This manual has been supplied electronically. A hard copy is available on request from hardware- support@chemtrac.com. Safety Precautions • Before attempting to unpack, set up, or operate this instrument, please read this entire manual.
Chapter 1. Introduction Refers to an imminent danger or a potential hazardous situation. Non-compliance can lead to death or extremely serious injury. Refers to a potential hazardous situation. Non-compliance can lead to injury or property damage. Draws attention to supplementary information to make the work easier and ensure trouble- free operation.
1.1 Safety Precautions 1.1.4 Safe Operation The safety instructions contained in this manual must be observed. The owner is responsible for ensuring compliance with local safety regulations.
Every analyzer is carefully checked before leaving the factory. If for any reason, you are unhappy with your purchase, please contact the organization that you purchased the analyzer from or Chemtrac, Inc directly.
Chapter 2. Overview Safety Precautions 2.1.1 Installation, Maintenance and Inspection The owner must ensure that all maintenance, inspection and installation work is undertaken by authorized and duly qualified personnel who have also studied this manual. • The HydroAct 4 must always be isolated before starting any work. •...
2.3 Installation Enclosure Material ABS flame retardant Seals EPDM HydroAct 4 Dimensions 1. 103mm 2. 309mm 3. 230mm Installation As with all instrumentation the installation and commissioning of this instrument is crucial to its safe and effective operation. This instrument must only be used for its purpose as outlined in this manual.
The analyzer enclosure can be panel mounted using the optional panel mount kit. The support bracket can be used as a template for cutting and drilling the panel. For panel or handrail mounting the enclosure requires optional mounting kits that can be ordered from Chemtrac.
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2.3 Installation HydroAct 4 Panel Mounting A - HydroAct 4 front section, B - Four M5 bolts, C - HydroAct 4 rear section, D - Rubber gasket, E - Panel, F - Support bracket, G - Four M5 washers, H - Four M5 nuts.
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Chapter 2. Overview 2.3.3.3 Handrail Mounting The analyzer enclosure can be handrail mounted using the optional handrail mount kit. By turning the brackets through 90° the analyzer can also be pole mounted. HydroAct 4 Handrail Mount- A HydroAct 4 B Large bracket C Four M5 8mm bolts D Handrail E Small bracket...
2.3 Installation 2.3.4 Electrical Connections 1. Auxiliary power from secondary PSU 2. 12V input from main PSU 3. Communication card slots 4. Sensor and output card slots 5. Digital input configuration jumpers 6. Relay and digital input connectors 7. AC Power to main PSU 8.
Chapter 2. Overview manual. Operation 2.4.1 User Interface The HydroAct 4 display is a 4.3“, 480 272, 24-bit color display and is best viewed from directly in front. The user interface is accessed via nine buttons embedded in the membrane overlay. There are also two status LEDs, showing power and alarm status, and an audible buzzer.
2.4 Operation menus accessible by highlighting the menu item and either pressing the Select button or the Right button. 2.4.3 Home Screens Home screens are used to display information from more than one source on a single display. They are accessed by pressing “Home” from any screen displaying the soft-key and then by pressing the Left or Right button to scroll through the available Home Screens.
Chapter 2. Overview HydroAct 4 Button Layout The analyzer is preconfigured with a default user called “user1” who has full access to the analyzer, with the default password of: 1, 1, 1, 1, 1, 1 From the button layout above. To force a user to log out, press and hold the “Home”...
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2.4 Operation 2.4.5.1 Analyzer Setup The date and time are used in the data logs and status logs of your controller and it is therefore important that they are set correctly. To modify the analyzer labels, time and date settings or language go to: Options Setup...
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Chapter 2. Overview Backlight Timeout In order to extend the life of the display a timeout can be set. At the end of the timeout the display will go dark. Any button press will turn the screen back on. Use the checkbox to enable or disable the backlight timeout and set the desired timeout using the up/down buttons.
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2.4 Operation Select the home screen type from the drop down list. Generic home screens allow up to 4 devices to be displayed in a variety of formats. Other home screen types are application-dependent and are described below, if applicable. For this example, select “Generic” and press “Create”. Editing an existing Generic home screen or creating a new Generic home screen will display the above form.
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Chapter 2. Overview Layout 3 Layout 4 Layout 5 Layout 6 Each window can display information about a device or a data log graph. To select what is displayed in each window of a particular layout, move the selection to highlight the window and press the select button.
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2.4 Operation Login Timeout If no user activity is detected within this given time period while the main menu or home screen is displayed, then the current user will be logged out. The time is in HH:MM:SS format. Default Access If enabled, then no user authentication will be attempted when accessing a device tile or using a quick access function from the home screen.
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Chapter 2. Overview To add a user, highlight “<+ Add User>” and press the select button. Enter the desired user name and access rights. To set the password, press “Password” and follow the on screen prompts. To delete a user, highlight the user name and press “Delete” .
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2.4 Operation The HydroAct 4 makes use of several internal read-only file systems as well as the micro SD card. Information regarding the file system usage can be viewed by selecting: Options Information File Systems All entries other than “/mnt” are internal read-only file systems and the information may be useful for technical support inquiries.
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Chapter 2. Overview The “re-alarm” feature can be enabled and the timeout set. If the analyzer is in alarm and that alarm is acknowledged (see below), then the analyzer will return to the alarm state after the timeout has expired if the error condition has not been rectified. The exact reason for the active alarm is shown by selecting: Options Alarm...
2.4 Operation Configuration Files Restore Clone Analyzer Settings (Name, Alarm, Users, etc) Communications Card Settings Data Logs Setup Home Screens Device Codes Device Settings Modbus Maps 2.4.6 Logs Selecting the log tile from the main menu will display a secondary logs menu. These available options are;...
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Chapter 2. Overview Use the arrow keys to scroll up, down, left and right. Press “Clear” to delete the current status log messages and truncate the status log. Press “Download” to save the status log to SD card. 2.4.6.3 Data Logs 2.4.6.3.1 Creating a Data Log To create a new data log, select “Create Data Log”.
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2.4 Operation 2.4.6.3.2 Viewing a Data Log Each data log configured will be displayed as a tile in the Logs menu. Select the data log of interest to view the data. The overview allows the renaming of the log and changing of the log interval. The “Delete” button will remove the log completely and prevent any further data logs being collected.
3. Sensors UV254 Sensor 3.1.1 General Information 3.1.1.1 Health and Safety The UV254 Sensor is designed to measure the absorbance and transmittance of UV light at a wavelength of 254nm in water. The sensor is often used in clean water and waste water applications. Health and safety precautions should be taken to protect against waste water when handling a used sensor.
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Chapter 3. Sensors 3.1.1.3 Theory of Operation The UV254 Sensor Split-Sense Pro technology is designed to take sensor readings at 90° to each other, where one reading is through the water sample under test and the other reading is through air. The two sensor readings enable the instrument to compensate for lamp and sensor drift over time due to instrument aging and temperature.
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3.1 UV254 Sensor The way the UV254 Sensor provides an output for a correlated parameter is by applying an offset and calibration to the UV254 measurement. This is calculated by setting up a “virtual channel” in the instrument. This channel is then related to the original UV254 measurement by way of a formula in the form: y = mx + c where,...
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Chapter 3. Sensors 3.1.1.5 Technical Data UV254 sensor profile view 1. 430 mm 2. 365 mm 3. 195 mm Range 0..5 UVA, 0..120% UVT Accuracy 0.5% FS Resolution 0.001 UVA. Path Length 2mm, 4mm, or 10mm (to be specified at the time of order) Sampling Time 10 seconds.
3.1 UV254 Sensor 3.1.2 Installation 3.1.2.1 UV254 Sensor The UV254 sensor enclosure should be mounted away from sources of heat and direct sunlight. It should be mounted so that the sensor is vertical and that there is sufficient clearance on the left-hand- side to allow the enclosure to be fully opened.
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Chapter 3. Sensors UV254 sensor side view 1. Sample inlet 2. Sample drain The customer must install a valve to shut off the flow to the sensor when servicing is required and a flow control valve to regulate the flow to 0.3-1.0 l/min. The recommended flow rate for the sensor is approximately 0.75 l/min.
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3.1 UV254 Sensor cards are installed in slots 2 to 4 it will be necessary to power up the HydroAct 4 and check the sensor name and/or connections diagram under the sensor menu to determine the correct slot position for the UV254 sensor input card.
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Chapter 3. Sensors For safety and correct operation, the sensor must be properly earthed.
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3.1 UV254 Sensor 3.1.2.4 Assembly To begin, remove the UV254 sensor from the packaging and carefully inspect the instrument to ensure that no visible damage has occurred during shipping. Next, remove any packaging material that is contained in the inside of the enclosure of the instrument. It is important to note that the quartz flow cell and the rotating arm for the UV254 sensor have been shipped separately.
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Chapter 3. Sensors Once in place, carefully and slowly lower clamp to ensure it is aligned with the flow tube. Connect the flex ribbon connector to the rotat- ing arm as shown.
3.1 UV254 Sensor Press the connector as shown, so the top and bottom hold down clamps click into position. 3.1.2.5 Start-Up Procedure Before plugging in the UV254 sensor, check to make sure the electrical connections are correct. Also, make sure the quartz flow cell is installed and the red flow cell lever is in the fully down position. In areas of high humidity, before turning on the water flow leave the enclosure door closed for a minimum of three hours to allow for the dehumidifier to dry the air inside the enclosure.
Chapter 3. Sensors 5. Hold a finger over the small vent hole in the center of the wash bottle cap. 6. Squeeze the bottle to get the DI water to flow through the sensor. 7. Once the fluid starts to flow remove your finger from the vent hole and place the bottle on top of the sensor enclosure.
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3.1 UV254 Sensor Name Edit the sensor name used to identify the sensor. Up to 25 characters. Display Options are “Show” or “Hide”. This relates to whether the tile for this sensor will show on the Menu screen. Enabled Options are “Yes” or “No”. If “No” is selected the sensor will not update and will not generate alarms.
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Chapter 3. Sensors Precision Select the number of digits following the decimal point to display. This should be appropriate for the measurement. Options are 0 to 5. Offline Value This is the value reported by the parameter when in ‘Offline’ mode, for example, if the sensor is in alarm.
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3.1 UV254 Sensor Type A selectable list of parameter types. The selection made here will affect what options are available below. Name Available if “User defined” is selected as the type. The name can be up to 25 characters. Units If “User defined” is selected above, set the units using the custom units’ entry screen that will be displayed when pressing the select button.
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Chapter 3. Sensors Units If “User defined” is selected above, set the units using the custom units’ entry screen that will be displayed when pressing the select button. Otherwise select from an appropriate list of units for the parameter type. Precision Select the number of digits following the decimal point to display.
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3.1 UV254 Sensor Options Setup Modbus Setup Slave Address Enter the Modbus slave address of the sensor. This is unlikely to change from 1. Mode Select the Modbus serial mode. Options are “ASCII” or “RTU”. Baud Rate Select the RS485 baud rate. Options are standard baud rates between 1200 and 115200. Parity Select the RS485 parity bit option.
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Chapter 3. Sensors TOC Enabled Options are “Yes” or “No”. Correlation Parameter Select which parameter to utilize for the linear relationship. Options are measured UVA or UVA compensated for sample turbidity. Slope Enter the calibration slope calculated from the linear correlation. Offset Enter the calibration offset calculated from the linear correlation.
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3.1 UV254 Sensor Conversion values here provide information about the sensor environment (temperature and humidity) and detector readings used to calculate the UV absorbance and transmittance. There are 6 values found in this sub menu including; raw Lamp and Water readings, and internal Temperature and Humidity.
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Chapter 3. Sensors 3.1.4.13 Turbidity Data Options Diagnostics Turbidity Data Turbidity Compensation Conversion values here provide information about the turbidity measurement that can be used to compensate the UV absorbance parameter. These values may be requested when contacting your supplier for support. 3.1.4.14 Modbus Statistics To access the Modbus statistics diagnostic information, select:...
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3.1 UV254 Sensor Display on main menu When active the device tile is displayed on the main menu. If inactive, the tile is hidden in the default view. Sensor enabled This flag is enabled if the sensor is enabled. Sensor on-line This flag is enabled if the sensor is on-line. Sensor reading in warm up If the sensor reports that the current reading is not ready, then this flag is set.
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Chapter 3. Sensors 3.1.4.17 Parameter Flags The parameter flags show the state of an individual parameter of a particular sensor. These flags can either be active or not. To see the state of these parameter flags, select: Options Device Flags Parameter Name Flags that are active are shown in black text on a white background, those that are not active are grayed out.
3.1 UV254 Sensor In the image above, the left side shows the position of the connector. The right side shows the connections required on the marked connectors. Disconnect the power before making or breaking electrical connections. Power to the UV254 Sensor can be provided by the HydroAct 4. Please check that the optional power supply is fitted in the top left corner of the HydroAct 4 enclosure.
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Chapter 3. Sensors 10. Note that it is recommended to recalibrate the sensor at this time. 3.1.5.1.2 Manual quartz flow cell cleaning method and quartz flow cell removal 1. Shut off the sensor and close the water supply. 2. Disconnect both inlet and outlet tubing from the sensor and allow the water to completely drain from the quartz flow cell before proceeding.
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3.1 UV254 Sensor 12. Reinstall the flow cell being careful the flow cell is properly aligned before lowering the toggle clamp. 13. Make sure the toggle clamp is pressed all the way down and the 1/4" tubing is reconnected before starting the water flow again. 14.
Chapter 3. Sensors 3.1.6 Troubleshooting 3.1.6.1 Leak detected Possible cause Possible solution A leak has been detected inside the ana- Immediately shut off the water flow to the analyzer. As- lyzer. sess the damage inside the analyzer and call your sup- plier for further instructions.
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3.1 UV254 Sensor Possible cause Possible solution The lamp output is too low to provide The lamp may need to be replaced if the lamp use is accurate measurements. close to or more than 4000 hrs. Contact your supplier for replacement. Note that the lamp may take several minutes to ignite after closing the door, especially after shipping.
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Chapter 3. Sensors LED 3 LED 2 LED 1 Possible cause Possible solution No power Check power connections. Check fuse on main circuit board. If blown replace with 20mm x5mm. reference position Check reference micro-switch check on motor bracket. If dam- aged it may need to be re- placed.
4. Controls PID Control 4.1.1 General Information 4.1.1.1 Theory of Operation The PID control calculates an error value as the difference between a desired setpoint and a measured sensor input, called the process variable. The control then calculates an output using this error value based on proportional, integral and derivative terms.
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Chapter 4. Controls and control offsets are to be expected. Control offsets in a purely proportional system are referred to as proportional droop. Offsets occur in systems where there is an opposing process affecting the process variable. For example, chlorine will evaporate from a pool surface. When the rate of loss is equal to the rate of chlorine addition then a steady state will be achieved.
4.1 PID Control 4.1.1.1.3 Derivative Term The derivative term is calculated by determining the slope of the error over time and multiplying this rate of change by the derivative gain, adjustable in the PID configuration. where D is the derivative term output, K is the derivative gain, t is the loop time, e is the error and p is the previous error.
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Chapter 4. Controls Name Enter the device name used to identify the control on the menu tiles, alarm messages etc. The name can be up to 25 characters. Display Setting used to determine if device tile is shown on default main menu screen. Options are “Show’‘or “Hide”...
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4.1 PID Control Update delay Update delay is the frequency that the feedback loop updates its output. The value is in HH:MM:SS format. The maximum update delay is 24 hours. 4.1.2.3 Output Setup The output is configured via the user interface of the HydroAct 4. To access the configuration go to: Options Setup Output Setup...
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Chapter 4. Controls Ramping Enable or disable setpoint ramping. Large step changes in process variable errors can pro- duce excessive PID output movements that could result in large over or undershoot, particularly for controllers using the I or D terms. These step changes are likely when the controller is first switched on or if the setpoint is changed.
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4.1 PID Control Enabled Enables the integral windup protection feature. Options are “Yes” or “No”. Minimum The smallest accumulated error the integral term is allowed to wind up, usually negative or commonly zero. Values from -1000.00/% to +1000.00/% Maximum The largest accumulated error that the integral term is allowed to windup, usually positive. Values from -1000.00/% to +1000.00/% 4.1.2.4.4 Overfeed Protection Tab...
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Chapter 4. Controls Enabled Enables the boost feature and allows users to initiate the boost from the “Boost Status” option. Action Options are “Output” or “Setpoint”. Selecting “Output” allows the user to set a pre-determined control output. Selecting “Setpoint” allows the user to set a new target for the PID control. Value Set the new output value or target setpoint, based on the selection above.
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4.1 PID Control The display has a tab for each alarm and threshold. Navigate to the tab using the Right and Left buttons or through the settings using the Up and Down arrows. Options are: Enabled Selecting this option turns the alarm/threshold on or off. Set The Value is used to trigger the alarm or threshold .
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Chapter 4. Controls Loop Output threshold N active If set, this flag indicates that the threshold N (where N is either 1 or 2) is active for the given output. Proportional control enabled If set, this flag indicates that the proportional control is active in the current PID configuration.
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4.1 PID Control Information displayed is only relevant if the control is in automatic mode. This display shows the diagram of the PID control and the current totalized PID output. For diagnostic information in automatic mode, the display is updated when the control loop is executed and there may be a delay equal to the loop time before all information is available.
Chemtrac utilizes the latest in firmware and electronic innovations and as such analog outputs and relays are extremely flexible, and are not tied to individual sensors. In the past outputs were typically fixed to a specific sensor or control and the range was also the same as the range of the sensor.
Chapter 5. Outputs 5.1.3 Commissioning When cables attach to analog outputs the instrument is forced to drive into different resistances. This can result in the analog range being slightly affected. For example a 4-20mA output at the analyzer could end up being 3.95mA to 19.9mA at the end of the cable. The HydroAct 4 has the capability to drive more or less current to account for this resistance so that the analog output is exactly that required at the end of the cable.
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5.1 Analog Outputs 5.1.4.1 Setup The setup of the analog output is split into three sections. Later sections can be accessed separately from the menu or by selecting “Next” from any of the previous pages. To access the analog output setup: Options Setup...
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Chapter 5. Outputs Type Choose the type of analog output from the drop down box. See technical data for a list of supported output types. See section 5.1.2. Manual Value Enter the manual value of the output as a percentage. For example if 4..20mA output type is selected a manual value of 50% will force the current output to 12mA.
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5.1 Analog Outputs Type Choose the type of analog output from the drop down box. See the technical data in section 5.1.2 for a list of supported outputs. Minimum Enter the parameter value that translates to a minimum output of e.g. 4mA if “type” is set to 4..20mA.
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I/O card in use This flag is set when two devices are attempting to use the same I/O card. I/O card configuration failed This flag is set if the I/O plugin card fails to respond correctly. Contact Chemtrac for advice. 5.1.4.7...
5.2 Relay Output The image above is for an output with the types selected as 0..20mA or 4..20mA. The connections will reflect the configuration of the device and differ between current and voltage outputs. Relay Output 5.2.1 General Information Relay outputs, typically mechanical reed relays are installed at time of manufacture. A relay is a mechanical or electronic device mounted on the electronics within the instrument that can switch.
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Chapter 5. Outputs Name Device name to identify control in menus. Text can be up to 25 characters long. Display Options are “Show” or “Hide” the device tile on the menu screen. Enabled Options are “Yes” or “No”. This option must be enabled for the option to function. Mode Options Options are “Manual”...
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5.2 Relay Output Polarity Options are “Normally Open” and “Normally Closed”. 5.2.3.3 Options for Control Output Mode 5.2.3.3.1 Map Output This configuration screen is accessed by pressing “Next” from the Output Setup configuration screen or navigating via the Options Menu. Options Setup Map Output...
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Chapter 5. Outputs In all cases the polarity and output mode of the relay will need to be configured. Pulse width modulation outputs a repeated pulse with a fixed width. The control signal is output by increasing the proportion of time the relay is active in any pulse as the value increases. Pulse frequency modulation outputs pulses of a fixed activated width, but increases the frequency of the pulses in respect of the control output value.
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5.2 Relay Output Sensor Select the appropriate sensor from the drop down list. Parameter Choose the appropriate parameter from the drop down list. If the selected sensor has only one parameter this option may not be available. The “Next” button is a shortcut to the following configuration screen. 5.2.3.4.2 Configuration Setup This configuration screen is accessed by pressing “Next”...
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Chapter 5. Outputs Device Choose from a list of available devices. The “Next” button is a shortcut to the following configuration screen. 5.2.3.5.2 Configuration This configuration screen is accessed by pressing “Next” from the Map Output configuration screen or navigating via the Options Menu. Options Setup Configuration...
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5.2 Relay Output Device Choose from a list of available devices. The “Next” button is a shortcut to the following configuration screen. 5.2.3.6.2 Configuration This configuration screen is accessed by pressing “Next” from the Map Output screen or navigating via the Options Menu.
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Chapter 5. Outputs Sensor Choose the appropriate sensor from the drop down list. Parameter Choose the appropriate parameter from the drop down list. The “Next” button is a shortcut to the following configuration screen. 5.2.3.7.2 Configuration This configuration screen is accessed by pressing “Next” from the Map Output screen or navigating via the Options Menu.
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5.2 Relay Output Flags that are active are shown in black text on a white background, those that are not active are grayed out. Selecting the flag will cause the relay to activate if that parameter flag becomes active. 5.2.3.8 Options for System Status 5.2.3.8.1 Map Output...
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Chapter 5. Outputs System Status Options are “Normal”, “Alarm Active” or “Alarm Acknowledged” 5.2.3.9 Status Flags The status flags show the state of a device. These flags can either be active or not. To see the state of these status flags, select: Options Device Flags Status Flags...
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5.2 Relay Output Options are Polarity Options are “Normally Open” or “Normally Closed” Active Options are “No” or “Yes” 5.2.3.12 Connections Options Connections This screen identifies the terminals to use for electrical connections for this relay. The left hand pane identifies the terminal block and the right hand pane the connectors on the terminal block.
6. Warranty Chemtrac, Inc warrants its product to be free of defects in material and workmanship for a period of one year from date of shipment to the original customer unless specifically agreed elsewhere. Upon receipt of written notice from the customer, Chemtrac shall issue a returns form for the defective product and, upon its receipt, shall repair or replace (at the discretion of Chemtrac) the defective equipment or components.
If the analyzer has to be repaired, please return it cleaned to your local service organization or Chemtrac, Inc at the address below. To return your equipment for repair: • Contact Chemtrac support, open a service ticket and request a returns form. • Complete the returns form, including the contaminant declaration.
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