All rights reserved. It is prohibited to reproduce this documentation, or any part thereof, without
the prior written authorisation of KROHNE Messtechnik GmbH.
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1 SAFETY INSTRUCTIONS
1.1 Software history
The "Electronic Revision" (ER) is consulted to document the revision status of electronic
equipment according to NE 53 for all GDC devices. It is easy to see from the ER whether
troubleshooting or larger changes in the electronic equipment have taken place and how that
has affected the compatibility.
Changes and effect on compatibility
1Downwards compatible changes and fault repair with no effect on operation (e.g. spelling
mistakes on display)
2-_Downwards compatible hardware and/or software change of interfaces:
HART
®
H
PPROFIBUS
FFoundation Fieldbus
MModbus
Xall interfaces
3-_Downwards compatible hardware and/or software change of inputs and outputs:
ICurrent output
F, PFrequency / pulse output
SStatus output
CControl input
CICurrent input
Xall inputs and outputs
4Downwards compatible changes with new functions
5Incompatible changes, i.e. electronic equipment must be changed.
OPTISENS MAC 100
INFORMATION!
In the table below, "x" is a placeholder for possible multi-digit alphanumeric combinations,
depending on the available version.
Release dateElectronic RevisionChanges and
Documentation
compatibility
2007-12-11ER 1.0.0-MA MAC 100 R01
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OPTISENS MAC 100
1.2 Intended use
DANGER!
Never install or operate the device in potentially explosive areas, it might cause an explosion that
can result in fatal injuries.
WARNING!
If the device is not used according to the operating conditions (refer to chapter "Technical data"),
the intended protection could be affected.
In combination with the different sensors of the OPTISENS 1000 series the MAC 100 measures
analytical parameters in water and waste water applications.
1.3 Certifications
DANGER!
Never install or operate the device in potentially explosive areas, it might cause an explosion that
can result in fatal injuries.
SAFETY INSTRUCTIONS 1
CE marking
The device fulfils the statutory requirements of the following EC directives:
• Low Voltage Directive 2006/95/EC
• EMC Directive 2004/108/EC
as well as
• EN 61010
• EMC specification acc. to EN 61326/A1
• NAMUR recommendations NE 21 and NE 43
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1 SAFETY INSTRUCTIONS
1.4 Safety instructions from the manufacturer
1.4.1 Copyright and data protection
The contents of this document have been created with great care. Nevertheless, we provide no
guarantee that the contents are correct, complete or up-to-date.
The contents and works in this document are subject to copyright. Contributions from third
parties are identified as such. Reproduction, processing, dissemination and any type of use
beyond what is permitted under copyright requires written authorisation from the respective
author and/or the manufacturer.
The manufacturer tries always to observe the copyrights of others, and to draw on works created
in-house or works in the public domain.
The collection of personal data (such as names, street addresses or e-mail addresses) in the
manufacturer's documents is always on a voluntary basis whenever possible. Whenever
feasible, it is always possible to make use of the offerings and services without providing any
personal data.
OPTISENS MAC 100
We draw your attention to the fact that data transmission over the Internet (e.g. when
communicating by e-mail) may involve gaps in security. It is not possible to protect such data
completely against access by third parties.
We hereby expressly prohibit the use of the contact data published as part of our duty to publish
an imprint for the purpose of sending us any advertising or informational materials that we have
not expressly requested.
1.4.2 Disclaimer
The manufacturer will not be liable for any damage of any kind by using its product, including,
but not limited to direct, indirect or incidental and consequential damages.
This disclaimer does not apply in case the manufacturer has acted on purpose or with gross
negligence. In the event any applicable law does not allow such limitations on implied warranties
or the exclusion of limitation of certain damages, you may, if such law applies to you, not be
subject to some or all of the above disclaimer, exclusions or limitations.
Any product purchased from the manufacturer is warranted in accordance with the relevant
product documentation and our Terms and Conditions of Sale.
The manufacturer reserves the right to alter the content of its documents, including this
disclaimer in any way, at any time, for any reason, without prior notification, and will not be liable
in any way for possible consequences of such changes.
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OPTISENS MAC 100
1.4.3 Product liability and warranty
The operator shall bear responsibility for the suitability of the device for the specific purpose.
The manufacturer accepts no liability for the consequences of misuse by the operator. Improper
installation and operation of the devices (systems) will cause the warranty to be void. The
respective "Standard Terms and Conditions" which form the basis for the sales contract shall
also apply.
1.4.4 Information concerning the documentation
To prevent any injury to the user or damage to the device it is essential that you read the
information in this document and observe applicable national standards, safety requirements
and accident prevention regulations.
If this document is not in your native language and if you have any problems understanding the
text, we advise you to contact your local office for assistance. The manufacturer can not accept
responsibility for any damage or injury caused by misunderstanding of the information in this
document.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device. Special considerations and precautions are also described in the
document, which appear in the form of underneath icons.
SAFETY INSTRUCTIONS 1
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1 SAFETY INSTRUCTIONS
1.4.5 Warnings and symbols used
Safety warnings are indicated by the following symbols.
DANGER!
This information refers to the immediate danger when working with electricity.
DANGER!
This warning refers to the immediate danger of burns caused by heat or hot surfaces.
DANGER!
This warning refers to the immediate danger when using this device in a hazardous atmosphere.
DANGER!
These warnings must be observed without fail. Even partial disregard of this warning can lead to
serious health problems and even death. There is also the risk of seriously damaging the device
or parts of the operator's plant.
OPTISENS MAC 100
WARNING!
Disregarding this safety warning, even if only in part, poses the risk of serious health problems.
There is also the risk of damaging the device or parts of the operator's plant.
CAUTION!
Disregarding these instructions can result in damage to the device or to parts of the operator's
plant.
INFORMATION!
These instructions contain important information for the handling of the device.
LEGAL NOTICE!
This note contains information on statutory directives and standards.
• HANDLING
HANDLING
HANDLINGHANDLING
This symbol designates all instructions for actions to be carried out by the operator in the
specified sequence.
iRESULT
RESULT
RESULTRESULT
This symbol refers to all important consequences of the previous actions.
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OPTISENS MAC 100
1.5 Safety instructions for the operator
WARNING!
In general, devices from the manufacturer may only be installed, commissioned, operated and
maintained by properly trained and authorized personnel.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device.
SAFETY INSTRUCTIONS 1
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2 DEVICE DESCRIPTION
2.1 Scope of delivery
INFORMATION!
Inspect the cartons carefully for damage or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
INFORMATION!
Check the packing list to check if you received completely all that you ordered.
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
OPTISENS MAC 100
1 Signal converter
2 Product documentation
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OPTISENS MAC 100
2.2 Device description
1 Display
2 Operation keys
3 Cable glands
DEVICE DESCRIPTION 2
The signal converter is able to measure different parameters in liquids and fluids which are
common in the water and waste water industry. It has three freely programmable current
outputs and optionally three mechanical relays which can be configured as alarm or status
relays or limit switches.
The manufacturer offers the device as a one channel version and a version with two channels.
The last one possesses two sensor inputs for using sensors with different measuring principles
as they are:
When ordering the one channel version, only the interface "Pos.A" is populated. In the version
with two channels the interfaces "Pos.A" and "Pos.B" are populated (for further information
refer to
Overview of the terminal compartment
on page 22):
INFORMATION!
•
The configuration of the signal converter (i.e. the number and type of sensor inputs) has to be
set in the factory and cannot be changed later.
•
The number and type of sensor inputs is specified via the order code and visible on the
nameplate.
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2 DEVICE DESCRIPTION
The manufacturer offers the signal converter as a wall mount version only. Each device has a
passive control input that can signal an external "out of specification error" (e.g. that there is no
flow). Additionally the control input can help to set the analog outputs (current outputs and limit
switches) to "zero" or to "manual hold" (e.g. for maintenance). For further details about the
control input please refer to
The type and design of the cable glands depend on the version of the converter. The following
types and designs are available (the drawings show the device from the bottom side):
Cable glands (1 channel)
Control input (passive)
OPTISENS MAC 100
on page 26.
1 Power (M20)
2 Current output or relay output (M20)
3 Current outputs or temperature sensor (M20)
4 Sensor input (M20)
5 Possibility to connect a functional earth (only relevant for version with 24 V, which is in preparation)
Cable glands (2 channel, separate temperature sensor)
1 Power (M20)
2 Current output or relay output (M20)
3 Current outputs or temperature sensor (M20)
4 Sensor input for sensor A and B (double PG two times 5 mm / 0.20" screwed connection)
5 Possibility to connect a functional earth (only relevant for version with 24 V, which is in preparation)
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OPTISENS MAC 100
Cable glands (2 channel, integrated temperature sensor)
1 Power (M20)
2 Current output or relay output (M20)
3 Current outputs (M20)
4 Sensor input for sensor A and B (double PG two times 8 mm / 0.31" screwed connection)
5 Possibility to connect a functional earth (only relevant for version with 24 V, which is in preparation)
2.3 Sensor input combinations
The following combinations of sensor inputs are possible:
DEVICE DESCRIPTION 2
Sensor typeMeasured
parameter
Measuring
principle
Signal converter
Input A Input B
PAS 1000 pHpH valuePotentiometricXX
PAS 1000 ORPORP valuePotentiometricXX
AAS 1000 Cl
AAS 1000 ClO
AAS 1000 H2O
AAS 1000 O
AAS 1000 DO 1Dissolved oxygenAmperometricXX
CAS 1000 1Conductivity /
IAS 1000 1ConductivityInductiveXX
1 In preparation
2
2
1OzoneAmperometricX-
3
Free chlorineAmperometricX-
1Chlorine dioxideAmperometricX-
1Hydrogen peroxide AmperometricX-
2
specific resistance
Conductive (2pole)
XX
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2 DEVICE DESCRIPTION
2.4 Nameplate
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
1 Manufacturer
2 CE marking
3 Power supply data
4 Tag number of the order
5 Sensor type input B
6 Sensor type input A
7 Article code
8 Serial number
9 Device name and order code
OPTISENS MAC 100
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OPTISENS MAC 100
3.1 Notes on installation
INFORMATION!
Inspect the cartons carefully for damage or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
INFORMATION!
Check the packing list to check if you received completely all that you ordered.
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
3.2 Storage and transport
• Store and transport the device in a dry, dust-free location.
• Avoid continuous direct sunlight.
• Store and transport the device in its original packing.
• Storage temperature: -40...+70°C / -40...+158°F
INSTALLATION 3
3.3 Wall mounting
DANGER!
Never install or operate the device in potentially explosive areas, it might cause an explosion that
can result in fatal injuries.
CAUTION!
Always note the following items to ensure a proper and safe installation:
•
Make sure that there is adequate space to the sides.
•
Protect the signal converter from direct sunlight and install a sun shade if necessary.
•
Signal converters installed in control cabinets require adequate cooling, e.g. by fan or heat
exchanger.
•
Do not expose the signal converter to intense vibration.
•
Use assembly materials and tools in compliance with the applicable occupational health and
safety directives (assembly materials and tools are not part of the scope of delivery).
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3 INSTALLATION
CAUTION!
Installation, assembly, start-up and maintenance may only be performed by appropriately
trained personnel. The regional occupational health and safety directives must always be
observed.
INFORMATION!
Assembly materials and tools are not part of the delivery. Use the assembly materials and tools
in compliance with the applicable occupational health and safety directives.
The mounting plate is fixed at the back side of the device in the delivery condition. The following
drawings illustrate the proper mounting:
Wall mounting with plugs
OPTISENS MAC 100
• Note the drawing above and mark all drill holes with the help of a pen, e.g. a felt pen (1).
• Fasten the device securely to the wall with the help of plugs, screws and the mounting
plate (2).
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OPTISENS MAC 100
Wall mounting of multiple devices
INSTALLATION 3
[mm]["]
aØ6.5Ø0.26
b87.23.4
c2419.5
d31012.2
e25710.1
For further information about the dimensions of the mounting plate refer to
page 80.
Mounting plate
on
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4 ELECTRICAL CONNECTIONS
4.1 Safety instructions
DANGER!
All work on the electrical connections may only be carried out with the power disconnected. Take
note of the voltage data on the nameplate!
DANGER!
Observe the national regulations for electrical installations!
WARNING!
Observe without fail the local occupational health and safety regulations. Any work done on the
electrical components of the measuring device may only be carried out by properly trained
specialists.
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
OPTISENS MAC 100
4.2 Used abbreviations
AbbreviationDescription
C
p
I
a
I
max
I
nom
R
L
R plus number (e.g. R1)Relay contact
PPower
U
ext
U
ext, max
U
int, nom
Control input passive
Current output active
Maximum current
Nominal current
Load resistance
External voltage source
Maximum voltage of the external voltage source
Nominal internal voltage
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OPTISENS MAC 100
ELECTRICAL CONNECTIONS 4
4.3 Important device-specific notes on electrical connection
DANGER!
Never install or operate the device in potentially explosive areas, it might cause an explosion that
can result in fatal injuries!
DANGER!
The device must be grounded in accordance with regulations in order to protect personnel
against electric shocks.
DANGER!
When installing and wiring the device, note the safety regulations of the current state of the art.
Also note the following items to avoid fatal injuries, destruction or damage of the device or
measuring errors:
•
De-energise the cables of the power supply before you start any installation works.
•
Always install input and control cables divided from each other and from high voltage current
cables.
•
Assure that all cables of the inputs and current outputs are shielded. Connect the shieldings
only to one side, e.g. to the device.
•
When using relays, note that with inductive loads the interference must be suppressed.
•
Assure that all electrical connection works are compliant with the VDE 0100 directive
"Regulations for electrical power installations with line voltages up to 1000 V" or equivalent
national regulations.
•
Use suitable cable glands for the various electrical cables and suitable connecting cables for
the field of application. The outer diameter of the connecting cables has to fit to the cable
glands.
•
The nominal voltage of the connecting cable has to fit to the operating voltage of the device.
INFORMATION!
Assembly materials and tools are not part of the delivery. Use the assembly materials and tools
in compliance with the applicable occupational health and safety directives.
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4 ELECTRICAL CONNECTIONS
4.4 Opening the converter housing
INFORMATION!
Clean and grease all threads each time you open the housing. Use only resin-free and acid-free
grease. Before closing the cover, ensure that the housing gasket is properly fitted, clean and
undamaged.
All installation works on the electrical connections require to open the converter housing:
• Loose the four screws (1) with a crosstip screwdriver.
• Lift the housing at the top and bottom at the same time (2).
• Slide the housing cover backward (3).
iThe housing cover is guided and held by the inside hinge; you have access to the terminal
compartment now (see 4 in the previous drawing and next section).
OPTISENS MAC 100
4.5 Overview of the terminal compartment
1 Cover of power supply terminal
2 Cover of relay outputs terminal
3 Current output terminal
4 Shield terminal
5 Terminals for sensor input A
6 Terminals for sensor input B
7 Possibility to connect a functional earth (only relevant for 24 V version, which is in preparation)
8 Cable glands
8
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OPTISENS MAC 100
4.6 Connecting the signal cables
INFORMATION!
The cable glands installed by the manufacturer are designed for a cable diameter of 8 to 13 mm.
If you are using cables with a larger diameter, you must replace the manufacturer's cable glands
with suitable ones.
For all information concerning the signal cables of the used sensor(s) and their connection refer
to the relevant sensor handbook(s).
4.7 Connecting the power supply
DANGER!
The device must be grounded in accordance with regulations in order to protect personnel
against electric shocks.
DANGER!
Never install or operate the device in potentially explosive areas, it might cause an explosion that
can result in fatal injuries!
ELECTRICAL CONNECTIONS 4
CAUTION!
When connecting the power supply, always note the safety regulations of the current state of the
art. To avoid fatal injuries, destruction or damage of the device or measuring errors, also note
the following items:
•
De-energise the cables of the power supply before you start any installation works!
•
Always keep the housing of the device well closed if you do not perform any installation
works. The function of the housing is to protect the electronic equipment from dust and
moisture.
•
Assure that there is a fuse protection for the infeed power circuit (I
≤ 16 A) and a
nom
disconnecting device (switch, circuit breaker) to isolate the signal converter.
•
Check the nameplate and assure that the power supply meets the voltage and frequency of
the device. You can operate the device in the range of 100...230 VAC and 8 VA with a tolerance
of -15/+10% while 240 VAC +5% is included in the tolerance range (a version with a power
supply of 24 VAC/DC is in preparation). A power supply outside these specifications may
destroy the device!
•
Assure that the protective earth conductor (PE) is longer than the L- and N-conductor.
INFORMATION!
The manufacturer has designed all creepage distances and clearances according to VDE 0110
and IEC 664 for pollution degree 2. The power supply circuits fulfil the overvoltage category III
and the output circuits fulfil the overvoltage category II.
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4 ELECTRICAL CONNECTIONS
Before you start to connect the power supply cables, note the following drawing with the function
of the terminals:
Afterwards connect the power supply cables accordingly:
OPTISENS MAC 100
CAUTION!
The manufacturer strongly recommends to use a slotted screwdriver with a tip of 3.5 x 0.5 mm /
0.14 x 0.02" to push down the lever! Otherwise you could damage the lever.
• De-energise the power supply cables with the help of a disconnecting device (switch, circuit
breaker)!
• Open the converter housing ( refer to
Opening the converter housing
on page 22).
• Remove the cover of the power supply terminal (1) by pressing it down and pulling forwards
at the same time (2 and 3), be careful and do not disrupt the retaining band (it prevents the
cover from getting lost)!
• Use a slotted screwdriver with a tip of 3.5 x 0.5 mm / 0.14 x 0.02" to push down the lever,
connect the wires to the terminals and pull up the levers again (4 and 5).
• Refasten the cover of the power supply terminal, close the converter housing and tighten all
screws of the housing.
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ELECTRICAL CONNECTIONS 4
4.8 Description and properties of the outputs and the input
4.8.1 Current output
DANGER!
Never install or operate the device in potentially explosive areas, it might cause an explosion that
can result in fatal injuries.
INFORMATION!
For further information refer to the connection diagrams and the technical data table.
• All outputs are electrically isolated from each other and from all other circuits.
• All operating data and functions can be adjusted.
• Output data: measuring results of the sensor inputs A and B inclusive temperature.
• Active mode: output range 0(4)...20 mA, load resistance R
U
int, nom
• Self-monitoring: interruption or load resistance too high in the current output loop.
• Error signalling possible via alarm relays, error indication on LC display.
• Current value error detection can be adjusted.
=15VDC.
≤ 550 Ω at I
L
max
≤ 22 mA,
4.8.2 Relay outputs
DANGER!
Never install or operate the device in potentially explosive areas, it might cause an explosion that
can result in fatal injuries.
INFORMATION!
For further information refer to the diagrams on page 28
data table
The device has three electro-mechanical relays that can work as alarm relays or limit switches
(electronic relays are in preparation):
• The relay contacts are electrically isolated from each other and from all other circuits.
• The output stages of the status outputs / limit switches behave like relay contacts.
• Possible conditions: NO (normally open) or NC (normally closed).
• Contact ratings:
- Relays for low voltages: U ≤ 30 VDC, I ≤ 1 A, resistive load (PELV / SELV) or U ≤ 50 VAC,
I ≤ 4 A, resistive load (PELV / SELV)
- Relays for high voltages: U = 100...230 VAC, I ≤ 4 A, max. 1000 VA resistive load
• The contact circuits have to be either PELV / SELV circuits or hazardous voltage circuits.
on page 75
and
on page 29
.
as well as the technical
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4 ELECTRICAL CONNECTIONS
4.8.3 Control input (passive)
CAUTION!
Pay attention to the maximum voltage and current values which can be applied to the control
input! Applying power outside the allowed range can destroy or damage the device!
INFORMATION!
The factory default is a disabled control input!
The passive control input can trigger different events in the converter from outside. It is engaged
via applying a voltage of U
properties in detail are the following:
• Passive, not polarity sensitive
• Condition "off": U
• Condition "on": U
• U
• I
• I
ext, max
nom
nom
≤ 32 VDC
=6.5mA with U
=8.2mA with U
off
on
> 8 VDC and disengaged via applying a voltage of U
on
≤ 2.5 VDC with I
≥ 8VDC with I
=24VDC
ext
=32VDC
ext
nom
nom
=0.4mA
= 2.8 mA
OPTISENS MAC 100
<2.5VDC. The
off
For instance the control input can work together with a flow monitor that monitors the sample
flow and gives a signal if the flow drops below a certain threshold. If in this case the control input
has the setting "flow control", it triggers an "out of specification error" (this errors indicates that
the measured value cannot be trusted anymore). For more information refer to
"Out of specification" (S)
on page 69.
Error category
There are other purposes for the usage of the control input. For detailed information refer to the
function C3.5 and especially C3.5.1 in the corresponding function table.
26
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