—
ABB MEASUREMENT & ANALYTICS | INSTRUCTION MANUAL | IM/AW4TX REV. H
AW400 series
Chlorine transmitter
Measurement made easy
For more information
Further publications are available for free download
from:
www.abb.com/analytical
or by scanning this code:
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Data Sheet
Residual chlorine monitor
Instruction Manual
Chlorine/Chlorine dioxide/Ozone
—
AW400 series
chlorine transmitter
Electrical safety
This equipment complies with the requirements of CEI/IEC
for Measurement, Control and Laboratory Use’. If the
equipment is used in a manner NOT specified by the Company,
the protection provided by the equipment may be impaired.
Symbols
One or more of the following symbols may appear on the
equipment labelling:
Warning – refer to the manual for instructions
Caution – risk of electric shock
Protective earth (ground) terminal
Earth (ground) terminal
Direct current supply only
Alternating current supply
Both direct and alternating current supply
The equipment is protected through double
insulation
Information in this manual is intended only to assist our
customers in the efficient operation of our equipment. Use of
this manual for any other purpose is specifically prohibited and
its contents are not to be reproduced in full or part without
prior approval of the Technical Publications Department.
Health and safety
To ensure that our products are safe and without risk to health,
the following points must be noted:
• The relevant sections of these instructions must be read
carefully before proceeding.
• Warning labels on containers and packages must be
observed.
• Installation, operation, maintenance and servicing must
only be carried out by suitably trained personnel and in
accordance with the information given.
• Normal safety precautions must be taken to avoid the
possibility of an accident occurring when operating in
conditions of high pressure and/or temperature.
• Chemicals must be stored away from heat, protected from
temperature extremes and powders kept dry. Normal safe
handling procedures must be used.
• When disposing of chemicals ensure that no two chemicals
are mixed.
Safety advice concerning the use of the equipment described in
this manual or any relevant hazard data sheets (where
applicable) may be obtained from the Company address on the
back cover, together with servicing and spares information.
1
TABLE OF CONTENTS Page N.
1 MODEL NUMBER BREAKDOWN ............................................................................................................................... 3
1.1 Ordering Guide .................................................................................................................................................... 3
2 INTRODUCTION .......................................................................................................................................................... 4
2.1 Classification ........................................................................................................................................................ 4
2.2 Glossary ............................................................................................................................................................... 4
2.3 General Description ............................................................................................................................................. 4
2.4 Technical Specifications ...................................................................................................................................... 5
2.5 Hardware structure of the system ........................................................................................................................ 7
2.6 Instrument operating block diagram ......................................................................................................................... 9
3 INSTALLATION .......................................................................................................................................................... 10
3.1 Dimensions and mounting ................................................................................................................................. 10
3.2 Mounting ............................................................................................................................................................ 11
3.2.1 Wall mounting ............................................................................................................................................ 11
3.2.2 2” Pipe mounting without sunshade ........................................................................................................... 12
3.3 Location ............................................................................................................................................................. 13
3.4 Electrical connections ........................................................................................................................................ 14
3.4.1 Power supply p.c. board ............................................................................................................................ 14
3.4.1.1 Power cable ....................................................................................................................................... 15
3.4.1.2 Installation of cables for power supply ............................................................................................... 15
3.4.2 Cable gland ................................................................................................................................................ 16
3.4.3 Digital I/O pc board .................................................................................................................................... 17
3.4.3.1 Digital Outputs ................................................................................................................................... 17
3.4.3.2 Digital input ........................................................................................................................................ 18
3.4.4 Analog input/output pc board ..................................................................................................................... 18
3.4.4.1 Temperature compensation ............................................................................................................... 19
3.4.5 Serial communication board ...................................................................................................................... 19
4 SET-UP AND CONFIGURATION .............................................................................................................................. 20
4.1 Keyboard functionality ........................................................................................................................................ 20
4.2 Display ............................................................................................................................................................... 22
4.3 Channel definition -This menu allows to select the type of sensor associated to each channel: ...................... 23
4.4 Set-up menu ...................................................................................................................................................... 25
4.4.1 Configuration .............................................................................................................................................. 26
4.4.1.1 Configuration parameters .................................................................................................................. 26
4.4.1.2 Configuration menu flowchart ............................................................................................................ 27
4.4.1.3 Cleaning functionality ......................................................................................................................... 28
4.4.1.4 Instrument test ................................................................................................................................... 29
4.4.2 Output setting ............................................................................................................................................. 31
4.4.2.1 Output signal hardware modification 4 to 20 and 0 to 20 mA ............................................................ 32
4.4.3 Alarms ............................................................................................................................................................ 33
4.4.3.1Alarm Display........................................................................................................................................... 33
4.4.3.2Alarm setting Menu .................................................................................................................................. 34
5 FUNCTIONALITY ....................................................................................................................................................... 35
5.1 Transmitter (AW401) .......................................................................................................................................... 35
5.2 Controller (AW402) ............................................................................................................................................ 36
5.2.1 General description .................................................................................................................................... 36
5.2.2 Controller‟s Parameters ............................................................................................................................. 36
5.2.2.1 PID Parameters ................................................................................................................................. 38
5.2.2.2 Feed Forward (FF) Configuration ...................................................................................................... 39
5.2.2.3 Sampling and/or Flow Pacing Controller ............................................................................................ 39
5.2.2.4 Error Squared Controller (pH Applications) ....................................................................................... 40
5.2.2.5 Contacts Output Controller ................................................................................................................ 40
5.2.3 Standard Controller .................................................................................................................................... 41
5.2.3.1 Std Controller Display ........................................................................................................................ 41
5.2.3.2 Std Controller Analog Output assignment .......................................................................................... 42
5.2.3.3 Std Controller Digital Input assignment .............................................................................................. 42
5.2.3.4 Std Controller Digital Output assignment ........................................................................................... 43
2
6 CALIBRATION ........................................................................................................................................................... 44
6.1 Calibration Procedure ........................................................................................................................................ 44
6.1.1 Calibration Menu ........................................................................................................................................ 44
6.1.2 Calibration Menu Flow Chart ..................................................................................................................... 45
6.1.3 pH Sensor Calibration ................................................................................................................................ 45
6.1.3.1 Double point calibration ..................................................................................................................... 45
6.1.3.2 Single point calibration (S.P.C.) ......................................................................................................... 46
6.1.4 ORP Sensor Calibration ............................................................................................................................. 47
6.1.4.1 "OXIDATION potential with NEGATIVE values" arrangement ........................................................... 48
6.1.4.2 "OXIDATION potential with POSITIVE values" arrangement ............................................................ 48
6.1.5 Chlorine / Chlorine Dioxide / Ozone ........................................................................................................... 49
7 START UP ................................................................................................................................................................. 51
7.1 Preliminary operations ....................................................................................................................................... 51
7.1.1 Getting started ........................................................................................................................................... 51
7.1.2 Personalization of Parameters ................................................................................................................... 52
7.2 Controller PID tuning .......................................................................................................................................... 52
8 MAINTENANCE ......................................................................................................................................................... 53
8.1 Periodical operations ......................................................................................................................................... 53
8.1.1 Automatic sensitivity check during dual point calibration ........................................................................... 53
8.1.2 Sensor signal check ................................................................................................................................... 53
8.1.3 Other checks .............................................................................................................................................. 53
9 ERROR MESSAGES & TROUBLESHOOTING ......................................................................................................... 54
9.1 Messages ........................................................................................................................................................... 54
9.1.1 Operation messages .................................................................................................................................. 54
9.1.2 Error messages .......................................................................................................................................... 54
9.1.3 Alarms page ............................................................................................................................................... 55
10 SERIAL COMMUNICATION .................................................................................................................................... 56
10.1 Standard of Communications .......................................................................................................................... 56
10.1.1 Software characteristics ........................................................................................................................... 56
10.1.2 Communication Protocol .......................................................................................................................... 57
10.1.3 Message Types and Commands Description .......................................................................................... 58
10.2 Communication Transaction Examples ........................................................................................................... 59
10.2.1 Transaction A Example ............................................................................................................................ 59
10.2.2 Transaction B Example ............................................................................................................................ 59
10.3 Serial link signal connection ............................................................................................................................ 60
10.4 Data-link Terminator ........................................................................................................................................ 61
10.5 AW400 Memory Map ....................................................................................................................................... 62
11 APPENDICES .......................................................................................................................................................... 65
11.1 EC Declaration ................................................................................................................................................. 65
11.2 APPENDIX B – WEEE Compliant .................................................................................................................... 65
12 Spare Parts .............................................................................................................................................................. 66
3
1 MODEL NUMBER BREAKDOWN
1.1 Ordering Guide
Residual Chlorine Monitor
AW4
XX
X
X
X
X
Transmitter Type
Transmitter
01
Transmitter with PID Control (Channel 1 only)
02
Sensor Type Channel 1
Chlorine Cell
1
Sensor Type Channel 2
No second input channel
0
Chlorine Cell
1
pH
6
ORP
7
Additional 4-20mA input/output (re-transmission or flow input)
8
Sensor Type Channel 3
No third input channel
0
Chlorine Cell
1
pH
6
ORP
7
Transmitter Voltage
115V AC ± 10%, 50/60 Hz
1
230V AC ± 10%, 50/60 Hz
2
4
2 INTRODUCTION
2.1 Classification
According to EN61010-1, AW400 is classified an:
electrical equipment for measurement and control
electrical equipment for process control
electrical equipment designed to be safe at least in the following conditions:
– altitude lower than 2000 m
– operation temperature limits -10 to + 50 °C (15°F to 122°F)
– storage temperature limits -40 to + 65 °C (-40°F to 150°F)
– maximum relative humidity: 80 % with temperature up to 31 °C, with linear decrease down to 50%
with temperature 40 °C
– supply voltage allowed variations: 115 or 230 V AC ± 10 %
– over voltage class (installation class): II
– pollution degree: 2
2.2 Glossary
PARAMETER SYMBOL
pH pH
ORP (oxidation reduction potential) mV
Dissolved Oxygen* O2
Residual Chlorine Cl
Chlorine Dioxide CD
Ozone O3
Temperature T
These symbols are also used in displayed indications.
* Not supported at this time.
2.3 General Description
AW400 Monitor/Controller Family includes 2 Types of instrument:
Transmitter (Instrument Type 1)
A group of transmitters, both single channel and dual channels and three channels.
Controller (Instrument Type 2)
PID controller for the installed Sensor, with specific algorithms for each type of measured parameter. It can
accept an optional 4–20 mA signal from a flow-meter on channel 2. This second input can be used as Feed
Forward input in the PID algorithm.
5
2.4 Technical Specifications
Display: digital LCD display, dot matrix, 16 + 16 characters, with back light.
Power supply, selectable through a soldered jumper on the rear of the power supply pc board (see Sect.
3.4.1):
115 V AC, ±10%, 50/60 Hz
230 V AC, ±10%, 50/60 Hz
Maximum consumption: 20 VA
Electrical classification: for non hazardous area
Fuses: T100mAL 250V @ 230 V AC
T200mAL 125V @ 115 V AC
Enclosure classification: IP65, suitable for outdoor mounting
Casing: NEMA 4X, material GREENLAC reinforced with fiberglass (17%), White RAL 9010, Class VØ (in
accordance to UL94)
IP protection: IP65 whether power and signal cables respect the indications in the following section
3.4.1.1
Mounting: hardware is supplied for the following mounting options
- wall mounting
- 2" pipe mounting
Isolating level: Signal inlet isolated at 2224Vrms referring to the power supply.
Analog outputs: one for each installed channel (analog I/O pc board); separately selectable for each
channel as 0–20 mA or 4–20 mA.
Outputs are galvanically isolated from inputs. Load 0–1000 , protected against short circuits.
Digital outputs:
7 relay outputs: 24 V / 230 V~; 3 A max.
Individually settable as Normally Open (NO) or Normally Closed (NC)
Digital inputs: 2 free contacts
Serial communication port: RS232, RS422 and RS485 with RJ45 plug-in sockets. The protocol used is
illustrated in a dedicated section at the end of this manual.
Alarm level setting: High and Low alarm for channel 1, High and Low alarm for channel 2. Separate
levels for each channel, freely selectable. Dead band freely selectable for each channel.
6
Measuring ranges: freely selectable for each channel within the limits indicated for each parameter, as
follows:
PARAMETER MINIMUM SPAN MAXIMUM RANGE DEFAULT SETTING
pH 1.00 pH 0.00 to 14.00 pH 2.00 to 12.00 pH
mV 100 mV -1500 to +1500 mV -500 to +500 mV
O3 0.25 ppm 0.00 to 10.00 ppm 0.00 to 1.00 ppm
Cl 0.25 ppm 0.00 to 10.00 ppm 0.00 to 1.00 ppm
CD 0.25 ppm 0.00 to 10.00 ppm 0.00 to 1.00 ppm
T 5 °C 0 to +100 °C 0 to +100 °C
mA 2 mA 0/4 to 20 mA 4 to 20 mA
Measure sensitivity:
Parameter Sensitivity
pH 0.0002 unit pH
ORP 0.0045 mV
chlorine 0.33 g/l (ppb)
chlorine dioxide 0.33 g/l (ppb)
ozone 0.15 g/l (ppb)
Analogue Input: up to 3 sensors (any of pH, ORP, Dissolved Oxigen, Residual Chlorine, Chlorine
Dioxide, Ozone, 0/4÷20 mA analogue signal and temperature (Pt100)
Weight: 3 kg
Outline dimensions: 250 mm x 250 mm x 120 mm. See Fig.1 for detailed outline dimensions
Ambient temperature limits for stocking: -40 °C to +65 °C (-40 °F to 150 °F).
Ambient temperature limits during operation: -10 °C to +50 °C (15 °F to 122 °F) (if the instrument is
expected to be installed in the sunlight, a sunshade protection is strongly recommended)
Thermal drift: within 0.2% of f.s. for a 10 °C temperature variation.
Relative humidity: 80 % with temperature up to 31 °C, with linear decrease down to 50% with
temperature 40 °C
Accuracy: within ± 0.2 % of f.s.
Transmitter response time: measure is refreshed at each microprocessor scan cycle (100 msec)
Microprocessor scan cycle: 100 msec
Smoothing: separately set for each channel inside Configuration menu.
7
2.5 Hardware structure of the system
The AW400 hardware is structured in a modular system, whereby only the electronic p.c. boards requested
for the specific application needs to be installed, thus achieving great flexibility and relevant cost benefits for
the user. The different p.c. boards are mounted in four separate layers, according to the following scheme:
FIRST LAYER OF P.C. BOARDS (bottom):
Power supply pc board
Digital I/O pc board with
expanded function board
Serial data link port
Power supply board
Digital output board
Digital input board
8
SECOND LAYER OF P.C. BOARDS (Analog Input/Output)
THIRD LAYER OF P.C. BOARDS (Main Board):
FOURTH LAYER OF P.C. BOARDS (Top):
Analog I/O pc board (channel cards) Channel 1
Channel 2 (optional)
Channel 3 (optional)
CPU pc board
Display and Keyboard
pc board
9
2.6 Instrument operating block diagram
CPU
configuration
output setting
alarms
algorithms and
routines
SERIAL
COMMUNICATION
RS485
RS422
RS232
DIGITAL I/O
CCI 1 freezes Ch.1
CCI 2 freezes Ch.2
CCI 1 + CCI 2 when
in OR freeze Ch.1 +
Ch.2
CCO 1
CCO 2
CCO 3
CCO 4
CCO 5
CCO 6
CCO 7 watch dog
G
C
B
D
ANALOG I/O
Channel 1
Type of chann.
Calibration data
Input signals:
pH, mV, O2, Cl,
CD, O3, mA
Output signal:
(0 – 20 or 4 – 20
mA)
A
POWER
SUPPLY
power supply to
all pc boards and
components
ANALOG I/O
Channel 2
Type of chann.
Calibration data
Input signals:
pH, mV, O2, Cl,
CD, O3, mA
Output signal:
(0 – 20 or 4 – 20
mA)
ANALOG I/O
Channel 3
Type of chann.
Calibration data
Input signals:
pH, mV, O2, Cl,
CD, O3, mA
Output signal:
mA)
E
F
CCO1Ö6
functions
depend on
type of
instrument
selected
Output signal:
(0 – 20 or 4 – 20
10
3 INSTALLATION
3.1 Dimensions and mounting
Side view
Cover for
terminal
board
connection
n° 4 cable
glands,
optional
Notes :
1 - All dimensions in mm
2 - Dimensions are guaranteed only if this print is original
3 - All dimensions subject to tolerance ±3 mm.
4 - Weight:
MicroChem 2 : 3 kg
MicroChem 2 c/w sunshade : 4 Kg.
Housing bottom
180 (7.2”)
31
(1.2”)
220 (9”)
n°5 cable
glands,
PG 11
allow enough space for
wiring
Rear view
250 (10”)
300 (12”)
hole
ø 9,5 for
sunshade wall
mounting
hole
ø 9,5 for wall
mounting of sunshade
n° 4 cable
glands,
optional
400 (16”)
400 (16”)
120 (4.8”)
31
(1.2”)
31
(1.2”)
31
(1.2”)
250 (10”)
120 (4.8”)
125 (5”)
120 (4.8”)
ø16
(0.4”)
Fig. 1 - AW400 dimensions
WARNING! When installing AW400 outdoors, the use of a sunshade is strongly
recommended.
11
3.2 Mounting
AW400 is available with the hardware for the following types of mountings:
Wall mounting (Fig. 2)
2” pipe mounting (Fig. 3)
3.2.1 Wall mounting
Fig. 2 - Typical Wall-mounting Installations of AW400
12
3.2.2 2” Pipe mounting without sunshade
Fig. 3 - Typical 2” pipe mounting of AW400
13
3.3 Location
The transmitter location should meet the following requirements:
- the site of installation should be free of vibrations
- the atmosphere should be free of corrosive substances
- enough space has to be left around the transmitter to allow easy operation and maintenance
- the transmitter should be mounted at a height of 1.6 - 1.7 m from floor level to make normal reading,
maintenance and calibration operations easier
- in outdoors installations a sunshade is strongly recommended
- power supply according to instrument tag should be available
14
3.4 Electrical connections
3.4.1 Power supply p.c. board
The power supply is connected to the terminal board TB1 (See Fig. 4).
The selection between the 115 V AC and 230 V AC power settings can be changed by moving a jumper (in
position JP1) on the power supply pc board. Jumpers are represented in Fig. 4. Power supply (230 V AC) is
factory set. Should any modification be needed, proceed as per the following steps:
See Figure 4 to change the jumper setting.
1. disconnect the power supply
2. open the upper enclosed cover
3. locate the JP1 jumper on the power board (Fig. 4)
4. move the jumper to the correct position
5. close the cover and reconnect the power
Figure 4 - Power supply jumper position 110 V AC or 220 V AC
Power Supply pc board-
reverse side
Jumper set
for 110 V AC
Jumper set
for 220 V AC
WARNING!
Only qualified personnel should conduct the tasks described in this section of the manual.
The transmitter is not fitted with a switch therefore a disconnecting device such as a switch or circuit breaker
conforming to local safety standards must be fitted to the final installation. It must be fitted in close proximity
to the transmitter within easy reach of the operator and must be marked clearly as the disconnection device
for the transmitter.
Remove all power from supply, relay and any powered control circuits and high common mode voltages
before accessing or making any connections.
Route signal leads and power cables separately, preferably in an earthed (grounded) flexible conduit.
15
3.4.1.1 Power cable
Power supply cable has to be supplied by the Customer and installed by qualified personnel. In accordance to
EN61010-1 power supply cable has to satisfy the following requirements:
must be certified or approved by an official national/international testing bureau (IMQ, UL, CSA...) and
according to the local law.
three-cores cable, each core with section 1 mm
2
or 1.5 mm
2
and with specific colours required by local
requirements.
must be suitable for ambient temperature up to 75°C (167°F)
must have a section of 6-10mm to guarantee the casing IP65 protection.
must include ground wire that has to be properly connected.
3.4.1.2 Installation of cables for power supply
Power cable inlet
The three-core power supply cable, as described in section 3.4.1.1, has to be wired to the board passing
through the specific gland. deve essere inserito attraverso il pressa cavo posto in corrispondenza della
morsettiera TB1. The gland itself can not be removed as its specific action is to avoid cable abrasions and
damages and to guarantee the IP protection.
The external wire sheathed shell be removed for at least 3-4 cm from the termination to allow the three cores
separation into the instrument while shell be kept in correspondence of the gland. Each wire shell be stripped
for about 1cm to allow the lugs crimping.
Cable anchorage (Customer Care)
Cable anchorage must be designed to avoid stresses, included torsion stresses to the conductors at the point
where they enter the transmitter. Cable anchorage has to satisfy the following requirements:
cable has not be fixed through a screw acting directly on the cable itself
never make knots on the cable itself
cable anchoring must be designed to make cable replacement easy and safe
cable has to be protected from any possible mechanical stress that may damage it or making it directly
or indirectly dangerous.
Plug (not supplied)
The plug shall be certified and approved (IMQ, UL, CSA...) and have the ground connection.
Circuit breaker (Customer care)
The instrument shall be equipped with a specific circuit breaker which have two main functions:
1. Main power supply disconnection
2. Over voltage protection.
Shall have the following characteristics:
DANGER!
Electrical shock hazard. Power supply cables are connected to 115 or 230 V AC voltage.
16
Shall be easily identifiable, easy to access and operate and shall be installed nearby the instrument
Shall be a certified and approved model according to the standard in use in the country where the
instrument will be installed
Shall clearly indicate if the power is activated and present or not
Shall be specific characteristics for protective action (10A curve “C” type)
Whether installed outdoor, shell have the appropriate IP protection rating.
Unauthorised personnel must not be able to open the instrument. AW400 is defined as an instrument "with no
accessible parts under dangerous voltage".
ABB can, on request, provide the specific item (part number 1T154E001U01).
3.4.2 Cable gland
Microchem is capable up to 9 holes that can be opened for electrical wires connection.
As standard 5 cable glands are installed on each unit.
Below, is an example of how to use the different cable glands (see pic.8).
1 cable with three wires for power supply
Cables from wet-end
Cable for 4-20mA signal retransmission
10 cables for digital output (CCO1÷7)
Cables with two wires for digital input (CCI1÷2)
1 cable RJ11 type for serial communication option.
RECOMMENDED: Do not put beside the power supply cable with other cables.
ANO1
ANO2
ANO3
ANI1
ANI2
ANI3
Power Supply
Serial communication
CCO1÷7
ANI 1,2
CCI1÷2
Figure 5 - Recommended use of cable glands
, 2 ,3 ,4 ,5 ,6 ,7
17
3.4.3 Digital I/O pc board
3.4.3.1 Digital Outputs
AW400 digital outputs are provided by seven 7 relays (physically 8 relays are installed but only 7 are
available). The function of each output contact depends on the type of instrument selected and its
configuration. The different possibilities are detailed in the sections dedicated to each specific type of
instrument, as detailed under each specific instrument section.
Fig. 6 shows how the terminal number assigned to each CCO on the I/O pc board.
The maximum rating of the relays are:
Maximum Voltage: 24V DC / 230 V AC;
Maximum Current: 3A
Figure 6 - Relays interconnection terminal barrier
CCO 8
15
16
Terminal board J3
18
3.4.3.2 Digital input
AW400 digital input (free contacts) are represented in Figure 7.
Two wires shielded cable
two-cores, section 0.5 to 1.0 mm
2
the shields has to be connected to ground shield terminal strip ( ) on the AW400 power supply board
(see Fig. 7).
Cables for digital outputs shall have a 80°C (176°F) rating.
Figure 7 - Digital inputs terminal barrier
3.4.4 Analog input/output pc board
Refer to each sensor I.B. for the colour/number codification of the sensors wires. The Pt100 shield and the
sensor shield, if present, has to be connected to ground shield terminal strip, inside AW400. Pleases notice
that, for pH and ORP sensors it is recommended to fix the cable near the sensor so that it doesn't move at the
outlet of the cable gland. The wear of the cable at that point is thus prevented.
The 0–20 mA or 4–20 mA signal INPUT is on terminals 5 and 6: when these terminals are used for the 0/4–20
mA INPUT, install a 100 resistor (0.1 % accuracy) across terminals 5 and 6.
Use two cores shielded cables for 4–20 mA output signals, section of each conductor 0.5 – 1.0 mm
2
; connect
shields to the shield ground terminal strip inside AW400.
Expanded function terminals
Digital inputs
Digital input
(+)
1
Digital input
(+)
2
Terminals: 3-8 not used
Terminals: 9-12 = +24V
Terminals: 13-16 0v (common)
USE ANY ONE OF THE 0v (COMMON) TERMINALS (13-16) TO
TERMINATE THE DIGITAL INPUT (-) WIRES
Terminal Board J4
19
Fig. 8 – Analog Input /Output terminal barrier
3.4.4.1 Temperature compensation
The thermo-compensation Pt100 is not necessarily present in each sensor, in fact in some installations the
different sensors are installed in the same cell, and therefore the reference temperature can be read from one
input only, namely from the sensor connected to channel 1.
In the installation menu, when configuring channel 2 and 3, after the choice of the type of sensor, it is
requested to specify if the reference temperature is to be "equal to first channel" or "independent". In the first
case the reference temperature for that channel is taken from channel 1, in the second case it is read from its
own Pt thermo-resistance which in this case must be present.
This option is not applicable for mA, ORP or Chlorine in CL4000 mode inputs measurements, as these
parameters are not influenced by operating temperature or already compensated.
3.4.5 Serial communication board
AW400 supports serial communication standards RS232 and RS422/485 by connection of a modular
telephone jack RJ45.
The 9 poles terminal board supports all three standards.
The pin-out of the RJ45 connectors and 9-pin terminal board is illustrated in Section 11.3 in this manual,
dealing with the serial communication option.
Out
mA
Uscita
mA
A in from
sensors
Cl,CD,O3
mV in from
sensors
(pH,ORP)
or 0/4-20
mA
Temperature
Pt100
20
4 SET-UP AND CONFIGURATION
4.1 Keyboard functionality
All the keys have dual functionality, except the ENTER key. Blue background keys are the ones whose
second function is only used in Controller option (AW402). The selection between numbers and functions is
automatically recognised by the instrument.
KEY
PRIMARY FUNCTION
SECONDARY
FUNCTION
MANUAL SELECTOR
Selects manual mode in Controllers (AW402).
0: digit zero
when allowed
DECREASE OUTPUT
Decreases output in Controller (AW402) when in manual mode.
1: digit 1 when
allowed
INCREASE OUTPUT
Increases output in Controller (AW402) when in manual mode.
2: digit 2 when
allowed
LIGHT
Light up / down the display.
3: digit 3 when
allowed
MENU
Calls for the menu and, inside a menu, cycles the parameters.
4: digit 4 when
allowed
ENTER: decimal point is not used, any parameter needing it already
includes the decimal point in the correct position.
Enter function: allows the user to enter the displayed menu or parameter;
once entered, allows parameter to be modified. A parameter can be
changed (set) when the cursor appears on the display. Once the cursor
has appeared, whether or not the parameter has been changed, the
Enter key confirms the displayed value.
In display mode Enter key allows to call the Warnings & Messages page.
None
AUTOMATIC SELECTOR
Selects Automatic/Manual operation mode in Controllers (AW402).
5: digit 5 when
allowed
SETPOINT DOWN ARROW
Decreases Set Point in Controllers (AW402).
6: digit 6 when
allowed
SETPOINT UP ARROW
Increases Set Point in Controllers (AW402)
7: digit 7 when
allowed
21
WASH
Starts a cleaning sequence when this option is activated and allowed
(timers set at any value different from zero).
8: digit 8 when
allowed
CANCEL
Cancel is used to load default parameters (power the instrument down
and power it up while keeping the Cancel key pressed) Cancel is also
used to modify a parameter wrongly written: when a parameter can be
modified the cursor appears on the display; when the cursor is in the last
right position pressing the Cancel key will delete the newly introduced
value and allow to re-write a new one
9: digit 9 when
allowed
END
End key allows to exit a parameter or a menu and return to upper menu.
-: negative sign
when allowed
Table 1 - Keyboard functionality
Use of MENU, ENTER and END keys to move inside menus and change parameters:
Initial
Display
Password
Menu
Configuration
Calibration
Channel
Definition
Press MENU Key
Insert Password: 1, 2 ... n, + ENTER Key
MENU Key
MENU Key
ENTER Key
MENU Key: moves to the next choice of menu
ENTER Key: enters the Configuration menu
ENTER Key: Allows to enter the submenu;
MENU Key: cycles thru the available parameters;
ENTER Key: confirms the choice shown
END Key: returns to the upper menu level
MENU Key: cycles back to Menu display
MORE CHOICES OF SET-UP MENUS
CHOICES OF
CONFIGURATION
PARAMETERS
END Key: returns to initial display
Fig. 9 – Example of menus navigation
22
4.2 Display
The AW400 display shows the instantaneous value of the parameter measured, it‟s identification symbol and
the temperature of the sampled liquid. Here is an example of the standard one-channel display:
1
2
.
5
2
p
H
1
5
.
5
°
C
If the instrument is configured to support two sensors, the display shows on the top line the metered value
and the temperature of parameter installed on Channel 1, and on the bottom line the metered value and the
temperature of parameter installed on Channel 2. When three sensors are installed, the process values are
displayed on two different pages. Press END key to toggle form one page to the other.
Channel 1 Measure
1
2
.
5
2
p
H
1
5
.
5
°
C
Channel 1
Temperature
Channel 2 Measure
0
.
1
1
4
O
3
0
.
1
5
8
C
l
Channel 3 measure
On the second page appears:
Channel 1 Measure
1
2
.
5
2
p
H
1
5
.
5
°
C
Channel 1
Temperature
Channel 2
Temperature
1
6
.
4
°
C
1
1
.
2
°
C
Channel 3
Temperature
When AW400 is configured as a Controller (AW402), the process information are displayed on a dedicated
page, as per following example:
Channel 1 measure
(Process variable)
1
0
.
1
2
p
H
1
0
.
4
°
C
Channel 1
Temperature
Setpoint
1
2
.
0
0
S
P
1
6
%
O
U
T
A
Output (%)-
Aut./Man.
23
4.3 Channel definition -This menu allows to select the type of sensor associated to each
channel:
OPERATION DISPLAY
PROCESS
PASSWORD
XXXXX
MENU
CALIBRATION
CHANN. DEFINITION
CHANN. DEFINITION
CHANNEL1
CHANN. DEFINITION
CHANNEL2
CHANN. DEFINITION
CHANNEL3
CHANNEL1
F*
CHANNEL2
F*
CHANNEL3
F*
CHANNEL1
Br*
CHANNEL2
Br*
CHANNEL3
Br*
CHANNEL1
pH
CHANNEL2
pH
CHANNEL3
pH
CHANNEL1
mV
CHANNEL2
mV
CHANNEL3
mV
CHANNEL1
O2
CHANNEL2
O2
CHANNEL3
O2
CHANNEL1
O3
CHANNEL2
O3
CHANNEL3
O3
CHANNEL1
CL (note2)
CHANNEL2
CL (note2)
CHANNEL3
CL (note2)
CHANNEL1
CD
CHANNEL2
CD
CHANNEL3
CD
CHANNEL1
T
CHANNEL2
T
CHANNEL3
T
CHANNEL1
mA (note3)
CHANNEL2
mA
CHANNEL3
mA
Only when channel 2 pc
board is installed
Only when channel 2 pc
board is installed
** Not Supported
(Please refer to the menu trees in the appendicies
for an overview of how to navigate through the
software.
Chann.Definition
Channel 2
Channel 2
pH
Channel 2
mV
Channel 2
O2
Channel 2
O3
Channel 2
Cl
Channel 2
CD
Channel 2
T
Channel 2
mA
Only when Channel 3
pc board is installed
Only when Channel 2
pc board is installed
Chann.Definition
Channel 1
Channel 1
pH
Channel 1
mV
Channel 1
O2
Channel 1
O3
Channel 1
Cl
Channel 1
CD
Channel 1
T
Channel 1
mA
Chann.Definition
Channel 3
Channel 3
pH
Channel 3
mV
Channel 3
O2
Channel 3
O3
Channel 3
Cl
Channel 3
CD
Channel 3
T
Channel 3
mA
Operation display
Process
Password
XXXXX
Menu
Calibration
Chann.Definition
1,2,3…..
Selects
pH
Moves
to next
choice
To Exit
menu
And so on
Chann.Definition
Channel 2
Channel 2
pH
Channel 2
mV
Channel 2
O2
Channel 2
O3
Channel 2
Cl
Channel 2
CD
Channel 2
T
Channel 2
mA
Only when Channel 3
pc board is installed
Only when Channel 2
pc board is installed
Chann.Definition
Channel 1
Channel 1
pH
Channel 1
mV
Channel 1
O2
Channel 1
O3
Channel 1
Cl
Channel 1
CD
Channel 1
T
Channel 1
mA
Chann.Definition
Channel 3
Channel 3
pH
Channel 3
mV
Channel 3
O2
Channel 3
O3
Channel 3
Cl
Channel 3
CD
Channel 3
T
Channel 3
mA
Operation display
Process
Password
XXXXX
Menu
Calibration
Chann.Definition
1,2,3…..
Selects
pH
Moves
to next
choice
To Exit
menu
And so on
Chann.Definition
Channel 2
Channel 2
pH
Channel 2
mV
Channel 2
O2
Channel 2
O3
Channel 2
Cl
Channel 2
CD
Channel 2
T
Channel 2
mA
Only when Channel 3
pc board is installed
Only when Channel 2
pc board is installed
Chann.Definition
Channel 1
Channel 1
pH
Channel 1
mV
Channel 1
O2
Channel 1
O3
Channel 1
Cl
Channel 1
CD
Channel 1
T
Channel 1
mA
Chann.Definition
Channel 3
Channel 3
pH
Channel 3
mV
Channel 3
O2
Channel 3
O3
Channel 3
Cl
Channel 3
CD
Channel 3
T
Channel 3
mA
Operation display
Process
Password
XXXXX
Menu
Calibration
Chann.Definition
1,2,3…..
Selects
pH
Moves
to next
choice
To Exit
menu
And so on
Chann.Definition
Channel 2
Channel 2
pH
Channel 2
mV
Channel 2
O2
Channel 2
O3
Channel 2
Cl
Channel 2
CD
Channel 2
T
Channel 2
mA
Only when Channel 3
pc board is installed
Only when Channel 2
pc board is installed
Chann.Definition
Channel 1
Channel 1
pH
Channel 1
mV
Channel 1
O2
Channel 1
O3
Channel 1
Cl
Channel 1
CD
Channel 1
T
Channel 1
mA
Chann.Definition
Channel 3
Channel 3
pH
Channel 3
mV
Channel 3
O2
Channel 3
O3
Channel 3
Cl
Channel 3
CD
Channel 3
T
Channel 3
mA
Operation display
Process
Password
XXXXX
Menu
Calibration
Chann.Definition
1,2,3…..
Selects
pH
Moves
to next
choice
To Exit
menu
And so on
Chann.Definition
Channel 2
Channel 2
pH
Channel 2
mV
Channel 2
O2
Channel 2
O3
Channel 2
Cl
Channel 2
CD
Channel 2
T
Channel 2
mA
Only when Channel 3
pc board is installed
Only when Channel 2
pc board is installed
Chann.Definition
Channel 1
Channel 1
pH
Channel 1
mV
Channel 1
O2
Channel 1
O3
Channel 1
Cl
Channel 1
CD
Channel 1
T
Channel 1
mA
Chann.Definition
Channel 3
Channel 3
pH
Channel 3
mV
Channel 3
O2
Channel 3
O3
Channel 3
Cl
Channel 3
CD
Channel 3
T
Channel 3
mA
Operation display
Process
Password
XXXXX
Menu
Calibration
Chann.Definition
1,2,3…..
Selects
pH
Moves
to next
choice
To Exit
menu
And so on
1,2,3. . . . . .
. . .
SELECT F
MOVES TO NEXT
CHOICE
AND SO ON
Chann.Definition
Channel 2
Channel 2
pH
Channel 2
mV
Channel 2
O2
Channel 2
O3
Channel 2
Cl
Channel 2
CD
Channel 2
T
Channel 2
mA
Only when Channel 3
pc board is installed
Only when Channel 2
pc board is installed
Chann.Definition
Channel 1
Channel 1
pH
Channel 1
mV
Channel 1
O2
Channel 1
O3
Channel 1
Cl
Channel 1
CD
Channel 1
T
Channel 1
mA
Chann.Definition
Channel 3
Channel 3
pH
Channel 3
mV
Channel 3
O2
Channel 3
O3
Channel 3
Cl
Channel 3
CD
Channel 3
T
Channel 3
mA
Operation display
Process
Password
XXXXX
Menu
Calibration
Chann.Definition
1,2,3…..
Selects
pH
Moves
to next
choice
To Exit
menu
And so on
TO EXIT
MENU
**
**
**
**
**
**
**
**
**
24
Notes:
1.When changing channel definition from one parameter to another, the AW400 transmitter/controller will set
the alarm outputs and the PID parameters to the default values.
2.If chlorine (CL) is selected, the type of CL measurement must be defined as either a cell (KC4000AB) or a
probe (CL4000AB). When CL4000AB probes are selected, you will be prompted to enter the (4mA and20mA)
probe settings to match the range of the probe supplied with the system (i.e. 0-2 or 0-10 ppm).
3.Sensors with a 4 to 20 mA output can be attached to the transmitter and the units and range can be set
within the channel configuration software and then the sensor output can be displayed on the screen – see
section 2.2 for the range of units that can be selected.
* Not available
OPERATION DISPLAY
PROCESS
PASSWORD
XXXXX
MENU MODE
MENU
MENU MODE
CALIBRATION
MENU MODE
CHANN. DEFINITION
CHANN. DEFINITION
CHANNEL1
CHANNEL1
CL
CL
CL PROBE (mA)
CL SETTINGS
4mA=
(DEFAULT VALUE)
CL SETTINGS
4mA=
(SET LOW RANGE)
CL SETTINGS
20mA=
(DEFAULT VALUE)
CL SETTINGS
20mA=
(SET HIGH RANGE)
Chann.Definition
Channel 2
Channel 2
pH
Channel 2
mV
Channel 2
O2
Channel 2
O3
Channel 2
Cl
Channel 2
CD
Channel 2
T
Channel 2
mA
Only when Channel 3
pc board is installed
Only when Channel 2
pc board is installed
Chann.Definition
Channel 1
Channel 1
pH
Channel 1
mV
Channel 1
O2
Channel 1
O3
Channel 1
Cl
Channel 1
CD
Channel 1
T
Channel 1
mA
Chann.Definition
Channel 3
Channel 3
pH
Channel 3
mV
Channel 3
O2
Channel 3
O3
Channel 3
Cl
Channel 3
CD
Channel 3
T
Channel 3
mA
Operation display
Process
Password
XXXXX
Menu
Calibration
Chann.Definition
1,2,3…..
Selects
pH
Moves
to next
choice
To Exit
menu
And so on
Chann.Definition
Channel 2
Channel 2
pH
Channel 2
mV
Channel 2
O2
Channel 2
O3
Channel 2
Cl
Channel 2
CD
Channel 2
T
Channel 2
mA
Only when Channel 3
pc board is installed
Only when Channel 2
pc board is installed
Chann.Definition
Channel 1
Channel 1
pH
Channel 1
mV
Channel 1
O2
Channel 1
O3
Channel 1
Cl
Channel 1
CD
Channel 1
T
Channel 1
mA
Chann.Definition
Channel 3
Channel 3
pH
Channel 3
mV
Channel 3
O2
Channel 3
O3
Channel 3
Cl
Channel 3
CD
Channel 3
T
Channel 3
mA
Operation display
Process
Password
XXXXX
Menu
Calibration
Chann.Definition
1,2,3…..
Selects
pH
Moves
to next
choice
To Exit
menu
And so on
Chann.Definition
Channel 2
Channel 2
pH
Channel 2
mV
Channel 2
O2
Channel 2
O3
Channel 2
Cl
Channel 2
CD
Channel 2
T
Channel 2
mA
Only when Channel 3
pc board is installed
Only when Channel 2
pc board is installed
Chann.Definition
Channel 1
Channel 1
pH
Channel 1
mV
Channel 1
O2
Channel 1
O3
Channel 1
Cl
Channel 1
CD
Channel 1
T
Channel 1
mA
Chann.Definition
Channel 3
Channel 3
pH
Channel 3
mV
Channel 3
O2
Channel 3
O3
Channel 3
Cl
Channel 3
CD
Channel 3
T
Channel 3
mA
Operation display
Process
Password
XXXXX
Menu
Calibration
Chann.Definition
1,2,3…..
Selects
pH
Moves
to next
choice
To Exit
menu
And so on
25
The Channel definition menus are in accordance to the number of the channels installed (e.g. if only Channel
1 is installed, only Channel 1 definition menu appears; if two channels are installed, both Channel 1 definition
menu and Channel 2 definition menu will appear. The same principle applies for Channel 3).
Select the type of channel according to the sensor installed (see glossary 2.2 for the symbols used).
NOTE: At power-up, the instrument loads data in memory according to the last channel definition.
When the Channel definition is modified, in order to have the new data properly stored, it is necessary
to exit the Channel definition menu and return to the operation menu (END key), switch-off power to the
instrument, then power it up again while keeping key 9 (CANCEL) pressed.
If the language selected was different from Italian, it is necessary to select again the desired language,
as this operation sets back instrument to default English language.
4.4 Set-up menu
The set-up menu is structured in three different submenus and namely:
Configuration to set the general operating parameters of the instrument, see 4.4.1;
Output settings to select 4–20 mA or 0–20 mA output for each channel, see 4.4.2;
Alarms to set alarms level; see 4.4.3.
Each of them will be discussed in detail in the following pages.
Configuration
Output Setting
Alarms
Password
XXXXX
Menu
Operation display
Process
Calibration
Channel definition
1,2,3….
To enter
Configuration:
To enter
Output setting:
To enter
Alarms setting:
(See Par. 4.4.1)
(See Par. 4.4.2)
(See Par. 4.4.3)
26
4.4.1 Configuration
The configuration menu consents to set the general parameters of the instrument. Only those parameters
which are pertinent to the selection made and to the hardware installed will appear in the menu. When a
digital value is requested, pressing the ENTER key will cause a cursor to appear in the display: at this point a
numeric value may be entered using the second function of the keyboard pushbuttons. When ENTER key is
pressed again, the value shown on the display will be confirmed, whether the latter has been modified or not.
Here is a description of the parameters appearing in the menu. A summary of the configuration menu
flowchart follows in the next page.
4.4.1.1 Configuration parameters
Language: select the language of the displayed messages. Available languages: Italian, English,
French, German, Spanish. Default: English
Password: set the password, that is an alphanumerical code composed of up to 5 characters. Default
setting by Factory: 00000
Serial link: optional serial communication link.
See Section 11.3 “Serial Communication” for detailed instructions
Cleaning: logical sequence for periodical cleaning of the sensors.
See paragraph 4.4.1.3 for details
Temperature select: select measuring units for displayed temperature value: °C or °F; default is °C.
Temperature set: define temperature at which operate temperature compensation when the thermo-
resistance is faulty; default is 20 °C.
Altitude: not supported.
CCI in ‘OR’: when AW400 is installed on a water analytical unit and another Micro2Chem is driving the
cleaning sequence for all the sensor installed on the water analytical unit, the AW400 that
is not driving the cleaning needs to be "informed" that its sensors are being cleaned: this
information comes through its CCI that are connected to the CCO driving the cleaning on
the other AW400. When CCI in OR option is chosen, if one or the other or both the CCI
is/are closed the AW400 "knows" that it has to freeze output signals.
Average: for dual channels transmitters, with identical sensors installed; the transmitter computes
the average of the two input signals. The choice is Average NO or Average YES; default is
NO (the average is not computed).
Delta: for dual channels transmitters, same installed parameter; the transmitter displays an alarm
when the difference between the two measured values is higher than the set value
allowed for the deviation. Default = 0.0 (the delta is not active).
Smoothing: The number is the smoothing in seconds on the input signal. It can be separately set for
the three channels. Allowed values are 0.00 – 10.00. Default is 1.00
Digital I/O Setting: allows to set the status of digital input and digital outputs.
Instrument test: see paragraph 4.4.1.4
27
4.4.1.2 Configuration menu flowchart
Language
Configuration
Password
Configuration
Serial Link
Configuration
Temp.Select
Configuration
Altitude value set*
Configuration
Altitude *
Configuration
‘OR’ CCI
Configuration
Average **
Configuration
Delta **
Configuration
Smoothing
Configuration
Digital I/O set
Configuration
Instrument Test
Italian
Italian
English
French
German
Spanish
Serial Link
Address
Serial Link
Ba
ud Rate
Serial Link
Serial Port
Temp.Select
°C/°F
Configuration
Temp. Set
Altitude
Eng.Unit Set
‘OR’ CCI
NO/YES/FF
Smoothing
Channel 1
Smoothing
Channel 2
Smoothing
Channel 3
Digital I/O Set
Digital Outputs
Digital I/O Set
Digital Inputs
END key to exit menu
Only when
Channel 2 pc
board is installed
Only when
Channel 3 pc
board is installed
Configuration
MENU key to search language
ENTER key to select language
Enter Configuration submenu
Enter Language submenu
Search next
Configuration
item
Configuration
Language
Language
Language
Language
Language
Configuration
Cleaning
Cleaning
NO/YES
* Only for DO analyser
**Only for dual channels transmitter,
with identical sensors
(See Paragraph 4.4.1.4) for
Instrument Test details)
(See Paragraph 4.4.1.3) for
Cleaning sequence details)
Not supported
28
4.4.1.3 Cleaning functionality
The cleaning functionality implemented in the AW400 supports a sequence of operations necessary to
perform a periodical cleaning of the sensors. This function is always present in the software and can be
enabled or disabled by a YES/NO selection in the configuration menu (default setting is NO).
When the selection is set to “YES”, the instruments activates the cleaning sequence and operates the output
contact relays associated to CCO5 and CCO6 to drive the solenoid valves for the washing and rinsing lines
(see Fig. 10). Each phase of the cleaning sequence requires a different timing, and this can be freely
configured in parameters T1, T2, T3 and T4 (see table 2 below for details). During the cleaning sequence
active phases, the measure is frozen to the last valid value, and when instrument is operating as a Controller,
the latter is automatically forced in manual mode.
The cleaning sequence can be started locally with a manual command by pressing Key 8 / WASHING, or it
can be triggered automatically by setting proper values in the timers T1–T4.
There are two cleaning sequences designed to work in conjunction with optional ABB devices: sequence “A”
(Water Analytic Unit) and sequence “B” (Sequential Cleaning Unit). If the hydraulic cleaning system used is
different from the a above specified devices, then select “B” option and use the output contacts as directed in
Figure 10 to drive the solenoid valves.
The cleaning sequence consists of the following four phases:
T1 - Analysis: Normal operation phase of the sensor, that is the time period between the end of a
cleaning sequence and the start of the next one in automatic mode. Allowed time values
are 1 sec. to 30 hours. Typical value is 23,5 hours.
T2 – Washing: Phase to be used to wash the sensor with chemical detergent. Allowed values are 0–30
minutes. Typical value is 10 min.
T3 – Rinsing: Phase to be used to rinse the sensor with pressurized clean water. Allowed values are 0–
30 minutes. Typical value is 10 min.
T4 – Pause: Pause period usually allowed to consent the sensor to recover sensibility before starting a
new measure. Allowed values are 0–30 minutes. Typical value is 10 min.
PHASES
TIME
CCO5
1
CCO6
1
MESSAGE
T1 Analysis
T1
T2 Washing
T2
O
WASH!
T3 Rinsing
T3
O
WASH!
T4 Pause
T4
WASH!
T1 Analysis
T1
Table 2 - Sequence of cleaning phases
CCO 5
NC
CCO 6
NC
9
10
11
12
Power supply
Power supply
Digital I/O board
Fig. 10 - Connection of solenoid valves
Legend
O = open
= closed
29
4.4.1.4 Instrument test
This submenu which is part of the Configuration menu, allows to perform self diagnostic routines on AW400
basic functions, sensor check and AW400 electrical calibration.
Pressing any key
its meaning will
appear on display.
To exit keep END
key pressed for
3 sec.
Shows all
characters
Present in the
display. To exit
press END key.
Instrument Test
Keyboard
Test
Instrument Test
Display Test
Instrument Test
Digital I/0
Instrument Test
Analog I/O
Instrument Test
ElectricalCalib.
See Paragraph
4.4.1.4.1
Instrument Test
Configuration
Test
See Paragraph
4.4.1.4.2
See Paragraph
4.4.1.4.3
Keyboard test: pressing any key the display will show the corresponding number (0....9) or function
(ENTER, END). To exit this submenu press END key and keep it pressed for 3 seconds,
until the display shows - - -.
Display test: once entered this submenu the display shows cyclically in all the 32 writing locations of
the display all the characters present. To exit press END key.
Digital I/O: see below
Analog I/O: see below
Electrical Calibration I/O: see below
Digital I/O Test
This submenu allows to verify the status and the correct functionality of the digital inputs and outputs:
Digital I/O
Input Signals
IN 1 2
ON ON
Digital I/O
Output Signals
1 2 3 4 5 6
7
0 0 0 0 0 0
Instrument Test
Digital I/O
30
Digital Input: Input signals submenu the display shows
" 1 2 "
" OFF OFF "
changing the status of one of the CCI by shorting the associated terminals (1-3 or 2-4) the
display shows ON below the number of the associated CCI.
Digital Output: the display will show the status of the 7 output contacts (relay):
" 1 2 3 4 5 6 7 "
" 0 0 0 0 0 0 0 "
pressing the key corresponding to displayed number (from 1 to 7) the display will change
the "0" in "1" or vice versa and the contact output status will be changed accordingly form
“OPEN” to “CLOSE”: verify with an ohmmeter the status of the pertinent CCO (see
table 3).
Contact Number (CCO)
CCO1
CCO2
CCO3
CCO4
CCO5
CCO6
CCO7
Terminal identification
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Table 3 - CCO Terminal identification
Analog I/O Test
The Analog I/O test allows you to verify the correct value of the input and output signals.
In the analog “Input” mode, the display shows the value of the signal generated by the sensor and the
pertinent Pt100, in order to verify the correct sensor operation in an easy and fast way.
In analog output mode the instrument allows to check correct functionality of the 4–20 mA output: operating
the OUT increase and OUT decrease keys the output value indicated on display can be changed and with a
multimeter connected to the pertinent channel output [terminals 1(-), 2(+)] it can be verified that the current
output changes accordingly.
Input Signals
Channel 1
Chn 1 1.234 µA
105 ohm
Input Signals
Channel 2
Chn 2 1.234 µA
105 ohm
Input Signals
Channel 3
Chn 3
105 ohm
Output Signals
Channel 1
OUT [4-20 mA]
4.0
Output Signals
Channel 2
OUT [4-20 mA]
4.0
Output Signals
Channel 3
OUT [4-20 mA]
4.0
Analog I/O
Input Signals
Analog I/O
Output Signals
Instrument test
Analog I/O
(Display shows actual input signal value read from sensor)
(Display shows actual output signal value generated)
Electrical calibration
The access to this menu is protected by a password that is only known to factory personnel, because the
included parameters must never be tampered with.
The electrical calibration is only performed in the Factory at the end of manufacturing process.
31
4.4.2 Output setting
The Output Settings menu allows to set current output (0–20 or 4–20 mA), zero (Out Zero) and full scale (Out
Max) values, in engineering units. Out Zero value corresponds to 0 mA or 4 mA (according to the output
chosen) and the Out Full Scale value to 20 mA.
WARNING! Set 0–20 mA or 4–20 mA accordingly. To modify output signal change Jumper JP1-
JP2 as shown in Par. 4.4.2.1 – Fig. 11
(See Section 4.4 to get here)
Output Settings
Channel 1
Channel 1
0-20 / 4-20 mA
Cannel 1
Out Zero
Channel 1
Out Span
Output Settings
Channel 2
Channel 2
0-20 / 4-20 mA
Channel 2
Out Zero
Channel 2
Out Span
Output Settings
Channel 3
Channel 3
0-20 / 4-20 mA
Channel 3
Out Zero
Channel 3
Out Span
Only when Channel 2
pc board is installed
Only when Channel 3
pc board is installed
Menu
Output setting
In the following table the default values of Out Zero and Out Max are presented. Minimum span and
maximum ranges are also presented.
Parameter
Unit
Out Zero
Out Max
Minimum Span
Maximum
range
pH
pH
2.00
12.00
1.00
0.00–14.00
mV
mV
-500
+500
100
-1500–+1500
O3
ppm
0.00
1.00
0. 25
0.00–10.00
Cl
ppm
0.00
1.00
0.25
0.00–10.00
CD
ppm
0.00
1.00
0.25
0.00–10.00
T
°C
-10.0
100.0
5
-20–+100
mA
mA
4.00
20.0
2
(0) 4–20.0
32
4.4.2.1 Output signal hardware modification 4 to 20 and 0 to 20 mA
To modify output signal from 4 to 20 and 0 to 20 mA make following hardware modification on Analog
In put/Output board:
Identify Jumper IP1 and JP2 on board (see figure 11);
Remove JP1 (cut copper, this jumper is factory-made by default);
Install Jumper in JP2 position.
Fig. 11 - Jumper position for 4–20 to 0–20 mA output signal modification
JP1
JP2
JP1
JP2
4-20 mA default setting
Setting for 0-20 mA
33
4.4.3 Alarms
This menu allows to set high and low alarm levels and the dead band. The alarm levels are freely selectable
by the user. Select the channel and press Enter to select alarms and dead band. Default levels are
automatically related to the set range of output: low alarm is set at 10 % of Out Zero and high alarm is set at
90 % of Out Max (see the following table for default alarm setting values).
Parameter
Unit
Alarm
low
high
dead band
pH
pH
3.00
11.00
0.00
mV
mV
-450
+450
0.00
O3
ppm
0.10
0.90
0.00
Cl
ppm
0.10
0.90
0.00
CD
ppm
0.10
0.90
0.00
T
°C
10.0
90.0
0.00
mA
mA
6.40
17.60
0.00
Dead band is useful to avoid a repeated switch on and off of an alarm condition. The operation principle is
represented in figure 12 below: if the measured value reaches the high alarm level, AW400 generates an
alarm message, but a second alarm condition is triggered only after the measure lowers below the set dead
band, and then rises again above the HI alarm level. A similar procedure of opposite sign is performed for low
alarm.
To identify contacts for alarm retransmission, see the operation description for each instrument type in the
following chapters.
Measured value
Low Alarm
High Alarm
Dead
Band
Dead
Band
LoAl
ON
HiAl
ON
Alarm
OFF
Measured value
Low Alarm
High Alarm
Dead
Band
Dead
Band
LoAl
ON
HiAl
ON
Alarm
OFF
Fig. 12 - HI and LO alarm dead-band
4.4.3.1Alarm Display
When an alarm occurs, the display indication will flash on and off to signal the alarm condition.
By pressing the ENTER key, the alarm page will be called on display, and it will be possible to identify the
channel and the alarm type .
See Par. 9.1.3 for details.
34
4.4.3.2Alarm setting Menu
(See Par. 4.4 to get here)
Alarms
Channel 1
Channel 1
Low Alarm
Cannel 1
High Alarm
Channel 1
Deadband
Alarms
Channel 2
Channel 2
Low Alarm
Channel 2
High Alarm
Channel 2
Deadband
Alarms
Channel 3
Channel 3
Low Alarm
Channel 3
High Alarm
Channel 3
Deadband
Only when Channel 2
pc board is installed
Only when Channel 3
pc board is installed
Configuration
Alarms
Press Enter Key to
access value, Enter
again to accept value
35
5 FUNCTIONALITY
The different functionality of the instrument depends on the Model Number selected, and it can be classified
in two main groups: Monitor-Indicator-Transmitter (AW401) or Monitor-Indicator-Transmitter-Controller
(AW402).
5.1 Transmitter (AW401)
The transmitter can support up to three sensors, and the association of input/output signals depend on the
configuration selected as per following tables.
Digital inputs:
CCI in ‘OR’ SELECTION
CCI1
CCI2
CCI in „OR‟ = NO
Freezes measured value of Channel
1
Freezes measured value of
Channel 2 ( Channel 3 alone
cannot be frozen)
CCI in „OR‟ = YES
Freezes measured value of all
Channels installed
Freezes measured value of all
Channels installed
Table 4 - Digital Inputs Funcionality for Transmitter
Digital outputs:
Transmitter
Type
CCO1
CCO2
CCO3
CCO4
CCO5
CCO6
CCO7
Without
Cleaning
HI Alarm
Ch. 1
LO Alarm Ch
1
HI Alarm Ch.
2 (1)
LO Alarm
Ch. 2 (1)
HI Alarm Ch.
3 (2)
HI Alarm Ch.
3 (2)
Watch
dog
With
Cleaning
HI Alarm
Ch. 1
LO Alarm Ch
1
HI Alarm Ch.
2 (1)
LO Alarm
Ch. 2 (1)
Washing
command
Washing
command
Watch
dog
Table 5 - Digital Output Functionality for Transmitter
Analog Signal output 0/4-20 mA:
Instrument
Channel 1
Channel 2
Channel 3
Transmitter
Retransmission of
analysis value for Sensor
on Ch 1
Retransmission of
analysis value for Sensor
on Ch 2 (1)
Retransmission of
analysis value for Sensor
on Ch 3 (2)
Table 6 - Analog Output Functionality for Transmitter
(1) – Only when Channel 2 is installed
(2) – Only when Channel 3 is installed
36
5.2 Controller (AW402)
The control strategies offered by the AW400 are:
Standard PID Controller, with Feed Forward option
Average Controller
These will be discussed in detail in the following paragraphs.
5.2.1 General description
The PID Controller of the AW400 is usable in the majority of process applications. In function of the difference
between the analytic measure (Process Variable, PV), and a Set-point (SP) value, it calculates an Output
(OUT), that is applied to a final control element (f.e. dosing pump) to restore actual process value to the set-
point demand. The output is calculated with the PID algorithm, which has Proportional, Integral and Derivative
actions. The effect these terms have on the calculated output is determined by the PID configuration.
The Controller can work in Automatic or Manual mode, pushing number 0 (zero). The Manual mode let the
user modify the output manually, whereby the PID calculated output is not used. The output is driven with
push-bottoms 1 (decrease) and 2 (increase). The Automatic mode is selected pushing button 5. The set-point
is modified with the push-bottoms 6 (decrease) and 7 (increase). The output signal to drive the control
element can be either a 4-20 mA analog signal or two contacts (increase-decrease). The user can choose to
control the final element according to the characteristics of the device used. The END key consents to change
the display to that of a different function.
5.2.2 Controller’s Parameters
When the instrument is operating as a controller (AW402), the following menu become accessible:
Configuration
Output Setting
Alarms
Password
XXXXX
Menu
Operation display
Process
Calibration
Channel definition
1,2,3….
To enter
Controller Menu:
Controller
PID1
Entering the Controller Menu the accessible parameters are presented as per the following table:
1 - General Parameters (valid for all control strategies)
Description
Symbol
Configuration
4/20 mA / Contacts
-
Selection of controller output as analog 4/20 mA
signal or Contact closure (See 5.2.2.5)
Proportional Band
PB
Numeric entry in % (Integer positive)
Default: 100 - Range: 2% – 500%
Time Reset or Integral action
TR
Numeric Entry in minutes per repetition
37
Default: 0 min/rep. – Range 0–30 min
Manual Reset
(Active when TR=0)
MR
Numeric entry in %
Default: 0 - Range 0–100%
Derivative
TD
Numeric Entry in minutes
Default: 0 min – Range 0–10 min
Process Variable (display only)
PV
Engineering units
Set Point
SP
Engineering units
Default: 0
Control zone
CZ
Numeric entry in Engineering units
Default: 0
Direct/Reverse Action
RSW
D = Direct; R = Reverse
Span
SPAN
Value configured in output setting
(Feed Forward parameters appear here if this option has been selected. - See Section 2 below)
High limit on controller‟s output
OH
Numeric entry in %
Default: 100 - Range 0–100%
Low limit on controller‟s output
OL
Numeric entry in %
Default: 0 - Range 0–100%
2 - Feed Forward action (this menu available only when option is activated – See Par. 5.2.2.2)
Limit output as function of flowrate?
OHLP
Enter No/Yes
Default: No
Factor to compute Max output based on
Flowrate value
FFH
Numeric entry in %/100
Default: 1 (=100%)
Factor to compute Min output based on
Flowrate value
FFL
Numeric entry in %/100
Default: 0 (=0%)
Absolute High limit on output when limits
based on flowrate are active
MAX ABS.
Numeric entry in %
Default: 100 - Range 0–100%
Gain factor applied on flowrate signal
GAIN
Numeric entry in %
Default: 100 - Range 0–100%
3 - Sampling and/or Flow Pacing Controller (Process with dead time - this menu available only when
Chlorine input Channel is selected – See Par. 5.2.2.3)
Sampling based on flow?
TATP
Enter No/Yes
Default: No
Scaling factor for flow
K
Numeric entry in Engineering units
Default: 0
Active time
Att
Numeric Entry in minutes
Default: 0 min – Range 0–10 min
Total Cycle time (or volume)
Cycle
Numeric Entry in minutes (or units sample)
Default: 0
4 - pH/ORP control (this parameter compares when pH/ORP is selected – See Par. 5.2.2.4)
Squared error control band
BAND
Numeric entry in %
Default: 0 - Range 0–100%
38
5 - Contact output controller – (this menu available when option is selected - See Par. 5.2.2.5)
Frequency / Relay
-
Function not supported at this time, leave always
the selection "Relay"
Gain
GAIN
Numeric entry in %/100
Default: 1 (=100%)
Dead Zone
DZ
Numeric entry in Engineering units
Default: 0
Cycle time
CYCLE
Numeric Entry in seconds
Default: 0 sec
Table 7 – Contgroller Parameters
5.2.2.1 PID Parameters
Variations in controller action are obtained by adjusting of parameters associated with the control modes.
These modes of control action that are combined to adjust the controller output signal are known as
Proportional, Integral (Reset) and Derivative.
Proportional Action (PB)
Percent proportional band is the full scale though which the error signal must vary to cause full scale output
variation due only to proportional control mode response. In Proportional Action there is a comparative
relationship between the controller loop output signal magnitude and the calculated error, which is the
difference between the process variable and the set-point. To properly use the proportional action follow
these indications: if it is desired that a small percentage of deviation of the process variable causes a full
scale output, the proportional band (PB) has to be set at a small value (high gain); on the contrary if it is
required that a large percentage of deviation causes a small scale output the proportional band has to be set
to a high value (low gain). Minimum value is 2%, maximum is 500%.
Integral Action (TR)
Integral action augments proportional action to cause a controller PID loop to drive its final control element
until the deviation is completely eliminated. It produces a corrective signal proportional to the error and the
length of time the controlled variable has been different from set-point. Integral action is expressed as the
length of time in minutes required for it to produce an output change equal in magnitude to that produced by
proportional action. The set of TR has to be in the following range: 0.02 minutes/repetition for the fastest
action, 30 minutes/repetition for the slowest action.
Derivative Action (TD)
Derivative action augments proportional action by responding to the rate of change of the process variable. It
is used to make each controller PID loop more responsive to sudden process disturbances. The derivative
time in minutes is the amount of time by which the proportional action (or proportional plus integral action) is
advanced. The minimum value for derivative action is 0.01 minutes for the fastest response, and the
maximum value is 8 minutes for the slowest response.
Control Zone
This parameter is used to avoid continuous control adjustments for small fluctuation from set-point. If for
example set-point is set to 7 and CZ = 1, control action is not active in the range 6.5 –7.5.
Manual Reset
This parameter represents the integral action set manually. It is activated by setting TR parameter to “0”.
Direct/Reverse action
This parameter has to be set according to the final control element: select Direct if to an output increase has
to correspond an increase in the final control element, select Reverse if to an output decrease has to
correspond a increase in the final control element and vice versa.
Span
Is the measuring range used by controller.
Output High and Low limits
39
These parameters represent the absolute high and low limits allowed for the controller output. The output
limits have to be set if required by the process. Default factory setting are: High Limit 100%, Low Limit 0%.
5.2.2.2 Feed Forward (FF) Configuration
The instrument will activate this function only if it detects the presence of a 4-20 mA input signal connected to
Channel 2.
If flow rate is variable, proper control action has to take into consideration this variable, and this strategy is
achieved with the Feed Forward action, which is calculated from a flow rate measure and it acts directly on
the controller‟s output, anticipating the correction eventually generated by the controller‟s PID algorithm.
Flow rate measure is a 4-20 mA analog signal coming from an external flowmeter connected to channel 2.
AW400 gives the possibility to calculate output limits as a function of the instantaneous flow rate. If this
functionality is active the standard High and Low limits on the controller‟s output are automatically disabled.
This functionality is useful when control action is aimed at the dosage of a reagent, as it prevents excess
dosages in the case of low flow rate. High limit is calculated by the multiplication of FFH (Feed Forward High
factor) and the instantaneous flow rate, low limit is calculated by the multiplication of FFL (Feed Forward Low
factor) and the instantaneous flow rate.
Example:
Flow rate is 20 %; FFH is 1.5 and FFL is 0.5. Limits are 30% and 10% of the controller‟s output range.
Absolute maximum limit of the control output is set with the parameter Abs. Max.
The Gain is multiplication factor of FF term.
5.2.2.3 Sampling and/or Flow Pacing Controller
Process with dead time, which is often the case for Chlorine dosage, can be best controlled with this strategy.
Therefore this menu is made available automatically when the instrument detects that Chlorine input Channel
has been selected, and it can be activated or deactivated at choice by the user.
Sampling control updates the PID function on a periodic basis (cycle) for a specified length of time (active
time). The sampling rate is determined by time (time sampling) or the amount of product measured (adaptive
sampling), the latter solution possible only when an external flowmeter is connected to Channel 2. To select “
time sampling” set TATP parameter to “NO”, to select “volume sampling (adaptive)” set TATP parameter to
“YES”. When volume sampling is selected, the parameter “K” becomes available: this is a factor
corresponding to the flowmeter full scale value expressed in cubic meters (m
3
) , and it can be set between 0
and 17000 m
3
.
The CYCLE parameters represent the complete control cycle and it has to be set in minutes (for time
sampling) or m
3
(for volume sampling), depending on TATP setting.
Active time parameter represent the period during which the PID parameters are updated in the cycle, and it
must be set in minutes (for time sampling) or m
3
(for volume sampling), depending on TATP setting.
Feed Forward action can be activated with this strategy, and it is operating regardless of the cycle phase, that
is also when the controller is not in the active phase.
40
5.2.2.4 Error Squared Controller (pH Applications)
When the instrument detects that pH sensor has been selected for the controller, it enables a special PID
algorithm with an “Error Squared” function. The error squared function is applied only within a band defined in
the “BAND” parameter of the controller‟s configuration menu. When the error is outside this band, the effective
error is a linear response (see Fig. 13).
If “BAND” parameter is set to “0”, then the controller operates like a standard PID controller
Fig. 13 - Error versus control band
5.2.2.5 Contacts Output Controller
This controller, also known as Proportional Speed Floating Controller, is particularly suitable for operation with
an electrically motorised control valve, or dosing pump, and it actuates the final control element through
output contacts closure rather than 4–20 analog signal. The controller performs process control through the
velocity algorithm, a term that describes a control action in which the direction and rate of motion of the final
control element is proportional to the deviation of the controlled variable from the set point.
In the control with contacts the PID algorithm is not active. and the output is calculated in function of the Gain
parameter. The Gain parameter is functionally similar to the Proportional Action; explaining with an example,
considering constant the difference between set-point and process variable, contact will be closed longer if
Gain parameter is low , while it will be closed shorter time if Gain parameter is high.
Gain is defined as:
Time cycle parameter represents the duty cycle of the contact output. Its action is similar to the Integral Action
(TR) , in fact it represents time (expressed in seconds) of a cycle of control. Considering the difference
constant, if it is set to a high value the control action will be slow, while if it is set to a low value the control
action will be faster.
Dead Zone parameter represents the range around set-point where control action has no effect. So, when the
difference between process variable and set-point is lower than this value contacts are kept open.
The contacts used by the controller to drive the final element are assigned as per the following table:
PID 1
PID 2 (optional)
CCO 3
CCO 4
CCO 5
CCO 6
Decrease
Increase
Decrease
Increase
Table 8 - Contacts Output Controller assignment
% output duty cycle
% input deviation
41
5.2.3 Standard Controller
This section deals with the functionality which is specific of the standard controller.
5.2.3.1 Std Controller Display
The standard controller display shows the following values:
Instantaneous value of process variable measure
process variable temperature (not present for ORP sensor)
set-point
output signal value
Controller status: A/M (A = Automatic, M = Manual).
Fields of display are configured as in the following draft:
Process measured value Process Temperature
1
2
.
5
2
p
H
1
5
.
5
°
C
1
2
.
0
0
S
P
1
6
%
O
U
T
A
Set-point Output (%) Automatic/Manual (A/M)
If the instrument is configured to perform additional functions beside operating as a controller, for example to
monitor another parameter with a second or third sensor installed on channel 2 or 3, the indication of these
values can be called on display by pressing the key END, which will cycle through the different displays
available, and eventually back to the controller display
42
5.2.3.2 Std Controller Analog Output assignment
The assignment of the analog output signals depends on the number of channels installed and on the type of configuration selected for the controller output, whether it
is to operate on a 4–20 analog signal or on contacts closure, as per the following table:
Type of Controller
Output option
4–20 mA Channel 1
4–20 mA Channel 2
4–20 mA Channel 3
Controller AW402
With 1 Channel installed
Analog output
PID Control output
---
---
Contacts output
Measured value retransmission of
Channel 1 analysis
Controller Mod AW402
With 2 Channels installed
Analog output
PID Control output
Measured value retransmission of
Channel 1 analysis (1)
---
Contacts output
Measured value retransmission of
Channel 1 analysis
Measured value retransmission of
Channel 2 analysis (1)
Controller Mod AW402
With 3 Channels installed
Analog output
PID Control output
Measured value retransmission of
Channel 1 analysis (1)
Measured value retransmission of
Channel 3 analysis
Contacts output
Measured value retransmission of
Channel 1 analysis
Measured value retransmission of
Channel 2 analysis (1)
(1) If the two sensors/channels are identical, and the PID option is selected on Channel 2, the output becomes the average of the two measured values
Table 9 - Std Controller Analog Outputs
5.2.3.3 Std Controller Digital Input assignment
The Digital Input functionality is identical for all type of instrument selected, as per following table:
CCI in ‘OR’ SELECTION
CCI1
CCI2
CCI in „OR‟ = NO
Freezes measured value of Channel 1
Freezes measured value of Channel 2
( Channel 3 alone cannot be frozen)
CCI in „OR‟ = YES
Freezes measured value of all Channels installed
Forces to 0 PID1 output signal
Table 10 - Digital Input Functionality for Controller
43
5.2.3.4 Std Controller Digital Output assignment
The assignment of the digital output signals depends on the number of channels installed, on the type of configuration selected, for the controller output, whether it is
to operate on a 4–20 analog signal or on contacts closure, and on the cleaning option configuration, as per the following table:
Controller Type
CCO1
CCO2
CCO3
CCO4
CCO5
CCO6
CCO7
Controller Model
AW402 Without
Cleaning
Analog output PID
HI Alarm Ch. 1
(1)
LO Alarm Ch 1
(1)
HI Alarm Ch. 2
(2)
LO Alarm Ch. 2
(2)
HI Alarm Ch. 3
(if Ch. 3 installed)
LO Alarm Ch. 3
(if Ch. 3 installed)
Watch
dog
Controller Model
AW402 Without
Cleaning
Contacts out PID
HI Alarm Ch. 1
(1)
LO Alarm Ch 1
(1)
PID control output
(decrease)
PID control output
(increase)
HI Alarm Ch. 3
(if Ch. 3 installed)
LO Alarm Ch. 3
(if Ch. 3 installed)
Watch
dog
Controller Model
AW402
With Cleaning
Analog output PID
HI Alarm Ch. 1
(1)
LO Alarm Ch 1
(1)
HI Alarm Ch. 2
(2)
LO Alarm Ch. 2
(2)
Washing command
(See Par. 4.4.1.3)
Washing command
(See Par. 4.4.1.3)
Watch
dog
Controller Model
AW402
With Cleaning
Contacts out PID
HI Alarm Ch. 1
(1)
LO Alarm Ch 1
(1)
PID control output
(decrease)
PID control output
(increase)
Washing command
(See Par. 4.4.1.3)
Washing command
(See Par. 4.4.1.3)
Watch
dog
(1) If two/three identical sensors/channels are installed, and PID option is selected on Channel 2/3, the alarm is based on the average of the two/three measured
values
(2) If two/three identical sensors/channels are installed, and PID option is selected on Channel 2/3, the alarm is triggered by the first of the two/three measured values
that reaches the alarm level configured (first-out functionality) .
Table 11 – Std. Controller Digital Output assignments
44
6 CALIBRATION
Calibration is required to align the sensor sensitivity. This operation is necessary at the start-up of the
instrument and at periodical intervals. New sensors have to be let in operation for at least 24 hours, to allow
the electrode to recover complete sensitivity, before performing the calibration procedure.
6.1 Calibration Procedure
When the instrument is powered up or when a channel is changed, the following message is displayed:
-calib-
To access the calibration procedure press the button MENU and insert the password, as shown in the
diagram at Paragraph 6.1.2. If the password is not correct, the access to the menu is refused and the
following message is displayed: -Access denied!-
If the code is the one previously set, it is possible to access to the Menu.
If problems are encountered during the calibration procedure, pressing the END key the calibration procedure
is aborted and the display returns to the main menu.
6.1.1 Calibration Menu
Calibration menu allows a dual point calibration procedure for the Monitors. In every dual point calibration, the
first number (P1) is the lower value point, and the second (P2) is the higher value point. The instrument has
P1 and P2 values assigned by default, as shown in the table 12. P1 and P2 values can be changed by the
user and have to be distant enough. Single point calibration (S.P.C.) is available for pH Monitor.
Parameter
P1 point value
P2 point value
PH
7.00
4.00
MV
-500
+500
O3
0.00
1.00
Cl
0.00
1.00
CD
0.00
1.00
T
0.00
100.00
mA
4.00
20.00
Table 12 - Default calibration values
WARNING !
If the calibration procedure is aborted, the read out value may become unpredictable.
45
6.1.2 Calibration Menu Flow Chart
Channel 2
*S.P.C.
Channel 2
Calibration P1
Channel 2
Calibration P2
Only when Channel 3
pc board is installed
Only when Channel 2
pc board is installed
Channel 1
*S.P.C.
Channel 1
Calibration P1
Channel 1
Calibration P2
Channel 3
Calibration P1.
Channel 3
Calibration P2
Operation display
Process
Password
XXXXX
Menu
Calibration
Chann.Definition
1,2,3…..
Selects
P1 value
Moves
to next
choice
To Exit
menu
Selects
P2 value
* Only when pH parameter is selected
6.1.3 pH Sensor Calibration
The calibration procedure is necessary to standardise the sensor sensitivity.
The double point calibration gives the maximum accuracy because it allows to set both the slope and the
offset of the curve giving displayed pH value as a function of the mV from the probe (sensitivity), pH = f (mV).
The first point can be calibrated by 7 pH buffer solution (0mV) and the second point can be calibrated by 4pH
buffer solution.
6.1.3.1 Double point calibration
The calibration procedure involves a series of operation on the pH probe and the transmitter. The following
description explains indicates step by step the calibration procedure.
To operate the calibration the following material is necessary:
- two plastic or glass beakers
- standard buffer solution, pH 7 and pH 4 or other, (see paragraph 6.1.3)
- de-mineralised water
- a thermometer
46
Put the two standard buffer solutions in two beakers in a sufficient amount to cover the sensor. Wash the
probe with de-mineralised water, dry it and dip it in the standard pH 7 buffer solution. Stir softly but
continuously the probe: in this way a lower stabilisation time will be required.
Press the MENU key to enter the Instrument Calibration submenu and enter the CALIBRATION menu and
then the channel of the pH probe. The display will show:
X
X
.
X
X
p
H
2
3
.
5
°
C
P
1
:
Y
Y
.
Y
P1 indicates the first point of calibration at HIGHER pH (pH 7). XX.XX is not a REAL pH value, but it shows
when stability of measure has been reached. YY.Y is a value set at the last calibration and can be freely
modified according to the chosen buffer solution. Press ENTER and insert the correct value. Wait 3 minutes
after the measure in XX.XX has stabilised (XX.XX is stable), then press ENTER to save the value (press END
if you don‟t want to save the value).
If the following message appears:
-Bad Input!-
It means the buffer solution is bad since the mV generated are too close.
Pass on to the second point (P2) of calibration pressing the MENU key. Take the sensor out of the 7 standard
buffer solution, rinse it thoroughly with de-mineralised water, dry it and immerse it in the 4 pH std buffer
solution. Stir softly but continuously the probe: in this way a lower stabilisation time will be required. Wait till
the value in XX.XX is stabilised (XX.XX is stable) and correct the pH value in YY.Y. Confirm by pressing the
ENTER key. Previously stored values are overwritten in not volatile memory. To start the measure press the
END key and the display will show the actual measured value.
6.1.3.2 Single point calibration (S.P.C.)
The single point calibration may be performed ONLY IF A DOUBLE POINT CALIBRATION HAS ALREADY
BEEN PERFORMED. The single point calibration is a fast procedure to correct the sensitivity of an instrument
leaving it working in field; however it's less accurate than the double point calibration and must be performed
as near as possible to the pH value of the process liquid. The single point calibration corrects the intercept of
the pH = f(mV) curve, but doesn't vary its slope.
To perform the single point calibration, measure the pH value of the process fluid near the location of the
sensor (if it is constant during the time interval needed for the calibration). Insert the pH value in YY.YY.
Entering the Calibration menu the following display will appear:
X
X
.
X
X
p
H
2
3
.
5
°
C
p
H
S
P
C
:
Y
Y
.
Y
Y
47
When a double point calibration is performed the S.P..C value is forced to 0.00.
500
400
300
200
100
0
-100
-200
-300
-400
-500
2
0
4
6
8
10
12
14
o
Curve relative to the initial
calibration
Curve relative to electrode
ageing
Curve corrected with a
single point calibration
Fig. 14 - pH Calibration curves examples
NOTE :
Single point calibration corrects the sensitivity in the zone where the correction is made. It is therefore
necessary to operate single point calibration as near as possible to the process fluid pH value.
IMPORTANT : THESE CURVES ARE ONLY A THEORETICAL REPRESENTATION, NOT BASED ON
EXPERIMENTAL VALUES.
6.1.4 ORP Sensor Calibration
The calibration procedure is necessary to standardise the sensor sensitivity. The double point calibration gives
the maximum accuracy because it allows to set both the slope and the offset of the curve giving displayed
ORP value as a function of the mV from the probe (sensitivity).
The calibration of ORP Monitor is not usually required, however the two point calibration procedure is
foreseen in the transmitter software.
NOTE: Calibration procedures are different if the arrangement “oxidation potential with negative value”
or “oxidation potential with positive value“ is used. Both are described in the following pages.
The calibration procedures involve both the electronic transmitter and the sensor. The following description
indicates step by step the double point calibration procedure:
To operate the calibration the following material is necessary:
- two plastic or glass beakers
- standard ORP solutions.
Pour the two standard ORP solutions in two beakers in a sufficient amount to cover the sensor. Wash the
probe with de-mineralised water, dry it and dip it in the first buffer solution. Stir softly but continuously the
probe : in this way a shorter stabilisation time will be required.
48
6.1.4.1 "OXIDATION potential with NEGATIVE values" arrangement
P1 will be the value of the oxidant standard solution, and P2 the value of the reducent standard solution. In
case both the standard solution have the same sign, P1 will be the standard solution with the lower value.
Press the MENU key to enter the Instrument Calibration submenu and enter the CALIBRATION menu and
then the channel of the ORP probe. The following display will appear:
X
X
.
X
X
R
X
2
3
.
5
°
C
P
1
:
Y
Y
.
Y
P1 indicates the first point of calibration. XX.XX is not a REAL value, but it shows when stability of measure
has been reached. YY.Y is a value set at the last calibration and can be freely modified according to the
chosen buffer solution. Press ENTER and insert the correct value. Wait 3 minutes after the measure in XX.XX
has stabilised (XX.XX is stable), then press ENTER to save the value (press END if you don‟t want to save the
value).
Pass on to the second point (P2, higher value) of calibration pressing the button MENU. Take the sensor out
of the first standard solution rinse it thoroughly with de-mineralised water, dry it and immerse it in the second
standard solution. Stir softly but continuously the probe: in this way a shorter stabilisation time would be
required.
Wait until the measurement is stabilised (no more variations of XXXX shown on the display). If needed,
correct the ORP value pressing the ENTER key and inserting the correct value, according to the second
buffer solution ORP value. If you want to save these values push the ENTER key. If you don't want to save
above mentioned calibration parameters press END. If the ENTER key is pressed new calibration data are
overwritten to previously stored values in not volatile memory.
To start the measure press the END key and the display will show the measured value.
NOTE:
The calibration procedure can be performed also at two values which are outside from the
measuring range selected, depending on the buffer solutions which are available for the
calibration.
6.1.4.2 "OXIDATION potential with POSITIVE values" arrangement
Calibration is similar to the previous one but P1 is the value of the reducent standard solution, and P2 the
value of the oxidant standard solution. In case both the standard solution have the same sign, P1 will be the
standard solution with the lower value.
49
6.1.5 Chlorine / Chlorine Dioxide / Ozone
The calibration procedure is necessary to standardise the sensor sensitivity. The calibration procedure allows
to set both the slope and the offset of the curve giving the chlorine/chlorine dioxide/ozone concentration as a
function of the µA from the cell (sensitivity).
The ABB Monitor allows an easy two point calibration and the two points can be freely chosen, provided they
are distant enough and inside the selected measuring range. In this way the instrument is given all the
parameters it needs to fix the calibration curve. The calibration procedures involve both the transmitter and
the sensor.
The following description indicates step by step the calibration procedure:
If the sensor is a new one leave it working for 24 hours so that the electrodes can gain the correct sensitivity.
Press the MENU key to enter the Instrument Calibration submenu and enter the CALIBRATION menu and
then the channel of the ORP probe. The following display will appear:
X
X
.
X
X
C
l
2
3
.
5
°
C
P
1
:
Y
Y
.
Y
P1 (YY.Y) indicates the first point in calibration (the lower one), XX.XX is a chlorine/chlorine dioxide/ozone
concentration reading. This reading, however is not a REAL value, but it's based upon calibration parameters
previously stored. XX.XX serves as an indication of the stability of the measure. 0.000 is a default ppm value
and can be freely changed. YY.Y is a value set at the last calibration and can be freely modified. Press
ENTER and insert the correct value.
Open the sample flow to the cell, with a chlorine concentration zero or near zero. Let the system stabilise and
then take a sample from the drain tube. Perform laboratory analysis of the chlorine species being measured
(free or total) or of the chlorine dioxide concentration. Correct the 0.000 if needed according to the lab
analysis. Confirm with the ENTER key.
If the following message appears: -Bad Input!-
It means the buffer solution is bad since the mV generated are too close. This message can be ignored by
pressing the END key.
If ENTER is pressed new calibration data (e.g. µA corresponding to the displayed ppm value) are overwritten
to previously stored values in not volatile memory
Pass on to the second point (P2) of calibration pressing the button MENU.
Allow a sample flow to the cell with a chlorine/chlorine dioxide concentration as near as possible to the chosen
full-scale, let it stabilise for some minutes (it depends upon the plant configuration) and then take a sample
from the drain tubing.
Analyse the solution for free or total chlorine or for chlorine dioxide, (depending upon the kind of measure the
Monitor is operating).
Correct the displayed ppm value in YY.Y according to the lab analysis as previously explained. If you want to
save these values (storing the values of µA corresponding to the measured chlorine concentration) push
ENTER. If you don't want to save above mentioned calibration parameters push END. So forth, previously
stored parameters aren't destroyed and they remain still valid for the computation (if the range setting has not
been changed).
To start the measure press the END key and the display will show the measured value.
50
REMARK :
if the sample is a chlorine dioxide solution and the displayed indication is desired to be in "ppm ClO2" multiply
the DPD analysis reading by 1.9.
WARNING !
It is advisable to repeat the calibration after 24 hours and after 2 or 3 days.
51
7 START UP
Before start up it is recommended to verify the following points:
Verify that the installation has been performed according to the section 3.3 of the present manual.
Verify that the power supply is in accordance with the value indicated in the instrument label.
Verify that the electrical wiring has been properly completed according to the recommendations
mentioned in section 3.4 of the present document.
Verify that power-up of the instrument will not cause any uncontrolled action related to the items
eventually connected to the output signals (i.e. dosing pumps, operating valves, fume extractors).
Verify that the probes connected to the instrument are properly installed and wired according to the
instructions indicated in the specific manual.
7.1 Preliminary operations
7.1.1 Getting started
Power the transmitter up and perform the following steps:
1. Turn on power supply;
2. Enter Configuration menu and set the desired language for the display messages;
3. If the displayed measured value is not in agreement with the connected sensor(s) enter the Channel
Definition menu, and set, for each installed channel, the correct type of measure. Refer to Sect. 4.3;
4. Verify that the selected measuring ranges correspond to the desired values; if not, modify ranges as
needed;
WARNING !
Maintenance staff must be authorised by Customer and must know in details the
content of the present Instructions Manual.
CAUTION!
Disconnect Power Supply before opening the transmitter covers.
CAUTION!
The transmitter must be closed before being powered up.
52
5. If the alarm levels are required at values that are not the 10 % and 90 % of measuring range, enter the
Alarms menu and set Low Alarm and High Alarm level as required. Refer to Sect. 4.4.3;
6. Verify that all Configuration parameters are set as required (See Sect. 4);
7. Once the sensor(s) sensitivity is stabilised the calibration procedure(s) has to be performed to
standardise the transmitter together with the connected sensor(s);
8. During the first 4 days of operation, it is suggested to verify every day the reading of the Monitor, and
repeat calibration if necessary;
9. Now the Monitor is in operation. It is important repeat periodically the maintenance procedures detailed
in the I.B. pertinent to each sensor.
7.1.2 Personalization of Parameters
1. If the Input / Output digital contacts are used, enter the Configuration menu and set the NO or NC
status of the contact as desired;
2. It is important to remember that any device connected to the digital output must be arranged in order to
operate in fail safe condition;
3. If the Serial Communication option has been selected, enter the Configuration menu and set the
desired instrument address, baud rate and selected communication port ;
4. Select the desired engineering unit for the temperature indication;
5. If it is desired to operate the controller with the average value of 2 or 3 identical sensors, select PID in
the Channel installation menu;
6. If it is desired that the transmitter calculates the difference between two identical sensors input values,
set a value in the “Delta” parameter;
7. If required, select a dumping value for each channel input;
8. Modify the “Password” in the Configuration menu, if it is desired to set a personalised access code.
7.2 Controller PID tuning
The PB, TR, and TD constants are preset to the default values shown in Table 7. If desired the control action
setting can be optimized by using a trial and error method as outlined below.
1. Set process to approximately normal conditions in MANUAL;
2. Preset constants to some acceptable starting point for the process. For example
PB = 500
TR = 100
TD = 0
3. Switch Controller to AUTO mode;
4. Decrease the PB setting to ½ the previous value. Then, alter the set point 2% by pressing one of the
set point pushbuttons;
5. Check that the process indication value does not oscillate;
6. Continue to decrease the PB setting by a factor of 2, altering the set point between steps until a point is
reached where process cycling is just evident. Then increase the PB setting by a factor of 2;
7. Introduce Automatic Reset slowly by decreasing TR until cycling starts;
8. Increase TR to approximately 1,5 times the value obtained in 7) above;
When PID tuning constants have been selected, the controller is ready for on-stream operation. Optional PID
tuning methods may be desired for slow response processes .
53
8 MAINTENANCE
AW400 housing can be externally cleaned with a cloth slightly wetted with alcohol and water, paying attention
not to damage the keyboard.
8.1 Periodical operations
All Monitors need cleaning of the sensors at periodical intervals, this depends on type of sensor and process
characteristics. For further details refer to the specific sensor Instruction Manual. The Monitors also need
periodical check of sensitivity and calibration if required.
8.1.1 Automatic sensitivity check during dual point calibration
During dual point calibration, and if no one of the two points is bypassed, AW400 performs an automatic
sensor sensitivity check. If the sensitivity is too low the display will show the message Bad In. Refer to the I.B.
pertinent to each specific sensor for details on how to fix the problem. If the message Fault appears the signal
generated by the sensor is abnormally high. Refer to the I.B. pertinent to each specific sensor for details on
how to fix the problem.
8.1.2 Sensor signal check
The signal generated by the sensor and by the temperature sensing element can be directly read (in µA or
mV and in Ω) on AW400 display simply by entering the Analog I/O, input signals submenu, under Instrument
Test submenu. This is a very easy way to define if the sensor is correctly working just verifying its signal and
comparing it to a lab analysis of the measured value. See the pertinent I.B. for nominal signal to be expected
from each type of sensor.
8.1.3 Other checks
Accessing to the menu at section INSTRUMENT TEST, is possible to verify the instrument features. Refer to
section 4.4.1.4. for further details.
CAUTION!
Do not use acids, chemicals solvents and organic substances for AW400 cleaning.
54
9 ERROR MESSAGES & TROUBLESHOOTING
Different levels of messages are generated by the instrument at need.
9.1 Messages
At power up, the AW400 instrument shows the following sequence of messages:
"MicroChem II"
"S.Rel...."
"Transmitter"
9.1.1 Operation messages
Messages displayed during operation to clarify what AW400 is doing.
"Loading default database"
is shown when a reset has been performed. After some seconds the instrument goes to normal display mode.
"-calib-"
is shown when the instrument is powered up and when a Channel has been changed. After some seconds the
instrument goes to normal display mode.
"---wash---"
flashing is displayed when the instrument is performing a cleaning sequence. "---wash---" is alternated to a
value that is the last measure before the starting of the cleaning sequence.
Both the displayed measure and the 4–20 mA output signal are frozen at that last value.
"Access denied"
is displayed when the inserted password is not correct.
"password"
is displayed when the menu key is pressed: the correct password must be entered in order to access the
menu.
9.1.2 Error messages
These messages are displayed when something is not correct in the unit.
"Error, no analog input"
is displayed when analog I/O pc board are missing (or contact in their connectors is failing).
"BadIn"
is displayed if the input signal generated by the sensor is too low, that is the sensitivity is too low.
"Fault"
is displayed if the signal generated by the sensor is too high.
"RTFault"
is displayed when the Thermo resistance is faulty and the instrument is currently using the default temperature
value
"Red LED lit (Watchdog)"
When Red LED watchdog is lit it means the microprocessor circuit is faulty.
55
9.1.3 Alarms page
It is accessed by pressing the Enter key in display mode.
If no alarm or no abnormal condition is present the display will show nothing.
The following messages are displayed with the indicated meaning:
A1L = low alarm on channel 1
A2L = low alarm on channel 2
A3L = low alarm on channel 3
A1H = high alarm on channel 1
A2H = high alarm on channel 2
A3H = high alarm on channel 3
=∂= = the value set for delta has been overcome
AVE = the instrument is computing the average of two measures (same parameter) and the averaged value is
indicated on the first line of the display instead of the measure of the first channel
Stop = When CCI in OR parameter is set to YES it means that output(s) is(are) frozen because either CCI1 or
CCI2 or both is(are) closed.
Run = When CCI in OR parameter is set to YES it means that output(s) is(are) working (not frozen) because
CCI1 and CCI2 are both open.
56
10 SERIAL COMMUNICATION
Note: This section applies only to instruments equipped with the optional Serial Communication P.C. Board.
10.1 Standard of Communications
Two digital communication standard are supported by the serial communication board of AW400, one port is
an RS232 serial interface and the other is an RS 422/485 serial interface. Only one port at a time can be
activated, and the selection of the desired standard is made via software at the Configuration Menu.
The Factory default setting is RS 422/485, which allows up to a maximum of 32 instruments to be connected
to the same Data-link, where each instrument must have a unique address number ranging from 00 to 31
(Factory setting is 00).
The RS 232 standard can be selected for a peer to peer communication mode.
Transmission speed can be adjusted between 1200 and 28800 baud in the Configuration Menu; default
setting is 28800, asynchronous by character.
One character can be defined as either one of the following two modes:
Mode 1 - (Standard PC mode - Default setting by Factory):
1 Start bit;
8 Data Bits – the Least Significant Bit (LSB) is transmitted first;
1 Stop Bit.
Mode 2 - (Optional setting):
1 Start bit;
8 Data Bits – the Least Significant Bit (LSB) is transmitted first;
1 Even Parity bit
1 Stop Bit.
NOTE: When operating in RS232 mode, the character definition must be set as Mode 1.
Mode 2 is active optionally only when operating in RS485.
To modify this selection, enter the Configuration menu and select the RS585 mode: the menu will
ask to select Mode 1 or Mode 2. When Mode 1 is selected and the communication is to work in
RS232, remember to set RS232 again in the menu after having selected "Mode 1" from the
RS485 menu.
10.1.1 Software characteristics
1. All transactions are initiated by the Host: The AW400 can only work as a responder to Host commands
(Interrogate or Change).
2. All AW400 begin their response within 10 ms after the end of the transmission by the Host, otherwise a
faulty transmission may be assumed.
3. The maximum number of data bytes per message is 32 (decimal).
4. Data type are made up of 1 (logical), 2 (integer), 4 (floating point) bytes or string type, with string length
bytes, according to Intel Format.
57
10.1.2 Communication Protocol
The communication protocol requires the Host to initiate all transactions. There are two basic categories of
message types: Interrogate , which is used to read data from an addressed AW400, and Change , which is
used to alter a value in an addressed AW400. The addressed instrument decodes the message and provides
an appropriate response. The protocol definitions for the message types are provided in the following table:
Message Field Definition
Symbol
Title
Definition
SOH
Start of Header
This character, 7E, denotes the beginning of a message
I.A.
AW400 Address
The address of the AW400 responding to the transaction. It must be within
a range of 00-1F (00-31 decimal).
CMD
Command
Is the operation to be performed or a description of the message that
follows the Command-I.A. byte. The Command-I.A. byte has two fields: the
Command field (3 bits), and the I.A. field (5 bits). There are the following
commands type:
Interrogate
Change
Acknowledge
Response
The command descriptions are covered in the following section.
NUM
Number
The number of data bytes transferred or requested. The NUM must be in a
range of 00-32 decimal.
LO-ADD
Lower Address Bits
The least significant 8 bits of a 16 bit address in the AW400 database (*)
HI-ADD
Higher Address Bits
The most significant 8 bits of a 16 bit address in the AW400 database (*)
DATA
An 8 bit data type
XXXX
Represents a variable number of data bytes
LRC
Longitudinal
Redundancy
Character
Is a character written at the end of the message that represents the byte
content of the message and is checked to ensure data was not lost in
transmission. Is the sum of all bytes Modulo 256 of the message not
including the SOH character or its own bit setting (LRC)
(*) The addresses of the single variables to be accessed in the AW400 database are listed in the
following pages.
58
10.1.3 Message Types and Commands Description
The types of messages that are sent between the host and the AW400 are formatted as follows:
Host to AW400
1. Interrogate – This message requests up to 20H consecutively stored bytes, beginning at the specified
memory address location of the addressed AW400.
01111110 E0H + I.A. NUM LO ADD HI ADD LRC
2. Change – This message sends up to 20H bytes of new data to the addressed AW400.
01111110 A0H + I.A. NUM LO ADD HI ADD Data 1 XXXXXXX Data N LRC
3. Acknowledge – This message signals the addressed AW400 that its last echoed change message was
received correctly; the AW400 performs the change requested.
01111110 80H + I.A.
AW400 to Host
1. Response – This message furnishes the data requested by the INTERROGATE command of the Host. It
is also used to echo back the previous CHANGE message of the Host.
01111110 20
H
+ I.A. NUM LO ADD HI ADD Data 1 XXXXXXX DataN LRC
59
10.2 Communication Transaction Examples
10.2.1 Transaction A Example
Host requests 9 bytes of data beginning at hexadecimal memory address 1000
H
from the AW400 at data-link
address 03:
1. Host sends interrogate message:
01111110 11100011 00001001 00000000 00010000 11111100
SOH Command NUM LO ADD HI ADD LRC
+ I.A.
2. AW400 sends response message:
01111110 00100011 00001001 00000000 00010000 XXXX XXXX XXXX LRC
SOH Command NUM LO ADD HI ADD Data 1 ………..Data 9
+ I.A.
10.2.2 Transaction B Example
Host sends two bytes of new data, to be loaded into the AW400 at data-link address 03 beginning at
hexadecimal memory address 1000
H
:
1. Host sends change message:
01111110 10100011 00000010 00000000 00010000 00001000 00001100 11001001
SOH Command NUM LO ADD HI ADD Data 1 Data 2 LRC
+ I.A.
2. AW400 sends response message:
01111110 00100011 00000010 00000000 00010000 00001000 00001100 01001001
SOH Command NUM LO ADD HI ADD Data 1 Data 2 LRC
+ I.A.
3. Host sends acknowledge message:
01111110 10000011
SOH Command
+ I.A.
4. AW400 performs the change requested at end of the current program scan.
Note: Database address table is shown at the end of this section.
60
10.3 Serial link signal connection
The AW400 optional serial communication P.C. Board is equipped with modular telephone RJ45 type jack
supporting both for RS 232 and RS 422/485 standards:
RJ45 TELEPHONE SIGNAL CONNECTION JACK LAY-OUT:
Pin N.
RS 232
RS 422
RS 485
1
GND
Ground
Tx +
Data transmission to PC, +
-
2
Rx IN
Data transmission from PC
Tx –
Data transmission to PC, -
-
3
Tx OUT
Data transmission to PC
GND
Ground
-
4
-
Rx +
Data transmission from PC, +
Data transmission to and from PC, -
5
-
Rx –
Data transmission from PC, -
-
6
GND
Ground
GND
Ground
Data transmission to and from PC, +
Table 13 - RJ45 Jack serial Communication connector pin-out
RJ45 Jack
Fig. 16 - RJ45 Connector layout
For RS232 and RS485 use shielded cables, two-cores twisted pair wire, section 0.5 1.0 mm
2
.
For RS422 use shielded cable, 4 cores, twisted pairs wire, section 0.5 1.0 mm
2
.
Connect shields to the ground shield terminal strip inside AW400.
1
6
61
10.4 Data-link Terminator
The datalink impedance should be 110 Ohm.
When the serial communication standard is selected as RS422 or RS485, and more than one AW400 are
installed on the same datalink, it is necessary to activate a terminator resistance, which is available on the
serial communication board.
This operation is to be made only on the last AW400 connected on the serial link.
If the host computer serial port is already equipped with a 220 Ohm resistor, then an identical resistor is to be
activated in parallel to obtain a 110 Ohm loop impedance. If no such resistor is present on the Host side, then
a 110 Ohm resistor is selected on the AW400 serial board.
The terminator resistance selection is made by installing a jumper on JP1 or JP2 for RS422 or RS485
respectively: the 110 Ohm resistor is selected by jumper between pin 1-2, while the 220 Ohm resistor is
selected by jumper between pin 2-3.
Please note:
- to select RS232 weld jumpers onto position 1,2 and 3.
- to select RS485 weld jumpers onto position 6 and 8.
- to select RS422 weld jumpers onto position 4,5,6,7 and 8.
jumpers
62
10.5 AW400 Memory Map
Increment: (figures between brackets „[x]‟ indicate the number of similar variables repeated).
Char type: 1 byte
int type: 2 bytes
float type: 4 bytes
string type: 1 byte x string length
Type
Hex addr.
Name
Description
int
0X0000
PgmMode
Program mode (0-4) Transmitter, Washing, Regulator…
int
0X0002
Lng
Language in use
char
0X0004
AccCode[6]
Miro2Chem Password
char
0X000A
TermAddr[4]
Serial line address
int
0X000E
SerSpeed
Serial line speed
int
0X0010
SerType
Serial line type
float
0X0012
Altitude
Altitude where AW400 is mounted
int
0X0016
CCIinOR
Set for CCI in OR mode
int
0X0018
Average
Set for Average count
float
0X001A
Delta
Delta limit
float
0X001E
pH_offset[3]
Offset for PH (SPC), for 3 channels
float
0X002A
P1[3]
Calibration P1 value for 3 channels
float
0X0036
P2[3]
Calibration P2 value for 3 channels
float
0X0042
P1U[3]
User Calibration P1 value for 3 channels
float
0X00AE
P2U[3]
User Calibration P2 value for 3 channels
int
0X005A
Light
Set when back-light is ON
int
0X005C
T_Units
Temperature units
float
0X005E
DefTemp
Default temperature for termo-compensation
int
0X0062
AltUnits
Altitude Units meters/feet
int
0X0064
Sigma
Sigma enabled or not
float
0X0066
sK1
Sigma K1 parameter
float
0X006A
sK2
Sigma K2 parameter
float
0X006E
Hyst[3]
Smoothing for each channel
int
0X007A
wType
Wash Type T17AU / T17SU
char
0X007C
wT[4][9]
Wash Timers T1-T4
float
0X00A0
Out_LO[3]
Min. output value for 3 channels
float
0X00AC
Out_HI[3]
Max. output value for 3 channels
int
0X00B8
DacType[3]
Type of DAC output
float
0X00BE
AlLO[3]
Alarms low level
float
0X00CA
AlHI[3]
Alarms high level
float
0X00D6
AlBA[3]
Alarms Band
int
0X00E2
DO_AIR[3]
Set when DO is in air
int
0X00E8
Reserved
Reserved
0X0108
SerMode
Type of RS485/422 serial line
int
0X0110A
CIO
0 = No I/O Board, 1 = Yes I/O Board
char
0X0110C
DoWash
When set, TX has washing
char
0X0110D
PidType
Determine program PID mode
char
0X0110E
Temp. Mode Ch. 2
When 0 use its own Temp. - When 1 uses Temp. Ch 1
char
0X0110F
Temp. Mode Ch. 3
When 0 use its own Temp. - When 1 uses Temp. Ch 1
int
0X01110
Ena[3]
Channels enabled
int
0X01116
Type[3]
Channel types
float
0X0111C
Chn_Val[3]
Actual channel measurement
float
0X01128
Temperature[3]
Actual channel temperature measurement
Table 14 - General Data Memory Map
63
PID 1 DATA
int
0X0134
Reserved
float
0X0136
PB
Proportional Band
float
0X013A
TR
Reset Time
float
0X013E
MR
Manual Reset
float
0X0142
TD
Rate Time
float
0X0146
SETPOINT
Set Point
float
0X014A
CONTROLZONE
Control Zone
int
0X014E
RSW
Direct/Reverse Action
float
0X0150
SPAN
Span
int
0X0154
OHLP
float
0X0156
FF HIGH
float
0X015A
FF LOW
float
0X015E
FF ABS MAX
float
0X0162
FF GAIN
float
0X0166
OH
float
0X016A
OL
int
0X016E
TATP
float
0X0170
K
float
0X0174
TATT
float
0X0178
TCYC
float
0X017C
LH
float
0X0180
LL
float
0X0184
PH BAND
int
0X0188
TIME CYCLE
float
0X018A
CONTACT GAIN
float
0X018E
DZ
int
0X0192
1C/2C
int
0X0194
PA
Table 15 - PID1 Data Memory Map
PID 2 DATA
int
0X0196
Reserved
float
0X0198
PB
Proportional Band
float
0X019C
TR
Reset Time
float
0X01A0
MR
Manual Reset
float
0X01A4
TD
Rate Time
float
0X01A8
SP
Set Point
float
0X01AC
CZ
Control Zone
int
0X01B0
RSW
Direct/Reverse Action
float
0X01B2
SPAN
Span
float
0X01B6
OH
High Limit
float
0X01BA
OL
Low Limit
int
0X01BE
TATP
Sampling on entire time or volume
float
0X01C0
K
Flowmeter span
float
0X01C4
TATT
float
0X01C8
TCYC
float
0X01CC
LH
float
0X01D0
LL
int
0X01D4
CT
float
0X01D6
CG
float
0X01DA
DZ
int
0X01DE
CONTACT
int
0X01E0
PA
Table 16 - PID2 Data Memory Map
64
OUTPUTS
int
0X01E2
WashSeq
Actual washing sequence
int
0X01E4
OUT_STATE[8]
CCO state
int
0X01F4
IN_STATE[8]
CCI state
float
0X0204
dev[2]
PID 1,2 DEV
float
0X020C
out[2]
PID 1,2 OUT
float
0X0214
ff[2]
PID 1,2 FF
…int
0X021C
HIAL Ch1-3 [3]
HI Alarm Channel 1-3
…int
0X0222
LOAL Ch1-3 [3]
LO Alarm Channel 1-3
…int
0X0228
PID1 A/M
PID1 Auto/Manual
…int
0X022A
PID2 A/M
PID2 Auto/Manual
Table 17 - Output Data Memory Map
65
11 APPENDICES
11.1 EC Declaration
EC Declaration
AW400 line (T17M*4000) fulfils the compliance to the mandatory tests specified by the applicable harmonised generic
rules to apply the CE Mark.
Specifically is compliant with:
• Low Voltage Directive 2006/95/EC
• Harmonized Regulation EN 61010-1:2001
• Electromagnetic Compatibility 2004/108/EC
• Harmonized Regulation: EN 61326-1:2006; EN 61000-3-2:2006; EN 61000-3-3:2008
11.2 APPENDIX B – WEEE Compliant
Severn Trent Water Purification S:p.A., as manufacturer of the electronic instrument described in
the present manual (Micro2Chem line) is registered at the WEEE register (Waste Electric and
Electronic Equipment).
Member registration WEEE number: IT11040000007171
66
12 SPARE PARTS
AW400 Transmitter Spare Parts
Power Supply Board
AW401054
Display Board
AW401115
CPU Board
AW401055
Analogue I/O Board
AW401015
Digital I/O & Serial Board
AW401119
Ribbon Cable CPU to PSU
AW401116
Ribbon Cable Digital I/O to CPU
AW401117
Interconnect Cable PSU to Digital I/O
AW401118
PG11 Cable Gland
AW401121
PG11 Blanking Disc
AW401122
67
Notes
68
Sales Service
IM/AW4TX Rev. H 11.2018
—
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without prior notice. With regard to purchase orders, the agreed particulars shall prevail.
ABB does not accept any responsibility whatsoever for potential errors or possible lack of
information in this document.
We reserve all rights in this document and in the subject matter and illustrations contained
therein. Any reproduction, disclosure to third parties or utilization of its contents – in
whole or in parts – is forbidden without prior written consent of ABB.
© ABB 2018
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