YSI 6500 User Manual

YSI i n c o r p o r a t e d
YSI MODEL 6500 Environmental Process Monitor
Operations Manual
CONTENTS
Page
Section 1 INTRODUCTION 1
1.1 6500 Monitor Features 1
1.2 How to Use This Manual 2
Section 2 INSTALLATION 3
2.1 Unpacking and Inspection 3
2.2 Selecting an Installation Location 3
2.3 Installing the Sonde 7
2.4 Installing the 6500 Monitor 9
2.5 Wiring Instructions 11
2.5.1 Sonde Connections 11
2.5.2 AC Power Connections 13
2.5.3 Relays and Output Wiring 14
2.5.4 Grounding Information 15
2.5.5 Safety Issues 15
2.5.6 Lightning and Surge Protection 15
2.6 Sealants, Desiccant and Securing the Monitor 16
2.7 Installation Check List 17
Section 3 SYSTEM SETUP 19
3.1 System Configuration 19
3.2 6-Series Sonde Setup 20
3.3 6500 Monitor Setup 23
3.3.1 Calibration setup 24
3.3.2 Display setup 26
3.3.3 Relays 29
3.3.4 4-20 mA channel setup 31
3.3.5 Modbus Setup 32
3.3.6 Change Sonde Address 33
3.3.7 System Status 35
Section 4 CALIBRATION 37
4.1 General Calibration Tips 37
4.2 Field Calibration Using the 6500 Monitor 40
4.3 6500 calibration Warning and Error Messages 42
Section 5 PROPER USE AND CARE OF THE 6500 MONITOR SYSTEM 43
5.1 Deciding How to Use Your Monitoring System 43
5.2 Quality Assurance 47
5.2.1 Sonde Maintenance and Deployment Site 48
5.2.2 Calibration Checks 49
5.2.3 Recommended Quality Assurance Protocol 49
5.2.4 Recommended Monthly Maintenance of DO Probe 51
5.2.5 Recommended Cleaning of the 6500 Enclosure 52
i
Section 6 TROUBLESHOOTING 53
6.1 Communication Problems 53
6.2 6500 Menu Choice Problems 55
6.3 Calibration Error Messages 56
6.4 Sensor Accuracy and Repeatability Problems 56
6.5 Alarm Function Problems 57
6.6 4-20 mA Loop Output Problems 58
Section 7 WARRANTY AND SERVICE INFORMATION 59
Appendix A SPECIFICATIONS 63 Appendix B HEALTH AND SAFETY 65 Appendix C REQUIRED NOTICE 73 Appendix D ACCESSORIES 75 Appendix E SOLUBILITY AND PRESSURE/ALTITUDE TABLES 99 Appendix F ADVANCED CALIBRATION SETUP 103 Appendix G INDEX 105
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SECTION 1 INTRODUCTION
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A
A
The 6500 Environmental Process Monitor is designed for configuration with YSI 6-Series sonde(s) to measure up to fifteen water quality parameters. All sensors that perform the parameter measurements are located on the 6-Series sonde, which is submersed and secured in the medium. Conversion of the sensor signals from analog to digital is performed by microprocessor based electronics located in the 6-Series sonde interior. The signals are transmitted via cabling to the 6500 Environmental Process Monitor using SDI-12 protocol.
The 6500 Environmental Process Monitor can be used for a wide variety of sampling and monitoring applications, including, monitoring at either municipal or industrial wastewater treatment plants, drinking water intake, source water, and a variety of other applications. Other municipal and industrial process applications encompass a wide range of matrices (e.g., influent and aeration basins) and the overall performance of the 6-Series sonde is typically site-specific, particularly with regard to fouling of the sensors. In addition, the industrial end-user should be aware of potential incompatibility of their process environment with the operating range and/or the construction materials of the sonde body and the sensors.
1.1 6500 MONITOR FEATURES
Water quality parameter data can be viewed on the liquid crystal display (LCD) of the 6500 Monitor. Additionally, the 6500 Monitor contains 8 x 4-20 mA loop outputs that can be assigned to the various parameters. The 4-20 mA loop outputs provide the means for logging parameter data either (1) by direct recording of the loop outputs with a data logging device or (2) by interfacing the loop outputs with a SCADA system. A set of 4 relays is also present that can be activated by pre-set limit values. The relays are intended to drive alarm indicators, such as lamps, horns or automatic phone dialer systems.
System set-up, including calibration of the 6-
21.2 Temp
6500
6500
ENVIRON MENTALENVIRON MENTA
7.35 DO
MONITORINGMONITORING
SYSTEM
SYSTEM
6.53 pH
Esc
SCADA
4-20 mA out Relay output
C power in
larms
Cal
Enter
Sonde cable
w/ MS-8
Sonde
Effluent Stream
Monitor is accomplished with a watertight connector located on the bottom panel of the 6500 Monitor. There are two means to connect the 6-Series Sonde to the 6500 Monitor. The sonde may be connected directly via the sonde cable, or if the sonde is not 6500 Monitor installation, an optional YSI #6508 Junction Box may be used with customer­supplied cabling.
Series Sonde sensors, can be performed at the site with the 6500 Monitor front panel keys and LCD or in the laboratory with a personal computer or a YSI 610 Display/Logger.
Ports for up to three non-metallic watertight conduit fittings are located on the 6500 Monitor bottom panel and provide the means for connecting the AC power input, the 4-20 mA loop outputs and the relay output conductors via conduit to the I/O plate located within the 6500 Monitor enclosure.
Connection of the 6-Series Sonde to the 6500
located in the vicinity of the
Introduction Section 1
With the optional Breakout Box (YSI #6504), the 6500 Environmental Process Monitor can be used with multiple sondes. The 6500 Monitor is designed for indoor or outdoor use, and features a watertight enclosure. An optional weather shield (YSI # 6505) is also available. Other optional accessories include several different mounting kits for the sondes and 6500 Monitor. See Appendix D, Accessories, for more information.
1.2 HOW TO USE THIS MANUAL
The manual is organized to let you quickly understand how to install and operate the 6500 Monitor system. However, it cannot be stressed too strongly that informed and safe operation is more than just knowing which buttons to push. An understanding of the principles of operation, installation, calibration techniques, system setup and maintenance is necessary to obtain accurate and meaningful results. Before you begin to use the 6500 Environmental Process Monitor, it is strongly recommended that you thoroughly read and understand the YSI 6-Series Sonde Manual. The sonde manual will be referenced in several parts of the 6500 Manual. Before using the sonde with the 6500 Monitor, you must:
9 Install the dissolved oxygen membrane 9 Install the probes 9 Learn how to access sonde software 9 Calibrate the sensors 9 Learn how to take readings
If you are using multiple sondes, each sonde must have a different address (name) and each sonde must be named separately. Assigning the names are done by accessing the sonde software and entering System Setup from the Main Menu. From the System Setup, then enter SDI-12 Address. A character (0-9 and A-F) may be assigned to each sonde that you are using, but each sonde have a different name. For more information about the other functions of the System Setup, see the 6-Series Sonde Operations Manual, Section 2.
Included with this manual is a laminated Field Operation Guide that allows quick and convenient reference to 6500 operation, maintenance and troubleshooting at the installation site. This guide references sections of the basic manual when more detailed information is needed.
MUST
YSI Incorporated 6500 Environmental Process Monitor 2
SECTION 2 INSTALLATION
2.1 UNPACKING AND INSPECTION
Inspect the outside of the shipping carton for damage. If damage is detected, contact the carrier immediately. Remove the instrument from the shipping container. Be careful not to discard any parts or supplies. Confirm that all items on the packing list are present. Inspect all assemblies and components for damage. The basic 6500 Environmental Process Monitor is shipped with the following major components.
6500 Monitor and mounting hardware 6506 Desiccant Kit 065926 Conduit Fittings (3) 065921 Industrial Encapsulant (sealer for conduit fittings) 065927 Knockout Plugs (2) 065902 Operations Manual 065979 Field Operation Guide
If you ordered a 6-Series Sonde and/or reagents, these may be shipped separately. For optional accessories information see Appendix D, Accessories.
If any parts are damaged or missing, contact your factory representative immediately. If you do not know from which dealer your 6500 Environmental Process Monitor was purchased, refer to Section 7, Warranty and Service Information. Check the monitor for any obvious external damage.
Save the original packing cartons and materials. Carriers typically require proof of damage due to mishandling. Also, if it is necessary to return the monitor, you should pack the equipment in the same manner it was received. Once the system is installed and working, maintaining original cartons and packing material is less critical.
If the monitor, sonde and associated components match the packing list and the components appear to be in satisfactory condition, proceed to the installation sections below.
WARNING! To avoid severe personal injury or damage to the equipment, installation, operation and service should be performed by qualified personnel who are thoroughly familiar with the entire contents of this manual.
2.2 SELECTING AN INSTALLATION LOCATION
The 6500 Monitoring System is an on-line continuous measurement tool that can provide valuable insight into your facility’s operation and performance. As with any instrument of this type, proper installation is the first important step to ensure you are provided with reliable performance and accurate data. Installation of the monitor and sonde should be carefully planned in advance to obtain the most effective and accurate utilization of the equipment.
Installation Section 2
Two major components make up the 6500 Environmental Monitoring System: the 6500 Monitor and the 6-Series Sonde that contains the sensors. The sonde is a multi-parameter sensor device that must be placed in a representative sampling location to monitor desired water quality parameters in the flow stream. Since the 6500 Monitor may be located considerable distance from the sonde, a specialized Breakout box and/or Junction Box may be required for your installation, see Appendix D for Accessories information. See Figures 2 and 3 for diagrams of the two most common installation configurations.
CHOOSING A SONDE LOCATION
The sonde installation will be determined by the site necessary to obtain water quality readings which are representative of the bulk flow stream. A suitable location should take a number of physical and chemical factors into consideration:
9 The sonde must be located in the flow stream where level fluctuations will not expose the
sensing probes to the atmosphere. The sonde sensors must remain submersed at all times during the monitoring.
9 The sonde must be placed in a well mixed, free flowing area of the process stream. The flow
stream should be representative of the process flow being monitored. For example, if effluent flow is being analyzed, extended detention time of the effluent desired for monitoring.
9 Ideally, the sonde should be placed at least three (3) feet away from the sidewall and at least
two (2) feet submersed. For most flow channels, midstream and mid-depth would be the most representative area for the sonde location.
9 Ideally, the sonde should be placed at an angle within 45
flow direction (see Figure 1). This location will provide for the least stress on the support arm holding the sonde while minimizing opportunity to collect debris. Placement against the flow stream or perpendicular to the flow stream also provides accurate monitoring, but inspection and cleaning may be required more frequently due to increased collection of debris.
do not place the sonde ahead of a tank or an area that provides for
0
of vertical and directed with the
YSI Incorporated 6500 Environmental Process Monitor 4
Installation Section 2
Not
Figure 1 Sonde orientation
to
scale.
drawn
Sonde
Stream
If the sonde is to be utilized in monitoring for results of chemical feeds and resulting chemical reactions, sufficient downstream mixing and reaction time should be provided prior to insertion of the sonde for monitoring. If pH adjustment is necessary, the sonde location should provide for sufficient mixing and reaction time upstream of the location. Thus, if you question the ideal location for monitoring, check your installation by manually testing upstream and downstream of the sondes proposed location. It may prove that you can utilize “less-than-ideal” sonde location in the flow stream, but take advantage of the location supports for mounting, proximity to the monitor or other factors that may facilitate the installation.
The flow stream should be as free as possible of debris (e.g., algae) which could collect on the sonde and cause erroneous readings.
Remember that this is an on-line device that is measuring actual conditions in real time. Composite sampling for pH, for example, will not match on-line monitoring. Therefore, pH values recorded by the chart recorder and/or plant control system connected to the 6500 Environmental Monitoring System cannot be averaged to equal the pH of the composite sample.
CHOOSING A MONITOR LOCATION
The sonde is a primary device that measures conditions in the flow stream and transmits a low voltage signal to the 6500 Monitor. The sonde is attached to a cable that is equipped with a “military grade” watertight connection to the monitor or optional breakout box.
Several optional accessories are available from YSI to make the 6500 Monitor extremely versatile. The YSI #6502 Breakout Box is an enclosure for the connections interface between the sonde cable(s) and customer supplied wiring and conduit which enables the sensor connection to the monitor to be extended up to 250 feet. The YSI #6503 Breakout Box is the same as #6502, but is also CE compliant for European users. The YSI #6504 Breakout Box is similar to the above description, but can also handle two sondes. These Breakout Boxes makes it possible to install the monitor in a location and environment different than the sonde(s). A YSI #6508 Junction Box is also needed if the 6500 Monitor is installed with multiple sondes, or if a single sonde is farther than 6 feet away.
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Installation Section 2
SYSTEM
N
Note: The 6500 Monitor is provided with a weatherproof enclosure that will withstand most environmental conditions with no compromise to system performance. An optional Weather Shield (YSI #6505) is available for added protection from the elements.
Figure 2 Monitor installed using sonde cable
6500 Monitor
21.2 Temp
6500
6500
ENVIRONM ENTALENVIRONMENTAL
7.35 DO
MONITORING
MONITORING SYSTEM
6.53 pH
Esc Cal
Enter
AC
Sonde
ot drawn to scale.
Stream
Locating the monitor near the sonde will have advantages since in-situ (on-line) calibration can be more easily facilitated under this arrangement. For example, a recently calibrated, hand-held dissolved oxygen meter and probe can be placed next to the sonde and readings compared between the monitor and the hand-held meter. In addition, operator checks to verify accuracy and determine the frequency of calibration for water quality measurement in the flow stream can be easily carried out with a variety of hand-held manual readings at the time of inspection by the operator if the monitor is conveniently located.
Two sondes, #6920 and #600XLM, have logging capability. These two sondes are able to store recorded data into their memory, which then can be downloaded into a PC or Display/Logger. If the 6500 cannot be connected to a system such as a SCADA, data can still be recorded using one of these two sondes. The 6500 itself does not record data; it only displays real-time monitoring.
YSI Incorporated 6500 Environmental Process Monitor 6
Installation Section 2
SYSTEM
N
Figure 3 Remote location of monitor relative to sonde
6500 Monitor
21.2 Temp
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6500
ENVIRONMENTALENVIRONMENTAL
7.35 DO
MONITORING
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6.53 pH
Esc Cal Enter
6508
Junction Box
Breakout Box
AC
6507
6’ Patch cable
w/ MS-8
Conduit & customer-supplied
3-conductor cable 250’ Maximu m
ot drawn to scale.
sonde cable
w/ MS-8
Sonde
Stream
YSI also provides a means for convenient and accurate bench calibration of the sonde. Refer to the Sonde Manual for bench calibration procedures. Bench calibration allows the operator to easily disconnect the sonde from the monitor and then reconnect the sonde to a laboratory computer or terminal device (YSI 610 display/logger). Under this protocol, the sonde can be fully checked in a user-friendly environment, recalibrated and then redeployed. If the sonde is equipped with a bulkhead connector rather than an integral cable, bench calibration is used.
If locating the monitor near the sonde is not possible due to environmental conditions and/or accessibility, bench calibration provides a very good alternative to on-line calibration.
Although the monitor is suitable for outdoor use, it should be located in an area where temperature extremes, vibrations, electromagnetic and radio frequency interference are minimal. Select an installation location that is at least two (2) feet from any high voltage conduit. Avoid mounting on severely vibrating structures. Be sure the monitor can be fully opened and serviced at its installed location by maintenance personnel. Be sure the site has easy access for operating personnel.
2.3 INSTALLING THE SONDE
After you have chosen suitable sites for the monitor and sonde, proceed with the installation as described below.
Avoid routing sonde cabling near wiring associated with rotating machinery and/or equipment involving electrical switching or regulation. Consider placing sonde cabling in grounded metallic conduit if unstable readings appear due to electromagnetic interference.
YSI Incorporated 6500 Environmental Process Monitor 7
Installation Section 2
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L
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A
RAIL MOUNT OPTION
The sonde can be mounted in a number of different configurations, but a rail mount with a fabricated bracket is recommended. A rail mount kit is also available from YSI, #6511 for 600 series sondes, and 6512 for 6820/6920 sondes. See Appendix D, Accessories for more information.
Figures 4 and 5 show the two common connection layouts and short and long-range wiring of the monitor to the sonde.
Figure 4 Direct connection
21.2 Temp
6500
6500
7.35 DO
ENVIRON MENTA
ENVIRON MENTA
MONITORING
MONITORING SYSTEMSYSTEM
6.53 pH
Esc
SCADA
Cal
Enter
4-20 mA out
sonde cable
Relay output
C power in
Sonde
Stream
larms
w/ MS-8
YSI Incorporated 6500 Environmental Process Monitor 8
Installation Section 2
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A
A
Figure 5 Sonde installed distant from the 6500 Monitor
SCADA
6500
6500
ENVIRONMENTA
ENVIRON MENTA
MONITORING
MONITORING
SYSTEM
SYSTEM
21.2 Temp
7.35 DO
6.53 pH
Esc
Cal
Enter
6508
Junction
Box
4-20 mA out Relay output
larms
C power in
6507
6’ Patch cable
w/ MS-8
customer-supplied
3-conductor cable
conduit
Breakout
up to 250 ‘
sonde cable
w/ MS-8
Sonde
Stream
2.4 INSTALLING THE 6500 MONITOR
The 6500 Monitor should be located within 250-ft (75 m) of the sonde. The distance limit is based on noise tolerance of the SDI-12 communication protocol. If you choose to install the monitor more than the length of the sonde cable away from the sonde, additional hardware and wiring will be necessary. A rail mount kit #6509, and panel mount kit # 6510 are also available for the 6500 Monitor. See Appendix D, Accessories, for more information.
WALL MOUNTING OPTION
Although the monitor is designed for outdoor deployment, some operators may prefer the convenience of reading the monitor under shelter, for example, inside a nearby building. Figure 4 shows this indoor type of installation. Wall-mounting the 6500 Monitor is a simple process using the enclosed mounting hardware.
YSI Incorporated 6500 Environmental Process Monitor 9
Installation Section 2
Figure 6 Attaching the Mounting Brackets
The following steps should be followed when wall mounting the 6500 Monitor.
1. Loosely fasten the mounting brackets
(included) to the back of the 6500 Monitor with the mounting screws provided as shown in Figure 6.
2. Tighten the screws, securing the
brackets to the Monitor.
3. Loosely fasten the 6500 Monitor to
the mounting surface with the mounting screws provided as shown in Figure 7.
4. Tighten the screws, securing the Monitor to the surface.
Figure 7 Securing the screws to the mounting surface
Wall Mount
2.5 WIRING INSTRUCTIONS
YSI Incorporated 6500 Environmental Process Monitor 10
Installation Section 2
WARNING!
A qualified electrician should perform wiring.
Do not make connections while power is applied. Disconnect power before proceeding.
This particular phase of the installation will vary considerably depending on the distance between the sonde and monitor and on which outputs you use in your particular configuration. In the simplest configuration in which the sonde is connected using the sonde cable and neither the relay outputs nor the 4-20 mA current loop outputs are used, only AC power wiring is required. The sonde connects to the monitor by the MS-8 sonde cable connector, which is pre-wired. The end connection of the cable is a military-style 8-pin connector (MS-8). If, however, the monitor is more than the length of the sonde cable away from the sonde and either of the outputs is wired to alarms or a SCADA system, additional wiring is required. Below are wiring instructions for all parts of the 6500 Environmental Process Monitoring system.
The 6500 Monitor has one MS-8 connector and three conduit openings in the bottom of the monitor housing which will accommodate ¾ inch conduit fittings. From a front view, the 2 conduit openings on the left are for the four relay outputs and the eight 4-20 mA outputs. The conduit opening on the right should be used for the AC power supply cable. The MS-8 connector is used to interface with the sonde cable in the close range system layout, or in the long distance wiring layout, the optionally-supplied 6 foot (1.8 m) patch cable (YSI #6507) to the #6508 Junction Box. Refer back to Figure 3 to review the configuration options.
IMPORTANT!
It is essential that all sensor wiring be run in a separate conduit from power wiring.
2.5.1 SONDE CABLE CONNECTIONS (SDI-12
COMMUNICATIONS LINK)
The sonde is equipped with a detachable or non-detachable cable. This connector plugs into the 6500 Monitor when the 6500 Monitor is within range of the sonde cable. This configuration is shown in Figure 2.
In remote sonde installations the 6500 Monitor uses a standard MS-8 connection to interface with the 6-ft (1.8 m) Patch Cable (YSI #6507) that will run to the #6508 Junction Box. The customer is advised to supply rigid conduit and 18 AWG or heavier shielded multi-conductor cable to connect between the local junction box and the remote 6502 Breakout Box at the sonde installation site. The cable from the Junction Box should be landed to TB-1 in the Breakout Box. The MS-8 connector for sonde hookup is pre-wired to TB-2 and TB-3.
directly
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Installation Section 2
L
3
2
2
SDI
The 6507 Patch Cable is pre-wired. The conductor color code is: Red +12 VDC Black Common Purple SDI-12
6502, Front Cover Removed
Figure 8 Connector TB-1 detail
6500
6500
ENVIRONMENTALENVIRONMENTA MONITORINGMONITORING SYSTEMSYSTEM
21.2 Temp
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+12 VDC
GND
SDI-12
TB-1
132
MS-8 to sonde
3/4” conduit to jct box
6508
Junction
Esc Cal Enter
Box
Breakout
+1 VDC
-
12
w/ MS-8
Sonde
GND
TB-1
1
6507
6’ Patch cable
w/ MS-8
customer-supplied
3-conductor cable
conduit
up to 250 ‘
sonde cable
Stream
IMPORTANT!
GND on TB-1 is for signal common only. Do not connect to earth ground.
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Installation Section 2
A
2.5.2 AC POWER INPUT WIRING
The 6500 Monitor has a switching power supply and can operate on 100 to 240 VAC power. When you remove the front panel of the 6500 Monitor, take care not to drop the cover since it is not hinged to the Monitor. Refer to figure 8 for power installation.
Connect AC power to TB1-1, L1 and L2. Connect ground wire to one of the three 10-32 grounding screws using a lug (not provided). To meet compliance with UL3010, EN61010 and CSA1010, install a power switch on the AC load line external to the 6500 Monitor (Note: AC on/off power switch is not included with the 6500 Monitor package).
CAUTION! The sensitivity and stability of the monitor will be impaired if the input wiring is not grounded. Do not apply power to the Monitor until all electrical connections are verified and secure.
Figure 10 6500 Terminal Connections (6500 Cover Removed)
RS485 for Modbus
RS232 for Modbus and software upgrades
B-A-
G N
8-pin connectors (2) for 4-20 mA outputs
Single 12-pin connector for relay outputs
C Power
connector
L1 L2
Grounding Screws (10-32)
Relays (4)... soldered to PCB
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Installation Section 2
Use the following precautions from UL 508 as a guide to safety for personnel and property. ¾ AC connections and grounding must be in compliance with UL 508 and/or local electrical
codes.
¾ The metal stiffener provides support and proper electrical continuity between conduit fittings. ¾ This type 4/4X enclosure requires a conduit hub or equivalent that provides watertight
connection, REF UL 508-26.10.
¾ Watertight fittings/hubs that comply with the requirements of UL 514B are to be used. ¾ Conduit hubs are to be connected to the conduit before the hub is connected to the enclosure,
REF UL 508.26.10.
¾ If the metal support plate is not used, plastic fittings must be used to prevent structural
damage to the Monitor. Also, the appropriate grounding lug and AWG conductor must be used with the plastic fittings. When using plastic connectors and non-metallic liquid-tight conduit note that the maximum conduit run length is 6 feet, REF NEC351-23-b3.
2.5.3 RELAY OUTPUT WIRING
The four (4) output relay connections are made to terminals 1 through 12 of TB-2. Relays may be wired normally open (N.O.) or normally closed (N.C.). Use appropriate wire in terms of gauge and insulation to adequately handle the voltage and current being switched by the relays. See Appendix A, Specifications, for relay specifications. Do not use power at TB-1 as a source for any of the relays in the 6500 system. Remember that relays are intended to activate alarms, phone dialers and similar devices. The relays are
4-20 MA CURRENT LOOP OUTPUT WIRING
The eight (8) 4-20 mA current output connections are made to TB3-1 through TB3-16. Use Belden cable #8164 (4-conductor), #8168 (8-conductor) or equivalent between the 6500 Monitor and the SCADA or recorder site.
RS232 AND RS485 TERMINALS
The RS232 port is used for 6500 Monitor software updates and optional Modbus interface. The RS485 port can also be used for an optional Modbus interface. Neither of these connectors is involved in the installation of the 6500 system.
not intended to switch heavy loads.
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Installation Section 2
2.5.4 GROUNDING INFORMATION
This section contains important installation information regarding grounding of the 6500 Monitor and 6-Series Sonde. The sonde is powered by the 6500 Monitor or by batteries (depending on which sonde you have chosen) and will be operated with a “floating” ground reference. This requires that the sonde cause a “ground loop”; i.e. one conductor of the sonde output grounded common to both the sonde and the meter. Grounding the sonde will cause significant performance problems with the sensors and likely result in erroneous readings.
not be individually grounded. Grounding the sonde individually will
IMPORTANT!
Do not ground the sonde body.
2.5.5 SAFETY ISSUES
The electrical system must be grounded to avoid possible electrical shock or damage to the equipment.
WARNING! Turn off all power and assure power “lockout” before servicing to avoid contact with electrically powered circuits.
To avoid possible electrical shock, do not touch other circuit components when making adjustments to the 6500 Monitor circuit board. Disconnect external power to the unit before connecting or disconnecting wiring.
2.5.6 LIGHTNING AND SURGE PROTECTION
Surge protectors are strongly recommended to protect from secondary surges and lightning on outdoor installations.
Surge suppression devices should be located on the AC line supplying power to the 6500 Monitor and any signal lines connecting the 6500 Monitor to alarms, a SCADA or other data collecting device.
AC line voltage surge suppressors protect field equipment on any AC line to ground from damage due to electrical transients induced in the interconnecting power lines from lightning discharges and other high voltage surges. The unit should include noise filtering, common mode and normal
YSI Incorporated 6500 Environmental Process Monitor 15
Installation Section 2
mode suppression and nanosecond reaction time. Surge suppressors should be internally fused to remove the load if the unit is overloaded or the internal protection fails.
Signal line suppressors protect 4-20 mA DC current loops, low voltage signals and relay outputs from damage due to electrical transients induced in the signal lines from lightning discharges or nearby electrical devices. Signal line suppressors should be installed at each end of an analog loop. Relay outputs should be protected at the receiver end. Signal line suppressors should consist of a three-element gas tube followed by metal oxide varistors and suppressor diodes. The protective elements should be matched such that high-energy surge voltages trigger the gas surge arrester, while low energy or surge voltages affect the MOV’s and suppressor diodes.
Lightning protection devices should be located as close to the sonde and monitor as possible and wired in accordance with the National Electric Code in approved watertight enclosures. If the distance between the sonde and the 6500 Monitor is less than 100 feet, only one protector per line is needed, otherwise lightning protection should be installed at both ends of the wiring runs.
IMPORTANT NOTICE This or any other installation procedure can not protect against a direct lightning strike. YSI Incorporated cannot accept liability for damage due to lightning or secondary surges.
2.6 SEALANTS, DESICCANTS AND SECURING THE MONITOR
Since the 6500 Monitor, Breakout Box(s) and/or Junctions Box will likely be subjected to environmental conditions that promote formation of condensation, it is very important to follow the instructions below before securing the cover to your unit(s). This will prevent damage to the electronic components within the Monitor and extend the life of the monitoring system.
Enclosed with shipment of every 6500 Environmental Monitoring System is industrial encapsulant (conduit sealer), in a cartridge for your convenience. After all wiring is complete apply the sealant to the conduit openings from the inside of the 6500 Monitor, Breakout Box and/or Junction Box if applicable. This will help prevent moisture from entering the inside of the 6500 Monitor from conduit that was used for AC power cable or signal cables.
Note: If any of the conduit fittings were not used in the installation, remove the fitting and replace with a 3/4” knockout plug provided with the unit. Two knockout plugs are provided.
Also enclosed with the 6500 Monitor is a box of desiccant packs. After all wiring is completed and sealant applied, place two desiccant packs inside, near the bottom right of the Monitor before securing the cover. This desiccant will consume any moisture captured during the closure to provide a low humidity environment within the Monitor.
To complete the installation secure the cover of the 6500 Monitor using the four mounting screws that you removed while doing the wiring operations. Note that the cover contains a captured rubber gasket that provides the weatherproofing. Make certain that the gasket is in place and not damaged. Check to make certain that the large blue ribbon cable is not trapped in the gasket
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Installation Section 2
channel before inserting the screws. When securing the screws, take care not to cross thread. The screws are stainless steel, and the receiving threads are brass. Do not over-tighten!
IMPORTANT!
Anytime the 6500 cover is removed, replace the desiccant packs with new packs.
Anytime the 6500 front panel is removed, place it on top of the 6500 Monitor
or secure it so that the blue ribbon cable does not bear the weight of the cover.
2.7 INSTALLATION CHECK LIST
9 Inspect packaging for damage 9 Verify that all components are included 9 Determine optimum mounting location for 6-Series Sonde based on process parameters being
measured
9 Determine optimum mounting location for 6500 Monitor 9 Determine preferred sonde location and fabricate mounting plate if necessary 9 Mount the sonde 9 Determine preferred monitor mounting location 9 If monitor is not located near sonde, mount junction box for the patch cable near the monitor 9 If monitor is not located near sonde, mount breakout box near the sonde deployment site 9 Make wiring connections for sonde 9 Make wiring connections for relays 9 Make wiring connections for 4-20 mA loops 9 Make wiring connections for AC power, including an AC power switch external to the unit 9 Apply industrial capsulant to conduit fittings 9 Insert desiccant pack(s) into 6500 Monitor 9 Reinstall front cover to 6500 and, if necessary, the 6502, 6504 or 6508 9 Verify that all wiring connections are secure and that the sonde is properly located in the flow
stream
9 Recheck grounding and surge protection installations 9 Connect calibrated sonde to mounting fixture and place in stream 9 Connect sonde cable to 6500 or 6502 or 6504 9 Allow sonde circuitry and sensors to warm up for several minutes before checking readings
YSI Incorporated 6500 Environmental Process Monitor 17
Installation Section 2
YSI Incorporated 6500 Environmental Process Monitor 18
SECTION 3 SYSTEM SETUP
This section is designed to quickly familiarize you with the hardware and software components of the 6500 Monitor, the 6-Series Sonde and the overall system. You will learn about cable connections and basic communication between the 6-Series Sonde and the 6500 Monitor. Diagrams, menu flow charts and basic written instructions will guide you through basic hardware and software setup. For the first time user, we encourage the reading and understanding of the 6­Series Sonde Operations Manual, with regard to the specific sonde that you own, before proceeding with the 6500 Monitor setup.
Before you begin 6500 Monitor Setup, you must setup the sondes:
9 Install the dissolved oxygen membrane 9 Install the sonde’s probes 9 Learn how to access sonde software 9 Calibrate the sonde sensors 9 Learn how to take readings with the sonde
These instructions are in the 6-Series Sonde Operations Manual, which was provided with your sonde, Section 2.
Successful completion of the above list is essential for you to continue on to Section 3 of the 6500 Environmental Process Monitor Operations Manual.
3.1 SYSTEM CONFIGURATION
The most common configuration for the system which you have purchased involves direct interaction of the 6500 Monitor with the 6-Series Sonde, but there are also ways in which you may configure the 6-Series Sonde with various computers or handheld data displays. The latter configurations are primarily used when setting up and calibrating your sensors in the laboratory. If you calibrate your sensors in the laboratory while the sonde is disconnected from the 6500 Monitor, you should make certain that you have all of the components you need to make your system work. See your sonde manual for other possible configurations.
System Setup Section 3
A
Sonde to 6500 Monitor
21.2 Temp
6500
6500
7.35 DO
ENVIRONMEN TAL
ENVIRONMENTAL MONITORINGMONITORING
6.53 pH
SYSTEM
SYSTEM
Esc
Cal
Enter
C power in 4-20 mA out Relay output
Sonde
MS-8
You will need...
T
Sonde and cable
T
60 0
6500 Monitor
T
AC Power
T
Mounting Hardware
3.2 6-SERIES SONDE SETUP
The 6-Series Sonde contains a powerful computer that allows the sonde to be configured for use with the 6500 Monitor. It is important to remember that the sonde setup information and calibration data are stored in the 6-Series Sonde and not in the 6500 Environmental Process Monitor. With this in mind, the following sections are designed to assure proper setup of the 6­Series Sonde software prior to deployment. This can be accomplished by two different methods:
1. Interface of the 6-Series Sonde with the 6500 Monitor via the matching MS-8
connectors on the sonde cable and the 6500 enclosure. To carry out this procedure, the 6500 Environmental Process Monitor must be installed in its permanent location with AC line power properly installed as described by local electrical codes.
2. Interface of the 6-Series Sonde with a laboratory computer or 610 display/logger. If
a computer is selected for setup, you must employ a YSI #6095B DB-9 to MS-8 adapter and a YSI #6038 external power supply with MS-4 connector that plugs into any 110 VAC outlet. If your sonde does not have an integral cable, it will require a #6067B calibration cable. All of these accessories are optional and must be ordered separately. After using this method to calibrate the sonde, proceed to section 3.3, 6500 Monitor Setup, in this manual.
Method 2 (above) is recommended. However, either method will result in identical setup of the 6-Series software. Instructions for the sonde calibration in a laboratory set-up are found in the 6­Series sonde manual. Choose only one of the two methods for calibration.
When installation of the 6500 Monitor is complete and power is supplied, connect the 6-Series Sonde to the 6500 Monitor via the matching MS-8 connectors. When power is applied to the
YSI Incorporated 6500 Environmental Process Monitor 20
System Setup Section 3
6500 Monitor, a “YSI” display will momentarily appear on the 6500 screen followed by display of actual parameter readings.
6500
6500
ENVIRONMENT AL
ENVIRONMENTAL
MONITORING
MONITORING
SYSTEM
SYSTEM
7.35 DO
6.53 pH
Esc
Cal
Enter
Multiple sondes may be attached to the 6500 Monitor using the optional 6504 Breakout Box. See Appendix D, Accessories, for more details.
Setup of both the sonde and monitor is achieved through use of the Main menu associated with the 6500 software. The Main menu is accessed by simultaneously pressing the Esc and Enter keys for 1 second after the parameter display is active. The Main menu contains the submenu options as shown in the following display.
21.2 Temp
Use the ↑↓ arrow keys to highlight the submenu options. Press Enter to select a highlighted option.
YSI Incorporated 6500 Environmental Process Monitor 21
System Setup Section 3
SENSOR
The first step that should be taken in setting up the sonde is to enable the proper sensors. This is accomplished by highlighting the Sensor selection and pressing Enter. The following display will appear.
The Sensor Menu allows the user to enable or disable any of the available sensors. Selected sensors have a check mark next to them. Using the ↑↓ arrows to highlight items, the Enter key will toggle selections on and off. When an item is selected, it is enabled and will be functional when the system is activated. When a sensor is activated, this parameter and some of the calculated parameters associated with the sensor will also automatically appear in the Report function described below.
In the above example, the temperature, conductivity, dissolved oxygen, and pH sensors are activated. ISE2, ISE3, and ISE4 are shown. ISE5, depth and turbidity can be found by scrolling down the display.
REPORT
After the appropriate sensors are enabled, press Esc to return to the Main menu and then highlight the Report selection and press Enter. The Report menu is used to select the displayed parameters and units of measure. The following screen will be displayed.
The Report menu allows the user to configure the 6500 display readouts. A list of the possible parameters and the currently selected units for each parameter will appear. The user can select a displayed parameter using the ↑↓ arrows to highlight. When the desired parameter is highlighted, the user can press Enter to display the Select Units menu for the specified parameter. The following screen will be displayed.
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System Setup Section 3
In the above example, the temperature parameter has been selected. The user can select a displayed unit using the ↑↓ arrows to highlight. If the user selects NONE, the temperature parameter will not appear in the report. When the desired selection has been made, press enter to activate the change. In this example, temperature in degrees Celsius has been designated for display and will appear on the display when the 6500 Monitor is in the Run mode. The main report menu will then reappear and reflect the change just made. Although not shown, unit changes to other parameters (conductivity, specific conductance, resistivity, TDS, depth, volume) can be made by using the arrow keys to scroll downward to display these selections and the Enter key to activate the Select Units menu. The appropriate unit selections can then be made.
After you have chosen the appropriate sensors and report parameters associated with your 6­Series Sonde, it is now configured properly for display of the desired parameters in the Run mode of the 6500 Monitor. To assure that everything is correct, press Esc until the Run display (similar to that shown below) appears on the 6500 screen.
If you are connecting multiple sondes to your 6500 Monitor, please see section 3.3.6 for instruction on multiple sonde configuration.
3.3 6500 MONITOR SETUP
After proper setup of your 6-Series Sonde, you must configure the options offered with the 6500 Monitor. It is not required that the sonde be attached to the monitor to implement this setup procedure.
With ac line power applied to the 6500 Monitor, press the Esc and Enter keys simultaneously for 1 second to display the Main 6500 menu on the monitor display.
YSI Incorporated 6500 Environmental Process Monitor 23
System Setup Section 3
3.3.1 CALIBRATION SETUP
Highlight the Calibration setup selection and press Enter. The following screen will be displayed.
The Calibration Setup submenu presents two items:
(1) Calibrations enabled is a list of all possible sensor calibrations that can either be enabled or disabled with regard to calibration from the Run mode.
(2) Advanced setup is a selection that allows the user to choose whether calibration errors can be overridden and defines the default calibration value that will appear on the display during the calibration protocol.
Highlight the Calibration enabled selection, press Enter, and the following screen will be displayed.
Once a calibration is selected as indicated by the check mark, that sensor may be calibrated using the Cal key during the Run mode. The user can select and deselect items using the ↑↓ arrows to highlight and press Enter to toggle selections on and off.
In the example shown above, the parameters specific conductance, DO % air saturation, DO mg/L (dissolved oxygen in mg/L concentration units) can be calibrated during the Run mode of the
6500. This selection will NOT allow calibration of conductivity or salinity even if these readings appear on the display.
Press Esc to return to the Calibrate setup menu.
YSI Incorporated 6500 Environmental Process Monitor 24
System Setup Section 3
Next highlight the Advanced setup selection, press Enter, and a display similar to the following for specific conductance will appear.
You need to consider
four options within this menu.
Is: Enabled. This determines whether or not the calibration of this parameter is enabled (allowed) from the Run mode of the 6500 display. Highlight the selection “Is: Enabled”. Press Enter to toggle back and forth between “Is: Enable” and “Is: Disabled”. Select the desired option.
Can override: Yes. This determines whether or not an error message can be overridden if it occurs during the calibration procedure. Highlight the “Can override: Yes” selection. Press Enter to toggle back and forth between “Can override: Yes” and “Can override: No”. Select the desired option. Remember that a calibration error message usually implies a significant malfunction of the 6-Series Sonde sensor that in turn indicates that service to that sensor is required if accurate readings are to be obtained. Therefore, it is usually proper to select the “No” option with regard to this selection. There are occasions when the user is aware that the error message is due to special circumstances and thus the “Yes” option is appropriate, but these are rare.
Vari from Probe, Vari from Default or Fixed from Default. The software allows you to choose only one of these three choices. During setup choose “Vari from Probe”. This is the default parameter value that appears on the 6500 display when the calibration procedure is initiated. With this selection, the current reading of the parameter will be displayed on calibration startup and this value can be varied from the 6500 keyboard to reflect the true value. For more detailed information on these choices, see Appendix F, Advanced Calibration Setup.
Default = 1000. The value of the default calibration value for this parameter is only needed if you choose one of the default choices above. If you choose “Vari from Probe”, you need not set a value here.
A calibration setup display for each activated parameter, except temperature that requires no periodic calibration, is accessible after the Advanced setup selection is made from the Calibrate setup menu. To view other parameters, use the right and left arrow keys to scroll horizontally between parameters using the scroll bar at the bottom of the screen (see screen above). Use the descriptions above to set each of the 4 options for these other parameters.
After configuring your sensor calibrations as described above, press Esc to return to the Main menu.
YSI Incorporated 6500 Environmental Process Monitor 25
System Setup Section 3
3.3.2 DISPLAY SETUP
Now highlight the Display selection from the Main menu and press Enter. The following screen will appear.
The Display menu contains options concerning the visual display of the 6500 Monitor. Use the ↑↓ arrows to highlight the desired display feature. Press Enter to select the feature.
First, highlight the Adjust contrast selection. This option allows the user to select the optimal screen contrast for the existing light conditions. Press Enter to access the Adjust contrast feature and the following display will appear.
Using the ↑↓ arrows, select the desired screen contrast. Then press Esc to return to the Display menu.
Tip: There is an alternate Adjust contrast feature. From the Run display screen, press and hold the Cal key while using the ↑↓ arrow keys to change contrast. This may be especially useful if bright sun or low light conditions make the display screen difficult or impossible to read.
Now highlight Relay status. This feature can be enabled and disabled by toggling the Enter key. If enabled a check mark will appear in the box and the display in the Run mode will contain a bar
YSI Incorporated 6500 Environmental Process Monitor 26
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