Mettler Toledo Thornton 770max Service Manual
Part No. 84373
770MAX
Multiparameter
Analyzer/Transmitter
Service Manual
IMPORTANT SAFETY INFORMATION
This instrument is compliant with safety standards as outlined in the European Community low voltage directive
EN61010-1 and with CSA Std C22.2, No. 0-M1982 General Requirements – Canadian Electrical Code, Part II,
0.4-M1982 Bonding and Grounding of Electrical Equipment and 142-M1987 Process Control Equipment.
Certification is pending.
Please read and observe the following:
INSTALLATION: This instrument must be installed by trained instrumentation personnel in accordance with
relevant local codes and instructions in this manual. Observe all instrument specifications an d ratings.
SHOCK HAZARD: Make sure power to all wires is turned off before proceeding with installation or service of this
instrument. High voltage may be present on the input power and relay wires.
RELAY CONTROL ACTION: 770MAX optional relays will always de-energize on loss of power, equivalent to
normal state, regardless of relay state setting for powered operation. Configure any control system using these
relays with fail-safe logic accordingly.
PROCESS UPSETS: Because process safety conditions may depend on consistent operation of this
instrument, take appropriate action to maintain conditions during sensor cleaning, replacement or sensor or
instrument calibration. A timed “Hold” function may be selected which holds analog output signals and relays
with their existing conditions for a set maintenance time interval.
This manual includes safety information with the following designations a nd formats:
WARNING: POTENTIAL FOR PERSONAL INJURY.
CAUTION: possible instrument damage or malfunction.
NOTE: important operating information.
On the instrument indicates: Caution, risk of electric shock
On the instrument indicates: Caution (refer to accompanying documents)
TABLE OF CONTENTS
CHAPTER 1: INTRODUCTION...........................................................................1
INSTRUMENT OVERVIEW .............................................................................................. 1
WIRING............................................................................................................................. 2
SENSOR WIRING............................................................................................................. 2
CHAPTER 2: METER CALIBRATION................................................................4
VERIFICATION PROCEDURE......................................................................................... 4
CALIBRATION PROCEDURE .......................................................................................... 5
CHAPTER 3: ANALOG OUTPUT CALIBRATION.............................................7
ANALOG OUTPUT CALIBRATION................................................................................... 7
ANALOG OUTPUT VERIFICATION ................................................................................. 7
CHAPTER 4: UPGRADES..................................................................................9
MAIN AND MEASUREMENT SOFTWARE UPGRADE.................................................... 9
OUTPUT UPGRADES...................................................................................................... 9
CHAPTER 5: TROUBLESHOOTING................................................................11
ON-LINE ERROR MESSAGES....................................................................................... 11
SENSOR TROUBLESHOOTING.................................................................................... 11
OFF-LINE DIAGNOSTICS.............................................................................................. 12
CHAPTER 6: RS232 COMMUNICATIONS......................................................14
GENERAL....................................................................................................................... 14
COMMAND FORMAT..................................................................................................... 14
RESPONSE FORMAT.................................................................................................... 14
ERROR CODES ............................................................................................................. 14
COMMAND SET............................................................................................................. 15
DATA OUTPUT FORMAT............................................................................................... 16
ATTENTION COMMAND................................................................................................ 17
GET DATA COMMAND.................................................................................................. 17
SET AUTO DATA OUTPUT COMMAND........................................................................ 20
RESET COMMAND........................................................................................................ 21
SET PARAMETER COMMAND...................................................................................... 22
GET PARAMETER COMMAND...................................................................................... 22
VARIABLES FOR GET AND SET PARAMETER COMMAND........................................ 23
KEYPRESS COMMAND................................................................................................. 33
DISPLAY MESSAGE COMMAND .................................................................................. 34
SELF-TEST COMMAND................................................................................................. 34
ECHO COMMAND.......................................................................................................... 35
SET ANALOG OUTPUT COMMAND.............................................................................. 35
RETURN ALL SETUP COMMAND................................................................................. 36
GET/SET OUTPUT LINE COMMAND............................................................................ 36
READ INPUT LINE COMMAND...................................................................................... 37
GET/SET DATE/TIME COMMAND................................................................................. 37
PRINT ERROR STATUS COMMAND ............................................................................ 38
COPY CALIBRATION COMMAND................................................................................. 39
GET MESSAGES COMMAND ........................................................................................ 39
PRINT SETUP COMMAND ............................................................................................ 39
TOC CONTROL COMMAND.......................................................................................... 40
CHAPTER 7: MENU TREES............................................................................41
MEASUREMENTS MENUS............................................................................................ 42
MESSAGES AND CALIBRATION MENUS..................................................................... 43
ANALOG OUTPUTS, SETPOINTS AND RELAYS MENUS........................................... 44
DISPLAY SETUP, SECURITY AND DIAGNOSTICS MENUS........................................ 45
RS232, NETWORK AND RESET MENUS ..................................................................... 46
TECH SUPPORT, SET HOLD TIME AND OTHER MENUS........................................... 47
CHAPTER 8: PRINTER INSTALLATION INSTRUCTIONS .............................48
INSTALLATION INSTRUCTIONS FOR USE WITH THE................................................ 48
THORNTON 770MAX SERIES INSTRUMENTS........................................................... 48
CHAPTER 9: ACCESSORIES AND SPARE PARTS......................................50
ACCESSORIES.............................................................................................................. 50
SPARE/REPLACEMENT PARTS................................................................................... 51
WARRANTY.................................................................................................................... 53
CHAPTER 1: INTRODUCTION
See Instruction Manual 84372 supplied with the
instrument for standard operating information for the
770MAX. This service manual covers instrument
calibration, upgrades, RS232 communications and
other information for troubleshooting and training.
The 770MAX is provided with a Help key which
provides supplementary information about the area
of the menus being displayed. It can be especially
helpful in initial configuration.
INSTRUMENT OVERVIEW
The 770MAX series utilizes 3 or 4 surface-mount
printed circuit boards plus a display module which
slide into the molded case and are held in place by
the front cover secured by two screws.
The main circuit board is located in the front of the
instrument. It contains the display module, main
processor, operating firmware and flash memory
which retains all setup configuration data plus
calibration data for (standard) analog outputs 1-4.
The power supply circuit board is located on the
left side of the instrument. It contains the universal
100-240 VAC or 24 VDC power supply plus terminal
connections for the 4 standard analog outputs,
RS232 communications, discrete inputs and outputs
and pulse flow input circuits.
The measurement circuit board is on the right side
of the instrument and contains the measuring and
communication interface circuits for smart sensors
plus the NVRAM with measuring circuit calibration
data.
The options circuit board, if used, is in the center
and contains 4 relays, and may contain 4 additional
analog output circuits and their calibration data,
depending on the option specified. The label on the
rear of the case depends on which, if any, options
board is installed. An options board may be installed
in the field using the appropriate kit of parts.
POWER SUPPLY PCB ASSEMBLY
DISPLAY ASSEMBLY
FACEPLATE ASSEMBLY
REAR LABEL
OPTIONAL PCB ASSEMBLY
CASE
MEASUREMENT PCB ASSEMBLY
MAIN PCB ASSEMBLY
Chapter 1 Introduction 1
770MAX exploded view
WIRING
For full installation wiring instructions, refer to
manual 84372. Information here is for reference
only.
CAUTION: Route all sensor and output signal
wiring away from power and switching circuits to
minimize noise pickup and interference.
AC Power Wiring
Board Terminal Connection
TB1 N AC power, neutral
L AC power, hot
CAUTION: Power wire insulation must be
stripped back 0.5 in. (13 mm) for reliable
connection.
Earth ground
DC Power Wiring
Board Terminal Connection
TB1 + DC power, positive
- DC power, negative
CAUTION: Power wire insulation must be
stripped back 0.5 in. (13 mm) for reliable
connection.
Earth ground
SENSOR WIRING
Rear panel terminal boards
Smart sensor patch cords plug into jacks CH1
through CH4. To avoid confusion when unplugged,
label the channel at the end of each patch cord.
Extending or making a break in patch cords must be
done only using extension cables 1005-87 (5 ft, 1.5
m) or 1015-87 (15 ft, 3 m) and union connector
25320.
CAUTION: Do not cut or shorten patch cords.
They use very fine gage shielded cable not
suitable for screw terminals or splicing. Do not
extend patch cords using computer network
cables since they provide only 8 of the 10
conductors needed by 770MAX and will damage
the modular jacks.
Pulse input flow sensor wiring is shown in Appendix
B of Instruction Manual 84372.
2 Introduction Chapter 1
Other Connections
Refer to rear panel figure for location.
Board Terminal Connection
1 Shield
2 Common
3 +5V
4 Discrete in 2
TB2 5 Discrete out 2
(All models) 6 Channel 6 flow
7 Channel 5 flow
8 Digital ground
9 RS232 receive
10 RS232 transmit
11 Shield
12 Common
13 Discrete in 1
14 Discrete out 1
TB3 15 Analog output 4 +
(All models) 16 Analog output 3 +
17 Analog output 18 Analog output 19 Analog output 2 +
20 Analog output 1 +
Board Terminal Connection
21 Shield
22 Not Used
23 Not Used
TB4 24 Analog output 5 +
(Model 25 Analog output 6 +
775-_ _2 26 Analog output -
only) 27 Analog output -
28 Analog output 7 +
29 Analog output 8 +
30 Shield
Board Terminal Connection
TB5 1 Relay 3, normally open
(Models 2 Relay 3, common
775-_ _1 & 3 Relay 3, normally closed
775-_ _2 4 Relay 4, normally open
only) 5 Relay 4, common
6 Relay 4, normally closed
TB6 7 Relay 1, normally open
(Models 8 Relay 1, common
775-_ _1 & 9 Relay 1, normally closed
775-_ _2 10 Relay 2, normally open
only) 11 Relay 2, common
12 Relay 2, normally closed
Chapter 1 Introduction 3
CHAPTER 2: METER CALIBRATION
The 770MAX has been factory calibrated to meet its
specifications. It is not normally necessary to recalibrate unless extreme conditions cause out-ofspec operation shown by verification. Periodic
verification or calibration may also be necessary to
conform with QC requirements.
The 770MAX may be calibrated using high
precision resistance decade boxes, voltage source
and frequency generator with the following
procedures. This is intended only for installations
that have a policy of traceability to their own internal
standards. Standards equipment accuracies must
exceed the 770MAX specifications as required by
the applicable QC policy.
NOTE: This is an extensive process requiring 72
calibration points to fully cover all measurement
ranges of all parameters on all channels. It is
strongly recommended, where possible, to use
the Thornton 1875 Automatic Smart Calibrator Kit
which is supplied with a traceable certificate of
accuracy. It also enables printing out calibration
certificates for instruments it has calibrated. It is
supplied with its own instruction manual.
It is necessary to verify and/or calibrate only those
measuring circuits actually being used in the
installation. The following Adapters are needed to
interface with standards equipment:
leads—two for resistance and two for
temperature.)
4. On the 770MAX front panel, press Menus.
5. Press the up arrow key until “Go to: Calibrate”
is displayed. Press Enter.
6. Press the down arrow key to display “Go to:
Meter-Verify”.
7. Press Enter. The channel, parameter and range
identification are displayed.
8. Select the channel and measurement type to be
verified using Enter and up arrow.
(Measurement types are Res_
i
, Temp, Volts
and Freq.)
9. Enter the verification value from Table A at
“Input:__ “, including any unit multiplier, e.g. K,
M, etc.
10. Set the test equipment for exactly the same
verification value from Table A.
11. Allow the error value to fully stabilize and then
confirm that the resulting Error (in percent of
reading, except for voltage) is acceptable.
12. NOTE: Calibration is unnecessary if the error is
smaller than the limit of error of the standard or
of the 770MAX specification.
1000-82 resistance adapter for conductivity,
resistivity, temperature.
1000-79 voltage adapter for pH, ORP, pressure,
level.
1000-83 frequency adapter for flow.
Before attempting calibration, perform a verification
to determine if calibration is, in fact, necessary.
Verify at least one value for each internal range.
Recommended values are given in the table at the
end of the verification procedure.
VERIFICATION PROCEDURE
1. If the 770MAX outputs are connected for alarm
or control, set a hold time per steps 3-6 of the
calibration procedure in the next section. Press
Menus twice to exit.
2. Connect the appropriate adapter to the patch
cord of the channel to be verified.
3. Connect the adapter leads to the test
equipment. (The resistance adapter has four
13. Press Enter to reach the parameter/range field,
e.g. Res #_.
14. Press up arrow to go to the next range and
repeat steps 8-12 for the 3 remaining resistance
verification points.
15. Repeat steps 8-13 for the other channels to be
verified.
16. For the temperature range, repeat steps 2-14
but with the decade box connected to the
temperature leads of the conductivity adapter.
17. For the voltage range, repeat steps 2-15 with a
precision voltage source connected to Smart
voltage adapter 1000-79.
18. For the frequency range, repeat steps 2-15 with
a precision frequency generator producing a
i
The meter will display Res #1, Res #2, Res #3, or Res
#4. This is to accommodate a future feature. All of these
selections are equivalent: the meter will auto-range to the
correct measuring circuit regardless of the number
indicated.
4 Meter Calibration Chapter 2
0-3 V square wave connected to Smart
frequency adapter 1000-83.
point calibrations for all other measurements,
including temperature.
19. For frequency verification of channels 5 and 6,
connect the frequency generator directly to TB2
terminals 7 (+) and 6 (+) respectively and to
common, TB2 terminal 2 (-). Repeat step 18,
omitting the adapter.
20. Press Menus twice to exit.
Recommended Verification Points
Parameter
& Range
Res 4*
Res 3*
Res 2*
Res 1*
Temp
Volts 0.5 V -1.5 to +1.5 V
Freq 500 Hz 0.5 – 4000 Hz
*The 770MAX automatically selects the appropriate
measuring range for the resistance it detects.
Verification
Point
Range of
Measurement
100 Ω 0 – 700 Ω
2000 Ω 300 – 14,000 Ω
50,000 Ω 3750 – 175,000 Ω
1 MΩ 150,000 – 10 MΩ
1100 Ω 900 – 1500 Ω
CALIBRATION PROCEDURE
1. Connect the appropriate adapter to the patch
cord of the channel to be calibrated.
2. Connect its leads to the test equipment. (The
resistance adapter has four leads—two for
resistance and two for temperature.)
3. On the 770MAX front panel, press Menus.
4. Press the up arrow key until “Go to Calibrate” is
displayed, then press Enter.
5. Press the up arrow key to display “Go to: Meter”
and press Enter.
6. In “Hold time= 0
connected for alarm or control, enter a value
greater than the time in minutes needed to
complete calibration. Analog and relay outputs
will be held at their current status for that period
of time to prevent upset while off-line.
7. Press Enter. The channel, parameter and range
identification are displayed.
0 mins”, if meter outputs are
9. Press Page Down to display the CALIBRATE
METER screen with the reading and the
recommended calibration value.
10. Set the test equipment for the exact calibration
value.
ii
11. Press Page Down and wait for the calibration to
be performed.
12. Repeat steps 10 and 11 for additional
calibration points.
13. On completion, “METER CAL IS DONE” will be
displayed. Correct the date if necessary and
page up twice to the main calibration screen.
14. Set the channel, parameter, range and type for
the next calibration and page down.
15. Repeat steps 8-14 for the remaining ranges.
16. Repeat steps 1 and 8-15 for the other channels
to be calibrated.
17. For the temperature range, repeat steps 1-2
and 8-16 but with the decade box connected to
the temperature leads of the conductivity
adapter.
18. For the voltage range, repeat steps 1-2 and 816 with a precision voltage source connected to
Smart voltage adapter 1000-79.
19. For the frequency range, repeat steps 1-2 and
8-16 with a precision frequency generator
producing a 0-3 V square wave connected to
Smart frequency adapter 1000-83.
20. For frequency calibration of channels 5 and 6,
connect the frequency generator directly to TB2
terminals 7 (+) and 6 (+) respectively and to
common, TB2 terminal 2 (-). Repeat step 19,
omitting the adapter.
21. Press Menus twice to exit.
8. Select the channel and range to be calibrated
using Enter and up arrow. Select the calibration
Type (number of points). It is recommended to
do 3-point calibrations for resistance and 2-
Chapter 2 Meter Calibration 5
ii
Units manufactured prior to March 00, may give an
erroneous default resistance on one range of 2Ω whic h
should be changed in the display and in the decade box
setting to 200Ω.
Calibration Values
Point 1 Point 2 Point 3
Res #1
Res #2
Res #3
Res #4
Temp
Voltage 1.000V -1.000V -
Freq. 100.0 Hz 1000.0 Hz -
4.000MΩ 160.0KΩ 1.8MΩ
160.0KΩ 7000Ω 25.0KΩ
7000Ω 500.0Ω 2000Ω
500.0Ω 10.0Ω 200.0Ω
1000Ω 1400Ω
-
6 Meter Calibration Chapter 2
CHAPTER 3: ANALOG OUTPUT CALIBRATION
ANALOG OUTPUT CALIBRATION
This section describes calibration of the 0/4-20 mA
output signals. For startup information to scale the
range that the signal represents in engineering
units, see main Instruction Manual 84372, Chapter
4. Analog output signals are factory calibrated
within specifications but may be re-calibrated if
necessary.
The 770MAX analog output calibration is performed
by measuring the output signal when it is set to its
minimum (4 mA) and maximum (20 mA) limits and
entering the exact mA value into the instrument’s
display. The 770MAX automatically computes any
deviation from 4 and 20 mA and adjusts itself
accordingly. Verification of outputs is accomplished
through a diagnostic menu.
It is desirable to calibrate and verify when the
system receiving instrumentation is connected in
the circuit to present the approximate operating
load to the circuit. Maximum load is 500 ohms.
Calibration Procedure
7. Read the exact output current on the milliammeter and enter that precise value into the
“20 mA reads= 20.000” screen of the 770MAX
and press Page Down. (NOTE: For meters with
software version 2.5 or greater, at the “20mA
adjust=” screen, use arrow keys and re-adjust
% value displayed until milli-ammeter reads
20.000mA and press Page Down.)
8. Enter the date and press Page Down to save it.
9. Press page up twice and repeat steps 2 and 5-8
for the additional outputs.
10. Press Menus twice to exit and resume normal
measurement. The 770MAX automatically
computes any deviation from 4 and 20 mA and
adjusts itself accordingly.
11. Reactivate any system suspended in step 1.
ANALOG OUTPUT VERIFICATION
Analog outputs may be verified using the 770MAX
diagnostic menu and a milli-ammeter. The menu
allows setting the analog outputs to specific mA
values.
1. Disable or place in manual any control system
using the analog output signals since they will
be interrupted during calibration.
2. Connect a high precision milli-ammeter in
series with the analog output signal to be
calibrated. (See Chapter 1 for terminal
connections.)
3. Press Menus and Up arrow to display “Goto:
Calibrate”, and press Enter.
4. Press Up arrow to display, “Goto: Analog”, and
press Enter twice, (press Enter once for meters
with software version 2.5 or greater), passing
through the Hold Time screen.
5. Select the output signal # to be calibrated and
press Enter.
6. Read the exact output current on the milliammeter and enter that precise value into the
“4 mA reads= 4.0000” screen and press Page
Down. (NOTE: For meters with software version
2.5 or greater, at the “4mA adjust=” screen, use
arrow keys and re-adjust % value displayed
until milli-ammeter reads 4.000mA and press
Page Down.)
Verification Procedure
1. Disable or place in manual any control system
using the analog output signals since they will
be interrupted during verification.
2. Connect a high precision milli-ammeter in
series with the analog output signal to be
verified. (See Chapter 1 or terminal
connections.)
3. Press Menus and Down arrow to display, “Goto:
Diagnostic” and press Enter.
4. Use Up/down arrows if needed to display,
“Goto: Analog Output” and press Enter.
5. Using up/down arrows select the Analog Output
# to be verified and press Enter.
6. Using Up/down arrows set Output @ 4.00mA or
another level to be verified.
7. Press Page Down.
8. Measure the actual output on the milli-ammeter,
record the value and compare it with 770MAX
output specifications.
Chapter 3 Analog Output Calibration 7
9. Repeat steps 6 through 8 for 8, 12, 16 and
20mA.
10. Press Menus twice to exit
12. Reactivate any system suspended in step 1.
8 Analog Output Calibration Chapter 3
CHAPTER 4: UPGRADES
There is software for various functions located in
the 770MAX. The need for field upgrade is likely to
occur only with the Main Program and
Measurement software.
Optional relays and additional analog outputs can
be added in the field using the appropriate kits
described later in this chapter.
770MAX to computer RS232 port wiring
DB9 Connector to
computer (view of end
of cable that plugs into
computer)
5
9
MAIN AND MEASUREMENT
SOFTWARE UPGRADE
For software upgrades, refer to upgrade kits: 91006
Upgrade Tools (one kit per site) and 91007
Upgrade Components (one kit per instrument) and
their instructions 84551. For reference, the
connections to the 770MAX RS232 port are given
below. If the computer has a 25-pin connector, on
that connector, pin 7 connects to Ground, pin 3
connects to Receive, and pin 2 connects to
Transmit. Software upgrade kits may only be used
in an instrument with main software revision 3.0 or
higher.
1
2
3
4
5
6
7
8
9
10
1
6
770MAX
TB2 terminals
Ground
Receive
Transmit
OUTPUT UPGRADES
Relays and additional analog outputs may be added
with circuit boards to an existing 775-_A0
Instrument (which has no option board already
installed). Kit 1000-91 adds 4 SPDT relays to
convert an instrument to model 775-_A1. Kit 100092 adds 4 SPDT relays and 4 additional analog
outputs, to convert an instrument to model 775-_A2.
CAUTION: Adding these outputs restricts
operating conditions:
Kit 1000-91 lowers the maximum ambient
temperature rating to 104°F (40°C) when
operating on 230 VAC power.
Kit 1000-92 lowers the maximum ambient
temperature rating to 104°F (40°C) on 115 VAC
power and cannot be used above 130 VAC. This
kit may only be installed in an instrument with
main software revision 1.5 or higher.
Chapter 4 Upgrades 9
Output Kit Installation Procedure
1. Disconnect power wiring and unplug all input
and output connections from the unit, labeling
the location of each plug-in connector for use in
re-installation.
2. Peel off the rear face terminal identification
label and replace it with the label supplied in the
kit which will have additional cutout(s).
3. Loosen the two front cover screws—they are
captive and will be retained in the cover.
4. Lift the front cover off the instrument and unplug
the keypad ribbon cable from the front circuit
board.
5. Carefully slide the entire assembly of circuit
boards out of the case onto a static-free
surface.
6. As shown in the exploded view in Chapter 1:
Introduction, align the new output option circuit
board with the large dual connector at the
bottom back, between the power supply and
measurement boards. Carefully plug it into the
back of the main circuit board.
7. Carefully align the entire circuit board assembly
so each circuit board keys into its respective
slot in the case and slide it in. Some flexing
may be necessary to assure complete
installation. The terminal blocks must fit into the
cutouts to be flush with the back of the case.
8. Plug the front cover keypad ribbon cable back
onto the display circuit board pins.
9. Replace the cover back onto the instrument and
tighten the two cover screws.
10. Mark the instrument identification label with the
appropriate model number: replace the final “0”
in 775-_A0 with a “1” if using 1000-91 or with a
“2” if using 1000-92.
11. Reinstall the existing wiring plugs to respective
receptacles and add connections to the new
outputs as required.
10 Upgrades Chapter 4
CHAPTER 5: TROUBLESHOOTING
ON-LINE ERROR MESSAGES
The following messages can appear in the “Go to:
Messages” menu to indicate error conditions or
problems with reading sensors. This menu area
should always be checked first when an operating
problem is encountered.
1. "Measure PCB failed" – hardware failure.
2. "No sensor on chan"
3. "Invalid sensor type"
4. "Sensor checksum err"
5. "Sensor const bad" – the sensor multiplier or
adder factor may be wrong.
6. "Invalid pipe ID"
7. "Invalid tank height"
8. "Invalid channel" – the selected channel is
wrong for the desired measurement (i.e.
%Rejection, ratio, etc.).
9. "Res sensor open" – patch cord or sensor cable
may be bad.
10. "Res sensor shorted" – patch cord or sensor
cable may be bad.
11. "Compensate error" – wrong compensation
method selected or conductivity may be too
high for this compensation method.
12. "Temp out of range"
13. "Unable to measure R" – unable to measure
resistance of sensor (air bubble, dry cell, etc.).
14. "Invalid max PSI"
23. "Range may be wrong" – measurement may
have a wrong range (i.e. set for S/cm instead of
uS/cm).
24. "Invalid setpoint #"
25. "Reference volts bad" – for pressure sensors
this is a bad sensor.
26. "Flow rate is 0" – the flow rate is zero gpm so
the calculated measurement is zero or over
range.
27. "Bad meter calibrate" – a meter calibration
factor is bad, should recalibrate.
28. "A/D over range" – the A/D convert reported an
error, may be a defective measurement board.
29. "Unknown error #xxxx"
“LSC is Locked” could appear in the startup screen
and indicates that internal local serial channel
communication has halted. This could be caused by
loose internal connections. Re-seat all circuit board
and ribbon cable connectors and re-power the
instrument. If the message persists, factory service
will be required.
NOTE: When a 500TOC Sensor is connected to a
770MAX instrument, the ‘Messages’ menu area will
appear different. There will be three options shown
on the message display; 1-Current Messages, 2Messages History, and 3-Clear History. There may
be Error and Fault messages specific to the
5000TOC Sensor within these menu options. Refer
to the 5000TOC operations manual, 84445 for
detailed information regarding Error and Fault
messages specific to the 5000TOC Sensor and the
use of these menus.
15. "Invalid tank area"
16. "Unknown measurement"
17. "Too big to display" – the measurement is too
large to be displayed.
18. "Total flow over" – total flow has reached the
upper limit.
19. "Temperature high"
20. "Voltage over range" – the voltage from the
sensor (pH, pressure) is too high (bad sensor).
21. "Invalid max GPM"
22. "Check TDS factor"
Chapter 5 Troubleshooting 11
SENSOR TROUBLESHOOTING
Temp. Compensated Measurements
Temperature compensated measurements such as
conductivity/resistivity and pH require the
temperature signal from the sensor to be within
range or the compensated measurement will
display asterisks. If the temperature signal has
failed or is not available, operation can be
continued by changing the temperature source
(under the Measurements menu) to a fixed value or
to use the temperature signal from another channel
that is also correct for this measurement. In some
cases, using temperature from another channel
may be desirable anyway, to obtain a faster
responding or more accurate temperature signal.
“Raw” Sensor Signals
Direct reading of the sensor output is available from
the “Measurements” menu. It gives “raw” readings
in base units, e.g. Hz for flowrate. It is not adjusted
with calibration factors, temperature compensation,
etc. and is helpful in finding the cause of erroneous
readings.
To view the “raw” reading, press Menus and select
the desired measurement. Page down to the last
normal screen (indicated by disappearance of the
down arrow in the lower right corner), then page
down one more to see “Raw reading from the
sensor= XXXXX XX” plus identification of channel
(and internal range for resistivity).
Smart Sensors
Select a channel to view the raw sensor data
(actual voltage, ohms, etc.).
Analog Output
Select an output to test, and then enter a current
value (milliamps) to send out the analog output then
press Page Down to set. Repeat test with a second
current value to verify range response.
Serial Port
On back of meter, use a jumper wire to connect
TB2 terminals 9 and 10 then press Enter to begin
test.
OFF-LINE DIAGNOSTICS
The Diagnostic Menu is used to run a series of offline automated diagnostic testing routines to verify
the operation of system components, including:
meter, sensors, analog output, serial port, network,
display, keypad, flow channels, inputs and outputs.
NOTE: Some diagnostic tests may interrupt normal
operation (such as analog outputs).
To access the Diagnostic Menu:
1. Press Menus.
2. Press the up arrow key until the Diagnostic
Menu is displayed, and then press Enter.
3. Use the up/down arrow keys to select a test,
then press Enter. The indicated test will be
performed and the results displayed.
4. To test another component, press Page Up to
return to the Diagnostic Menu and select the
next component.
5. After completing the desired diagnostics, press
Menus twice to exit the menu system and
return to display mode.
See the appropriate section below for information
regarding the specific diagnostic tests.
Network
Diagnostic not currently available.
Display
An automated sequence will test the display of all
characters (alpha, numeric and symbol). Press
Enter to stop the test.
Keypad
Press any key to test its response; the correct name
of the key should be displayed. Press Menus twice
to exit this test.
Flow Channels
Diagnostic not currently available.
Inputs
The level of the input lines (high or low) will be
displayed and updated every second.
Outputs
Set the outputs low or high for testing. Press 1 to
set low or 2 to set high.
Meter Tests
Use to test the timers, ROM checksum, and RAM.
Tests are performed sequentially, press Enter to
perform next test.
12 Troubleshooting Chapter 5
Self Tests
An automated series of tests will check the
operation of the following components:
• Smart sensors
• Analog outputs
• Discrete outputs
• Discrete Inputs
• Network
• Display circuit board
• Measurement circuit board
• Options circuit board
• Other circuits (ROM, RAM, etc.)
The display shows how many tests have run, the
elapsed time and the number of errors found. Press
Menus to stop the test sequence.
Chapter 5 Troubleshooting 13
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