Honeywell DirectLine DL421 User Manual

DirectLine® DL421 Sensor Module

®

for Durafet

Meredian

®

II, and HPW7000 pH

II, Durafet® III,

Electrodes

User Manual

70-82-25-102

Rev. 5

2/04

Industrial Measurement and Control

Notices and Trademarks

Copyright 2004 by Honeywell

February, 2004

Warranty/Remedy

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

[phone] 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.

ATTENTION, Electrostatic Discharge (ESD) hazards. Observe precautions for handling
electrostatic sensitive devices

2/04 DirectLine® DL421 Sensor Module User Manual iii

Contents

1. INTRODUCTION....................................................................................................................1

1.1 Overview.........................................................................................................................................1

1.2 Electronics Module ......................................................................................................................... 1

1.3 Operator Interface........................................................................................................................... 2

1.4 Specifications.................................................................................................................................. 3

1.5 Model Selection Guide ................................................................................................................... 4

2. INSTALLATION ..................................................................................................................... 5

2.1 Assembly and Wiring...................................................................................................................... 5

2.2 Integral Mounting............................................................................................................................ 7

2.3 Remote Mounting ...........................................................................................................................8

2.4 Conduit connections ..................................................................................................................... 13

3. CONFIGURATION ............................................................................................................... 14

3.1 Overview.......................................................................................................................................14

3.2 Configuration Set Up Procedure................................................................................................... 15

4. CALIBRATION.....................................................................................................................18

4.1 Calibration Diagnostics................................................................................................................. 18

4.2 Calibration Diagnostic Reset ........................................................................................................ 18

4.3 Calibration..................................................................................................................................... 19

4.4 Calibration in High Purity Water ...................................................................................................22

5. OPERATION ........................................................................................................................ 23

5.1 Displays ........................................................................................................................................ 23

5.2 Diagnostic Error Messages .......................................................................................................... 25

5.3 Unit Reset ..................................................................................................................................... 26

6. SPARE PARTS....................................................................................................................27

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

Selections: 0.00pH/10°C
–0.16pH/10°C
–0.32pH/10°C

Weatherproof, corrosion-resistant plastic housing, NEMA4X

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.

Key Number I II III IV

_ _ _ _ _ -_-

-_ _ _ _

Key Number - DirectLine®Sensor Electronics Module

(Specify electrodes/cells/probes separately) Selection

Availability

pH For use with Durafet II, Meredian II & HPW7000 pH electrodes DL421
ORP For use with ORP electrode DL422
Conductivity For use with Contacting Conductivity Cells DL423
DO - PPM For use with Dissolved Oxygen ppm Probes DL424

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 connector 1
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

0 ddddd

e

7 e
2

e

8

e
e

3
3
4

5
6

e

e

e

ee

TABLE III - REMOTE MOUNTING OPTIONS

Mounting Kit for None Integral unit - mounting not required A
Remote Mounting 2" (5,08 cm) Pipe mtg. bracket, wall mtg, & DIN Rail clip B

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.

Cordset SAC-3P-5.0-PUR/M12FSSH Stainless RKV4T-6/S618

M12 Field Wiri ng Connector

Cable

Phoenix Contact

SACC-M12FS-4CON-PG7 B8141-0

2-wire twisted shielded pair

Turck

00 _ _

SS _ _

_ _ 00

_ _ CC

3

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 With Not Available With

Table

IIl A
III B

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