User Guide OI/TB82TE–EN Rev. B Type TB82TE Advantage SeriesTM 2-wire, 2-electrode conductivity transmitter WARNING notices as used in this manual apply to hazards or unsafe practices which could result in personal injury or death. CAUTION notices apply to hazards or unsafe practices which could result in property damage. NOTES highlight procedures and contain information which assist the operator in understanding the informa- tion contained in this manual. All software, including design, appearance, algorithms and source codes, is copyrighted by ABB Inc. and is owned by ABB Inc. or its suppliers. WARNING POSSIBLE PROCESS UPSETS. Maintenance must be performed only by qualified personnel and only after securing equipment controlled by this product. Adjusting or removing this product while it is in the system may upset the process being controlled. Some process upsets may cause injury or damage. NOTICE The information contained in this document is subject to change without notice. ABB Inc., its affiliates, employees, and agents, and the authors of and contributors to this publication specifi- cally disclaim all liabilities and warranties, express and implied (including warranties of merchantability and fit- ness for a particular purpose), for the accuracy, currency, completeness, and/or reliability of the information contained herein and/or for the fitness for any particular use and/or for the performance of any material and/or equipment selected in whole or part with the user of/or in reliance upon information contained herein. Selection of materials and/or equipment is at the sole risk of the user of this publication. This document contains proprietary information of ABB Inc., and is issued in strict confidence. Its use, or repro- duction for use, for the reverse engineering, development or manufacture of hardware or software described herein is prohibited. No part of this document may be photocopied or reproduced without the prior written con- sent of ABB Inc.. Copyright 2002 ABB Inc. [December 2002] Preface This publication is for the use of technical personnel responsi- ble for installation, operation, maintenance, and repair of the ABB Type TB82TE Advantage Series™ Two-Wire, Two-Elec- trode Conductivity/Concentration Transmitter. The Type TB82TE transmitter is delivered with default hard- ware and software configurations. These settings may need to be changed depending on the application requirements. Some sections of this instruction have been prepared in proce- dure format. There is a sequence flowchart or table that fol- lows the introduction to the section and any nonprocedural information. This flowchart directs personnel to the appropri- ate procedure located in the back of this instruction. By treat- ing each task as a separate entity, the procedures provide an easy method for finding the information needed to perform each task. The procedures have check boxes in the margin by each step. When performing a procedure, check each box as each step is completed. It is important for safety and operation that this instruction be read and understood before attempting anything related to installation, operation, maintenance, or repair. WTPEEUI520002A1 List of Effective Pages Total number of pages in this instruction is 150, consisting of the following: Page No. Change Date Page No. Change Date Preface Original PR9-1 through PR9-2 Original List of Effective Pages Original PR10-1 Original iii through x Original PR11-1 through PR11-4 Original 1-1 through 1-9 Original PR12-1 Original 2-1 through 2-3 Original PR13-1 Original 3-1 through 3-4 Original PR14-1 Original 4-1 through 4-4 Original PR15-1 Original 5-1 through 5-3 Original PR16-1 through PR16-3 Original 6-1 through 6-4 Original PR17-1 through PR17-3 Original 7-1 through 7-2 Original PR18-1 Original 8-1 through 8-6 Original PR19-1 through PR19-2 Original 9-1 through 9-2 Original PR20-1 through PR20-4 Original 10-1 through 10-2 Original PR21-1 through PR21-2 Original 11-1 through 11-2 Original PR22-1 through PR22-4 Original 12-1 through 12-8 Original PR23-1 through PR23-4 Original 13-1 through 13-2 Original PR24-1 Original 14-1 through 14-2 Original PR25-1 through PR25-2 Original 15-1 through 15-2 Original PR26-1 through PR26-2 Original A-1 through A-3 Original PR27-1 through PR27-2 Original B-1 Original PR28-1 Original C-1 through C-4 Original PR29-1 Original Worksheet 1 Original PR30-1 Original PR Index-1 through PR Index-2 Original PR31-1 Original PR1-1 through PR1-2 Original PR32-1 through PR32-2 Original PR2-1 through PR2-2 Original PR33-1 Original PR3-1 through PR3-2 Original PR34-1 Original PR4-1 through PR4-2 Original PR35-1 Original PR5-1 through PR5-4 Original PR36-1 Original PR6-1 through PR6-2 Original PR37-1 Original PR7-1 through PR7-2 Original Index-1 through Index-4 Original PR8-1 through PR8-2 Original When an update is received, insert the latest changed pages and dispose of the superseded pages. NOTE: On an update page, the changed text or table is indicated by a vertical bar in the outer margin of the page adjacent to the changed area. A changed figure is indicated by a vertical bar in the outer margin next to the figure caption. The date the update was prepared will appear beside the page number. WTPEEUI520002A1 Table of Contents Page SECTION 1 - INTRODUCTION....................................................................................................1-1 OVERVIEW..................................................................................................................1-1 INTENDED USER.........................................................................................................1-1 FEATURES...................................................................................................................1-2 EQUIPMENT APPLICATION..........................................................................................1-2 INSTRUCTION CONTENT.............................................................................................1-3 HOW TO USE THIS INSTRUCTION...............................................................................1-4 DOCUMENT CONVENTIONS........................................................................................1-4 REFERENCE DOCUMENTS..........................................................................................1-4 NOMENCLATURE........................................................................................................1-5 SPECIFICATIONS.........................................................................................................1-6 ACCESSORIES.............................................................................................................1-9 SECTION 2 - DESCRIPTION AND OPERATION........................................................................2-1 INTRODUCTION...........................................................................................................2-1 FUNCTIONAL OPERATION...........................................................................................2-1 USER INTERFACE.......................................................................................................2-1 MODULAR ELECTRONICS...........................................................................................2-1 TEMPERATURE COMPENSATION................................................................................2-1 DAMPING.....................................................................................................................2-2 DIAGNOSTICS.............................................................................................................2-2 Transmitter Diagnostics.........................................................................................2-2 Sensor Diagnostics.................... ............................................................................2-3 Spike Output.........................................................................................................2-3 SECTION 3 - INSTALLATION.....................................................................................................3-1 INTRODUCTION...........................................................................................................3-1 UNPACKING AND INSPECTION....................................................................................3-1 LOCATION CONSIDERATIONS.....................................................................................3-1 Hazardous Locations..............................................................................................3-2 Radio Frequency Interference.................................................................................3-2 WIRING CONSIDERATIONS.........................................................................................3-3 OTHER EQUIPMENT INTERFACE................................................................................3-3 TRANSMITTER ROTATION...........................................................................................3-3 INSTALLATION SEQUENCE.........................................................................................3-3 SECTION 4 - OPERATING PROCEDURES................................................................................4-1 INTRODUCTION...........................................................................................................4-1 OPERATOR INTERFACE CONTROLS............................................................................4-1 Liquid Crystal Display............................................................................................4-1 Smart Keys............................................................................................................4-2 MODES OF OPERATION..............................................................................................4-3 HOLD ICON.................................................................................................................4-4 FAULT ICON................................................................................................................4-4 SPIKE ICON.................................................................................................................4-4 SECTION 5 - MEASURE MODE..................................................................................................5-1 INTRODUCTION...........................................................................................................5-1 BOREDOM SWITCH.....................................................................................................5-1 PRIMARY DISPLAY.......................................................................................................5-1 SECONDARY DISPLAY.................................................................................................5-1 WTPEEUI520002A1 iii Table of Contents (continued) Page SECTION 5 - MEASURE MODE (continued) Fault Information Smart Key.................................................................................5-1 Menu Smart Key....................................................................................................5-2 SECTION 6 - CALIBRATION.......................................................................................................6-1 INTRODUCTION..........................................................................................................6-1 CALIBRATE STATES....................................................................................................6-1 CALIBRATION SEQUENCE..........................................................................................6-1 SECTION 7 - OUTPUT/HOLD MODE..........................................................................................7-1 INTRODUCTION..........................................................................................................7-1 OUTPUT/HOLD STATES OF OPERATION....................................................................7-1 SECTION 8 - CONFIGURATION.................................................................................................8-1 INTRODUCTION..........................................................................................................8-1 PRECONFIGURATION DATA REQUIRED.....................................................................8-1 CONFIGURATION SEQUENCE.....................................................................................8-2 SECTION 9 - SECURITY MODE.................................................................................................9-1 INTRODUCTION..........................................................................................................9-1 SECURITY STATE........................................................................................................9-1 ENTERING PASSWORD...............................................................................................9-1 SECURITY SEQUENCE................................................................................................9-1 SECTION 10 - SECONDARY DISPLAY MODE........................................................................10-1 INTRODUCTION........................................................................................................10-1 SECONDARY DISPLAY STATES OF OPERATION........................................................10-1 SECONDARY DISPLAY OPERATION...........................................................................10-1 SECTION 11 - UTILITY MODE..................................................................................................11-1 INTRODUCTION........................................................................................................11-1 FACTORY AND USER STATES...................................................................................11-1 SECTION 12 - DIAGNOSTICS AND TROUBLESHOOTING....................................................12-1 INTRODUCTION........................................................................................................12-1 FAULT CODES..........................................................................................................12-1 Problem Codes....................................................................................................12-1 Error Codes.........................................................................................................12-5 CALIBRATION DIAGNOSTICS....................................................................................12-6 ADDITIONAL DIAGNOSTICS......................................................................................12-7 TROUBLESHOOTING SEQUENCE.............................................................................12-7 SECTION 13 - MAINTENANCE.................................................................................................13-1 INTRODUCTION........................................................................................................13-1 PREVENTIVE MAINTENANCE SCHEDULE.................................................................13-1 iv WTPEEUI520002A1 Table of Contents (continued) Page SECTION 14 - REPAIR AND REPLACEMENT.........................................................................14-1 INTRODUCTION.........................................................................................................14-1 REPAIR AND REPLACEMENT SEQUENCE.................................................................14-1 SECTION 15 - SUPPORT SERVICES.......................................................................................15-1 INTRODUCTION.........................................................................................................15-1 RETURN MATERIALS PROCEDURES.........................................................................15-1 REPLACEMENT PARTS..............................................................................................15-1 RECOMMENDED SPARE PARTS KITS........................................................................15-2 APPENDIX A - TEMPERATURE COMPENSATION..................................................................A-1 INTRODUCTION..........................................................................................................A-1 TEMPERATURE COMPENSATION TYPES....................................................................A-1 Standard KCl........................................................................................................A-1 Temperature Coefficient........................................................................................A-2 User-Defined.........................................................................................................A-3 Pure Water............................................................................................................A-3 APPENDIX B - CONCENTRATION PROGRAMMING...............................................................B-1 INTRODUCTION..........................................................................................................B-1 USER-DEFINED CONDUCTIVITY-TO-CONCENTRATION CURVES...............................B-1 APPENDIX C - PROGRAMMING TEXT STRING GLOSSARY.................................................C-1 INTRODUCTION..........................................................................................................C-1 TEXT PROMPTS..........................................................................................................C-1 FLOW TREE................................................................................................................C-4 List of Procedures No. Title PR1 - PIPE MOUNTING PR2 - PANEL MOUNTING PR3 - WALL MOUNTING PR4 - HINGE MOUNTING PR5 - WIRING AND GROUNDING PR6 - TEMPERATURE CALIBRATION PR7 - PV CALIBRATION PR8 - OUTPUT CALIBRATION PR9 - EDIT CALIBRATION PR10 - RESET CALIBRATION PR11 - OUTPUT/HOLD MODE PR12 - SELECTING VIEW OR MODIFY CONFIGURATION STATE PR13 - MODIFYING CONFIGURATION WHILE VIEWING PR14 - PROGRAMMING MODE CHANGE PR15 - ANALYZER AND SENSOR CELL CONSTANT TYPE SELECTIONS PR16 - CONCENTRATION PROGRAMMING WTPEEUI520002A1 v List of Procedures (continued) No. Title PR17 - TEMPERATURE SENSOR AND COMPENSATION TYPE SELECTIONS PR18 - TEMPERATURE COMPENSATION COEFFICIENT SETTING PR19 - USER-DEFINED TEMPERATURE COEFFICIENT PROGRAMMING PR20 - COMPLETING CONFIGURATION PR21 - CONFIGURATION LOCKOUT PR22 - SECURITY AND PASSWORD ASSIGNMENT PR23 - UTILITY MODE PR24 - SENSOR INSPECTION PR25 - ELECTRONIC SENSOR TEST PR26 - TRANSMITTER TROUBLESHOOTING WITHOUT SENSOR PR27 - SENSOR CLEANING PR28 - KEYPAD CLEANING PR29 - FRONT BEZEL REMOVAL PR30 - POWER SUPPLY PCB REMOVAL PR31 - TWO-ELECTRODE CONDUCTIVITY INPUT PCB REMOVAL PR32 - MICROPROCESSOR PCB REPLACEMENT PR33 - TWO-ELECTRODE CONDUCTIVITY INPUT PCB INSTALLATION PR34 - POWER SUPPLY PCB INSTALLATION PR35 - FRONT BEZEL INSTALLATION PR36 - REAR COVER REPLACEMENT PR37 - SHELL REPLACEMENT List of Figures No. Title Page 1-1. Load Limits...........................................................................................................1-9 3-1. Transmitter Dimensions........................................................................................3-2 3-2. Transmitter Rotation.............................................................................................3-4 3-3. Installation Sequence............................................................................................3-4 4-1. Liquid Crystal Display...........................................................................................4-2 5-1. Operating Mode Screen Flow.................................................................................5-3 6-1. Calibrate Mode Screen Flow...................................................................................6-3 6-2. Calibration Sequence.............................................................................................6-4 7-1. Output/Hold Mode Screen Flow............................................................................7-2 8-1. Modify/View and Basic/Advanced States Screen Flow...........................................8-2 8-2. Modify Configure States Screen Flow.....................................................................8-3 8-3. Configuration Sequence.........................................................................................8-4 8-4. Advanced Configuration Sequence.........................................................................8-5 8-5. Basic Configuration Sequence...............................................................................8-6 9-1. Security State Screen Flow....................................................................................9-2 10-1. Secondary Display Mode Screen Flow..................................................................10-2 11-1. User State Screen Flow........................................................................................11-2 12-1. Troubleshooting Sequence...................................................................................12-8 14-1. Repair and Replacement Sequence......................................................................14-2 15-1. Exploded View.....................................................................................................15-2 C-1. Function Flow Tree................................................................................................C-4 PR1-1. Pipe Mounting...................................................................................................PR1-2 vvii WWTTPPEEEEUUII552200000022AA11 List of Figures (continued) No. Title Page PR2-1. Panel Mounting.................................................................................................PR2-2 PR3-1. Wall Mounting..................................................................................................PR3-2 PR4-1. Hinge Mounting................................................................................................PR4-2 PR5-1. Load Limits.......................................................................................................PR5-2 PR5-2. Wiring and Grounding......................................................................................PR5-3 PR8-1. Output Calibration Setup..................................................................................PR8-2 PR16-1. Linear Curve Fit...............................................................................................PR16-2 PR19-1. User-Defined Temperature Compensation Curve..............................................PR19-2 PR21-1. Configuration Lockout Jumper.........................................................................PR21-2 PR26-1. Sensor Simulation Setup.................................................................................PR26-1 PR30-1. Power Supply PCB Removal.............................................................................PR30-1 PR31-1. Conductivity Input PCB Removal.....................................................................PR31-1 PR32-1. Microprocessor PCB Replacement....................................................................PR32-1 List of Tables No. Title Page 1-1. Reference Documents............................................................................................1-5 1-2. Nomenclature........................................................................................................1-5 1-3. Specifications.........................................................................................................1-6 1-4. Accessory Kits........................................................................................................1-9 1-5. Sensors..................................................................................................................1-9 4-1. Smart Key Functions.............................................................................................4-3 4-2. Modes of Operation................................................................................................4-4 5-1. Engineering Units..................................................................................................5-1 6-1. Calibrate States.....................................................................................................6-1 7-1. Output/Hold States...............................................................................................7-1 8-1. Default Configuration............................................................................................8-1 11-1. User States..........................................................................................................11-1 12-1. Common Problem Codes......................................................................................12-2 12-2. Uncommon Problem Codes..................................................................................12-3 12-3. Error Codes.........................................................................................................12-6 13-1. Preventive Maintenance Schedule........................................................................13-2 15-1. Spare Parts Kits...................................................................................................15-2 A-1. Standard KCl Data Breakpoints............................................................................A-2 A-2. Pure Water Coefficient Values...............................................................................A-3 C-1. Text Prompt Equivalents.......................................................................................C-1 PR5-1. Sensor Connections..........................................................................................PR5-4 PR11-1. Output Ranges.................................................................................................PR11-2 PR15-1. Analyzer States................................................................................................PR15-1 PR16-1. Conductivity-to-Concentration Data.................................................................PR16-2 PR17-1. Temperature Compensation States...................................................................PR17-2 PR19-1. User-Defined Temperature Compensation Data................................................PR19-1 PR20-1. Sensor Full Scale Measurement Ranges...........................................................PR20-1 PR23-1. Default Configuration......................................................................................PR23-2 PR26-1. Sensor Simulation Values................................................................................PR26-2 WTPEEUI520002A1 vii Safety Summary Electrostatic Sensitive Device Devices labeled with this symbol and the equipment described in this instruction require special handling precautions. This equipment contains components that can be damaged from discharges of static electricity; therefore, avoid contact with terminal block conduc- tors and electronic components on the circuit boards. Ordinarily, components will not be damaged if circuit boards are handled by the edges. Refer to Electronic Industries Alliance (EIA) standard EIA-625, Requirements for Handling Electrostatic-Discharge-Sensitive (ESDS) Devices for detailed procedures on handling electronic components. This standard is the most comprehensive semicon- ductor ESD handling procedure in the industry. GENERAL Equipment Environment WARNINGS All components, whether in transportation, operation or storage, must be in a noncorrosive environment. Electrical Shock Hazard During Maintenance Disconnect power or take precautions to insure that contact with energized parts is avoided when servicing. SPECIFIC Use this equipment only in those classes of hazardous locations WARNINGS listed on the nameplate. Uses in other hazardous locations can lead to unsafe conditions that can injure personnel and damage equipment. (p. 3-2) All error conditions are considered catastrophic and require trans- mitter replacement. Replace the transmitter with a transmitter that is known to be operable. Leaving an inoperable transmitter in the pro- cess could cause process upsets. Some process upsets can lead to dangerous conditions that can harm personnel and damage equipment. (p. 12-6) Allow only qualified personnel (refer to INTENDED USER in Section1) to commission, operate, service, or repair this equip- ment. Failure to follow the procedures described in this instruction or the instructions provided with related equipment can result in an unsafe condition that can injure personnel and damage equipment. (p. 13-1) ix WTPEEUI520002A1