Honeywell warrants goods of its manufacture as being free of defective materials and faulty
workmanship. Contact your local sales office for warranty information. If warranted goods are returned to
Honeywell during the period of coverage, Honeywell will repair or replace without charge those items it
finds defective. The foregoing is Buyer's sole remedy and is in lieu of all other warranties, expressed or implied, including those of merchantability and fitness for a particular purpose. Specifications may
change without notice. The information we supply is believed to be accurate and reliable as of this
printing. However, we assume no responsibility for its use.
While we provide application assistance personally, through our literature and the Honeywell web site, it
is up to the customer to determine the suitability of the product in the application.
CE Conformity
This product is in conformance with the protection requirements of the following European Council
Directives: 89/336/EEC, the Electromagnetic Compatibility Directive and 73/23/EEC, the Low Voltage
Directive. Conformance of this product with any other “CE Mark” Directive(s) shall not be assumed.
ATTENTION
The emission limits of EN 61326 are designed to provide reasonable protection against harmful
interference when this equipment is operated in an industrial environment. Operation of this equipment in
a residential area may cause harmful interference. This equipment generates, uses and can radiate radio
frequency energy and may cause interference to radio and television reception when the equipment is
used closer than 30 m to the antenna(e). In special cases, when highly susceptible apparatus is used in
close proximity, the user may have to employ additional mitigating measures to further reduce the
electromagnetic emissions of this equipment.
Industrial Measurement and Control
Honeywell
1100 Virginia Ave.
Fort Washington, PA 19034
DirectLine is a registered trademark of Honeywell
Durafet and Meredian are U.S. registered trademarks of Honeywell
Other brands or product names are trademarks of their respective owners
Insert 70-82-10-01 should accompany this document.
ii DirectLine® DL421 Sensor Module User Manual 2/04
About This Document
Abstract
This manual contains all the information that is needed to install, configure, calibrate,
operate, and troubleshoot the DirectLine® Sensor. Insert 70-82-10-01, a quick
reference guide for configuring and calibrating the DL421, should accompany this
document.
Contacts
World Wide Web
The following lists Honeywell’s World Wide Web sites that will be of interest to our
customers.
Honeywell Organization WWW Address (URL)
Corporate
Industrial Measurement and Control
International
http://www.honeywell.com
http://www.honeywell.com/imc
http://www.honeywell.com/Business/global.asp
Telephone
Contact us by telephone at the numbers listed below.
United States and
Canada
Honeywell 1-800-423-9883
Organization Phone Number
(215) 641-3610 Tech. Support
1-888-423-9883 Q&A Faxback (TACFACS)
1-800-525-7439 Service
Symbol Definitions
The following table lists any symbols used in this document to denote certain conditions.
Symbol Definition
Earth Ground. Functional earth connection. NOTE: This connection shall be bonded to
Protective earth at the source of supply in accordance with national and local electrical
code requirements.
5.3 Unit Reset ..................................................................................................................................... 26
7. APPENDIX: CE MARK APPLICATIONS ............................................................................30
8. SALES AND SERVICE........................................................................................................ 32
iv DirectLine® DL421 Sensor Module User Manual 2/04
Tables
Table 2-1 Assembly and Wiring Procedure for Field Wiring Connector___________________________ 6
Table 2-2 Integral Mounting Procedure (refer to Figure 2-3) __________________________________ 7
Table 2-3 Remote Mounting Procedure for Durafet II and Durafet III Electrodes __________________ 8
Table 2-4 Remote Mounting Procedure for Meredian II Electrodes_____________________________ 9
Table 2-5 Remote Mounting Procedure for HPW7000 Electrodes ____________________________ 10
Table 3-1 Buffer Groups and the pH standard values ______________________________________ 14
Table 3-2 Configuration Set Up Procedure ______________________________________________ 15
Table 4-1 Standard pH Buffer Values __________________________________________________ 20
Table 4-2 Zero (Standardization) Calibration Procedure ____________________________________ 21
Table 4-3 Slope Calibration Procedure _________________________________________________ 22
Table 4-4 High purity water calibration Procedure_________________________________________ 22
Table 5-1 Online Parameter Descriptions _______________________________________________ 23
Table 5-2 Display Navigation Procedure ________________________________________________ 24
Table 5-3 Online Diagnostic Errors ____________________________________________________ 25
Table 5-4 Factory Default Values _____________________________________________________ 26
2/04 DirectLine® DL421 Sensor Module User Manual v
Figures
Figure 1-1 DirectLine® Sensor ________________________________________________________ 1
Figure 1-2 Electronics Module _________________________________________________________ 2
Figure 2-1 Cordset Connection and Wiring ________________________________________________ 5
Figure 2-2 Field Wiring Connector______________________________________________________ 6
Figure 2-3 Integral Mounting __________________________________________________________ 7
Figure 2-4 Remote Mounting _________________________________________________________ 11
Figure 2-5 Remote Mounting Hardware_________________________________________________ 12
Figure 7-1 Wiring for CE Mark Applications______________________________________________ 30
vi DirectLine® DL421 Sensor Module User Manual 2/04
Introduction
1. Introduction
1.1 Overview
The DirectLine® Sensor consists of an electronics module connected to a
Durafet® II, Durafet® III, Meredian® II or HPW7000 pH electrode that eliminates
the need for pre-amps, transmitters, and analyzers in pH applications.
The modular electronics design can be separated from the sensor, allowing the
sensor to be easily removed or replaced while retaining power to the electronics
module.
The DL421 electronics module is contained in a Nema Type 4x polysulfone
housing. The Module can be mounted as an integral unit directly connected to the
electrode or remotely using an electrode with a cable. The sealed plastic housing
has plug-in connections for the pH electrode and 4-20 mA cordset.
Figure 1-1 DirectLine® Sensor
1.2 Electronics Module
The electronics module is loop-powered by 16-42 Vdc and will modulate its supply
current from 4 mA to 20 mA, depending upon the pH value that is sensed by the
electrode. The transmitted loop current is compensated for temperature internally
using the standard Honeywell 8550 thermistor.
For submersion or special wiring applications, the remote electronics module is
compatible with the existing Durafet II, Meredian II or HPW7000 technology without
modification. A Durafet II or Meredian II cable length is supported with direct
connection to the electronics module.
A 4-20 mA output connection is provided via a 6m cordset or a customer supplied
cable used in combination with a field wiring connector.
2/04 DirectLine® DL421 Sensor Module User Manual 1
Introduction
Figure 1-2 Electronics Module
1.3 Operator Interface
The DirectLine® Sensor operator interface consists of three pushbuttons and one 4digit, 7-segment LCD display with 3 decimal points, plus (+), and minus (–) signs. It
is responsible for the display of measured values and configuration of parameter
values.
2 DirectLine® DL421 Sensor Module User Manual 2/04
Introduction
1.4 Specifications
Displayed pH 0-14 pH
Displayed Temperature Range –10 °C to +110 °C (14 °F to 230 °F)
Process Temperature –10 °C to +110 °C (14 °F to 230 °F)
Sensor Survivable Temperature Range
Durafet II & III
Meredian II
Electronics Module Ambient Temperature –20 °C to +85 °C (–4 °F to +185 °F)
Output Type 4-20 mA (2-wire loop powered)
Output Scale 0-14 pH
Output Calibration 4-20 mA
Mating Connector Rating Submersible to 6.1m (20’)
Output (Loop)
User Termination Tinned leads
Cable Lengths
Sensor:
Power
Local Display and Buttons LCD 4-digit, 7-segment
Engineering Units
Calibration Options
Solution Temperature Compensation
Diagnostics Sensor and electronics
Case
Approvals
Remote Mounting Pipe, Wall, or DIN Rail
Dimensions H 123 mm (4.84”) x W 48 mm (1.89”) x D 46 mm (1.81”)
Weight Approximately 142 g (5.0 oz.)
–10 °C to +130 °C (14 °F to 266 °F)
0 °C to 110 °C (32 °F to 230 °F)
6m (19.7’) cordset or Shielded twisted pair with field
wiring connector
Durafet II & Durafet III: 6.1m (20’) or 15.24m (50’)
Meredian II: 3.65m (12’) or 6.1m (20’)
HPW7000: .45m (1.5’) or 10.97m (36’)
16-42 Vdc, 23mA max
Maximum load resistance: 250 ohms at 16 Vdc
600 ohms at 24 Vdc
1400 ohms at 42 Vdc
pH
degrees F
degrees C
1 point Sample or 2 point Sample
Auto Buffer Recognition
Selections: US, NIST, EURO
CE Mark for Industrial Applications
UL – General Purpose for Process Control
CSA – General Purpose
FM – CLI, DIV1, Groups A, B, C & D and CLI, Zone 0
AEx ia IIC (IS)
FM – CLI, DIV2, Groups A, B, C & D and CLI, Zone 2,
Groups IIC (N.I. Field Wiring)
2/04 DirectLine® DL421 Sensor Module User Manual 3
Introduction
_-_
y
1.5 Model Selection Guide
Instructions
Select the desired key number. The arrow to the right marks the selection available.
Make the desired selections from Tables I through IV using the column below the
proper arrow.A dot ( ) denotes availability.
pH For use with Durafet II, Meredian II & HPW7000 pH electrodesDL421
ORPFor use with ORP electrode DL422
ConductivityFor use with Contacting Conductivity CellsDL423
DO - PPMFor use with Dissolved Oxygen ppm ProbesDL424
DO - PPB
TABLE I - OUTPUT CABLE
Output Cable for
Integral or Remote
Mounting
For use with Dissolved Oxygen ppb Probes
None
(replacement module or customer supplied output cable)Cordset - 6m (19.7 ft.) - includes connector and cable Field Wiring Connector only - customer supplies cable only -
Note 1
Note 2
Note 2
DL425
D
E
F
TABLE II - SENSOR CABLE/REMOTE CONNECTOR (between electronic module and electrode, sensor or probe)
Integral Mounting
Remote Mounting
Cable Durafet Onl
Remote Mounting
Connector (Cable
is supplied with
sensor or probe)
No cable or connector required
6,096m (20 ft.) of sensor cable - Durafet II Remote Mtg w/PWB connector1
6,096m (20 ft.) of sensor cable-Durafet III Remote Mtg w/Vario Pin connector-
15,24m (50 ft.) of sensor cable - Durafet II Remote Mtg w/PWB connector
15,24m (50 ft.) of sensor cable - Durafet III Remote Mtg w/Vario Pin connector-Note 3
Remote Mounting Connector - Meredian II pH
Remote Mounting Connector - Meredian II ORP
Remote Mounting Connector - HPW7000
Remote Mounting Connector - Conductivity
Remote Mounting Connector - Dissolved Oxygen
Note 3
0ddddd
e
7e
2
e
8
e
e
3
3
4
5
6
e
e
e
ee
TABLE III - REMOTE MOUNTING OPTIONS
Mounting Kit forNone Integral unit - mounting not requiredA
Remote Mounting2" (5,08 cm) Pipe mtg. bracket, wall mtg, & DIN Rail clipB
TABLE IV - OPTIONS
Tagging
Certificates
None
SS Customer ID Tag - 3 lines w/22 characters/line
None
Calibration & Conformance
Notes:
1
Customers may procure their own output cordsets from the vendors listed below.
2
Customers may make their own 4-20 mA output cordset using a 2-wire twisted shielded pair,
and M12 field wiring connector procured from one of the vendors listed below.
Use only UV rated outdoor cable to maintain NEMA 4 rating.
Durafet III cables with Vario Pin connector require Durafet III electrode with Vario Pin connector
RESTRICTIONS
Restriction
Letters
d
e
ORDERING INSTRUCTIONS:
1. Part numbers are provided to facilitate Distributor Stock.
2. Orders may be placed either by model selection or by part number.
3. Part numbers are shown within the model selection tables to assist with compatibility information.
4. Orders placed by model selection are systematically protected against incompatibility.
5. Compatibility assessment is the responsibility of the purchaser for orders placed by part number.
6. Items labeled as N/A are not available via the stocking program and must be ordered by model selection.
4 DirectLine® DL421 Sensor Module User Manual 2/04
Available Only WithNot Available With
Table
IIlA
IIIB
Table
SelectionSelection
2. Installation
2.1 Assembly and Wiring
Depending on the customer selected output cable options, the DirectLine can be
wired to an appropriate 16-42 Vdc source using 2 different methods:
1) cordset
2) field wiring with customer supplied cable.
Refer to Section 7 for wiring for CE Mark applications.
2.1.1 Cordset
Power Supply
Minimum: 16 V @ 250 ohms (max.)
Maximum: 42 V @ 1400 ohms (max.)
__
_
++
Installation
Chart Recorder,
Controller, etc.
(Use 250 ohms
for 1-5 V signal)
Load
Resistance
+
Black (–)
*Blue wire not used
Shield
Wire
(Ground)
*
Brown (+)
Cordset 6m (19.7’)
Electronics
Module
Figure 2-1 Cordset Connection and Wiring
2/04 DirectLine® DL421 Sensor Module User Manual 5
Installation
2.1.2 Field Wiring
Refer to Figure 2-2. The field wiring connector supports customer supplied cable with an
outer diameter of 4-6mm.
Table 2-1 Assembly and Wiring Procedure for Field Wiring Connector
Step Procedure
1 Disassemble field wiring connector
a) Unscrew parts to separate pressure screw, clamp type cage, gasket,
housing and female insert.
2 Insert customer supplied cable through connector parts
a) Slide pressure screw over skin and tinned customer cable (note
orientation).
b) Slide clamp type cage over cable (note orientation).
c) Slide gasket over cable.
d) Slide housing over cable (note orientation).
3 Connect wires to pins
Look closely at end of female insert to locate pin numbers. Connect
positive wire to pin 1 and negative wire to pin 4. Remaining wires and
female insert pins 3 and 2 are unused.
4 Assemble field wiring connector
a) Screw female insert to housing until female insert’s o-ring is
compressed.
b) Slide clamp type cage/gasket into housing.
c) Thread pressure screw into housing until ¼ turn past finger tight.
5 Connect cable to source
Wire the other end of the Output cable to a 16-42 Vdc source as indicated
in Figure 2-1. Note: your wire colors may be different.
To Power Supply
Output cable
(Customer supplied)
Pos +
Neg -
Pressure screw
Clamp-type cage
Gasket
Housing
Female insert with 4
numbered pins
6 DirectLine® DL421 Sensor Module User Manual 2/04
Figure 2-2 Field Wiring Connector
2.2 Integral Mounting
Table 2-2 Integral Mounting Procedure (refer to Figure 2-3)
Step Procedure
Connect Electrode to Pipe and Electronics Assembly
1 Screw the electrode into the pipe tee (3/4 “ NPT thread).
Make sure that the final position of the installed electronics module allows the display to
be easily viewed by plant personnel.
2 Align the slots in the electronics module with those in the electrode and press down to
connect the electronics to the electrode.
Installation
3
Tighten the locking screw on the bottom rear of the electronics module.
Electronics
Module
Locking Screw in
Rear of Housing
Step 2
Step 3
2/04 DirectLine® DL421 Sensor Module User Manual 7
Electrode
Step 1
Figure 2-3 Integral Mounting
Installation
2.3 Remote Mounting
Table 2-3 Remote Mounting Procedure for Durafet II and Durafet III Electrodes
Step Procedure (Refer to Figure 2-4 and Figure 2-5)
1 Apply a thin film of silicon grease to the ID of electronics module’s remote mounting
cavity.
2 Connect Remote Sensor Wiring Cable to the Remote Electronics Housing
a) Remove the cover from the remote cable connector.
b) Align the slots in the cable connector housing with those in the electronics module
and push up to connect the cable to the electronics module.
c) Tighten the locking screw on the rear of the electronics module. Make sure the
connector is completely seated.
3 Secure Electronics Module with Wall, Pipe, or DIN Rail Mounting
Mount bracket with clips facing forward, smaller clip on top and larger clip on bottom.
Wall: Use one of three through-holes to secure to wall.
Pipe: Feed hose clamp through two slots and secure to pipe.
DIN rail: Attach the appropriate DIN rail clip to the mounting bracket:
“U” DIN rail—use metal clip and shorter screw (8 mm)
“G” DIN rail—use gray clip and longer screw (10 mm)
Clip can be rotated for horizontal or vertical DIN rails.
Push electronics module onto the remote mounting bracket until it snaps into position.
4 Connect Remote Sensor Wiring Cable to the Remotely Mounted Electrode
Durafet II with PC Board type connector:
a) Remove cover from the remote cable connector.
b) Loosen the ferrule and slide back the ferrule, small O-ring, and plastic cover to
expose the remote cable connector. Align the cable connector keyway with the
electrode key (small black tab on the top of the electrode). Slide the plastic cover
over the electrode end and hand-tighten the cover onto the electrode. Be careful not
to cross the threads of the connector.
Slide the O-ring and ferrule down the cable to the back of the cover cap. Handtighten the ferrule onto the cover cap.
-OR-
Durafet III with Vario Pin, 11 conductor connector:
Electrostatic Discharge (ESD) hazards. Observe precautions for handling
electrostatic sensitive devices.
a) Remove cover from the cable connector.
b) Make sure electrode connector and cable connector are clean and dry.
c) Align keyway of Vario Pin connector on electrode with tab inside mating connector
on cable. Press cable connector onto electrode firmly.
d) Tighten knurled busing of cable connector by hand to ensure waterproof seal.
8 DirectLine® DL421 Sensor Module User Manual 2/04
Installation
When the DL421 is specified with Table II = 3, the Remote Connector Assembly (part number
51500768-001) is supplied loose for connection of the Meredian II pH electrode cable to the
DL421 module. Table 2-4 gives the mounting procedure.
Table 2-4 Remote Mounting Procedure for Meredian II Electrodes
Step Procedure (Refer to Figure 2-4 and Figure 2-5)
1 Turning counterclockwise, remove strain relief/cover combination from the remote
connector assembly.
2 Remove the protective plastic bag from the end of the electrode cable. Be careful to
keep bare fingers away from coax cable termination.
3 Loosen and remove compression cap from strain relief fitting. Carefully push cable end
through cap and strain relief fitting so that these parts are strung back along cable
jacket.
4
5
6 Slide cap along cable and tighten onto cable jacket with small wrench until cable cannot
7
8 Apply a thin film of silicon grease to the ID of electronics module’s remote mounting
9 Plug remote connector assembly into DL421 module aligning polarity tab of module
10 Secure Electronics Module with Wall, Pipe, or DIN Rail Mounting
Connect cable leads as follows:
Terminal 1 = Orange Reference Electrode Lead
Terminal 2 = White Temperature Compensation Lead
Terminal 3 = White Temperature Compensation Lead
Terminal 4 = Pigtail Shield Lead
Terminal 5 = NC (No Connection)
Terminal 6 = Coax Measuring Electrode Lead
Earth Ground = Yellow
Slide cover along cable and tighten by hand onto the remote connector assembly.
slide within strain relief rubber bushing.
Remove yellow protective sleeve from opposite end of connector assembly.
cavity.
housing and mating groove on connector.
Mount bracket with clips facing forward, smaller clip on top and larger clip on bottom.
Wall: Use one of three through-holes to secure to wall.
Pipe: Feed hose clamp through two slots and secure to pipe.
DIN rail: Attach the appropriate DIN rail clip to the mounting bracket:
Clip can be rotated for horizontal or vertical DIN rails.
Push electronics module onto the remote mounting bracket until it snaps into position.
2/04 DirectLine® DL421 Sensor Module User Manual 9
“U” DIN rail—use metal clip and shorter screw (8 mm)
“G” DIN rail—use gray clip and longer screw (10 mm)
Installation
When the DL421 is specified with Table II = 4, the Remote Connector Assembly (part number
51500768-002) is supplied loose for connection of the HPW7000 electrode cables to the DL421
module. Table 2-5 gives the mounting procedure.
Table 2-5 Remote Mounting Procedure for HPW7000 Electrodes
Step Procedure (Refer to Figure 2-4 and Figure 2-5)
1 Turning counterclockwise, remove strain relief/cover combination from the remote
connector assembly.
2 Remove the protective plastic bag from the end of the measuring electrode cable. Be
careful to keep bare fingers away from coax cable termination.
3 Loosen and remove compression cap from strain relief fitting. Carefully push all 3 cable
ends through cap and strain relief fitting so that these parts are strung back along cable
jacket.
4
5
6 Slide cap along cables and tighten onto cable jackets with small wrench until cables
7
8 Apply a thin film of silicon grease to the ID of electronics module’s remote mounting
9 Plug remote connector assembly into DL421 module aligning polarity tab of module
10 Secure Electronics Module with Wall, Pipe, or DIN Rail Mounting
Connect cable leads as follows:
Terminal 1 = Clear Reference Electrode Coax Lead
Terminal 2 = Black Temperature Compensation Lead
Terminal 3 = White Temperature Compensation Lead
Terminal 4 = Black/White Measuring Electrode Coax Shield
Terminal 5 = Clear Measuring Electrode Coax Lead
Terminal 6 = No Connection
Earth Ground = (3) Green/White Leads from Measuring, Reference and
Temperature
Slide cover along cables and tighten by hand onto the remote connector assembly.
cannot slide within strain relief rubber bushing.
Remove yellow protective sleeve from opposite end of connector assembly.
cavity.
housing and mating groove on connector.
Mount bracket with clips facing forward, smaller clip on top and larger clip on bottom.
Wall: Use one of three through-holes to secure to wall.
Pipe: Feed hose clamp through two slots and secure to pipe.
DIN rail: Attach the appropriate DIN rail clip to the mounting bracket:
Clip can be rotated for horizontal or vertical DIN rails.
Push electronics module onto the remote mounting bracket until it snaps into position.
10 DirectLine® DL421 Sensor Module User Manual 2/04
“U” DIN rail—use metal clip and shorter screw (8 mm)
“G” DIN rail—use gray clip and longer screw (10 mm)
Electronics
Module
Cable
Connector
Housing
Cable
Connector
Cover
Remote Electronics
Module for
Durafet II or III Electrodes
Locking Screw in
Rear of Housing
Remote Wiring Cable
20 or 50 Feet
Electrode
Electronics
Module
Protective
Vinyl Boot
(remove)
Cover
Strain
Relief
Compression
Cap
Remote Wiring Cable
12 or 20 Feet for
Meredian II Electrodes,
1.5 or 36 Feet for
HPW7000
Electrode
Meredian II Electronics
1
Orange Reference Electrode Lead
2
White Temperature Compensation Lead
3
White Temperature Comp ensation Lead
4
Pigtail Shield Lead
5
1 Meg-ohm resistor (pre-installed by
Honeywell)
6
Coax Measuring Electrode Lead and
1 Meg-ohm resistor (pre-installed by
Honeywell)
6
5
4
1
2
3
6
5
4
1
2
3
HPW7000 Electronics
1
Clear Referen ce Coax Lead
2
Black Temperature Sensor Lead
3
White Temperature Sensor Lead
4
Black/White Measuring Shield
5
Clear Measuring Coax Lead
6
No Connection
Note: Three Green/White leads to DL421
mounting bracket screw. Mounting bracket
must be connected to earth ground.
Installation
2/04 DirectLine® DL421 Sensor Module User Manual 11
Remote Electronics
Module for
Meredian II Electrodes
and HPW7000
Figure 2-4 Remote Mounting
Installation
Hose Clamp Slot
for Pipe Mounting
(Hose Clamp
included in kit)
Through Hole for
DIN Rail Mounting
Metal clip for
“U” DIN rail mounting
Gray clip for
“G” DIN rail mounting
Mounting Kit
View from End
Panel
Terminal Connectors
Front View
“U” Style DIN Rail
Barriers, Repeater, Isolators
View from End
PanelPanel
Front View
“G” Style DIN Rail
Figure 2-5 Remote Mounting Hardware
12 DirectLine® DL421 Sensor Module User Manual 2/04
Installation
2.4 Conduit connections
The DirectLine provides a male ½” NPT thread to accommodate a customer conduit
connection. Use ½” conduit coupling (min. 38.1mm (1.5”) long) on DL conduit
connection to clear cordset connector. Conduit can not be used with field wiring
connector due to size restriction.
Do not exceed 200in-lb. torque when attaching fixed piping.
Use wrench flats provided under the ½” NPT threads to support the DirectLine
during installation.
2/04 DirectLine® DL421 Sensor Module User Manual 13
Configuration
3. Configuration
3.1 Overview
Configuration Parameters
Set Up consists of configuring the following functions:
• Buffer Group Selection – Only used with Auto Buffer Recognition calibrations.
Determines the set of standard pH buffer values to be used for Zero
(standardization) and Slope calibration by automatic buffer recognition. Each of
the available Buffer Groups is a set of 5 pH buffer standards that you can
select.
The available groups are: US (default), NIST, and EURO.
Table 3-1 Buffer Groups and the pH standard values
Buffer Group pH Buffers Display
US (default)
NIST
EURO
2 4 7 10 12
1.68 4.01 6.86 9.18 12.45
1 3 6 8 10
• Solution Temperature Coefficient – Typically only used in power plants for
condensate/feedwater applications. Measured pH is displayed and transmitted
to a pH value normalized to what the pH value would be if the temperature of
the process was 25 °C. Magnitude of normalization is dependent upon the
Solution Temperature coefficient, expressed in units of pH/10 °C with precision
to the hundredth decimal place.
The three available values are: 0.00 (standard setting, default), −0.16 pH/10 °C
(pure water), and −0.32 pH/10 °C (condensate/feedwater).
• Noise Suppression Frequency Selection – Selection of 50 Hz or 60 Hz.
Defaults to 60 Hz at unit reset.
• Output Configuration – The following Output Configuration functions can be
selected:
0% Range 0 % Range values can be adjusted within a range
0.00 to 14.00 pH in 0.50 pH increments.
100% Range 100 % Range values can be adjusted within a range
0.00 to 14.00 pH in 0.50 pH increments.
0% Calibration Output current can be typically adjusted to within a
range of 3.80 mA to 4.40 mA.
100% Calibration Output current can be typically adjusted to within a
range of 19.60 mA to 20.40 mA.
US
nISt
Euro
14 DirectLine® DL421 Sensor Module User Manual 2/04
Configuration
3.2 Configuration Set Up Procedure
ATTENTION:
In Table 3-2, under the Press column:
• Hold means to hold the button down until the display changes.
• Momentarily means to press and release the indicated button.
From the Online pH display, follow this procedure.
ATTENTION:
If no key is pressed for 60 seconds, the display will abort the entry mode and default to Online Display.
Table 3-2 Configuration Set Up Procedure
Step Operation Press Display
Enter Buffer Group
1
Selection
Edit Buffer Group
Select desired Buffer
Group
Save the Buffer Group
Enter Solution
2
Temperature
Coefficient Selection
Edit Solution
Temperature Coefficient
Select desired
Coefficient
Save the Solution
Temperature coefficient
MODE
Hold
MODE
Hold
Momentarily
MODE
Momentarily
MODE
Momentarily
MODE
Hold
Momentarily
MODE
Momentarily
bFrG (for 1 second) then,
(Current Buffer Group Selection)
Flashing Display – You are now in EDIT mode
(Value of current Buffer Group selection)
To select US (default), NIST, or Euro
Selection for group
COEF (for 1 second) then,
(Solution Temperature Coefficient Selection)
Flashing Display – You are now in EDIT mode
(Value of current Coefficient selection)
To select: 0.00 pH/10°C (default) or
−0.16 pH/10°C (pure water)
−0.32 pH/10°C (AVT, Amine, Phosphate or Oxygenated Treatment
Selection for coefficient
2/04 DirectLine® DL421 Sensor Module User Manual 15
Configuration
Step Operation Press Display
Enter Noise
3
Suppression
Frequency
Edit Noise Suppression
Frequency
Select desired
Frequency
Save the Noise
Suppression Frequency
Enter Output
4
Configuration
0% Range Value
Selection
Edit 0 % Range Value
Selection
Select desired 0 % pH
Value
Save the New 0 %
Range Value
MODE
Momentarily
MODE
Hold
Momentarily
MODE
Momentarily
MODE
Momentarily
Momentarily
MODE
Hold
Momentarily
MODE
Momentarily
nSUP (for 1 second) then,
(Noise Suppression Frequency Selection)
Flashing Display – You are now in EDIT mode
(Value of current Frequency selection)
To select 50 Hz or 60 Hz (default)
Selection for frequency
OutC Enter Output Calibration
rnGL (for 1 second) then,
(value of current 0 % Range Value Selection)
Flashing Display – You are now in EDIT mode
Value of current 0 % selection)
Selected 0 % pH Value in 0.50 pH increments
Range: 0.00 to 14.00 pH (default 0.00)
(New Value)
100 % Range Value
5
Selection
Edit 100 % Range Value
Selection
Select 100 % pH Value
Save the New 100 %
Range Value
0 % Calibration
6
Adjust 0 % Calibration
Save 0 % Calibration
Momentarily
MODE
Hold
Momentarily
MODE
Momentarily
Momentarily
MODE
Hold
Momentarily
MODE
Momentarily
rnGH (for 1 second) then,
(value of current 100% Range Value Selection)
Flashing Display– You are now in EDIT mode
(value of current 100 % selection)
Selected 100 % pH Value in 0.50 pH increments
Range: 0.00 to 14.00 pH (default 14.00)
(New Value)
AdJL
AdJL (flashes) – You are now in EDIT mode
Range: 3.80 to 4.40 mA typically (default 4.00 mA)
+AdJL (increments value)
−AdJL (decrements value)
AdJL
16 DirectLine® DL421 Sensor Module User Manual 2/04
Configuration
Step Operation Press Display
100 % Calibration
7
Adjust 100 %
Calibration
Save 100 % Calibration
Return to Online Display
8
Momentarily
MODE
Hold
Momentarily
MODE
Momentarily
MODE
Momentarily
AdJH
AdJH (flashes) – You are now in EDIT mode
Range: 19.60 to 20.40 mA typically
(default 20.00 mA)
+AdJH (increments value)
−AdJH (decrements value)
AdJH
Returns to Online Display
2/04 DirectLine® DL421 Sensor Module User Manual 17
Calibration
4. Calibration
4.1 Calibration Diagnostics
Introduction
The manual and automatic standardization and slope adjustments change the zero
offset and the percent theoretical slope calibration diagnostics used by this system.
These values are viewed as read-only information. It is good practice to observe
these values after calibration. Monitoring the values over time will help you predict
when the electrode will need to be replaced.
Zero Offset pH Value
When Online pH value is displayed, PRESS 1button momentarily to display the
current Zero Offset value in fixed hundredths decimal position.
Zero Offset is non-volatile and is initialized to 0.00 pH at unit reset.
It has a range of –2.00 pH to +2.00 pH and it is updated after each calibration.
Percent Theoretical Slope Value
When Online pH value is displayed, PRESS 2 button momentarily to display the
current Percent Theoretical Slope value in fixed tenths decimal position.
Percent Theoretical Slope is non-volatile and is initialized to 100.0 % at unit reset.
It has a range of 80.0 % to 105.0 % and it is updated after each calibration.
60 Second Timeout
If no key is pressed for 60 seconds, the display will abort the entry mode and default
to Online Display.
4.2 Calibration Diagnostic Reset
Introduction
When a new electrode is installed, the indicated pH will use the zero offset and
percent theoretical slope values from the previous calibration. Depending on the
condition of the replaced electrode, the difference between the known and indicated
pH of the new electrode may vary as much as several pH units. A calibration on the
new electrode will correct this difference.
ATTENTION:
If Auto Buffer Recognition (ABR) calibration is used when the new electrode is calibrated for the first time,
the ABR calibration may select a buffer value from the selected standard buffer group table (Table 4-1)
that is directly above or below the actual buffer value.
To avoid this discrepancy, follow one of the two procedures listed below:
1. Select the correct buffer value by following Step 2B of Table 4-3.
2. Perform a calibration diagnostic reset as described below prior to performing an ABR calibration on
the new electrode.
18 DirectLine® DL421 Sensor Module User Manual 2/04
Calibration
Zero Offset pH Value and Percent Theoretical Slope Value
a) Momentarily press 1 to view the Zero Offset value. From this display press and
hold the 1 button until the Zero Offset pH value resets to factory default “0.00”.
The Percent Theoretical Slope value resets to factory default “100.0” at the same
time (approximately 10 seconds).
b) Press MODE button, or wait 60 seconds, to return to Online pH.
4.3 Calibration
Overview
ATTENTION:
If a Solution Temperature Compensation Coefficient was selected per Configuration Section 3.2, this
coefficient is disabled while calibration is being performed.
Calibration consists of the following functions:
• Calibrating the Zero (Standardization) – Manual or automatic pH calibration. In
auto calibration, you can select one of the other buffer pH values directly above
or below the recognized buffer value in the current buffer group. (See Table
4-1.)
• Calibrating the Slope - Manual or automatic pH calibration. In auto calibration,
you can select one of the other buffer pH values directly above or below the
recognized buffer value in the current buffer group. (See Table 4-1.)
2/04 DirectLine® DL421 Sensor Module User Manual 19
20 DirectLine® DL421 Sensor Module User Manual 2/04
Calibration
Calibration Procedures
ATTENTION:
CAL2 must be done within 10 minutes of CAL1, otherwise CAL1 must be repeated to enable CAL2.
ATTENTION:
In Table 4-2 and Table 4-3, under the Press column:
• Hold means to hold the button down until the display changes.
• Momentarily means to press and release the indicated button.
Table 4-2 Zero (Standardization) Calibration Procedure
Step Operation Press Display
OR
Enter Zero
1
(Standardization)
Calibration
Do Sample (Manual)
2A
Calibration
Edit Buffer Value
Save New Buffer
Value
Do Auto Buffer
2B
Recognition
Calibration
Edit Group Buffer
Value
1
Hold
1
Momentarily
Momentarily
Momentarily
Momentarily
or
MODE
1
Hold
or
CAL1
For Sample (Manual) calibration, go to step 2A.
OR
For Auto Buffer Recognition calibration, go to
step 2B.
SCAL for one second,
then displays Live Buffer Value.
To edit Buffer Value (Flashing Display)
Buffer Value is saved and goes to Online Display.
ACAL for one second,
then displays closest Group Buffer Value.
(Flashing Display until stable reading is achieved
“New Value” – Selects ± 1 buffer group
(Flashing Display until stable reading is achieved)
then goes to Online Display.
2/04 DirectLine® DL421 Sensor Module User Manual 21
Calibration
Table 4-3 Slope Calibration Procedure
Step Operation Press Display
2A
OR
2B
Enter Slope Calibration
1
Do Sample (Manual)
Calibration
Edit Buffer Value
Save New Buffer
Value
Do Auto Buffer
Recognition
Calibration
Edit Group Buffer
Value
2
Hold
2
Momentarily
Momentarily
Momentarily
Momentarily
or
MODE
Hold
2
or
CAL2
For Sample (Manual) calibration, go to step 2A.
OR
For Auto Buffer Recognition calibration, go to
step 2B.
SCAL for one second then,
displays Live Buffer Value
To edit Buffer Value (Flashing Display)
Buffer Value is saved and goes to Online Display.
ACAL for one second then,
displays closest Group Buffer Value
(Flashing Display until stable reading is achieved
“New Value” – Selects ± 1 buffer group
(Flashing Display until stable reading is achieved)
then goes to Online Display
4.4 Calibration in High Purity Water
When the DirectLine module is used with the HPW7000 High pHurity Water
Assembly an addition calibration step may be required. This involves doing an
independent check of the pH with a portable lab meter and then, if necessary, a
Sample Cal to correct the reading.
Table 4-4 High purity water calibration Procedure
Step Procedure
Perform a 2-point calibration using either the Auto Buffer Recognition Calibration or Manual
1
Calibration per section 4.3.
Return the HPW7000 electrodes to the flow chamber and restart flow to the chamber.
2
Allow the flow chamber to “clean out” by flowing sample through the chamber for at least an
3
hour.
Check the pH of the process using a portable instrument that uses a flowing reference type
4
electrode. Make sure the sample is not exposed to air, otherwise the pH due to absorption
of carbon dioxide from the air.
If necessary adjust the HPW7000 pH to agree with the portable instrument reading by doing a 1-
5
point Sample Cal per section 4.3.
22 DirectLine® DL421 Sensor Module User Manual 2/04
Operation
5. Operation
5.1 Displays
Overview
The DirectLine® DL421 displays the pH value, Temperature, Zero Offset pH value, and Percent
Theoretical Slope online. The table below describes these parameters.
Table 5-1 Online Parameter Descriptions
Parameter Description
Online pH
Online Temperature
Zero Offset pH
Value
Percent Theoretical
Slope Value
Measured pH expressed with fixed hundredths decimal precision.
Range: 0.00 to 14.00
Measured temperature expressed with fixed tenths decimal precision.
Temperature displayed in °C or °F
Range: −10.0 to 110.0 °C
−14.0 to 230.0 °F
Zero Offset pH value expressed with fixed hundredths decimal precision.
Range: −2.00 to +2.00 pH
Percent Theoretical Slope value expressed with fixed tenths decimal precision.
Range: 80.0 % to 105.0 %
The default display and home position is the Online pH display. It appears when:
The unit is powered up
No button presses for 60 seconds
A successful Zero (Standardization) or Slope calibration has occurred in Auto Buffer
Recognition
The Mode button has been pressed during Zero (Standardization) or Slope calibration
(Sample Calibration)
The Mode button has been pressed during a configuration edit
The measurement and display of pH is updated at a rate of 500 ms.
2/04 DirectLine® DL421 Sensor Module User Manual 23
Operation
ATTENTION:
In Table 5-2, under the Press column:
• Momentarily means to press and release the indicated button.
Table 5-2 Display Navigation Procedure
Step Operation Press Display
View Online pH valueMODE
1
View Online Temperature MODE
2
Toggle Online
2A
Temperature display units
Return to home position MODE
3
Momentarily
Momentarily
or
Momentarily
Momentarily
(measured pH)
(measured temperature in °C or °F)
Proceed to step 2A or step 3.
(measured temperature in °C or °F)
Proceed to step 3.
(measured pH)
24 DirectLine® DL421 Sensor Module User Manual 2/04
Operation
5.2 Diagnostic Error Messages
When a diagnostic error or status condition occurs, the Online Display alternates
between measured pH and a text message.
Table 5-3 Online Diagnostic Errors
What you see What it is What to do
CNFG
FALT
These errors may occur when online pH or temperature is displayed.
P HI
P LO
PRBE
T HI
T LO
These errors may occur during probe calibration and abort the calibration process.
FAIL
Data error detected. Reset unit or cycle power.
Second occurrence will show
FALT.
Unit electronics are defective. Replace electronics module.
Measured pH is > 14.00 pH Bring process within limits
Measured pH is < 0.00 pH Bring process within limits
Probe is defective, removed from process, or not
connected.
Forces the output to burnout level (greater than
21.8 mA).
Measured temperature is > 110 °C
Measured temperature is < −10 °C
These error messages are preceded by the
message “FAIL”
BFRS The Slope buffer is less than 2 pH from
Zero (Standardization) buffer.
SRNG The Slope calibration failed due to a
calculated Percent Theoretical Slope value
outside the range of 80.0 % to 105.0 %.
STBL The Zero (Standardization) or Slope
calibration failed due to measured pH
instability.
TRNG The Zero (Standardization) or Slope
calibration failed due to solution
temperature outside the range of 0 °C to 50
°C. (Auto Buffer Recognition calibration
only)
ZRNG The Zero (Standardization) calibration
failed due to a calculated Zero Offset value
outside the range of –2.00 pH to 2.00 pH.
Check probe, connection and
presence of sample.
When the source of the error is
removed, the error will clear and
the output will return to normal
operation.
Bring process within limits
Bring process within limits
Press Mode to return to online
display.
2/04 DirectLine® DL421 Sensor Module User Manual 25
Operation
5.3 Unit Reset
Overview
Unit Reset initializes all of the DirectLine® Sensor’s calibration and configuration
data to factory default values.
Procedure
• From the Online pH display, press and hold the 1 and 2 buttons
simultaneously until “rSEt” appears on the display (minimum of 10 seconds).
• “rSEt” will remain on the display until reset is complete. Next, the firmware
version number appears briefly and the unit then returns to the Online pH
display.
Table 5-4 Factory Default Values
Data Default Values
Zero Offset
Slope
Online Temperature
Buffer Group Selection
Solution Temperature Coefficient Selection
Noise Suppression Frequency Selection
Output Configuration – 0 % Range Value
Output Configuration – 100 % Range Value
Output Configuration – 0 % Calibration
Output Configuration – 100 % Calibration
0.00 pH
100.0 %
°C
US
0.00 pH/10 °C
60 Hz
0.00 pH
14.00 pH
4.00 mA typically
20.00 mA typically
26 DirectLine® DL421 Sensor Module User Manual 2/04
51452655-001 Remote Mounting Kit for Wall, Pipe, or DIN Mounting
51500768-001
51500768-002
51452706-001 Locking screw (locks sensor module to electrode or remote connector)
O-ring for Integral Durafet Electrode or Remote Electrode Mounting Cable
or
External O-ring for Integral Meredian Electrode or Remote Electrode Cable
Connector
Remote Electrode Cable Connector Assembly (Meredian II Electrodes)
— Includes O-rings and strain relief
Remote Electrode Cable Connector Assembly (HPW7000 Electrodes)
— Includes O-rings and strain relief
Cordset
The cordset connection is an M12 female type that can be purchased directly from
Honeywell or from multiple vendors including:
Turck Industries
Part Number RKV4T-6/S618 for a 6 m cordset with a stainless coupling nut
Part Number RK4T-6/S618 for a 6 m cordset with a nickel plated coupling nut
Phoenix Contact
Part Number SAC-3P-5.0-PUR/M12FSSH Stainless for a 5m cordset with a stainless coupling nut
Part Number SAC-3P-5.0-PUR/M12FSSH for a 5m cordset with a nickel plated coupling nut
Field Wiring connector
The Field Wiring Connector is an all-plastic screw terminal M12 female type that can
be purchased directly from Honeywell or from multiple vendors including:
Turck Industries
Part Number B8141-0 for a M12 field wiring connector that accommodates customer supplied
cable.
Phoenix Contact
Part Number SACC-M12FS-4CON-PG7 for a M12 field wiring connector that accommodates
customer supplied cable.
2/04 DirectLine® DL421 Sensor Module User Manual 27
Spare Parts
28 DirectLine® DL421 Sensor Module User Manual 2/04
Spare Parts
2/04 DirectLine® DL421 Sensor Module User Manual 29
Appendix: CE Mark Applications
7. Appendix: CE Mark Applications
In situations where the pH display appears to fluctuate (short deviations above 0.2 pH
points) due to field wiring electrical noise, the noise may be reduced by making the
additional ground connections as described in Figure 7-1.
Output cable
Qty. (2)
#8 screws
Step 3
Connect yellow
wire to screw on
mounting bracket.
Figure 7-1 Wiring for CE Mark Applications
Step 1
Connect or mount
bracket to earth
ground.
Step 2
Carefully remove
shrink tubing cover
(Durafet II only)
Remote cable option
30 DirectLine® DL421 Sensor Module User Manual 2/04
Appendix: CE Mark Applications
2/04 DirectLine® DL421 Sensor Module User Manual 31
Appendix
For application assistance, current specifications, pricing, or name of the nearest Authorized Distributor,
contact one of the offices below.
ARGENTINA
HONEYWELL S.A.I.C.
BELGRANO 1156
BUENOS AIRES
ARGENTINA
Tel. : 54 1 383 9290
ASIA PACIFIC
HONEYWELL ASIA
PACIFIC Inc.
Room 3213-3225
Sun Kung Kai Centre
N° 30 Harbour Road
WANCHAI
HONG KONG
Tel. : 852 829 82 98
AUSTRALIA
HONEYWELL LIMITED
5 Thomas Holt Drive
North Ryde Sydney
NSW AUSTRALIA 2113
Tel. : 61 2 353 7000
AUSTRIA
HONEYWELL OY
Ruukintie 8
FIN-02320 ESPOO 32
FINLAND
Tel. : 358 0 3480101
FRANCE
HONEYWELL S.A.
Bâtiment « le Mercury »
Parc Technologique de St
Aubin
Route de l’Orme
(CD 128)
91190 SAINT-AUBIN
FRANCE
Tel. from France:
01 60 19 80 00
From other countries:
33 1 60 19 80 00
HONEYWELL
Otomasyon ve Kontrol
Sistemlen San ve Tic
A.S.
(Honeywell Turkey A.S.)
Emirhan Cad No 144
Barbaros Plaza C. Blok
Kat 18
Dikilitas 80700 Istanbul
TURKEY
Tel : 90-212 258 18 30
UNITED KINGDOM
HONEYWELL
Unit 1,2 &4 Zodiac House
Calleva Park
Aldermaston
Berkshire RG7 8HW
UNITED KINGDOM
Tel : 44 118 906 2600
U.S.A.
HONEYWELL INC.
INDUSTRIAL PROCESS
CONTROLS
1100 VIRGINIA DRIVE
PA 19034-3260
FT. WASHINGTON
U.S.A.
Tel. : 1-800-343-0228