ABB AW400 Series User manual

Instruction Manual

IM/AW4TX Issue 1

Chlorine Monitor

AW400 Series

ABB

EN ISO 9001:2000

Cert. No. Q 05907

EN 29001 (ISO 9001)

Lenno, Italy – Cert. No. 9/90A

Stonehouse, U.K.

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

Caution – Risk of electric shock Alternating current supply only

Protective earth (ground) terminal Both direct and alternating current supply

Earth (ground) terminal

The equipment is protected

through double insulation

The Company

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.

As a part of ABB, a world leader in process automation technology, we offer customers

application expertise, service and support worldwide.

We are committed to teamwork, high quality manufacturing, advanced technology and

unrivalled service and support.

The quality, accuracy and performance of the Company’s products result from over 100 years

experience, combined with a continuous program of innovative design and development to

incorporate the latest technology.

The UKAS Calibration Laboratory No. 0255 is just one of the ten flow calibration plants operated

by the Company and is indicative of our dedication to quality and accuracy.

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.

Health and Safety

To ensure that our products are safe and without risk to health, the following points must be noted:

1. The relevant sections of these instructions must be read carefully before proceeding.

2. Warning labels on containers and packages must be observed.

3. Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel and in accordance with the

information given.

4. Normal safety precautions must be taken to avoid the possibility of an accident occurring when operating in conditions of high pressure

and/or temperature.

5. Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry. Normal safe handling procedures

must be used.

6. When disposing of chemicals ensure that no two chemicals are mixed.

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.

1

TABLE OF CONTENTS Page N.

1 MODEL NUMBER BREAKDOWN ............................................................................................................... 3

2 INTRODUCTION ....................................................................................................................................... 4

2.1 Classification .................................................................................................................................... 4

2.2 Glossary........................................................................................................................................... 4

2.3 General Description........................................................................................................................... 4

2.4 Technical Specifications..................................................................................................................... 5

2.5 Hardware structure of the system........................................................................................................ 7

2.6 Instrument operating block diagram ............................................................................................................ 9

3 INSTALLATION ....................................................................................................................................... 10

3.1 Dimensions and mounting ................................................................................................................ 10

3.2 Mounting ........................................................................................................................................ 11

3.2.1 Wall mounting............................................................................................................................. 11

3.2.2 2” Pipe mounting without sunshade .............................................................................................. 12

3.3 Location ......................................................................................................................................... 13

3.4 Electrical connections .................................................................................................................. 14

3.4.1 Power supply p.c. board .............................................................................................................. 14

3.4.1.1 Power supply cable ............................................................................................................ 14

3.4.1.2 Installation of cables for power supply .................................................................................. 15

3.4.2 Digital I/O pc board ..................................................................................................................... 15

3.4.2.1 Digital Outputs ................................................................................................................... 15

3.4.2.2 Digital Inputs...................................................................................................................... 17

3.4.3 Analog input/output pc board........................................................................................................ 17

3.4.3.1 Temperature compensation................................................................................................. 18

3.4.4 Serial communication board......................................................................................................... 18

3.4.5 Cable glands .............................................................................................................................. 18

4 SET-UP AND CONFIGURATION .............................................................................................................. 20

4.1 Keyboard functionality...................................................................................................................... 20

4.2 Display........................................................................................................................................... 22

4.3 Channel definition -This menu allows to select the type of sensor associated to each channel: ..... 23

4.4 Set-up menu................................................................................................................................... 25

4.4.1 Configuration........................................................................................................................... 26

4.4.1.1 Configuration parameters.................................................................................................... 26

4.4.1.2 Configuration menu flowchart .............................................................................................. 27

4.4.1.3 Cleaning functionality.......................................................................................................... 28

4.4.1.4 Instrument test................................................................................................................... 29

4.4.2 Output setting............................................................................................................................. 31

4.4.2.1 Output signal hardware modification 4 to 20 and 0 to 20 mA................................................... 32

4.4.3 Alarms ........................................................................................................................................... 33

4.4.3.1Alarm Display ....................................................................................................................... 33

4.4.3.2Alarm setting Menu................................................................................................................... 34

5 FUNCTIONALITY .................................................................................................................................... 35

5.1 Transmitter (AW401) ....................................................................................................................... 35

5.2 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.................................................................................................. 40

5.2.3 Standard Controller ..................................................................................................................... 41

5.2.3.1 Std Controller Display ......................................................................................................... 41

5.2.3.2 Std Controller Analog Output assignment ............................................................................. 42

5.2.3.3 Std Controller Digital Input assignment ................................................................................. 42

5.2.3.4 Std Controller Digital Output assignment .............................................................................. 43

2

6 CALIBRATION.................................................................................................................................... 44

6.1 Calibration Procedure ...................................................................................................................... 44

6.1.1 Calibration Menu......................................................................................................................... 44

6.1.2 Calibration Menu Flow Chart ........................................................................................................ 45

6.1.3 pH Sensor Calibration ................................................................................................................. 45

6.1.3.1 Double point calibration....................................................................................................... 45

6.1.3.2 Single point calibration (S.P.C.) ........................................................................................... 46

6.1.4 ORP Sensor Calibration............................................................................................................... 47

6.1.4.1 "OXIDATION potential with NEGATIVE values" arrangement ................................................. 48

6.1.4.2 "OXIDATION potential with POSITIVE values" arrangement................................................... 48

6.1.5 Chlorine / Chlorine Dioxide / Ozone .............................................................................................. 49

7 START UP .............................................................................................................................................. 51

7.1 Preliminary operations ..................................................................................................................... 51

7.1.1 Getting started............................................................................................................................ 51

7.1.2 Personalization of Parameters...................................................................................................... 52

7.2 Controller PID tuning ....................................................................................................................... 52

8 MAINTENANCE....................................................................................................................................... 53

8.1 Periodical operations ....................................................................................................................... 53

8.1.1 Automatic sensitivity check during dual point calibration.................................................................. 53

8.1.2 Sensor signal check .................................................................................................................... 53

9 ERROR MESSAGES & TROUBLESHOOTING .......................................................................................... 54

9.1 Messages....................................................................................................................................... 54

9.1.1 Operation messages ................................................................................................................... 54

9.1.2 Error messages .......................................................................................................................... 54

9.1.3 Alarms page............................................................................................................................... 55

10 PARTS LIST............................................................................................................................................ 56

10.1 AW400 assembly, Parts List............................................................................................................. 57

11 SERIAL COMMUNICATION...................................................................................................................... 58

11.1 Standard of Communications............................................................................................................ 58

11.1.1 Software characteristics .......................................................................................................... 58

11.1.2 Communication Protocol ......................................................................................................... 58

11.1.3 Message Types and Commands Description............................................................................. 59

11.2 Communication Transaction Examples.............................................................................................. 60

11.2.1 Transaction A Example ........................................................................................................... 60

11.2.2 Transaction B Example ........................................................................................................... 60

11.3 Serial link signal connection ............................................................................................................. 61

11.4 Data-link Terminator ........................................................................................................................ 62

11.5 AW400 Memory Map ....................................................................................................................... 63

12 APPENDICES ......................................................................................................................................... 66

12.1 EC Declaration................................................................................................................................66

3

1 MODEL NUMBER BREAKDOWN

Ordering Information

Residual Chloride Monitor AW4

XX/ X X X

Transmitter 01

1st Input

Free Chlorine, no reagent pump (includes 3m [10 ft] sensor cable)

Free Chlorine, 220V reagent pump (includes 3m [10 ft] sensor cable)

Free Chlorine, 110V reagent pump (includes 3m [10 ft] sensor cable)

Total Chlorine, 220V reagent pump (includes 3m [10 ft] sensor cable)

Total Chlorine, 110V reagent pump (includes 3m [10 ft] sensor cable)

1

2

3

4

5

2nd Input

No second input channel

Free Chlorine, no reagent pump (includes 3m [10 ft] sensor cable)

Free Chlorine, 220V reagent pump (includes 3m [10 ft] sensor cable)

Free Chlorine, 110V reagent pump (includes 3m [10 ft] sensor cable)

Total Chlorine, 220V reagent pump (includes 3m [10 ft] sensor cable)

Total Chlorine, 110V reagent pump (includes 3m [10 ft] sensor cable)

pH

ORP

0

1

2

3

4

5

6

7

3rd Input

No third input channel

Free Chlorine, no reagent pump (includes 3m [10 ft] sensor cable)

Free Chlorine, 220V reagent pump (includes 3m [10 ft] sensor cable)

Free Chlorine, 110V reagent pump (includes 3m [10 ft] sensor cable)

Total Chlorine, 220V reagent pump (includes 3m [10 ft] sensor cable)

Total Chlorine, 110V reagent pump (includes 3m [10 ft] sensor cable)

pH

ORP

0

1

2

3

4

5

6

7

Controller (Regulated input out of 1st channel) 02

1st Input

Free Chlorine, no reagent pump (includes 3m [10 ft] sensor cable)

Free Chlorine, 220V reagent pump (includes 3m [10 ft] sensor cable)

Free Chlorine, 110V reagent pump (includes 3m [10 ft] sensor cable)

Total Chlorine, 220V reagent pump (includes 3m [10 ft] sensor cable)

Total Chlorine, 110V reagent pump (includes 3m [10 ft] sensor cable)

4 to 20 mA Input for use on controllers only (e.g. flow rate signal)

1

2

3

4

5

8

2nd Input

No second input channel

Retransmission of 1st channel signal (and FF input signal)

0

1

3rd Input

No third input channel

Free Chlorine, no reagent pump (includes 3m [10 ft] sensor cable) – transmitter only

Free Chlorine, 220V reagent pump (includes 3m [10 ft] sensor cable) – transmitter only

Free Chlorine, 110V reagent pump (includes 3m [10 ft] sensor cable) – transmitter only

Total Chlorine, 220V reagent pump (includes 3m [10 ft] sensor cable) – transmitter only

Total Chlorine, 110V reagent pump (includes 3m [10 ft] sensor cable) – transmitter only

pH – transmitter only

ORP – transmitter only

0

1

2

3

4

5

6

7

IP66 Version available on request

4

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

– operation temperature limits -10 ÷ + 50 °C

– storage temperature limits -40 ÷ + 65 °C

– maximum relative humidity: 80 % with temperature up to 31 °C, with linear decrease down to 50%

with temperature 40 °C

– supply voltage allowed variations: 115 or 230 V ac ± 10 %

– over voltage class (installation class): II

– pollution degree: 2

2.2 Glossary

PARAMETER SYMBOL

pH pH

ORP (oxidation reduction potential) mV

Dissolved Oxygen* O2

Residual Chlorine Cl

Chlorine Dioxide CD

Ozone O3

Temperature T

These symbols are also used in displayed indications.

* Not supported at this time.

2.3 General Description

AW400 Monitor/Controller Family includes 2 Types of instrument:

• Transmitter (Instrument Type 1)

A group of transmitters, both single channel and dual channels and three channels.

• Controller (Instrument Type 2)

PID controller for the installed Sensor, with specific algorithms for each type of measured parameter. It can

accept an optional 4÷20 mA signal from a flow-meter on channel 2. This second input can be used as Feed

Forward input in the PID algorithm.

5

2.4 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

• Maximum consumption: 20 VA

• Electrical classification: for non hazardous area

• Enclosure classification: IP65, suitable for outdoor mounting

• Housing construction material: Goodlac V0 532 ULSD F17 (ABS with 17% Fiberglass)

• Mounting: hardware is supplied for the following mounting options

- wall mounting

- 2" pipe mounting

• Analog outputs: one for each installed channel (analog I/O pc board); separately selectable for each

channel as 0÷20 mA or 4÷20 mA.

• Outputs are galvanically isolated from inputs. Load 0÷1000 Ω, protected against short circuits.

• Digital outputs: through relays. Rating: 24 Vdc and 24 Vac, 2 A max. Contact output status can be

selected as NO or NC separately for each contact by a specific selection in the Configuration menu.

• Serial communication port: RS232, RS422 and RS485 with RJ45 plug-in sockets. The protocol used is

illustrated in a dedicated section at the end of this manual.

• Alarm level setting: High and Low alarm for channel 1, High and Low alarm for channel 2. Separate levels

for each channel, freely selectable. Dead band freely selectable for each channel.

• Measuring ranges: freely selectable for each channel within the limits indicated for each parameter, as

follows:

PARAMETER MINIMUM SPAN MAXIMUM RANGE DEFAULT SETTING

pH 1.00 pH 0.00 ÷ 14.00 pH 2.00 ÷ 12.00 pH

mV 100 mV -1500 ÷ +1500 mV -500 ÷ +500 mV

O3 0.25 ppm 0.00 ÷ 10.00 ppm 0.00 ÷ 1.00 ppm

Cl 0.25 ppm 0.00 ÷ 10.00 ppm 0.00 ÷ 1.00 ppm

CD 0.25 ppm 0.00 ÷ 10.00 ppm 0.00 ÷ 1.00 ppm

T 5 °C 0 ÷ +100 °C 0 ÷ +100 °C

mA 2 mA 0/4 ÷ 20 mA 4 ÷ 20 mA

6

• Measure sensitivity:

Parameter Sensitivity

pH 0.0002 unit pH

ORP 0.0045 mV

chlorine 0.33 μg/l (ppb)

chlorine dioxide 0.33 μg/l (ppb)

ozone 0.15 μg/l (ppb)

• Weight: 3 kg

• Outline dimensions: 250 mm x 250 mm x 120 mm. See Fig.1 for detailed outline dimensions

• Ambient temperature limits for stocking: -40 °C ÷ +65 °C

• Ambient temperature limits during operation: -10 °C ÷ +50 °C (if the instrument is expected to be

installed in the sunlight, a sunshade protection is strongly recommended)

• Thermal drift: within 0.2% of f.s. for a 10 °C temperature variation.

• Relative humidity: 80 % with temperature up to 31 °C, with linear decrease down to 50% with

temperature 40 °C

• Accuracy: within ± 0.2 % of f.s.

• Transmitter response time: measure is refreshed at each microprocessor scan cycle (100 msec)

• Microprocessor scan cycle: 100 msec

• Smoothing: separately set for each channel inside Configuration menu.

7

2.5 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. BOARDS (bottom):

Power supply pc board

Di

g

ital I/O pc board with

expanded function board

Serial data link port

Power supply board Digital output board Digital input board

8

SECOND LAYER OF P.C. BOARDS (Analog Input/Output)

THIRD LAYER OF P.C. BOARDS (Main Board):

FOURTH LAYER OF P.C. BOARDS (Top):

Analog I/O pc board (channel cards) Channel 1

Channel 2 (optional)

Channel 3 (optional)

CPU pc board

Display and Keyboard

pc board

9

2.6 Instrument operating block diagram

CPU

configuration

output setting

alarms

algorithms and

routines

SERIAL

COMMUNICATION

RS485

RS422

RS232

DIGITAL I/O

CCI 1 freezes Ch.1

CCI 2 freezes Ch.2

CCI 1 + CCI 2 when

in OR freeze Ch.1 +

Ch.2

CCO 1

CCO 2

CCO 3

CCO 4

CCO 5

CCO 6

CCO 7 watch dog

G

C

B

D

ANALOG I/O

Channel 1

Type of chann.

Calibration data

Input signals:

p

H, mV, O2, Cl,

CD, O3, mA

Output signal:

(0÷20 or 4÷20

mA)

A

POWER

SUPPLY

p

ower supply to

all pc boards and

components

ANALOG I/O

Channel 2

Type of chann.

Calibration data

Input signals:

p

H, mV, O2, Cl,

CD, O3, mA

Output signal:

(0÷20 or 4÷20

mA)

ANALOG I/O

Channel 3

Type of chann.

Calibration data

Input signals:

p

H, mV, O2, Cl,

CD, O3, mA

Output signal:

(0÷20 or 4÷20

mA)

E

F

CCO1÷6

functions

depend on

type of

instrument

selected

Output signal:

10

3 INSTALLATION

3.1 Dimensions and mounting

S

ide view

Cover for

terminal

board

connection

n° 4 cable

glands,

optional

N

otes :

1 - All dimensions in mm

2 - Dimensions are guaranteed only if this print is original

3 - All dimensions subject to tolerance ±3 mm.

4 - Weight: MicroChem 2 : 3 kg

MicroChem 2 c/w sunshade : 4 Kg.

H

ousing bottom

180 (7.2”)

31

(1.2”)

220 (9”)

n°5 cable

glands,

PG 11

allow enough space for

wiring

R

ear view

250 (10”)

300 (12”)

hole ø 9,5 for

sunshade wall

mounting

hole

ø 9,5 for wall

mounting of sunshade

n° 4 cable

glands,

optional

400 (16”)

120 (4.8”)

31

(1.2”)

31

(1.2”)

31

(1.2”)

250 (10”)

120 (4.8”)

125 (5”)

120 (4.8”)

ø16

(0.4”)

Fig. 1 - AW400 dimensions

!

WARNING! When installing AW400 outdoors, the use of a sunshade is strongly

recommended.

11

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 mountin

g

Caution ! Danger

Follow instructions written on

Instruction Bulletin.

120 (4.8”)

cover for terminal

board wiring

Minimum distance

for cover opening

Power supply cable

!

allow enough

clearance for wiring

!

180 (7.2”)

allow enough

clearance for wiring

n°2 holes ø 6,5 for wall mounting

(n°2 screws c/w inserts for wall

mounting are supplied)

Power supply cable.

!

Caution ! Danger

F

ollow instructions written on

Instruction Bulletin.

800 (32”)

minimum

clearance

0.00

n°2 slots 6,5 - R. 3,25

(n°2 screws c/w inserts

supplied for wall mounting)

500

(20”)

minimum

clearance

1600 (64

”

) approx

Installation height

from floor level

1500 (60”)

Fig. 2 - Typical Wall-mounting Installations of AW400

12

3.2.2 2” Pipe mounting without sunshade

!

cover for, terminal

board connections

800 (32”)

Minimum

clearance

0.00

500

(20”)

!

cover for terminal

board connections

800 (32”)

minimum

clearance

0.00

500

(20”)

minimum

clearance

Power supply cable

Caution ! Danger

follow instructions written on

Instruction Bulletin

!

Power supply cable

Caution ! Danger

follow instructions written on

Instruction Bulletin

!

AW400 2” horizontal pipe mounting

AW400 2” vertical pipe mounting

1500 (60”)

minimum

clearance

for cover

opening

n.2 brackets

c/w screws

supplied for 2”

p

ipe mounting

Power supply cable

!

Power supply cable

!

2” pipe

n.2 brackets c/w

screws supplied for

2” pipe mounting

1500 (60”)

minimum

clearance

for cover

opening

Caution ! Danger

follow the instructions written on

Istruction Bulletin

Caution

! Danger

follow the instructions written on

the Instruction Bulletin

Minimum

clearance

1600 (64”) approx

Installation height

from floor level

600 (64”) approx

Installation heigh

t

from floor level

Fig. 3 - Typical 2” pipe mounting of AW400

13

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

- power supply according to instrument tag should be available

14

3.4 Electrical connections

3.4.1 Power supply p.c. board

The power supply is connected to the terminal board TB1.

The AW400 is shipped with the input voltage jumper set to 220 Vac. The selection between the

110 Vac or 220 Vac power settings can be changed by moving a jumper (in position JP1) on the power supply

pc board.

See Figure 4 to change the jumper setting.

1. disconnect the power supply

2. open the upper enclosed cover

3. move the jumper to the correct position

4. close the cover and reconnect the power

Figure 4 - Power supply jumper position 110 Vac or 220 Vac

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. Alternatively, the cable should fulfil IEC 227 and IEC 245 requirements

• three-cores cable, each core with section 1 mm

2

or 1.5 mm

2

• cable gland installed on AW400 is PG11, with flexible protection for cable. It has to be suitable for

cables with 6 to 10 mm diameter and to assure IP 68 sealing.

• the cable has to include ground wire and have to be properly grounded.

Power Supply pc board-

reverse side

Jumper set

for 220 Vac

Jumper set

for 110 Vac

15

3.4.1.2 Installation of cables for power supply

DANGER!

Electrical shock hazard. Power supply cables are connected to

115 or 230 V ac voltage.

3.4.1.2.1 Cable inlet

The three-core power supply cable, to be supplied by customer, has to be inserted complete with the external

sheath into the cable gland. The cable gland supplied with the instrument serves as a protection to the cable

at its inlet into the transmitter, so avoiding abrasions and too tight bends.

3.4.1.2.2 Cable anchorage (to be made by Customer)

Cable anchorage must be designed to avoid stresses, included torsion stresses to the conductors at the point

where they enter the transmitter. Cable anchorage must also prevent conductors abrasion. Cable anchorage

has to satisfy the following requirements:

• the bushing inside the cable gland is designed to suit cables with 6÷10 mm diameter assuring an IP 68

seal. Tighten it correctly, making sure you prevent the cable to be pushed further inside the transmitter

causing damage to the hardware or danger to the operator.

• cable has not be fixed with a screw acting directly on the cable itself

• never make knots on the cable itself

• cable anchoring must be designed to make cable replacement easy and safe.

3.4.1.2.3 Plugs (to be supplied by Customer)

The plug for supply voltage must be certified (IMQ, UL, CSA...) and has to include ground conductor.

3.4.1.2.4 Supply voltage circuit-breaker (to be installed by the Customer)

The equipment has to be provided with a switch that allows the user to disconnect the instrument from the

power source. Isolating switch has to be easy to identify and reach.. Install the isolating switch near the

AW400. The distance from AW400 has to be shorter than 2 m. The isolating switch must have the following

characteristics:

• magneto-thermic circuit breaker

• the switch must be certified (IMQ, UL, CSA...)

• the switch must have I and O symbols to make clear if power supply is present or disconnected

• if the switch has to be installed outdoor, it must be suitable for such application (IP 65)

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. The

different possibilities are detailed in the sections dedicated to each specific type of instrument, as detailed

under each specific instrument section.

Fig. 5 shows how the terminal number assigned to each CCO on the I/O pc board.

16

The rating of relays are:

• 24 Vdc or 24 Vac

• 5 A max.

• 95-115 mW

Characteristics of commutation are:

• max voltage: 380Vac, 300Vdc

• max current: 8A

• max capacity: 50W-270W in alternate current; 2000W in direct current.

CCO 1 CCO 2 CCO 3 CCO 4 CCO 5 CCO 6 CCO 7

1234567891011121314

Fig. 5 – Relays interconnection terminal barrier

!

Any valve or device connected to AW400 contact outputs

CAUTION! must be chosen and wired in order to be fail safe.

17

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.

Fig. 6 – Digital inputs terminal barrier

3.4.3 Analog input/output pc board

Refer to each sensor I.B. for the colour/number codification of the sensors wires. The Pt100 shield and the

sensor shield, if present, has to be connected to ground shield terminal strip, inside AW400. Pleases notice

that, for pH and ORP sensors it is recommended to fix the cable near the sensor so that it doesn't move at the

outlet of the cable gland. The wear of the cable at that point is thus prevented.

The 0÷20 mA or 4÷20 mA signal INPUT is on terminals 5 and 6: when these terminals are used for the

0/4÷20 mA INPUT, install a 100 Ω resistor (0.1 % accuracy) across terminals 5 and 6.

Use two cores shielded cables for 4÷20 mA output signals, section of each conductor 0.5 ÷ 1.0 mm

2

; connect

shields to the shield ground terminal strip inside AW400.

Expanded function power supply

Digital inputs

Digital input

(+)

1

Digital input

(+)

2

Terminals: 3-8 not used

Terminals: 9-12 = +24

Terminals: 13-16 0v (common)

USE ANY ONE OF THE 0v (COMMON) TERMINALS (13-16) TO

TERMINATE THE DIGITAL INPUT (-) WIRES

18

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.

In the installation menu, when configuring channel 2 and 3, after the choice of the type of sensor, it is

requested to specify if the reference temperature is to be "equal to first channel" or "independent". In the first

case the reference temperature for that channel is taken from channel 1, in the second case it is read from its

own Pt thermo-resistance which in this case must be present.

This option is not applicable for mA and ORP inputs measurements, as these parameters are not influenced

by operating temperature.

3.4.4 Serial communication board

AW400 supports serial communication standards RS232 and RS422/485 by connection of a modular

telephone jack RJ45.

The 9 poles terminal board supports all three standards.

The pin-out of the RJ45 connectors and 9-pin terminal board is illustrated in Section 11.3 in this manual,

dealing with the serial communication option.

3.4.5 Cable glands

The instrument case houses 9 pre-formed holes that can be opened for wiring entrance. Five of them are

made ready for use in the factory and protected.

AW400 fully wired is connected as follows (Fig 8):

• 1 three-core cable for power supply

• cables from sensors

• cables for 4÷20 mA retransmission

• wires for digital outputs (CCO1÷7)

• 2 two-core cable for digital inputs (CCI1÷2)

• 1 three-core cable for serial link (or cable with modular telephone jack RJ45 type)

In case not all the connections are required, the most important rules to follow are:

Out

mA

μA in from

sensors

Cl,CD,O3

mV in from

sensors

(pH,ORP)

or 0/4-20

mA

Temperature

Pt100

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ABB AW400 Series User manual

ABB AW400 Series User manual

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