ABB AW400 Series Instruction Manual
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ABB AW400 Series Instruction Manual

ABB AW400 Series Instruction Manual

Chlorine transmitter
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Instruction Manual
Chlorine Transmitter
IM/AW4TX
Issue 5
AW400 Series

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Summary of Contents for ABB AW400 Series

  • Page 1 Instruction Manual Chlorine Transmitter IM/AW4TX Issue 5 AW400 Series...
  • Page 2 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) We are committed to teamwork, high quality manufacturing, advanced technology and unrivalled service and support.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Page N. MODEL NUMBER BREAKDOWN ....................... 3 Ordering Guide ..........................3 INTRODUCTION ............................4 Classification ............................ 4 Glossary............................4 General Description........................... 4 Technical Specifications ........................5 Hardware structure of the system ....................... 7 2.6 Instrument operating block diagram......................9 INSTALLATION ............................
  • Page 4 FUNCTIONALITY ............................ 35 Transmitter (AW401) ........................35 Controller (AW402).......................... 36 5.2.1 General description........................36 5.2.2 Controller’s Parameters....................... 36 5.2.2.1 PID Parameters ......................... 38 5.2.2.2 Feed Forward (FF) Configuration..................39 5.2.2.3 Sampling and/or Flow Pacing Controller................39 5.2.2.4 Error Squared Controller (pH Applications)................40 5.2.2.5 Contacts Output Controller....................

  • Page 5: Model Number Breakdown

    1 MODEL NUMBER BREAKDOWN 1.1 Ordering Guide Residual Chlorine Monitor Transmitter Type Transmitter Transmitter with PID Control (Channel 1 only) Sensor Type Channel 1 Chlorine Cell Sensor Type Channel 2 No second input channel Chlorine Cell Additional 4-20mA input/output (re-transmission or flow input) Sensor Type Channel 3 No third input channel Chlorine Cell...

  • Page 6: Introduction

    2 INTRODUCTION 2.1 Classification According to EN61010-1, AW400 is classified an: • electrical equipment for measurement and test • electrical equipment for process control • electrical equipment designed to be safe at least in the following conditions: altitude lower than 2000 m –...

  • Page 7: Technical Specifications

    Technical Specifications • Display: digital LCD display, dot matrix, 16 + 16 characters, with back light. • Power supply, selectable through a soldered jumper on the rear of the power supply pc board (see Sect. 3.4.1): 115 Vac, ±10%, 50/60 Hz 230 Vac, ±10%, 50/60 Hz •...
  • Page 8 • Measure sensitivity: Parameter Sensitivity 0.0002 unit pH 0.0045 mV 0.33 μg/l (ppb) chlorine 0.33 μg/l (ppb) chlorine dioxide 0.15 μg/l (ppb) ozone • Weight: 3 kg • Outline dimensions: 250 mm x 250 mm x 120 mm. See Fig.1 for detailed outline dimensions •...

  • Page 9: Hardware Structure Of The System

    Hardware structure of the system The AW400 hardware is structured in a modular system, whereby only the electronic p.c. boards requested for the specific application needs to be installed, thus achieving great flexibility and relevant cost benefits for the user. The different p.c. boards are mounted in four separate layers, according to the following scheme: FIRST LAYER OF P.C.
  • Page 10 SECOND LAYER OF P.C. BOARDS (Analog Input/Output) Analog I/O pc board (channel cards) Channel 1 Channel 2 (optional) Channel 3 (optional) THIRD LAYER OF P.C. BOARDS (Main Board): CPU pc board FOURTH LAYER OF P.C. BOARDS (Top): Display and Keyboard pc board...

  • Page 11: Instrument Operating Block Diagram

    2.6 Instrument operating block diagram POWER SUPPLY SERIAL power supply to configuration COMMUNICATION all pc boards and output setting components alarms RS485 algorithms and RS422 routines RS232 Output signal: DIGITAL I/O ANALOG I/O ANALOG I/O ANALOG I/O CCI 1 freezes Ch.1 Channel 1 Channel 2 Channel 3...

  • Page 12: Installation

    3 INSTALLATION 3.1 Dimensions and mounting Rear view Side view ø16 (0.4”) Cover for terminal board connection n° 4 cable n°5 cable glands, 220 (9”) glands, optional PG 11 120 (4.8”) 125 (5”) allow enough space for wiring 300 (12”) 250 (10”) hole ø...

  • Page 13: Mounting

    3.2 Mounting AW400 is available with the hardware for the following types of mountings: • Wall mounting (Fig. 2) • 2” pipe mounting (Fig. 3) 3.2.1 Wall mounting AW400 wall mounting 180 (7.2”) 800 (32”) 120 (4.8”) n°2 holes ø 6,5 for wall mounting minimum (n°2 screws c/w inserts for wall clearance...

  • Page 14: 2" Pipe Mounting Without Sunshade

    3.2.2 2” Pipe mounting without sunshade AW400 2” vertical pipe mounting 800 (32”) Minimum clearance 1500 (60”) (20”) minimum Minimum clearance clearance for cover n.2 brackets opening c/w screws supplied for 2” pipe mounting cover for, terminal board connections Power supply cable Power supply cable Caution ! Danger Caution ! Danger...

  • Page 15: Location

    3.3 Location The transmitter location should meet the following requirements: - the site of installation should be free of vibrations - the atmosphere should be free of corrosive substances - enough space has to be left around the transmitter to allow easy operation and maintenance - the transmitter should be mounted at a height of 1.6 - 1.7 m from floor level to make normal reading, maintenance and calibration operations easier - in outdoors installations a sunshade is strongly recommended...

  • Page 16: Electrical Connections

    3.4 Electrical connections 3.4.1 Power supply p.c. board WARNING! Only qualified personnel should conduct the tasks described in this section of the manual. The transmitter 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.

  • Page 17: Power Supply Cable

    3.4.1.1 Power supply cable Power supply cable has to be supplied by the Customer and installed by the maintenance staff. In accordance to EN61010-1 power supply cable has to satisfy the following requirements: • power supply cable must be certified (e.g. IMQ, UL, CSA...) or approved by an official national testing bureau.

  • Page 18: Digital I/O Pc Board

    Unauthorised personnel must not be able to open the instrument. AW400 is defined as an instrument "with no accessible parts under dangerous voltage". 3.4.2 Digital I/O pc board 3.4.2.1 Digital Outputs AW400 digital outputs are provided by seven (7) relays. The function of each output contact depends on the type of instrument selected and its configuration.

  • Page 19: Digital Inputs

    3.4.2.2 Digital Inputs AW400 digital input are represented in Fig. 6. Characteristics of digital input cables are: • shielded • two-cores, section 0.5 – 1.0 mm2 • the shields has to be connected to ground shield terminal strip inside AW400. Expanded function power supply Digital inputs Terminals: 3-8 not used...

  • Page 20: Temperature Compensation

    µ A in from mV in from sensors sensors (pH,ORP) Cl,CD,O3 or 0/4-20 Temperature Pt100 Fig. 7 – Analog Input /Output terminal barrier 3.4.3.1 Temperature compensation The thermo-compensation Pt100 is not necessarily present in each sensor, in fact in some installations the different sensors are installed in the same cell, and therefore the reference temperature can be read from one input only, namely from the sensor connected to channel 1.
  • Page 21 In case not all the connections are required, the most important rules to follow are: • never run cable for power supply with other cables • never run analog I/O cables with other cables • never run CCO cables or wires with other cables Pleases notice that cable gland for power supply cable includes the cable protector: this avoids dangerous cable abrasion and bending at the point of its inlet in the transmitter.

  • Page 22: Set-Up And Configuration

    4 SET-UP AND CONFIGURATION 4.1 Keyboard functionality All the keys have dual functionality, except the ENTER key. Blue background keys are the ones whose second function is only used in Controller option (AW402). The selection between numbers and functions is automatically recognised by the instrument.
  • Page 23 WASH Starts a cleaning sequence when this option is activated and allowed (timers set at any value different from zero). 8: digit 8 when allowed CANCEL Cancel is used to load default parameters (power the instrument down and power it up while keeping the Cancel key pressed) Cancel is also 9: digit 9 when used to modify a parameter wrongly written: when a parameter can be allowed...

  • Page 24: Display

    4.2 Display The AW400 display shows the instantaneous value of the parameter measured, it’s identification symbol and the temperature of the sampled liquid. Here is an example of the standard one-channel display: 1 2 . 5 2 1 5 . 5 °...

  • Page 25: Channel Definition -This Menu Allows To Select The Type Of Sensor Associated To Each Channel

    4.3 Channel definition -This menu allows to select the type of sensor associated to each channel OPERATION DISPLAY (Please refer to the menu trees in the appendicies PROCESS for an overview of how to navigate through the software. PASSWORD XXXXX 1,2,3.
  • Page 26 Notes: 1.When changing channel definition from one parameter to another, the AW400 transmitter/controller will set the alarm outputs and the PID parameters to the default values. 2.If chlorine (CL) is selected, the type of CL measurement must be defined as either a cell (KC4000AB) or a probe (CL4000AB).

  • Page 27: Set-Up Menu

    The Channel definition menus are in accordance to the number of the channels installed (e.g. if only Channel 1 is installed, only Channel 1 definition menu appears; if two channels are installed, both Channel 1 definition menu and Channel 2 definition menu will appear. The same principle applies for Channel 3). Select the type of channel according to the sensor installed (see glossary 2.2 for the symbols used).

  • Page 28: Configuration

    4.4.1 Configuration The configuration menu consents to set the general parameters of the instrument. Only those parameters which are pertinent to the selection made and to the hardware installed will appear in the menu. When a digital value is requested, pressing the ENTER key will cause a cursor to appear in the display: at this point a numeric value may be entered using the second function of the keyboard pushbuttons.

  • Page 29: Configuration Menu Flowchart

    4.4.1.2 Configuration menu flowchart Configuration MENU key to search language Enter Configuration submenu Configuration Language Language Language Language Language French English German Spanish Italian Language Enter Language submenu ENTER key to select language Configuration Search next Password Configuration END key to exit men item Configuration Serial Link...

  • Page 30: Cleaning Functionality

    T1–T4. There are two cleaning sequences designed to work in conjunction with optional ABB devices: sequence “A” (Water Analytic Unit) and sequence “B” (Sequential Cleaning Unit). If the hydraulic cleaning system used is different from the a above specified devices, then select “B”...

  • Page 31: Instrument Test

    4.4.1.4 Instrument test This submenu which is part of the Configuration menu, allows to perform self diagnostic routines on AW400 basic functions, sensor check and AW400 electrical calibration. Configuration Instrument Test Instrument Test Instrument Test Instrument Test Instrument Test Instrument Test Keyboard Display Test Digital I/0...
  • Page 32 Digital Input: Input signals submenu the display shows " " " OFF OFF " changing the status of one of the CCI by shorting the associated terminals (1-3 or 2-4) the display shows ON below the number of the associated CCI. Digital Output: the display will show the status of the 7 output contacts (relay): "...

  • Page 33: Output Setting

    4.4.2 Output setting The Output Settings menu allows to set current output (0–20 or 4–20 mA), zero (Out Zero) and full scale (Out Max) values, in engineering units. Out Zero value corresponds to 0 mA or 4 mA (according to the output chosen) and the Out Full Scale value to 20 mA.

  • Page 34: Output Signal Hardware Modification 4 To 20 And 0 To 20 Ma

    4.4.2.1 Output signal hardware modification 4 to 20 and 0 to 20 mA To modify output signal from 4 to 20 and 0 to 20 mA make following hardware modification on Analog In put/Output board: • Identify Jumper IP1 and JP2 on board (see figure 11); •...

  • Page 35: Alarms

    4.4.3 Alarms This menu allows to set high and low alarm levels and the dead band. The alarm levels are freely selectable by the user. Select the channel and press Enter to select alarms and dead band. Default levels are automatically related to the set range of output: low alarm is set at 10 % of Out Zero and high alarm is set at 90 % of Out Max (see the following table for default alarm setting values).

  • Page 36: 2Alarm Setting Menu

    4.4.3.2Alarm setting Menu (See Par. 4.4 to get here) Configuration Alarms Alarms Alarms Alarms Channel 1 Channel 2 Channel 3 Press Enter Key to Channel 1 Channel 2 Channel 3 access value, Enter again to accept value Low Alarm Low Alarm Low Alarm Cannel 1 Channel 2...

  • Page 37: Functionality

    5 FUNCTIONALITY The different functionality of the instrument depends on the Model Number selected, and it can be classified in two main groups: Monitor-Indicator-Transmitter (AW401) or Monitor-Indicator-Transmitter-Controller (AW402). 5.1 Transmitter (AW401) The transmitter can support up to three sensors, and the association of input/output signals depend on the configuration selected as per following tables.

  • Page 38: Controller (Aw402)

    5.2 Controller (AW402) The control strategies offered by the AW400 are: • Standard PID Controller, with Feed Forward option • Average Controller These will be discussed in detail in the following paragraphs. 5.2.1 General description The PID Controller of the AW400 is usable in the majority of process applications. In function of the difference between the analytic measure (Process Variable, PV), and a Set-point (SP) value, it calculates an Output (OUT), that is applied to a final control element (f.e.
  • Page 39 Default: 0 min/rep. – Range 0–30 min Manual Reset Numeric entry in % (Active when TR=0) Default: 0 - Range 0–100% Derivative Numeric Entry in minutes Default: 0 min – Range 0–10 min Process Variable (display only) Engineering units Set Point Engineering units Default: 0 Control zone...

  • Page 40: Pid Parameters

    5 - Contact output controller – (this menu available when option is selected - See Par. 5.2.2.5) Frequency / Relay Function not supported at this time, leave always the selection "Relay" Gain GAIN Numeric entry in %/100 Default: 1 (=100%) Dead Zone Numeric entry in Engineering units Default: 0...

  • Page 41: Feed Forward (Ff) Configuration

    These parameters represent the absolute high and low limits allowed for the controller output. The output limits have to be set if required by the process. Default factory setting are: High Limit 100%, Low Limit 0%. 5.2.2.2 Feed Forward (FF) Configuration The instrument will activate this function only if it detects the presence of a 4-20 mA input signal connected to Channel 2.

  • Page 42: Error Squared Controller (Ph Applications)

    5.2.2.4 Error Squared Controller (pH Applications) When the instrument detects that pH sensor has been selected for the controller, it enables a special PID algorithm with an “Error Squared” function. The error squared function is applied only within a band defined in the “BAND”...

  • Page 43: Standard Controller

    5.2.3 Standard Controller This section deals with the functionality which is specific of the standard controller. 5.2.3.1 Std Controller Display The standard controller display shows the following values: • Instantaneous value of process variable measure • process variable temperature (not present for ORP sensor) •...

  • Page 46: Calibration

    6 CALIBRATION Calibration is required to align the sensor sensitivity. This operation is necessary at the start-up of the instrument and at periodical intervals. New sensors have to be let in operation for at least 24 hours, to allow the electrode to recover complete sensitivity, before performing the calibration procedure. ATTENTION! The calibration procedure must be accomplished having the sensor and the AW400 connected and powered.

  • Page 47: Calibration Menu Flow Chart

    6.1.2 Calibration Menu Flow Chart Operation display Process Password XXXXX 1,2,3….. Chann.Definition Calibration Menu Channel 1 Channel 3 Channel 2 Calibration P1. *S.P.C. *S.P.C. Selects Channel 3 Channel 1 Channel 2 P1 value Calibration P2 Calibration P1 Calibration P1 Moves to next Only when Channel 3 choice...

  • Page 48: Single Point Calibration (S

    Put the two standard buffer solutions in two beakers in a sufficient amount to cover the sensor. Wash the probe with de-mineralised water, dry it and dip it in the standard pH 7 buffer solution. Stir softly but continuously the probe: in this way a lower stabilisation time will be required. Press the MENU key to enter the Instrument Calibration submenu and enter the CALIBRATION menu and then the channel of the pH probe.

  • Page 49: Orp Sensor Calibration

    When a double point calibration is performed the S.P..C value is forced to 0.00. C urve relative to the initial calibration C urve relative to electrode ageing C urve corrected w ith a single point calibration -100 -200 -300 -400 -500 Fig.

  • Page 50: Oxidation Potential With Negative Values" Arrangement

    6.1.4.1 "OXIDATION potential with NEGATIVE values" arrangement P1 will be the value of the oxidant standard solution, and P2 the value of the reducent standard solution. In case both the standard solution have the same sign, P1 will be the standard solution with the lower value. Press the MENU key to enter the Instrument Calibration submenu and enter the CALIBRATION menu and then the channel of the ORP probe.

  • Page 51: Chlorine / Chlorine Dioxide / Ozone

    µA from the cell (sensitivity). The ABB Monitor allows an easy two point calibration and the two points can be freely chosen, provided they are distant enough and inside the selected measuring range. In this way the instrument is given all the parameters it needs to fix the calibration curve.
  • Page 52 REMARK : if the sample is a chlorine dioxide solution and the displayed indication is desired to be in "ppm ClO2" multiply the DPD analysis reading by 1.9. WARNING ! It is advisable to repeat the calibration after 24 hours and after 2 or 3 days.

  • Page 53: Start Up

    7 START UP WARNING ! Maintenance staff must be authorised by Customer and must know in details the content of the present Instructions Manual. CAUTION! Disconnect Power Supply before opening the transmitter covers. Before start up it is recommended to verify the following points: •...

  • Page 54: Personalization Of Parameters

    Verify that the selected measuring ranges correspond to the desired values; if not, modify ranges as needed; If the alarm levels are required at values that are not the 10 % and 90 % of measuring range, enter the Alarms menu and set Low Alarm and High Alarm level as required. Refer to Sect. 4.4.3; Verify that all Configuration parameters are set as required (See Sect.

  • Page 55: Maintenance

    8 MAINTENANCE AW400 housing can be externally cleaned with a cloth slightly wetted with alcohol and water, paying attention not to damage the keyboard. CAUTION! Do not use acids, chemicals solvents and organic substances for AW400 cleaning. 8.1 Periodical operations All Monitors need cleaning of the sensors at periodical intervals, this depends on type of sensor and process characteristics.

  • Page 56: Error Messages & Troubleshooting

    9 ERROR MESSAGES & TROUBLESHOOTING Different levels of messages are generated by the instrument at need. 9.1 Messages At power up, the AW400 instrument shows the following sequence of messages: "MicroChem II" "S.Rel.." "Transmitter" 9.1.1 Operation messages Messages displayed during operation to clarify what AW400 is doing. "Loading default database"...

  • Page 57: Alarms Page

    9.1.3 Alarms page It is accessed by pressing the Enter key in display mode. If no alarm or no abnormal condition is present the display will show nothing. The following messages are displayed with the indicated meaning: A1L = low alarm on channel 1 A2L = low alarm on channel 2 A3L = low alarm on channel 3 A1H = high alarm on channel 1...

  • Page 58: Serial Communication

    10 SERIAL COMMUNICATION Note: This section applies only to instruments equipped with the optional Serial Communication P.C. Board. 10.1 Standard of Communications Two digital communication standard are supported by the serial communication board of AW400, one port is an RS232 serial interface and the other is an RS 422/485 serial interface. Only one port at a time can be activated, and the selection of the desired standard is made via software at the Configuration Menu.

  • Page 59: Communication Protocol

    10.1.2 Communication Protocol The communication protocol requires the Host to initiate all transactions. There are two basic categories of message types: Interrogate , which is used to read data from an addressed AW400, and Change , which is used to alter a value in an addressed AW400. The addressed instrument decodes the message and provides an appropriate response.

  • Page 60: Message Types And Commands Description

    10.1.3 Message Types and Commands Description The types of messages that are sent between the host and the AW400 are formatted as follows: Host to AW400 1. Interrogate – This message requests up to 20H consecutively stored bytes, beginning at the specified memory address location of the addressed AW400.

  • Page 61: Communication Transaction Examples

    10.2 Communication Transaction Examples 10.2.1 Transaction A Example Host requests 9 bytes of data beginning at hexadecimal memory address 1000 from the AW400 at data-link address 03: 1. Host sends interrogate message: 01111110 11100011 00001001 00000000 00010000 11111100 Command NUM LO ADD HI ADD + I.A.

  • Page 62: Serial Link Signal Connection

    10.3 Serial link signal connection The AW400 optional serial communication P.C. Board is equipped with modular telephone RJ45 type jack supporting both for RS 232 and RS 422/485 standards: RJ45 TELEPHONE SIGNAL CONNECTION JACK LAY-OUT: Pin N. RS 232 RS 422 RS 485 Tx + Ground...

  • Page 63: Data-Link Terminator

    10.4 Data-link Terminator The datalink impedance should be 110 Ohm. When the serial communication standard is selected as RS422 or RS485, and more than one AW400 are installed on the same datalink, it is necessary to activate a terminator resistance, which is available on the serial communication board.

  • Page 64: Aw400 Memory Map

    10.5 AW400 Memory Map Increment: (figures between brackets ‘[x]’ indicate the number of similar variables repeated). Char type: 1 byte type: 2 bytes float type: 4 bytes string type: 1 byte x string length Type Hex addr. Name Description 0X0000 PgmMode Program mode (0-4) Transmitter, Washing, Regulator…...
  • Page 65 PID 1 DATA 0X0134 Reserved float 0X0136 Proportional Band float 0X013A Reset Time float 0X013E Manual Reset float 0X0142 Rate Time float 0X0146 SETPOINT Set Point float 0X014A CONTROLZONE Control Zone 0X014E Direct/Reverse Action float 0X0150 SPAN Span 0X0154 OHLP float 0X0156 FF HIGH...
  • Page 66 OUTPUTS 0X01E2 WashSeq Actual washing sequence 0X01E4 OUT_STATE[8] CCO state 0X01F4 IN_STATE[8] CCI state float 0X0204 dev[2] PID 1,2 DEV float 0X020C out[2] PID 1,2 OUT float 0X0214 ff[2] PID 1,2 FF …int 0X021C HIAL Ch1-3 [3] HI Alarm Channel 1-3 …int 0X0222 LOAL Ch1-3 [3]...

  • Page 67: Appendices

    11 APPENDICES 11.1 EC Declaration EC Declaration AW400 line (T17M*4000A) fulfils the compliance to the mandatory tests specified by the applicable harmonised generic rules to apply the CE Mark, according to European Directive 89/336/EEC and subsequent modifications. As the final environment may be industrial or residential, the test were performed according to the worst case test set (industrial test for immunity, residential test for emission).

  • Page 68: Spare Parts

    12 SPARE PARTS AW400 Transmitter Spare Parts Power Supply Board AW401054 Display Board AW401115 CPU Board AW401055 Analogue I/O Board AW401015 Digital I/O & Serial Board AW401119 Ribbon Cable CPU to PSU AW401116 Ribbon Cable Digital I/O to CPU AW401117 Interconnect Cable PSU to Digital I/O AW401118 PG11 Cable Gland...
  • Page 69 Notes...

  • Page 71: Customer Support

    – Chemical & Pharmaceutical details on your nearest Service and Repair Centre. – Food & Beverage United Kingdom – Manufacturing ABB Limited – Metals and Minerals Tel: +44 (0)1235 512000 – Oil, Gas & Petrochemical Fax: +44 (0)1235 512020 –...
  • Page 72 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 (06.09) © ABB 2009...

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