YOKOGAWA ISC450G User's Manual

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User’ s Manual

Model ISC450G [Style: S2] Inductive Conductivity Converter

IM 12D06D05-01E

3rd Edition

Note This page may be referred to when

reading pages where subsequent submenu screens are shown in the text. Connection to the relevant submenu screen is indicated by a doted line with an arrow. Note that screens in the text are typical examples and actual screens may differ depending on the set parameters.

Measurement setup

 Measure Conductivity only Configure sensor

 Temperature settings  Temp. Compensation  Calibration settings  Concentration

Enter

Commissioning

Connection to the relevant submenu screen is indicated by a doted line with an arrow.

PREFACE

Electrostatic discharge

The EXAxt converter 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.

WARNING

Installation and wiring

The EXAxt converter 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.

CAUTION

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.

WARNING

• Do not use an abrasive or organic solvent in cleaning the instrument.

• Do not modify the ISC450G converter.

• Substitution of components may impair

suitability for Division 2.

Do not remove or replace while circuit is live

unless area is know to be non-hazardous.

Explosion Hazard – Do not disconnect

equipment unless area is known to be nonhazardous.

Do not reset circuit breaker unless power

has been removed from the equipment or the area is known to be non-hazardous.

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.

DANGER

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.

WARNING

This symbol indicates that the operator must refer to the instructions in this manual in order to prevent the instrument (hardware) or software from being damaged, or a system failure from occurring.

CAUTION

This symbol gives information essential for understanding the operations and functions.

Note!

This symbol indicates information that complements the present topic.

This symbol indicates Protective Ground Terminal

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 organisations 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 organisation 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 failure of the device.

• A statement whether warranty or nonwarranty 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.

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.

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.

TABLE OF CONTENTS

PREFACE

1. INTRODUCTION AND GENERAL DESCRIPTION .....................................................1

1-1. Instrument check ................................................................................................... 1

1-2. Application .............................................................................................................1

2. GENERAL SPECIFICATIONS OF EXAxt ISC450G ....................................................2

3. INSTALLATION AND WIRING .....................................................................................5

3-1. Installation and dimensions ...................................................................................5

3-1-1. Installation site ..........................................................................................5

3-1-2. Mounting methods .....................................................................................5

3-2. Wiring ....................................................................................................................7

3-2-1. Preparation ................................................................................................7

3-2-2. Cables, Terminals, glands and conduit adapter .......................................8

3-3. Wiring the power supply ........................................................................................ 9

3-3-1. General precautions ..................................................................................9

3-3-5. Grounding the housing ............................................................................10

3-3-6. Switching on the instrument ....................................................................10

3-3-2. Access to terminal and cable entry .........................................................10

3-3-3. AC power ................................................................................................10

3-3-4. DC power ................................................................................................10

3-4. Wiring the contact signals.................................................................................... 11

3-4-1. General precautions ................................................................................11

3-4-2. Contact outputs .......................................................................................11

3-4-3. Contact input ...........................................................................................11

3-5. Wiring the mA-output signals............................................................................... 11

3-5-1. General precautions ................................................................................11

3-5-2. Analog output signals ..............................................................................11

3-6. Wiring the sensor.................................................................................................12

3-6-1. General precautions ................................................................................12

3-6-2. Connecting the sensor cable to the converter ........................................12

3-6-3. Installation of the sensor .........................................................................12

3-6-4. Sensor cable connections using junction box (BA10) and

extension cable (WF10) ..........................................................................13

iii

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4. OPERATION OF EXAxt ISC450G .............................................................................16

4-1. Main display functions ......................................................................................... 16

4-2. Trending graphics ................................................................................................16

4-3. Zoom in on details ............................................................................................... 16

4-3-1. Actual mA1 ..............................................................................................17

4-3-2. Actual mA2 ..............................................................................................17

4-3-3. S1/S2/S3/S4 ............................................................................................17

4-3-4. C.C. (factory). ..........................................................................................17

4-3-5. C.C. (adjusted) ........................................................................................17

4-3-6. Temp. comp 1 .........................................................................................17

4-3-7. Temp. comp 2 .........................................................................................17

4-3-8. Sensor ohms. ..........................................................................................17

4-3-9. Last calibrated at .....................................................................................17

4-3-10. Calibration due at ..................................................................................17

4-3-11. Projected calibration at .........................................................................17

4-3-12. HART ID ................................................................................................17

4-3-13. Software revision ...................................................................................18

4-3-15. Logbook ................................................................................................18

4-3-16. Trouble shooting ..................................................................................18

4-4. Information function .............................................................................................18

4-5. Setup-Calibration & commissioning.....................................................................18

4-6. Secondary- primary value display switch ............................................................18

4-7. Navigation of the menu structure ........................................................................19

5.MENU STRUCTURE COMMISSIONING ....................................................................20

5-1. Configure sensor ................................................................................................ 20

5-2. Temperature setting ............................................................................................. 20

5-3. Temperature compensation .................................................................................20

5-4. Calibration settings ..............................................................................................22

5-5. Concentration ...................................................................................................... 22

5-6. mA output setup...................................................................................................24

5-7. Contact output setup ...........................................................................................26

5-8. Fail .......................................................................................................................28

5-9. Simulate...............................................................................................................28

5-10. Input contacts .................................................................................................... 28

5-11. Error configuration .............................................................................................30

5-12. Logbook configuration .......................................................................................30

5-13. Advanced setup .................................................................................................32

5-14. Display setup .....................................................................................................34

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6. CALIBRATION ...........................................................................................................36

7. MAINTENANCE .........................................................................................................38

7-1. Periodic maintenance .........................................................................................38

7-2. Periodic maintenance of the sensor ....................................................................38

7-3. Cleaning methods................................................................................................38

7-4. Contrast adjustment ............................................................................................38

8. TROUBLESHOOTING ...............................................................................................39

8-1. General ...............................................................................................................39

8-2. Calibration check .................................................................................................39

8-3. Predictive maintenance .......................................................................................39

8-4. Poor calibration technique ...................................................................................39

8-5. Error displays and actions ................................................................................... 39

9. QUALITY INSPECTION .............................................................................................40

10. SPARE PARTS ........................................................................................................44

APPENDICES ................................................................................................................45

APPENDIX 1 Temperature compensation ..................................................................45

APPENDIX 2 Temperature compensation matrix. ......................................................48

APPENDIX 3 Calibration solutions for conductivity ....................................................49

APPENDIX 4 Measurement principle ........................................................................ 50

APPENDIX 5 HART HHT (275/375) Menu structure ..................................................51

APPENDIX 6 Control drawing for FM approval ..........................................................55

Customer Maintenance Parts List (for Style: S2) ......................CMPL 12D06D05-02E

Revision Record ..............................................................................................................i

IM 12D06D05-01E

1. INTRODUCTION AND GENERAL DESCRIPTION

1 INTRODUCTION AND GENERAL DESCRIPTION

The Yokogawa EXAxt ISC450G is a converter 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 EXAxt converter 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 nameplate affixed to the top of the instrument agrees with your order. Example of the nameplate is shown below.

INDUCTIVE CONDUCTIVITY TRANSMITTER

MODEL SUFFIX

SUPPLY OUTPUTS AMB. TEMP. STYLE NO.

CUS

N200

ISC450G

4-20mA(mA1: +HART)

-20 to +55

°C

CL I, DIV 2, GROUPS ABCD T6 FOR Ta -20 to +55°C

SEE INSTRUCTION MANUAL TYPE 4X SEE CONTROL DRAWING NFM016-A9 P.1

Made in Japan

Figure 1-1. Nameplate

Note! The nameplate will also contain

the serial number and any relevant

certification marks. Be sure to apply

correct power to the unit, as detailed

on the nameplate.

1-2. Application

The EXAxt converter is intended to be used for continuous on-line measurement of Conductivity and/or Concentration 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 operating limits of a process, to monitor product quality, or to function as a controller for a dosing/dilution system.

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, and up 10 metres standard sensor cable.

The EXAxt is delivered with a general purpose default setting for programmable items (see Chapter 5). 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 EXAxt can be adjusted for a number of different types of temperature sensors.

Details provided in this instruction manual are sufficient to operate the EXAxt 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.

Yokogawa designed the EXAxt converter to withstand industrial environments. It meets all the CE regulatory standards. The unit meets or exceeds stringent requirements (see section

2) without compromise, to assure the user of continued accurate performance in even the most demanding industrial installations.

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2. GENERAL SPECIFICATIONS OF EXAxt ISC450G

A) Input specifications : Compatible with the Yokogawa inductive conductivity ISC40 series with

integrated temperature sensor: NTC30k or Pt1000

B) Input range

Conductivity : 0 to 1999 mS/cm at 25 °C (77 °F) reference temperature Minimum : 1 μS/cm (at process temperature) Maximum : 2 S/cm (at process temperature) Temperature : -20 to +140 ºC (0 to 280 ºF) Cable length : max. 60 metres (200 feet)

10 metres (35 feet) fixed sensor cable + 50 metres (165 feet) WF10 extension cable. Influence of cable can be adjusted by doing an AIR CAL with the cable connected to a dry cell

C) Accuracy (under reference conditions):

Conductivity : ≤ 0.5 % of reading ± 1.0 μS/cm Temperature : ≤ 0.3ºC (0.6ºF) Temp.compensation: ≤1 % for NaCl, ≤ 3 % for Matrix Step response : ≤ 4 seconds for 90 % (for a 2 decade step)

Note on performance specifications The following tolerance is added to above performance. mA output tolerance: ±0.02 mA of “4-20 mA“

D) Transmission signals

General : Two isolated outputs of 4-20 mA. DC with common negative. Maximum

load 600Ω. Bi-directional HART

digital communication, superimposed

on mA1 (4-20 mA) signal. Output function : Linear or 21-step table for Conductivity, Concentration or Temperature. Control function : PID control. Burn out function : Burn up (21.0 mA) or burn down (3.6 mA) to signal failure. acc.

NAMUR NE43. Parameters : Adjustable damping : Expire time Hold : The mA-outputs are frozen to the last/fixed value during calibration/

commissioning Cond. range : min span 10 μs/cm≥10% of high valve (20 mA)

max span 1999 mS/cm

E) Contact outputs

General : Four SPDT relay contacts with display indicators Switch capacity : Maximum values 100 VA, 250 VAC, 5 Amps. (*)

Maximum values 50 Watts, 250 VDC, 5 Amps. (*) Status : High/Low process alarms, selected from conductivity, concentration or

temperature. Configurable delay time and hysteresis : PID duty cycle or pulsed frequency control : FAIL alarm Control function : On / Off : Adjustable damping : Expire time

IM 12D06D05-01E

Hold : Contact can be used to signal the HOLD situation. Fail safe : Contact S4 is programmed as fail-safe contact. (*)Note: When contact output current is more than 4 Amps, ambient temperature should be

less than 40 ºC.

F) Contact input : Remote range switching to 10 times the programmed range.

Contact open : If impedance > 100 kΩ: "Range1, 2" (“Programmed range for mA1 and mA2 output" is "Range1, 2.”) Contact closed : If impedance < 10 Ω: 10 x “Range1, 2"

G) Temperature compensation

Function : Automatic or manual, for temperature ranges mentioned under B

(inputs). Reference temp. : Programmable from 0 to 100 ºC or 30 - 210 ºF (default 25 ºC).

H) Calibration : Semi-automatic calibration using pre-configured OIML (KCl) buffer

tables, with automatic stability check

Manual adjustment to grab sample * Organisation Internationale de Metrologie Legale, international

recommendation nr. 56 standard solutions reproducing the conductivities of electrolytes, 1981.

GENERAL SPECIFICATIONS

I) Logbook : Software record of important events and diagnostic data readily

available in the display or through HART®.

J) Display : Graphical Quarter VGA (320 x 240 pixels) LCD with LED backlight and

touchscreen. Plain language messages in English, German, French,

Spanish, Italian, Swedish, Portuguese and Japanese.

K) Shipping details

Package size : 290 x 300 x 290 mm (L x W x D) (11.5 x 11.8 x 11.5 inch) Package weight : app. 2.5 kg (5.5 lbs) Converter weight : app. 1.5 kg

L) Housing : Cast aluminum housing with chemically resistant coating;

Polycarbonate cover with Polycarbonate flexible window : Protection IP66 / NEMA 4X / CSA Type 3S Colour : Silver grey ISC450-A(D)-A : IP66 cable glands are supplied with the unit ISC450-A(D)-U : NEMA 4X close up plugs are mounted in the unused cable entry holes

and can be replaced by conduit fittings as required

Pipe, Panel or Wall mounting using optional hardware Optional conduit adapter G1/2, 1/2NPT or M20 female

M) Power supply

ISC450G-A : Ratings; 100-240 V AC Acceptable range; 90 to 264 V AC

Ratings; 50/60 Hz Acceptable range; 50 Hz ±5%, 60 Hz ±5%

Power Consumption; 15 VA ISC450G-D : Ratings; 12-24 V DC Acceptable range; 10.8 to 26.4 V DC

Power Consumption; 10 W

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N) Safety and EMC conforming standards Safety : EN 61010-1

CSA C22.2 No.61010-1 UL 61010-1 FM3611 Class I, Div.2, Group ABCD,T6 for Ta -20 to 55ºC EMC : conforms to EN61326 Class A, AS/NZS CIPR 11 Installation altitude: 2000 m or less Category based on IEC 61010: II (Note) Pollution degree based on IEC 61010: 2 (Note) Note: Installation category, called over-voltage 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.

O) Environment and operational conditions

Ambient temperature: -20 to +55 ºC (-5 - 130 ºF) Storage temperature: -30 to +70 ºC (-20 - 160 ºF) Humidity : 10 to 90% at 40 ºC (100 ºF) RH (non-condensing) Data protection : EEPROM for configuration data and logbook. Lithium cell for clock Watchdog timer : Checks microprocessor Power down : Reset to measurement Automatic safeguard: Auto return to measuring mode when touchscreen is untouched for 10

min.

Model and Suffix Codes [Style: S2]

Model Suffix code Option code Description

ISC450G ----------------- ----------------- Inductive conductivity Converter

Power - A

- D

Type - A

- U

Mounting Hardware

Hood

Conduit adapter

Tag Plate

*1 If the tag number is predefined with the purchase, Yokogawa will inscript the tag plate with the specified tag number, and

program the tag number in the converter.

*2 Option codes /U, /PM, /H5, /AFTG, /ANSI and /AM20 are not specified for FM version (-U).

-----------------

/UM /U /PM /H5 /AFTG /ANSI /AM20 /SCT

AC version (100…240 VAC) DC version (12…24 VDC)

General purpose version FM version

Universal mounting kit (panel, pipe, wall) Pipe and wall mounting hardware (*2) Panel mounting hardware (*2) Awning hood (stainless steel) (*2) G1/2 (*2) 1/2NPT (*2) M20 (*2) Stainless steel tag plate (*1)

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3. INSTALLATION AND WIRING

3-1. Installation and dimensions 3-1-1. Installation site

The EXAxt 450 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 60 metres (200 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)

F Hood (Option code: /H5, some cutout on the left side cover)

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 EXAxt 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 Size nominal 50A

Unit: mm (inch)

220(8.66")184(7.2")

3 INSTALLATION AND WIRING

144(5.67")

72(2.8")

(0.79")

144(5.67")

24.5(1") M20 cable gland

(0.79")

121.5(4.78")

(When shipped, not installed)

DEF

Grounding terminal (M4 screw)

A : For output signal B : For contact input C : For sensor cable D : For contact output (S1 and S2) E : For contact output (S3 and S4) F : For power supply

F Adapter for Coduit Work (optional)

(option code : / AFTG, / ANSI, / AM20)

Adapter

F G1/2 screw (/AFTG), F 1/2 NPT screw (/ANSI) F M20 screw (/AM20)

Figure 3-1. Housing dimensions and layout of glands

(1.93")

Approx. 55(2.2")

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138

(5.43

)

min.195(7.75

138(5.43")

)

min.185 (7.25")

138 (5.43

Unit: mm (inch)

)

138

(5.43

+1 0

)

Figure 3-2. Option /PM: panel mounting diagram (Note) When option code "/UM" is specified, universal pipe/wall/pannel mounting kit are supplied-

--same as option code "/U" and "/PM" both specified.

pipe mounting (horizontal)

2" ND. pipe

(7.87")

(1.38")

200

(0.6")

(3.15")

(2.75")

2x Ф6.5 (0.26")

4x Ф10 (0.4")

wall mounting

(0.51")

154.5

(6.08")

pipe mounting (vertical)

Figure 3-3. Option /U: wall and pipe mounting diagram

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potentiomerter

WARNING

This connector for software must be used only by

Yokogawa’s service personnel.

connector for (future) software

input terminal block

LCD bracket

6 X M20 glands

Note: ISC450G-A(D)-U

The enclosure is provided with stoppers in stead of M20 cable glands for the unused holes. These stoppers must be removed and replaced by FM approved conduit fittings in accordance with good installation practice. See APPENDIX 6, Control drawing for FM approval.

Figure 3-4. Internal view of EXAxt wiring compartment

3-2. Wiring 3-2-1. 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 HART

To open the EXAxt 450 for wiring:

1. Loosen the four frontplate screws and swing open the cover.

2. The upper terminal strip is now visible.

3. Remove the screen (shield) plate covering the lower terminal strip.

4. Connect the power supply and contact outputs. Use the three glands at the back for these cables.

communication connections last.

WARNING

Always place the screen plate over the power supply and contact terminals for safety reasons and to avoid interference.

5. Put back (replace) the screen (shield) plate over the lower terminals.

6. Connect the analog output(s), the sensor inputs, and, if necessary, the HART and input contact.

7. Use the front three glands for analog output, sensor inputs, contact input and HART® wiring (see figure 3-5).

8. Swing back the cover and secure it with the four screws.

9. Switch on the power. Commission the instrument as required or use the default settings.

output terminal block

protective shield bracket

wiring

3 INSTALLATION AND WIRING

DANGERDANGER

• Cables that withstand temperatures of at least 70 °C should be used for wiring.

• Wiring work should be performed to meet IP66 or higher requirements. Tighten four frontplate screws to 1.5 N·m torque.

CAUTION

Do not turn on power with the touchcsreen

pressed, otherwise inaccurate screen positioning will occur. If it occurs, leave the touchscreen unpressed, turn off power then on again. The screen positioning will be accurate.

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3-2-2. Cables, T erminals, glands and conduit adapter

ISC450G-A(D)-A The ISC450 is supplied with terminals suitable for the connection of finished wires in the size range of 0.13 to 2.5 sq.mm. (26 to 14 AWG). The cable glandes supplied will form a tight seal on cables with an outside diameter of 6 to 12 mm (0.24 to 0.47 inches). Unused cable entry holes must be sealed with cable glands including the blind plugs supplied.

ISC450G-A(D)-U The ISC450 is supplied with terminals suitable for the connection of finished wires in the size range of 14- 26 AWG. The cable entry holes are sealed with FM certified plugs. Prior to cable entry the plugs can be removed with allen key size 3/8” The cable conduit fittings can be mounted in the holes of the housing as required. The cable glands supplied with the unit will give a tight seal on cables with outside diameter of 0.24 to 0.47 inches.

High voltage section

Contact

(S1, S2)

output cables

Suitable for cables with an outside diameter between 6 - 12 mm (0.24 - 0.47”)

cables

Contact

(S3, S4)

output cables

Figure 3-5a. Cable glands diagram

Gland nut

O-ring

Gland

Input

contact

Contents:

NOTE: The glands must be installed properly to meet IP66 and NEMA 4X rating. Use close up plug for unused glands.

Power

cable

6 X Gland M20 6 X Close up plug 6 X Gland nut M20 6 X O-ring 17.12 X 2.62 EPDM 70° sh.

Sensor Cables

Close up plug

Figure 3-5b. How to install cable glands

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NOTE: Moisturize O-ring before assembling.

FRONT GLANDS REAR GLANDS

Sensor

output signals

HART

Contact output

Power

Contact input

mA1

mA2

Adapter for conduit work

When protect the cable with a conduit, replace the M20 cable gland with a cable gland of optional conduit adapter, and set the adapter shown as Figure 3-5c.

Nut

Approx. 55(2.2")

(1.93")

Adapter

Figure 3-5c. Conduit adapter

Unit: mm(inch)

Packing

3 INSTALLATION AND WIRING

G1/2 screw (/AFTG), 1/2 NPT screw (/ANSI)

M20 screw (/AM20)

Figure 3-6. System configuration

3-3. Wiring the power supply 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 EXAxt and that the supply agrees with the voltage specified on the textplate.

DANGERDANGER

1. Install an external switch or circuit breaker

to the power supply of the 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 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 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.

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 IEC127.

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WARNING

Fuse replacement should be performed only by a qualified service person. See Sec.7. MAINTENANCE, Fuse.

Fuse ratings:

Power supply Fuse type 12-24VDC, 10W max 2A/250V, Slow 100-240VAC, 15VA max 0.5A/250V, Slow

3-3-2. Access to terminal and cable entry

Terminals 1 and 2 are used for the power supply. Guide the power cables through the gland closed to the power supply terminals. The terminals will accept wires of 2.5 mm Always use cable finishings if possible.

(14 AWG).

3-3-3. AC power

Connect terminal L to the phase line of the AC power and terminal N to the zero line. See figure 3-8 for the power ground.

3-3-4. DC power

Connect terminal 1 to the positive outlet and terminal 2 to the negative outlet.

The size of conductors should be at least 1.25

. The overall cable diameter should be

between 7 & 12 mm.

POWER

12-24 V /10 W

FUSE: 2A/250 VAC/T

POWER

100-240 VAC/15 VA/ 50/60Hz FUSE: 500 mA/250 VAC/T

32 31 33 42 41 43 52 51 53 72 71 73

NC C NO NC C NO NC C NO NO C NC

S1 S2 S3CONTACTS S4

63 66 65 61 22 21 12 16 15

SHLD

-+-+

mA OUTPUTS

62 11 17

mA1

(+HART)

CONTACT SENSOR(S)

REFER TO INSTRUCTION MANUAL FOR CONNECTIONS ISC

Figure 3-7. Input and output connections

3-3-5. Grounding the housing

For the safety of the user and to protect the instrument against interference, the housing must always be connected to ground. This has to be done by a large area conductor. This cable can be fixed to the rear of the housing or by using the internal ground connections using a braided wire cable. See figure 3-8.

250V / 5A

AC / DC

100VA / 50W

(fail-safe)

TEMPmA2

RECEIVE DRIVESHLD

COILS

3-3-6. 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. After a brief interval, the display will change to the measured value. If errors are displayed or a valid measured value is not shown, consult the troubleshooting section (Chapter 8) before calling Yokogawa.

DANGER

The minimum cross sectional area of the protective grounding wire should be 0.75 mm

IM 12D06D05-01E

(M4 screw)

POWER

100-240 VAC/15 VA/ 50/60Hz

FUSE: 500 mA/250 VAC/T

(M4 screw)

Figure 3-8-a. External grounding Figure 3-8-b. Internal grounding

3 INSTALLATION AND WIRING

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 EXAxt 450 unit’s four contacts (switches) that can be wired and configured to suit user requirements. Contact S4 is programmed as a fail-safe contact. Please refer to section 5-7, Contact output setup for functionality description.

Alarm (limits monitoring)

Contacts configured as “ALARM” can be energized when limits are crossed.

Fail

Contacts configured as “FAIL” will be energized when a fail situation occurs. Some fail situations are automatically signaled by the internal diagnostics (electronics) of the converter. Others can be configured by the user (see section 5-11 Error Configuration). By pressing the “INFO” button on the main screen the user is given an explanation as well as a remedy for the current fail situation. Always connect the fail contact to an alarm device such as a warning light, alarm bell or displayed on an annunciator.

“ALARM” Contact “FAIL” Contact

Power Off NC NC

Power On NC NC

Alarm NO NC

Fail NC NO

Fail and Alarm NC* NO

HOLD NC NC

* When a fail situation occurs which is related

to the parameter associated with the contact (Conductivity, Concentration or temperature) the contact will go to NC. When the fail situation is not related to the parameter associated with the contact the contact will remain in the state it is currently in.

3-4-3. Contact input

It is necessary to use screening/shielding on the input signal cables. Terminal 63 is used to connect the shielding.

3-5. Wiring the mA-output signals 3-5-1. General precautions

The analog output signals of the EXAxt 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 4-20 mA. The maximum load can be 600 ohms on each.

IM 12D06D05-01E

It is necessary to use screening/shielding on the output signal cables. Terminal 63 is used to connect the shielding.

3-6. Wiring the sensor 3-6-1. General precautions

The sensor cable transmits low voltage, high frequency signals and should be installed separately from any high voltage, high cur rent and/or power switching cables. This is to avoid any unintentional cross talk or other kind of interference of the conductivity meas ure ment.

3-6-2. Connecting the sensor cable to the

converter

1. To access terminals remove the front cover of the EXAxt ISC450G by releasing the 4 captive screws.

2. Loosen the cable gland and pull the ca ble in the connection compartment.

3. The sensor leads are numbered and the leads must be connected to the ter mi nals with the corresponding number, re fer to Fig. 3-4: the temperature com pen sa tor with 11/12

- the drive coil with 15/16

- the receive coil with 13/17

Terminal 14 is for connection of the shield.

4. Screw the cable gland tight to en sure IP66 (NEMA 4X) environmental pro tec tion. An optional protection hose (flexible con duit) is available for additional me chan i cal protec tion of the sensor cable.

3-6-3. Installation of the sensor

The Model ISC40 is a “doughnut” shaped sensor. Preferably, the process will flow through the hole of the donut with the temperature compensator up-stream. For minimal obstruction of the flow and for accurate measurement without the need for calibration of the cell constant, the process will flow freely around the doughnut, allowing a minimum distance of 25 mm (1”) between doughnut and process piping (d). The sensor is provided with a gasket and retaining nut. This allows “bulkhead mounting” in tank wall or standard flange through a hole of 27 mm (1.1”) diameter (A). The insertion is 125 mm under the flange. Two flats are provided with wrench size 20 mm (0.8”) to allow easy mounting and alignment of the sensor. The model identification on one flat aligns with the “up-stream” position of the sensor.For On-line mounting adapters are available for standard 2” process connection (Gas thread, NPT, ANSI-flange, DIN-flange). For by-pass measurement flow fittings are available in polyporpylene, polyvinylidene flouride and Stainless Steel. For measurements in open ducts or vessels an immersion fitting in CPVC or Stainless Steel is available. For easy wiring the sensor must be located within 5 m (15”) from the converter using the integral sensor cabling.

Figure 3-9a. Dimensions

IM 12D06D05-01E

DIMENSIONS INSTALLATION INSTRUCTIONS

L= 5000 ( 200 )

YOKOGAWA

40 (1.57)

ca 240 (9.45)

100 (3.94)

47(1.85)

G3/4

thermistor

12 17

secondary

13 15

primary

ground

wrench opening 20 ( 0.79 )

wrench opening 32 ( 1.42 )

Ø 40 ( 1.57)

BULK-HEAD MOUNTING

UNIT: mm (inch)

Hole in flange Ø 27 mm (1.06")

d = distance min 25 mm (1") D = acces port size min 48 mm (1.89")

distance min. 25 mm (1) access port side min 48 mm (1.89)

3 INSTALLATION AND WIRING

Figure 3-9b. Dimensions

3-6-4. Sensor cable connections using junc-

tion box (BA10) and extension cable (WF10)

Where a convenient installation is not possible using the standard cables between sensors and converter, a junction box and extension cable may be used. The Yokogawa BA10 junction box

and the WF10 extension cable should be used. These items are manufactured to a very high standard and are necessary to ensure that the specifications of the system can be met. The total cable length should not exceed 60 metres (e.g. 5 m fixed cable and 55 m extension cable).

IM 12D06D05-01E

BA10 WF10 EXA TRANSMITTER

/ CONVERTER

1314141615

11 Red

12 Blue

14 16

15 Core 16 Screen White Co-axial cable

14 Overall Screen

13 Core 17 Screen Brown Co-axial Cable

12 (blue)

14 (overall screen)

13 (core)

17 (screen)

Co-axial cable

(brown)

Co-axial cable

(white)

15 (core)

16 (screen)

11 (red)

Figure 3-10. Connection of WF10 extension cable and BA10 junction box

Extension cable may be purchased in bulk quantities or in pre-finished lengths. In the case

4. Strip insulation from the last 3 cm of the brown, and the white coaxial cores.

of bulk quantities cut to length, then it is necessary to terminate the cable as shown below.

5. Extract the coaxial cores from the braid, and trim off the black (low-noise)

Termination procedure for WF10 cable.

screening material as short as possible.

1. Slide 3 cm of heat shrink tube (9 x 1.5) over the cable end to be terminated.

6. Insulate the overall screen and the 2 coaxial screens with suitable plastic

2. Strip 9 cm of the outer (black) insulating

tubing.

material, taking care not to cut or damage internal cores.

7. Strip and terminate all ends with suitable (crimp) terminals and identify with

3. Remove loose copper screening, and cut

numbers as shown.

off the cotton packing threads as short as possible.

8. Finally shrink the overall heat shrink tube into position.

IM 12D06D05-01E

Figure 3-11.a.

3 INSTALLATION AND WIRING

Figure 3-11.b.

Figure 3-11.c.

IM 12D06D05-01E

Maximum

Minimum

Maximum

Average

4. OPERATION OF EXAxt ISC450G

4-1. Main display functions

- Go to graph screen

- Go to detail screen

- Go to info screen

- Go to setup screen

Figure 4-1. Main Display

4-2. Trending graphics

Pressing the button changes the display into a graphical mode in which the average measured value is shown on a time scale. The “Live” value is also digitally displayed in a text box. The time scale ( X-axis) and the primary value scale (Y-axis) are set in the “DISPLAY SETUP” menu. The full screen displays a trend of 51 points that represent the average of the selected time interval. The analyzer samples the measurement every second. The trending graphic also shows the maximum and minimum measured value in that interval. For example if the time scale is set to 4 hours, then the trend is shown for 4 hours prior to the actual measurement. Each point on the trend line represents the average over 4*60*60/51= 282 measurements (seconds).

4-3. Zoom in on details

This button gives access to the diagnostic information of the analyzer. The following messages will appear under normal (default) conditions:

- Home key back to mainscreen.

- One level up.

- Scroll choices (grey means deactivated).

- Enter selected data

or choice.

First zoom screen gives you inside into the parameters involving current measurement. All following zoom screens give additional information about the device and lead to logbook data.

ISC

450

120.0

90.0

60.0

30.0

109.3 μS/cm

Figure 4-2. Trend screen

IM 12D06D05-01E

Figure 4-3. Detail screen

Live reading

4-3-1. Actual mA1 = the current output in mA of

the first current output, which is defined as mA1. The range and function of this mA output can be set in:

Routing: Commissioning >> Output setup >> mA1

4-3-2. Actual mA2 = the current output in mA of

the second current output, which is defined as mA2. The range and function of this mA output can be set in:

Routing: Commissioning >> Output setup >> mA2

4-3-3. S1/S2/S3/S4 = the current state of

contacts 1 to 4. The functions and settings of the contacts can be set in:

Routing: Commissioning >> Output setup >> S1/S2/S3/S4

4-3-4. C.C. (factory) = the nominal cell constant

as determined by the factory calibration during production. This value is set during commissioning, and is found on the nameplate of the sensor or the calibration certificate.

Routing: Commissioning >> Measurement setup >> Configure sensor

4-3-5. C.C. (adjusted) = the calibrated cell

constant. When the cell constant of the system is adjusted on-line by grab sample or by calibrated solution technique, the new cell constant is recorded here. This value should not deviate greatly from the original factory calibration. In the event that there is a significant discrepancy seen between this reading and the C.C. (factory) value, the sensor should be checked for damage and cleanliness. Routing is via the “Calibration” menu.

4-3-6. T emp. comp 1 = the chosen temperature

compensation method for the primary measurement.

Routing: Commissioning >> Measurement setup >> Temp.compensation

4-3-7. T emp. comp 2 = the chosen temperature

compensation method for the secondary measurement. Note: This does not imply two separate measurements. There is the possibility to set two separate compensation methods so that two different stages of the same process can be monitored accurately. An example is process/ cleaning fluid interface.

Routing: Commissioning >> Measurement setup >> Temp.compensation

4-3-8. Sensor ohms = the input measurement

as an uncompensated resistance value.

4-3-9. Last calibrated at = the date of the last

calibration

4-3-10. Calibration due at = in the time frame

scheduled for the next calibration. This field is determined by the calibration interval.

Routing: Commissioning >> Measurement setup >> Calibration settings

4-3-11. Projected calibration at =

a diagnostic output, showing the time frame when the unit should next be maintained according to the sophisticated self-diagnostic tools built into the EXAxt software. Prior to calibration the sensor should be well cleaned and rinsed.

4-3-12. HART ID = a part of the HART device ID

(descriptor)

OPERATION OF EXAxt ISC450G

4-3-13. Software revision = the revision level of

the software in the instrument.

IM 12D06D05-01E

4-3-14. HART Device revision

Sometimes the firmware of a device is updated in a way that the communication file (HART DD) need revision too. In this case the revision level is increased by one. The revision level of the HART DD must match the revision level of the Firmware. The revision level is expressed by the first two characters of the filename. The following files should be used when the HART Device revision level is 2.

(0201.aot, 0201.fms, 0201.imp, 0201.sym)

4-3-15. Logbook

The EXAxt contains several logbooks to store historical information on events, changed settings and calibrations. The logbooks have been categorized to simplify the retrieval of this information.

Calibration will give information of previous

calibrations. This logbook is useful as one now can

1) Monitor the sensor performance over time.

2) Monitor the sensor(s) lifetime.

Sensor will give historical information on

parameter settings concerning the sensor(s). The events logged in this logbook are user definable. This is done in:

Commissioning >> Configure Logbook >> Sensor Logbook.

mA1/mA2 shows all (dynamic) events concern-

ing the analog outputs

S1/S2/S3/S4 shows all (dynamic) events con-

cerning the contacts.

Each HMI screen can contain up to 5 events. As each logbook can contain 50 events in total, one can access previous events by selecting another page 1 to 10.

4-3-16. Trouble shooting

If you contact the local sales/ service organization the serial number and software revision is necessary information. Without that information it is impossible to help you. It is also very useful to report all the information that you find on the zoom-in display.

4-4. Information function

In this field an information sign sign

or a fail sign can appear. Pushing

, a warning

this button, the user gets detailed information about the status of the sensor or the instrument if applicable. See troubleshooting (chapter 8) for further details.

4-5. Setup-Calibration & commissioning

By pressing the setup key, you get access to the operating system of the converter based on menus and submenus.

Settings wil give all history information on pa-

rameter settings concerning the analog outputs (mA1/mA2) and contact (S1…S4). This logbook is useful to trace back differences in performance due to changed settings. The events logged in this logbook are user definable. This is done in:

Commissioning >> Configure Logbook >> Settings Logbook – mA and/or Settings Logbook – contact

IM 12D06D05-01E

Browse through the list using the key till you find the required menu and press the

key to enter this menu.

It is also possible to press on the

or sym-

bol found beside the menu item.

4-6. Secondary- primary value display switch

Pressing on this text block automatically switches the secondary value to the main display (Large font size).

25.025.0

4-7. Navigation of the menu structure

Main display

OPERATION OF EXAxt ISC450G

Primary setup display

Instrument in HOLD

“RETURN KEY” exit to previous display

Commisioning menu display

IM 12D06D05-01E

5.MENU STRUCTURE COMMISSIONING

5-1. Configure sensor Measuring unit /cm /m

Either /cm or /m can be chosen here. The Process values will be expressed in S/cm or S/m respectively.

Cell constant (factory)

Cell constant given by factory calibration. Usually given on a label on the sensor or the calibration certificate.

Measure

Process values to be measured can be selected to suit the user’s preference.: Conductivity only, Concentration only or one of both Conductivity and Concentration.

5-2. Temperature setting T emperature Element

Selection of the temperature sensor used for compensation. The default selection is the Pt1000 Ohm sensor, which gives excellent precision with the two wire connections used. The other options give the flexibility to use a very wide range of other conductivity sensors.

T emperature Unit

Celcius or Fahrenheit temperature scales can be selected to suit the user’s preference.

5-3. Temperature compensation Compensation

Two types of methods can be used here. Automatic for use of temperature element. Select one of the Temperature elements used. The other is a manual set temperature. The manual temperature that represents the process temperature must be set here.

Reference T emperature

Choose a temperature to which the measured conductivity value must be compensated. Normally 25°C (77ºC) is used, therefore this temperature is chosen as default value.

Method TC In addition to the temperature coefficient

calibration routine it is possible to adjust the compensation factor directly. If the compensation factor of the sample liquid is known from laboratory experiments or has been previously determined, it can be introduced here. Adjust the value between 0.00 to 3.50 % per °C. In combination with reference temperature a linear compensation function is obtained, suitable for all kinds of chemical solutions.

NaCl Temperature compensation according

NaCl curve. See appendix 1 for values.

Matrix The EXAxt is equipped with a ma-

trix type algorithm for accurate temperature compensation in various applications. Select the range as close as possible to the actual temperature/concentration range. The EXAxt will compensate by interpolation. If user defined 1 or user defined 2 is selected, the temperature compensation range for the adjustable matrix must be defined. See Appendix 5 for matrix interpolation.

IM 12D06D05-01E

Note! Extra information on temperature

compensation is given in appendix 1.

Measurement setup

 Measure Conductivity only Configure sensor

 Temperature settings  Temp. Compensation  Calibration settings  Concentration

Enter

MENU STRUCTURE COMMISSIONING

Menu Parameter Default Range values min. max.

-1

Configure Sensor Cell constant 1.88 cm

0.2 cm-1 50.0 cm-1 Temp. Comp. Reference Temp. 25ºC, 77ºF 0ºC, 32ºF 100ºC, 211ºF Manual Comp. Manual Temp. 25ºC, 77ºF -20ºC, -3.9ºF 139ºC, 284ºF Temp. Coef T.C.methods 1 2.10%/ºC 0%/ºC, 0%/ºF 3.5%/ºC, 2.0%/ºF Temp. Coef T.C.methods 2 2.10%/ºC 0%/ºC, 0%/ºF 3.5%/ºC, 2.0%/ºF

IM 12D06D05-01E

5-4. Calibration settings Air adjust limit

To avoid cable influences on the measurement, a “zero” calibration with a dry sensor may be done. If a connection box (BA10) and extension cable (WF10) are being used, “zero” calibration should be done including this connection equipment. As the calibration is performed in air the resistivity is infinite (open connection). Higher conductivity values than the air adjust limit indicate the cell is not in air or is still wet. To prevent wrong air calibrations a limit must be given here.

Note The temperature compensation should be set to NaCl when confirming zero at air adjust.

c.c. high limit

High limit of the cell constant expressed in % of nominal value. During calibration this value is used to check if the calibrated cell constant remains within reasonable limits.

5-5. Concentration

Concentration has a direct relation with the conductivity value at reference temperature. This relation is built in every matrix which are used for temperature compensation. These can be found in:

Commissioning >> Measurement setup >> Temp. compensation >> Method

By selecting one of the matrices for temperature compensation directly gives the concentration value on the main display. If another temperature compensation method is chosen (NaCl or T.C.), the relation between the conductivity at reference temperature and the concentration is obtained from the “Concentration table”.

Additional table

This 21x2 user defined concentration table is used to come to more accurate concentration values compared to the temperature compensation matrix. Enabling this additional table overrules the concentration values obtained from the matrix (if used).

c.c. low limit

Low limit of the cell constant expressed in % of nominal value. During calibration this value is used to check if the calibrated cell constant remains within reasonable limits.

Stabilization time

During calibration the stability of the measurement is constantly monitored. When the value is within a bandwidth of 1% over a period of the stabilization time, the calibration is considered stable and the calibration may be completed.

Calibration Interval

A user defined interval in which a new calibration should take place. If the interval is exceeded the instrument will give a warning or a fail (user definable in error configuration 2/3)

Unit for table

The way the concentration values are presented to the user. Changing the unit will not result in a re-calculation of the table.

IM 12D06D05-01E

Measurement setup

 Measure Conductivity only Configure sensor

 Temperature settings  Temp. Compensation  Calibration settings  Concentration

Enter

Concentration measurement is only possible if “measure” in the “Configure sensor” menu is set to “conductivity + concentration” or “Concentration only”.

MENU STRUCTURE COMMISSIONING

Menu Parameter Default Range values min. max.

Calibration Air adjust 100.00 μS 0 μS 100 μS c.c. high 120% 100% 120% c.c. low 80% 80% 100% Stabilization time 5 s 2 s 30 s Calib. interval 250 days 1 day 250 days Concentr. Table Table See appendix

IM 12D06D05-01E

5-6. mA output setup

The general procedure is to first define the function (control, output, simulate, off) of the output and second the process parameter associated to the output. Available process parameters depend on selected “sensor type” and “measurement setup”. Off : When an output is set off the

output is not used and will give an

output of 4 mA. Control : A selection of P- PI- or PID control Manual : Static output required to maintain reset equilibrium state with setpoint. Direction : Direct

If the process variable is too high

relative to the SP, the output of

the controller is increased (direct

action). : Reverse

If the process variable is too high

relative to the SP, the output of the

controller is decreased (reverse

action). Output :

Linear or non linear table output.

The table function allows the configu-

ration of an output curve by 21 steps

(5% intervals). In the main menu

concentration can be selected to set

the concentration range. Simulate : Percentage of output span.

Normal span of outputs are limited

from 3.8 to 20.5 mA Fail safe : Contact S4 is programmed as a

fail-safe contact.

Burn Low or High will give an output of 3.6 resp. 21 mA in case of Fail situation.

Note! When leaving Commissioning, Hold

remains active until switched off manually. This is to avoid inappropriate actions while setting up the measurement.

Proportional control will reduce but not eliminate the steady state error. Therefore, proportional Control action includes a Manual Reset. The manual reset (percentage of output) is used to eliminate the steady state error.

Note! Any changes (disturbances) in the

process will re-introduce a steady state error.

Proportional control can also produce excessive overshoot and oscillation. Too much gain may result in an unstable- or oscillating process. Too little gain results in a sustained steady

state error. Gain = 1/Range. [PV units]

Integral Control

Integral control is used to eliminate the steady state error and any future process changes. It will accumulate setpoint and process (load) changes by continuing to adjust the output until the error is eliminated. Small values of integral term (I-time in seconds) provide quick compensation, but increase overshoot. Usually, the integral term is set to a maximum value that provides a compromise between the three system characteristics of: overshoot, settling time, and the time necessary to cancel the effects of static loading (process changes). The integral term is provided with an anti windup function. When the output of PI portion of the controller is outside the control range (less than -5% or greater than 105%), the I-part is frozen.

Controller

Range

ºe dt

dPV

Actuator

Process

Figure 5-1. Control Diagram

Proportional control

Proportional Control action produces an output signal that is proportional to the difference between the Setpoint and the PV (deviation or error). Proportional control amplifies the error to motivate the process value towards the desired setpoint. The output signal is represented as a percentage of output (0-100%).

IM 12D06D05-01E

Derivative control

The control acts on the slope (rate of change) of the process value, thereby minimizing overshoot. It provides “rate” feedback, resulting in more damping. High derivative gains can increase the rizing time and settling time. It is difficult to realize in practice because differentiation leads to “noisy” signals.

MENU STRUCTURE COMMISSIONING

mA2 similar structure to mA1

Menu Parameter Default Range values min. max.

mA1 (output) Damping time 0.0 sec. 0.0 sec. 3600 sec.

Linear mA1 0% Value 0.000 S/cm - inf + inf Linear mA1 100% Value 1.000 S/cm - inf + inf

Linear mA2 0% Value 0.0 ºC/ºF - inf + inf Linear mA2 100% Value 100.0 ºC/ºF - inf + inf

P-control mA1 Setpoint 500.0 mS/cm - inf + inf P-control mA1 Range 100.0 mS/cm - inf + inf P-control mA1 Manual Reset 0.000 % 0% 100%

P-control mA2 Setpoint 25.0 ºC/ºF - inf + inf P-control mA2 Range 10.0 ºC/ºF - inf + inf P-control mA2 Manual Reset 0.000 % 0% 100%

mA1 (simulate) Simulation perc. 50% 0% 100%

Hold Fixed value mA1 12.00 mA 3.6 mA 21 mA Hold Fixed value mA2 12.00 mA 3.6 mA 21 mA

IM 12D06D05-01E

Expire time

If the output is over 100% for longer than the expire time, the output will return to 0%.

Damping time

The response to a step input change reaches approximately 90 percent of its final value within the damping time.

100%

manual

reset

100%

range

set

point

range

process

value

Direct

Setpoint

off on off

Hys.

Delay time Delay time

t (sec)

Figure 5-3. Alarm contact (on/off control)

% controller output

100

off

> 0.1 sec

manual

reset

set

point

process

value

Reverse

Figure 5-2. Direct/Reverse action

5-7. Contact output setup

S1/S2/S3/S4 Each Switch (contact) can have the following functions.

1. Control : A selection of P- PI- or PID control

2. Alarm : Low or high value Limits monitoring

3. Hold : A hold contact is energised when

the instrument is in HOLD

4. Fail : S4 is set as fail-safe contact.

Simulate

: To test the operation of the contact,

simulate can be used. The contact can be switched on or off or a percentage of duty cycle can be entered (DC period time)

7. Off : Switch is not used.

power down activated

S1, S2, S3 S4

power on

normal opened

power on

contact

Duty cycle

Range

50%

Duty cycle

ton> 0.1 sec

Duty cycle

Figure 5-4. Duty cycle control

% controller output

100

Range

0.3 s

Maximum pulse frequency

0.3 s

50% pulse frequency

No pulses

Figure 5-5. Pulse frequency control

50%

off

Above table shows contact output status between common to NO.

Configure hold

Hold is the procedure to set the outputs to a known state when going into commissioning. Du ring commissioning HOLD is always enabled, out puts will have a fixed or last value. During ca libra tion the same HOLD function applies. For ca libra tion, it is up to the user if HOLD is enabled or not.

IM 12D06D05-01E

Lifetime contacts

One should note that the lifetime of the con-

tacts is limited (10

). When these contacts are used for control (pulse frequency or duty cycle with small interval times), the lifetime of these contact should be observed. On/Off control is preferred over Pulse/duty cycle.

S2, S3, S4 Similar structure to S1

MENU STRUCTURE COMMISSIONING

Menu Parameter Default Range values min. max.

Alarm S1 Setpoint 900.0 mS/cm (high) - inf + inf Alarm S1 Hysteresis 9.000 mS/cm 0.0 μS/cm + inf Alarm S1 Delay Time 0.2 sec. 0.0 sec. + inf Alarm S1 Expire Time 0.0 sec. 0.0 sec. 1800 sec.

Alarm S2 Setpoint 100.0 mS/cm (low) - inf + inf Alarm S2 Hysteresis 1.000 mS/cm 0.0 μS/cm + inf Alarm S2 Delay Time 0.2 sec. 0.0 sec. + inf Alarm S2 Expire Time 0.0 sec. 0.0 sec. 1800 sec.

S1 (control) Expire Time 0.0 sec. 0.0 sec. 1800 sec.

P-control S1 Setpoint 500.0 mS/cm - inf + inf P-control S1 Range 100.0 mS/cm - inf + inf P-control S1 Manual Reset 0.000% 0% 100%

PID-control S1 I-time 3600 sec. 1.0 sec. 3600 sec. PID-control S1 D-time 0.0 sec. 0.0 sec. 60 sec.

IM 12D06D05-01E

5-8. Fail

A fail contact is energized when a fail situation occurs. Fail situations are configured in secton 5-11. For SOFT Fails the contact and the display on LCD are pulsating. For HARD Fails the contact and the display on LCD are energized continuously.

Hard fail only

The contact reacts to Hard Fails Only

Hard + soft fail

The contact reacts to Hard and Soft Fails

Only contact S4 is programmed as a fail-safe contact. This means that contact S4 wil be de-energized when a fail situation occurs.

5-9. Simulate

The contact can be switched on/off or a percentage of output can be simulated. On/Off enables the user to manually switch a contact on or off. The percentage is an analogue value and represents the on time per period.

The Duty cyde Period time (see figure 5-4) is used as a period for percentage simulation.

Note that the (simulated) settings of the contacts become visible in measuring mode and after HOLD has ended c.q. has been overruled. A warning is activated in case of a simulated output contact.

5-10. Input contacts

The terminal of the ISC450G provides for an input contact (see Figure 3-7). This input contact can be used to switch the range of the outputs. The range can be increased by 1 decade.

IM 12D06D05-01E

S2, S3, S4 Similar structure to S1

MENU STRUCTURE COMMISSIONING

(depending on mA1 and mA2 output settings)

Menu Parameter Default Range values min. max.

Simulation Percentage 50% 0% 100%

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5-11. Error configuration Errors 1/3 ~ 3/3

Errors are intended to notify the user of any unwanted situations. The user can determine which situations should be classified as: FAIL, immediate action is required. The process variable is not reliable. WARN, the process variable processes by the converter is still reliable at this moment, but maintenance is required in the near future.

“FAIL” gives a flashing “FAIL” flag in the main display. The contact configured as FAIL

(Commissioning >> output setup) will be en-

ergized continuously. All the other contacts are inhibited. A Fail signal is also transmitted on the mA-outputs when enabled (burn high/low).

(Commissioning >> output setup)

“WARN” gives a flashing “WARN” flag in the display. The contact configured as FAIL is pulsed. All the other contacts are still functional, and the converter continues to work normally. A good example is a time-out warning that the regular maintenance is due. The user is notified, but it should not be used to shut down the whole measurement.

Flashing “Fail” flag in main display

Flashing “Warn” flag in main display

5-12. Logbook configuration General

Logbook is available to keep an electronic record of events such as error messages, calibrations and programmed data changes. By reference to this log, users can for instance easily determine maintenance or replacement schedules.

In “Configure Logbook” the user can select each item he is interested in to be logged when the event occurs. This can be done for three separate logbooks. Each logbook can be erased individually or all at once. Enable the ”Warn if Logbook full” when you would like to be warned when the logbook is almost full.

The content of the logbook(s) can also be retrieved from the converter using the “EXAxt Configurator” software package which can be downloaded from the Yokogawa Europe website.

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MENU STRUCTURE COMMISSIONING

Menu Parameter Default Range values min. max.

Errors High limit 1.000S 0.1S 3S Errors Low limit 5.000μS 0.0S 100μS

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5-13. Advanced setup Defaults

The functionality of the EXAxt allows to save and load defaults to come to a known instrument setting. The EXAxt has both factory and user defined defaults. After a “load default” the instrument will reset. The following parameters are not included in the defaults:

1. X-axis timing

2. Auto return (10 min / disabled)

3. Tag

4. Passwords

5. Date and time

6. Language

7. The contents of all logbooks

8. HART parameters (address, tag, descriptor, message)

Tag

A tag provides a symbolic reference to the instrument and is defined to be unique throughout the control system at one plant site. A tag can contain up to 12 characters. If the instrument is purchased with the /SCT option, the TAG is pre-programmed with the specified tagnumber.

Factory adjustment

This menu is for service engineers only. This section is protected by a password.

Attempting to change data in the factory adjustment menu without the proper instructions and equipment, can result in corruption of the instrument setup, and will impair the performance of the unit.

Passwords

Calibration and Commissioning may be separately protected by a password. By default both passwords are empty. Entering an empty password results in disabling the password check. A password can contain up to 8 characters. When a password is entered for the calibration and commissioning a 4-digit operator ID can be entered. One can also leave the ID empty.

Date/time

The Logbooks and trend graph use the clock/ calendar as reference. The current date and time is set here. The current time is displayed in the third “zoom” menu.

Note! The fixed format is YYYY/MM/DD HH:

MM:SS

HART

The address of the EXAxt in a HART network can be set. Valid addresses are 0...15.

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MENU STRUCTURE COMMISSIONING

Menu Parameter Default Range values Low High

HART Network address 0 0 15

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5-14. Display setup Main display

The main display consists of three lines with Process Values. Each line is user definable with the restriction that each line should have a different Process Value. The default settings can be defined here. By pressing one of the two smaller process values, this will become the main process value in the main screen. Autoreturn will cause the main display to go to default setting. See also 4-6 Secondary to Primary Value display Switch.

Note! Configuration possibilities in the

main and secondary display lines are determined by the choices made in the menu measurement

Measurement setup >> Measurement

Additional text

Each process value can be given an additional text containing up to 12 characters per text. This text is displayed on the main display next to the process value. This way the user can distinguish separate measurements.

X-axis timing

The time range of the trend graph can be set from 15 minutes up to 14 days.

Y-axis limits

The ranges for each measurement need to be set according the application.

Auto return

When Auto return is enabled, the converter reverts to the measuring mode (main display) from anywhere in the configuration menus, when no button is pressed during the set time interval of 10 minutes.

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MENU STRUCTURE COMMISSIONING

Menu Parameter Default Range values Low High

Y-axis Conduct low 0 μS/cm - inf + inf Y-axis Conduct high 500 μS/cm - inf + inf Y-axis Conduct 2 low 0 μS/cm - inf + inf Y-axis Conduct 2 high 500 μS/cm - inf + inf Y-axis Temp. low 0ºC, 32ºF - inf + inf Y-axis Temp. high 100ºC, 212ºF - inf + inf

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6. CALIBRATION

1. When is calibration necessary?

Calibration of con duc tiv i ty in stru ments is not nor mal ly nec es sary as the con duc tiv i ty cells are man u fac tured to close tol er anc es and do not al ter in use.

If the cell has severe fouling or been sub ject to abrasion (possibly during cleaning) it may be necessary to calibrate.

Since the ISC450G/ISC40 inductive con ductiv i ty system measures the conductivity of the “liq uid winding” through the doughnut, part of this “measuring cell” is outside the dough nut. If there is little space between dough nut and process piping, calibration with a sam ple of the process fluid is necessary to en sure ac cu rate measurement.

2. How is calibration done?

Calibration is carried out by measuring a so lu tion which has known conductivity and ad just ing the instrument to show the cor rect conductivity value.

er ence tem per a ture of the instrument (usu al ly 25 °C). The actual conductivity value of the solution is taken from tables. To calibrate the in stru ment, the sensor is removed and sus pend ed in the solution, the conductivity val ue from the tables is then entered and the cal i bra tion routine completed. Make sure the sensor does not touch the sides of the container, refer to Figure 6-1.

2) Alternatively the instrument can be cal i brat-

ed using the process solution meas ured with a standard instrument. Care must be taken to make the measurement at the ref er ence tem per a ture since differences in the type of tem per a ture compensation of the instruments may cause an error.With this method the sensor is not removed from the process. This method is the most convenient method of calibrating the ISC450G converter. Since the sensor is im mersed in the process, errors caused by in stal la tion characteristics are compensated for.

The calibration can be achieved using one of two methods:

1) A calibration solution can be prepared in

the laboratory. A salt solution is prepared with a known precise concentration. Thetem per a ture is stabilized to the ref-

Note! The standard instrument used as

ref er ence method must be ac curate. Yokogawa recommends that the Model SC72 pocket conductivity meter be used for this purpose.

igure 6-1. Sensor in calibration solution

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X = MIN 25 mm

Cell constant: The nominal cell constant of the sensor is 1.88 cm-1 for the PEEK sensor types and 3.00 cm-1 for the PFA sensor. The calibrated values are indicated on the cable

Only for PEEK

1.30

1.25

1.20

1.15

1.10

1,05

1.00

0.95

Correction factor (x nominal C.C.)

0.90

non conductive

piping

conductive

piping

0 10 20 30 40 50

markers and the actual installation can change this factor. If there is less than 25 mm spacing between sensor and holder, in-situ calibration is necessary to meet the specified accuracies.

D in millimeters

CALIBRATION

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7. MAINTENANCE

7-1. Periodic maintenance

The converter requires very little periodic maintenance, except to make sure the front window is kept clean in order to permit a clear view of the display and allow proper operation of the touchscreen. If the window becomes soiled, clean it using a soft damp cloth or soft tissue. To deal with more stubborn stains, a neutral detergent may be used.

When you must open the front cover and/or glands, make sure that the seals are clean and correctly fitted when the unit is re-assembled in order to maintain the housing’s weatherproof integrity against water and water vapor.

Note! Never use harsh chemicals or solvents.

In the event that the window does become heavily stained or scratched, refer to the parts list (Chapter 10) for replacement part numbers.

Battery

The EXAxt converter contains a logbook feature that uses a clock to provide the timings. The instrument contains a lithium cell (battery) to support the clock function when the power is switched off. The cell has an expected working life of 10 years. Should this cell need to be replaced, contact your nearest Yokogawa service center.

7-3. Cleaning methods

1. For normal applications hot water with

domestic washing-up liquid added will be effective.

2. For lime, hydroxides, etc., a 5 ...10%

solution of hydrochloric acid is recommended.

3. Organic contaminants (oils, fats, etc.) can be

easily removed with acetone.

4. For algae, bacteria or moulds, use a solution

of domestic bleach (hypochlorite).

* Never use hydrochloric acid and bleaching

liquid simultaneously. The release of the very poisonous chlorine gas will result.

7-4. Contrast adjustment

During the life of the analyzer the contrast of the display may fade. The contrast can be adjusted using the potentiometer on the backside of the LCD board. This adjustment must be done only by Yokogawa’s service personnel. The position is shown on the picture below. For units manufactured after July 2007, the potentiometer is placed behind the little hole in the LCD bracket as shown in Figure 3-4 on page 7. For units manufactured between April 2006 and April 2007, the potentiometer is located as shown below.

Fuse

There is a circuit board mounted fuse protecting the instrument. If you suspect that this needs to be replaced, contact your nearest Yokogawa service center.

7-2. Periodic maintenance of the sensor Note! Maintenance advice listed here is

intentionally general in nature. Sensor maintenance is highly application

specific. In general conductivity measurements do not need much periodic maintenance. If the EXAxt indicates an error in the measurement or in the calibration, some action may be needed (ref. chapter 8 troubleshooting).

IM 12D06D05-01E

Do not turn on power with the touchcsreen

CAUTIONCAUTION

pressed, otherwise inaccurate screen positioning will occur. If it occurs, leave the touchscreen unpressed, turn off power then on again. The screen positioning will be accurate.

8. TROUBLESHOOTING

8-1. General

The EXAxt is a microprocessor-based analyzer that performs continuous self-diagnostics to verify that it is working correctly. Error messages resulting from faults in the micro-processor systems itself are monitored. Incorrect programming by the user will also result in an error, explained in a message, so that the fault can be corrected according to the limits set in the operating structure. The EXAxt also checks the sensor system to establish whether it is still functioning properly.

In the main display screen is a “Status Information“ button that will show.

For information

For warning - a potential problem is diag-

nosed, and the system should be checked.

For FAIL, when the diagnostics have confirmed

a problem, and the system must be checked. This button gives access to a status report

page, where “The most applicable error” will be displayed. (“No errors” is displayed during

proper operation)

Explanation >> Description or error message

and possible remedies

8-3. Predictive maintenance

EXAxt has a unique prediction feature. Calibration, data is stored in software data logbooks. This data is then used to calculate a prediction for maintenance purposes.

8-4. Poor calibration technique

When the calibration data is not consistent this fact is used as a diagnostic tool. The significance of this error message is to require the user to improve his calibration technique. Typical causes for this error are attempting to calibrate dirty sensors, calibration solution contamination and poor operator technique.

8-5. Error displays and actions

All errors are shown in the “Main Display” screen, however, the EXAxt makes a distinction between diagnostic findings. The error messages may be set to OFF, WARN or FAIL. For process conditions where a particular diagnostic may not be appropriate, the setting OFF is used. FAIL gives a display indication only of that the system has a problem and inhibits the relay control action, and can be set to trigger the “Burn” function. “Burn-up” or “Burn-down” drives the mA output signal to 21 mA or 3.6 mA respectively.

TROUBLESHOOTING

Advanced troubleshooting >> Error code

screen that is used in conjunction with the service manual. This data will also be needed in the event that you request assistance from a Yokogawa service department.

What follows is a brief outline of the EXAxt troubleshooting procedures including possible causes and remedies.

8-2. Calibration check

The EXAxt ISC450G converter incorporates a diagnostic check of the adjusted cell constant value during calibration. If the adjusted value stays within 80-120 % of the factory value, it is accepted, otherwise, the unit generates an error message, and the calibration is rejected.

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9. QUALITY INSPECTION

Quality Inspection

ISC450G Inductive Conductivity Converter

Standards

1. Scope

This inspection standard applies to the ISC450G Inductive Conductivity Converter.

2. Inspection Items

2.1 Insulation resistance test *2.2 Dielectric strength test *2.3 Sensor signal input test

2.4 Temperature indication check

2.5 Current output test

Note: Items marked with an asterisk (*) may only be confirmed by a test certificate.

3. Inspection Methods, Standards and Conditions

z Connect the testing circuit as shown in Figure 1. Allow the instrument to warm up for

at least 5 minutes before conducting the tests. For the connections for the insulation resistance and dielectric strength tests, follow the instructions in Sections 3.1 and 3.2.

3.1 Insulation Resistance Test

Apply 500 V DC between the terminals shown below. The insulation resistance must be 100 MΩ or greater.

(1) Between the power supply terminals shorted together (1 and 2) and the protective

earth terminal (

(2) Between the contact output terminals shorted together (32, 33, 42, 43, 52, 53, 72 and

73) and the protective earth terminal (

(3) Between the current output terminals shorted (62) and the protective earth terminal

)

(

3.2 Dielectric Strength Test

(1) Apply 1390 V AC, an AC voltage of substantially sinusoidal waveform with a frequency

of 50 Hz or 60 Hz, between the power supply terminals shorted together (1 and 2) and the protective earth terminal (

this voltage. (The sensed current should be 10 mA.)

(2) Apply 1390 V AC, an AC voltage of substantially sinusoidal waveform with a frequency

of 50 Hz or 60 Hz, between the contact output terminals shorted together (32, 33, 42, 43, 52, 53, 72 and 73) and the protective earth terminal (

The insulation must withstand this voltage. (The sensed current should be 10 mA.)

(3) Apply 500 V AC, an AC voltage of substantially sinusoidal waveform with a frequency

of 50 Hz or 60 Hz, between the current output terminals shorted (62) and the protective earth terminal ( ), for at least 2 seconds. The insulation must withstand

this voltage. (The sensed current should be 10 mA.)

3.3 Sensor Signal Input Test

Connect the testing circuit as shown in Figure 1 and set the equipment as follows:

Decade resistance box 1 (temperature simulation input): 1097.3 [Ω]

Decade resistance box 2 (conductivity simulation input): 150 [Ω] The power supply voltage should be set in accordance with the specifications of the converter.

)

), for at least 2 seconds. The insulation must withstand

), for at least 2 seconds.

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QIS 12D06D05-01E

1st Edition: Jul. 2007

This test is done on the “HIF” display of “Factory Mode”.

a. Touch the [Setup] icon. b. Touch the [Commissioning]. c. Touch the [Advanced setup]. d. Touch the [Factory adjustment]. e. Enter a password. f. Select the [Factory Mode] in “Key.” g. Select the [HIF] in “Execute.”

Wind ten turns of wire onto ISC40 sensor. When the resistance of the decade resistance box 2 to the corresponding value “RANGE1” to “RANGE3” in Table 1 is set, check the data display and the value must be within the range shown in Table 1.

Table 1

RANGE

RANGE1 150 1.5 ±0.01

RANGE2 1.5k 15 ±0.1 RANGE3 15k 150 ±1

Resistance (Ω) of

Decade Resistance Box 2

Data Display (Ω)

2/3

After the above test is completed, wind one turn of wire onto ISC40 sensor. When the resistance of the decade resistance box 2 to the corresponding value “RANGE4” to “RANGE6” in Table 2 is set, check the data display and the value must be within the range shown in Table 2.

Table 2

RANGE

RANGE4 1.5k 1.5k ±0.01k

RANGE5 15k 15k ±0.2k RANGE6 150k 150k ±12k

After the above test is completed, touch the [Exit] to return to the “HIF” display.

3.4 Temperature Indication Check

Following Section 3.3, select the [PT1000] in “Temperature” of the “HIF” display. In this state, change the resistance of the decade resistance box 1 and check the data display. The value on the data display must be within the range shown in Table 3.

Table 3

Temperature (°C)

–10 960.9 –10 ±0.3

25 1097.3 25 ±0.3

130 1498.2 130 ±0.3

Resistance (Ω) of

Decade Resistance Box 2

Resistance (:) of

Decade Resistance Box 1

Data Display (Ω)

Data Display (°C)

QUALITY INSPECTION

After the above test is completed, touch the [Exit] to return to the “HIF” display.

3.5 Current Output Test

Following Section 3.4, select the [Check] in “mA outputs” of the “HIF” display. “Set value

4.000 mA” appears at the bottom of the display. Select “Next value” in the “Command” and touch “Enter,” the value on the data display increases in steps of 4 mA. Check the current outputs 1 and 2 corresponding to the data display, the current output must be within the range shown in Table 4.

QIS 12D06D05-01E

IM 12D06D05-01E

3/3

Table 4

Data Display Current Output (mA DC)

4 4 ±0.02 12 12 ±0.02 20 20 ±0.02

After all tests are completed,

a. Touch the [Exit] twice to return to the “Service” display. b. Select “Normal” in “Key”. c. Touch the [Home] icon to return to the initial display.

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Figure 1 Testing Circuit and Test Equipment

QIS 12D06D05-01E

QUALITY INSPECTION

IM 12D06D05-01E

10. SPARE PARTS

See Customer Maintenance Parts List.

IM 12D08N05-01E

APPENDICES

APPENDIX 1

Temperature compensation

The conductivity of a solution is very dependent on temperature. Typically for every 1°C change in temperature the solution conductivity will change by approximately 2%. The effect of temperature varies from one solution to another and is determined by several factors like solution composition, concentration and temperature range. A coefficient (α) is introduced to express the amount of temperature influence in % change in conductivity/°C. In almost all applications this temperature influence must be compensated before the conductivity reading can be interpreted as an accurate measure of concentration or purity.

NaCl or standard temperature compensation

From the factory the EXAxt is set with the default of a general temperature compensation function based on a Sodium Chloride (table salt) solution. This is suitable for many applications and is compatible with the NaCl compensation functions of typical laboratory or portable instruments. ISC temperature compensation.

Table 11-1. NaCl-compensation according to IEC 60746-3 with Tref = 25 °C

Configure calculated temperature coefficient (TC).

Follow routing

Commissioning >> Measurement setup >> Temp.compensation >> T.C.

Enter the temperature coefficient calculated from the following formula:

A. Calculation of temperature coefficient factor

( With known conductivity at reference temperature).

α =

t-Kref

T-T

ref

100

ref

α = Temperature compensation factor in %/°C T = Measured temperature in °C Kt = Conductivity at T T

= Reference temperature

ref

= Conductivity at T

ref

APPENDICES

IM 12D06D05-01E

B. Calculation of temperature coefficient factor

(with two known conductivity values at different temperatures) Measure the conductivity of the liquid at two temperatures, one below the reference and above the reference temperature with the temperature coefficient set to 0,00%/°C and use the following equation to calculate a temperature coefficient (α).

ref

1+α (T-T

)

ref

1+α (T

(1 + α (T2-T

K1+α (T2-T

1(T2-Tref

)

1-Tref

)) = K2(1 + α (T1-T

ref

)-K2+α (T1-T

ref

K2-K

)-K2(T1-T

1+α (T

)=K2-K

ref

)

ref

2-Tref

ref

)

))

Where T1 , T2 : liquid temperature (°C) K K

: conductivity at T1 (°C)

: conductivity at T2 (°C)

Figure 11-1. Conductivity

Calculation example Calculate the temperature co-efficient of a liquid from the following data. Conductivity 124.5 μS/cm at a liquid temperature of 18.0 °C and a conductivity 147.6 μS/cm at a liquid temperature of 31.0 °C.

Substituting the data in the above formula gives the following result.

147.6 - 124.5

α =

x 100= 1.298 %/C

124.5(31.0 - 25) - 147.6(18.0 - 25)

Set the temperature coefficient in the ISC450G converter.

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• Checking

When the temperature coefficient already set is accurate, the conductivity to be displayed must be constant regardless of liquid temperature. The following check will make sure that the temperature coefficient already set is accurate. If, when the liquid temperature is lowered, a larger conductivity value is indicated, the temperature coefficient already set is too small. The opposite also applies. If a smaller conductivity value is indicated, the temperature coefficient already set is too large. In either case, change the temperature coefficient so that the conductivity no longer changes.

Matrix compensation

The compensation matrix is a table of temperature and conductivity values at differing concentrations. These values are used to calculate the temperature compensation applicable for a particular solution. Choose the component that you will be measuring in your application, and where appropriate the concentration range. EXAxt will do the rest.

By following the routing:

Commissioning>> Measurement setup>> Temp.compensation>> Matrix

you gain access to the Matrix selection area.

Matrices are available for the common mineral acids and bases. In addition Ammonia and Morpholine are included. In short by using the matrix method, specialist compensation is available for the majority of applications in the power industry, water treatment, and chemical manufacturing. The following matrices are available initially, but as with all Yokogawa products, we are continually striving to improve both the quality and technological content. Further solutions will be added to this list.

H2SO

2SO4

HCl 1..5% 0..60 ˚C

HCl 0..18% -10..65 ˚C

HCl 24..44% -20..65 ˚C

HNO

NaOH 1..5% 0..100 ˚C

1..5% 0..100 ˚C

1..27% -1..99 ˚C

39..85% -18..116 ˚C

93..100% 10..90 ˚C

1..5% 0..80 ˚C

0..25% 0..80 ˚C

35..85% -16..60 ˚C

NaOH 0..15% 0..100 ˚C

NaOH 25..50% 0..80 ˚C

APPENDICES

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APPENDIX 2

Temperature compensation matrix.

1. A minimum number of values is required to make interpolation possible.

The highlighted values marked as

Concent Tref T1 .... Tx .... T10

Sol1 C1 S1Tr S1T1 S1T10

....

Solx SxTx

....

Sol10 C10 S10Tr S10T1 S10T10

are mandatory to enter.

2. Tref (reference temperature) is defined in the Temperature Compensation menu. If Tref is

between T1 and T10 then the value of Tref needs to be entered as Tx (T2....T9).

Concent Tref T1 .... Tx .... T10

Sol1 C1 S1Tr S1T1 S1T10

....

Solx

....

Sol10 C10 S10Tr S10T1 S10T10

3. For every SxTx that is entered the following values become mandatory to enter:

Cx, SxTr, SxT1, SxT10 and Tx.

Concent Tref T1 .... Tx .... T10

Sol1 C1 S1Tr S1T1 S1T10

....

Solx Cx SxTr SxT1 SxTx SxT10

....

Sol10 C10 S10Tr S10T1 S10T10

The matrix can be cleared before entering new values. Next new matrix values can be entered as described above. The EXAxt can interpolate the matrix. During this process it will check if the matrix is completely ascending/descending. This is necessary as otherwise the lookup function can give two results for one temperature. If an error is found, the EXAxt will specify the location of the error as shown in the user interface screen “user defined 1/2”.

The backspace key should be used for deleting an individual matrix value.

An empty value is shown as

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APPENDIX 3

Calibration solutions for conductivity

Note!

This section should be read in conjunction with the calibration section (Chapter 6) and the maintenance section (Chapter 7). The calibration (cell constant) of a sensor does not change unless the sensor is damaged. It can also appear to change because of coating of the electrodes, or partial blockage. Because these changes should be handled as described in the maintenance section, it does not make sense to regularly recalibrate the ISC450G.

A calibration check, however, is another matter. When the objective is clearly defined as a diagnostic exercise a regular check can bring an extra level of security and confidence to the measurement.

Sensor damage, and/or coatings can be difficult to see and the calibration check can confirm their presence, by a deviation from the known solution conductivity. The remedial action should be to clean the sensor, and carefully check for blockage or damage (not simply to recalibrate).

Higher conductivity solutions should be used where possible. The lower the conductivity of the test solution, the easier it is to contaminate. Carbon dioxide from the air can be quickly absorbed to cause an error. All containers must be suitably clean, and all materials suitably pure. Outside of a well-equipped laboratory these conditions are hard to meet.

EXAxt ISC450G is programmed with the following table of conductivity of Potassium Chloride (KCl) solutions at 25°C. This is used in the Automatic Cell Constant setting calibration feature. (See chapter 6 on calibration) The table is derived from the Standards laid down in “International Recommendation No. 56 of the Organisation Internationale de Métrologie Legale”.

Table 11-2. KCl values at 25 °C

mol/l

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APPENDICES

If it is more convenient, the user may make solutions from Sodium Chloride (NaCl or common table salt) with the help of the following

Table 11-3. NaCl values at 25 °C

Weight % mg/kg Conductivity

0.001 10 21.4 μS/cm

0.003 30 64.0 μS/cm

0.005 50 106 μS/cm

0.01 100 210 μS/cm

0.03 300 617 μS/cm

0.05 500 1.03 mS/cm

0.1 1000 1.99 mS/cm

0.3 3000 5.69 mS/cm

0.5 5000 9.48 mS/cm 1 10000 17.6 mS/cm 3 30000 48.6 mS/cm 5 50000 81.0 mS/cm

10 100000 140 mS/cm

APPENDIX 4

relationship table. This table is derived from the IEC norm 60746-3.

Measurement principle

Contrary to contact electrode conductivity, the EXA ISC Series analyses the con duc tiv i ty with out any contact between electrodes and proc ess fluid. The measurement is based on inductive coupling of 2 ring trans form ers (Toroids) by the liquid.

Drive coilReceive coil

The converter supplies a reference volt age at a high frequency to the “drive coil”. The core of this coil is of a high permeability mag net ic material, and a strong magnetic field is generated in the toroid. The liquid passes through the hole in the toroid and can be considered as a “one turn” secondary winding.

The magnetic field will induce a voltage in this secondary winding. The induced cur rent in the liquid winding is proportional to this volt age and the conductance of the liquid “one turn winding” is according to Ohm’s law.

The conductance (1/R) is proportional to the specific conductivity and a constant factor that is determined by the geometry of the sensor (length divided by surface area of the hole in the toroid) and the installation of the sensor.

There are 2 toroids mounted in the “dough nut” shaped sensor. The liquid also flows through the second toroid and therefore the liquid turn can be considered as a primary wind ing of the second ring transformer.

The current in the liquid will create a mag net ic field in the second toroid. The induced volt age being the result of this magnetic field can be measured as an output.

The output voltage of this “receive coil” is therefore proportional to the specific con duc tiv i ty of the process liquid.

IM 12D06D05-01E

APPENDIX 5

HART HHT (275/375) Menu structure

Online menu Level 1 menu Level 2 menu Level 3 menu Level 4 menu

Process values

Zoom Zoom sensor Fact CC

Primary value (SC/Conc.)

Secondary value (Temp.) Tertiary value (SC/Cond)

Adj CC Method SC1 Method SC2* Ohms

Zoom outputs mA1 value

mA2 value S1 perc. S2 perc. S3 perc. S4 perc.

Zoom device Serial number

(Note)

Software Revision Device Revision DD Revision

Logbook Sensor data Calibration

Sensor

(Note):

Output data Settings

A part of the HART device ID (descriptor)



mA1 mA2 S1 S2 S3 S4

APPENDICES

IM 12D06D05-01E

Online menu Level 1 menu Level 2 menu Level 3 menu Most appl. Error

Calibration

Hold Instrument

Commissioning

Error description / remedy

CC Calibration SC1 CC Calibration SC2 Air Calibration Sample calibration SC1 Sample calibration SC2 TC Calibration SC1* TC Calibration SC2* Temp. Calibration

Hold Instrument

Hold Outputs Hold Off

Measurement setup

Configure sensor

Temp settings Temp sensor

Temp compensation

Meas unit

Fact CC Measure*

Temp unit

Temp comp

Man value* Ref temp Method SC1 TC SC1* Matrix SC1* Method SC2* TC SC2* Matrix SC2*

Level 4 menu

Calib. settings Air adjust limit

cc hi limit cc lo limit Stab time cal interval

Concentration

Additional table*

Conc table unit*

IM 12D06D05-01E

Online menu Level 1 menu Level 2 menu Level 3 menu Level 4 menu

Commissioning

Output setup mA1 setup

mA2 setup (similar to mA1)

S1 setup S2 setup (similar to S1) S3 setup (similar to S1) S4 setup (similar to S1)

Type = control Func

Process parameter PID SP PID Rng PID dir PID MR* PID I-time* PID D-time* Burn Expiry time

Type = control Func

Process parameter Expire time PID SP PID Rng PID dir PID MR* PID I-time* PID D-time* Analog output DC period time* max. pulse freq.*

Type = fail func

Type = output Func

Process parameter Lin 0%* Lin 100%* Burn Damping time

Type = simulate Func

Sim. Perc.

Type = Off

Type = alarm Func

Process parameter alarm SP alarm dir. alarm hyst. alarm delay expiry time

Type = simulate func

on/off* percentage*

Type = hold func Type = Off

HOLD setup HOLD L/F

mA1 fixed * mA2 fixed * Hold during cal

Input contact Configure Input

contact

Error config Configure error

Off/Warn/Fail

set limits

Logbook config Sensor logbook

mA logbook Contact logbook

Erase logbook

Warn logbook full

Calibration

Sensor

All logbooks

APPENDICES

IM 12D06D05-01E

Online menu Level 1 menu Level 2 menu Level 3 menu Level 4 menu

Loop test

Basic setup Tag

Distributor Model

Device information Date

Descriptor Message Poll addr Num resp preams

Review Model

Distributor Write protect Manufacturer Dev id Tag Descriptor Message Date Universal rev Fld dev rev Sofware rev Poll addr Num req preams

(Note):

HART protocol DD files can be downloaded by following URL.



http://www.yokogawa.com/an/download/an-dl-fieldbus-001en.htm

IM 12D06D05-01E

APPENDIX 6, Control drawing for FM approval

IM 12D06D05-01E

APPENDICES

IM 12D06D05-01E

Customer Maintenance Parts List

Model SC450G [Style: S2] Conductivity / Resistivity Converter

5a, 5b

6a, 6b

1a, 1b

Item Part No. Qty Description

*1a K9676GA 1 Power board assembly AC version *1b K9676HA 1 Power board assembly DC version

*2 K9677EA 1 Main board assembly SC version *3 K9676MA 1 LCD module

*5a K9676MX 1 Cable assembly (3 core) *5b K9676MW 1 Cable assembly (10 core) *5c K9676MY 1 Cable assembly (shield) *6a A1108EF 1 Fuse AC version (1 pcs.) *6b A1111EF 1 Fuse DC version (1 pcs.)

*7 K9676BE 1 Cover assembly without, screws and hingepins

8 K9676BU 1 Cable glands assembly (6 pcs. M20) 9 K9676DL 1 Stainless tagplate blank

10 K9676BT 1 Screw assembly to fix cover (M4 screws, washer, O-ring, hingepins)

*11 K9676CM 1 Housing assembly polyurethan baked finish

12 — Adapter assembly for conduit work

K9171SU 1 For G1/2 screw when /AFTG specified K9316AF 1 For 1/2NPT screw when /ANSI specified K9676BC 1 For M20 screw when /AM20 specified

*) Do not exchange these parts. Call service personnel.

CMPL 12D08N05-02E

Pipe/Wall Mounting Hardware (Option code: /U)

Panel Mounting Hardware (Option code: /PM)

UNIVERSAL MOUNT SET

(Option code : /UM) includes

both “/U” and “/PM”.

Awning Hood (Option code: /H5)

Item Part No. Qty Description

2 Y9608KU 4 Screw 3 D0117XL-A 1 U-Bolt Assembly 4 K9171SY 1 Plate 5 K9171SX 1 Bracket

6 K9171ST 1 Mounting Set (/PM) 7 Y9520LU 2 Screw 8 K9171SW 2 Bracket 9 Y9608KU 4 Screw

1 K9171SS 1 Mounting Set (/U)

CMPL 12D08N05-02E

10 K9676BA 1 Awning hood assembly (/H5)

2nd Edition : Jul.2008(YK)

Revision Record

Manual Title : Model ISC450G [Style: S2] Inductive Conductivity Converter Manual Number : IM 12D06D05-01E

Edition Date Remark (s)

1st Jul. 2007 Newly published 2nd Sep. 2007 Revisions:

Back-side of cover, note added; p1, FM approval description of Figure 1-1 changed; p7, some CAUTION of Figure 3-4 and the touchscreen added; p16, sec. 4-3-12 Serial number changed; p19, parameter values corrected; p21, parameter values corrected; p22, note added; p29, made some revisions; p37, some CAUTION of the touchscreen added; p39 to p42 Sec. 9 QUALITY INSPECTION inserted; p43 Sec. 10 SPARE PARTS section and page moved; p44 to p54 APPENDICES page moved (p50, note of serial number added; p54, APPENDIX 6, Control drawing for FM approval added); CMPL 12D06D05-02E, 1st Edition, made some revisions.

3rd Aug. 2008 Revisions:

Back-side of cover, note illustration added; p3, Japanese added to display language; p4, option codes /U, /PM, /H5, /AFTG, /ANSI, /AM20 added to Model and codes; p5 to 6, Layout changed (Figure 3-1. moved and changed, because external dimensions for awning hood /H5, conduit adapter /AFTG, /ANSI, /AM20 added); p7, Figure 3-4 title modified; p8, conduit adapter work added to subsection 3-2-2; p9 to 14, Layout changed (descriptions after conduit adapter work moved.); p17, Subsection 4-3-12. Serial number --> HART ID. changed; p20 to 35 Layout changed (illustration of submenu screen placed on appropriate page); p37, error corrected; p41, some error corrected; p45, some error corrected; p49, some error corrected; p50, some error corrected; p54, Note of HART protocol DD files URL added; Customer Maintenance Parts List CMPL 12D06D05-02E revised to 2nd edition, because Part No. for option codes /U, /PM, /H5, /AFTG, /ANSI, /AM20 added.

YOKOGAWA ISC450G User's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

PREFACE

1. INTRODUCTION AND GENERAL DESCRIPTION

1-1. Instrument check

1-2. Application

2. GENERAL SPECIFICATIONS OF EXAxt ISC450G

3. INSTALLATION AND WIRING

3-1. Installation and dimensions 3-1-1. Installation site

3-1-2. Mounting methods

3-2. Wiring 3-2-1. Preparation

3-2-2. Cables, T erminals, glands and conduit adapter

3-3. Wiring the power supply 3-3-1. General precautions

3-3-2. Access to terminal and cable entry

3-3-3. AC power

3-3-4. DC power

3-3-6. Switching on the instrument

3-4. Wiring the contact signals 3-4-1. General precautions

3-4-2. Contact outputs

3-4-3. Contact input

3-5. Wiring the mA-output signals 3-5-1. General precautions

3-5-2. Analog output signals

3-6. Wiring the sensor 3-6-1. General precautions

3-6-3. Installation of the sensor

4. OPERATION OF EXAxt ISC450G

4-1. Main display functions

4-2. Trending graphics

4-3. Zoom in on details

4-3-11. Projected calibration at =

4-3-14. HART Device revision

4-3-15. Logbook

4-3-16. Trouble shooting

4-4. Information function

4-5. Setup-Calibration & commissioning

4-6. Secondary- primary value display switch

4-7. Navigation of the menu structure

5.MENU STRUCTURE COMMISSIONING

5-1. Configure sensor Measuring unit /cm /m

5-2. Temperature setting T emperature Element

5-3. Temperature compensation Compensation

5-4. Calibration settings Air adjust limit

5-5. Concentration

5-6. mA output setup

5-7. Contact output setup

5-8. Fail

5-9. Simulate

5-10. Input contacts

5-11. Error configuration Errors 1/3 ~ 3/3

5-12. Logbook configuration General

5-13. Advanced setup Defaults

5-14. Display setup Main display

6. CALIBRATION

7. MAINTENANCE

7-1. Periodic maintenance

7-3. Cleaning methods

7-4. Contrast adjustment

7-2. Periodic maintenance of the sensor Note! Maintenance advice listed here is

8. TROUBLESHOOTING

8-1. General

8-3. Predictive maintenance

8-4. Poor calibration technique

8-5. Error displays and actions

8-2. Calibration check

9. QUALITY INSPECTION

10. SPARE PARTS

APPENDICES

APPENDIX 1

APPENDIX 2

APPENDIX 3

APPENDIX 4

APPENDIX 5

APPENDIX 6, Control drawing for FM approval

Revision Record