Honeywell DirectLine DL422 User Manual

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

[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.

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

Introduction

_-_-_

o

(

g

_

r

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)
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

TABLE II - SENSOR CABLE/REMOTE CONNECTOR (between electronic module and electrode, sensor or pr

Integral Mounting

Remote Mounting Cable

- Durafet only

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 Mounting 1 e

50 ft.) of sensor cable - Durafet II Remote Mountin

15,24m
Remote Mounting Connector - Meredian II pH
Remote Mounting Connector - Meredian II ORP
Remote Mounting Connector - HPW 7000
Remote Mounting Connector - Conductivity
Remote Mounting Connector - Dissolved Oxygen

-

_ _ _

customer supplies cable only-

only -

Note 2

Note 1

Note 2

Selection

DL425

D
E
F

0

2
3
3
4

5
6

Availability

ddddd

e
e

e

e

e

ee

TABLE III - REMOTE MOUNTING OPTIONS

Mounting Kit for

Remote Mounting

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

TABLE IV - OPTIONS

Tagging

Certificates

None
Linen Customer ID Tag - 3 lines w/22 characters/line
SS Customer ID Tag - 3 lines w/22 character/line

None
Calibration & Conformance

Notes:

Customer supplies cordset o

1

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

M12 Field Wiring Connector

Cable

2

Recommended cable is 2-wire twisted shielded pair

RESTRICTIONS

Restriction

Letters

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.

Table

d

e

cable with M12 connecter. Suppliers & P/Ns include:

Phoenix Contact

SACC-M12FS-4CON-PG7 B8141-0

Available Only With Not Available With

Selection Table

IIl A
III B

2-wire twisted shielded pair

Selection

Turck

00 _ _
LT _ _

SS _ _

_ _ 00

_ _ CC

4 DirectLine® DL422 Sensor Module User Manual 1/03

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. See Figure 2-1.

2) Field wiring connector with customer supplied cable. See page 6.

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

1/03 DirectLine® DL422 Sensor Module User Manual 5

Installation

2.1.2 Field Wiring Connector with customer supplied cable

Refer to Figure 2-2. The field wiring connector supports customer supplied cable with an
outer diameter of 4-6mm, 2-wire twisted shielded pair.

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 2 and 3 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 power supply

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® DL422 Sensor Module User Manual 1/03

Figure 2-2 Field Wiring Connector

2.2 Integral Mounting

Table 2-2 Integral Mounting Procedure for ORP Electrodes

Step Procedure

Connect Electrode to Pipe and Electronics Assembly (Figure 2-3)

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

Step 2

Step 3

Rear of Housing

Step 4

1/03 DirectLine® DL422 Sensor Module User Manual 7

Electrode

Step 1

Figure 2-3 Integral Mounting

Installation

2.3 Remote Mounting

When the DL422 is specified with Table II = 3, the Remote Connector Assembly (part number
51500768-002) is supplied loose for connection of the Meredian II ORP electrode cable to the
DL422 module. Table 2-3 gives the mounting procedure.

Table 2-3 Remote Mounting Procedure for ORP 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 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.

3

4

5 Slide cap along cable and tighten onto cable jacket with small wrench until cable cannot

6

7

8 Plug remote connector assembly into DL422 module aligning polarity tab of module

Connect cable leads as follows:

Terminal 1 = Black Reference Lead
Terminal 2 = 100K ohm resistor (pre-installed by Honeywell)
Terminal 3 = 100K ohm resistor (pre-installed by Honeywell)
Terminal 4 = Shield
Terminal 5 = 1 Megohm resistor (pre-installed by Honeywell)
Terminal 6 = Red Measuring Lead and
1 Megohm resistor (pre-installed by Honeywell)

Slide cover along cable and tighten by hand onto the remote connector assembly.

slide within strain relief rubber bushing.

Remove red protective vinyl boot from opposite end of connector assembly.

Apply a thin film of silicon grease on the ID of the electronics module’s electrode
mounting cavity.

housing and mating groove on connector.

8 DirectLine® DL422 Sensor Module User Manual 1/03

Electronics
Module

Protective
yellow vinyl sleeve
(remove)

1

Black Reference Lead

2

100K-ohm resistor (pre-installed by Honeywell)

3

100K-ohm resistor (pre-installed by Honeywell)

4

Shield Lead

5

1 Megohm resistor (pre-installed by Honeywell)

6

Red Measuring Lead and
1 Megohm resistor (pre-installed by Honeywell)

Installation

Cover

Strain
Relief

Compression
Cap

Remote Wiring Cable

12 or 20 Feet

Electrode

Remote Electronics

Module for

Meredian II Electrodes

1/03 DirectLine® DL422 Sensor Module User Manual 9

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

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.

10 DirectLine® DL422 Sensor Module User Manual 1/03

Configuration

3. Configuration

3.1 Overview

Configuration Parameters

Set Up consists of configuring the following functions:

• 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 of

–1600 mV to +1600 mV in 10 mV increments.

 100 % Range 100 % Range values can be adjusted within a range of

–1600 mV to +1600 mV in 10 mV 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.

Table 3-1 provides steps and entry information for the complete configuration sequence.

1/03 DirectLine® DL422 Sensor Module User Manual 11

Configuration

3.2 Configuration Set Up Procedure

ATTENTION:

In Table 3-1, 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 ORP 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 3-1 Configuration Set Up Procedure

Step Operation Press Display

1 Enter Noise

Suppression
Frequency

Edit Noise Suppression

Frequency

Select desired

Frequency

Save the Noise

Suppression Frequency

2 Enter Output

Configuration

0 % Range Value

Selection

Edit 0 % Range Value

Selection

Select desired 0 % ORP

Value

Save the New 0 %

Range Value

MODE

Hold

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 % ORP Value in 10 mV increments

Range: –1600 to +1600 mV (default –1600 mV)

(New Value)

12 DirectLine® DL422 Sensor Module User Manual 1/03

Configuration

Step Operation Press Display

3 100 % Range Value

Selection

Edit 100 % Range Value

Selection

Select 100 % ORP

Value

Save the New 100 %

Range Value

0 % Calibration

4

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 % ORP Value in 10 mV increments

Range: –1600 to +1600 mV (default 1600 mV)

(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

100 % Calibration

5

Adjust 100 %

Calibration

Save 100 % Calibration

Return to Online Display

6

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

1/03 DirectLine® DL422 Sensor Module User Manual 13

Calibration

4. Calibration

4.1 Calibration Diagnostics

Introduction

The manual standardization adjustment changes the zero offset diagnostics used by this
system. This value is viewed as read-only information. It is good practice to observe this
value after calibration. Monitoring the value over time will help you predict when the
electrode will need to be replaced.

Zero Offset Value

When Online ORP value is displayed, PRESS 1button momentarily to display the current
Zero Offset value.

Zero Offset is non-volatile and is initialized to 0 mV at unit reset.

It has a range of ± 120 mV 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 ORP will use the zero offset value from the
previous calibration. Depending on the condition of the replaced electrode, the difference
between the known and indicated ORP of the new electrode may vary as much as several
millivolts. A calibration on the new electrode will correct this difference.

Zero Offset ORP Value

1

a) Momentarily press

1

the

button until the Zero Offset ORP value resets to factory default “0”.

to view the Zero Offset value. From this display press and hold

b) Press MODE button, or wait 60 seconds, to return to Online ORP.

4.3 Calibration

Overview

Calibration consists of the following function:

• Calibrating the Zero (Standardization) – Manual ORP calibration. In manual
calibration, you can select a new ORP value above or below the recognized live ORP
value.

14 DirectLine® DL422 Sensor Module User Manual 1/03

Calibration

ORP Calibration Using Reference Solution

Recommended to adjust for changes in electrode potential over time

An ORP measuring system can be checked by measuring a solution having a known
oxidation-reduction potential, then adjusting the sensor to match. Although a reference
solution provides only an approximation of ORP potential, the system can be adjusted
periodically to compensate for changes in electrode potential over time.

Materials

The materials required to use the ORP standardization method are:

• A solution with a known oxidation-reduction potential. (See “Instructions for
preparing solution” below.)

• A container for the solution, large enough to immerse the electrode to measuring
depth.

• Distilled or de-ionized water to rinse the electrode.

Instructions for preparing solution

To prepare an ORP standardization solution, dissolve 0.1 g of quinhydrone powder (available
as Honeywell part number 31103015 for a 2 oz. bottle) in 5 cc of acetone or methyl alcohol
(methanol). Add this to not more than 500 cc of a standard pH reference solution (buffer),
about 1 part saturated quinhydrone to 100 parts buffer solution. The oxidation potential of
this solution is listed below for several temperatures. The polarity sign shown is that of the
measuring element with respect to the reference element.

These solutions are unstable and should be used within eight hours of preparation.

All mV values in Table 4-1 have a ± 30 mV tolerance.

Table 4-1 Oxidation-Reduction Potential of Reference Solutions at Specified Temperature

pH Buffer Solution

(Honeywell Part Number)

4.01 @ 25 °C (31103001)

6.86 @ 25 °C (31103002)

7.00 @ 25 °C (not available from Honeywell)

9.00 @ 25 °C (not available from Honeywell)

9.18 @ 25 °C (31103003)

20 °C 25 °C 30 °C

267 mV 263 mV 259 mV

100 mV 94 mV 88 mV

92 mV 86 mV 80 mV

–26 mV –32 mV –39 mV

–36 mV –43 mV –49 mV

Temperature

1/03 DirectLine® DL422 Sensor Module User Manual 15

Calibration

Calibration Procedures

ATTENTION:

In Table 4-2, under the Press column:

• Hold means to hold the button down until the display changes.

• Momentarily means to press and release the indicated button.

Table 4-2 Zero (Standardization) Calibration Procedure

Step Operation Press Display

1 Enter Zero

(Standardization)
Calibration

Do Sample (Manual)

2

Calibration

Edit ORP Value

Save New ORP
Value

1

Hold

1

Momentarily

Momentarily

Momentarily

or

MODE

CAL1

SCAL for one second,

then displays Live ORP Value.

To edit ORP Value (Flashing Display)

ORP Value is saved and goes to Online Display.

16 DirectLine® DL422 Sensor Module User Manual 1/03

Operation

5. Operation

5.1 Displays

Overview

The DirectLine® DL422 displays the ORP value and Zero Offset ORP value. The table below
describes these parameters.

Table 5-1 Online Parameter Descriptions

Parameter Description

Online ORP Measured ORP expressed with fixed whole number precision.

Range: –1600 mV to +1600 mV

Zero Offset ORP
Value

Zero Offset ORP value expressed with whole number precision.
Range: −120 mV to +120 mV

The default display and home position is the Online ORP display. It appears when:

 The unit is powered up
 No button presses for 60 seconds
 The Mode button has been pressed during Zero (Standardization) calibration (Sample

Calibration)

 The Mode button has been pressed during a configuration edit

The measurement and display of ORP is updated at a rate of 500 ms.

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 ORP value

1

MODE

Momentarily

(measured ORP)

2 View Zero Offset ORP

value

Return to home position

3

1/03 DirectLine® DL422 Sensor Module User Manual 17

Momentarily

MODE

Momentarily

(Zero Offset ORP)

(measured ORP)

Operation

5.2 Diagnostic Error Messages

When a diagnostic error or status condition occurs, the Online Display alternates between
measured ORP 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 ORP is displayed.

O HI

O LO

PRBE Probe is defective, removed from process, or not

This error may occur during probe calibration and abort the calibration process.

FAIL This error message is preceded by the message

Data error detected. Reset unit or cycle power.

Second occurrence will show FALT.

Unit electronics are defective. Replace electronics module.

Measured ORP is > 1600 mV Bring process within limits

Measured ORP is < –1600 mV Bring process within limits

Check probe, connection and

connected.

Forces the output to burnout level (approximately

21.8 mA).

“FAIL”

ZRNG The Zero (Standardization) calibration

failed due to a calculated Zero Offset
value outside the range of –120 mV to
+120 mV.

presence of sample.

When the source of the error is
removed, the error will clear and the
output will return to normal
operation.

Press Mode to return to online
display.

18 DirectLine® DL422 Sensor Module User Manual 1/03

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 ORP display, press and hold the 1 and 2 buttons simultaneously
until the “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 ORP display.

Table 5-4 Factory Default Values

Data Default Values

Zero Offset

Noise Suppression Frequency Selection

Output Configuration – 0 % Range Value

Output Configuration – 100 % Range Value

Output Configuration – 0 % Calibration

Output Configuration – 100 % Calibration

0 mV

60 Hz

–1600 mV

1600 mV

4.00 mA typically

20.00 mA typically

1/03 DirectLine® DL422 Sensor Module User Manual 19

Operation

6. Spare Parts

Part Number Description

51452682-001 DirectLine® Sensor Module (Replacement Module)

51452683-001 6m cordset

51452684-001 Field Wiring Connector supports customer supplied cable (4-6 mm OD)

51500768-002

51451371-001 Cable Strain Relief

51198302-006 Internal O-ring for Remote Electrode Cable Connector

31086221

51452655-001 Remote Mounting Kit for Wall, Pipe, or DIN Mounting

51452706-001 Locking screw (locks sensor module to electrode)

Remote Electrode Cable Connector Assembly– Includes O-rings, strain relief,
and pre-installed resistors

External O-ring for Integral Meredian Electrode or Remote Electrode Cable
Connector

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.

20 DirectLine® DL422 Sensor Module User Manual 1/03

7. Sales and Service

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. : [phone]

ASIA PACIFIC

HONEYWELL ASIA
PACIFIC Inc.
Room 3213-3225
Sun Kung Kai Centre
N° 30 Harbour Road
WANCHAI
HONG KONG
Tel. : [phone]

AUSTRALIA

HONEYWELL LIMITED
5 Thomas Holt Drive
North Ryde Sydney
NSW AUSTRALIA 2113
Tel. : [phone]
AUSTRIA

HONEYWELL AUSTRIA

G.m.b.H.
Handelskai 388
A1020 VIENNA
AUSTRIA
Tel. : [phone]

BELGIUM

HONEYWELL S.A.
3 Avenue de Bourget
B-1140 BRUSSELS
BELGIUM
Tel. : [phone]

BRAZIL

HONEYWELL DO
BRAZIL

AND CIA
Rua Jose Alves Da
Chunha
Lima 172
BUTANTA

05360.050 SAO PAULO
SP
BRAZIL
Tel. : [phone]

BULGARIA

HONEYWELL EOOD
14, Iskarsko Chausse
POB 79
BG- 1592 Sofia
BULGARIA
Tel : [phone]/
794027/ 792198

CANADA

HONEYWELL LIMITED
THE HONEYWELL

CENTRE
300 Yorkland Blvd.
NORTH YORK,

ONTARIO
M2J 1S1
CANADA
Tel.: [phone]
Fax:: [phone]

CZECH

REPUBLIC
HONEYWELL, Spol.s.r.o.
Budejovicka 1
140 21 Prague 4
Czech Republic
Tel. : [phone]

DENMARK

HONEYWELL A/S
Automatikvej 1
DK 2860 Soeborg
DENMARK
Tel. : [phone]

FINLAND

HONEYWELL OY
Ruukintie 8
FIN-02320 ESPOO 32
FINLAND
Tel. : [phone]

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

GERMANY

HONEYWELL AG
Kaiserleistrasse 39
D-63067 OFFENBACH
GERMANY
Tel. : [phone]

HUNGARY

HONEYWELL Kft
Gogol u 13
H-1133 BUDAPEST
HUNGARY
Tel. : [phone]

ICELAND

HONEYWELL
Hataekni .hf
Armuli 26
PO Box 8336
128 reykjavik
Iceland
Tel : [phone]

ITALY

HONEYWELL S.p.A.
Via P. Gobetti, 2/b
20063 Cernusco Sul
Naviglio
ITALY
Tel. : [phone]

MEXICO

HONEYWELL S.A. DE
CV
AV. CONSTITUYENTES
900
COL. LOMAS ALTAS
11950 MEXICO CITY
MEXICO
Tel : [phone]

THE NETHERLANDS

HONEYWELL BV
Laaderhoogtweg 18
1101 EA AMSTERDAM
ZO
THE NETHERLANDS
Tel : [phone]

NORWAY

HONEYWELL A/S
Askerveien 61
PO Box 263
N-1371 ASKER
NORWAY
Tel. : [phone]

POLAND

HONEYWELL Sp.z.o.o
UI Domainewksa 41
02-672 WARSAW
POLAND
Tel. : [phone]

PORTUGAL

HONEYWELL
PORTUGAL LDA
Edificio Suecia II
Av. do Forte nr 3 - Piso 3
2795 CARNAXIDE
PORTUGAL
Tel. : [phone]

REPUBLIC OF IRELAND

HONEYWELL
Unit 1
Robinhood Business
Park
Robinhood Road
DUBLIN 22
Republic of Ireland
Tel. : [phone]

REPUBLIC OF
SINGAPORE

HONEYWELL PTE LTD
BLOCK 750E CHAI
CHEE ROAD
06-01 CHAI CHEE IND.
PARK
1646 SINGAPORE
REP. OF SINGAPORE
Tel. : [phone]

REPUBLIC OF SOUTH
AFRICA

HONEYWELL
Southern Africa
PO BOX 138
Milnerton 7435
REPUBLIC OF SOUTH
AFRICA
Tel. : [phone]

ROMANIA

HONEYWELL Office
Bucharest
147 Aurel Vlaicu Str.,
Sc.Z.,
Apt 61/62
R-72921 Bucharest
ROMANIA
Tel : [phone]/
211 79

RUSSIA

HONEYWELL INC
4 th Floor Administrative
Builiding of AO "Luzhniki"
Management
24 Luzhniki
119048 Moscow
RUSSIA
Tel : [phone]

SLOVAKIA

HONEYWELL Ltd
Mlynske nivy 73
PO Box 75
820 07 BRATISLAVA 27
SLOVAKIA
Tel. : [phone]/
425

SPAIN

HONEYWELL S.A
Factory
Josefa Valcarcel, 24
28027 MADRID
SPAIN
Tel. : [phone]

SWEDEN

HONEYWELL A.B.
S-127 86 Skarholmen
STOCKHOLM
SWEDEN
Tel. : [phone]

SWITZERLAND

HONEYWELL A.G.
Hertistrasse 2
8304 WALLISELLEN
SWITZERLAND
Tel. : [phone]

TURKEY

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 : [phone]

UNITED KINGDOM

HONEYWELL
Unit 1,2 &4 Zodiac House
Calleva Park
Aldermaston
Berkshire RG7 8HW
UNITED KINGDOM
Tel : [phone]

U.S.A.

HONEYWELL INC.
INDUSTRIAL PROCESS

CONTROLS
1100 VIRGINIA DRIVE
PA 19034-3260
FT. WASHINGTON
U.S.A.
Tel. : [phone]

VENEZUELA

HONEYWELL CA
APARTADO 61314
1060 CARACAS
VENEZUELA
Tel. : [phone]

1/03 DirectLine® DL422 Sensor Module User Manual 21

22 DirectLine® DL422 Sensor Module User Manual 1/03

Industrial Measurement and Control

Honeywell
1100 Virginia Drive
Fort Washington, PA 19034

70-82-25-107 0103 Printed in USA www.honeywell.com/imc