DirectLine® DL422 Sensor Module
®
for Meredian
II ORP Electrodes
User Manual
70-82-25-107
Rev. 2
1/03
Industrial Measurement and Control
Notices and Trademarks
Copyright 2003 by Honeywell
Revision 2 January 2003
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.
Industrial Measurement and Control
DirectLine is a registered trademark of Honeywell
Meredian is a U.S. registered trademark of Honeywell
Other brands or product names are trademarks of their respective owners
Insert 70-82-10-02 should accompany this document.
ii DirectLine® DL422 Sensor Module User Manual 1/03
Honeywell
1100 Virginia Drive
Fort Washington, PA 19034
About This Document
Abstract
This manual contains all the information that is needed to install, configure, calibrate,
operate, and troubleshoot the DirectLine® Sensor. Insert 70-82-10-02, a quick reference
guide for configuring and calibrating the DL422, 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.
1/03 DirectLine® DL422 Sensor Module User Manual iii
Contents
1. INTRODUCTION....................................................................................................................1
1.1 Overview.........................................................................................................................................1
1.2 Electronics Module ......................................................................................................................... 2
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 ..................................................................................................................... 10
3. CONFIGURATION ............................................................................................................... 11
3.1 Overview.......................................................................................................................................11
3.2 Configuration Set Up Procedure................................................................................................... 12
4. CALIBRATION.....................................................................................................................14
4.1 Calibration Diagnostics................................................................................................................. 14
4.2 Calibration Diagnostic Reset ........................................................................................................ 14
4.3 Calibration..................................................................................................................................... 14
5. OPERATION ........................................................................................................................ 17
5.1 Displays ........................................................................................................................................ 17
5.2 Diagnostic Error Messages .......................................................................................................... 18
5.3 Unit Reset ..................................................................................................................................... 19
6. SPARE PARTS....................................................................................................................20
7. SALES AND SERVICE........................................................................................................ 21
iv DirectLine® DL422 Sensor Module User Manual 1/03
Tables
Table 2-1 Assembly and Wiring Procedure for Field Wiring Connector___________________________ 6
Table 2-2 Integral Mounting Procedure for ORP Electrodes __________________________________ 7
Table 2-3 Remote Mounting Procedure for ORP Electrodes__________________________________ 8
Table 3-1 Configuration Set Up Procedure ______________________________________________ 12
Table 4-1 Oxidation-Reduction Potential of Reference Solutions at Specified Temperature_________ 15
Table 4-2 Zero (Standardization) Calibration Procedure ____________________________________ 16
Table 5-1 Online Parameter Descriptions _______________________________________________ 17
Table 5-2 Display Navigation Procedure ________________________________________________ 17
Table 5-3 Online Diagnostic Errors ____________________________________________________ 18
Table 5-4 Factory Default Values _____________________________________________________ 19
1/03 DirectLine® DL422 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 __________________________________________________________ 9
Figure 2-5 Remote Mounting Hardware_________________________________________________ 10
vi DirectLine® DL422 Sensor Module User Manual 1/03
Introduction
1. Introduction
1.1 Overview
The DirectLine® Sensor consists of an electronics module connected to a Meredian
II ORP electrode that eliminates the need for pre-amps, transmitters, and analyzers
in ORP applications.
The modular electronics design can be separated from the electrode, allowing the
electrode to be easily removed or replaced while retaining power to the electronics
module.
The DL422 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 polysulfone
housing has plug-in connections for the Meridian II ORP probe and 4-20 mA output
connection.
1/03 DirectLine® DL422 Sensor Module User Manual 1
Figure 1-1 DirectLine® Sensor
Introduction
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 ORP value that is measured by the
Meridian II electrode.
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.
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® DL422 Sensor Module User Manual 1/03
1.4 Specifications
Introduction
Displayed ORP
Meredian Sensor Survivable Temperature
Range
Electronics Module Ambient Temperature
Output Type
Output Scale
Output Calibration
Output Cordset
User Termination
Sensor Cable Length
Power
Local Display and Buttons
Engineering Units
Calibration Options
Diagnostics
Case
Approvals
Remote Mounting
Dimensions
Weight
–1600 mV to +1600 mV
–10 °C to +130 °C (14 °F to 266 °F)
–20 °C to +85 °C (–4 °F to +185 °F)
4-20 mA (2-wire loop powered)
–1600 mV to +1600 mV
4-20 mA
Shielded twisted pair, length 6 m (19.7’)
Tinned leads
3.65 m (12’) or 6.096 m (20’)
16-42 Vdc
Maximum load resistance: 250 ohms at 16 Vdc
600 ohms at 24 Vdc
1400 ohms at 42 Vdc
LCD 4-digit, 7-segment
mV
1 point Sample
Sensor and electronics
Weatherproof, corrosion-resistant plastic housing
CE Mark for Industrial Applications
UL – General Purpose for Process Control
CSA – General Purpose
FM – CLI, DIV1, Groups C & D and CLI, Zone 0 AEx ia
IIB (IS)
FM – CLI, DIV2, Groups C & D and CLI, Zone 2,
Groups IIB (N.I. Field Wiring)
Pipe, Wall, or DIN Rail
H 123 mm (4.84”) x W 48 mm (1.89”) x D 46 mm (1.81”)
Approximately 142 g (5.0 oz.)
1/03 DirectLine® DL422 Sensor Module User Manual 3
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