The EXA analyzer contains devices that can be damaged by electrostatic discharge. When servicing
this equipment, please observe proper procedures to prevent such damage. Replacement components
should be shipped in conductive packaging. Repair work should be done at grounded workstations using
grounded soldering irons and wrist straps to avoid electrostatic discharge.
Installation and wiring
The EXA analyzer should only be used with equipment that meets the relevant IEC, American or
Canadian standards. Yokogawa accepts no responsibility for the misuse of this unit.
The Instrument is packed carefully with shock absorbing materials, nevertheless, the instrument may be
damaged or broken if subjected to strong shock, such as if the instrument is dropped. Handle with care.
Although the instrument has a weatherproof construction, the transmitter can be harmed if it becomes
submerged in water or becomes excessively wet.
Do not use an abrasive or solvent in cleaning the instrument.
Notice
• This manual should be passed on to the end user.
• The contents of this manual are subject to change without prior notice.
• The contents of this manual shall not be reproduced or copied, in part or in whole, without permission.
• This manual explains the functions contained in this product, but does not warrant that they are suitable
the particular purpose of the user.
• Every effort has been made to ensure accuracy in the preparation of this manual.
However, when you realize mistaken expressions or omissions, please contact the nearest Yokogawa
Electric representative or sales office.
• This manual does not cover the special specifications. This manual may be left unchanged on any
change of specification, construction or parts when the change does not affect the functions or
performance of the product.
• If the product is not used in a manner specified in this manual, the safety of this product may be
impaired.
Yokogawa is not responsible for damage to the instrument, poor performance of the instrument or losses
resulting from such, if the problems are caused by:
• Improper operation by the user.
• Use of the instrument in improper applications
• Use of the instrument in an improper environment or improper utility program
• Repair or modification of the related instrument by an engineer not authorized by Yokogawa.
Safety and Modification Precautions
• Follow the safety precautions in this manual when using the product to ensure protection and safety of
the human body, the product and the system containing the product.
The following safety symbols are used on the product as well as in this manual.
This symbol indicates that an operator must follow the instructions laid out in this manual in order to
avoid the risks, for the human body, of injury, electric shock, or fatalities. The manual describes what
special care the operator must take to avoid such risks.
DANGER
IM 12J05D02-01E
This symbol indicates that the operator must refer to the instructions in this manual in order to prevent
WARNING
CAUTION
the instrument (hardware) or software from being damaged, or a system failure from occurring.
This symbol gives information essential for understanding the operations and functions.
This symbol indicates Protective Ground Terminal
This symbol indicates Function Ground Terminal (Do not use this terminal as the protective ground
terminal.)
This symbol indicates Alternating current.
This symbol indicates Direct current.
Warranty and service
Yokogawa products and parts are guaranteed free from defects in workmanship and material under
normal use and service for a period of (typically) 12 months from the date of shipment from the manufacturer. Individual sales organizations can deviate from the typical warranty period, and the conditions of
sale relating to the original purchase order should be consulted. Damage caused by wear and tear, inadequate maintenance, corrosion, or by the effects of chemical processes are excluded from this warranty
coverage.
In the event of warranty claim, the defective goods should be sent (freight paid) to the service department of the relevant sales organization for repair or replacement (at Yokogawa discretion). The following
information must be included in the letter accompanying the returned goods:
• Part number, model code and serial number
• Original purchase order and date
• Length of time in service and a description of the process
• Description of the fault, and the circumstances of failure
• Process/environmental conditions that may be related to the installation failure of the device
• A statement whether warranty or non-warranty service is requested
• Complete shipping and billing instructions for return of material, plus the name and phone number of a
contact person who can be reached for further information.
Returned goods that have been in contact with process fluids must be decontaminated/disinfected before
shipment. Goods should carry a certificate to this effect, for the health and safety of our employees.
Material safety data sheets should also be included for all components of the processes to which the
equipment has been exposed.
IM 12J05D02-01E
Introduction 1-1
WARNINGWARNING
Made in Japan
MODEL
SUFFIX
SUPPLY
OUTPUT
No.
STYLE
DO402G
115VAC
50/60Hz MAX.10VA
0-20mADC or 4-20mADC
1. INTRODUCTION AND GENERAL DESCRIPTION
The Yokogawa EXA is a 4-wire coverter designed for industrial process monitoring, measurement and
control applications. This instruction manual contains the information needed to install, set up, operate
and maintain the unit correctly. This manual also includes a basic troubleshooting guide to answer typical user questions.
Yokogawa can not be responsible for the performance of the EXA analyzer if these instructions are not
followed.
1-1. Instrument Check
Upon delivery, unpack the instrument carefully and inspect it to ensure that it was not damaged during
shipment. If damage is found, retain the original packing materials (including the outer box) and then
immediately notify the carrier and the relevant Yokogawa sales office.
Make sure the model number on the textplate affixed to the top of the display board of the instrument
agrees with your order.
The textplate will also contain the serial number and power supply selection.
Be sure to apply correct power to the unit.
Figure 1-1. Nameplate example
Check that all the parts are present, including mounting hardware, as specified in the option codes at the
end of the model number. For a description of the model codes, refer to Chapter 2 of this manual under
General Specifications.
Basic Parts List: Converter EXA 402
Instruction Manual (See model code for language)
Optional mounting hardware when specified (See model code)
IM 12J05D02-01E
IM 12J05D02-01E
1-2 Introduction
1-2. Application
The EXA converter is intended to be used for continuous on-line measurement in industrial installations.
The unit combines simple operation and microprocessor-based performance with advanced self-diagnostics and enhanced communications capability to meet the most advanced requirements. The measurement can be used as part of an automated process control system. It can also be used to indicate
dangerous limits of a process, to monitor product quality, or to function as a simple controller for a dosing/neutralization system.
Yokogawa designed the EXA analyzer to withstand harsh environments. The converter may be installed
either indoors or outside because the IP65 (NEMA 4X) housing and cabling glands ensure the unit is
adequately protected. The flexible polycarbonate window on the front door of the EXA allows pushbutton access to the keypad, thus preserving the water and dust protection of the unit even during routine
maintenance operations.
A variety of EXA hardware is optionally available to allow wall, pipe, or panel mounting. Selecting a proper installation site will permit ease of operation. Sensors should normally be mounted close to the converter in order to ensure easy calibration and peak performance. If the unit must be mounted remotely
from the sensors, WF10 extension cable can be used up to a maximum of 50 metres (150 feet) with a
BA10 junction box.
The EXA is delivered with a general purpose default setting for programmable items. (Default settings
are listed in Chapter 5 and again in Chapter 10). While this initial configuration allows easy start-up, the
configuration should be adjusted to suit each particular application. An example of an adjustable item
is the type of temperature sensor used. The EXA can be adjusted for any one of four different types of
temperature sensors.
To record such configuration adjustments, write changes in the space provided in Chapter 10 of this
manual. Because the EXA is suitable for use as a monitor, a controller or an alarm instrument, program
configuration possibilities are numerous.
Details provided in this instruction manual are sufficient to operate the EXA with all Yokogawa sensor
systems and a wide range of third-party commercially available probes. For best results, read this manual in conjunction with the corresponding sensor instruction manual.
Introduction 1-3
1-3. General information
Flexibility, reliability and low maintenance are among the benefits provided by the EXA DO402G dissolved oxygen analyzer. Designed to meet the exacting requirements of measuring dissolved oxygen in
the modern industrial environment, it contains many features to ensure the best precision whatever the
application.
This 4-wire converter is housed in a robust IP65 field mountable case. Two mA outputs, four relays, digital communication and a clear LCD make the DO402G a truly comprehensive package.
The DO402G features PI control on both the auxiliary mA output and the pulse proportional relay outputs, thus avoiding the need for a separate controller.
The famous EXA sensor diagnostics are now expanded with a logbook facility in combination with the
RS485 two wire communication software option. This can be used to record events like calibration and
diagnostic messages, and to update configuration of the converter remotely.
The DO402G accepts inputs from both galvanic and polarographic sensors. Percent saturation, mg oxygen/l water, and ppm DO can be displayed and transmitted. Compensation for atmospheric pressure
altitude, salinity and temperature are included for the best accuracy of measurement.
Features
• Simple 3 Ievel operation
• Display mg/l, ppm, % saturation
• Air calibration or saturated water calibration
• Chloride concentration compensation can be programmed
• Automatic temperature compensation
• Built-in barometric air pressure compensation
• “Hold” function enables fixed output signal during maintenance
• Two separate mA output signals
• Wide flexibility incorporating free programmable range settings, selection of output signals and alarm
functions
• Analog output with adjustable damping time
• Password protection for each programming level
• Built-in wash timer with remote start possibility
• IP65 weather protection
• Universal mounting possibilities
• Sensor diagnostics
• RS 485 bi-directional communication
• Logbook via RS 485 link
• PI control on mA and pulsed contact controls
Method of operation
The EXA DO30 operates on a galvanic cell principle.
The sensor contains a measuring cell consisting of a silver cathode and a lead anode. The voltage generated by this electrode pair is sufficient to generate a spontaneous reduction of oxygen at the cathode,
so no external voltage source for this reaction is required. The electrodes are immersed in an electrolyte
containing potassium hydroxide. Oxygen molecules can pass through a permeable membrane into the
cell. The output current of the cell is directly related to the partial pressure of oxygen at the sample side.
In the sensor a thermistor is integrated to be able to correct for temperature changes. Both signals are
used in the converter to ensure an automatically compensated value for dissolved oxygen. Calibration
is worked out by simple air calibration to make sure that the performance of the instrument will be maintained.
Display functions and ranges
The display continuously gives you all necessary information at a glance. The process values are shown
in easily readable programmable units. Either mg/l. % saturation or ppm can be chosen.
The user-interface is simplified to a basic set of 6 keys accessible through the flexible window cover. It
uses a simple step by step, question and answer style to communicate with the operator by giving messages on the second line of the display and indicating which keys are to be pressed in the display.
IM 12J05D02-01E
IM 12J05D02-01E
1-4 Introduction
Automatic air calibration
Calibration for a dissolved oxygen instrument is performed by simple air calibration.
Criteria for automatic calibration (stabilization time, DO values) can be set to suit the sensor.
In addition to the air calibration three additional calibration procedures can be used:
1. Span calibration using air saturated water
2. Zero calibration using sulfite saturated water
3. Process calibration using laboratory reference method
Alarm and control functions
The EXA D0402 has four built-in relay contacts. From the factory the first two contacts are pre-defined
as a high or low alarm.
The third contact its pre-defined as a wash contact. This wash contact is driven by a wash-timer with
adjustable wash-time, interval time and relaxation time to control the wash cycle.
The fourth contact is fixed to function as an alarm, indicating that the EXA has found a fault in the measuring loop. FAIL safe.
Cleaning
ln combination with the appropriate sensor and immersion type fitting the wash timer with remote start
possibility can be used. Interval-time, washing time and relaxation time are free programmable.
Damping time on output signal
Under certain circumstances disturbances can cause high peaks in the output signal. To avoid these disturbances the EXA DO402 has an electronic filtering which averages the output signal during a programmable period. This damping time is programmable between 0 and 120 seconds.
Salinity compensation
In order to take the effect of salinity into account for oxygen measurement an average chloride concentration can be programmed. The chloride concentration value is set manually via the service level. The
EXA D0402 takes account of the effects of salinity and temperature simultaneously. The advantage of
this construction is that the result of the measurement is available immediately. A separate conversion
table is not necessary.
Temperature compensation
The micro-processor makes an accurate temperature compensation possible that performs well over the
entire range of the instrument. No further adjustment tables are required.
Barometric air pressure compensation
Air pressure differences, due to weather conditions or altitude, can cause a variation up to 20 % in the
dissolved oxygen concentration. A built-in air pressure sensor automatically compensates for barometric
influences between 900 to 1100 mbar (90 to 110 kPa).
Sensor diagnostics
The DO sensor is checked for low impedance between the silver electrode and an earth contact in
the liquid, to detect membrane integrity. Temperature sensor connections and sensor connections are
checked for impedance. These faults are signalled by the FAIL contact and can be signalled to the control room by an output of 0/3.5 mA or 22 mA. The fault is also signalled by a special marker held on the
display, a LED on the front and an error code in the message display.
During calibration of a DO measuring system the slope deviation from nominal value (%) and sensor output (µA) at 0 mg/l are calculated and checked.
If any of these are outside the limits, an error is signalled.
Logbook
Software record of important events and diagnostic data. Available through RS485, for use with the
Yokogawa PC402 communication software.
Serial Communication
Bi-directional according to the EIA-485 standard using HART-protocol and PC402 software.
Introduction 1-5
1-4. Configuration checklist for DO402
Standard configuration Options Reference for change
Measured variable(s)
Primary inputs D.O. and Temp
DO range 0- 20 mg/l any span within 0-50 mg/l “range”
DO units mg/l ppm. % saturation code 56
Temperature range 0- 50 °C 25 °C minimum span “range”
Temperature unit Celsius Fahrenheit code 11
Outputs
Analog output 4- 20 mA for DO 0-20 mA or 4-20 mA code 30
Second output 4- 20 mA for Temp 0-20 mA or 4-20mA code 30
Output allocation DO and Temp DO, Temp, Table, Pl control code 31
Contact outputs S1= high at 19.5 mg/l (4) freely programmable “setpoint”
S2= low at 1.0 mg/l code 40. 41, 42, 43
Contact allocation mg/l and FAIL mg/l, temp, wash, Pl control, HOLD code 40- 43
Contact variables dead time= 0.2 s; hyst= 0.1 mg/l time: 0- 200 s; hyst 0- 20 mg/l code 44
Add. contact functions none time out alarm code 47
Control functions none Pl on contacts or mA2 output code 45, 46, 34 33
Digital outputs none RS485 code 60
Communication
Digital interface disabled RS485 code 60
Communication software disabled PC402 contact factory
Variables on display mg/l and temp %sat, °C, mA1, mA2, SL, ZR, REL “display”
Burn out disabled burn low (3.5)/ high (22) on mA1/ mA2 code 32
Password protection disabled for mains/ comm./ serv level code 52
Autoreturn return to measure in 10 minutes enable or disable code 50
Add. functions in MAINT disabled wash start/ setpoint adj code 51
Diagnostics
Membrane condition active enable or disable code 02
Check on Slope active enable or disable code 02, 22
Check on zero disabled enable or disable code 02, 21, 22
Check on stability 0.05 mg/l per 60 s 0-50 mg/l in 10-600 s code 20
Compatibility
DO sensor DO30 DOX8, DO410, Ingold code 01, 10
Temperature sensor Pt1000 Pt 100, 22k NTC, PB36 code 10
Membrane thickness 50 µm ( 2 mil) 25 or 50 µm (1 or 2 mil), adj. slope code 01
Sensor principle galvanic galvanic or polarographic code 01, “wiring”
Manual temp. comp. disabled disable or enable code 13
Special Features
Salinity compensation disabled comp. for 0- 100 ppt NaCI code 04
Temperature calibration none adjustment +/- 7.5 °C code 12
Zero calibration disabled disable or enable code 21
Sensor washing disabled
HOLD during maintenance disabled hold last or hold fix “Hold”
Contact during HOLD disabled possible on S1,S2, S3 or S4 code 40-42
Atm. press. compensation active active or manual
Soft fail alarm disabled
Logbook disabled 2 volumes of 50 events code 61,62
interval < 36 hours, wash time 0.1-10 min.
possible for E1..E4, E7..E9, E12, E16, E22
“Wash”
code 53
IM 12J05D02-01E
1-6 Introduction
1-5. System Configuration
1-5-1. Dissolved Oxygen Sensor
The DO402G can be used with a variety of sensors. Some specific programming may be necessary to
match the converter with the sensor.
a. Model DOX8SM sensor
This sensor is a galvanic sensor with a PB36 type temperature compensator and a 25 micron
membrane (1 mil).
This sensor has a nominal output current of 7.5µA in ambient air under reference conditions. In
Service code 01 selection 1 must be programmed when this sensor is used. The membrane check
is inactive with this sensor unless external solution ground is used. ( metal holder or sample line )
b. Model DO30G sensor
This sensor is essentially the same as the DOX8SM sensor, but it has a 50 micron membrane,
fixed sensor cable, Pt1000 RTD temperature compensation and integral solution ground that allows
membrane checking. The nominal output of this sensor is 3.75 µA in air under reference conditions.
In Service item ”*I.CELL” selection 0 must be programmed when this sensor is used.
For details, refer to GS12J05D03-01E.
c. Model DO30 sensor
This sensor is specified in GS12J6K4 and it can be supplied with 50 or with 25 micron membrane.
Normally 50 micron membrane is used and no reprogramming is necessary. Otherwise Service
code 01 setting must be changed from 0 to 1.
d. Ingold model 32 sensors with 12, 19 and 25 mm shaft
These sensors are available in many different configurations. The sensor is a polarographic sensor
and therefore settings of service code 01 has to be changed from 0 to 1.
The sensor output is normally between 30 and 100 nA in ambient air under reference conditions,
but the “large cathode” version has a current output between 200 and 700 nA. To utilize Slope
diagnostic features, it is best to read current output during first air calibration in “display” mode and
to enter that value in service code 01.
The temperature compensator is a NTC resistance and that can be chosen by entry of 3 in code 10.
The wiring of the sensor is different as well:
The red wire: the anode goes to terminal 18
The white wire: the cathode goes to terminal 17
The green/yellow wire: the shield goes to terminal 14 and the 2 black wires for NTC go to terminal
11 and 12.
The membrane checking feature cannot be used for these sensors, due to the construction of the
sensor.
1-5-2. The holders
a. PB30 floating ball holder
All Yokogawa sensors are compatible with the floating ball holder that is specified in GS12J6K4
and GS12J5A1.
b. FD30 immersion fitting
The DO30 sensor is compatible with the FD30 immersion holder as specified in GS12J6K4 and with
all flow fittings and flow fitting subassemblies that are specified in GS12D7K2.
c. DOX8HS submersion type holder
The DOX8SM and the DO30G sensor are compatible with the DOX8HS holder and all PH8 model
holders.
IM 12J05D02-01E
2. DO402G SPECIFICATIONS
2-1. General
A. Input specifications
: The DO402G Dissolved Oxygen
converter measures the current, that is generated by the
Dissolved Oxygen sensor. The
flexibility of the input circuit
allows the use of many commercially available sensors,
whether they are of the Galvanic
type (driving voltage generated
internally) or Polarographic type
(driving voltage supplied by converter)
The input range varies from
0.0 nA up to 500 nA for polarographic sensors and 0.0 to
50 µA for galvanic sensors.
Temperature measurement for
automatic temperature compensation utilizes Pt100, PT1000
RTD elements or PB36 as used
in DOX8 and DO30 sensors, as
well as the 22 k NTC as used by
the Hamilton Oxyferm.
mA DC with common negative. Maximum load 600 Ohm.
Auxiliary output can be chosen
from Temperature, DO, PI control, table, burn up (22 mA) or
burn down (0 or 3.5 mA) to signal failure
: 300 %
: 50 ºC (122 ºF)
Specification 2-1
E. Temperature compensation
: 0- 50 ºC
Sensor types: Pt100 or Pt1000
RTD; PB36 (Yokogawa compatible);
22 k NTC (Ingold compatible)
Automatic or Manual temperature compensation
F. Calibration
: Semi-automatic calibration with
automatic compensation for
influence of barometric pressure
and altitude on partial pressure
of oxygen in air (or solubility
of oxygen in water). Automatic
compensation for influence of
salinity of water on solubility of
oxygen in water is programmable.
The correction for pressure,
salinity and temperature meets
ISO 5814
Possible calibration routines are:
- Slope (span) calibration in
ambient air. The calibration
table is based on 70 % RH and
is determined empirically.
- Slope (span) calibration in- Slope (span) calibration in
water, saturated with air:
according ISO 5814
- Zero calibration (normally inactive)
G. Serial Communication
: Bi-directional according to the
EIA-485 standard using HART
protocol and PC402 software.
H. Logbook
: Software record of important
events and diagnostic data.
Available through RS485, with
key diagnostic information available in the display.
I. Display
: Custom liquid crystal display,
with a main display of 31/2 digits
12.5 mm high. Message display
of 6 alphanumeric characters, 7
mm high.
IM 12J05D02-01E
IM 12J05D02-01E
2-2 Specification
J. Contact outputs
- General : Four (4) SPDT relay contacts
with LED indicators. For S1,
S2, and S3, the LED is on
when relay is powered.
NOTE:
For S4 (FAIL) LED lights when
power is removed (Fail safe).
Contact outputs configurable
for hysteresis and delay time.
- Switch capacity
: Maximum values 100 VA,
250 V AC, 5 Amps.
Maximum values 50 Watts,
250 V DC, 5 Amps.
- Status : High/Low process alarms,
selected from process
parameters and temperature.
Contact output is also available
to signal “Hold Active”
- Control function
: On/Off
PI pulsed Proportional duty cycle control
with integral term.
PI frequency Proportional frequency control
with integral term. In addition
wash cleaning control signal on
S3, and FAIL alarm for system
and diagnostic errors on S4
K. Contact input : Remote wash cycle start.
L. Power supply
Supply voltage rating
: 100, 115, 230 VAC
Applicable range
: �5 to 115, ��.� to 132.2, �5 to 115, ��.� to 132.2,�5 to 115, ��.� to 132.2,
1�5.5 to 264.5 VAC
Supply frequency rating
: 50 / 60 Hz
Applicable range
: 50 Hz ± 5% / 60 Hz ± 5%
Power consumption
: Maximum 10 VA for steady
operation
M. Safety and EMC conforming standards
Safety : conforms to EN 61010-1,
CSA C22.2 No.1010.1 certified
EMC : conforms to EN61326 Class A
(Note 1), EN61000-3-3 ,
AS/NZS CISPR 11
Category based on IEC 61010: II (Note 2)
Pollution degree based on IEC 61010:2 (Note
2)
Installation altitude: 2000 m or less
Note 1:
Note 2:
N. Shipping details
: Package size w x h x d
2-2. Operating specifications
A. Performance : DO (at t process = 25 °C)
- Linearity : ± 0.03 mg/l or ± 0.5%FS,
- Repeatability: ± 0.03 mg/l or ± 0.5%FS,
- Accuracy : ± 0.05 mg/l or ± 0.5%FS,
B. Performance : Temperature (Pt1000, PB36,
22kNTC)
- Linearity : ± 0.3 ºC
- Repeatability : ± 0.1 ºC
- Accuracy : ± 0.3 ºC
Performance : Temperature (Pt100)
- Linearity : ± 0.4 ºC
- Repeatability : ± 0.1 ºC
- Accuracy : ± 0.4 ºC
Note on performance specifications:
The specifications are expressed with sim-
ulated inputs, because the DO402G can
be used with many different sensors with
their unique characteristics.
The following tolerance is added to above
performance.
mA output tolerance : ± 0.02 mA of
"0/4 - 20 mA"
Digital display tolerance : +1 digit
C. Response time
0- �0% : 10 s
D. Ambient operating temperature
: -10 to +55 �C (14 to 131 ºF)�C (14 to 131 ºF)C (14 to 131 ºF)
This instrument is a Class A product,
and it is designed for use in the
industrial environment. Please use
this instrument in the industrial
environment only.
Installation category, called overvoltage category, specifies impulse
withstand voltage. Category II is for
electrical equipment.
Pollution degree indicates the degree
of existence of solid, liquid, gas or
other inclusions which may reduce
dielectric strength. Degree 2 is the
normal indoor environment.
2�0 x 300 x 2�0 mm.
11.5 x 11.� x 11.5 in.
Packed weight approx.
2.5 kg (5lb).
whichever is greater
whichever is greater
whichever is greater
Specification 2-3
E. Storage temperature
: -30 to +�0 �C (-22 to 15� ºF)�C (-22 to 15� ºF)C (-22 to 15� ºF)
F. Humidity : 10 to �0% RH non-condensing
G. Housing
Case : Cast aluminium with chemically
resistant coating
Cover : flexible polycarbonate window.
Case color : off-white
Cover color : moss green.
Cable entry :
Cable terminals:
via six Pg13.5 nylon glands.
for up to 2.5 mm2 finished wires.
Protection : weather resistant to IP65 /
NEMA 4X / CSA Type 3S
standards.
Mounting : Pipe, wall or panel, using
optional hardware.
H. Data protection
:
Non volatile memory for
configuration and logbook, and
lithium battery for clock support.
Pipe, wall mounting
bracket (Stainless steel)
Panel mounting bracket
(Stainless steel)
Hood for sun protection
(Carbon steel)
Hood for sun protection
(Stainless steel)
Stainless steel tag plate
G 1/2
1/2 NPT
Epoxy baked finish (*1)
*1 The housing is coated with epoxy resin.
J. Automatic safeguard
: Return to measuring mode
when no keystroke is made
for 10 min.
K. Power interruption
:
Less than 50 milliseconds no
effect.
L. Operation protection
:
3-digit programmable password.
IM 12J05D02-01E
Installation and wiring 3-1
184
144
72
20
144
220
23
112
Four M6 screws, 8 (0.31) deep
80
80
3636
36
38
ABC
D
EF
□ Hood (optional)
Option code : /H
□
Cable inlet port (21 (0.83) dia. holes)
DIN PG13.5 cable gland
Ground terminal
(M4 screw)
Weight: Approx. 2 kg
A : Spare (can be used for contact input separately)
B : For sensor cable
C : For output signal
D : For contact output (S3 and S4)
E : For contact output (S1 and S2)
F : For power supply
Adaptor for conduit work
(option code : /AFTG, /ANSI)
Unit: mm (inch)
Approx. 55
Adaptor
G 1/2 female ( / AFTG)
1/2 NPT female ( / ANSI)
49
(7.24)
(8.66)
(3.15)
(3.15)
(1.93)
(2.17)
(5.67)
(5.67)
(2.83)
(0.79)
(0.91)
(4.41)
(1.42)
(1.42)
(1.42)
(1.50)
WARNINGWARNING
3. InstallatIon and WIrIng
3-1. Installation and dimensions
3-1-1. Installation site
This instrument is a Class A product, and it is designed for use in the industrial environment. Please use
this instrument in the industrial environment only.
The EXA converter is weatherproof and can be installed inside or outside. It should, however, be
installed as close as possible to the sensor to avoid long cable runs between sensor and converter. In
any case, the cable length should not exceed 50 meters (162 feet). Select an installation site where:
• Mechanical vibrations and shocks are negligible
• No relay/power switches are in the direct environment
• Access is possible to the cable glands (see figure 3-1)
• The converter is not mounted in direct sunlight or severe weather conditions
• Maintenance procedures are possible (avoiding corrosive environments)
The ambient temperature and humidity of the installation environment must be within the limits of the
instrument specifications. (See chapter 2).
3-1-2. Mounting methods
Refer to figures 3-2 and 3-3. Note that the EXA converter has universal mounting capabilities:
• Panel mounting using optional brackets
• Surface mounting on a plate (using bolts from the back)
• Wall mounting on a bracket (for example, on a solid wall)
• Pipe mounting using a bracket on a horizontal or vertical pipe (maximum pipe diameter 50 A)
Figure 3-1. Housing dimensions and layout of glands
Figure 3-4. Internal view of EXA wiring compartment
• Never apply power to the DO402G converter and other instruments connected to the DO402G
converter until all wiring is completed.
• This product complies with the CE marking and CSA certified.
Where compliance with the CE marking and relevant standard is necessary, the following wiring is
required.
1. Install an external switch or circuit breaker to the power supply of the DO402G converter.
2. Use an external switch or circuit breaker rated 5A and conforming to IEC 60947-1 or IEC 60947-3.
3. It is recommended that the external switch or circuit breaker be installed in the same room as the
DO402G converter.
4. The external switch or circuit breaker should be installed within reach of the operator and identified
with marking as a power supply switch to the DO402G converter.
5. Power lines such as power cables and contact outputs should be fixed securely onto a wall or
construction using cable racks, conduit tubing, nylon bands or other appropriate ways. Accidental
removal from terminals by pulling may result in electric shock.
IM 12J05D02-01E
3-4 Installation and wiring
WARNING
12D7C3-04
GLANDS TO BE
USED FOR CABLING
3-2. Preparation
Refer to figure 3-4. The relay contact terminals and power supply connections are under the screening
(shielding) plate. These should be connected first. Connect the sensor, outputs and data communication
connections last.
To open the EXA 402 for wiring:
1. Loosen the four frontplate screws and remove the cover.
2. Use the rubber knob in the lower right hand corner and swing open the display board to the left.
3. The upper terminal strip is now visible.
4. Remove the screen (shield) plate covering the lower terminal strip.
5. Connect the power supply and contact outputs. Use the three glands at the back for these cables.
6. Replace the screen (shield) plate over the lower terminals.
Always replace the screen plate over the power and contact outputs for safety and to avoid interference.
7. Connect the analog output(s), the sensor input, and, if necessary, the RS485 serial bus.
8. Use the front three glands for analog output, sensor input, contact input and communication cabling
(see figure 3-5).
9. Close the display board and switch on the power. Commission the instrument as required or use the
default settings.
10. Replace the cover and secure frontplate with the four screws.
Tighten four frontplate screws to 1.5 N·m torque.
Contact
(S3,S4,FAIL)
output cables
Suitable for cables with an outside diameter between 6 - 12 mm (0.24 - 0.47 in.)
Figure 3-5. Glands to be used for cabling
Communi-
cation,
contact
input
Contact
(S1,S2)
output
cables
High voltage section
Sensor
cables
Power
cable
Analog
output
cables
IM 12J05D02-01E
Installation and wiring 3-5
DANGER
FRONT GLANDS
Figure 3-6. System configuration
3-3. Wiring the power supply
Sensor
Output
signals
RS485
Contact intput
Power
Contact
output
Contact
output
REAR GLANDS
S1
S2
S3
S4/FAIL
3-3-1. General precautions
Make sure the power supply is switched off. Also, make sure that the power supply is correct for the
specifications of the EXA and that the supply agrees with the voltage specified on the textplate. Remove
the front cover by unscrewing the four screws to check this textplate on the top of the display board.
Local health and safety regulations may require an external circuit breaker to be installed. The instrument is protected internally by a fuse. The fuse rating is dependent on the supply to the instrument. The
250 VAC fuses should be of the “time-lag” type, conforming to IEC60127.
The internal fuse is located next to the power terminals (in the lower right hand corner).
Use only a fuse of the specified current, voltage and type ratings to prevent fire. For fuse replacement,
refer to Section 7-3, “Fuse Replacement.”
3-3-2. Access to terminal and cable entry
Terminals 1 and 2 on the bottom terminal strip are used for the power supply. Guide the power cables
through the gland closest to the power supply terminals. The terminals will accept wires of 2.5 mm2 (14
AWG). Use cable finishings if possible.
Connect the wires as indicated in the wiring diagram (refer to figure 3-6).
IM 12J05D02-01E
3-6 Installation and wiring
DANGER
CAUTION
71
S4
S3
S2
S1
C NC NO
72 73 51 52 53 4143 31334232
FUSE
100
115
230
250VAC; T
312
C NC NO C NC NO C NC NO
VAC
VAC
VAC
200 mA
200 mA
100 mA
Relay Contacts
Power Supply
1213
1516
63 66 65 62 61 95 94 93 92 91
SCREEN
mA2
mA1
SCREEN
TLTL
17 11
Sensor InputsmA Outputs
Digital
Communications
Contact
Input
CONT SENSOR mA OUTPUT RS485
14
22
21
- - - polarographic sensor galvanic sensor
High voltage compartment
G N L
18
Liquid
earth
Shield
Temp
SCREEN
99
SCREEN 2
23
250VAC
5A
100VA
250VDC
5A
50W
(M4 screw)
Figure 3-7. Input and output connections
3-3-3. AC power
Connect terminal 1 to the phase line of the AC power and terminal 2 to the zero line. The size of conductors should be at least 1.25 mm2. The overall cable diameter should be between 6 & 12 mm (0.24 & 0.47
in).
3-3-4. Grounding the housing
Protective grounding must be made to prevent electric shock.
To protect the instrument against interference, the housing should be connected to ground by a large
area conductor. This cable can be fixed to the rear of the housing using a braided wire cable. See figure
3-8. This is separated from input ground by a galvanic isolation.
Please be sure to connect protective grounding of
DO402G with cable of 1.25 mm2 or larger cross
section in order to avoid the electrical shock to the
operators and maintenance engineers and prevent
the influence of external noise. And further connect
the grounding wire to the
3-3-5. Switching on the instrument
After all connections are made and checked, the
power can be switched on from the power supply. Make sure the LCD display comes on. All
segments will illuminate, then the instrument will
momentarily display its unique serial number. After
a brief interval, the display will change to the meas-
mark (100Ω or less).
ured value. If errors are displayed or a valid measured value is not shown, consult the troubleshooting
section (Chapter 8) before calling Yokogawa.
Figure 3-8. Grounding the housing
IM 12J05D02-01E
Installation and wiring 3-7
WARNING
3-4. Wiring the contact signals
3-4-1. General precautions
The contact output signals consist of voltage-free relay contacts for switching electrical appliances
(SPDT). They can also be used as digital outputs to signal processing equipment (such as a controller or
PLC). It is possible to use multi-core cables for the contact in and output signals and shielded multi-core
cable for the analog signals.
3-4-2. Contact outputs
The EXA unit’s four contact outputs can be wired to suit your own custom requirements (Figure 3-6).
In the Non-Alarm or Power Off states, contacts S1, S2 and S3 are OFF, Common (C) and Normally
Closed (NC) are in contact.
In the “Fail” or Power Off states, contact S4 is ON, Common (C) and Normally Closed (NC) are in con-
tact.
You can either use them to switch AC power, or switch a DC Voltage for digital interfacing.
Default settings
• The contact S1 is pre-programmed for high alarm function.
• The contact S2 is pre-programmed for a low alarm function.
• The contact S3 is pre-programmed for wash function.
• The contact S4 is pre-programmed for FAIL.
The three control contacts (S1 to S3) can be used for simple process control by programming their function (Chapter 5). The FAIL contact is programmed to signal a fault in the measuring loop. Always connect the FAIL contact to an alarm device such as a warning light, sound annunciator, or alarm panel to
make full use of the fault detection possibilities (self diagnostics) of the EXA converter.
3-4-3. Contact input
It is necessary to use screening/shielding on the output signal cables. Screw (M3) 23 is used to connect
the shielding.
On resistance: 10Ω or less
Off resistance: 100kΩ or more
IM 12J05D02-01E
3-8 Installation and wiring
3-5. Wiring the analog output signals
3-5-1. General precautions
The analog output signals of the EXA transmit low power standard industry signals to peripherals like
control systems or strip-chart recorders (Figure 3-6).
3-5-2. Analog output signals
The output signals consist of active current signals of either 0-20 mA or 4-20 mA. The maximum load
can be 600 ohms on each.
It should be necessary to use screening/shielding on the output signal cables. Terminal 63 is used to
connect the shielding.
3-6. Wiring the standard galvanic sensor
The sensor cable has markers on the individual wires.
These markings refer to the markers on the terminals.
The temperature compensator has two wires with the markings
T1, T2 and/or 11, 12 and must be connected to terminal 11
and 12.
The measuring electrode: the cathode is marked with IE and/or 13
and must be connected to terminal 13.
The reference electrode: the anode is marked with RE and/or
15 and must be connected to terminal 15.
The liquid earth ( solution ground) is marked with 16 and must
be connected to terminal 16.
Note:
The liquid earth (solution ground) connection is valid
only when the floating ball holder, Model PB350G or
PB360G, is used. Otherwise, do not make a connection
to terminal 16. The connection, if made, may result in
abnormal readings. Even if the floating ball holder is
Figure 3-9. Cable gland assembly
used, when the liquid earth (solution ground) connection is not used, then disconnect the wiring
to terminal 16. (The disconnected wire should be covered with an insulating tube to avoid contact
with other terminals.)
The overall shield of the cable is marked with 14 and must be connected to terminal 14.
Note:
Always interconnect terminal 13 and 17 to reduce noise voltage onto measurement.
3-7. Wiring other galvanic sensors
Consult the users manual for the color identification of the sensor cable and connect temperature compensator, cathode and anode to the terminals: 11, 12, 13 and 15 as described above.
Connect the cable shield to 14 if there is one available. Sensor diagnostics is normally not possible.
Note:
Always interconnect terminal 13 and 17 to reduce noise voltage onto measurement.
3-8. Wiring polarographic sensors
Consult the owners manual for the color identification of the sensor cable and connect temperature compensator, cathode and anode to terminals 11, 12, 17 and 18 in this sequence.
Connect the cable shield (when provided) to terminal 14.
Note:
A shorting cable is connected between converter terminals 13 and 17.
When a polarographic sensor is to be connected, the cable is not used, so disconnect it.
It is recommended to save the shorting cable for future use—if may be needed when a galvanic sen-
sor is used.
3-9. Wiring RS485 signal
It is necessary to use screening/shielding on the output signal cables. Screw (M3) 99 is used to connect
the shielding.
IM 12J05D02-01E
Operation 4-1
4. OPERATION; DISPLAy FUNCTIONS AND SETTING
4-1. Operator interface
This section provides an overview of the operation of the EXA operator interface. The basic procedures
for obtaining access to the three levels of operation are described briefly. For a step-by-step guide to
data entry, refer to the relevant section of this instruction manual. Figure 4-1 shows the EXA operator
interface.
LEVEL 1: Maintenance
These functions are accessible by pushbutton through a flexible front cover window. The functions make
up the normal day-to-day operations that an operator may be required to complete. Adjustment of the
display and routine calibration are among the features accessible in this way. (See table 4-1).
LEVEL 2: Commissioning
A second menu is exposed when the EXA front cover is removed and the display board is revealed.
Users gain access to this menu by pressing the button marked * in the lower right of the display board.
This menu is used to set such values as the output ranges and hold and wash features. It also gives
access to the service menu. (See table 4-1).
LEVEL 3: Service
For more advanced configuration selections, press the button marked * , then press “NO” repeatedly
until you reach *SERV. Now push the “YES” button. Selecting and entering “Service Code” numbers in
the commissioning menu provide access to the more advanced functions. An explanation of the Service
Codes is listed in chapter 5 and an overview table is shown in chapter 10.
Table 4-1. Operations overview
Routine Function Chapter
MaintenanceAIR. CAL Calibration in air ( preferred method) 6
(level 1) H2O. CAL Calibration in aerated water 6
MAN. CAL Process calibration based on grab sample 6
DISP Read auxiliary data and set message display 4
HOLD Switch HOLD on/off *) 5
SETP Adjust alarm setpoints *) 5
WASH Start wash cycle manually *) 5
M.TEMP Adjust manual temp*) 5
M.PRESS Adjust manual press 5
Commissioning*SETP Adjust alarm setpoints 5
(level 2) *RANGE Adjust output range(s) 5
*HOLD Activate HOLD function 5
*WASH Activate and configure the wash timer 5
Service*SERV Configure the specialized functions of the converter 5
(level 3)
)
Only possible if activated
*
NOTE:
All three levels may be separately protected by a password. See Service Code 52 in chapter 5
Service Code table for details on setting passwords.
IM 12J05D02-01E
IM 12J05D02-01E
4-2 Operation
HOLDFAIL
YES NO
ENT
SETPOINTS
RANGE
SET HOLD
SERVICE
MEASURE
H2O.CAL
DISPLAY
HOLD
NOMODEYES
ENT
S1
S2
WASH/S3
FAIL/S4
YOKOGAWA
MODE
AIR.CAL
WASH
TEMP.MAN.
CONTACTS
MARKINGS
WITHIN
ENCLOSURE
MAN.CAL
12J6B2-04
FRONTEXADO402
Output hold flag
Main display
Message display
Key prompt flags
Selection keys
YES : Accept setting
NO : Change setting
Adjustment keys
> : Choose digit to
adjust
^ : Adjust digit
ENT : Confirm change
Figure 4-1. DO402 operator interface
Manual temperature
compensation flag
Fail flag
Broken line indicates area
that can be seen through
front cover
Menu pointer flags
Commissioning
function menu
Commissioning
mode access key
Relay contact
status indicators
Measure/Maintenance
mode key
4-2. Explanation of operating keys
MODE key This key toggles between the Measuring and Maintenance modes. Press once to obtain
access to the maintenance function menu. (Level 1 see table 4-1)
Press again to return to the Measuring mode (press twice when hold is activated).
yES/NO keys These are used to select choices from the menu.
YES is used to accept a menu selection.
NO is used to reject a selection, or to move ahead to the next option.
DATA ENTRy keys ( ENT)
is used as a “cursor” key. Each press on this key moves the cursor or flashing digit
one place to the right. This is used to select the digit to be changed when entering
numerical data.
is used to change the value of a selected digit. Each press on this key increases
the value by one unit. The value can not be decreased, so in order to obtain a
lower value, increase past nine to zero, then increase to the required number.
ENT
When the required value has been set using the > and ^ keys, press ENT to confirm the data entry. Please note that the EXA 402 does not register any change of
data until the ENT key is pressed.
* key This is the Commissioning mode key. It is used to obtain access to the Commissioning
menu. This can only be done with the cover removed or opened. Once this button has
been used to initiate the Commissioning menu, follow the prompts and use the other
keys as described above.
Operation 4-3
4-3. Setting passcodes
In Service Code 52, EXA users can set passcode protection for each one of the three operating levels,
or for any one or two of the three levels. This procedure should be completed after the initial commissioning (setup) of the instrument. The passcodes should then be recorded safely for future reference.
When passcodes have been set, the following additional steps are introduced to the configuration and
programming operations:
Maintenance
Press MODE key. The display shows 000 and *PASS*
Enter a 3-digit passcode as set in Service Code 52 to obtain access to the Maintenance Mode
Commissioning
Press * key. The display shows 000 and *PASS*
Enter a 3-digit passcode as set in Service Code 52 to obtain access to the Commissioning Mode.
Service
From the commissioning menu, select *SERV by pressing YES key. The display shows 000 and *PASS*
Enter a 3-digit passcode as set in Service Code 52 to obtain access to the Service Mode.
NOTE:
See Service Code 52 for the setting of passcodes.
IM 12J05D02-01E
4-4 Operation
YES
YES
NO
MODE
NO
YES
YES
NO
NO
YES
NO
YES NO
YES NO
DISPLAY
HOLD
AIR.CAL
H2O.CAL
NO
NO
NO
NO
NO
NO
NO
NO
YES
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
DISPLAY
DISPLAY
DISPLAY
DISPLAY
DISPLAY
DISPLAY
DISPLAY
DISPLAY
MAN.CAL
YES
NO
NO
NO
YES
NO
NO
YES
NO
NO
YES
NO
NO
YES
NO
(See H2O
calibration
Chapter 6)
MEASURE
H2O.CAL
DISPLAY
HOLD
AIR.CAL
When enabled in
Hold (SET HOLD)
mode.
Manual press.
when enabled
in service code 51
(See Manual
calibration
Chapter 6)
Process
temperature
Barometric
pressure
Software release
number
Slope
Cell current
Manual press.
when enabled
in service code 51
Display Access
% Saturation
Current
output 1
Manual temp.
when enabled
in service code 13
Manual press.
when enabled
in service code 51
(Note 1)
(Note 2)
MAN.CAL
(See Air
calibration
Chapter 6)
Note 1: Manual temperature compensation menu
The menu can be displayed in maintenance mode.
This can be done by enabling the function in Service Code 13.
Manual temperature compensation menu is displayed and
temperature can be entered manually.
Note 2: Pressure is in bars.
Default: 1.013 bar
Setting range: 0.500 to 5.000 bar
Current
output 2
Press YES to fix
the selected second
line of display
4-4. Display functions (default)
IM 12J05D02-01E
Parameter setting 5-1
5. PARAMETER SETTING
5-1. Maintenance mode
Standard operation of the EXA instrument involves use of the maintenance (or operating) mode to set up
some of the parameters.
Access to the Maintenance mode is available via the six keys that can be pressed through the flexible
window in the instrument cover. Press the MODEkey once to enter this dialog mode.
NOTE:
At this stage the user will be prompted for pass code where this has been previously set up in
service code 52 in chapter 5.
Air calibration See “calibration” section 6.
AIR.CAL
H20 calibration See “calibration” section 6.
H2O.CAL
Display See “operation” section 4.
DISP
Setpoint Select and adjust setpoint (when enabled in service menu section 5, service
SETP
Wash Manually start/stop wash cleaning (when enabled in service menu section 5,
WASH
Hold Manually switch on/off HOLD (when enabled in commissioning menu section).
HOLD
code 51). See adjustment procedure 5-4.
service code 51). See adjustment procedure 5-3.
See adjustment procedure 5-2.
IM 12J05D02-01E
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