Dissolve Oxygen ABB Monitor
Dissolve Oxygen ABB Monitor
Dissolve Oxygen ABB Monitor
IM/9438 Issue 11
Monitor
9438
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ABB
The Company EN ISO 9001:2000
We are an established world force in the design and manufacture of instrumentation for
industrial process control, flow measurement, gas and liquid analysis and environmental
applications. Cert. No. Q 05907
As a part of ABB, a world leader in process automation technology, we offer customers
application expertise, service and support worldwide. EN 29001 (ISO 9001)
0255
Electrical Safety
This equipment complies with the requirements of CEI/IEC 61010-1:2001-2 'Safety Requirements for Electrical Equipment for
Measurement, Control and Laboratory Use'. If the equipment is used in a manner NOT specified by the Company, the protection
provided by the equipment may be impaired.
Symbols
One or more of the following symbols may appear on the equipment labelling:
Warning – Refer to the manual for instructions Direct current supply only
Protective earth (ground) terminal Both direct and alternating current supply
Information in this manual is intended only to assist our customers in the efficient operation of our equipment. Use of this manual for
any other purpose is specifically prohibited and its contents are not to be reproduced in full or part without prior approval of the
Technical Publications Department.
Safety advice concerning the use of the equipment described in this manual or any relevant hazard data sheets (where applicable) may be
obtained from the Company address on the back cover, together with servicing and spares information.
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Low and High Level Dissolved Oxygen Monitor
9438 Contents
Contents
1 INTRODUCTION .............................................................. 2 7 PROGRAMMING AND ELECTRICAL CALIBRATION .. 20
7.1 Access to Secure Parameters ............................... 20
2 MECHANICAL INSTALLATION ....................................... 3 7.2 Language Page ..................................................... 20
2.1 Siting Requirements ................................................. 3 7.3 Set Up Parameters Page ....................................... 21
2.1.1 Instruments ................................................... 3 7.4 Set Up Alarm Page ................................................ 22
2.1.2 Dissolved Oxygen Flowcell ............................ 3 7.5 Set Up Retransmission Page ................................. 24
2.2 Mounting the Instrument .......................................... 3 7.6 Electrical Calibration .............................................. 27
2.2.1 Wall-mounted Instrument .............................. 3 7.6.1 Equipment Required .................................. 27
2.2.2 Panel-mounted Instrument ........................... 4 7.6.2 Preparation ................................................ 27
2.3 Installing the Dissolved Oxygen Flowcell ................... 5 7.7 Factory Settings Page ........................................... 28
2.3.1 Flowcell Dimensions (Overall) ........................ 5
2.3.2 Enclosure Dimensions (Optional) ................... 5 8 MAINTENANCE ............................................................. 31
2.3.3 Connecting the Sample Lines ....................... 5 8.1 Introduction ........................................................... 31
8.2 Cleaning/Changing the Sensor .............................. 31
3 ELECTRICAL CONNECTIONS ........................................ 6 8.2.1 Cleaning ..................................................... 31
3.1 Access to Terminals ................................................. 6 8.2.2 Changing the Sensor .................................. 32
3.1.1 Wall-mounted Instruments ............................ 6
3.1.2 Panel-mounted Instruments .......................... 6 9 SIMPLE FAULT FINDING ............................................. 33
3.2 Connections, General ............................................... 7 9.1 Diagnostic Messages ............................................. 33
3.2.1 Relay Contact Protection 9.2 Low Sensor Efficiency/Slow Sensor
and Interference Suppression ....................... 7 Cal. or No Response to D.O. Changes .................. 34
3.2.2 System Wiring Schematic ............................. 8 9.3 Checking the Temperature Input ............................ 34
3.3 Wall-mounted Instrument Connections .................... 8 9.4 High Sample Readings .......................................... 34
3.4 Panel-mounted Instrument Connections .................. 9
3.5 Selecting the Mains Voltage ................................... 10
10 Specification ................................................................. 35
3.5.1 Wall-mounted Instrument ........................... 10
3.5.2 Panel-mounted Instrument ......................... 10
3.6 Flowcell Solenoid Valve Connections ...................... 11 11 SPARES ........................................................................ 37
11.1 Strategic Spares .................................................... 37
4 SETTING UP .................................................................. 12
4.1 Fitting the Dissolved Oxygen Sensor ...................... 12 Appendix A 9438 080 24 V DC POWER SUPPLY UNIT
4.2 Connecting the Flowcell ......................................... 13 (OPTIONAL) .................................................................. 39
4.3 Checking Sample Flow .......................................... 14 A.1 Description ............................................................ 39
A.2 PSU Dimensions .................................................... 39
5 CONTROLS AND DISPLAYS ........................................ 15 A.3 Accessing PSU Terminals ...................................... 39
A.4 PSU Connection .................................................... 40
5.1 Displays ................................................................. 15
A.5 Wiring Schematic .................................................. 40
5.2 Switch Familiarization ............................................. 15
A.6 Specification .......................................................... 40
1 INTRODUCTION
Model 9438
This manual describes how to install and operate the 9438 Low Wall-Mounted Transmitter
Level Dissolved Oxygen Monitoring system. Fig. 1.1 shows the
main elements of the system. Mechanical and electrical ABB
4600
D.O.
1. µg/kg
A2
9438 080
24 V DC P.S.U.
(optional)
Fixing Centers
232 250 214
Maximum distance
30 metres
IP54
IP66 Environmental cover
IP65
Liquid handling panel Mark fixing centers
(see Fig. 2.3)
96
92 +0.8
0
3 Secure plates
2.3 Installing the Dissolved Oxygen Flowcell 2.3.3 Connecting the Sample Lines
Mount the flowcell vertically (with or without the enclosure) as
2.3.1 Flowcell Dimensions (Overall)
shown in Fig. 2.7 and Fig. 2.8. Connect the sample inlet and
outlet tubes as shown in Fig. 2.9.
Dimensions in mm.
Note.
142 The sample flowrate must be between 100 and 400
140 approximately
ml min–1.
100 116
85 approximately The Company recommends that stainless steel tubing
is used for sample inlet lines.
All sample drains should be kept as short as possible
and be vertical to allow the sample to drain freely.
175
440
325
Drain see Note
3 ELECTRICAL CONNECTIONS
Warning.
Before making any connections, ensure that the power supply, any high voltage-operated control circuits and high
common mode voltage are switched off.
Although certain instruments are fitted with internal fuse protection, a suitably rated external protection device, e.g. fuse or
miniature circuit breaker (m.c.b.), must also be fitted by the installer.
Earth Stud
Remove
protection
cover
4
1
Slide
down
3
Mains
Slacken 1 Cover
2 captive Remove
screws Earth Studs Remove nuts and 2 mains cover
Pull out protection cover
slightly. . . . . . and
2 slide off
Note.
Earthing (grounding) – stud terminals are fitted to the transmitter case for bus-bar earth (ground) connection – see Fig. 3.1
or Fig. 3.2.
Cable lengths – the cable length between the flowcell and the electronics unit is provided as ordered, and suitably
terminated at both ends.
Cable routing – always route the signal cable and mains-carrying/relay cables separately, ideally in earthed metal conduit.
Ensure that the cables enter the transmitter through the glands nearest the appropriate screw terminals and are short and
direct. Do not tuck excess cable into the terminal compartment.
Cable glands & conduit fittings – ensure a moisture-tight fit when using cable glands, conduit fittings and blanking
plugs/bungs (M20 holes). The M16 glands ready-fitted to wall-mounted instruments accept cable of between 4 and 7 mm
diameter.
Alarm Relay – the relay contacts are voltage-free and must be appropriately connected in series with the power supply
and the alarm/control device which they are to actuate. Ensure that the contact rating is not exceeded. Refer also to
Section 3.2.1 for relay contact protection details when the relays are to be used for switching loads.
Retransmission output – do not exceed the maximum load specification for the selected current retransmission range –
see section 7, page 20.
Since the retransmission output is isolated the –ve terminal must be connected to earth (ground) if connecting to the
isolated input of another device.
Note. For reliable switching the minimum voltage must be greater than 12 V and the minimum current greater than 100 mA.
Diode
R C
Load Load
External L N External +
AC Supply DC Supply
A AC Applications B DC Applications
1 2 3 1 2 3
1 2 3 4 5 6 7 + N L
4 5 6 4 5 6
Warning. The power supply earth (ground) must be connected to ensure safety to personnel, reduction of the effects of RFI and
correct operation of the power supply interference filter.
Earth Stud
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
E 10
N 11
L 12
TBA TBB
Retransmission + 1 1 0V
Output 2 2 Rx RS422/RS485 Retrans 2
3 3 Rx+ Serial Interface Output (if fitted)
Normally Closed 4 4 Tx (if fitted) 4 ve
Relay 1 Common 5 5 Tx+ 5 +ve
Normally Open 6 6 Link Pt1000
7 Green Temperature
Solenoid Valve Common 8 8 White compensator
Calibration Normally Open 9
Relay
E 10 ve (Black)
Neutral N 12 D.O. Sensor
Mains Supply Live L +ve (Red)
Earth Braid
Earth Stud (on case)
Earth Stud (on case)
Warning. The power supply earth (ground) must be connected to ensure safety to personnel, reduction of the effects of RFI and
correct operation of the power supply interference filter.
Note. Some versions are fitted with a switch in place of Note. Some versions are fitted with a switch in place of
links. The applied voltage should be as indicated on the links. The applied voltage should be as indicated on the
switch, when positioned. switch, when positioned.
Slide instrument
out of case
2
4 Remove cap
Remove front and screw
panel 3 230
Undo captive
1 screw
5 110 V AC or
2
Slacken
captive
screws and
remove
protection
cover
3
Remove front
panel screws 4 110 V AC
1 5
Remove cover (see Fig. 3.1) 240 V AC
240 V AC 3
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Low and High Level Dissolved Oxygen Monitor
9438 3 ELECTRICAL CONNECTIONS
Note.
Use 2 core cable with 9438 080 PSU (ABB part number 0233 731).
Use 3 core cable with customer supplied 24 V DC supply.
Diode
gland. 3
2
2
4 SETTING UP
4.1 Fitting the Dissolved Oxygen Sensor
Caution.
Only install the oxygen sensor immediately prior to use, otherwise leave it stored in its protective container. The sensor has
a limited shelf life and should NOT be stored longer than about 6 months. Store under cool conditions.
Take special care to line up the two pins in the oxygen sensor with their respective sockets before making the connection
and tightening.
Take care not to damage the delicate membrane on the end of the oxygen sensor.
Ensure that the mating surfaces (carrying the electrical connection) of the oxygen sensor and connector body are clean and
completely dry.
Oxygen
Sensor
O-ring
Connector Insert the complete assembly
Body 6 into the flowcell ensuring that
the O-ring is in place.
Thrust Connector
Washer Nut
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9438 4 SETTING UP
Note.
The plug is a latching type to prevent it's accidental removal. To remove, hold the plug at its widest point and pull out.
The plug is protected against spillage and corrosion by a sleeve which slides over it.
Flow Indicator
Drain
Sensor
Sample
Flow In
Regulating
Valve Sample In
Solenoid Solenoid
Operated Operated
Valve Closed Valve Open
Drain
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9438 5 CONTROLS AND DISPLAYS
Page X
Parameter 1
Upper
Display Line Advance to
next parameter
Lower Parameter 2
Display Line
Parameter 3
Parameter 4
Alarm
LEDs
B Moving Between Parameters
New value is
or
Membrane Switches automatically stored
Fig. 5.1 Location of Controls and Displays C Adjusting and Storing a Parameter Value
Parameter X
Y Select
Z
New value is
or
automatically stored
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Operation Page Secure Parameters Set Up Parameters Page Set Up Alarm Page Set Up Retransmission Page Factory Settings Page
Section 6.2.1 Section 7.3 Section 7.4 Section 7.5 Section 7.6
Access to Secure Parameters
Section 7.1
Bi-Linear
1Day Alter Sec. Code 2 .0
Linear
1 0 .0 RTX Zero mg/kg XXXX
Calibration Page
Linear
Bi-Linear
Section 6.2.2 00000 Enter Input % C Temp Span (1k5)
Reset Cal. NO Alter Cal. Code
YES 5 0 .0 1 0 .0
Enter Output % Enter Input % Adjust RTX Zero
SENSOR CAL.
00000 5 0 .0
Diagnostics YES Enter Output % Adjust RTX Span
Cal. User Code
NO
2
30 Diagnostics YES Cal Time 1 (min)
Calibrate YES NO
Cal. Time s
NO 30
30 30 Cal Time 2 (min)
8 .7 9 Fail M.time s Cal. Time s
Calibrating Air 00000
30 Alter Fact. Code
Note. The values shown on the pages in this illustration are the factory default values.
Operating parameters. 30
To Set up Retrans 2
Fail S.time s Fail M.time s
Cal. Aborted
Available only when 2nd 30
retransmission output is fitted. Fail S.time s
Sensor Effnnnnn
Secure parameters.
If NO Retrans 2
Slow Sensor Cal. 00
Test Retrans. (%)
5. 2 0
Recovery Period
IM/9438
Issue 11
6 START UP AND OPERATION
Low and High Level Dissolved Oxygen Monitor
9438 6 START UP AND OPERATION
Sample Temperature
2 0.0 The sample temperature is displayed in either ºC or ºF – see section 7.1, page 20.
Temperature ( C)¡
Sensor Output
––––– Raw current signal (µA) generated by the sensor.
Sensor O/P (µA)
Sensor Efficiency
––––– Bar graph indication of the sensor performance, based on last calibration – see see section
Sensor Eff 6.2.2, page 19.
High Setpoint
1 5.0 The High alarm setpoint value is only visible if the alarm is programmed for either D.O. or
High Set µg/kg Temperature and is set to High or High/Low.
Low Setpoint
5.0 The Low alarm setpoint value is only visible if the alarm is programmed for either D.O. or
Low Set µg/kg
Temperature and is set to Low or High/Low.
Open Valve
––––– Manually open the calibration valve to drain the flowcell prior to accessing the sensor. The
Open Valve NO reading displayed when the valve is open does not represent the dissolved oxygen content of
YES air-saturated water at the prevailing ambient temperature.
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Low and High Level Dissolved Oxygen Monitor
9438 6 START UP AND OPERATION
Calibration Access
00000 Enter the required calibration code number, between 00000 and 19999. If an incorrect value is
Cal. User Code entered, access to calibration is prevented and Calibration Page is displayed.
Select YES to enable manual calibration and press to start the calibration sequence.
–––––
Calibrate YES
NO
NO
YES
Calibrating in Air
8 .7 9 The calibration valve opens exposing the sensor to air. A flashing dot indicates that a calibration
Calibrating Air
is in progress and the displayed value is the sensor reading based on the LAST calibration. See
timings below.
Wait Period Where the sensor is exposed to air before the stability of the sensor is
checked. This is preset at 2 minutes (Cal Time 1).
Stability Period The readings are monitored for between 1 and 5 minutes until a stable
response is achieved.
Abort
When stability has been achieved the calibration valve closes allowing sample to flow past the
for 2 secs sensor
Abort Calibration
––––– Pressing during Calibrating in Air aborts the calibration and the Cal. Aborted message is
Cal. Aborted
displayed for 2 seconds. The calibration valve closes allowing the sample to flow past the
sensor again.
Note that the A2 LED continues to indicate that a calibration is in progress, and will do so for the
duration of the programmed recovery period.
Sensor Efficiency
––––– A five-bar display provides an indication of the sensor's performance.
Sensor Eff
>85% efficiency
OR
>70% efficiency
>60% efficiency Pass
>50% efficiency
>40% efficiency
<40% efficiency Low sensor efficiency
18.1 The display automatically returns to the Operating Page at the end of this period.
D.O. µg/kg
Security Code
00000 Enter the required code number between 00000 and 19999 to gain access to the secure
SECURITY CODE parameters. If an incorrect value is entered, access to subsequent programming pages is
prevented and the display reverts to the Operation Page.
Advance to Language Page, see section 7.2, page 20.
–––––
Espanol
Language Page
_____
Select the language to be displayed on all subsequent pages: Español, Francais, Deutsch or
˜
Espanol
English.
Francais
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20 IM/9438 Issue 11
Low and High Level Dissolved Oxygen Monitor
9438 7 PROGRAMMING AND ELECTRICAL CALIBRATION
Auto Calibration
––––– Select the frequency of automatic calibrations: 1 Day, 1 Week or 4 Weeks. Select Off to disable
Autocal 4 Weeks
1 Week
automatic calibrations. Only manual calibrations may be carried out.
1 Day
Off
Calibration Fail will cause the Relay and LED to pulse every second.
Temp The instrument alerts the operator if the temperature of the process fluid
exceeds or drops below the set point value parameter, depending on the type
of Alarm Action selected below.
D.O. The instrument alerts the operator if the Dissolved Oxygen value of the sample
exceeds or drops below the set point value parameter, depending on the type
of Alarm Action selected below.
Off If selected, no alarm is set and the alarm l.e.d. is off and the relay de-energized
at all times.
Alarm Action
For 'Fail-safe' alarm operation the relay's alarm state must be the same as the powerdown
A1 Action Hi/Lo
state, i.e. the relay is de-energized.
High
Low For High alarm operation the relay must be energized below the alarm set point.
For Low alarm operation the relay must be energized above the alarm set point.
The alarm LEDs are illuminated in the alarm condition.
Alarm LED Action for LED Action for Relay Action for Relay Action for
Action Input Above Set Input Below Set Input Above Set Input Below Set
Point Point Point Point
High ON OFF De-energized Energized
Low OFF ON Energized De-energized
Hi/Lo Alarm activates above the High Set Point or below the Low Set Point.
High Alarm activates above the High Set Point.
Low Alarm activates below the Low Set Point.
The set point band is defined as the actual value of the set point plus or minus the hysteresis
value. The hysteresis value is ±1% of the Alarm 1 Set Point. Alarm action occurs if the input
value is above or below the set point band. If the input moves within the set point band, the last
alarm action is maintained.
1 5 .0
Continued on next page…
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Low and High Level Dissolved Oxygen Monitor
9438 7 PROGRAMMING AND ELECTRICAL CALIBRATION
Set Up Retransmission 1
–––––
SET UP RETRANS 1
Retransmission 1 Span
2 0 .0 The span current output can be set to any value between:
RTX Span mg/kg
Linear 20 µg kg–1 and 20 mg kg–1
Bi-Linear
Linear
Enter Input %
1 0 .0
Enter Input % Set the percentage of the display span at which the breakpoint occurs: 1.0 to 100% in 0.1%
increments. This is point A on Fig. 7.1.
Enter Output %
5 0 .0 Set the percentage output at which the breakpoint occurs: 0.0 to 100% in 0.1% steps.
Enter Output %
This is point B on Fig. 7.1.
Diagnostics
Select whether the current output diagnostics are required. See Appendix B.
Diagnostics YES
NO
No Ye s
Continued on next page…
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24 IM/9438 Issue 11
Low and High Level Dissolved Oxygen Monitor
9438 7 PROGRAMMING AND ELECTRICAL CALIBRATION
Yes
No Calibration Pulse time
30 Set the frequency of the calibration pulse signal. Programmable frequency of 15, 30, 45
Cal. Time s
seconds, 1, 2, 3, 4, 5 minutes.
See Appendix B.
Calibration Fail Mark Time
30 Set the mark time period for the current output to be driven hard upscale. Programmable
Fail M.time s period of 30 seconds, 1, 2, 3, 4, 5,…,10 minutes.
See Appendix B.
Calibration Fail Space Time
30 Set the space time period for the current output to be driven to 0%. Programmable period of
Fail S.time s 30 seconds, 1, 2, 3, 4, 5, …,10 minutes.
See Appendix B.
––––– The retransmission 2 output can be selected from three mA current ranges to ensure
compatibility with the peripheral device connected. Select the current range required for
RTX Type 4-20
0-20 retransmission 2 output.
0-10
Retransmission 2 Output Assignment
Select the Retransmission output required:
––––– Temp – Temperature
RTX O/P Temp
D.O. – Dissolved Oxygen
D.O.
Temp D.O.
Retransmission 2 Span
2 0 .0 Set the span to the required value. See Table 7.1 for details.
RTX Span mg/kg
Bi-Linear
o
C
Linear
Log
Retransmission 2 Zero
2 .0 Set the zero to the required value. See Table 7.1 for details.
RTX Zero mg/kg
o
C
Bi-linear Linear
Enter Input %
1 0 .0 Set the percentage of the display span at which the breakpoint occurs: 1.0 to 100% in 0.1%
Enter Input %
increments. This is point A on Fig. 7.1.
Enter Output %
5 0 .0 Set the percentage output at which the breakpoint occurs: 0.0 to 100% in 0.1% steps.
Enter Output % This is point B on Fig. 7.1.
Diagnostics
Select whether the current output diagnostics are required. See Appendix B.
Diagnostics YES
NO
No Ye s
No Retrans 2
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Low and High Level Dissolved Oxygen Monitor
9438 7 PROGRAMMING AND ELECTRICAL CALIBRATION
Note. The instrument is calibrated by the company prior to despatch and an electrical calibration should be carried out only if the
accuracy of the instrument is suspect and suitably calibrated test equipment is available.
Note. Resistance boxes have an inherent residual resistance which may range from a few milliohms up to 1 ohm. This value
must be taken into account when simulating input levels, as should the overall tolerance of the resistors within the boxes.
7.6.2 Preparation
1. Switch off the supply and disconnect the sensor, temperature compensator and current output from the electronics unit
terminal block – see Fig. 3.5 or Fig. 3.6.
2. Connect the current source / resistance box to the appropriate terminals – see Table 7.2.
Connect the milliammeter to the retransmission output terminals – see Fig. 3.5 or Fig. 3.6.
3. Switch on the supply and allow ten minutes for the circuits to stabilize.
4. Select the Factory Settings Page and carry out the procedure in Section 7.7.
Wall Mounted 1 2 3 4 5 6 7
Panel Mounted 12 11 10 9 8 7 6
–––––
ELECTRICAL CAL
Select YES to access the electrical calibration sequence. Select NO to advance to Cal Time 1.
–––––
Calibrate YES
NO Caution. Do not select YES unless instrument calibration is required.
NO YES
Microamp Zero
XXXX Set the current source to 0 µA and allow the instrument display to stabilize.
µA Zero (0µA)
Microamp Span
XXXX
µA Span (100µA) Set the current source to +100 µA and allow the instrument display to stabilize.
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9438 7 PROGRAMMING AND ELECTRICAL CALIBRATION
Calibration Time 1
2 Wait period before the stability of the sensor is checked during the calibration sequence.
Cal Time 1 (min) Programmable from 1 to 10 minutes (default = 2 minutes), see section 7.5, page 24.
Calibration Time 2
30 Recovery period where the sample is allowed to flow and the instrument settles on reading, before
Cal Time 2 (min) the instrument is brought back on-line (default = 30 minutes), see section 7.5, page 24.
Alter Fact. Code Set the security code to a value between 00000 and 19999.
100
90
80
70
% Retransmission Output
60
B 50
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100
100
90
80
70
% Retransmission Output
60
50
40
30
20
10
0
1% 10% 100%
Dissolved Oxygen Measurement shown as % of Display Span
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30 IM/9438 Issue 11
Low and High Level Dissolved Oxygen Monitor
9438 8 MAINTENANCE
store sensors in a refrigerator to extend their life, but 4. Insert the sensor assembly into the flowcell.
DO NOT allow them to freeze. 5. Use the clamp screw to secure the assembly. Screw in
firmly using finger pressure only.
DO NOT:
allow sensors to dry out, either in storage or in use. Caution. Do not overtighten the clamping screw.
leave sensors in vehicles where they are likely to
freeze or be exposed to high temperatures. 6. Close the solenoid valve – Select NO to 'Open Valve' on
the main operating page of the transmitter – see section
leave sensors on-site without protection from direct
6.2.1, page 18.
sun or high temperatures.
7. Carry out a calibration – see section 6.2.2, page 19. If a
use the sensor if it's sealed environment has dried
low sensor efficiency is displayed, see section 9.2, page
out.
34.
Caution.
Only install the oxygen sensor immediately prior to
use, otherwise leave it stored in its protective
container.
Take special care to line up the two pins in the oxygen
sensor with their respective sockets before making
the connection and tightening.
Take care not to damage the delicate membrane on
the end of the oxygen sensor.
Ensure that the mating surfaces (carrying the electrical
connection) of the oxygen sensor and connector body
are clean and completely dry.
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Low and High Level Dissolved Oxygen Monitor
9438 9 SIMPLE FAULT FINDING
STATUS Alarm A1
Diagnostic Message LED Action Relay Action Possible Cause Remedy
(Failsafe)
Flashing Display OFF Energized Reading is outside of the measuring range See Sections 9.2 & 9.3.
0 to 20 mg Kg–1.
LOW SENSOR EFF. ON/OFF De-energized Output from D.O. sensor during calibration See Section 9.2.
(1s period) / energized less than 40 % of expected output.
(1s period)
SLOW SENSOR ON/OFF De-energized Output from D.O. sensor during calibration See Section 9.2.
CAL. (1s period) / energized not achieving required stability.
(1s period)
COLD ON De-energized Sample temperature <5 ºC. If sample temperature is not <5 ºC, check
(Solution too cold) the temperature input of the transmitter –
see section 9.3, page 34. If fault persists
contact the Company.
HOT ON De-energized Sample temperature >55 ºC. This causes If sample temperature is not >55 ºC, check
(Solution too hot) the calibration valve to open and drain the the temperature input of the transmitter –
flowcell to prevent damage to the sensor. see section 9.3, page 34. If fault persists
After 30 minutes the valve closes and the contact the Company.
sample temperature is measured again.
This process continues until the sample
temperature is <55 ºC.
FAULTY PT1000 ON De-energized Temperature compensator/ associated Check that all signal connections are
connections are either open or short made. If fault persists, check for a
circuit. response to a temperature input – see
section 9.3, page 34.
INVALID INPUT ON De-energized Input signal is outside of measuring range Check that instrument responds to an
of the electronics. input signal by carrying out an electrical
calibration as described in Section 7.6.
NV MEMORY ON De-energized Contents of non-volatile memory have not Switch off transmitter, wait 10 seconds
ERROR been read correctly during power up. and switch on again. If fault persists
contact the Company.
9.2 Low Sensor Efficiency/Slow Sensor Cal. or No 9.3 Checking the Temperature Input
Response to D.O. Changes Check that the instrument responds to a temperature input.
1. Check that the sample drains fully from flowcell. If the Disconnect the PT1000 leads and connect a suitable resistance
sample does NOT drain fully check: box directly to the transmitter inputs – see section 7.6, page 27.
a. Operation of solenoid valve. Check that the transmitter displays the correct values as set on
the resistance box – see Table 9.2.
b. Sample inlet flow rate does not exceed 400 ml min–1
maximum. Incorrect readings usually indicate an electrical calibration
problem. Recalibrate the instrument – see section 7.6, page 27.
c. Sample fluid paths are free flowing and clear of
partial blockages. 9.4 High Sample Readings
If the sample reading is higher than expected, the most likely
d. Solenoid valve drain tube is not kinked, blocked,
reason is air ingress into the main sample line.
excessively long, does no rise along its length.
Check and tighten ALL sample connections as it is possible to
e. Flow gauge is not blocked or dirty.
have an air leak into the sample without sample leaking.
2. Replace the sensor (see section 8.2.2, page 32) as an
Temperature (ºC) Input Resistance (Ω)
initial check. It is also important that all program
parameters have been set correctly and have not been 0 1000.0
altered inadvertently – see section 7, page 20.
10 1039.0
If the fault persists:
20 1079.3
3. Carry out an electrical calibration as detailed in Section 7.6
and check that the instrument responds correctly to the 30 1116.7
current input. 40 1155.4
Failure to respond to the input usually indicates a fault with 50 1194.0
the transmitter, which must be returned to the Company
for repair. 60 1232.4
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34 IM/9438 Issue 11
Low and High Level Dissolved Oxygen Monitor
9438 10 Specification
10 Specification
System
Measuring ranges Transmitter
Electrodes Power supply 100 to 130 V or 200 to 260 V, 50/60 Hz
Programmable within the ranges 0 to 20.0 µg/kg and 0 to 20 mg/kg Power consumption <10 VA
Scaling Insulation, mains to earth
µg/kg, mg/kg or ppb, ppm 2kV RMS
Accuracy Solenoid valve
±5 % of reading or ±1 µg/kg, whichever is the greater Power supply 90 to 132 V or 180 to 264 V, 47/63 Hz
Response time Power consumption <11 VA
90 % of a step change in 1 minute
Resolution
Mechanical Data
0.1 µg/kg
Mounting
Stability Transmitter Wall or panel
±5 % of reading or ±1µg/kg per week, whichever is the greater
Liquid-handling panel/enclosure Wall
Not applicable when autocalibration is in operation
Solenoid valve power supply Wall
Temperature compensation
Overall Dimensions
5 to 55 ºC (41 to 131 ºF) automatic using Pt1000 resistance
Liquid handling panel
thermometer
With environmental enclosure
Salinity correction
250 x 440 x 160 mm
Preset within the range 0 to 80 PPT (9.84 x 17.32 x 6.3 in)
Barometric pressure correction Without unions and without environmental enclosure
Preset within the range 500 to 800 mm Hg 100 approx. x 310 x 118 mm
Sample flow (3.94 approx. x 12.2 x 4.65 in)
100 to 400 ml/min Transmitter
Sample pressure Wall-mount 160 x 214 x 68 mm
Maximum 2 bar (6.29 x 8.43 x 2.68 in)
Sample temperature Panel-mount 96 x 96 x 191 mm
5 to 55 ºC (41 to 131 ºF) (3.78 x 3.78 x 7.52 in)
Sensor ambient temperature Panel cut-out 92 x 92 mm
0 to 55 ºC (32 to 131 ºF) (3.62 x 3.62 in)
Autocalibration frequency Solenoid valve power supply 92 x 92 mm
1, 7 or 28 days (3.62 x 3.62 in)
Weights
Environmental Data
Liquid handling panel
Operating temperature limits
–20 to 55 ºC (–4 to 131 ºF) With sensor fitted and with environmental enclosure
3.9 kg (8.6 lb)
Operating humidity limits
With sensor fitted, without environmental enclosure
Up to 95 % RH non-condensing
1.3 kg (2.87 lb)
Storage temperature limits
Transmitter
Liquid-handling panel –25 to 70 ºC (–13 to 158 ºF)
Wall-mount 2 kg (4.41 lb)
Sensor 0 to 55 ºC (32 to 131 ºF)
Panel-mount 1.5 kg (3.31 lb)
Transmitter –25 to 70 ºC (–13 to 158 ºF)
Solenoid valve power supply 0.7 kg (1.54 lb)
Solenoid valve power supply –25 to 70 ºC (–13 to 158 ºF)
Sample connections
Compression fitting to accept either 6 mm OD tubing
Protection or 1/4 in OD tubing – to be specified when ordering
Liquid handling panel
IP65
IP54 Liquid-handling panel enclosure
Transmitter
Panel-mountIP66/NEMA4X
Wall-mount IP66/NEMA4X front
Solenoid valve power supply IP65
Power requirements
System
Power consumption <21 VA
Retransmission
No. of retransmission signals
One, fully isolated current output
0 to 10, 0 to 20 or 4 to 20 mA programmable
Optional second current output
0 to 10, 0 to 20 or 4 to 20 mA programmable
Maximum load resistance
500 Ω (20 mA maximum)
Serial communication
RS422/RS485 (optional, with one current output signal)
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36 IM/9438 Issue 11
Low and High Level Dissolved Oxygen Monitor
9438 11 SPARES
11 SPARES
Normal, replacement spares are shown in Fig. 11.1. Strategic
spares are listed below.
O-ring
O-ring
(3/4 in I.D. x 0.070 in cord)
Compression Coupling
Connector (to suit 6 mm or 1/4 in
Body o.d. stainles steel pipe)
Connector Nut
Thrust Washer
Sensor Connector
Plug Cable Assembly:
Clamping Screw 9437 029/031/032/034
(1 m/5 m/10 m/30 m respectively)
Connector Body
Sensor Connector Cable Assembly
Connector Nut
Thrust Washer
Clamping Screw
Plug
Note. Ensure that the correct O-rings are fitted in the appropriate positions as shown.
Fit new O-rings when a new sensor is fitted.
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38 IM/9438 Issue 11
Low and High Level Dissolved Oxygen Monitor
9438 Appendix A 9438 080 24 V DC POWER SUPPLY UNIT (OPTIONAL)
Warning.
Before making any connections, ensure that the
power supply, any high voltage-operated control
circuits and high common mode voltage are switched
off.
Although certain instruments are fitted with internal
fuse protection, a suitably rated external protection
device, e.g. fuse or miniature circuit breaker (m.c.b.),
must also be fitted by the installer.
98 136
CTRS
fixing
63
M6 stud for
earth 145 CTRS
bonding Fixing screws M4
All dimensions in mm
Pre-wired to
terminal block
+24V
+24V
+24V
+24V
0V
0V
0V
0V
Mains cable in E N L
To earth
terminal in lid
N/O
N/O
N/O
N/O
COM
COM
COM
COM
TX4 TX3 TX2 TX1
TO RELAY 2 OF TRANSMITTERS
0V +24V
C N/O
C NO
Relay 2
9438 Transmitter
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40 IM/9438 Issue 11
Low and High Level Dissolved Oxygen Monitor
9438 Appendix B CALIBRATION DIAGNOSTICS
100
Output Current (%)
Cal Pulse
50
0
Expose to Air Recovery Period
Time
100
Mark Space
(30 s to 5 min) (30 s to 5 min)
Output Current (%)
50
0
Expose to Air
Time
Notes
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42 IM/9438 Issue 11
Low and High Level Dissolved Oxygen Monitor
9438 Notes
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44 IM/9438 Issue 11
PRODUCTS & CUSTOMER SUPPORT
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ABB has Sales & Customer Support expertise The Company’s policy is one of continuous product
in over 100 countries worldwide improvement and the right is reserved to modify the
information contained herein without notice.
www.abb.com
Printed in UK (03.09)
© ABB 2009
Issue 11
IM/9438
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