YOKOGAWA SC402G User's Manual

Instruction Manual

Model SC402G Conductivity and Resistivity Converter

IM 12D7C3-E-E

6th Edition

OKOGAWA

IM 12D7C3-E-E

TABLE OF CONTENTS

PREFACE

1. INTRODUCTION AND GENERAL DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

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

2. SC402 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-2. Operating specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-3. Model and suffix codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

3. INSTALLATION AND WIRING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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

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

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

3-2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-3. Wiring the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

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

3-3-2. Access to terminal and cable entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3-3. AC power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-3-4. DC power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

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

3-3-6. Switching on the instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-4. Wiring the contact signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-4-1. General precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-4-2. Contact outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-5. Wiring the analog output signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-5-1. General precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-5-2. Analog output signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-6. Sensor wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-7. Sensor connection using junction box and extension cable . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-8. Other sensor systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-9. Tag plate mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

4. OPERATION; DISPLAY FUNCTIONS AND SETTINGS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1. Operator interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2. Explanation of operating keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-3. Setting passcodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4-4. Display example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4-5. Display functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

5. PARAMETER SETTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1. Maintenance mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1-1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-1-2. Manual activation of Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-1-3. Setpoint adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-2. Commissioning mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-2-1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-2-2. Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5-2-3. Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-2-4. Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-2-5. Temperature compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5-2-6. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

IM 12D7C3-E-E

5-3. Notes for guidance in the use of service coded settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-3-1. Parameter specific functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-3-2. Temperature measuring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-3-3. Temperature compensation functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-3-4. mA output functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5-3-5. Contact outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-3-6. User interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

5-3-7. Communication setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

5-3-8. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

5-3-9. Test and setup mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

6. CALIBRATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1. When is calibration necessary? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2. Calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-3. Calibration with HOLD active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

7. MAINTENANCE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-1. Periodic maintenance for the EXA 402 converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-2. Periodic maintenance of the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

8. TROUBLESHOOTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1. Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1-1. Off-line checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1-2. On-line checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

9. SPARE PARTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9-1. Itemized parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

10. APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10-1. User setting for non-linear output table (code 31, 35 and 36) . . . . . . . . . . . . . . . . . . . . . . . 10-1

10-2. User entered matrix data (code 23 to 28) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10-3. Matrix data table (user selectable in code 22) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

10-4. Sensor Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

10-4-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

10-4-2. Sensor selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

10-4-3. Selecting a temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

10-5. Setup for other functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

10-6. USP <645> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

10-7. User setting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

10-8. Configuration checklist for SC402G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

10-9. Software history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

ERROR CODES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

QUALITY INSPECTION STANDARD & CERTIFICATE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11

IM 12D7C3-E-E

PREFACE

Electric discharge

The EXA analyzer contains devices that can be damaged by electrostatic discharge. When servicing this equipment, please observe proper procedures to prevent such damage. Replacement components should be shipped in conductive packaging. Repair work should be done at grounded workstations using grounded soldering irons and wrist straps to avoid electrostatic discharge.

Installation and wiring

The EXA analyzer should only be used with equipment that meets the relevant IEC, American or Canadian standards. Yokogawa accepts no responsibility for the misuse of this unit.

The Instrument is packed carefully with shock absorbing materials, nevertheless, the instrument may be damaged or broken if subjected to strong shock, such as if the instrument is dropped. Handle with care.

Although the instrument has a weatherproof construction, the transmitter can be harmed if it becomes submerged in water or becomes excessively wet.

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

Notice

Contents of this manual are subject to change without notice. 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.

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 installation failure of the device

● A statement whether warranty or non-warranty service is requested

● Complete shipping and billing instructions for return of material, plus the name and phone number of a

contact person who can be reached for further information.

Returned goods that have been in contact with process fluids must be decontaminated/disinfected before shipment. Goods should carry a certificate to this effect, for the health and safety of our employees. Material

WARNING

CAUTION

Introduction 1-1

1. INTRODUCTION AND GENERAL DESCRIPTION

The Yokogawa EXA 402 is a 4-wire transmitter designed for industrial process monitoring, measurement and control applications. This instruction manual contains the information needed to install, set up, operate and maintain the unit correctly. This manual also includes a basic troubleshooting guide to answer typical user questions.

Yokogawa can not be responsible for the performance of the EXA analyzer if these instructions are not followed.

1-1. Instrument Check

Upon delivery, unpack the instrument carefully and inspect it to ensure that it was not damaged during shipment. If damage is found, retain the original packing materials (including the outer box) and then immediately notify the carrier and the relevant Yokogawa sales office.

Make sure the model number on the nameplate affixed to the top of the display board of the instrument agrees with your order.

NOTE: The nameplate will also contain the serial number and power supply selection. Be sure to apply correct power to the unit.

Figure 1-1. Nameplate

Check that all the parts are present, including mounting hardware, as specified in the option codes at the end of the model number. For a description of the model codes, refer to Chapter 2 of this manual under General Specifications.

Basic Parts List: Converter EXA 402 Instruction Manual (See model code for language) Packet with 4 screws for mounting on a panel (M6x8mm) Optional mounting hardware when specified (See model code)

MODEL SERIAL NO

SUPPLY

SC402G-E-1-E

FD 020 034

0-120 VAC, 50/60 Hz, 10 VA

N200

IM 12D7C3-E-E

1-2 Introduction

1-2. Application

The EXA converter is intended to be used for continuous on-line measurement in industrial installations. The unit combines simple operation and microprocessor-based performance with advanced self-diagnostics and enhanced communications capability to meet the most advanced requirements. The measurement can be used as part of an automated process control system. It can also be used to indicate dangerous limits of a process, to monitor product quality, or to function as a simple controller for a dosing/neutralization system.

Yokogawa designed the EXA analyzer to withstand harsh environments. The converter may be installed either indoors or outside because the IP65 (NEMA4X) housing and cabling glands ensure the unit is adequately protected. The flexible polycarbonate window on the front door of the EXA allows pushbutton access to the keypad, thus preserving the water and dust protection of the unit even during routine maintenance operations.

A variety of EXA hardware is optionally available to allow wall, pipe, or panel mounting. Selecting a proper installation site will permit ease of operation. Sensors should normally be mounted closely to the converter in order to ensure easy calibration and peak performance. If the unit must be mounted remotely from the sensors, WF10 extension cable can be used up to a maximum of 50 metres (150 feet) with a BA10 junction box.

The EXA is delivered with a general purpose default setting for programmable items. (Default settings are listed in Chapter 5 and again in Chapter 10). While this initial configuration allows easy start-up, the configuration should be adjusted to suit each particular application. An example of an adjustable item is the type of temperature sensor used. The EXA can be adjusted for any one of five different types of temperature sensors.

To record such configuration adjustments, write changes in the space provided in Chapter 10 of this manual. Because the EXA is suitable for use as a monitor, a controller or an alarm instrument, program configuration possibilities are numerous.

Details provided in this instruction manual are sufficient to operate the EXA with all Yokogawa sensor systems and a wide range of third-party commercially available probes. For best results, read this manual in conjunction with the corresponding sensor instruction manual.

Yokogawa designed and built the EXA to meet the CE regulatory standards. The unit meets or exceeds stringent requirements of EN 55082-2, EN55022 Class A and low voltage safety directive IEC1010 without compromise, to assure the user of continued accurate performance in even the most demanding industrial installations.

IM 12D7C3-E-E

Specification 2-1

2. SC402G SPECIFICATIONS

2-1. General A. Input specifications

: Two or four electrodes

measurement with square wave excitation, using max. 60 m (200 ft) cable (WU40/WF10) and cellconstants from 0.008 to 50.0 cm-1

B. Detection method

: Frequency, read-pulse position

and reference voltage are dynamically optimized.

C. Input ranges

- Conductivity : 0.000 µS/cm to 1999 mS/cm at 25 °C (77 °F) reference temperature.

- Minimum : 0.1 µS x C at process temperature (underrange 0.000 µS/cm).

- Maximum : 500 mS x C at process temperature (overrange 550 mS x C).

- Resistivity : 0.000 k1/2 x cm - 999 M1/2 x cm at 25 °C (77 °F) reference temperature.

- Minimum : 0.002 k1//C at process temperature (underrange 0.000 k1/2 x cm).

- Maximum : 1 M1//C at process temperature (overrange 999 M1/2 x cm).

- Temperature

- Pt1000 : -20-250 °C (0-500 °F)

- Pt100/Ni100 : -20-200 °C (0-400 °F)

- 8K55 NTC : -10-120 °C (10-250 °F)

- PB36 NTC : -20-120 °C (0-250 °F)

D. Span

- Conductivity : - min. 0.010 µS/cm,

- max. 1999 mS/cm. (max 90% zero suppression)

- Resistivity : - min. 0.001 k1/2 x cm

- max. 999 M1/2 x cm. (max 90% zero suppression)

- Temperature : Dependent on temp. sensor type:

Sensor type min. max.

Pt1000 25 °C (50 °F) 250 °C (500 °F)

Pt100, Ni100 25 °C (50 °F) 200 °C (400 °F)

PB36NTC, 8K55NTC 25 °C (50 °F) 100 °C (200 °F)

The instrument is user

programmable for linear or nonlinear conductivity ranges.

E. Transmission signals

: Two isolated outputs of 0/4-20

mA DC with common negative. Maximum load 600 Ω. Auxiliary output can be chosen from conductivity, resistivity, temperature or PI control Burn up (22 mA) or Burn down (0/3.5 mA) to signal failure.

F. Temperature compensation

: Automatic, for temperature

ranges mentioned under C (inputs).

Reference temp : programmable from 0 - 100 °C

or 30 - 210 °F (default 25 °C).

G. Compensation algorithm

: According IEC 746-3 NaCl

tables (default). Two independent user programmable temperature coefficients, from 0% to 3.5 % per °C (°F) by adjustment or calibration.

- Matrix compensation : With conductivity function

of concentration and temperature. Choice out of 5 preprogrammed matrices and a 25- points userprogrammable matrix.

H. Serial Communication

: Bi-directional according to the

EIA-485 standard using HARTprotocol and PC402 software.

I. Logbook : Software record of important

events and diagnostic data. Available through RS485.

J. Display : Custom liquid crystal display,

with a main display of 31/2 digits 12.5 mm high. Message display of 6 alphanumeric characters, 7 mm high. Warning flags and units (mS/ cm, k1/.cm, µS/cm and M1/. cm) as appropriate.

IM 12D7C3-E-E

2-2 Specifications

K. Contact Outputs

- General : Four (4) SPDT relay contacts with LED indicators. For S1, S2, and S3, the LED is on when relay is powered. NOTE: For S4 (FAIL) LED lights when power is removed (Fail safe). Contact outputs configurable for hysteresis and delay time.

- Switch capacity : Maximum values 100 VA, 250 VAC, 5 Amps. Maximum values 50 Watts, 250 VDC, 5 Amps.

- Status : High/low process alarms, selected from conductivity, resistivity and temperature. Contact output is also available to signal “Hold active”

- Control function : On / Off

PI pulsed - Proportional duty cycle control with integral term. PI frequency Proportional frequency control with integral term. In addition FAIL alarm for system and diagnostic errors on S4

L. Contact Input : Remote range switching to

times the programmed range.

- Contact open : If impedance > 100 kΩ: Range 1

- Contact closed : If impedance < 10 Ω: Range 2 (10 x Range 1)

M. Power Supply : - 230 VAC ±15%, 50/60 Hz,

maximum consumption 10 VA.

- 115 VAC ±15%, 50/60 Hz, maximum consumption 10 VA.

- 100 VAC ±15%, 50/60 Hz, maximum consumption 10 VA.

- 24 VDC -20% / +30%, maximum consumption 10 Watts.

N. Input isolation : 1000 VDC

O. Shipping Details : Package size w x h x d

290 x 225 x 170 mm.

11.5 x 8.9 x 6.7 in. Packed weight approx. 2.5 kg (5lb).

2-2. Operating specifications A. Performance : Conductivity

- Linearity :

≤ 0.5 % ± 0.02 mA

- Repeatability : ≤ 0.5 % ± 0.02 mA

- Accuracy : ≤ 0.5 % ± 0.02 mA

Performance : Resistivity

- Linearity : ≤0.02 M1/2 ± 0.02 mA

- Repeatability : ≤0.01 M1/2 ± 0.02 mA

- Accuracy : ≤0.03 M1/2 ± 0.02 mA

Performance : Resistivity (other ranges, up

to 5 MΩ x cm)

- Linearity : ≤0.5 % ± 0.02 mA

- Repeatability : ≤0.5 % ± 0.02 mA

- Accuracy : ≤0.5 % ± 0.02 mA

Performance : Temperature with Pt1000Ω,

Ni100Ω and PB36 NTC

- Linearity : ≤0.3 °C ± 0.02 mA

- Repeatability : ≤0.3 °C ± 0.02 mA

- Accuracy : ≤0.3 °C ± 0.02 mA

Performance : Temperature with PT100Ω

and 8k55Ω

- Linearity : ≤0.4 °C ± 0.02 mA

- Repeatability : ≤0.4 °C ± 0.02 mA

- Accuracy : ≤0.4 °C ± 0.02 mA

Performance : Temperature compensation

- NaCl table : ≤1 %

- Matrix : ≤3 %

- Ambient influence : ≤ 0.05 %/°C

- Step response : 90 % (< 2 decades) in ≤ 3 seconds

B. Ambient operating temperature

: -10 to +55 oC (10 to 130 ºF)

Excursions to -30 to +70 °C (-20 to 160 ºF) will not damage the instrument

C. Storage temperature

: -30 to +70 °C (-20 to 160 ºF)

D. Humidity : 10 to 90% RH non-condensing

E. Housing : Cast aluminium case

with chemically resistant coating, cover with flexible polycarbonate window. Case color is off-white and cover is moss green. Cable entry is via six 1/2” polyamide glands. Cable terminals are provided for up to 2.5 mm2 finished wires. Weather resistant to IP65 and NEMA 4X standards. Pipe wall or panel mounting, using optional hardware.

IM 12D7C3-E-E

Specifications 2-3

F. Data protection : EEPROM for configuration and

logbook, and lithium battery for clock.

G. Watchdog timer : Checks microprocessor

H. Automatic safeguard

: Return to measuring mode

when no keystroke is made for 10 min.

I. Power interruption

: Less than 50 milliseconds no

effect. More than 50 milliseconds reset to measurement.

J. Operation protection

: 3-digit programmable password.

K. Regulatory compliance

- EMC : meets council directive 89/336/EEC

- Emission : meets EN 55022 Class A

- Immunity : meets EN 50082-2

- Low voltage : meets council directive 73/23/ EEC

- Installation : Designed for installation conforming to IEC 1010-1, Category II.

2-3. Model and suffix codes

* For other languages contact local sales office

Model Suffix Option Description code code

SC402G ................................... Conductivity/resistivity

transmitter

-E ............................... Always E

Supply -1 .......................... 115 Volts 50/60 Hz

voltage -2 .......................... 230 Volts 50/60 Hz

-4 .......................... 24 Volts DC

-5 .......................... 100 Volts 50/60 Hz

Instruction manual -E ................... English language*

Options /U ........ Pipe and wall mounting

hardware

/PM ..... Panel mounting hardware

/Q ........ Quality certificate

/SCT ... Stainless steel tag

3-1 Installation and wiring

IM 12D7C3-E-E

3. INSTALLATION AND WIRING

3-1. Installation and dimensions

3-1-1. Installation site

The EXA converter is weatherproof and can be installed inside or outside. It should, however, be installed as close as possible to the sensor to avoid long cable runs between sensor and converter. In any case, the total cable length should not exceed 60 meters (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 transmitter is not mounted in direct sunlight or severe weather conditions

● Maintenance procedures are possible (avoiding corrosive environments)

The ambient temperature and humidity of the installation environment must be within the limits of the instrument specifications. (See chapter 2).

3-1-2. Mounting methods

Refer to figures 3-2 and 3-3. Note that the EXA converter has universal mounting capabilities:

● Panel mounting using optional brackets

● Surface mounting on a plate (using bolts from the back)

● Wall mounting on a bracket (for example, on a solid wall)

● Pipe mounting using a bracket on a horizontal or vertical pipe (maximum pipe diameter 50 mm)

Figure 3-1. Housing dimensions and layout of

glands

Figure 3-2. Panel mounting diagram

144(5.67)

115.5(4.55)

24(1)

16.5

(0.65)

min. 185 (7.25)

min. 195 (7.75)

cut - out = 138 x 138 (5.43 x 5.43)

138

(5.43)

138

(5.43)

IM 12D7C3-E-E

wall mounting

Installation and wiring 3-2

Figure 3-3. Wall and pipe mounting diagram

Figure 3-4. Internal view of EXA wiring compartment

pipe mounting (horizontal)

(3.15)

2x ø6.5

(0.26)

4x ø10

(2.75)

145

(5.70)

200

(7.87)

2” ND. pipe

OPTION/U: Universal pipe/wall mounting kit

pipe mounting (vertical)

(0.4)

IM 12D7C3-E-E

3-3 Installation and wiring

3-2. Preparation

Refer to figure 3-4. The relay contact terminals and power supply connections are under the screening (shielding) plate. These should be connected first. Connect the sensor, outputs and data communication connections last.

To open the EXA 402 for wiring:

1. Loosen the four frontplate screws and remove the cover.

2. Use the rubber knob in the lower righthand corner and swing open the display board to the left.

3. The upper terminal strip is now visible.

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

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

6. Replace the screen (shield) plate over the lower terminals.

Always replace the screen plate over the power and contact outputs for safety and avoid interference.

7. Connect the analog output(s), the sensor input, and, if necessary, the RS485 serial bus.

8. Use the front three glands for analog output, sensor input, contact input and communication cabling (see figure 3-5).

9. Close the display board and switch on the power. Commission the instrument as required or use the default settings.

10. Replace the cover and secure frontplate with the four screws.

Figure 3-5. Glands to be used for cabling

WARNING

Suitable for cables with an outside diameter between 7 - 12 mm (9/

in.)

Contact

(S3,S4,FAIL)

output cables

Sensor

cables

Contact

(S1,S2)

output cables

Analog

output cables

Power

cable

Commu-

nication,

contact

input

High voltage section

IM 12D7C3-E-E

12D8C3-06

SYSTEM CONFIGURATION

FRONT GLANDS

Sensor

Output signals

RS485

Power

Contact output

Contact input

REAR GLANDS

Installation and wiring 3-4

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 EXA and that the supply agrees with the voltage specified on the textplate. Remove the front cover by unscrewing the four screws to check this nameplate on the top of the display board.

Local health and safety regulations may require an external circuit breaker to be installed. The instrument is protected internally by a fuse. The fuse rating is dependent on the supply to the instrument. The 250 VAC fuses should be of the “time-lag” type, conforming to IEC127.

Fuse ratings are 230 VAC - 50 mA; 100 VAC - 100 mA; 115 VAC - 100 mA; 24 VDC - 1.0 A.

The internal fuse is located next to the power terminals (in the lower right hand corner).

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

Terminals 1, 2 and 3 on the bottom terminal strip are used for the power supply. Guide the power cables through the gland closest to the power supply terminals. The terminals will accept wires of 2.5 mm

(14

AWG). Use cable finishings if possible.

Connect the wires as indicated in the wiring diagram (refer to figure 3-6).

S4/FAIL

IM 12D7C3-E-E

3-5 Installation

Figure 3-7. Input and output connections

3-3-3. AC power

Connect terminal 1 to the phase line of the AC power and terminal 2 to the zero line. Terminal 3 is for the power ground. This is separated from input ground by a galvanic isolation.

3-3-4. DC power

Connect terminal 1 to the positive outlet and terminal 2 to the negative outlet. Terminal 3 is for the power ground. This is separated from input ground by a galvanic isolation. A 2-core screened cable should be used with the screen connected to terminal 3. The size of conductors should be at least 1.25 mm2. The overall cable diameter should be between 7 and 12 mm.

3-3-5. Grounding the housing

To protect the instrument against interference, the housing should be connected to ground by a large area conductor. This cable can be fixed to the rear of the housing using a braided wire cable. See figure 3-8.

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. All segments will illuminate, then the instrument will momentarily display its unique serial number. 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.

Figure 3-8. Grounding the housing

131415

22 21

63 66 65 62 61 95 94 93 92 91

SENSOR

CONT

SCREEN

mA2

mA1

SCREEN

TL TL

Sensor Inputs

Contact Input

mA Outputs

Digital Communications

C NC NO

72 73 51 52 53 41 43 31 3342 32

250 VAC

5 A

100 VA

250 VDC

FUSE

100

230

250V

AC; T

3 12

C NC NO C NC NO C NC NO

VAC

VDC

100 mA

50 mA

Relay Contacts Power Supply

12D7C3-01

CONNECTION DIAGRAMS

High voltage compartment

IM 12D7C3-E-E

Installation 3-6

3-4. Wiring the contact signals

3-4-1. General precautions

The contact output signals consist of voltage-free relay contacts for switching electrical appliances (SPDT). They can also be used as digital outputs to signal processing equipment (such as a controller or PLC). It is possible to use multi-core cables for the contact in and output signals and shielded multi-core cable for the analog signals.

3-4-2. Contact outputs

The EXA unit’s four contact outputs can be wired to suit your own custom requirements (Figure 3-6).

In the Non-Alarm or Power Off states, contacts S1, S2 and S3 are OFF, Common (C) and Normally Closed (NC) are in contact.

In the “Fail” or Power Off states, contact S4 is ON, Common (C) and Normally Closed (NC) are in contact.

You can either use them to switch AC power, or switch a DC Voltage for digital interfacing. Default settings

● The contact S1 is pre-programmed for high alarm function.

● The contact S2 is pre-programmed for a low alarm function.

● The contact S3 is not activated as an alarm (off).

● The contact S4 is pre-programmed for FAIL.

The three control contacts (S1 to S3) can be used for simple process control by programming their function (Chapter 5). The FAIL contact is programmed to signal a fault in the measuring loop. Always connect the FAIL contact to an alarm device such as a warning light, sound annunciator, or alarm panel to make full use of the fault detection possibilities (self diagnostics) of the EXA converter.

3-5. Wiring the analog output signals

3-5-1. General precautions

The analog output signals of the EXA transmit low power standard industry signals to peripherals like control systems or strip-chart recorders (Figure 3-6).

3-5-2. Analog output signals

The output signals consist of active current signals of either 0-20 mA or 4-20 mA. The maximum load can be 600 ohms on each.

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

IM 12D7C3-E-E

3-6. Sensor wiring

Refer to figure 3-9, which includes drawings that outline sensor wiring.

The EXA SC402G can be used with a wide range of commercially available sensor types if provided with shielded cables, both from Yokogawa and other manufacturers. The sensor systems from Yokogawa fall into two categories, the ones that use fixed cables and the ones with separate cables.

To connect sensors with fixed cables, simply match the terminal numbers in the instrument with the identification numbers on the cable ends.

The separate sensors and the WU40-LHkk cables are also numbered, but the numbers do not always match with the terminal numbers in the instrument. Figure 3-9 indicates how to connect the different sensor types.

Figure 3-9. Sensor wiring diagrams

3-7 Installation

11 TEMPERATURE

12 TEMPERA

TURE

13 CELL

14 CELL

15 CELL

16 CELL

CONDUCTIVITY / RESISTIVITY TRANSMITTER

SEPARATE SENSORS WITH WU40-LH . . CABLE

11 TEMPERATURE

12 TEMPERATUR

13 OUTER ELECTRODE

14 OUTER ELECTRODE

15 INNER ELECTROD

16 INNER ELECTROD

RED

GREE

WHITE

BLACK

11 TEMPERATURE

12 TEMPERATURE

13 CELL

14 CELL

15 CELL

16 CELL

RED

11 TEMPERATURE

12 TEMPERA

TURE

13 OUTER ELECTRODE

14 OUTER ELECTRODE

15 INNER ELECTROD

16 INNER ELECTROD

YELLOW / GREEN

BROWN

SX42-SX . . - . F SENSORS

12D7C3-06

NOTE: Use shielded cable

A-15 B-16 C-13 D-14 E-11 F-12 S-3 or 63

temp

>Connections differential 4-electrode

IM 12D7C3-E-E

3-7. Sensor connection using junction box and extension cable

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. 10 m fixed cable and 50 m extension cable).

Note: Numbers 17 of both WF10 and BA10 do not need to be used.

3-8. Other sensor systems

To connect other sensor systems, follow the general pattern of the terminal connections as listed below: 11 and 12 Always used for temperature compensation resistor input (Pt1000, Ni100, Pt100, PB36

and 8k55) 14 Normally used for the outer electrode 15 Used for inner electrode In case a 4-electrode measuring system will be used, 14 and 16 should be used for the current electrodes. Please ensure that shielded cabling will be used. In figure 3-10 this is shown in a schematic way.

Figure 3-10. Connection diagram for other sensors

Figure 3-11. Terminal identification labels

Sensor Inputs

Contact Input

mA Outputs

Digital Communications

SCREEN

mA2

mA1

SENSOR

mA OUTPUT RS485

CONT

REFER TO

INSTRUCTION MANUAL FOR CONNECTIONS

1516 131412 11

22 21 63 66 65

94 93 92 91

SCREEN

Relay Contacts

Power Supply

C NC NO

72 73 51 52 53 41 43 31 3342 32

250VAC

100V

250VDC

50W

FUSE

100

230

250V

AC; T

3 12

C NC NO C NC NO C NC NO

VAC

VDC

100 mA

50 mA

12D7C3-05

INPUT & OUTPUT

CONNECTIONS

Installation 3-8

11 12 13 14 15 16

12D7C2-10

2-/4 ELECTRODES SYSTEM

2-electrode configuration

4-electrode configuration

IM 12D7C3-E-E

3-9 Installation

Figure 3-12. Sensor cable connections with tag plate

3-9. Tag plate mounting

When option /SCT is specified, a stainless steel tagplate is supplied with the designated Tag No. stamped or engraved. It is mounted as shown in figure 3-12 using one of the cable glands.

12D7C3-15

GLANDS EXA 402

Operation 4-1

4. OPERATION; DISPLAY FUNCTIONS AND SETTING

4-1. Operator interface

This section provides an overview of the operation of the EXA operator interface. The basic procedures for obtaining access to the three levels of operation are described briefly. For a step-by-step guide to data entry, refer to the relevant section of this instruction manual. Figure 4-1 shows the EXA operator interface.

LEVEL 1: Maintenance

These functions are accessible by pushbutton through a flexible front cover window. The functions make up the normal day-to-day operations that an operator may be required to complete. Adjustment of the display and routine calibration are among the features accessible in this way. (See table 4-1).

LEVEL 2: Commissioning

A second menu is exposed when the EXA front cover is removed and the display board is revealed. Users gain access to this menu by pressing the button marked

in the lower right of the display board. This menu is used to set such values as the output ranges and hold features. It also gives access to the service menu. (See table 4-1).

LEVEL 3: Service

For more advanced configuration selections, press the button marked

, then press “NO” repeatedly until you reach SERVICE. Now push the “YES” button. Selecting and entering “Service Code” numbers in the commissioning menu provide access to the more advanced functions. An explanation of the Service Codes is listed in chapter 5 and an overview table is shown in chapter 10.

Table 4-1. Operations overview

Routine Function Chapter

Maintenance SETPOINTS Adjust alarm setpoints (when activated) 5

CALIB Calibration with a standard solution or a sample 6

DISPLAY Read auxiliary data or set message display 4

HOLD Switch hold on/off (when activated) 5

Commissioning SETPOINTS Adjust alarm setpoints 5

RANGE Adjust the output range 5

SET HOLD Activate the hold function 5

TEMP Select method of temperature compensation 5

Service SERVICE Fine tune the specialized functions of the 5

(Access to coded entries converter

from the commissioning

level)

Note: All three levels may be separately protected by a password. See Service Code 52 in chapter 5

Service Code table for details on setting passwords.

IM 12D7C3-E-E

4-2 Operation

Figure 4-1. SC402G operator interface

4-2. Explanation of operating keys

MODE key This key toggles between the measuring and maintenance modes. Press once to obtain

access to the maintenance function menu.

SETPOINTS CALIBRATE DISPLAY HOLD Press again to return to the measuring mode (press twice when hold is activated).

YES/NO keys These are used to select choices from the menu.

YES is used to accept a menu selection.

NO is used to reject a selection, or to move ahead to the next option.

DATA ENTRY keys ( ENT)

is used as a “cursor” key. Each press on this key moves the cursor or flashing digit

one place to the right. This is used to select the digit to be changed when entering numerical data.

is used to change the value of a selected digit. Each press on this key increases

the value by one unit. The value can not be decreased, so in order to obtain a lower value, increase past nine to zero, then increase to the required number.

ENT When the required value has been set using the > & ^ keys, press ENT to confirm

the data entry. Please note that the EXA 402 does not register any change of data until the ENT key is pressed.

This is the commissioning mode key. It is used to obtain access to the commissioning menu.

This can only be done with the cover removed or opened. Once this button has been used to initiate the commissioning menu, follow the prompts and use the other keys as described above.

HOLD

FAIL

YES

ENT

SETPOINTS

RANGE

SET HOLD

SERVICE

MEASURE

CALIBRATE

DISPLAY

HOLD

NO MODEYES

ENT

YOKOGAWA

MODE

TEMP.

CONTACTS

FAIL/S4

m S/ c m

S /c m

k c m

M c m

SETPOINTS

12D7C3-13

FRONT EXA SC402

Output hold flag

Fail flag

Menu pointer flags

Commissioning function menu

Commissioning mode access key

Relay contact status indicators

Measure/Maintenance mode key

Broken line indicates area that can be seen through front cover

Adjustment keys > : Choose digit to

adjust ^ : Adjust digit ENT : Confirm change

Selection keys YES : Accept setting NO : Change setting

Key prompt flags

Message display

Main display

Units

IM 12D7C3-E-E

Operation 4-3

4-3. Setting passcodes

In Service Code 52, EXA users can set passcode protection for each one of the three operating levels, or for any one or two of the three levels. This procedure should be completed after the initial commissioning (setup) of the instrument. The passcodes should then be recorded safely for future reference.

When passcodes have been set, the following additional steps are introduced to the configuration and programming operations:

Maintenance

Press MODE key. The display shows 000 and *PASS* Enter a 3-digit passcode as set in Service Code 52 to obtain access to the Maintenance Mode

Commissioning

Press

key. The display shows 000 and *PASS*

Enter a 3-digit passcode as set in Service Code 52 to obtain access to the Commissioning Mode.

Service

From the commissioning menu, select *Service by pressing YES key. The display shows 000 and *PASS* Enter a 3-digit passcode as set in Service Code 52 to obtain access to the Service Mode.

Note: See Service Code 52 for the setting of passcodes.

4-4. Display example

The next page shows the sequence of button presses and screens displayed when working in default configuration. More or less options will be made available by the configuration of some service codes, or by choices made in the commissioning menu.

The following deviations are possible:

 Items marked are omitted when switched off in commissioning mode and/or service code 51.

 Temperature compensation will be displayed dependent on chosen compensation method:

NaCl, TC 2.1 or matrix.

 DISP.2 only appears if mA2 is configured for a 2nd (different) temperature compensation

or if % by weight.2 is enabled in code 55.   W/W % only appears if switched on in service code 55.

IM 12D7C3-E-E

4-5. Display functions

Sequence for resistivity function parallels this conductivity example.

4-4 Operation

S /c m

YES

(See Setpoint menu Chapter 5.2)

YES

S /c m

Current output 2

Press YES to fix

the selected second

line of display

YES

S /c m

Process

tempe-

rature

Current output 1

YES

S /c m

12D7C3-20

Display Functions

(Sequence for resistivity function equals this conductivity example).

MODE

YES

(See Hold menu Chapter 5.1)

Actual cell constant

Temperature compensation for mA1 or mA2 (DISP.2)

Software release number

YES

YES NO

YES

SETPOINTS RANGE SET HOLD

SERVICE

TEMP.

HOLD FAIL

YES NO

ENT

m S/ c m

S /c m

k c m

M c m

MEASURE

CALIBRATE DISPLAY HOLD

NO MODEYES

ENT

YOKOGAWA

MODE

CONTACTS

FAIL/S4

SETPOINTS

S /c m

Reference temperature

YES

DISP.1

DISP.2

compensated

value

YES NO

S /c m

w/w %

YES

(See Calibration menu Chapter 6)

IM 12D7C3-E-E

Parameter setting 5-1

5. PARAMETER SETTING

5-1. Maintenance mode

5-1-1. Introduction

Standard operation of the EXA instrument involves use of the Maintenance (or operating) mode to set up some of the parameters.

Access to the maintenance mode is available via the six keys that can be pressed through the flexible window in the instrument front cover. Press the “MODE” key once to enter this dialog mode. (Note that at this stage the user will be prompted for a pass code where this has been previously set up in service code 52, section 5.)

Setpoint Select and adjust setpoint (when enabled in service menu section 5-3, service

code 51). See adjustment procedure 5-2-2. Calibrate See “calibration” section 6. Display setting See “operation” section 4. Hold Manually switch on/off “hold” (when enabled in commissioning menu). See adjustment

procedure 5-2-4.

5-1-2. Manual activation of Hold

NO MODEYES

ENT

YOKOGAWA

MODE

CONTACTS

FAIL/S4

12D7C3-27

YES

MODE

YES

M c m

HOLD

YES

5.1.2 Manual Activation of Hold.

Note

: The HOLD feature must first be activated in the commissioning mode section 5.2.4

YES

MEASURE

M c m

CALIBRATE

SETPOINTS

RANGE

SET HOLD

SERVICE

TEMP.

M c m

MEASURE

M c m

YES

M c m

HOLD

YES

+ 53 hidden pages