27 5.2 Cleaning Procedure ................................................. 28 SCC 3000XR Page 2 of 29 6.0 CONFIGURATION SIIEET Pagc 29 SAFETY PRECAUTIONS BEFORE ATTEMPTING TO UNPACK, SET UP~ OR OPERATE THIS INSTRUMENT, PLEASE READ Tills ENTIRE MANUAL. MAKE CERTAIN THE UNIT IS DISCONNECTED FROM THE POWER SOURCE BEFORE ATTEMPTING TO SERVICE OR REMOVE ANY COMPONENT. FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT. WARRANTY INFORMATION Chcmtrac*; Systems, Inc. warrants its equipment to be free flora defects in material and workmanship tbr a period of one (1) year fr{3m date of shipment to the original purchaser. Upon receipt of written notice from purchaser, seller shall repair or replace the equipment (at option of Chc~ntrac~ Systems, Inc.). Chcmtrac® Systems, Inc. assumes no responsibility fbr equipment damage or f:ailurc caused by: I. hnpropcr installation, operation, or mai ntenance of equipment. 2 Abnmmal wear and tear on moving parts caused by some processes. 3. Acts o£ nature (i.e. lightning, etc.) [his warranty represents thc exclusive remedy ol damage or f;ailurc t)l equipment. In no event shall Chemtraca' Systems. Inc. be liable roi' any special, incidenlal, ol consequential damage stroh SCC 3000XR Page 3 of 29 1.0 GENERAL INFORMATION 1.I DESCRIPTION OF OPERATION 'Ibc primary instrument included with the Treatment Control System is the Streaming Current Controller (SCC). The SCC includes a sensor placed at thc dcsired sample point, and a signal processor mounted in the control module. The SCC is a charge measuring device. The charge that it measures is the net ionic and colloidal surface charge (positive and negative) in the sample being tested. Streaming current is related to zeta potential, however, they are not the same value. The treated water sample flows into the smnple cell where it is drawn into the bore during the upstroke of the piston cycle and is expelled from the bore on the piston downstroke. Particles contained in the water are temporarily immobilized on the piston and cylinder surfaces. As the water is moved back and forth by the piston, charges surrounding these particles ( t and -) are moved downstream to the electrodes. This movement of like charges causes an alteraating current to be generated, defined as "streaming current." A five position switch is used to select Ibc best signal amplification. The signal amplification should be set where a normal chm~ge in dosage results in a desired deviation in streaming current. The meter indication should be considered as a relative reading due to amplification of the primary signaI. The streaming current amplitude and polarity is a function of sampling location in file treatment process. It is importam to understand why the streaming current varies at different points in the systems to properly interpret thc readings. Therefore, the following section (1.2) on sampling should be read very carefully. SCC 3000XR Page 4 of 29 1.2 SELECTING PROPER SAMPLE POINT The sample must be taken at a point where uniform distribution and mixing of coagulant is obtained for all flow rate conditions. If uniform distribution and mixing is not being obtained at a selected sample point, the streaming current reading will oscillate. When possible, avoid sampling from places where sludge, grit, etc., will be drawn into the SCC sample cell. Sample lines must be sized to provide velocities that will prevent floc/sludge accumulation. Keep sample lines as shore as possible to minimize delay in response time. Figure 1, on page 6, is a "STREAMING CURRENT PROFILE" normally observed in a typical water plant, and should be referred to in reading the following paragraph. When coagulant is added to raw water, the charge neutralization process begins immediately. The time required for this neutralization process to go to completion is primarily a fimction of mixing, time, raw water characteristics, type of coagulant, and to a lesser degree, tclnperature. Untreated raw water has a net negative charge. Cationic coagulant charges, (alum, polymer, etc.) produce a net positive streaming current early in the system. As shown on the graph, this current becomes less positive as negative charges react with the coagulant. At the settling basin outlet, the streaming current value is nearly the same as raw water. If raw water flow or sample flow rate is increased, the total time for the sample to travel from point of coagulation injection to the cell is decreased. This may cause a change in SCC reading (in the positive direction), even though the coagulant dosage (PPM) remains constant. Conversely, if raw water or sample flow rate is decreased, stremning current readings may go more negative. Plants that have a shifting set point caused by wide swings in raw water flows can minimize this effect by moving the sample point further downstream, lengthening sample line, or adding a detention pot. It is important to maintani the sample flow at +/- 10% of the rate initially set. Based upon the above discussion, the proper sample point for a specific plant depends upon the following conditions: I. Point or points of coagulant 2. Mixing efficiency of raw water and coagulant. 3. Magnitude of raw water flow swings. 4. Type and quantity of coagulants used. SCC 3000XR Pag* 5 of 29 FIGURE 1 STREAhflNO ALUM +3 ~ +2 ~z 0 -5 -7 -8 CURRENT PROFILE · BASIN TOTAL ELAPSED TIME FROM PDINT OF COAGULANT ADDITION iUNTIL SAMPLE REACHES SCM CELL RAW WATER SCM READING SCC 30OOXR Pase 6 of 29 1.3 PROCESS CONTROL PROCEDURES In order for the SCC to be used for autotnatically controlling the coagulant feed (alum, polymer, ferric chloride), the following guidelines must be followed: 1. The coagulant must be thoroughly mixed with the raw water by the time the sample is taken. 2. "Lag time" (i.e., the time it takes for the SCC to see a change in coagulant feed) should be no greater thm~ 5 minutes. 3. Variability in sample flow rates should be no greater than +/- 10 % of the rate initially. 4. Coagulant pumps must be kept in good mechanical condition to respond quickly and accurately to process changes. 5. Raw water quality should be in a stable condition (turbidity, pH, color, etc. should not change rapidly or widely) when selling up thc system. The SCC should be operated a few days in manual control to observe how it responds to nom~al process operation. Recording streaming current changes on a strip chart recorder is very helpful in anticipating factors that may have to be dealt with when automatic control is started. This period, if using the SCC with a recorder for monitoring, is also a good time to determine the optimum coagulant dosage and establish the operating "sctpoint". This enables thc system to be put on automatic control very simply. scc 3000XR Page 7 of 29 1.4 GENERAL SPECIFICATIONS Remote Sensor Power ................................ Sample Flow Rate .............. Sample Cell Type .............. Probe Type ....................... Water Sample Connections ..... Materials Contacting Sample ..... Output Wiring .............. Enclosure Type .............. Module Size ....................... Weight ....................... Mounting I Ioles .............. Operating Temperature ..... I 15 VAC, 60 Hz (standard) 230 VAC, 50 Hz (optional) 5.0 Oal/Min External Receiver, High Flow Quick Replacement Cartridge Inlet-3/4" O.D., Barb Type Outlet - 1" O.D. Delrin, Nylon, Neoprene Viton, PVC, Stainless Steel 1 ca. Coaxial RG-59/U, 22 AWG 1 ea. Slfielded, Twisted Pair, 22 AWG Nema 4X, Polycarbonate 7.40"W, I4.14"H, 5.4T'D 10 Poands 7.66" x 7.66" 32 degrees F to 120 degrees F Controller Power ............................... Meter Readout .............. Reference Output Signals ..... Control Output Signals ..... Self Diagnostics .............. High & Low Alarms .............. Gain Adjustment ............ Alarm Adjustments .............. Zero Adjustment .............. Enclosure Type .............. Module Size ....................... Weight ....................... Mounting Holes .............. Operating Temperature ..... 115 VAC, 60 llz (standard) 230 VAC, 50 IIz (optional) Digital Configurable Fluorescent (-10 to +10) 4-20mA (350 ohm Load) Standard 0-10 VDC, Standard -10/+ 10 VDC, Standard 4-20mA (1000 ohm Load) Standard Electronic Pulse - Optional Standard 5A, 120VAC, SPST Relays External, 5 Pos. Switch (1X, 2X, 5X, 10X, 20X) lntemal, Continuous Adjustment lbr Higher Gain Full Scale All 'Ranges Full Scale All Ranges Wall Mount NEMA 4X, Polycarbonate 9 ¼"W, 12"I1, 11 3/8" D 14 Pounds 7.66"W x I 1.20"H 32 degrees F to 120 degrees F SCC 3000XR Page g of 29 2.0 INSTALLATION 2.1 SENSOR I 2.1.1 Location The sensor can be located several hundred feet t¥om the monitor. Typically, the sensor is mounted as close as possible to thc sampling point. Minimizing sample line lengths provides quicker response to process changes. You may use a sample pump, tap ofl'a pressurized line, or use a gravity feed system to get smnple to the sensor. The sample flow rate should not exceed 5.0 gpm. A free, unobstructed drain must be provided. We recommend draining to atmosphere, and not into a closed pipe. 2.1.2 Power Requirements Insert the power cord plug into a properly grounded receptacle (110 VAC). For safety and proper operation, the SCC must be properly grounded through its power cord. Follow the provisions in the National Electric Code (NEC) mid local electrical and safety codes when providing electrical power to this and any other device, in cases where potential noise sources could affect the performance of the equipment, a "surge suppressor" must be installed with the unit. 2.1.3 Signal Transmission Wiring The sensor output must bc sent to the transmitter through properly selected wire. A multiconductor cable can be used. A detailed wire description is given below, as well as, two recmnmended manut~cturers with respective product numbers for the wire: Wire description: Shielded Coax, RG 59-U, Twisted Pair; 22 Gauge AWG ManulXacturc Name/Product #: Belden / 9265 or Carrol / C8025 The cable should be enclosed th conduit for maximum protection against damage or electrical intcrllzrcnce. Do not run cable in same conduit with any other wiring. SCC 3000XR Page 9 of 29 Make connections to the sensor terminal block as follows: (See External Wiring Diagram, pp. 15) Terminal 1: Center conductor of coaxiai cable Terminal 2: Coax ground Terminal 3: Twisted pair, red wire Terminal 4: Twisted pair, black wire If different color coded wire is used for the twisted pair, make sure colors are matched with terminal at the sensor and at the monitor. 2.2 CONTROL MODULE (See External Wiring Diagram, pp. 15) The hookup diagram is in the back of this manual. The junction box cover must be removed to access terminals for hookup. The strain reliefs on the side of the junction box must be loosened to feed through all wiring. The control module input terminals are as follows (i.e. from sensor): Terminal 11: Center conductor of coaxial cable Terminal 12: Coax ground Terminal 13: Twisted pair, red wire Terminal 14: Twisted pair, black wire Separate output signals are provided at the junction box that indicate the streaming current value, but do not have to be wired for the system to operate. Terminal 6:0-10 VDC Terminal 7:-10 to ~ 10 VDC Terminal 8: Common ground (for terminals 6 8: 7) **Terminal 15: (+) 4-20 mA (INDICATES STREAMING CIIRRENT ONLY - **Terminal 16: (-) 4-20 mA DO NOT CONNECT TO PUMP) *~NOTE: When not in use, a 0 ohm shunt must be used between terminals 15 and 16. The maximum load for this current output is 350 ohms. SCC 3000XR Page 10 of 29 The Stremning Current controller utilizes a Honeywell UDC 3300 controller to provide control outputs to the chemical feed system. The Honeywell product manual is included with the system. A shielded twisted pair is used to connect the current output to the feed pump. On the integral systems, dic controller connections are fed back into the junction box, so the outputs to the pump are located on thc junction terminal block. Terminal 5: (+) 4-20 mA output Terminal 9: (-) 4-20 mA. output The alarm outputs arc located on the junction box terminal block. Terminal 1 & 2: Alarm relay #1 Terminal 3 & 4: Alarm relay #2 2.2.1 CONTROL MODULE RS422/485/MODBUS A RS422/485/MODBUS communication option is availble with the SCC3000. The option must have been specified when the unit was ordered. Thc eommurdcafion terminals will be located in the junction box of the instrument on terminals 3 & 4. The alarm relay (Alarm Relay #2) that is normally located on those terminals in units without the communication option will be moved and combined with the alarm relay (Alarm Relay #1) on terminals 1 & 2. In this configuration, m~y alarm event will result in closed connection (relay energized) between terminals 1 & 2. The wiring diagram inside the lid of the junction box will illustrate where to make the proper connections for communications. Terminals 3 & 4 inside the control module's junction box are prewired to the IloneywelI UDC3000 communication termitrals 14 & 15 (as shown on page 30 of the UDC3300 Product Manual). This is a half duplex configuration. RelEr to the Honeywell documentation that was supplied with this unit for more information on the communication capabilities. SGC 3000XR Poge I 1 of 29 2.3 SYSTEM START-UP 2.3.1 Initial Monitor Settings A. GAIN Switch ................................. 5X C. ZERO OFFSET Switch ..................... Out (Yellow LED should be off) D. ZERO ADJUST Knob .................... Mid-range (5 tums from fully CW) 2.3.2 Water Connections Connect 3/4" tubing to thc barbed fitting on side of sample cell; this is the inlet~ The I" PVC elbow opposite the inlet, is the outlet. The outlet sample must flow to an open drain (sample receiver). The cell cmmot operate properly if pressurized. DO NOT REPLACE EITHER FITTING WITH ANY OTItER TYPE OF FITTING. Start treated water sample through the cell at a rate of less than 5.0 gpm. Make sure the outlet is free of obstructions. Continuous reliability of the sample flow is essential. Interruption of the sample flow may result in erroneous signals being sent to the chemical pump when the system is operating in the automatic mode. A suitable flow alarm is recommended for maximum reliability. Contact Chemtrac® Systems, Inc. for suggestions concerning suitable devices. IMPORTANT: The controller must be operated in the MANUAL mode if the sensor is flushed or cleaned or if power to the sensor is interrupted for any mason. The system can be placed back in automatic once power m~d sample flow is restored to the unit. NOTE: Always disconnect the power cord betbre operating or servicing this unit. Also mm off power to the outpuffalarm terminal block if alarms have been wired tbr 110 VAC. 2.4 SENSOR MOUNTING INSTRUCTIONS 1 The sensor must be mounted in a vertical position with the sample flowing into the inlct (barb firing) and exiting from the outlct (1' PVC elbow). 2 DO NOT REPLACE THE INLET BARBED FITT1NG WITh ANY OTHER TYPE OF FITTING. Use plastic tubing to make intcrconnections to sample line. SCC 3000XR Page 12 of 29 DIAGRAM - MOUNTING OUTLINE & DIMENSION S oI~o SCC 3000XR P~ge 13 of 29 DIAGRAM - MOUNTING OUTLINE & DIMENSIONS SCC 3000XR Page 14 of 29 DIAGRAM - EXTERNAL WIRING SCC 3000XR Page 15 of 29 3.0 OPERATION 3.1 SYSTEM OPERATION After satnplc flow is established and power has been applied to the sensor and monitor, allow 10-15 minutes, or longer, for the meter to stabilize. The SENSOR LED should be blinking which indicates proper mechanical/electrical functions. If I.ED is not blinking, see Troubleshooting Guide. The second decimal digit may fluctuate, even under stable conditions. If readings fluctuate widely, refer to Troubleshooting Guide. The meter reading may be negative, zero, or positive. Tbe SCC is simply indicating the streaming current value of the sample. Depress the ZERO OFFSET rockerswitch to the "IN" position. The yellow LED light should co,ne on. A4just thc ZERO ADJUST knob until the meter reads zero. This function provides the option of using zero as the operating setpoint, once the optimum treatment dosage has been determined (see Treatment Optimization Procedure). LEAVE THE SWITCH AT THE "IN" POSITION AFTER ZEROING METER READING. NOTE: lfthe GAIN setling is changed with the ZERO OFFSET function "IN", the meter must be rezeroed for that gain. 3.2 TREATMENT OPTIMIZATION PROCEDURE The treatment optimiTation process should be done slowly and stepwise. Assunfing that the plant is producing acceptable water with present chemical dosages, thin approximately 10%. You may need to change GAIN setting to increase magnitude of response. If the settled and finished water quality is still acceptable at the reduced dosages, trim another increment. Continue this process, being sure to wait long enough each thne to see the fiill effect. Rezero meter reading using the ZERO ADJUST knob. Ifa cationic coagulant is being used, the streaming current value will become more negative with cach reduction in dosage. If prelime or caustic is being scc 3000XR Page 16 of 29 used, a decrease in alum feed will require a decrease in lime feed to maintain proper pH for coagulation~ The "optimum setpoinf' (zero) is obtained when the minimum coagulant can be fed that produces desired results for the particular treatment process. This setpoint will remain very close to the same reading even when raw water turbidities increase or decrease. Simply adjust the coagulant dosage to maintain this zero reading on the SCC. NOTE: If automatic control is being used, refer to section on AUTOMATIC control. 3.3MANUALCONTROL USING CONTROLLER A. Observe and record chemical pump % at optimum dosage. B. Make electrical co~mections between SCC and pump. C. The A~/!AN indicator should rcad MAN. Press MAN/AUTO key (firmly) ifit shows A. In either mode, the upper display will indicate the streaming current value. If the 7l~ro adjust function is being used, this reading should be near zero. If there is no input signal, or the wrong signal, the message INI RG will flash. In MAN, thc bottom display will show the controller % output value. Press the increase/x or decrease ~' key to match the chemical pump % recorded above, if it is different. NOTE: Maintaining continuous pressure on either of these keys will cause the value to change in increments of 0.10. This can be accelerated by holding pressure on one key and pressing the other key once lbr incremcnlal changes of 1.0, and twice for changes of 10.0. In AUTO, the bottom display will indicate the selected setpoint, SP. A setpoint of 0.00 has been preset at the factory, assuming that the plant wants to use zero as the operating sctpoint. This cml be easily changed by pressing directional keys ms described above. Pressing the LOWER DISP key will show DEV, the deviation between the setpoint and streaming c[lrrcllt value. SCC 3000XR Page 17 of 29 3.4 AUTOMATIC CONTROL Automatically controlling the treatment process with the Streaming Current Controller (SCC) is a very simple operation, once you know how the controller works. Most controller manuals do not explain, in simple terms, the purpose of so-called "tuning constants" termed PROPORTIONAL BAND, RATE, ,and RESET. Controllers with these three fmmtions are sometimes called "3-mode controllers," or "P.I.D. controllers". In order to explain thc purpose of these functions, a brief review of how a simple proportional controller works may be helpful. Many water treatment plants have "flow controlled" coagulant feed, i.e., when raw water flow increases, a signal is sent to the coagulant pump that immediately increases the feed rate. In other words, there is no "lag time" between water flow increasing and coagulant increasing. This system works extremely well in maintaining proper dosage as long as thc water flow is the only thing changing. However, if turbidity is changiug, the proper chemical dosage camlot be maintained with a simple proportional controller. Since the SCC is taking its sample downstream of the coagulant feed point, there will be some "lag time" before it can sense a change in turbidity, alum feed, raw water flow, etc. If, for instance, the SCC reading should start going more negative due to an increase in turbidity, it will cause the controller to increase coagulant feed. This will cause the streaming current reading to go more positive, which will cause the pump to decrease coagulant. The result is continuous cycling above and below the setpoint, thus, the need for a controller with "tuning constants" mentioned earlier. The PROPORTIONAL BAND, RESET, and RATE functions provide a way to eliminate cycling due to the lag time between coagulant addition and streaming current sensing. Rctcr to Figures 2 and 3 (page 20) for illustrations of responses to controller adjustments. PROPORTIONAL BAND (PROP BD): Basically, the longer the lag time, the higher PROP BD should be set. If cycling continues when a change occurs in the process, PROP BD is set too Iow and should be increased. SCC 3000XR Page 18 of 29 NOTE: There will normally be a small amount of cycliug for a few minutes adler a process change, even if PROP BD is set correctly. If PROP BD is set too high, thc controller will be slow in adjusting coagulant dosage when something changes in the process. RESET (RSET MIN): The longer tile lag time, the higher RSET MIN should be. If cycling continues when a process change ocewcs, the RSET MIN value is too low and should be increased. IfRSET MIN is set too high, the controller will bc slow in adjusting coagulant feed ad~er a process change. RATE (RATE MIN): The RATE MIN function is used when large, sudden, changes occur in the process. Normally, proper setting of PROP BD and RSET MIN will handle most process changes and give good feed control. A RATE MIN input should be put into thc control set-up only alter PROP BD and RSET MIN adjustments have been made, and then only if required. OUPUT HI/LO LIMITS (OUTHILIM): This control be can be used to limit the % output of the controller, high or low. On a 4-20 n~k controller with OUTHILIM = 50, the output would never be greater than 12mA (i.e., the chemical pump could not go above 50% output). This thnction can be used as a safety measure to prevent overfeed or underfeed. SCC 3000XR Page 19 of 29 FIG 2 Figure 2 SET POINT PROPORTIONAL BAND TOO NIGH SET POINT PROPORTIONAL BAND ADJUSTED CORRECTLY SET POINT PROPORTIONAL BAND TOO LOW Figure 3 SET POINT RESET {M[N/REPEAT} TOO LOW SCC 3000XR Page 20 of 29 3.5 AUTOMATIC CONTROL SET-UP The controller can be progranuned while it is operating in thc ~naoual mode. This allows a smooth transfer from manual to automatic. When the controller is in SET-UP mode, displays can be altered to review and adjust the tuning constants. Control action continues undisturbed, except for the normal consequences of changing a certain parameter. To adjust tuning constants: 1. Press SET-UP key once. TUNING wilI replace the numeric value in the bottom display, indicating that thc controller is ready for you to proceed. This segment acts as a cursor to identify parameters available for adjustment. 2. To advance through the tuning parameters, press the FUNC key. The display will then jump to the first parameter, (which is PROP BD for this mode1 of controller). 'llm top display will now show the present value of the identified parameter. (This parameter has been preset at 100, but may need to be changed for your plant operation). This value may be incremented through its available range by using the INCREASE trod DECREASE keys. If this is the only parameter you wish to change, exit the SETUP mode by pressing LOWR DISP. To examine or change other parameters, advance the cursor by repeating the SETUP sequence described previously. 'ilae pmnary programmable parameters are PROP BD, RAIE MIN, RSET MIN, etc. for this model of controller. NOTE: Deliberately exiting the SETUP mode or advancing the cursor causes the currently displayed value of a parameter to be loaded in permanent memory, replacing the previous value. If no keys are operated for approximately 1.5 minutes, the controller will automatically return to the RI IN mode, but will revert to thc previously stored value ot' the parameter indexed at that time. SCC 3000XR Page 21 of 29 3.6 GENERAL OPERATING GUIDELINES Follow these three guidelines when establishing correct tuning constants: 1. Change only one control action at a time. Making two or more corrections is confusing and can cause the system to get out of control. 2. Never make a large change in a tuning constant. Make a small change and observe the effect it has on the control action. 3. Allow plenty of time for the process to stabilize before making another change. Making changes in an unstable process can be misleading. 3.6.1 Tuning Constant Specifications Tuning constants am stored digitally in non-volatile memory and changed by ll-ont panel switches. PROP BD RSET MIN RATE MIN -Proportional Band adjustable to either 0.1 to 9999. -Adjustable to either 0.00 to 50.00 repeats/minute or min/repeats. -Adjustable to either 0.00 to 10.00rain rateisoffvaluesof0.08 or less) Parameters shown below have been preset by Chemtrac at the following values: PROPBD - 100 RSET MIN 3.00 RATE MIN - 0.00 Experience has shown these values to be a good starting point for most water plants. However, significant changes may be necessary to tune the controller to your specific operation 3.6.2 Automatic Control Tuning Procedures 1. Depress the MAN/AUTO key to put the controller in automatic. MAN is replaced by A. Thc Streaming Current (SC) reading should be stable if no process changes are occurring at the time. SCC 3000XR Page 22 of 29 2. After each change in a tuning constant (steps 4 and 5 below), a change in the setpoint is necessary to check the operation of the control action. A simple method of doing this is to change the setpoint from 0.00 to 1.00 at2cr changing the first tuning constant. Watch the SC reading to evaluate if other tuning constant changes arc necessary (i.e., oscillations, long settling times indicate fi~rlher tuning). The use ora recorder allows the observation of overshoots and setlling times. To make another change in the tuning constant, change the setpoint from 1.00 back to 0.00 after making a correction. Observe the process again. This procedure should be repeated until tuning is complete. 3. If the SC reading will not stabilize after several minutes (10 - 20), go back to manual control by depressing MAN/AUTO key and a4just the % pmnp setting to get SC reading close to 0.00. This procedure will allow starting over. 4. Change the setpoint from 0.00 to 1.00 to observe accuracy of preset parmnetcrs. Allow 10 - 20 minutes to evaluate. a. If the SC reading is stable, decrease the PROP BD one increment, change the setpoint, and allow time to evaluate. Repeat until SC reading continuously oscillates slightly, then increase PROP BD slightly. b. If the SC reading is unstable, increase PROP BD. 5. Tune RSET MIN similar to PROP BD~ a. If the SC reading is stable, decrease RSET MIN in a small increment, change the setpoint, and allow thne to evaluate. Repeat until SC reading oscillates. Then slightly increase RSET MIN until oscillations cease. b. If the SC reading is unstable, increase RSET MIN in small increments until oscillations cease. Wait for the SC reading to settle down after each adjustment. SCC 3000XR Page 23 of 29 4.0 TROUBLESHOOTING GUIDE PROBLEMS 1. Controller display fluctuates rapidly and widely on treated sample. 2. Controller display does not change with change in coagulm~t dosage. 3. Controller displays 0.00, or closely thereto, and does not chmlge with change in coagulan~ dosage. 4. SENSOR lED on ~nonitor is not blinking. POSSIBLE CAUSE(S) A. hrcomplctc dispersion or mixing of coagulant(s) in raw water at point of sampling. B. Chemical feeders erratic. C. Raw water flow-turbidily fluctuating. D. SCC GAIN setting too sensitive. E. Cell bottom plug loose or O-ring missing. A. SCC GAIN setting too low B. Wrong sample. C. Sample cell dirty. D. Excessive "lag time" between coagulant injection point and SCC sample cell. A. No water sample to sensor. B. Dirty or inoperative probe. C. Optoswitcb misaligned. D. Optoswitch inoperative. E. Sensor Otltput COtlnectioI1s ill¢orfect. F. Controller bad. G. Circuit card component lhulty. CORRECTIVE ACTION A. Check stability of readings on raw or finished water. If stable, incomplete mixing is the problem. Move sampling point further downstream, or resolve mixing problems. B. Fix feeders. C. Check R/W flow controls/charts, and turbidity. D. Decrease GAIN setting. E. Tighten plug. Check O-ring figee (¥eaning Procedures). A. Increase GAiN setting. B. Select correct sample (coagulated). C. Clean cell (see Cleaning Procedures). D. Move smnpling point closer to coagulant feed point m~d/or decrease sample TRANSPORT time (See Selecting Proper Sample PoinO. A. Establish proper sample flow. B. Clean or replace probe. C. Adjust optoswitch position for maximum meter reading on water sample and tighten securely in place. D. Replace optoswitch, E. Check wiring. F. Check SCC outputs. If present, controller is bad. Replacemeter. G. Replace circuit card. lhe SENSOR light is provided to alert the operator ti) any mechanical problem at the sensm, or in associated wiring If there is a problem, the LED will be on or off, but not blinking. Operator should immediately check to see that sensor has I I 0 VAC power, motor is running, and all output wiring is correct. SCC 3000XR Page 24 of 29 DIAGRAM - iNTERNAL WInG DIAG~ SCC 3000XR Page 25 of 29 DIAGRAM - PARTS IDENTIFICATION SCC 3000XR Page 26 of 29 5.0 PROBE REPLACEMENT AND CLEANING PROCEDURES The Dura-Trac sensor is supplied with two (2) probes mid pistons so freshly cleaned parts can always be on hand. 5.1 REPLACEMENT PROCEDURE: NOTE: ifSCC is being used for automatic dosage control, put the chemical feed pump controller into MANIJAL mode before starting proccdurc. 1. Disconnect the lead wire fi'om the enclosure emd remove the lower retaining slip nut from the probe. 2. Remove probe by pulling on the tab. You may need to twist slightly. 3. Remove the piston using a ¼" flatblade screwdriver. 4. Clean any debris from cell housing. 5. Screw clean piston into place. Do not ovcrtightcn. Only slight torque is necessary. 6. lnsert clean probe into cell housing. 7. Slip retaining nut over probe lead wire and tighten onto probe. Finger tight is adequate. BE CAREFUL TO AVOID CROSSTHREADING NUT. 8. Connect lead wire to enclosure. 9. It may take scvcraI minutes for SCM readings to stabilize with a new probe. Sensitivity to process changes may also be greater~ After readings stabilize, adjust to zero reading. With zero offset switch in the IN position, turn zero adjust Imob to read 0.00 on display. Thc outer ring must be depressed to turn knob~ SCC 3000XR Page 27 of 29 5.2 CLEANiNG PROCEDURE Depending on the type o1' contamination, different cleaning procedures are recommended: TYPE of CONTAMINATION CLEANING PROCEDURE Mineral scale from alum/lime addition ] )eposits caused by raw water iron/manganese, or where ferric salts or potassium permanganate is used for treatmcllt. Organics from raw water or where polymers arc used. Oil/Grease Comet or other Abrasive Cleaner ROVER (available from Hach Chemical) I spoonful per pint tap water Comet or other Abrasive Cleaner Comet or other Abrasive Cleaner A "soak and brush" method is recommended for any contanfinant. Soak only long enough to dissolve/remove the material. Wash surfaces thoroughly wilh clean water to remove any residual cleaning compound. NOTE: DO NOT SOAK ENTIRE PROBE CARTRIDGE. ONLY SOAK INSIDE TIlE BORE. SCC 3000XR Page 28 of 29 6.0CONFIGURATION SHEET CONFIGURATION RECORD SHEET AUX OUT - UDC 3000 SCC 3000XR HACH COMPANY Cat, No. 54400-18 CL17 CHLORINE ANALYZER INSTRUMENT MANUAL 10/00 2ed Table of Contents Trademarks of Hach Company ...................................................................................... 2 Safety Precautions .................................................................................................................................. $ Specifications 7 INSTALLATION ........................................................................................................9 OPERATION .......................................................................................................................................... 29 Section 2 Starting the Instrument ...................................................................................................... 31 21 Keypad and Display information ................................................................................................. 31 2.2 Introduction ................................................................................................................................. 32 Table of Contents MAINTENANCE ........................................................................................................................... 41 3.1 Scheduled Maintenance .............................................................................................................. 43 3.1,2 Replacing the Pump Tubing ............................................................................................. 43 3.1.3 Replacing the Analyzer Tubing 44 3.2.3 Cleaning the Colorimeter ......................................................................................................... 47 3.2.4 Replacing the Sample Conditioning Filter ............................................................................ 49 3.2.5 Reagent Spill Clean Up Instructions ............................................................................... 49 Section 4 Troubleshooting ............................................................................................................... 51 4.1 Troubleshooting Guide ................................................................................................................... 51 4.2 System Alarms ................................................................................................................................. 52 4.3 System Warnings 53 Appendix A General Information ............................................................................................. 55 Instrument Description ......................................................................................................................... 55 Method of Analysis ........................................................................................................................... 56 Principle of Operation 57 Appendix B Hach Network Interface Card for the CL17 Chlorine Analyzer .................................... 59 Attaching the CL17 Analyzer to the Network Via an AquaTrend Interlace ......................................... 60 Adding the Measurement to a Channel 60 Alarms and Warnings ......................................................................................................................... 61 Logging Data via the Hach Serial Input/Output Module .................................................................. 61 Manually Polling Data 62 Using the Signal Output Module ............................................................................................................. 62 Logging Data via the Hach MOD I/O Module .................................................................................... 62 GENERAL INFORMATION .......................................................................................................... 63 Replacement Items ................................................................................................................................ 65 How to Order ......................................................................................................................................... 66 Repair Service ..................................................................................................................................... 67 Page 4 Table of Contents Safety Precautions Please read this entire manual before unpacking, setting up, or operating this instrument. Pay particular attention to afl danger and caution statements. Failure to do so could result in serious injury to the operator or damage the equipment. To ensure the protection provided by t~is equipment is not impaired, do not use or install this equipment in any manner other than that which is specified in this manual. Use of Hazard Information If multiple hazards exist, this manual will use the signal word (Danger, Caution, Note) corresponding to the greatest hazard. DANGER Indicates a potentially or imminently hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a potentially hazardous situation that may result in minor or moderate injur~ NOTE Information that requires special emphasis. Precautionary Labels Read ail labels and tags attached to the instrument. Personal injury or damage to the instrument could occur if not observed. This if noted on the instrument, references symbol, the instruction manual for operation and/or safety information. This symbol, if noted on the product, indicates the need for protective eye wear, //~.~ Section 1.2 Instrument Environmental Considerations on page 11 /~\ Section 1.4 Plumbing Connections on page 14 ~ Section 1.70ptionalAirPurge on page 20 /~. ~, Section 1.8 Electrical Connections on page 20 //~\ Section 1.& l Power Connections on page 21 z .~ Section 1.&2 Wiring the lnstrument on page 23 /'/~ Section 1.&3 Voltage Selection for Alternate Voltage Operation on page 24 ~ Section 1.8.4 Alarm Connections on page 24 0 Section 2.2 Introduction on page 32 //~ Section 2.11.2 Calibration on Known Standards on page 39 Page 5 Safety Precautions Safety Precautions Section 3 Maintenance on page 43 Section 3. I Scheduled Maintenance on page 43 Section 3.2.1 Fuse Replacement on page 46 Section 3.2.3 Cleaning the Colorimeter on page 47 Page 6 Safety Precautions Specifications General Sample Requirements Display: LCD, 3¥,-digit measurement readout and six-character alphanumeric scrolling text line. Enclosure: IP62-rated with the gaskeled door latched Instrument Dimensions: 34.3 cm width x 41.9 cm height x 19.1 cm depth (135 in.x 16.5in x75in) Mounting: Wall mount Instrument Shipping Weight: 11 3 kg (25 lb) Sample Flow Rate to Sample Conditioning: 200 to 500 mL/min Inlet Pressure to Instrument: I to 5 psig; 1 5 p$ig rs optimum Exceeding 5 psig can cause sample tubing failure. Inlet Pressure to Sample Conditioning: 1.5 te 75 psig (with sample tube level with the bottom of the instrumen~see Figure 6 on page 19) Sample Temperature Range: 5 to 40 °C (41 to 104 °F) Inlet Fitting: at instrument--¼-inch OD polyethylene tubing with quick-disconnect fitting Drain Fitting: ~/4-inch hose barb Sample Conditioning: Use provided sample conditioning Reagent/Standard Requirements Maximum Reagent Usage: one-half liter per month (each of the two reagents) Reagent Containers: High-density polyethylene (2) Y~-Iiter bottles. Reagent Containment: Reagent bottles are contained inside the analyzer enclosure and are vented externally. Electrical Power Requirements: 100-115/230 V ac (selection swilch inside instrument); 95 VA, 50/60 Hz, 2.5 Amp fuse Power Connection: Connection made by three wire barrier terminal block through a Y2-inch conduit hole in the case. Wire range: 12-18 AWG. Installation Category: II Page 7 Specifications Specifications Optical Performance Environmental Alarm Contact Rating: Two relays each rated at 5 A resistive, 240 V ac maximum. Use either high voltage (greater than 30 V RMS and 422 V PEAK or 50 V dc) or Iow voltage (less than 30 V RMS and 42.2 V PEAK or 60 V dc) Do not use a combination of high and Iow vottage. Alarm Connection: Connection made by a removable three wire plug through a ¥2-inch conduit hole in the case. Wire range: 12 18 AWG. Recorder Output: One isolated recorder output, 4-20 mA (can be adjusted to 0-20 mA). Recorder Output Connections: Connection made by a removable three wire plug through a ~/2-inch conduit hole in the case. Wire range: 12 22 AWG, Light Source: Class 1 LED (light emitting diode) with a peak wavelength of 520 nm; 50,000 hours estimated minimum life Operating range: 0-5 mg/L free or residual chlorine Accuracy: +5% or ±0.035 ppm whichever is greater Precision: ±5% or :=0 005 ppm whichever is greater Detection Limit: 0.035 ppm CycleTIme: 25 minutes Calibration: Uses default calibration curve Power Switch: User accessible power switch is required. Recorder: One 4 20 mA/0-20 mA Alarm Relay Outputs: Two SPD? relays, 5A resistive Icad at 240 V ac Can function as sample set point alarms (high or Iow) or as a system warning indicator or a system alarm indicator Optional External Outputs: Hach AquaTrend® Network Interface Storage Temperature Range: -40 to 60 °C (-40 to 140 ~F) Operating Temperature Range: 5 to 40 ~C (41 to 104 ~F) Humidity: 90% at 40 °C (90% at 104 ~F) Air Purge (optional): 01 CFM instrument quality air at 20 psig maximum, IA-inch OD tubing Page 8 Specifications INSTALLATION DANGER Some of the following manual sections contain information in the form of warnings, cautions and notes that ~quire special attention. Read and follow these instructions carefully to avoid personal injury and damage to the instrument. Only personnel qualified to do so should conduct the installation/maintenance tasks described in this portion of the manual. DANGER Certains des chapitres suivants de ce mode d'emploi contiennent des informations sous la forme d'avertissements, messages de prudence et notes qui demandent une attention particuli~re. Lire et suivre ces instructions attentivement pour ~viter les risque$ de blessures des personnes et de d~t~riorafion de I'appareil. Les t~che$ d'installatlon et d'entretien d~crites dans cette pattie du mode d'emplol doivent ~tre seulement effectu~es par le personnel qualifi~ pour le faire. PELIGRO Algunos de los cap£tulos del manual que presentamos contienen informacidn muy importante en forma de alertas, notas y precauciones a romar. Lea y siga cuidadosamente estas instrucciones a fin de evitar accidentes personales y da~os al instrumento. Las tareas de Instalaci~n y mantenimiento de$critas en la presente seccidn deber~n set efectuadas dnicamente por personas debidamente cuallficadas. GEFAHR Einige der folgenden Abschnitte dieses Handbuchs enthalten Informafionen in Form von Warnungen, VorsichtsmaSnahmen oder Anmerkungen, die besonders beachtet werden m(Jssen. Lesen und befolgen Sie diese Instruktionen aufmerksam, um Verletzungen von Personen oder Sch~den am Ger~t zu vermeiden. In diesem Abschnitt beschrlebene Installations- und Wartungsaufgaben d~rfen nut yon quallfizlertem Personal durchgefDhrt werden. PERIGO Algumas das seguintes secFdes do manual contdm informa~es em forma de advert~ncias, precau~Oes e notas que requerem especial aten~o. £eia e siga atentamente as presentes instru~es para evitar ferimentos pessoai$ e ndo danlficar o instrumento. As tarefas de instala~o/manuten~§o descrlta$ nesta parte do manual sd poder~o set executadas por pessoal qualificado para o fazer. Section I Installation DANGER This instrument should be installed by qualified technical ~ersonnel to ensure adherence to ag applicable electrical and plumbing codes. DANGER Cat appareil doit ~tre install~ par du personnel technique qualifi~, afln al'assurer le respect de routes les holmes applicables d¥1ectricit~ et de plomberie. PELIGRO Este instrumento debe sar instalado por persor~ai t~cnico capacitado para assegurar el cumplimiento con t~dos los cddigos el~ctricos y de plomerla GEFAHR Elektrizit~ts- und Wasserwerke erfE~llt warden, darf dieses Ger~t nut yon geschuttem Fachpersonal installiert ~erden. PERIGO Este instrumenta dave sar instalado pot passoal t~cnico qualificado para asegurar o cumprimenlo de fodas as normas el~tricas e de canaliza~o 1.1 1.2 Unpacking the Instrument Remove {he analyzer from its shipping carton and inspect it for any damage. Verify that the Installation Kit, Cat. No. 55164-00, and Maintenance Kit, Cat No 54443-00, are included in addition to reagents. If damage is evident or the shipment is incomplete, please contact the Customer Service Department, Hach Company, Loveland, Colorado for instructions The toll-free number is 800-227-4224. Contents of the Installation and Maintenance kits are listed in on Replacement Items on page 65. Instrument Environmental Considerations The instrument enclosure is designed for general-duty, indoor installation with a nearly constant ambient temperature between 5" and 40 °C (18= to 104 °F) The enclosure environmental rating is IP62 with the door closed and latched. Do not mount the instrument in direct sunlight; shield from dripping water. 1.3 Mounting the Instrument on the Wall The instrument case i~ designed for wall mounting Refer to Figure 1, Figure 2, and Figure 3 for dimensions and other installation information. Use ¼-inch screws for mounting Mount the instrument as close to the sampling point as practical to ensure complete purging of the sample line during each cycle. Leave adequate clearance at the sides and boY(om of the instrument case for plumbing and wiring connections Page 11 Installation Section 1 Figure 1 CL17 Instrument Dimensions (1 of 3) Air Purge QuickConnect 25 O,D. P~lyethyleneTublng (Cat. No47438-00) Contsot ConnectJon~ 4-20 mA 4 x 1/4" Recommended Mounting Bolt 06" (2699 mm) RELAYS NO NO COM NC Drawing Number; 54400 87 Revision: A, 02-16-00 Page 12 Mounting the Instrument on the Wall Section 1 Figure 2 CL17 instrument Dimensions (2 of 3) Drawing Number: 54400-~17 Revision: A, 02-16-00 Page 13 Mounting the Instrument on the Wall Section 1 Figure 3 CL17 Instrument Dimensions (3 of 3) 1995~ (506.78 mm) Sample Inlet Quick Connect 25 O C) Polyethylene Tubing (Cat. NO 47438-00) Orawlng NurTIber 54400 87 Revision: A 02 16 00 1.4 Plumbing Connections analysis wastes, which include both sample and chemical reagents The event of spills or leaks, some waste may be produced. Although the concentratton, it ~s best to check with local authorities concerning proper disposat of waste from thts product, Sample inlet and drain connections are made on the bottom of the instrument using a quick connect fitting for ¼ inch OD tubing. See Figure 4. Connect the ¼-inch O.D. poly tubing by pushing it into the fitting. Two distinct "stops" will be felt as the tubing is correctly attached. If the tubing is not properly seated, it will come loose when water pressure is applied. The sample drain fitting ~s sized for Y2-inch ID flexible tubing (not supplied). Page 14 Plumbing Connections Section I DANGER The ~-Inch enclosure drain must have at least 3 ~eet of tubing Installed to ensure the analyzer remains dust-tight. Never plug the drain. The drain must remain open to remove sample water in the event of a leak. CAUTION This analyzer is intended to be used for water samples only. ATTENTION Alln que I'analyseur soil herm~tique ~ ia poussi~re, le drain d'~ pouce du boitier doit ~tre connect~ ~ un tuyaux d'eu moins un m~tre. Ne jamal$ obstruer le drain. Le drain doit rester li~)re pour permettre I'~vacuation de I'eau en cas de tulle. PELIGRO El desag~e de la caja de Y= pulgadas debe tener pot IQ menos I metro (3') de tuber[a para asegurar que el analizedor conllnt~e herm~llco al polvo. No taponar o permltir que el desag~e se atasque, pue$ debe ser capaz de eliminar el liquido de las muestras en caso de derrame. GEFAHR An dem ~/= Zoll Ablaut des Geh~use$ mtlss eltle ml[ldestens 90 cm lange Schlauchleilung installiert sein, damit gewiJhrleistet ist, dass der Analysator vor Staub gesch~zt isl. Der Ablaut dart nienals verschfossen werden sondern muss stets often sein, damit Probenwasser im Fall elner Undlchtlgkelt ablaufen kann. PERIGO 0 dreno do envoltdrio de ~/= polegada deve ter pelo menos 3 p~s de tubula¢~o instalados para garantlr que o anallsador permane~a imperme~vel a pd. Jameis tempe o dreno. 0 dreno deve permanecer aberto para rerno¢~o de ~gua de amostra caso ocorra um vazamento. PRUDENCE Cet analyseur est prevu pour utlllsation avec des ~chantillons d'eau uniqu~n?ent. CUIDADO Este analisador deve set utillzado apenas em amostres de ague. VORSiCHT Dieser Analysator dart nut fur Wasserproben benutzt werden. CUIDADO Este anallzador est~ dise~ado para muestras acuosas solamente. Figure 4 Plumbing Connections Sample Drain sized for Y2-inch ID flexible tubing Front of Instrument ~- Sample Inlet Quick Connect Fitting Bottom View for ~A -inch O.D. Tubing Page 15 Plumbing Conn~tions Section 1 1.5 Installing the Sample Line Selecting a good, representative sampling point is important for optimum performance of your instrument The sample analyzed must be representative of the condition of the entire system. Erratic readings will be seen if sample is drawn from a location too close to points of chemical additions to the process stream, if mixing is inadequate, or if the chemical reaction is incomplete. if the sample pressure into the instrument exceeds 5 psig at the analyzer inlet, flooding and instrument damage may result unless the sample conditioning kit is installed. Install sample line taps into the side or center of larger process ptpes to minimize the chance of ingesting sediment from the pipe line bottom or air bubbles from the top. A tap projecting into the center of the pipe is ideal See Figure 5. Figure 5 Sample Ltne Location in the Process Stream Poor (Typical) Good Best Poor 1.6 Sample Conditioning All samples are "conditioned" using the single-sample, basic sample conditioning kit shipped with each analyzer. The kit eliminates large particles using a 40 mesh strainer. The ball valve on the raw sample inlet line may be used to control the amount of bypass flow that is delivered to the filter. For dirty water, high bypass will adjust it to help keep the strainer clean longer, or adjust it to any partially open position for continuous bypass. Adjust the ball valve on the instrument supply line to control the flow rate of filtered sample to the instrument Note: Installing the dra~n tee more Mount the centerline of the bypass drain tee two feet above the instrument, than 2feetabove the instrument can see Figure 6. When properly mounted, the vacuum breaker design of the result in excessive pressure which bypass drain tee prevents negative sample pressure and establishes the may cause leaks, needed positive sample pressure for sample flow through the analyzer. Page 16 Installing the Sample Line Section I 1,6.1 Assembling the Sample Conditioning Kit Refer to the tips below and to the complete system diagram in Figure 6 to assemble the components. Seal all threaded fittings with two wraps of Teflon® tape (provided). Two stops should be felt when installing tubing into the push-in fitting The first is when the tubing clears the gripper ring, and the second is when the tubing bottoms out in the fitting Improperly installed tubing will leak; take care to push the tubing all the way rn. Be sure to cut all tubing used in the push-in fittings with a sharp knife so the ends are round, cleanly cut and not angled The push-in fittings are designed for use with soft, ¼-inch OD plastic tubing as included in the kit. Tubing material such as PTFE or HDPE is recommended. The push-in fitting will not grip hard plastic or metal tubing and the tubing will slip out 1.6.2 Using the Sample Conditioning Kit Assemble the head height regulator (stand-pipe) and filter as shown in Figure 6. Make sure the sample pressure to the sample conditioning is between I 5 and 75-psig for proper operation. Set flow by adjusting the ball valve (item 18, in Figure 6). The valve is fully closed when the lever is perpendicular to the valve body and fully open when the lever is parallel with the valve body 2. Observe the flow in the unfiltered sample bypass (clear tube, item t 3 in Figure 6). Make sure the flow is adjusted so there is always bypass flow. 3. Use the ball valve (item 19) to turn off sample flow to the instrument Page 17 Sample Conditioning Section 1 Item Table 1 Sample Conditioning Parts List Clamp, Conduit Hanger, 1 -inch C ling ~-inch $CH 40 PV pe I Qty I Catalog Number 4 47849-0~ ! I 54175-00 I~ 54176-00 Coupling, P2 inch FPT x Y2 FPT PVC 23002-00 54180-00 5 7 8 Fitiing, Tea, 1-inch x 1-inch Fitting. Tube. Connector, Male (~z inch tubing) Fitting, Tube, Connector, Mate (Va-inch [ubing} 9 Fitting, Tube, ~-inch O.D x V,-inch Male NPT Pi.lng, Tube, F2-inch O.D. Union Elbow Fitling, Tube, Y2-inch 0 D, Union Straight Pipe, Pre cut Drain, 1 inch Diameter, PVC Pipe, Drain, Clear Strainer, Y-body Filter, 40 mesh Screen (provided with strainer and in Maintenance Kit, 55165-00) 15 Teflon®, Thread Tape, Vd-inch wide Tubing, Polyethylene, 0 250 O D 0 040 W, Black Tubing, Polyethylene, 0.500 O.D, 0.062 W, Black 18 Valve, Ball, PVC, Y, NP~ PVC 19 Valve, Ball. PVC, ~/4 NPT PVC 46622 00 51246-00 51262-00 54178 O0 54179-00 51239-00 54174-00 54183-00 I 54104-00 70608-24 30616-00 10feeti 51159-00 1 54177-00 Page 18 Sample Conditioning Section I Figure 6 Sample Conditioning Kit Page Sample Conditioning Section I 1.7 Optional Air Purge Air purge may be necessary it the analyzer ks located in an environment with high humidity and/or caustic vapors. The goal is to maintain a slight positive pressure in the instrument with dry instrument air, The air purge connection is located on the left side of the instrument enclosure To connect an air supply, remove the plug in the quick connect fitting then connect ¼-inch poly tubing by pushing the tubing into the fitting. Two distinct "stops" will be felt as the tubing is correctly attached. If the tubing ~s not properly seated, it will come loose when air pressure is applied Use only dry, oil-free instrument air at 15 scfh 1.8 /!,, Electrical Connections All power connections are made through the conduit openings in the upper left side of the instrument. The instrument is shipped with plugs in all of the conduit opemngs. Wire the instrument for power, alarms, and re~ay connections using sealing-b/pe conduit fittings, to maintain the IP62 environmental rating. If connections are not made through a conduit opening, install an oil-tight seal m place of the plugs to maintain the IEC 529 IP62 r~ting See Optional Accessories on page 65 Figure 7 Location of Air Purge and Electrical Connections Intended for wLring relays Use sealing type fittings made, an Oil-tight sea~ (Cat No. 42210-00), mus~ be installed to maintain the IEC 529 IP62 rating. Section 1 1.8.1 Figure 8 Power Connections Power connections are made at the terminal strip located in the left siae of the electrical compartment and are accessible when the customer access cover is opened. See Figure 8 and Figure 10 For process or industriar applications, the national electrical codes of most countries require that AC service feeds be hard-wired and contair~ed in conduit systems. The CL17 Chlorine Analyzer has been designed to conform to this requirement Locating and Removing the Customer Access Cover Page 21 Electrical Connections Section I 1. it is generally required by most local electrical codes. 2. Use of metal conduit can improve immunity to lightning surges and AC power transients, Additionally, electrical and instrumentation standards require a local means of removing power from the product. The instrument is supplied with a power on/off switch that is located inside the instrument enclosure. TO remove relay power from the instrument, an external customer- supplied 5A fused switch or a 5A breaker is required. In hard-wired electrical applications, the power and safety ground service drops for the instrument should be no longer than 6 meters (20 feet) unless metal conduit is used to shield the AC power wiring. The wire should be 18 to 12 AW G. In applications where power cords are allowed by local electrical codes and power surges and transients are not a great concern, a sealing-type strain relief and power cord with three 18 gauge conductors (including a safety ground wire) can be used. See Figure 9 for strain relief ssembly The length of the power cord must not exceed 3 meters (10 feet). Figure 9 Assembling the Optional Power Cord Hardware Wall section of the ---% instrument enclosure ~-~ Description 115 V Power cord with strain relief Catalog Number 54&98-00 230 V Power cord with strain relief 54489-00 Page 22 Electrical Connections t Section I 1.8.2 Wiring the Instrument Connect the unpowered wires to the instrument power terminal as follows: 1. Strip the outside insulatior~ of each wire back Y~ inch. 2. Connect the three wires to the terminal using the information in the following table. 3. Ensure the voltage setting is correct and supply power to the instrument Wire Color Code for: North America Protective Earth Ground Hot or ~1 Neutral or Black White lEO i Green with Yellow Tracer Brown Blue Figure 10 Power Connections A method to remove power from / the relays locally must be available in case o[ an emergency or for servicing the instrument Since the ON/OFF switch can be accessed without the use of a to~ an external switch is not required for instrument power Page 23 Electrical Connections Section I 1,8.3 ~ Voltage Selection for Alternate Voltage Operation voltage to be used An improper The instrument is switched fur 115-volt operation when it leaves the factory. To convert the instrument for 230-volt operation, slide the AC line conversion switch (shown in Figure 11) to the 230V position The fuses used in this product are 5 mm x 20 mm The fuses used are approved for both North American and European use; they do not need to be changed when voltage is converted. Figure 11 Voltage Selector Switch and Fuse Replacement Voltage Selection Switch (SW1) Factory set at 115V. Fuses (Fl, F2) (T, 1 25A, 250V) 1.8.4 ,/~\ Alarm Connections Note: Current to the relay contacts must be limited to 5 amps resistive. A method to remove power from the relays locally must be available ~n case ct an emergency or for servicing the product, Power removal can be switched 5-amp circuil t)reakeL The analyzer contains two alarm relays designed for use with either high voltage (greater than 30V-RMS and 42 2V-PEAK or 60 V dc) or Iow voltage (less than 30V-RMS and 42.2V PEAK, or less than 60 V dc), but not a combination of both high and Iow voltage Refer to Figure 13 and the instructions that follow for connection information The Normally Open and Common relay contacts will be connected when an alarm condition is active. The relay connector accepts 18-12 AWG wire Wire gauge should be determined by Icad application. Wire gauge less than 18 AWG is not recommended. Make sure no power is supplied to the instrument. 2. Strip the insulation on each wire back Y4 inch. See Figure 12. Page 24 Electrical Connections Section I 3. Remove the connector from the instrument if desired. Insert the wire ends into the connector until the insulation seats against the connector See Figure 12 (Do not seat the insulation under lhe terminal pinch plates.) Replace the connector if necessary and supply power to the instrument. Figure 12 Proper Wire Preparation and Insertion Wire insulalion should be seated against connector, Do not leave any of the bare wi~e exposed. Figure 13 Alarm Connections Current to the relay contacts must be limited to 5amps __ supplied to the instrument. Page 25 Section I 1.8.5 Recorder Output Connections The recorder output is a 4-20 mA current-source output Make recorder connections with twisted-pair shielded wire and connect the shield at the recorder, controlled component end or at the analyzer end. Do not connect the shield at both ends of the cable Make wiring connections at the analyzer end as follows: 1. Make sure no power is supplied to the instrumenL 2. Remove the Customer Access Cover (see Figure 8 in the manual) higher than allowed 3. Strip the insulation on each wire back '/~-inch, See Figure 12. 4. F~oute the wire through an available strain relief. 5. Remove the connector from the instrument See Figure 14 for connector position, 6. Insert the wire ends into the connector (see the table below) until the insulation seats against the connector as shown in Figure 12. (Do not seat the insulation under the terminal pinch plates.) Recorder Wires Circuit Board Markings Shield GND 7. Replace the connector and supply power to the instrument. Figure 14 Recorder Connections Make sure no power is supplied to the instrument. GN[ Page 26 ElectricaJ Connections Section I 1.9 Installing Pump/Valve Pinch Plate To eliminate the effects of constant pressure on the pump tubes during shipment and storage, the pinch plate ~nd screws for the pump/valve module are shipped in the installation kit and the pump tubes are held in place with tape. Reagent flow through the pump/valve module must be from bottom to top. If reversed, fluid mixture will be pumped from the colorimeter sample cell. causing reagent bottles to overflow Complete the assembly of the pump/valve module as follows: 1. Remove the tape. 2. Make sure the individual pinch blocks are positioned as shown in Figure 15, with the dissimilar-shaped block on top. 3. Align the pinch plate on the pump/valve module (refer to Figure 16) 4. Install the two screws through the pinch plate and into the pump/valve module. Secure the pinch plate by turning the screws in small increments moving from one screw to the other so that the plate is drawn down evenly. Tighten u~tit the plate is seated against the pump/valve module. Figure 15 Installing Pump/Valve Module Pinch Blocks PumpNalve Module The dissimilar shaped block should he on top Page Instatling Pump/Valve Pinch Prate Section I Figure 16 Installing Pump/Valve Module Pinch Plate Align Pinch Plate with PumpNalve Module --... Page 28 Installing Pump/Valve Pinch Plate OPERATION DANGER Handling chemical samples, standards, and reagents can be dangerous. Review the necessary Material Safety Data Sheets and become familiar with all safety procedures before handling any chemicals. DANGER La manipulation des ~chant#1ons chlmlques, ~talons et r~actlfs peut &tTe dangereuse. Lire les Fiches de Donn~es de $~curit~ des Produits (FDSP) et se familiariser avec toutes les procedures de s~curit~ avant de manipuler tous les produits chimiques. PELIGRO La manipulacidn de muestras quimicas, est;~ndares y reactivos puede set peligrosa. Revise las fichas de seguridad de materiales y familiar[cese con los pr~cedirnientos de seguridad antes de rnanipuiar productos qufmlcos. GEFA HR Das Arbeiten mit chemischen Proben, Standards und Reagenzien ist mit Gefahren verbunden. Es wird dem Benutzer dieser Produkte empfohlen, sich vor der Arbeit mit sicheren Verfahrenswelsen und dem richtigen Gebrauch der Chemika#en vertraut zu machen und alle entsprechenden MaterialsicherheitsdatenblJtter aufmerksam zu lesen. PERIGO A manipula~o de amostras, padrbes e reagentes qu[mlcos pode set perigosa. Reveja a folha dos dados de seguran~a do material e familiarize-se corn todos os procedimentos de seguran~a antes de manipular quaisquer produtos qu[micos. Page 29 OPERATION Section 2 Starting the Instrument 2.1 Keypad and Display Information The instrument display defaults to normal Concentration Measurement Mode unless keys are pressed to change it. Table 2 shows the functions for each key. Figure 17 Analyzer Keypad and Display \ x \, Table 2 Keypad Description Number Key MeRu Right Arrow Up Arrow Left Arrow Description Allows movement so different components of the display can be edited, Active when the right arrow icon is shown on the display Use to scroll through menu options or edit display components. Active when the up / down arrow icons are shown on the display. Allows movement so different components of the display can be edited. Active when the reft arrow icon is shown on the display, Use to scroll through menu options or edit display components Active when the up / down arrow icons are shown on the display. 6 Exit Rejects an edited value or backs out of the mef~u structure, 7 Enter Alarm LED Accepts an edited value, moves deeper into the menu structure, or accepts a menu option. Indicates an active alarm. 9 Display Screen Display area for measurement and menu information Page 31 Starling the Instrument Section 2 2.2 Introduction ~ CAUTION To famlllerlze yourself with handling precautions, dangers and emergency procedures, always review the Material Safety Data Sheets prior to handling containers, reservoirs, and delivery systems that contain chemical reagents and standards. Protective eye wear is always recommended when contact with chemicals is possible. Preliminary tasks necessary for placing the instrument in operation are defined below in their recommended sequence. Once these preliminary steps are performed, the instrument will be operational. PRUDENCE Pour se temiliarleer avec les precautions ~ prendre lois de la manipulation, les dangers et les procedures d'urgence, touJours lire les Fiches de Dorm&es de Introduction Section 2 2.3 Installing the Reagents The analyzer requires two reagents, a butter solution and ~tn indicator, Space is provided in the instrument enclosure for a 500-mL boffle of each of the reagents. Two reagents used in lhe chlorine analysis are installed in the analyzer hydraulic section and replenished at monthly intervals. One is the buffer solution, Free Chlorine Butter, Cat. No. 23141-00, used to determine free available chlorine, or Total Chlorine Buffer, Cat No. 22635-00, used for total chlorine analysis The buffer solutions are completely formulated at the factory and are ready to install. Remove the cap and seal from the buffer solution bottle and install the cap and tubing labeled BUFFER to the butter solution bottle reagent tubing to become The second reagent, the indicator solution, must be prepared. The indicator solution and indicator powder must be mixed just before use to ensure the best instrument performance Using the powder funnel provided in the maintenance kit, add the contents of one bottle of DP[3 High Range Powder, Cat. No, 22972-55, to a bottle of Total Chlorine Indicator Solutlon, Cat. No. 22634-00, or a bottle of Free Chlorine Indicator Solution, Cat No. 23140-00 Stir or shake until the powder is dissolved completely. Remove the cap from the reagent bottle and install the cap and tubing labeled INDICATOR to the reagent boffle Tubing should be inserted to the bottoms of the boBles to prevent air from being drawn in when the level in the bottle drops. Test Type Required Reagent Free Chlorine Buffer Solution Free Chlorine Total Chlorine Cat. No. Free Chlorine Indicator Solution 23140-1 t DPD Indicator Powder 22972 55 Total Chlorine Buffer Solution L Total Chlorine indicator Solution DPD Indicator Powder 22635-11 22972-55 Reagent Set Cat. NO. 25569-00 25570 00 Remove each reagent boffle cap and replace it with the special two part boffle cap that is connected to the delivery tube inside the instrument. Page 33 installing the Reagents Section 2 2.4 Installing the Stir Bar A small stir bar for the sample cell in the colorimeter assembly is included in the installation kit furnished with the instrument. The stir bar must be installed for the ir~strument to operate properly. Install the stir bar as follows: 1. Remove the plug in the top of the colorimeter 2. Drop the stir bar into the hole. See Figure 18 The bar should rest on the bottom of the vertical bore. 3. Replace the plug. Figure 18 Installing the Stir Bar Drop the Stir Bar into the hole and replace the plug, (The stir bar is shown much larger than actual size ) Remove the plug from the top hole of the coiorimeter Colodmeter Assembly Page 34 Installing the Stir Bar Section 2 2.5 Supplying Sample Start sample flow through the instrument by opening the supply valve (item 19 in Figure 6 on page 19). Allow lhe pressure in the tubing to stabilize and check for leaks Until the sudace of the sample cell becomes completely wetted, bubbles may cling Io the sample cell and cause erratic readings This condition is temporary. Its duration depends on the sample properties 2.6 Supplying Power Set the POWER (I/O) switch to ON (I) and allow the analyzer to operate for approximately two hours to ensure the system is completely wetted with reagents and sample. 2.7 Instrument Setup Menus Setups for day-to-day analyzer functions are accessed from the SETUP menu To enter the SETUP menu, press the MENU key, then use the ARROW keys to scroll down to the sEruI' option Press ENTER. Scroll through the SETUP menu options with the ARROW keys. Press ENTER to select the displayed menu option. Arrow icons are displayed if the display is editable. Press the EXIT key to back out of a menu and return to SETU[ The menu information delow rs presented in the order it appears in the SETUP menu. SIGAVG--Use the ARROW keys to select 1,2, or 3 then press ENTER to accept the displayed selection. Depending on the value selected, the last t, 2, or 3 measurements are averaged and the reported concentration is of the averaged values CAL ZERO Use to force the measurement to zero by adjusting the offset. CAL ST~Use to make the measured value equal to a desired value by adjusting the gain. CAL DEFAULTS--Sets the Gain to 1.0 and sets the Offset to 0. OFFSET--Momentarily displays the current Zero correction factor. GAIN Momentarily displays the current Gain correction factor. DISPLAY TEST--Momentarily displays all LCD segments, RECMIN--Sets Recorder output to Iow setling (normalry 4 mA). RECMAX--Sets Recorder output to high setting (normally 20 mA). REC ADJUST--Allows the Recorder Minimum and Recorder Maximum values to be modified. Use the right and left ARROW keys to select Page 35 Supplying Sample Section 2 2.8 Alarm Setup RELAY TEST--Momentarily turns the relays off, then sequentially turns on ALARM1 and ALARM 2 Automatically clears both alarms to complete the test, REF--Momentadly displays the last Reference AJD counts SAMPLE Momentarily displays the last Sample A/D counts. ZERO--Momentarily displays the last Zero ND counts CYCLE TIME--Momentarily displays the Motor On time (in seconds) POWER FAIL WARNING--Set the power fail warning to ON or OFF. Press ENTER then use the ARROW keys to toggle between ON and OFF Press ENTER to select. Press EXIT to reject changes and return to If the power fail warning is already on and the power is interrupted, a system warning will be generated when power is restored. DIAG OUTPUT--ON or OFF Press ENTER then use the ARROW keys to toggle between ON and OFF. Press ENTER to select. Press EXIT to reject changes and return to SETrJR If DD, C OL"rPUT is on and the optional LonWorks® interface is present, diagnostic data will be sent out, KEYBOARD LOCKOUT~N or OFF. Press ENTER then use the ARROW keys to toggle between ON and OFE Press ENTER to select. Press EXIT to return to SETIJP If the keyboard is locked out, no editing functions are allowed and all diagnostics are disabled except this one. Default is OFF LANGUAGE--English/default), Spanish, French, and German. Press ENTER then use the ARROW keys to move between the availadle options. Press the ENTER key when the language of choice is displayed. Press the EXIT key to reject changes and return to DEFAULT SETUP Sets the instrument to factory defaults. All user-specified settings will be lost. Two alarms (Al and A2) are available. Either alarm may de set for the options listed below. Use the ARROW keys to scroll through the menu selections then press ENTER to select the displayed menu option. SYSTEM ALARM (SA)--Activ&tes &n alarm when a system alarm occurs. SYSTEM WARNING (SW~Activates an alarm when a system warnir~g occurs. HI-- Alarm is triggered if concentration is greater than or equal to the trip point (00 mg/L to 5.0 mg/L limits) LO--Alarm is triggered if concentration is less than or equal to the trip point. (00 mg/L to 5.0 mg/L limits) Page 36 Alarm Setup Section 2 In addition, a selection to recall or clear warnings is available. RECALL WARNINGS--Momentarily shows all active warnings then displays CLEAR WARNING~Clears all warnings then momentarily displays 2.9 Recorder Output Setup Adjust the recorder output minimum and maximum values using the analyzer keypad. From the Recorder Menu select one of the following then press ENTER, Use the ARROW keys to adjust the value if appropriate then press ENTER to accept. REC LO 0.0 mg/L to 5.0 mg/L limits REC HI 0.0 mg/L to 5.0 mg/L limits. ON SYSTEM ALARM--Recorder will go to minimum, maximum or hold when a system alarm is initiated. 2.10 Maintenance Menus The following selections allow the user to perform standard maintenance tasks. Use the ARROW keys to scroll through the menu selections then press ENTER to select the displayed menu option, PRIME--Allow 39 concurrent accelerated cycles to prime the reagent fines. CLEAN--Stops the measurement cycle with sample and reagents in the sample cell. The analyzer remains in the clean mode for 60 minutes or until the EXIT key is pressed. HOLD OUTPUTS--Enables the Alarm Lockout function, disabling alarms and illuminating (flashing) the Alarm LED. Remains active for 60 minutes or until the HO,L~) OUTPUTS is turned off Page 37 Recorder Output Setup J Section 2 2.11 Calibration The Hach CLJ 7 Chlorine Analyzer is factory calibrated. A builtdn electronic curve is preprogrammed into the instrument. This instrument does not require recalibration unless specified by your regulatory agency for compliance reporting purposes. 2.11.1 Calibration Setup Menu Functions The offset can be adjusted using the CAE ZERO function The calibration gain can be adjusted with the CAE STD function. The gain adjustment is best accomplished when the standard value is greater than 50% of the instrument measurement range. Adjusting the calibration gain when the standard value is close ~o the zero value can generate potentially large gain errors, resulting in significant measurement errors on high levels of sample CALZERO Successful Calibration If a current measured value exists and the ENTER key i$ pressed, the current measured value wilt be displayed. If the ENTER key is pressed a second time, and the current measured value is less than 0.5 rog/L, DONE will momentarily appear and the current measured value will be OFFSET to 0.0 mg/L. If the erigrnal measured value was greater than 02 mg/L, a marginal zero system warning (~,IARG Z) will occur. Failure to Calibrate If there is no current measurement. ERROR will be momentarily displayed when the ENTER key is pressed the first time. If the current measured value is greater than 05 mg/L and the ENTER key is pressed a second time, ERROR will be momentarily displayed and no zero calibration will occur. CALSTD Successful Calibration if a current measured value exists and the ENTER key is pressed, the current measured value will be displayed. If the ENTER key is pressed a second time, the current value is available for editing Edit the value using the left and right ARROW keys to highlight a digit and the up and down ARROW keys to change its value. When the expected value has been entered, press the ENTER key to adjust the gain to yield the edited value. If the required gain is greater than 0.5 and Jess than 2.0, the measured value will be forced fo be the expected value. If the resulting gain is greater than 1.1 or less than 0.9, a marginal gain system warning (',E~,RG C) will occur Failure to Calibrate If there is no current measurement, ERROR will be momentarily displayed when the ENTER key is pressed the first tlme. If, affer editing the current value, the required gain is greater than 2.0 or less than 0,5 and the ENTER key ~s pressed a second time, no gain adjustment will take place and the current value will not change to the expected value. Page 38 Calibration Section 2 2.11.2 Calibration on Known Standards 0 CAUTION To familiarize yourself with handling precautions, dangers PRUDENCE Pour se farniliariser avec les precautions ~ prendre lore de ia manipulation, les dangers et les procedures d"ucgence, toujours lire les Fiches de Donn~es de S~curit~ dee Produite avant de rnanipuler les r~cipients, les r~servoire et les systgrnes de distribution contenant les r&actifs chimiques et les solutions ~talons. II est toujours recommand~ de porter des lunelfes de protection Iorsqu'un contact avec les prodults chirniques est possible. CUIDAUO Para familterizarse con las precauciones de manipulacidn, los poligros ¥ los procedimientos de emergencte, stempre estudle las Hojas de Datos de Seguridad de los Materiales antes de maniputer recipientes, dep~$itos y $istetnas de entrega quo contengan reactivos y patrones qu/micos. Siempre se recomienda el uso de protectores ocuteres cuando sea poslble el contecto con productos qu[micos. VORISCHT ES wird dringend empfohlen, die SicherheltsdatellblCJlfer vor der Handhabung yon Beh~ltern, Tanks und Zufuhrsystemen, die chemische Reagenzlen und Stendardsubstenzen enihalten, aufrnerksam durchzulesen, damit Sie sich mit den beim Umgang mit diesen Chemikalten nofwendigen VorslchtsmaBnahmen, Rislken Und Noffallschu~.magnahmen vertraut machen, ES wi~ empfohlen, in allen Situationen, in denon mit einem Kontekt mit Chemikalten zu rechnen ist, eine Schutzbrille zu tragen. CUIDADO Para familiarizar-$e cum as precaucGes de rnanipute¢ao, riscos e procedimentos de emerg~ncia, examine sempre o Folheto de Dados de Seguran~a antes de rnanipular os recipientes, tenque$ e sistemas da distribui~&o quo contenham reagentes quimicos e outros elementes padronizados. Se recomenda sempre o uso de protetores para o/hoe, quando possa acontecer cotlteto cum OS produtos qulrnicos. This procedure provides the best over all accure, cy by establishing the zero mg?L reference amd the span setting. Pedorm the calibration as follows: 1. Prepare a zero chlorine reference solution by adding approximately 4 mL of Ferrous Ammonium Sulfate, Cat. Ne, 1811-33, fo approximately 2 liters of the normal sample or chlorir~e free deminera~ized wafer. Place a container of zero reference water above the analyzer with at least two feet of head, Plumb the system to enable the sample flow to be shut off so the zero reference water can enter the analyzer in its place. Allow the analyzer to run on zero reference water for approximately 10 minutes. 3. When the readings are stable, set the zero reference. a. Enter the SETL~P menu b. Press the down ARROW key until C&[, ZEI[O is displayed. c. Press ENTER to display the current measured value. d. Press ENTER agai~ to force the value to zero. Page 39 Calibration Section 2 Prepare a chlorine standard solution with a value between 3 and 5 mg/L. Determine the value of tbe standard to the nearest 0.01 mg/b Remove the container of zero reference water and substitute the chlorine standard solution. Allow the analyzer to run on the standard solution for approximately 10 minutes When the readings are stable, enter the SETUP menu Press the down ARROW key until CAL STD is displayed. Press ENTER The current measured value is displayed. Press ENTER and edit the value Press ENTER again to accept the value. The measured value will be forced to the entered value Press the EXIT key to return to normal display mode Remove the standard and restore sample flow to the analyzer The instrument is now calibrated. 2.11.3 Calibration by Comparison Calibration by comparison involves analyzing the sample stream with a reliable, accurate laboratory method, such as a DPD spectrophotometric or amperomefoc titration method then setting the analyzer to match. Accuracy specifications over the full 0-5 mg/L range cannot be assured unless sample chlorine concentration is greater than 3.0 mg/L. Setting the calibrabon at lower concentrations may provide accuracy at that point but can cause large errors in other portions of the span, 2.11.3.1 Calibration by Comparison at Concentrations Lower than 0.5 mg/L Tu ensure accuracy with this mett~od at concentrations less than 0 5 rog/L, establish a zero reference by adding a dechlorinating agent to the sample cell during one measurement cycle Obtain Dechlorinating Solution reagent, Hach Cat. No. 323-32, and use the following procedure to set the zero reference: Observe the front of the pump module throughout a measurement cycle. Make note of the point where reagents are added as indicated by the flattening of the two center tubes in the pump module. When the reagent tubes degin to flatten during the next cycle, remove the top plug on the colodmeter, add two drops of dechlorinating solution through the hole and replace the plug. 3. Wait until the display is updated with the nexl reading 4. Set the zero reference as follows; b. Press the down ARROW key until CAI. ZERO is displayed. Page 40 Calibration MAINTENANCE DANGER Some of the following manual sections contain information in the form of warnings, cautions and notes that require special attention. Read and follow these instructions carefully to avoid personal injury and damage to the instrument. Only personnel qualified to do so should conduct the/maintenance tasks described in this portion of the manual~ DANGER Certains des chapitres suivants de ce mode d'emploi contiennent des informations sous la forme d'avertissements, messages de prudence et notes qul demandent une attention particuli~re. Lire et suivre ces instructions attentivement pour ~viter les risques de blessures des personnes et de d~t~rioration de Fappareil. Les t~ches et d'entretien d~crites dans cette partie du mode d'emploi doivent ~tre seulement effectu~es par le personnel qualifi~ pour te faire. PELIGRO Algunos de los cap£tutes del manual que presentamos contienen informaci6n muy importante en forma de alertas, notas y precaucfones a romar. Lea y siga cuidadosamente estes instrucclones a fin de evitar accidentes personales y da~os al instrumento. Las tateas de mantenlmtenfo descritas en la presente seccldn deber~n set efectuadas dnicamente por personas debidamente cualificadas. GEFA HR Einige der folgenden Abschnitte dieses Handbuchs enthalten Informationen in Form yon Warnungen, Vorsichtemaf3nahmen oder Anmerkungen, die besonders beachtet werden mOssen. Lesen und befolgen Ste dlese Instruktionen aufmerksam, um Verletzungen von Personen oder Sch~den am Ger~f zu vermeiden. In dtesem Abschnitt beschriebene Wartungsaufgaben d~t~en nut Yon qualifiziertem Personal durchgefOhrt werden. PERIGO Algumas das seguintes sec~es do manual contain informa~6es em forma de advert~ncias, precau~e$ e notas que requerem especial aten~o. Leia e slga atentamente as presentes instru~e$ para evlter terimento$ pessoais e n~o dantticar o Instrumento. As terefas de manuten~o descritas nesta parte do manual s~ poder~o ser executedas por possoal qualificado para o fazer. Page 41 MAINTENANCE Section 3 ; Maintenance CAUTION TO familiarize yourself with handling precautions, dangers and emergency procedures, always review the Material Safety Data Sheets prior to handling containers, reservoirs, and delivery systems that contain chemical reagents and standards. Protective eye wear is always recommended when contact with chemicals is possible. PRUDENCE P¢~ur se familiariser avec les precautions ~ prendre lore de Fa manipulation, les dangers et les procedures d'urgence, touJours lire les Fiches de Donn~es de S~curit~ des Pr~duits avant de manipuler les r~cipients, les r~servoirs et lea syst~mes de distribution COtltenant les r~actifs chirniques et les solutions ~telons. fl est teujours recommand~ de porter des lunettes de protection Iorsqu'un contact avec les produite chimiques est possible. CUIDADO Para familJarizarse con las prgcauciones de manipulacion, tee peligros y los procedimiento$ de emergencia, $iempre esfudie las Hojas de Datos de Seguridad de los Matertales antes de maniputer recipiente$, depdsitos y sistemas de entrega quo contengan reactivos y patrones qu[micos. Siempre se recomienda el uso de protectores ocufares cuando sea posibie el contecto con productos qu[micos. VORSICHT ES wird dringend empfohlen, die Sicherheitsdatenbliitter vor der Handhabung yon Beh~ltern, Tanks und Zufuhrsystemen, die chemische Reagenzien und Standardsubstanzen enthalten, aufmerksam durchzulesen, damit Sie sich mit den beirn Umgang mit diesen Chemlkalien notwendigen Vorsichtemal~nahmen, RisJken und NoffallschutzmaBnahrnen vertrauI machen, ES wird empfohlen, In agen Situationen, in denon mil einem Kontekt mit Chemikallen zu rechnen ist, eine Schutzbrille zu tragen. CUIDADO Para familiarizar-se eom as precau~es de rt~anipula~o, riscos e procedimento$ de emerg~ncia, examine sempre o Folheto de Dados de Seguran~a antes de manipular os reciptentes, tanques e sistemas de distribuiF~o quo contenham reagentee qu[micos e outres eiementos padronizado$. Se reconlenda sempre o uso de protetores para olhos, quando possa acontecer conteto corn os produtos quimlcos. 3.1 Scheduled Maintenance 3.1.1 Replenishing the Reagents One 500-mE bottle each of buffer and indicator solution lasts approximately one month. Discard the old containers with any unused contents end install the new bottles as described in Section 2,3 on page 33. 3.1.2 Replacing the Pump Tubing Over a period of time, the clamping action of the pump/valve module will soften the tubing and cause it to collapse and obstruct liquid flow. This breakdown is accelerated at high temperatures. The following replacement schedules, based on ambient operating temperature, are recommended: Below 27 °C (80 °F), replace at six-month intervals. · Above 27 °C, replace at three-month intervals. Section 3 Install the replacement tubing as follows: 1. Shut off sample flow to the instrument and set the POWER (I/O) switch to OFF (O) Remove the screws securing the pinch pi&to to the pump/valve module. See Section 1 9 on page 27. Loosen in small increments, moving from one screw to the other to allow tension to be relieved evenly. Remove the plate, 3. Disconnect the pump tubes from the inlet and outlet fittings and discard the tube assemblies Cut four 2-inch lengths of 1/16-inch ID tubing (white). Install one 1/16-to 1/8-barb elbow fittings in one of the 1/16 inch lB tubes (white) and 1/16-inch barb union fittings in the three remaining tubes. Aghough one of the pump tubes is net used for fluid flow, it must be included to provide even compression on all four tubes. Install the two screws through the pinch plate and info the pump/valve module. When securing the pinch plate, advance the screws in small ~ncrements moving from one screw to the other so that the plate is drawn down evenly. Tighten until snug, do not overtighten Set the POWER (I/O) switch to ON (I) and restore sample flow through the instrument. Allow the instrument to run for approximately one hour to fill the reagent lines 3.1.3 Replacing the Analyzer Tubing Remaining tubing in the analyzer should be replaced annually, The maintenance kit is available with the tubing harnesses assembled (Cat No 54443-01) or unassembled (Cat. No. 54443-00) If you have ordered the unassembled maintenance Kit, use Figure t9 and Table 3 on page 45 to determine the tubing lengths and positions. When installing new tubing it is helpful to dip the ends in hot water before making the connections. It also is recommended that one tube at time be removed and replaced. Numbers on the illustration correspond to the item numbers listed in the legend where the size, catalog number, and quantity also are given. The length given in Table 3 tells how long that particular tubing segment should be; the operator must cut a piece to that length from a coil of the proper tubing The catalog number given for the tubing in the legend identifies the coil of tubing to cut tbe segment from and not the number of the segment itself DPD Reagent tubing may darken before the scheduled replacement time but that will not affect the performance of the instrument. Page 44 Scheduled Maintenance Section 3 Figure 19 Plumbing Oiagram THIS CLASS A DIGITAL APPARATUS MEET~ BROUILLEUR DU CANADA 1/2 IN. LO. TUBE lAX Table 3 Replacement Tubing Lengths for Figure 19 ttem Description Length (Qty) From.,, 1 1/8" ID, 1/4" OD 4 5 inches (t) Pump Body Out 2 1/32" ID, 3/32" OD 7 5 inches (2) Pump Body Out 3 1/16" ID, 3/32" OD 20 inches (4) Pump Body In 4 1/32" lBr 3/32" OD 70 inches (2) Reagent Bottle Cap 5 1/32" ID, 3/32" OD 60 inches (2) Reagenl Botile Cap 6 ! 1/32" ID, 3/32" OD ~ 70inches (2) Reagent Bottle Bodon 7 1/8" ID, 1/4" OD 7.0 inches (t) Sample Bypass Tee 8 1/8" ID, 1/4" OD 1 ~5 inches Sample Bypass Tee 9 1/4" OD x 0 04 W, Black vanes (1) Sample Conditionfng O 10 ti2" ID varies (1) Instrument Drain 11 1/32" ID, 3/32" OD~ 3 inches Sample Bypass Tee 12 I 1/32" ID, 3/32" OD! I 0 inch (1) Y-Fitting From.,, To... Catalog Number Pump Body Out Colorirneter 43293-00 Pump Body Out Y-Fitting 44253-00 Pump Body In Pump Body Out 42717-00 Reagent Bottle Cap Pump Body In 44253-00 Reagent Betile Cap Reagent Vent FitPng 44253 O0 ~eagent Bottle Bodom Reagent Bottle Cap 44253-00 Sample Bypass Tee Pump Body In 43293-00 Sample Bypass Tee Sample Inlet Fitting 43293 00 ~mple Conditioning Out Case Fitting 30616-00 Instrument Drain Customer Drain (not supplied) Sample Bypass Tee Drain fitting 44253-00 Y-Fitting Colorirnel~r 44253-00 Page 45 Scheduled Maintenance Section 3 3.2 3.2.1 DANGER Remove power from the instrument when removing or installing a fuse. Unscheduled Maintenance Fuse Replacement The T, 25A, 250V fuse used in this instrument is used for both 115V and 230V operation DANGER Couper I'alimentatio~l ~lectrique de I'appareil pour retirer ou installer un fusible. PELIGRO Apagar la electricidad del Instrumento al quitar o instalar fusibles. GEFAHR Beim Entfernen oder Einsatzan der Sicherung muss die Stromzufuhr zum Ger~t unterbrochen werden. PERIGO Oesconecte a energia do instrumento ac remover Gu instalar um fusivei. Replace as follows: Make sure there is no power supplied to the instrument the instrument power switch does not remove power from the fuses, Power must be disconnected remotely to remove power from the fuses. Remove the customer access cove~ DANGER For continued protection against tire hazard, replace the fuse only with a fuse of the same type and rating. 3. Locate the fuse holders (near the terminal strip in the customer wiring compartment). See Figure 11 on page 24 DANGER Pour assurer la protection centre les risques d'incendies, remplacez les fusibles PERIGG Para prote~ao continua contra fogo, troque os fua[veis somente per fus[veis do ripe especificado para a forca da corrente. 4. Remove the two fuses (Fl and F2) and replace them with two new fuses with the same specifications (T, 2 5A, 250V). See Replacement Items on page 65. 5. Reinstall the customer access cover a~d resupply power Page 46 Unscheduled Maintenance Section 3 Figure 20 Removing the stir bar Gently insert a straightened paper clip into the hole, at the top of the colorimeter, and slowly pull out the stir bar Remove the plug from the top hole of the colorimeter. ,.~ Colorimeter Assembly 3.2.2 Cleaning the Instrument Enclosure With the enclosure securely latched, use a soft cloth and a mild detergent to wipe the outside of the encrosure Do not allow moisture to enter the enclosure. O CAUTION The chemicals used in this p~ocedure may be hazardous if inappropriately handled or accidentally misused. Please read all warnings on ihe reagent labels. Protective eye wear is always recommended when contact with chemicals ia 3.2.3 Cleaning the Colorimeter The coforimeter measuring cell may collect sediment or develop a film growth on the inside walls. Cleaning with an acid solution and a cotton swab on a monthly basis is recommended. Depending on sample conditions, it may be necessary to clean the cell more often. CUIDADO Les produits chimiques utili$&$ dans cede procddure peuvent ~tre dangereux S 'ils sont manias d'une mani&re inappropri& ou mai utllis~s par m~garde. Pri&re de lire toute$ les raises en garde apparaissant sur les &tlquettes des r~ctifs. II est toujours recommand~ de porler des lunettes de protection Iorsqu'un contact avec les produits chimlq[le$ esi possible. PRUDENCE Los p~oductos qu~micoa utllizado$ en este pn~.~edimiento pueden set peligroso$ si se manejan inadecuadamente o se emplean ma! accidentalmente. Tonga a Page 47 Unscheduled Maintenance Section 3 VORSlCHT Die in diesem Verfahren verwendeten Chemlka#en kOnnen bel unsachgem~Ber Handhabullg und versehentlfchenl M#~brauch gef~hrlich sein. Biffe ella Warnungen auf den Reagenz-E#keffen lesen. ES wird empfohfen, in allen Situat[onen, in denon mit ainem Kontakt mit Chemlka#en zu rechnen ist, eine Schutzbr#le zu trsgen. CUIDADO OS produtos qufmicos usados haste processo podem sar perigosos se manuseados inapropriadamente ou usados acldentalmente de forma indevida. Leia todo$ os avi$os de precau~ao contido$ nos ~5tulos de reagentes. Se recomenda sempre o uso de protetores para olhos, quando possa acontecer contato corn os produtos qu[mlcos. Clean the colorimeter cell as follows: 1. Press the MENU key, then press the down ARROW key until the t'4A[P4T menu appears. Press ENTER, 2. Press the down ARROW key to scroll to the CLEA~ option. Press ENTER. 3. Refer to Figure 20 and locate the colorimeter 4. Remove the rubber plug on the top of the colorimeter assembly 5. Remove the magnetic stir bar using a bent steel paper clip as a retrieval tool See Figure 20 6. Wait until CI~EAN flashes on the status line of the display, then filr the colodmeter with 19 2 N Sutfuric Acid Standard Solution (Cat. No. 2038-32) Insert a wooden or paper cotton tipped swab* into the opening and move it up and down with a gentle scrubbing action, cleaning the interior surfaces of the colorimeter cell. Refer to Figure 21 Clean the stir bar with the cotton swab. 9. Reinstall the stir bar. 10. 11, Replace the rubber plug on the top of the colorimeter assembly and make sure the cover is on the viewing port of the colobmeter. Press the EXIT key to immediately return to normal operation; the instrument will return to normal operation automatically after 60 minutes. · Do not use a plastic swab when cleaning the colodmeter with sulfuric acid, the acid will dis. solve the plastic. Page 48 Unscheduled Maintenance Section 3 Figure21 Cleaning the Colorimeter Remove the plug from the top hole of the colorimeter Colorimeter Assembly 3.2.4 Replacing the Sample Conditioning Filter To insert the filter into the housing; 1. Isolate the filter by turning the valves on each side to OFF 2. Unscrew the top of the filter housing. See Figure 6 on page 19. 3. Insert the filter element and push until it stays in place. 4. Replace the filter housing top. 3.2,5 Reagent Spill Clean Up Instructions wipe up spills with a clean, disposable wipe and discard according to applicable Federal, State, and Local regulations. Page 49 Unscheduled Maintenance Section 4 Troubleshooting In the event the instrument should malfunction, the following troubleshooting guide may be used to help isolate the problem. Please contact the nearest Hach Service Center for assistance or shipping instructions if Ihe instrument must be returned 4.1 Symptom Troubleshooting Guide Table 4 supplies troubleshooting information for the instrument. After determining the symptom and probable cause, pedorm the corrective action steps in the order g~ven Table 4 Troubleshooting Guide Probabre Cause Corrective Action Display does not light and the pump motor is not operating NO operating power Check power switch position, fuses, and power cord connections. Display does not light and the pump Prnblem with power supply Replace the main circuit board. motor operates, DispJay lights LOW operating power Verify lhe line voltage is within specifications. motorand thedoesPUmp Incorrect line vnrtage selector switch setting CheckCheck tic--the line voltage selector switch position. not operate. Motor cable not connected to ihe circ[~it board Defective motor NO Stir Bar ~re Plate thumb screws are not fully Zero reading tightened Sample is not flowing to the instrumen Sample is even'lowing from the Drain liile clogged or a~r lock in drain line coIorimeter Ture' analyzer environment is too large. Low reading Clogged tubing Replace motor. Place Stir Bar into Colorimeter (Refer to the CL 17 Tighten the thumb screws, Check the sample conditioning and other sample supply lines Remove the plug from the top of the colorimeter and use a gashlight to illuminate the inside of fhe cell Look bar Js inside Remove excess stir bars into the colorimeter to determine if more than one stir Clean drain line and/or eliminate air look from drain plumbing. When practical, allow the sample temperature to warm iture before it enters the analyzer. Page 51 Section 4 4.2 System Alarms An &latin message is displayed and the instrument ceases to function normally when a System Alarm is activated, Resolve the alarm to resume normal operation. Table 5 System Alarms A2D Error LED Failure Motor Failure SCR Error What the Alarm Indicates Inability to write to the E£ ROM A/D counts rndicams that the colorimeter is reading zero light throughput, So Jt is Ifkely the photo detector/analog to digital converter is faulty, The colorimeter's photo detector is reading an extremely Iow level of light for the reference reading (less than 100 A/D counts) Indicates that the pump motor's home position flag was not detected The Cycle Motor does not turn off at the appropriate time, resulting in a short total cycle time, Alarm Display and Instrument Indication EE ERROR A~[~ ERROR - EXIT TO RESTART Alarm LED is lit TEl) ERROR - EXIT TO RESTART Alarm LED is lit Alarm LED is lit SCR ERROR - EXIT TO RESTART Alarm LED is lit Call Hach Service Press the EXIT key to restart the instrument If the problem recurs, there is a problem may not be making a proper conneogon. with the colorimeter. The connector belween the instrument and the co[orimeter Remove the colodmeter, inspect the necessary Reinstall Ihe colorimeter If the connector pins and straighten the pins if problem remains, replace the colorime~tte~ Press the EXIT key Io restart the instrumenten~l~ If lhe problem recurs clean the sample c If the problem is not yet resoi,ved, remove I the plug from the colorimeter s sample viewing port. You should be able to observe a green light (YOU must wait several minutes from instrument turn on for the light to come on) It will remain on continuously the earle If the light does no come on and the colorimeter has just been removed and re-inserted, the colodmeter connector is not making a proper bent, straighten them and rainsoft the connection Remove the oolorlmeter and inspect the connector pins If the pins are colorimeter If the problem still remains, replace the colobmeler Contact Rach Service Press the EXIT key o restart the instrument. If the problem recurs, check the forlowing If the motor does not turn when the instrument is turned on, try the main circuit board 1. Check that the motor JS plugged into the 2. Replace the motor. 3. Replace the main circuit board, If the motor does run and the motor coupler is turning, try the following: I Check that the optical switch is properly plugged into the main c~rcuit board and the switch is properly located in the chassis. 2 Replace the optical switch. ' 3, Replace the main circuit beard. Press the EXIT key to restart the the main circuit board. instrument, If the problem recurs, replace Page 52 System Alarms 4.3 System Warnings Section 4 POWER Low Signal Table 6 System Warnings What the Alarm Indicates Alarm Display and Instrument Indication Powe~ tailed In default condition, this warning rs disabled Reference measurement is less than 2000 A/D Resolution Marginal Gain Marginal Zero Marginal Offset calibration resulted in a gain correction factor eater than 1.1 or less than 09 The calfbration standard and the value that the operator is afiempting to input do not match. Re test the calibration standard and pedorm a new calibration on the CLI 7. A calibratio~q resulted ~n an offset correction factor greater than 0 2 and less than 0.5 Inspect wiring and circuit POWER breakers that delNer 2ewer to the CL17, t,ow$1c Clean sample cell Replace sample cell Set CAL Defaults. MARC G Verify standard varue Recalibrate the Set CAL Defaults Verily zero value Recalibrate the instrufflent Verify the colorimeter end caps are firmly screwed in place Check for light leaks A high offset count was measured with the LED off. Usually caused by fight leaks. MARG Z MARG 0 Page 53 System Warnings Replacement Items Replacement Parts and Reagents Description Unit Cat. No. Circuit Board Assembly, main ............................................................................... each ...... 54404 00 Colorimeter Module each ........ 54455-00 Colorimeter Plug each ..........51224-00 Connector for Alarm or Recorder ........................................................................... each ....... 44582-00 Cam/Coupler Assembly each ..... 54452-00 Follower Block, Reagent each ......... 42741-00 Follower Block, Sample each ...... 42742700 Fuse, (~ 2.5 A, 250V) UL/CSA/CE accepted, 2 needed ................................................. each ..........49526-00 Installation Kit each ..........55164-00 Maintenance Kit each .... 54443-00 Maintenance Kit, preassembled each ....... 54443 01 Motor Assembly each ..........54446-00 Pressure Plate each ..........54118-00 Reagent Kit for Free Chlorine testing each .......... 25569 00 Includes: Free Chlorine Buffer Solution 23141-11 Free Chlorine Indicator Solution 23140-11 DPD Indicator Powder 22972-55 Reagent Kit for Total Chlorine testing each .........25570-00 Includes: Total Chlorine Buffer Solution 22635-11 Total Chlorine Indicator Solution 22634-11 DPD Indicator Powder 22972-55 Screen, 40-mesh, replacement for Sample Conditioning ................................................... each ...... 54184-00 Stir Bar, Micro, 3mm x 8mm each ........ 54129-00 Thumb Screw, to hold Pressure Plate 8 .......... 54101-00 Optional Accessories Flow Meter with 1/4-inch OD tubing each ....... 46436-00 Power Cord kit with strain relief, 115 V, North American Operation .................................. each ..........54488 00 Power Cord Kit with strain relief, 240 V, European Operation ............................................. each ........ 54489-00 Page 65 Replacement Items GE Fanuc Automation GFK-1411C IVlay ~OOO Warnings, Cautions, and Notes as Used in this Publication warning I Note Revisions to This F&mual Content of This Manual Chapter 3. Appendix A. Appendix B. Appendix C. Preface Appendix D. Related Contents Chapter I Chapter 2 Sy~em Operation ............................................................................................ 2-1 Section 1: PLCSweepSnmmary ................................................................. 2-2 Stm~iard Program Sweep ........................................................................................... 2-2 Sw~p Time Calcu]atlon ........................................................................................ 2-7 Example of Sv~ep Time Calcalati~n ................................................... 2-7 HousekeL-ping 2-7 Input Sc-aa 2-7 Application Pr og~am Lc~gic Scan or Solution 2-8 Output Scaa 2 $ Logic Program Ch~.ksum Calcula~oa ........................................................ 2-8 Prngramm~ Communications Window ......................................................................... 2-9 System Commumcations Window .............................................................................. 2- l 0 PCM Communications with the PLC (Models 33 l aod Higher) ................................... 2 - l 1 DSM Comrnunications with the PLC ......................................................................... 2- I 1 Standard Prngxam Sweep Variations ........................................................................... 2-12 Constant Sweep T~m¢ Mode ................................................................................. 2-12 PLC S w~'ep When in STOP Mode ........................................................................ 2-12 commumcation Window Modes ...........................................................................2-13 Key Switch on 35x and 36x Serie~ CPU$: Change Mode ~nd Flash Protect ................. 2-13 Using the Release 7 and Late Key Switch ............................................................ 2-13 Cleam~g the Fault Table with the Key Switch ....................................................... 2-14 Er~hancod Memory Pro,eta with Release 8 m~d Later CPUs ................................... 2-14 Section 2: Progmm Organization and User References/Data .................. .2-15 Subroutine Blocks ...................................................................................................... 2 - 16 Examples of Using Subroutine Blocks .................................................................. 2-16 How Blocks Are Called ........................................................................................ 2-17 Periodic Subroutines ............................................................................................. 2- I 8 User References .......................................................................................................... 2-19 Transitions and Overrides ..................................................................................... 2-20 Retentiveness of Data .......................................................................................... 2-20 Data Types ................................................................................................................. 2-21 System Status References ........................................................................................... 2-22 Ftmctlon Block Structure ............................................................................................ 2-25 Format of Ladder Logic Relays ............................................................................ 2-25 Format of Program Function Blecks ..................................................................... 2-26 Function Block Parar~ter$ ......................................................................................... 2-27 Power Flow In and Out of a Function ............................................................... 2-28 Seetion 3: Power-Up and Power-Down Sequenc~ ...................................... 2-29 Power-Up ................................................................................................................... 2-29 Power-Down ............................................................................................................... 2-31 Contents Chapter 3 Section 4: Clocks and Timers .................................................................... 2-32 l/lapsed Time Clock .................................................................................................... 2-32 Time-of-Day Clock .................................................................................................... 2-32 Watchdog Timer ......................................................................................................... 2-33 Constant Sweep Timer ............................................................................................. 2-33 Tune-Tick Contacts .................................................................................................... 2-33 Section 5: System Se~urit~ ............................................................................. 2-34 Contents Appendix A Appendix B Append~ C Appendix D Progrmn Block Checkstm~ Failure ......................................................................... 3-11 Low ft artery Signal ............................................................................................... 3- I 1 Conslam Sweep Time Exee~nted ........................................................................... 3-12 Application Fault .................................................................................................. 3-12 No User Program Present .................................................................................... 3-12 Corrupted Use~ Program on Power-Up ................................................................. 3-13 Pasawc~d Access Failure ................................................................................... 3-13 PLC CPU System Software Failut~ ..................................................................... 3-14 C oraraunica~oas Failure Du~ng Store .................................................................. 3-!6 Section 3: I/O Faull Table Explanations ..................................................... 3-I7 Contents Con~n~ Contents Chapter Introduction 1 No~e Chapter 2 System Operation GFK-1411C 2-1 Section 1: PLC Sweep Summary Standard Program Sweep TIME OF PLC contribute to the total sweep time ~ shown in the following table 2A76 0.334 I 248 0,517 1.043 0.482 0463 0.319 0.031 0.010 35x anti 36x Series CPUs Main ! Expan$ioa Retake N/A N/A N/A N/A Module Type 1.083 ~06t ?97 .253 .054 ltig~h $~ed C~ln~r ! 2.070 ~ 2.[90 ~22.86~- ~ 75.587 ~ 2.175 ] 4.897 ~ 8~ntae~c~ [11.~20 [t1570 ~13,247 21.288 ]9.536 10.~8 ~19.485 [~M~ ] ~ dev~i~ ~887 %7 t.l~ 1.920 [.6~ .~1 '1.626 ]32~inl a:20 ~6250 ~8.529 21352 ]5~3 71~ [20.0~2 / Ma.e, ,~ ~nt ] 6.020 6A70 8.399 !2t.291 a.~ 6.98~ 20.010 Sweep Time Calculation Example of Sweep Time Calculation Hous~keepin9 Input Scan Application Program Logic Scan or Solution Out,out Scan Logic Program Checksum Calculation Programmer Communications Window Note The timc limit for the communications window is 6 migiseconds for the m~lel 340 and laigh*r CPU$ and 8 milliseconds for lhe 31 I. 313. 323. and 331 medels. Thc following figure is a flow char~ for the programmer communications potion of the sw~p. System Communications Window NO PCM Communications with the PLC (Models 331 and Higher) a43067 NO DSM Communications with the PLC Standard Program Sweep Variations cncountcred or forced. These variations, described in the fo]lowing paragraphs, can be displayed Constant Swee~ Time Mode Note PLC Sweep When in STOP Mode Communication Window Modes Note Key Switch on 35x and 36x Series CPUs: Change Mode and Flash Protect Each of the 35x and 36x series £'PUs has a key switch o¢~ the from of the module that allows yau Beginning with Beleaae 7 of the 351and 352 CPUs, the Key Switch has another ~nctiom it allows Using the Release 7 and Later Key Switch Clearing the Fault Table with the Key Switch Note Key Swii~ h ON Toggle Enham;ed Memo~] Protect t~th Release 8 and Late* CPUs Section 2: Program Organization and User References/Data U~r Logig Memor~ Modela (Kbytes) CPU31 I 6 CPU313, CPU323 12 CPU331 16 CPU340 32 Subroutine Blocks Examples of Using Subrou~ne Blocks As an example, the logic fc~ a program could be divided into three subroutines, each of whlch could be called as needed from thc program. In this example, thc program block might comain little logic, serving primarily to sequence the subroutine blccks a45f161 How Blocks Are Called This example shows thc subroutine CALL instruction as it will appear in thc calling block. Periodic Subroutines User References Note TaMe 2-5. Discrete References [module A pa.ica,ar %Q rcferc.cc may be eithcr rctcn.~c or nu~'¢lc.dve~* Transitions and Overrides ~etentiveness of Oma Data Types BIT Bit DWORD System Stalu$ References I Reference ~Nickname ] %sooo.~ !T ~OMS ' %S0010 I0 FULL Definition Reset from I to 0 when the currem sweep ~s the last sweep. Always OFF %S~20 %S~21 FF_OVR %S~22 USR_$W %S~32 Table 2-7. $ Reference %SAO001 I%SAO009 Ci'G_MM [$¢1 whm. Co~ flgnatic~ mismat ci~ is detected during system %SA0020 SIO SFT SIO BAD_RAM BAD PWD SFT_CPU Tab{e zJ. Syslem S~ms R c.~m:~s - CemJmzed Function Block Structure Format of La~ler Logic Relays Format of Program Function Blocks Some functions are very simple, like the MCR function, which is shown with the a~or eviated Function Block Parameters Each linc exiting the right side of the ~nction block represents an eutpul. There is only one form Power Flow In and Out of a Function Section 3: Power-Up and Power-Down Sequences Power-Up A cold power-up consists of the following sequence ofevenis A warm power up sequence skips Step I Prior to thc START statemcnt on the Power Up Flowchart, the CPU goes through power up diagnostics which test various peripheral devtces used by the CPU and tests RAM. At,er intbmlation on the USD valid? (16) Is thc battery Iow? Power-Down Section 4: Clocks and Timers Clocks and timers provided by thc Set ic~ 90-30 PLC include an elapsed time clock, a time-of-day Elapsed Time Clock Time-of-Day Clock Watchdog Tim~ Constant Sweep Timer Tim~Tick Contacts Section 5: System Security Passwords Privilege Level Change Requests '[he privilege Icv¢I can be s~t in Control sollware (not ia VersaPro), ^ progrmnmcz rcqucsts a privilege level change by supplying the new privilege level and the possword f~r that Icvel. A Locking/Unlocking Subroutines or Pe,,,,anently Locking a Subroutine Section 6: Series 90-30 I/0 System The PLC I/O system prov/des the interface between the Series 90-30 PLC and user supplied devlce~ and equipment. The PLC system FO is called Series 90-30 l~O. Sc~es 90-30 FO modules plug directly into *lots in the CPU baseplate m- into slots in any of the expansion Imaeplatea for the Serie~ 90-30 PL£ Model 331 or higher Model 331,340, and 341 l/O systems support up to 49 Serie~ 90-30 b'O modules (5 racks). Model 350 to 364 I/O aysxeras suppotx up to 79 Series 90-30 I/O module~ (8 rocks) The Series 9(~30 PLC Model 311 or Model 313 5-slot ha.~epla~e supports up to 5 Series 90 30 FO modules; the Model 323 10 slot baseplate suppomq up to I0 Serle~ 90-30 I/O modules. Thc I/O structure for the Series 90-30 PLC is shown in the following figure. PLC I/0 System Series 90-30 I/0 Modules Note IC693 MDL230 8 32 32 32 24 VDC Negative Lo~¢ GFK-0898 GFK4)898 GFK4)898 GFK4898 GFKq)898 GFK4}$9§ GFK-089g GFK4}898 GFKd,1898 GFK4)898 [C693MDL310 [C693MDL330 IC693MDL3a0 IC693MDL390 IC693MDL730 IC693MDL73 I lC693MDL732 IC693MDL?33 IC693MDL734 IC693 MDL?40 , IC693MDL741 IC693MDL742 i IC693MDL750 ~L693MDL751 IC693MDL?52 IC693MDL753 IC693MDL930 IC693MDL93 I IC693MDL940 [C693DVM3D0 IC693ALG220 IC693ALG22 [ IC693ALG222 IC693ALG223 IC693AL0390 [C693AL0391 iC693AL,G392 12 ] 120 VAC, 0.5A ! 120/2a0 VAC, 2A 16 120 VAC, 0.SA 8 4ch 2 ch 2ch 8 ch 4/2 0FKO895 GFKq~g98 GFK4}898 GFK4)898 GFK4)g98 GFK4)898 0FK~895 OFK~898 IC693APU305 t ~ IC693BEM320 I/0 Data Formats Default Conditions for Series 90-30 Oulput Modules At power-up, Series 90 30 discrete omput modules default to ~utputs ott~ They will retain this default condttion until the first outpm scan from thc PLC. Analog output module~ can be Di~nostic Data Global Data Genius Global Data Ethernet Global Data Similar to Genios Global Data~ Ethernet Global Data (EOD) allows onc device (thc produce~) to Local Lo~ic Pro0rams Chapter 3 Fault Explanation and Correction [ hge Section 1: Fault Handling Faults occur in the Series 90-30 PLC sy~em when certain failm-es or conditions happen which Alarm Processor ~he condition or failure itself is called a fault. When a fault is r~ceived and processed by the CPU, it is called an alarm. The sol°cerar e in the CPU which handles these condinons is called lhe Alarm Classes of Faults System Reaction to Faults Fault Tables Table 3-1. Fa~k ,.~mmm~ Fault Group Fault Action Reboot Aft~ Fatal FauR This.leature is applicable fi}r CPU models 350, 352, 360, 363 and 364, PLC CPU Firmware release 10 O. or later and I/~rsaPro ! lO PLC software are required to use thi.~ fealure. A t~.er Fatal Fault, if enabled, allows the Sexies 90-30 PLC system to automatically resmae normal operation after a t~at al fault has occurged. This feature is useful in applications where the PLC feature, as no~ed in thc wanting below. Period (in minutes). ~et to STOP/FAULT Fault References Fault Reference Definitions Additional Fault Effects Side Effect Description [~ceded wi~h the sl:eCla[ Stari-~f-Sequence oammarM.and ending PLC Fault Table Display Thc PLC Fault Table screen displa3,s PLC faults such as password wolations, PLC/configm-abon I/0 Fault Table Display Accessing Additional Fault Information Section 2: PLC Fault Table Explanations 3-9 3-9 3-12 312 3-13 Fau#AcUons lnfornla~o~l faul~ are simply logged in the PLC fault table. Loss of, or Missing, Option Module Reset of, Addition of, or Extra, Oplion Module System Confkjuration Mi~al~ Option Module Software Failure Program Block Checksum Failure LowBattmySignal Constant Sweep Time Exceeded Application Fault No User Program Present Corrupted Use~ Program on Power-Up Password Access Fail~'e PLC CPU System Software Failure Communications Failure During Store Section 3:I/0 Fault Table Explanations The FO thuh robie reporls data about fauhs in three classifications: Fault category Fault type. Fault description. Ibc faults dc~cribad on the followiag page have a fault category, but do not have a fault type or fault group. Eacl~ t~ault cxpfanafion cc*ut ainu a fault description and inswumions to correct the fault. Many fault descriptions have multiple muses. The Fault Category is thc firat two hexadecimal digits in the Thc following table enables you to quickly find a particular 1/0 fault explanation in this section. Each cntry i~ listed as it appears on the prograraracr screen. Loss of I/0 Module Addition of I/0 Module Appendix A Instruction Timing Note Instruction Timing Tables TaMe A-3. SER Funclio~ Block Tm~ing Contlguoua 16 saml~es 24 samples 32 ~unples Register Value (dec) Value (hex) %R206 Parameter Value (dec) Value (hex} Instruction Sizes for High Performance CPUs Boolean Execution Times Appendix B Interpreting Fault Tables PLC Fault Table The following paragraphs d~cnbe each field in thc fi~ult entry. Included are tables describing the rmxge of values each field may have. S~are 0) Task PLC Fault Gro4Jp Fault group is thc highest classification of a fault. It identifies thc gcn~:r al category of thc fault. lahlc B-1 lists the possible fault groups in the PLC fault table. 129 137 4 4 B C D E 80 g2 87 89 Fault Ac'don £rror Code TaMe 8-3. ~ E~TOr Codes fei' PLC CPU Soltlftare Fakirs Decimnl ] Hexad~'¢imnl F Nnme 44 t 2C 45 2D 79 4F 255 FF 2 4 4 5 8 23 Mismatch of Dau ghler4aoard 3 401 3 I 2 2 5 6 6 7 2 3 4 FaLR E.x~a Data This field c~ntains d~tai]$ of the f~ult enn'y An examp]c of what data may he present arc: [4.51 Pl.c Fault rmte Stamp Table B*6. PLC Fault T*m~e S~ep ' Byte Nnmber i Description I/0 Fault Table The fbllowing paragraphs deacribe each field in the I/0 fault table, lu¢luded are tabl~ describing the range of values each field may have. Long/$ho~ Indicator Table B-L I/0 Fault T~ble Format In(icalor B~te Type [ (:ode [ Fault Specific Da~a Re/ezence Address [ Memo~ Type ]0 FF I~0 Faul~ Address Rack The rack numbec ranges from 0 to 7. Zero is the main tack, i.e., th~: one containing thc PLC. Packs I through 7 are expansion racka. ,~ot Ihe slot number ranges from 0 to 9 Fhc PLC CPU always occupies slot I in the main rack (rack 0) I/0 Fault Group l~agnostic I/0 Fault Actkm Thc ~*ult action specifics what aciion thc PLC CPU should takc when a fault cccurs. Table B- I 1 lists pe~iblc ~ul~ actions I/0 Fault Specific Oata Symboic Fault Specific Data Decimal Number [ ilex C~de i Description L 2 Fault Actions for Specific Faults Appendix C Using Floating-Point Numbers Note Floating-Point Numbers Ibc programming software provides the ability to edit, display, store, and retrieve numbers with Note The following format is used For numbers in the range 9999999 to .O001, die display has no exponent and up to six or seven significant digits For example: Intemal Format of Floating-Point Numbers Values of Floating-Point Numbers Expoueat ] Mantissa (f) [ Value of Floating P~int Number Foc example, c~sider the floating-point number 12.5. The IEEE floating point binary or 41480000 hex The mc/st significant bit (the sign bit) is zero (s 0) The next eight mnst Entedng and Displaying Floating-Point Numbers Errors in Floating-Point Numbers and Operations Note If you are using soft.axe floating point (all models capable of floating point operations except the 352 CPU), numbers are rounded to zero (0) at ~1 175494E 38 NaNSW = FFFFFFFFh NaN_ADD = 7F81FFF,t'h NaN_SUB = 7FRI FFFFh NaN_MUL - 7Fii2FFFFh NaN_DIV = 7Fll3FFFFh Note Operation lnpul I Input 2 Output Power Flow Appendix Setting Up a Modem D Modem Configuration and Cabling PLC CPU Configuration 3. Save the configuration of the CPU and download it to the PLC. Installing the Modem into Windows 5. Click OK until you have closed thc Modem IPropertics dialog box Setting Up the Communications Configuration Utility (CCU) In VersaPro, in the Tools menu, and password (dcl'ault is netutil). Once in CCU, ~lect the M~xiems tab. Click New co~e and phone number Click OK to 3 In the CCU, click on the Devices tab. Click New to add a new device to the list Connecting to the PLC Using the HyperTerminal Utility to Establish Connection Note 6. To hang up, first disconnect the PLC programmer connection Ithis will flee up the corem port for use with HyperTerminal) Then connect to the modem with HyperTerminal While connected, wait at least I second, then B'pe three plus signs (~+). One second later, the modem should respond with aa "OK". Next, enter ATH, the hang up command. The modem should resI~Ond "OK" ab~in. Remember that the HypcrTcrminal connection must bc set to the ~m¢ baud rate that rl~e modem is currcmly communicanng at. If not, the escape sequence may not bc rec%mizcd. Other Issues c set Break Flow ConSol, Da~a Compression, and Error Correclm~ modem conncc~ procedure within the programming software in orde~ to kc~p Ibc corn pon dictate what baud rate is acceptable. SNP does not use hardware flow con~-ol and all data quality featur~ of thc modems mum be disabled. Therefore we are rel3n ng on an 8-bit Index 35x and 36x series CPUs: key switch, 2-13 ADD IOM, 2 24 ADD_SIO, 2-24 Additiort of lJO module, 3-18 Alarm, 3-2 Alaml error codes. 1t-5 B CCU Checksum calculation, 2-8 COMMI~EQ Data types, 2-21 BCIY4, 2 21 BIT, 2-21 BYTE, 2-2 I Defaults conditions for Model 30 outpm Diagnostic data, 240 Diagnostic faults, 34 applicanon faulL 3-12 DIN'f, 2-21 Discrete re ferenc*% 2-19 gl e~aal data, 2-20 E EDITLOCK. 2 35 Elapsed t~me clock, 2-32 Error code~, B 5 Etheamet Gltg~al Data, 240 External l/O failures, 3-2 Index F Fatal faults. 3 4 Fault action. 34, 3 9 Function block structure. 2-25 G Genius GIc6al Data, 240 Global data. 240 Global data references. 2 20 Index H Housekeeping, 2 7 HRD_CPU, 2-24 HRD FLT, 2-25 HRD SIO, 2 24 HyperTerafinak D-7 I I/O data formats. 2 39 I/O t:ault table, 3-3, 3-6, B-8 I( 1 0 P Password acccgs fail~e, 3-13 Passwords. 2-34 PB_SLrM, 2-24 PCM c~mmunications with thc PLC, 2-11 Index R REAL Index PB SUM, 2-24 SFI CPU, 2-24 SFf FLT, 2 25 SFT_SIO, 2-24 SN ?~IRD, 2-22 SNPX V, rr, 2 22 1 Temporary rett-re~ces, discrete, 2-19 Time of day clock, 2 32 Iimers, 2-32 constant ~p timer, 2 33 Watchdog t~mer, 2 33 Window WORD, 2-21 Chapter Introduction 1 access, and ovenqdc capability. VersaMax Micro PLC and Nano PLC Models VersaMax Nano PL Cs VersaMax Micro PL Cs Versal~a~ Micro PL C Expansion Units Program and Data Memory Available PLC Features Ch.) ' ~NP~NPX Ma~ler Nano PtCs 1/0 and Power Features uc o.t~ts Example Applications Automo#ve IndusOy- Fluid Pumping ConZrol Bakery Industry - Pasi~y Line Conveyor ConZrol 16 GFK-1645A Chemical lndusb*y . ChemicaI Pumping Station A [ 4point VersaMax Micro PLC is used wi~ a compatible Operator Interface Terminal Commercial Ag~culture Industry. Grain Processing Commercial Laundry Induslzy . Garment Storage Rail Conlrol Const~uclfon Equipment Industzy- Pipe Measuring System lengths in fc~t, h~ches, and fractions of mche~ Operates sp~ify pipe length and the General Purpose Machinery - Automated Picture Frame Stapler Lumber IndusUy - Pallet Rebuil~ng Packag~j Industry. Shrink Wrapping Machine Videocassette Pacl~ging Plastics Industry. Injection Molding Plastic Parts Manufactutfng Public Emergency Services Industry - Storm Warning Systems Water and Was~ewater IndusZry. Flood Control Monitoring Sewa§e/Wastewater Lilt Star, ns Water Flow ConSol Chapter 4 VersaMax 23-Point Analog Micro PLC GFK 1~4§A Descri~ of Featums o[ the Z3-Point Micro PLC Rm/~np Smith Z3.Point Micro PLC with AC Power, 2 Analog ln~ 13 DC Inlxds, ICZOOUALO06 23.Po~nt Micro PLC with AC Power, Z Analog In~ut$, 13 DC Inlets, · Nme Form A relay outputs (SPST-single pole single throw). switch, and also used for clearing faults when a fatal fauh exists. · Time-of-Day Clock. Z3.Point Jicro PLC with AC Power, Z Analog lnputs, 13 DC Inlx~s, f,~cro PLC ICZOOIJAL~ Speci~alfons ~mm~ and Em/ss/on S~aUe~s IIC200UALO06 2$.Po~nt Micro PLC wilh AC Power, Z Analog lnFuts, 13 DC tnpu~s, AC Power Z3-po~t f/~ro PLC v, W AC Power, Z An~k~J h~Ou~, ~3 OC lnpu~,I (PWM) output rep~ac,~e. IC200UAL~06 ~ 23.Po~nt P$icro PLC with AC Power, Z Ana~og ~ds, 13 DC InlNItS, Z3.Po~nt ~cro PLC wilh AC Power, 2 Analog lnlxds, 13 DC InlX~S,~ ~ Ana~t Outl~ ~ ~C Out/~ S Re/ay Ouq~sl H~ Speed Cour~ers ICZOOIJALO06 Z3-Poin; Micro PLC with AC Power, 2 Analog ln~uts, 13 DC Inplds, Ana~g ~ (o de~ CmSSde~ C) Z3.Po~ Micro PLC with AC Powec 2 Analog lnlx~s, 13 DC Inl~ts, 1Analog O~pu~, ~ oc o. q~ ~ eday ~ Confiffurable Fealures of Analog IC200UALO06 23-PoJnt Micro PLC wifh AC Power, 2 Analog l~, 13 DC Inl~t$, Field W~'ing and C~cuil Diagrams Z3-Point Micro PLC with AC Power, 2 Analog lnputs, 13 DC Inpufs, 1AnalogI °/~4I (A/D count X Gain) + Q/'fset Gain and Offset are internally calibrated values. Any calculated value exceeding 32,767 is Analog I/0 Calibration kgx~ Charme/Ddau~f Ca/~at~w Charmel Default Calibration from the application program using a Service Requ~t (SVCREOO funcaion. sto~V Calibration Cor~ants f~ofes on Us~ SVCREO 35 SVCREQ 35 Parameter B/~ Chapter Configuration 8 Autoconfiguration The Default Configuration Storing a Configuration from a Programmer CPU Co~figuration Port I Configuration Fea~me Descfip~on De~au~ Choices rtmin*j Note for RTU CommunicaEon$ Port 2 Configuration On 23 and 2g-point Micrn PLCs, Port 2 provides general-purpose communications using F~a~un~ ~ De~ Ch~ces Configuring Expansion Units Default Sta~dng Rderence Addresses for IC200UEX011, 01Z. and 014 Configuring High-speed Counter, PI~VM or Pulse Output Operation Analog Configuration Micro PLC model IC200UAL006 has 2 analog input~ and I amalog outpuL AI001~ Mode V~a~ o~ c~enl mede VOi~j~, Currerd V~ ,qna~j ou~u~ Conr~g~ra~m PLC Operation OperaUn~ I~fes Parts of the CPU Sweep Par~s of/he CPU Standard CPU Sweep Operation Standard Sweap oo~ratic~ is the normal operating mode of~he PLC CPU. In Standard Swo2p operation, the CPU repeatedly exccutc~ thc application program, updatea 1/0, and TI~ Sweep Windows Tho Watchdog Timer When thc CPU is in $1andard Sweep modc, thc Watchdog Tim~ catchc~ failure conditi~s that could cause an unusually long swcap. Thc Icmgth of thc Walchdog Timm' Constant Sweep Time Operation Changing the Confic~ured Default for Constant Sweep Id, ode The Constant Saeep Timtr ~ Constant Sweep rime, Rea~ng or Seffing the tength of the Timer CPU Stop Modes Controlling the Execution o fa Program Calling a Subrout~e Block Creat~j a T~ary End ot Lo~ic Executir~ Runs o[ Logic ~ LogicaI Poew Flow jumpmg to Another Pa~t of the Program Privilege Levels and Passwords Passwords are an optional configurable feaVar e of the VersaMax PLC. passwords provide Changing programs Reading programs There is one passw~d for each privilege level in the PLC Each password may I:e unique PA~ection LeveI Re~est [rom [fores on Using Passwords The OEM Protection Feature C/eanng A//~en~x7 Run/Stop Mode Switch Operation Conrtgutat~ s.~tcn Operat~n CoAt. able ~ ~'~e~ Con£~uralion Parameters and Switch Position for Run/Stop Modes conr~juration Parameters and Switch Pesili~ [or Memory Pro~ection Configuration parameters and Switch Pos~ion for 5imuttaneous Run/Stop Ope~atim and Memoff Proteclion ConF~juration Parameters and Switch Position for Fault ~,erations Powerup and Power-Down Sequence Powerup .~e pmeenlp ~ Optio~s f~' a14-, 23-, or 28-Point l~cro PLC Defau/t Cond~/ons fo~ M/cro PL C Output Po/ms Power Cy~/e co~lgura~l, e~ r defe~ce ta~ dala to flas~ c~ral~ a e(erence ~i~le dala 'a~) ~e~c~aniue eU F'LC base ual ~ Input Filters Oiscret~ tnp~ Fi~erfng Filter COrdT~ Reference Analog Potentiometer Input Filtering Inpm Senings FJff~r ~Of~lol Default F~ Y~ Chapter 11 Fault Handling 'l~is chapter discusst~ how thc Micro PLC handles s~tem faults Technical Suppo~ Center Faults and Fault Handling Fault Handlin9 Cgasses of Faults ~3 Sequence fau]t System Responses to Faults Fault Acfions Fault References The PLC defines a set of spccial fault references that can be included in the application program clears the fault. £xarnl~ Pro,ram Lo~ic for Fautt References [C h~p~er [ The Service Request Function · SVCREQ 13: Shut Dov~ (Stop) PLC · SVCREQI4: ClearFault · SVCREQ 15: Rea~ tast-Logg~d Fault Table Entzy SVCREQ Function Numbers Each Service R~quest has its own function amber, as liste~t irs the following table 7 9 11 Read PLC iD 27, 28 29 31-255 Format of the SVCREQ Function The SVCREQ function ha8 three inpu~ and one output. Whe~ the SVCREQ rec¢iv~ power flow, the PLC is roquesled to pex form foe fonctic~ Parameters ot the SVCREQ Funclion ~ olive SVCREQ Funcg~n SVCREQ I: Change/Read Constant Sweep Timer Input Parameter E4ock for SCVR£O I F~r this ~nction, the parameter block has a length of two wot&, To disable Constant Sw~'p m~e. ~ter SVCREQ function #1 with flli8 param¢mr block: Exan~le oI SVC~EQ ! SVCREQ 2: Read Window Times Completion Mode. Mod, I~m tinited Mode A window is disabled when the time value is zero. Outp~ Parameter BIl~lffof SVCREO 2 Example of SVCREQ Z In the tbllou~g example, whca calabllng 0u~put %Q00102 is se~ the Micro PLC CPU places the ctm~t ume yah:c~ of thc windov~ in the parameto' block marring at location %R0010. SVCREQ 3: Change Programmer Communications Window Mode Use SVCILEQ 3 to change the ~'ogrammer commtmications window mode (Limited High Byte Low Byte Examl~ of SVCREQ 3 SVCREQ 4: Change System Communications Window Mode Use SVCREQ 4 to change t~e sy~ra communications window mode (Limited or Run-to- Changing the System Communications Window Mode change the ~ogrammer vandow, enter SVCREQ 4 with this paramele~ block: High Byte Low Byte Ezan~te of SVCREQ 4 SVCREQ 6: Change/Read Number of Words to Checksum P~'amel~' Bl~li F~m,~s ~m' SI~REO 6 Example of SVCR£~ ; % SVCREQ 7: Read or Change the Time-of-Day Clock Patmr~et Btoclt Forr~t for SVCREQ 7 SVCREQ 7 Parameter Block Conlen~: BCD Formal 4-0~ rear The parametcr bltvzk ha~ six words. All byte* arc used. [ dayofv~ek ~ seconds add~ess+5 19 (year) / 98 (year) ~03 (day) ~ 07 (July) 45 (milJutes) / ~-- 06 (FAday) I 30 (~nds) SVCREQ 7 Parameter Block Content: Packed ASC# Format r 31(1) Example of SVCREQ 7 SVCREQ 8: Reset Watchdog Timer Usc SVCREQ 8 to reset the walchdog timer during thc sweep. Ordinarily, when the Parameter Block Format for SVCR~Q 8 Example of SVCRE~ 8 CONST SVCREQ 9: Read Sweep Time from Beginning of Sweep Ou~ Parameter' ~ Format for SVCREQ 9 ~Or~ [time ~ ~ ~ ~P J Ex~ of SV~EO 9 SVCREQ 10: Read Folder Name Ou~ut Parameler Block Format for SVCREQ 10 Example o[ SVCREQ 10 L~ Byte High Byte SVCREQ 11: Read PLC ID Out, ut parame~ Block Fon~; for SVCR£Q 11 Low Byte High Byte Example of SVCREO 11 SVCREQ 13: Shut Down (Stop) PLC Parameter BIo¢~; for SVCREQ 13 Example otSVCREQ 13 SVCREQ 14: Clear Fault Input Parameter' Block for SVCREQ 14 Example o[ $VCREQ 14 SVCREQ 15: Read Last-Logged Fault Table Entry z-oW input Parameter Block for SVCREQ ~5 a~r~s ~---~:~,/%c2~'t~,7' [;:~2 ~;~*~:'::~' the PLC fauh tabtc or thc I/O fiul: table. High 1~7te Lef, u Bylm High BId~ _ IJe ~)'t~ spa~e ~rr~d:h I address + 21 Ipare I r00¢61 t o~]/s~ Va~ue 01 = 24 bytes (long) 02 = 5 bytes (sheet) Example of 5VCREQ ~5 SVCREQ 16: Read Elapsed Time Clock O~Jt~ Parameter Block for SVCREQ 16 address seconds from power? (!ow ord?) Example of SVCREQ ~6 SVCREQ 18: Read I/0 Override Status Output P~ameter Bloclt for SVCR£Q 18 I Example o[ SVCREQ lB SVCREQ 23: Read Master Checksum Oufpuf Parameter Block for $VCREQ 23 Example o!$VCREQ 23 SVCREQ 26/30: Interrogate 1/0 Example of SVCREO 26 SVCREQ 29: Read Elapsed Power Down Time Output Parameter Block for SVCREQ 29 Example of S VCREQ Z9 VersaMax Micro PLC Backup Battery Product Information fh~s ~s an optional backup batlery for a 23-point or 28 po~¢l VersaMax Micro PLC CPU IC200UDR005. tJOR010 UDDI10 UAA007 or UAL006 Its purpese ~s to protect :he RAM memory ¢onle~Is of the PLC when the PLC powe¢ Installing the Battery User's Manual LLM 1 1 O0 Bell 202 1200 Baud Modem It is essential that all instructions contained in this manual are followed precisely to ensure proper operation of equipment. SIEMENS ~ ............... ~DATA-LINC GROUP LLM1100 User's Manual LLM1100 Bell 202 1200 Baud Modem Table of Contents Introduction 4 User Modem Configurations Full Duplex 4 Wire 4 Half Duplex 2 Wire Mode 4 Half Duplex 4 Wire Mode 5 Simplex or Bits Mode 5 Making Connections 6 Connections Diagram ................................................. 6 Power Connector 6 RS232 Serial Connector ......................................................... 7 Operating Mode Selection and Wiring ................................... 7 Component Locator Diagram 8 Baud Rate Selection ......................................................................... 9 Character Format ................................................................ 9 Handshake Lines ......................................................................... 9 Self-Test ............................................................................... 9 Technical Specifications ....................................................................... 10 Technical Support ................................................................... 10 Product Warranty .......................................................................... 10 Return Material Auth(3rization 11 Contact Information .............................................................................. 11 PN 161-09998A302A 2 ~DATA-LINC GROUP LLM1100 Use(s Manua~ PN 161-09998-002A 3 ~DATA-LINC GROUP LLM1100 Users Manual Introduction The Data-Linc Group LLM1100 is a Bell 202 (CCITT V23 optional) voice band, 1200 baud modem The LLM 1100 is designed for use on private, leased un-switched telephone lines or any dedicated 2 or 4 conductor wire (twisted or untwisted, shielded or unshielded) It has a range of up to 20 miles on any ordinary wire pairs or unlimited on "loaded" telephone company voice grade (VG-6) leased lines The LLM1100 has the ability to operate without handshake lines using the proprietary DataSense ~M (DSCC) microprocessor firmware. This feature detects and buffers incoming RS232 data to allow the assertion and stabilization of the FSK carrier before transmitting the buffered characters. The nominal operating supply voltage for the LLM 1100 is t2VDC An isolated or ungrounded supply, such as a wall plug-in 120VAC to 12VDC power supply (provided as standard) is normally used but the unit can be supplied with an optional 2 conductor screw terminal power connector for use with other external DC supplies User Modem Configurations Full Duplex 4 Wire Mode To operate in full duplex, the LLM1100 must use a 4 wire connection and can have only ~'o units in a point to-point connection In full duplex, there is no need for carrier control as both modems will have their carriers transmitting at all times. NO handshake signals are used by the modems, but the signals can be asserted by the users equipment and fed back to the connecting equipment if needed When operating, the Carrier Detect LED of both modems should be on at all times. The carrier reflects the presence of the FSK frequency on the connecting wires. The Oata In (Yellow) LED and the Data Out LED (Green) or the modem will follow the data at the RS232 9 pin connector. The two modems are cross connected via the "2 wire" and "4 wire" connectors. Half Duplex 2 Wire Mode The LLM 1100 can operate in half duplex 2 wire mode with one master and one or more remote modems The setup configuration is the same for the master and remote modems. It is the users systems responsibility to provide a timing delay between a received message and a transmitted answer to allow the FSK carrier time to switch directions. The data flow control can be either DataSense (DSCC) or the RTS line from the connected equipment. In DSCC mode, the modem senses the characters from the users equipment, turns on the FSK carrier and then sends the buffered characters. Alt receiving modems detect the carrier, then send the received data out the RS232 port to the users equipment. In DSCC mode, a minimum line turnaround delay of 40 milliseconds is required. With RTS control, the assertion of the RTS line by the users equipment tells the modem to turn on the transmission carrier. Only the carrier at one modem can be on at any time in a half duplex system or carrier collision will occur and no data can be transferred, The minimum RTS timings are 20 milliseconds pre-transmit delay, 60 milliseconds RTS te data and zero (0) milliseconds RTS off delay at end of data. If adding LLM1100s to an existing system with LLM1000s, a minimum of 100 milliseconds RTS to data delay ~s required. PN 161-09998-002A 4 ~DATA -LINC GROUP LLM1100 User's Manual In any half duplex system the users system must recognize that incoming data is for this equipment and to respond with data (DSCC) or RTS handshake line to provide the correct timing delays to prevent carrier In two wire systems, only the left connector marked "2 WIRE" is used to interconnect ail the modems in the system wired in parallel. When a modem is transmitting data, the local Data In LED (Yellow), the Carrier Detect (Amber) and the Data Out (Green) LEDs on all other modems in the system should be flashing. If they are not, then there is no data flowing between modems Half Duplex 4 Wire Mode The LLMt 100 will operate in half duplex 4 wire mode with one master and one or more remote modems The master's carrier transmitter "4 wire" line must be connected to the remote's receiver line "2 wire" and vise versa The master modem's carrier is being transmitted at all times so the remote(s) carrier (Amber) LED will always be on. The remote modem's carrier is only transmitted when a remote modem is actively sending data to the master. No data flow control is needed at the master as its carrier is always on and ready to transfer data The data flow control at the remotes can be either OataSense or the RTS line from the connected equipment. h~ DSCC mode, the modem senses the RS232 characters from the users equipment, turns on the FSK carrier and then sends the characters. The master modem detects the carrier then the data and sends the received data out their RS232 port to the users equipment. With RTS control, the assertion of the RTS line by the users equipment tells the remote modem to turn on the transmission carrier Only one remote carrier can be on at any time in a half duplex system or carrier collision will occur and no data can be transferred. At a remote modem the users system must recognize that incoming data is for this unit and to respond with data (DSCC) or RTS handshake line to provide the correct timing delays to prevent carrier collisions. The minimum R'fS timings are 20 milliseconds pre-transmit delay, 60 milliseconds RTS to data and zero (g) milliseconds RTS off delay at end of data. Ir adding LLM1100s to an existing system with LLM1000s, a minimum of 100 milliseconds RTS to data delay is required The Carrier Detect (Amber) LED on all remote modems in the system should be on at al~ times. FSK data received at the remote will flash the Out (Green) LED when data is sent out its RS232 port When a remote modem is transmitting data In(Yellow) flashing, the master's Carrier Detect and Data Out (Green) LED will flash Simplex or Bits Mode In Bits mode, the LLM 1100 sends data from a master to a remote(s) in one direction only. In this mode, the modem is protocol or format transparent and will only operate in 2 wire mode. The data line is either a binary 1 or a 0 producing a 1 or 0 at the receiving modem(s). When connecting the modems to each other, make sure to use only the "2 wire" connector terminal block on all modems in the system. PN 161-09ggB-002A 5 ~DATA-LINC GROUP LLM1100 User's Manual With the modems connected, the Carrier detect LED on the remote modem(s) should be on at all times. The Carnet LED on the master will never be on. When data is moving from the master to the remote modem(s), the Data In (Yellow) LED on the master and Data Out (Green) LED on the remote(s) will flash with the data, Making Connections The LLM 1100 has four connection points. On the left is the DC power connection. The standard modem has a barrel jack connector for use with the supplied wall mount power supply. A two- position terminal block version is available for applications using a power source other than the standard supply. The DB 9 connector is the RS-232 interface. To the right of the DB-9 are two connections for the carrier wire palm marked "2 wire" and "4 wire." These are two-position removable terminal block connectors. In 2 wire mode, the left connector acts as both the transmitter and receiver connector For 4 wire mode, both connectors are used wilh one connector as the transmitter and the other as the receiver Note: When using the LLM1100 in 4 wire configuration, the transmitter of the master "4 wire" must be connected to the "2 wire" of all of the remote(s) and all remote transmitter "4 wire" are wired in parallel to the master's receiver connector "2 wire." Connection Diagram F RS232~ [ DCPowerln ] DB-9 Power Serial Cartier LED Connection Interface Connections Indicators LEDs Red (P) Power Amber (C) Carrier detect Yellow (I} RS232 In Green (O) RS232 Out Power Connector The barrel jack connector is center pin positive. The two position terminal connector is left pin ground ( ) and right pin positive (+) if optional screw terminal block is used, right terminal is positive (+) and left terminal is negative (-). DC negative is not connected to the chassis. PN 161-09998-00ZA 6 (~DATA-LINC GROUP LLM1100 User's Manual RS232 Serial Connector in number Nomenclature Function TxDCD* RsReceived2~~carrler detect out Rx RS-232 Data Into Modem Not Connected in Unit 4 DTR 5 Gnd Signal Ground ~ DSR* Data Set Ready (connected to CTS) RTS* Ready to Send (transmit enable) CTS Clear to Send (may be connected to RTS or DCD) (connected to DSR) Not Connected in Unit 'See handshake description section. DCD via factory jumper to pin 1 Operating Mode Selection and Wiring Mode Use Connectors Half Duplex 2 wire te 2 wire Master or remote(s) )arallel all units Simplex wire I (Bits) Master Simplex wire (Bits) Remote Master Half Duplex Remote Full duplex 2 wire is out Cross wire 4 wire to all remote 2 wire & 2 wire from all remote 4 wire Same as 4 wire Master Cross wire Cross connect 2 wire to 4 wire between both units SW2-5 OFF ON ON ON ON OFF Notes One master with 1 or more remotes. Carriers flash, Data flows from master to remote(s) only No carrier Data flows from master to remote(s) only Carrier on One master with 1 or more remotes. Remote carder LED 2 LLM1100 modems only. Both carrier LEDs on. Note: SW3-2 wire with SW2-5 off & SW2 6 on will enter self test display (see page 9). SW3-4 wire with SW2-5 off & SW2-B off is invalid combination. ~DATA-LINC GROUP Component Locator Diagram ON OFF Standard LLM 1000 Carrier Compatible \ ,/ sw3 /\ 2Wfte 4wire Po er CarTier LEDs Lines If LLM1100 is to be used with existing DLG LLMI000s, the SW1 must be set for LLM1000 mode (SW1 set away from SW3) The LLM1100 is normally pre-configured at the facto~ to customer specifications. If you need to field configure an LLM1100, you will need the following information: Baud rate of the serial device you are connecting with (unless using simplex). Character format (1 start bit + # data bits + parity + 1 stop bit) This must add to10 or l l bils. SetSW2-30n=llbits Off =10 bits. 3. Use of RTS line from user equtpment to control the flow of data into and between modems. If RTS use is unknown set the unit for DSCC DataSense mode. Off = DSCC-OataSense Set SW2-4 On: RTS 4. Either 1 wire pair (2 wire mode) or 2 wire pairs (4 wire mode) Set SW3. 5 Half or full duplex data transmission method, bi-directional or one way data flow (Simplex). Set SW2-5 and SW2-6 from chad. Note: After changing any switches, remove DC power and reapply to memorize the changes. Switches are only read during power on. ~DATA-LINC GROUP LLM1100 User's Manual Baud Rate Selection The LLM1100 will operate at 300, 000 and 1200 baud in a 10 or 11 bit word format. The modem is parity transparent; however, it must know if there are 8 or 9 bits of data/parily in Bits mode, the LLM1100 is baud rate and protocol transparent The Baud rate is set using switches SW2-1 and SW2 2. Baud Rate SW2-1 SW2-2 1200 OFF OFF 600 ON OFF 300 - ON ON Not Used OFF ON Character Format Find the character format of the users equipment and take the number of data bits in a character, If parity used (odd, even, mark, space) add one (1), If parity is none, do not add anything Add two (2) for one start bit and one stop bit. The result must be 10 or 11 Use SW2-3 to set the length SW2-3 is OFF for 10 bits, and ON for 11 bits. This switch ignored in simplex mode. Handshake Lines It RTS handshaking mode is set the LLM 1100 needs the RTS asserted when it is time to transmit data onto the FSK carrier from the users equipment. Depending upon how the modem is configured, it can provide DCD, CTS and DSR signaling back to the users equipment. JP3 is used to configure these lines, ir these lines are needed, perform the following: Shorting pins 1 and 2 will pull DCD (pin 1) logic high at the DB-9 connector Shoaling pins 2 and 3 will pass carrier status to DCD (pin 1) at the DB-9 connector Shor[ing pins 4 and 5 will route incoming RTS (pin 7) to outgoing CTS (pin 8) and outgoing DSR (pin 6) at the DB-9 connector Shoaling pins 5 and 6 will route DSR and CTS to pin 1. If also shorting pins 2 and 3 will also connect DCD (pin 1) to outgoing CTS (pin 8) and outgoing DSR (pin 6) at the DB-9 connector Note: DSR (pin 6) and CTS pin(8) are always connected and DTR Self-Test The LLM1100 has a built- in test mode that can verify whether the processor is operating normally. It displays the operating configuration as set by the SW2 switches and the 2/4 wire mode switch SW3. Note: This feature is only available with firmware version LLM1100548- 10007-001A and later To conduct the selFtest, perform the following: 1. Remove DC power and remove the cover. 2. Temporarily short together the JP1 header pins 1 and 3while re-applying DC power. A repeating sequence will occur: the Green LED (Q) will flash, followed by seven (7) flashes of the Amber LED ("C"). PN161-09998 G32A 9 ~DATA-LINC GROUP LLM1100 User's Manual 5 The blinking Green LED is the processor outputting the switch setup and operating mode as serial data at 1200 baud, formatted as 8 data, no parity, 1 stop bit To view this data, connect a PC to the 9 pin Dsub connector using 3 wires (pins 2,3,5) or a straight-thru serial cable Stad a communications program such as ProcomTM or HyperterminaF" set to 1200,n,8,1 The next set of Green flashes will put the modem configuration on the PC display 6 The Amber LED flashes are the six positions of SW2 and the position of SW3. A shod flash means the switch is in the OFF position A long flash means it is in the ON position, For SW3 OFF is towards SWI (4 wire} and ON is away from SW1 (2 wire}. 7 Compare the ON/OFF pattern to the setup tables for baud, handshake, number of bits and user operating mode. 8 Remove DC power and any JP1 connections. 9. Reapply DC power to enter your selected operating setup mode. Technical Specifications Range Up to 20 miles on unloaded lines, depending upon line characteristics. Unlimited on loaded lines, Qperating frequency 1200/2200 Hz (Bell 202 or 1300/2100 CCITT V,23) FSK {Frequency Shift Key) Data rates 300,600 or 1200 baud half or full duplex I. .u?to 1200 baud simplex. Handshake modes DataSense (DSCC) or RTS line Environmental -20 C to 70 C Power requirements 100 milliamps max 11 to 24 VDC external supply barrel jack standard. Optional screw terminal c_o~0_ector__~_ _ Enclosure Standard NEMA 1; 18-gauge steel with mounting flanges. Dimensions Length: 9" over mounting flanges; Width: 5"; Height: 1,5" Technical Support Data-Linc Group maintains a fully trained staff of service personnel who are capabte of providing complete product assistance. They can provide you with technical, application and troubleshooting, spare pads and warranty assistance. Our technical staff is based in Redmond, WasHington USA and may be reached at 425,882.2206 or email su[}[}ortf~data-linc.com Product Warranty Data-Linc Group warrants equipment of its own manufacture to be free from defects in material and workmanship for one year from date of shipment to original user. Data-Linc Group will replace or repair, at our option, any part found to be defective. Buyer must return any part claimed defective to Data-Linc Group, transpodation prepaid. Return Material Authorization If a pad needs to be sent to the factory for repair, contact Data-Linc Group's corporate office and request a Return Materlal Authorization (RMA) number. The RMA number identifies the part and the owner and must be included with the part when shipped to the factory. PN 161-09998-002A 10 ~DATA-LINC GROUP LLM 1100 User's Manual Contact Information Corporate Office Eastern Regional Office Southern Regional Office Data. Linc Group 2635 15¢t Place Northeast Redmond, Washington 98052 USA Telephone: 425.882.2206 Fax: 425.867.0865 Email: info@dataJinc.com Web site: www.data linc.corn Data-Linc Group P.O. Box 404 Lawrence, Pennsylvania 15055 Telephone: 724.942.4524 Fax: 724,942.3875 Data-Linc Group 4301 Cavern Springs Road Austin, Texas 78727 Telephone: 512.431.7806 Fax: 7202234687 DataSense is a trademark of Data-Linc Group. · Ethernet connectivity for Macs, PCS and printeFs with built-in Ethernet card and 14-pin AAUI connector · One-halE meter cable with AAUI and latch foreither desk placement or back drop · §witch-selectable SQE test and LED · Polarity detection and correction (both models) and LED (AT-M×6OT) · Link integrity test function and LEO (AT-MX6OT) · Lifetime warranty Allied Telesyn 10Base'2^r t×?o IEEE 802 3 COMPL[AN I/ELHERNET COMPATIBLE Signal Quality Error (SQE)/H~rrhPa[ SQE/Heartbeat test status is indicated by LEDs on both the AT MXT0 and AT. MXGOT, AT-MXTO +TD I'D ORDER[NC INFORMATION Allied Telesyn