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ABB AX418 User Manual

Single and dual input analyzers for dissolved oxygen
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Single and Dual Input Analyzers
User Guide
for Dissolved Oxygen
IM/AX4DO_5
AX418, AX438, AX480, AX468 and AX488

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  • Page 1 Single and Dual Input Analyzers User Guide for Dissolved Oxygen IM/AX4DO_5 AX418, AX438, AX480, AX468 and AX488...

  • Page 2: Electrical Safety

    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. Q05907 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) We are committed to teamwork, high quality manufacturing, advanced technology and unrivalled service and support.

  • Page 3: Table Of Contents

    CONTENTS Section Page Section Page 1 INTRODUCTION .............. 2 6 INSTALLATION .............. 39 System Description ..........2 Siting Requirements ..........39 PID Control ............. 2 Mounting ............... 40 AX400 Series Analyzer Options ....... 2 6.2.1 Wall-/Pipe-mount Analyzers ....... 40 6.2.2 Panel-mount Analyzers ......41 2 OPERATION ..............

  • Page 4: Introduction

    1 INTRODUCTION 1.1 System Description 1.2 PID Control – AX480 Analyzer Only The AX480 Single Input and AX488 Dual Input Dissolved Oxygen The AX480 single input dissolved oxygen analyzer incorporates (DO) analyzers and associated sensors have been designed for Proportional Integral Derivative (PID) control as standard. For a continuous monitoring and control in a wide range of full description of PID control, refer to Appendix B.

  • Page 5: Operation

    2 OPERATION 2.1 Powering Up the Analyzer 2.2.1 Membrane Key Functions – Fig. 2.2 Warning. Ensure all connections are made Menu 1 correctly, especially to the earth stud – see Section 6.3. Advance to next menu 1) Ensure the input sensor(s) is/are connected correctly. Menu 2 2) Switch on the power supply to the analyzer.

  • Page 6: Operating Page

    …2 OPERATION Use the Menu Key Use the Sidescroll Key to scroll through the Pages within each Menu to scroll through the Menus Section 2.3, Page 6 Section 3.1, Page 9 Section 3.2, Page 10 Section 3.3, Page 10 Section 3.4, Page 11 Section 3.5, Page 11 Section 3.6, Page 14 VIEW SETPOINTS...
  • Page 7 2 OPERATION… Use the Menu Key Use the Sidescroll Key to scroll through the Pages within each Menu to scroll through the Menus Section 5.5, Page 28 CONFIG. OUTPUTS Config. Output 1 Config. Output 2 Config. Output 3 Config. Output 4 AO1: Assign AO2: Assign AO3: Assign...

  • Page 8: Single Input Dissolved Oxygen

    …2 OPERATION 2.3 Operating Page 2.3.1 Single Input Dissolved Oxygen Measured Values 100. 0 %Sat Dissolved Oxygen. 25. 0 Deg.C Temperature. Dissolved Oxygen Note. The measured dissolved oxygen value is displayed in the units set in the Controller frame – see Section 5.3. –...

  • Page 9: Dual Input Dissolved Oxygen

    2 OPERATION… …2.3 Operating Page 2.3.2 Dual Input Dissolved Oxygen Measured Dissolved Oxygen 100. 0 %Sat Sensor A. 9. 0 7 Sensor B. Dual D.O. Note. The displayed readings are the actual values of the sample. Measured Temperature 20. 0 Deg.C Sensor A.

  • Page 10: Wash Function

    …2 OPERATION …2.3 Operating Page 2.3.3 Wash Function Note. The Wash function is available only if is set to – see Section 5.4. A3: Type Wash Wash Function Manual – Wash function off. Lower display line of Operating Page shows WASH INHIBITED ----- –...

  • Page 11: Operator Views

    3 OPERATOR VIEWS 3.1 View Set Points View Set Points This page shows alarm set points. The value of each of the set points is shown, together with the name of the parameter it's assigned to. ----- Alarm assignments, set point values and relay/LED actions are programmable – see VIEW SETPOINTS Section 5.4.

  • Page 12: View Outputs

    …3 OPERATOR VIEWS 3.2 View Outputs Theoretical Analog Output There are up to four analog outputs, each showing information for one sensor. ----- Note. Analog outputs 3 and 4 available only if option board fitted and analog features enabled – see Section 7.3. VIEW OUTPUTS 12.

  • Page 13: View Software

    3 OPERATOR VIEWS… 3.4 View Software ----- VIEW SOFTWARE Issue Shows the version number of the software. 7. 0 5 AX400/2000 Issue Option board fitted and analog features enabled (Section 7.3) and VIEW LOGBOOK set to (Section 5.9) – see Section 3.5. Logbook VIEW SOFTWARE Dissolved Oxygen...
  • Page 14 …3 OPERATOR VIEWS …3.5 Logbook Alarms View Logbook Cals Use the keys to access the logbook. Errors Power ----- Errors Note. If no entries are stored in the logbook, the display shows No More Entries VIEW LOGBOOK Errors Errors Sen.A logbook contains up to 5 entries (entry 1 is the most recent), each comprising Errors the sensor letter, error number and the date/time of the occurrence.

  • Page 15: View Logbook

    3 OPERATOR VIEWS… …3.5 Logbook Power View Logbook Errors Use the keys to access the logbook. Cals Alarms ----- Cals VIEW LOGBOOK Note. If no entries are stored in the logbook, the display shows No More Entries Cals Calibration (Entry 1) logbook contains up to 5 entries (entry 1 is the most recent), each comprising 2 Cals frames.

  • Page 16: View Clock

    …3 OPERATOR VIEWS 3.6 View Clock Note. The View Clock function is available only if the option board is fitted and analog features enabled – see Section 7.3. ----- VIEW CLOCK Date Shows the current date. ----- Date 05:03:04 Time Shows the current time.

  • Page 17: Setup

    4 SETUP 4.1 Sensor Calibration Notes. • Sensor calibration involves standardizing the analyzer and the sensor using sample solutions and air. • A 5% sodium sulphite, zero calibration solution is required for an automatic, commisioning calibration. Automatic, full scale (span) calibration is carried-out either in air or air-saturated water – see Appendix A3. Sensor Calibration ----- SENSOR CAL.
  • Page 18 …4 SETUP …4.1 Sensor Calibration A: Cal. Type. set to Manual Adjust Zero 0. 0 %Sat value, between –2.000 and 2.000 in 0.001 A increments, until the A Adjust the %Sat value matches that from the reference instrument. 0. 0 00 A: Adjust Zero Although the sensor can be immersed in a 5% sodium sulphite zero calibration solution (see Appendix A3.1) and zero adjusted manually, it is strongly recommended that, if this...
  • Page 19 4 SETUP… …4.1 Sensor Calibration A: Cal. Type. set to None Sensor Output The sensor efficiency calculated from the last successful calibration is displayed. When five bars are displayed, the sensor has maximum life remaining. When one bar is displayed and ----- flashing, the sensor is exhausted.
  • Page 20 …4 SETUP …4.1 Sensor Calibration Zero Calibration Immerse the sensor in a 5% sodium sulphite solution. 0. 0 %Sat Press the key to initiate calibration. Immerse Zero Sol Note. To abort calibration, press the key again at any time before calibration is complete –...
  • Page 21 4 SETUP …4.1 Sensor Calibration The center display line shows, in the units selected in the page (Section CONFIG. SENSORS 5.3), the value to which the instrument's reading will be set following a successful span calibration. If either automatic barometric or altitude correction were selected, the 0.

  • Page 22: Programming

    5 PROGRAMMING 5.1 Security Code Note. This frame is displayed only if is not set to zero – see Section 5.8. Alter Sec. Code Enter the required code number (between 0000 and 19999), to gain access to the 0000 configuration pages. If an incorrect value is entered, access to the configuration pages is prevented and the display reverts to the Operating Page –...

  • Page 23: Configure Display

    5 PROGRAMMING… 5.2 Configure Display ----- CONFIG. DISPLAY Set Language Sets the language to be used on all displays. ----- Set Language Language Use the keys to select the required language. ----- English Deutsch Francais Espanol Italiano Set Language Set Temperature Units ----- Set Temp.

  • Page 24: Configure Sensors

    …5 PROGRAMMING 5.3 Configure Sensors ----- CONFIG. SENSORS Configure Sensor A ----- Config. Sensor A Sensor B configuration (dual input analyzers only) is identical to Sensor A Config. Sensor B configuration. Single input analyzers only – return to main menu. CONFIG.
  • Page 25 5 PROGRAMMING… 5.4 Configure Alarms ----- CONFIG. ALARMS Configure Alarm 1 ----- Config. Alarm 1 Alarms 2 and 3 configuration (and Alarms 4 and 5 if option board fitted and Config. Alarm 2 analog features enabled – see Section 7.3) is identical to Alarm 1. Alarm 3 can also be configured as a Wash alarm if is set to –...

  • Page 26: Configure Alarms

    …5 PROGRAMMING …5.4 Configure Alarms A1: Type set to Alarm A–B Temp.B Alarm 1 Assign Sen.B Select the alarm assignment required: Temp.A ----- Sen.A – The analyzer activates an alarm if the dissolved oxygen content of the Sen.A A1: Assign Sen.B process fluid measured by the selected sensor exceeds or drops below the value set in the...
  • Page 27 5 PROGRAMMING… …5.4 Configure Alarms Alarm 1 Failsafe Select to enable failsafe action, otherwise select See also Figs. 5.2 to 5.6 (page 27). ----- A1: Failsafe Alarm 1 Action Select the alarm action required, High High See also Figs. 5.2 to 5.6 (page 27). ----- A1: Action Alarm 1 Set Point...

  • Page 28: Wash Cycle Configuration (Applicable Only To Alarm 3)

    …5 PROGRAMMING …5.4 Configure Alarms 5.4.1 Wash Cycle Configuration (applicable only to Alarm 3) A3: Type set to Wash Wash Mode Select the wash mode required. Cont. ----- Pulsed – (continuous) the relay remains energized for the wash duration Cont. Wash Mode Pulsed –...
  • Page 29 5 PROGRAMMING… …5.4 Configure Alarms Note. The following examples illustrate , i.e. the alarm is activated when the process variable exceeds the High Alarm Actions defined set point. are the same, except the alarm is activated when the process variable drops below the Low Alarm Actions defined set point.
  • Page 30 …5 PROGRAMMING 5.5 Configure Outputs ----- CONFIG. OUTPUTS Configure Output 1 ----- Config. Output 1 Output 2 configuration (and Outputs 3 and 4 if option board fitted and analog Config. Output 2 features enabled – see Section 7.3) is identical to Output 1 configuration. A–B Temp.B Assign...

  • Page 31: Configure Outputs

    5 PROGRAMMING… …5.5 Configure Outputs Zero Value 250. 0 %Sat 0. 0 %Sat ) and are shown alternately on the center display line. Use the %Sat mg/l Adjust keys to adjust the displayed reading to the required zero value: AO1: Zero Value %Sat –...

  • Page 32: Configure Clock

    …5 PROGRAMMING 5.6 Configure Clock Note. The Configure Clock function is available only if the option board is fitted and analog features enabled – see Section 7.3. ----- CONFIG. CLOCK Set Clock Set the system clock. ----- Set Clock? Return to main menu. CONFIG.
  • Page 33 5 PROGRAMMING… 5.7 Configure Control Notes. • PID control is applicable only to single input analyzers. • Before configuring the PID controller, refer to Appendix B for further information. ----- CONFIG. CONTROL Controller Type Select the controller type: ----- – Disables the controller –...

  • Page 34: Configure Control

    …5 PROGRAMMING …5.7 Configure Control 5.7.1 Configure Single PID Controller Controller set to ---- PID Controller See Section 5.7.2. Power Recovery Control Action Set the required control action: Rev. Rev. – Reverse acting – see Appendix B, Fig. B2. ---- Direct –...

  • Page 35: Configure Single Pid Controller

    5 PROGRAMMING… …5.7 Configure Control …5.7.1 Configure Single PID Controller Output Type set to Time Time Proportioning Output The Time Proportioning Output is interrelated to the retention time of the vessel and the flow of the chemical reagent and is adjusted experimentally to ensure that the chemical 10.
  • Page 36 …5 PROGRAMMING …5.7 Configure Control …5.7.1 Configure Single PID Controller Output Type set to Pulse Pulse Frequency Ouput The pulse frequency output is the number of relay pulses per minute required for 100% control output. The Pulse Frequency Output is interrelated to the chemical reagent strength and the solution flow rate.

  • Page 37: Configure Power Failure Recovery Mode

    5 PROGRAMMING… …5.7 Configure Control 5.7.2 Configure Power Failure Recovery Mode ---- Power Recovery Power Failure Recovery Mode Last When power to the analyzer is restored, (Section 2.3) is set automatically Control Mode Manual according to the chosen Power Failure Recovery Mode selected in this frame. ---- Auto Power Rec.

  • Page 38: Configure Security

    …5 PROGRAMMING 5.8 Configure Security ----- CONFIG. SECURITY Alter Security Code Set the security code to a value between 0000 and 19999. 00000 Alter Sec. Code Alter Calibration Code Set the sensor calibration access code to a value between 0000 and 19999. 00000 Alter Cal.
  • Page 39 5 PROGRAMMING… 5.10 Test Outputs and Maintenance ----- TEST/MAINTENANCE Test Outputs Displays the output test details for the analog outputs. ----- Note. Outputs 3 and 4 are available only if the option board is fitted and analog features enabled – see Section 7.3. Test Outputs frame only is shown;...

  • Page 40: Test Outputs And Maintenance

    …5 PROGRAMMING …5.10 Test Outputs and Maintenance Hold Outputs set to Auto. Automatic Time If required, set a time period between 1 and 6 hours, in 30 minute increments, for which the outputs are held when is set to Hold Outputs Auto.

  • Page 41: Installation

    6 INSTALLATION 6.1 Siting Requirements Notes. • Mount in a location free from excessive vibration. • Mount away from harmful vapours and/or dripping fluids. • Where possible, mount the analyzer at eye level to allow an unrestricted view of the front panel displays and controls.
  • Page 42 …6 INSTALLATION 6.2 Mounting 6.2.1 Wall-/Pipe-mount Analyzers – Figs. 6.2 and 6.3 Dimensions in mm (in.) Fixing Centers 94 (3.7) 210 (8.23) 192 (7.56) 96 (3.76) Fig. 6.2 Overall Dimensions 61 (2 ) OD Position 'U' bolts on pipe Vertical or Horizontal Position plate over 'U' bolts Drill suitable...

  • Page 43: Mounting

    6 INSTALLATION… …6.2 Mounting 6.2.2 Panel-mount Analyzers – Figs. 6.4 and 6.5 Dimensions in mm (in.) +0.8 +0.03 (3.62 –0 –0 137.50 (5.41) (0.98) 96 (3.78) +0.8 –0 Panel Cut-out +0.03 (3.62 –0 5.40 (0.2) Fig. 6.4 Overall Dimensions Cut a hole in the panel (see Fig. 6.4 for dimensions). Instruments may be close stacked to DIN 43835 Remove the panel clamp and anchors from the instrument case...

  • Page 44: Wall-/Pipe-Mount Analyzers

    …6 INSTALLATION 6.3 Electrical Connections Warnings. • The instrument is not fitted with a switch therefore a disconnecting device such as a switch or circuit breaker conforming to local safety standards must be fitted to the final installation. It must be fitted in close proximity to the instrument within easy reach of the operator and must be marked clearly as the disconnection device for the instrument.

  • Page 45: Electrical Connections

    6 INSTALLATION… …6.3 Electrical Connections 6.3.1 Relay Contact Protection and Interference Suppression – Fig. 6.6 If the relays are used to switch loads on and off, the relay contacts can become eroded due to arcing. Arcing also generates radio frequency interference (RFI) which can result in analyzer malfunctions and incorrect readings. To minimize the effects of RFI, arc suppression components are required;...

  • Page 46: Cable Entry Knockouts

    …6 INSTALLATION …6.3 Electrical Connections 6.3.2 Cable Entry Knockouts, Wall-/Pipe-mount Analyzer – Fig. 6.7 The analyzer is supplied with 7 cable glands, one fitted and six to be fitted, as required, by the user – see Fig. 6.7. Release the four captive screws and remove the terminal cover plate Factory-fitted cable gland...

  • Page 47: Wall-/Pipe-Mount Analyzer Connections

    6 INSTALLATION… 6.4 Wall-/Pipe-mount Analyzer Connections 6.4.1 Access to Terminals – Fig. 6.8 Release the four captive screws and remove the terminal cover plate Terminal Block C (Option Board) Case Earth Terminal Block A Terminal Block B (Ground) Stud Fig. 6.8 Access to Terminals, Wall-/Pipe-mount Analyzer...

  • Page 48: Wall-/Pipe-Mount Analyzer Connections

    …6 INSTALLATION …6.4 Wall-/Pipe-mount Analyzer Connections 6.4.2 Connections – Fig. 6.9 Earth (Ground) Terminal Block C Stud on Case (Option Board) (see Fig. 6.8) Terminal Block B Temperature Compensator Temperature Compensator Connections Connections Before making any electrical connections, see Warnings on page 42 Terminal block A Terminal Block B Sensor B...
  • Page 49 6 INSTALLATION… 6.5 Panel-mount Analyzer Connections 6.5.1 Access to Terminals – Fig. 6.10 Terminal Block A Earth (Ground) Stud Terminal Block C Terminal Block B (Option Board) Fig. 6.10 Access to Terminals, Panel-mount Analyzers...

  • Page 50: Panel-Mount Analyzer Connections

    …6 INSTALLATION …6.5 Panel-mount Analyzer Connections 6.5.2 Connections – Fig. 6.11 Terminal block A Terminal Block C Terminal Block B (Option Board) 85 to 265 V AC + Not Used Line Power Common Supplies Link Neutral Not Used 24 V AC –...

  • Page 51: Calibration

    Analog-to-Digital converter chip self-compensates for zero and span drift. It is therefore unlikely that the calibration will change over time. • attempt recalibration without first contacting ABB. Do Not • attempt recalibration unless the input board has been replaced or the Factory Calibration tampered with.
  • Page 52 …7 CALIBRATION 7.3 Factory Settings Use the Sidescroll Key to scroll through the Pages within each Menu Section 7.3, Page 51 FACTORY SETTINGS Factory Set Code Cal. Sensor A Cal. Sensor B Cal. Output 1 Calibrate I/P ? Calibrate I/P ? O1: Adjust 4mA Use the Menu A: Zero (0uA)

  • Page 53: Factory Settings

    7 CALIBRATION… …7.3 Factory Settings ----- FACTORY SETTINGS Factory Settings Access Code Enter the required code number (between 0000 and 19999) to gain access to the factory settings. If an incorrect value is entered, access to subsequent frames is prevented and the 0000 display reverts to the top of the page.
  • Page 54 …7 CALIBRATION …7.3 Factory Settings Temperature Span (150R) 150. 0 Ohms Set the temperature simulator to 150 150. 0 Calib The display advances automatically to the next step once a stable and valid value is A: T.Span (150R) recorded. Reference Resistance Checking 100.
  • Page 55 7 CALIBRATION… …7.3 Factory Settings Calibrate Output 1 Note. When adjusting the 4 and 20mA output values, the display reading is unimportant ----- and is used only to indicate that the output is changing when the keys are pressed. Cal. Output 1 See below.
  • Page 56 …7 CALIBRATION …7.3 Factory Settings Option Board Fitted and Analog Features Enabled Calibrate Output 3 Notes. ----- • Output 3 (and Output 4) calibration is applicable only if the option board is fitted and analog features enabled – see below. Cal.

  • Page 57: Simple Fault Finding

    8 SIMPLE FAULT FINDING 8.1 Error Messages 8.2 No Response to DO Changes If erroneous or unexpected results are obtained the fault may be The majority of problems are associated with the DO sensor. indicated in the Operating Page by an error message – see Table Replace the sensor as an initial check –...

  • Page 58: Specification

    SPECIFICATION Dissolved Oxygen – AX480, AX488 and AX468 Range Temperature sensor Programmable 0 to 250% saturation, 0 to 25 mgl or 0 to 25ppm Programmable Pt100 (3-wire), Pt1000 & Balco 3k. Minimum span Calibration Ranges 0 to 2 mgl or ppm Check value (zero point) 0 to 14pH 0 to 20% saturation...
  • Page 59 SPECIFICATION… Relay Outputs – On/Off Control Function – AX480 Only Controller Type Number of relays Three supplied as standard or five with option board fitted P, PI, PID (Configurable) Control Outputs Number of set points Three supplied as standard or five with option board fitted Output Can be assigned a maximum of two relays, two analog outputs Set point adjustment...
  • Page 60 …SPECIFICATION Mechanical Data Wall-/Pipe-mount versions Emissions and immunity IP66/NEMA4X Meets requirements of: Dimensions 192mm high x 230mm wide x 94mm deep EN61326 (for an industrial environment) (7.56 in. high x 9.06 in. wide x 3.7 in. deep) EN50081-2 Weight 1kg (2.2 lb) EN50082-2 Panel-mount versions Hazardous area approvals...

  • Page 61: Oxygen Solubility In Pure Water

    APPENDIX A A1 Oxygen Solubility in Pure Water A2 Correction for Salinity Table A1 gives values for the solubility of oxygen in pure water at Automatic correction for the effect of salinity on oxygen solubility various temperatures. The solubility values are given in is available for the measurement of dissolved oxygen mg/l (ppm) and relate to pure water in equilibrium with water concentrations in saline water, provided the salinity value of the...

  • Page 62: A3 Do Calibration

    …APPENDIX A A3 DO Calibration A3.2 Span Calibration Either air or air-saturated water may be used. Air calibration is more convenient and is likely, in practice, to be at least as Note. Both the oxygen and the temperature sensors accurate as calibration in air-saturated water. must be exposed to the calibration medium.

  • Page 63: B1.1 Reverse Acting Single Pid Control

    APPENDIX B B1 Single PID Controller – Fig. B1 The single PID controller is a basic feedback control system using three-term PID control with a local set point. Manual Output Control Set Point Output 1 PID Control Loop PID Output Process Variable Fig.

  • Page 64: B1.2 Direct Acting Single Pid Control

    …APPENDIX B B1.2 Direct Acting Single PID Control – Fig. B3 Direct acting control is used when the process DO is greater than the required output DO. 100% Control Output Direct Acting 100% Process Variable Range Fig. B3 Direct Acting Single PID Control B2 Ouput Assignment The output signal is assignable to either relay 1 (Time or Pulse output type) or analog output 1 (Analog output type).

  • Page 65: B3 Setting Up Three Term (Pid) Control Parameters

    APPENDIX B B3 Setting Up Three Term (PID) Control Parameters g) Set Derivative Time To enable a process to be controlled satisfactorily, the following (for P+I+D control) conditions must apply: a) The process must be capable of reaching a natural balance (for P+D control) with a steady load.
  • Page 66 NOTES...
  • Page 67 Service and Repair Centre. – Food & Beverage – Manufacturing United Kingdom – Metals and Minerals – Oil, Gas & Petrochemical ABB Limited – Pulp and Paper Tel: +44 (0)1453 826661 Fax: +44 (0)1453 829671 Drives and Motors United States of America •...
  • Page 68 ABB has Sales & Customer Support The Company’s policy is one of continuous product improvement and the right is reserved to modify the expertise in over 100 countries worldwide information contained herein without notice. Printed in UK (06.06) www.abb.com © ABB 2006 ABB Limited ABB Inc.

This manual is also suitable for:

Ax438Ax480Ax468Ax488

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