Operating Manual - en · Operating Manual Page 8 2. Description Lineguard 97 Controller is a stand-alone process control unit designed for the control and monitoring of cleaners,

Operating ManualLineguard 97 MeasConControl and Monitoring Unit

Operating Manual Page 2

Contents

1. Please Observe the Following ................................................................................ 6

1.1. Emphasized Sections ............................................................................................... 6

1.2. For Your Safety ........................................................................................................ 6

1.3. Unpacking and Inspection ....................................................................................... 6

1.4. Items supplied......................................................................................................... 6

1.4.1. 1598686 Lineguard 97 Controller................................................................. 6

1.4.2. Mounting and installation kit ....................................................................... 6

1.4.3. Operation manual ....................................................................................... 6

1.5. Features .................................................................................................................. 6

1.5.1. 3 inputs – any combination of conductivity, pH or ORP (redox).................... 6

1.5.2. 3 control relay outputs ................................................................................ 6

1.5.3. LCD Display with push button operation ...................................................... 7

1.5.4. Password protection ................................................................................... 7

1.5.5. Corrosion resistant, NEMA12 Enclosure. ...................................................... 7

2. Description ............................................................................................................ 8

2.1. Product Benefits...................................................................................................... 8

2.2. Unit Structure ......................................................................................................... 8

2.3. Exploded View ........................................................................................................ 9

2.4. Installing Modules – Initial Configuration .............................................................. 10

3. Technical Data ..................................................................................................... 13

3.1. Basic Lineguard 97 Controller ................................................................................ 13

3.2. pH measuring ........................................................................................................ 13

3.3. ORP (Redox) Measuring......................................................................................... 13

3.4. Temperature Measuring........................................................................................ 14

3.5. Conductivity, Electrodless Measuring .................................................................... 14

3.6. Conductivity, Contact Measuring ........................................................................... 14

3.7. Standard Signal ..................................................................................................... 14

3.8. Controller functions / Signal unit ........................................................................... 14

3.9. Limit-Contact ........................................................................................................ 15

4. Installation........................................................................................................... 16


4.1. Installation Instructions ......................................................................................... 16

4.2. Wall Mounting ...................................................................................................... 16

4.3. Control Cabinet Installation ................................................................................... 16

4.4. Dimensions, E-CO Lineguard 97 Controller & Wall Mounting Holes ........................ 17

4.5. Base Board (Main Mother Board) .......................................................................... 17

4.5.1. Terminal Connection Diagram ................................................................... 17

4.5.2. Electrical Connections ............................................................................... 18

4.5.2.1. Main Power Supply ....................................................................... 18

4.5.2.2. Relay Outputs ............................................................................... 18

4.5.2.3. Current Outputs ............................................................................ 18

4.5.2.4. Serial Output ................................................................................. 18

4.6. 1739319 LG97 Relay Output Module ..................................................................... 18

4.6.1. Relay Module Outputs ............................................................................... 19

4.7. Sensor Information and Connections ..................................................................... 19

4.7.1. Sensor Immersion Installation Requirements ............................................. 20

4.8. Start up ................................................................................................................. 20

4.8.1. Typical Start-Up for measurement type ..................................................... 21

4.8.2. Configuration ............................................................................................ 21

4.8.3. Configuration Error.................................................................................... 21

4.8.4. Configuration Menu .................................................................................. 22

4.8.5. Initiation.................................................................................................... 22

4.8.6. Measurement Screen ................................................................................ 22

5. Operation ............................................................................................................ 23

5.1. General notes for Operation ................................................................................. 23

5.2. Operating Flow Chart ............................................................................................ 23

5.3. Operating Level ..................................................................................................... 24

5.4. Main Menu ........................................................................................................... 24

5.5. Settings ................................................................................................................. 24

5.5.1. Main Menu................................................................................................ 24

5.5.2. Measurement Parameter Settings ............................................................. 24

5.5.3. Controller Parameter Settings ................................................................... 24

5.5.4. Calibration................................................................................................. 24

5.6. Configuration ........................................................................................................ 25

5.6.1. Configuration System PAGE 1 .................................................................... 25

5.6.2. Configuration System PAGE 2 .................................................................... 25


5.6.3. Configuration Module ............................................................................... 26

5.6.4. Manual Functions ...................................................................................... 26

6. Control Operation ................................................................................................ 28

6.1. General ................................................................................................................. 28

6.2. Signal Unit ............................................................................................................. 28

6.3. Parameters Setpoint ............................................................................................. 28

6.4. Switching Performance ......................................................................................... 29

6.5. Limit-Contact ........................................................................................................ 29

6.6. Parameters Limit ................................................................................................... 29

7. Additional Operation Functions ........................................................................... 30

7.1. Access Protection .................................................................................................. 30

7.1.1. System Configuration PAGE 1 .................................................................... 30

7.1.2. Access Code Input ..................................................................................... 30

7.1.3. Protective Mechanism ............................................................................... 30

7.1.4. Password Error Message ........................................................................... 31

7.1.5. Measurement Parameters ......................................................................... 31

7.1.6. Use of Master Code ................................................................................... 31

7.1.7. Reset ......................................................................................................... 31

7.1.7.1. Reset Option Menu ....................................................................... 32

7.1.8. Adoption of Standard Values for Measuring Module X............................... 32

7.1.9. Multiple pH Measurement ........................................................................ 32

7.1.9.1. System Configuration PAGE 1 ........................................................ 32

8. Troubleshooting .................................................................................................. 33

8.1. Display Blank After Turning ON Power................................................................... 33

8.2. Configuration Error After Turning ON Power ......................................................... 33

8.3. Display Value Remains Zero Despite Altered Conductivity Value ........................... 33

8.4. Display Value Unstable .......................................................................................... 33

8.5. Error Message “Plausibility Error” During Calibration. ........................................... 33

8.6. Error Message “Timeout” During Calibration ......................................................... 34

8.7. Display Value Fails to go to Value of pH Buffer Solution When Calibrating ............. 34

8.8. Display OK in Buffer Solution; Measured Value Changes in Measured Solution ...... 34

8.9. Display Remains Constant Despite Altered pH Value ............................................. 34


8.10. Display Remains Constant Despite Altered Conductivity Value .............................. 34

8.11. Display Too Sluggish .............................................................................................. 34

9. Care and Maintenance ......................................................................................... 35

9.1. Sensor & Module Service ...................................................................................... 35

9.2. Setting the Display Contrast .................................................................................. 35

9.3. Replacing the Main Power Fuse (F1) ...................................................................... 35

9.4. Replacing a Module ............................................................................................... 35

9.5. Replacing the Door ................................................................................................ 36

9.6. Replacing the Base Board ...................................................................................... 36

10. Accessories and Spare Components ..................................................................... 37

10.1. Accessories ........................................................................................................... 37

10.2. Measurement Modules ......................................................................................... 37

11. LG97 Wiring Diagram ........................................................................................... 38

12. Warranty ............................................................................................................. 39


1. Please Observe the Following1.1. Emphasized Sections

Warning!

Refers to safety regulations and requires safety measures that protect the operator or otherpersons from injury or danger to life.

Caution!

Emphasizes what must be done or avoided so that the unit or other property is not damaged.

Notice:

A notice gives recommendations for better handling of the unit during operation oradjustment as well as for service activities.

1.2. For Your Safety

For safe and successful operation of the unit, read these instructions completely. If theinstructions are not observed, the manufacturer can assume no responsibility.

Do not expose the connecting cable to heat, oil, or sharp edges.

Make sure the Unit stands stable and secure.

Use only original equipment replacement parts.

Always disconnect the power supply before servicing the unit.

Observe general safety regulations for the handling of chemicals such as Bonderiteproducts. Observe the manufacturer’s instructions as stated in the Safety Data Sheet.

While under warranty, the unit may be repaired only by an authorized Henkel servicerepresentative.

1.3. Unpacking and Inspection

Carefully unpack the Bonderite E-CO Lineguard LG97 Controller and examine the itemscontained in the carton. Inspect the unit for any damage that might have occurred in transit. Ifsuch damage has occurred, notify the carrier immediately. Claims for damage must be madeby the consignee to the carrier and should be reported to the manufacturer.

1.4. Items supplied

1.4.1. 1598686 Lineguard 97 Controller

1.4.2. Mounting and installation kit

1.4.3. Operation manual

1.5. Features

1.5.1. 3 inputs – any combination of conductivity, pH or ORP (redox)

1.5.2. 3 control relay outputs


1.5.3. LCD Display with push button operation

1.5.4. Password protection

1.5.5. Corrosion resistant, NEMA12 Enclosure.


2. DescriptionLineguard 97 Controller is a stand-alone process control unit designed for the control andmonitoring of cleaners, rinses and treatments. This controller can be configured with up to 3individual control loops. The individual control loops can be in any combination of sensortypes; electrodeless conductivity, contact conductivity, or pH/ORP.

Process control set points and alarms are easily set via the front panel push buttons.

2.1. Product Benefits

Automatic chemical additions to process tank

Reduce chemical handling by personal

Easily adjustable alarm settings

RS232 communication output

2.2. Unit Structure

Item Designation

1 Chemical-resistant housing made of Noryl for wall-mounting or installation inswitch cabinet

2 Illuminated graphic display

3 Operator push button

4 Cover screws

5 Cable connections


2.3. Exploded View

Item Designation

1 Housing, lower section

2 Housing, cover

3 Processor board with EPROM

4 Base (Mother) board

5 Retainer band

6 Cover screws

7 Relay board

8 Measuring (control) modules

9 PU screw connections

10 Plug for relay outputs


2.4. Installing Modules – Initial Configuration

The controller will be shipped without any modules installed and will need to be configuredonce all control modules have been installed.

When more than one module is used for controlling devices, such as pumps and/or solenoidvalves, a Relay Module (IDH #1739319) will be required. The relay module is located to the leftof the control modules, inside the LG97 control panel. See Figure below and section.

Inside View of Base LG97/47 Control Panel

Pin Sockets

Motherboard


Modules are supplied with mounting hardware to mount them inside the control panel.

Relay Module with Mtg. Hardware Relay Module Pins

The Relay Module is supplied with (3) plastic Standoffs and (3) screws.

Install the standoffs into the threaded holes in the motherboard.

Install the Relay Module, after installing the standoffs, by carefully inserting the pins intothe socket on the motherboard.

When installing the modules pay special attention to the pins on the back side of themodule. These pins must be carefully aligned and inserted into the sockets on thecontroller motherboard.

After Relay Module is seated into the socket on the motherboard, insert screws thru themodule boards and thread into standoffs to secure module in place.

Do not over tighten the screws, the plastic components can strip out and break veryeasily.

Control modules will be installed into the Module 1, Module 2 and Module 3 positions onthe motherboard. The control modules are supplied with one stand off and one plasticscrew to secure it into place.

If there is only one control module installed, the module will need to be installed in“Module 1” location. There always needs to be a module installed in this location forproper operation of controller.

Additional modules can be installed in the remaining locations, as required.

Install the standoff into the treaded hole on the motherboard.

When installing the control module, carefully align the pins on the back of module with thesockets on the motherboard. Press into place to seat properly.

When installing the modules pay special attention to the pins on the back side of themodule. These pins must be carefully aligned and inserted into the sockets on thecontroller motherboard.

Install plastic screw, near center of the module and thread into the standoff.

Do not over tighten the screws, the plastic components can strip out and break veryeasily.

Once all required modules are installed and power is applied to the panel, initial set up willneed to be made to configure proper language, measurement units and initial settings for thecontroller. Initial setting suggestions can be found in on the following pages.

RELAY MODULE PINS


Suggested Initial SettingsParameters(*modified byoperator) Description

Settings:ElectrodelessConductivity

Settings:ContactConductivity Settings: pH

Settings:Redox (ORP)

Controller Type Standard configuration is forON/OFF control

ControlDeviation

ControlDeviation

ControlDeviation

ControlDeviation

Range Measuring range 0-200 mS 0-20 uS 0-14 pH 0-1000 mVCurrent Output For transmission to

Documentation System4-20 mA 4-20 mA 4-20 mA 4-20 mA

CD Min Measurement at 4 mA 0.0 mS 0.0 uS 0.00 pH 0.0 mVCD Max Measurement at 20 mA 200.0 mS 20.0 uS 14.00 pH 1000 mVTemperatureCompensation

Method of temperaturecompensation

Auto Auto Manual Notemperaturecompensation

Manual. Notemperaturecompensa-tion

Sensitivity Sensitivity is specific to eachmeasurement

N/A N/A 63 mV slope.Fault if <56mV slope

Calculated atcalibrationtemperaturewith standardsolutions

*Set-point (W) Primary control point 50.0 mS 10.0 uS 4.00 pH 350 mVSense of Control:Control Direction

Positive if energized belowset-point (W)Negative if energized aboveset-point

Negative forrinse controlPositive forchemicalcontrol

Negative forrinse controlPositive forchemical control

Negative foralkali ControlPositive foracid Control

Positive forAutophore-tic™ chemicalcontrol

SwitchDifference (XSD)

Dead band at Control Point 1as % of set-point (W)

0.0% 0.0% 0.0% 0.0%

*Switch DelayTime ON

Output switched ON nseconds after signal dropsbelow set-point (W) if controlis Positive.Output switched ON nseconds after signal risesabove set-point (W) if controlis Negative.

10 seconds 10 seconds 10 seconds 10 seconds

*Switch DelayTime OFF

Output switched OFF nseconds after signal returnsabove set-point (W) if controlis Positive.Output switched OFF nseconds after signal returnsbelow set-point (W) if controlis Negative.

20 seconds 20 seconds 20 seconds 20 seconds

Set-pointDifference (LW)

Second control point(not utilized)

+10.0 mS +1.0 uS +1.00 pH +5 mV

SwitchDifference(first X2SD)

Dead band of second controlpoint (not utilized)

0.5% 0.5% 0.5% 0.5%

External ControlEnable

Disabling of external spraypump interlock. Enable ifexternal interlock is used.

Disabled Disabled Disabled Disabled

*Limit Contact(L-)

Absolute low alarm 45.0 mS 5.0 uS 4.50 pH 400 mV

*Limit Contact(L+)

Absolute high alarm 55.0 mS 15.0 uS 3.50 pH 300 mV

SwitchDifference(second X2SD)

Dead band of Alarm LimitContacts (L-) and (L+)

2.0% 2.0% 2.0% 2.0%


3. Technical Data3.1. Basic Lineguard 97 Controller

Mains voltage 230/115 V AC + 6 % -10 %, 50 - 60 HzPower consumption 25 WFuse protection 2,5 A delayProtection class IProtection category IP 65Power output, 0(4) - 20 mA Option: galvanic isolation for power outputsmax. load 600 maximal output current (distribution), adjustableAccuracy < 1 % of measuring range endFault indications floating fault indication relayRelay contact loading 3 A/230 V ohmic load

(with RC contact-protection circuit) to drive anelectromotor the starting current is relevant. Thestarting current may be 3 to 7 times above thenominal current.

Weight 2.5 kgPermissible operation temperature 0 to +45 °CPermissible storage temperature - 20 to + 60 °CDimensions 224 mm 8.818 inches / 290 mm 11.417inches / 95 mm 3.700 inches (W/D/H)

3.2. pH measuring

Measuring range 0 - 14 pH, 2 - 12 pH, 3 - 8 pH, adjustableAccuracy < 1% of measuring range endResolution 0.01 pHTemperature compensation Manual, 0 - 100 °C

Automatic with Pt 1002/3-wire connection possible 0 - 100 °CTemperature unit °C or °F

Calibration Two freely selectable buffer values with plausibilitycontrol, checking for electrode faults(mutual conductance < 56 mV) Auto-read functionfor stable measured value

3.3. ORP (Redox) Measuring

Measuring range 0 - 1000 mV-500 mV - 500mV

Accuracy < 1 % of measuring range end valueResolution 1 mVCalibration Single-point calibration with plausibility control,

auto-read function for stable measured valuecapturing


3.4. Temperature Measuring

Measuring range 0 - 100 °CAccuracy, measuring amplifier < 1 % of measuring range end valueResolution 0.1 °C

3.5. Conductivity, Electrodless Measuring

Measuring range 0-2 mS, 0-20 mS, 0-200 mS, 0-2000 mSconfigurable

Accuracy < 1% of measuring range end valueResolution 1 - 0.001 mS depending on measuring rangeTemperature compensation Manual: 0 - 100 °C

Automatic with NTC: 0 - 100 °CReference temperature: 25 °CTemperature unit °C or °F

Calibration with calibrating box, depending on measuringrangeAuto-read function for stable measured value

3.6. Conductivity, Contact Measuring

Measuring range 0-2 µS, 0-20 µS, 0-200 µS, configurableAccuracy < 1% of measuring range end valueResolution 1 – 0.001 µS depending on measuring rangeTemperature compensation Manual: 0 - 100 °C

Automatic with PF100: 0 - 100 °CReference temperature 25 °CTemperature unit °C or °F

Calibration with calibration box, depending on measuringrangeAuto-read function for stable measured value

3.7. Standard Signal

Signal input terminal 1 0(4)-20 mA (Option: galvanic separation)Signal input terminal 2 0(4)-20 mA (Option: galvanic separation)Selection of display units pH, redox (mV), mA, mV, conductivity,

Celsius, FahrenheitSelection of measuring ranges Redox: 0 - 1000 mV or – 500 - + 500 mV

Celsius: 0 - 100 °CFahrenheit: 32 - 212 °F

3.8. Controller functions / Signal unit

Set-point value (W): Measuring module rangeSwitch difference (XSD): 0 .. 30.0 %ON delay: 0 .. 240 secondsOFF delay: 0 .. 240 secondsSwitching point distance (LW): ± Measuring range


Switch difference (X2SD): 0 .. 30.0 %

3.9. Limit-Contact

Limit contact (L-): Measuring module rangeLimit contact (L+): Measuring module rangeSwitch difference (X2SD): 0 .. 30.0 %


4. InstallationBefore using the equipment for the first time check it carefully for signs of externaldamage. If any shipping damage is found DO NOT USE THE EQUIPMENT – return it to yoursupplier immediately.

4.1. Installation Instructions

The Lineguard 97 Controller can be wall mounted or installed in a control cabinet without anyadditional components.

Room conditions for Lineguard 97 controller installation should be free of vibrations and drywith ambient temperature 0° – 45° C [32° - 113° F].

Failure in observing the installation requirements can result in damage of the unit.

4.2. Wall Mounting

Open housing of the Lineguard 97 Controller by loosening the 4 cover screws.

Use the housing as a template and scribe the 4 mounting holes onto the surface where thecontroller will be mounted.

Drill the scribe marks using a 6 mm [ 1/4”] drill bit.

Insert dowel plugs supplied with the controller.

Attach housing using the screws provided.

Close the housing and tighten the 4 cover screws.

When Closing the housing, ensure that the seal is not damaged and it is seated exactly inthe seal groove.

4.3. Control Cabinet Installation

Cut a 213 x 259 mm [ 8.3” x 10.1”] (w x h) opening in the control cabinet.

Scribe the holes as per the drawing.

Drill the mounting holes using a 4.5 mm [ 3/16”) drill bit.

Insert the unit into the opening from the control cabinet front.

Use M4 x 15 screws, from the inside of the control cabinet, to fasten the E-CO Lineguard97 Controller.

Will damage the Lineguard 97 Controller housing if using screws longer than the suggested15 mm.


4.4. Dimensions, E-CO Lineguard 97 Controller & Wall Mounting Holes

4.5. Base Board (Main Mother Board)

4.5.1. Terminal Connection Diagram


4.5.2. Electrical Connections

4.5.2.1. Main Power SupplyUtility: 120 VAC 60 Hz, 1 phase

L1 – Line

N – Neutral

PE - Ground

4.5.2.2. Relay OutputsRelay No. Signal Description Terminal Position Contact type

1 Alarm output1 & 2 Normally Open

1 & 2a Normally Closed

2 Measurement (Control) Module 1(Switching Point 1)

3 & 4 Normally Open3 & 4a Normally Closed



All E-CO Lineguard 97 Controller relay contacts are potential-free contacts. If relayoutputs are also needed for measurement (control) modules 2 and 3, an additional relaymodule must be installed (See Section 4.6).

4.5.2.3. Current OutputsModule

No Signal Description Terminal Position

1 Measurement (control) Module 1 7 & 82 Measurement (control) Module 2 9 & 103 Measurement (control) Module 3 11 & 12

When Connecting the power outputs, pay careful attention to the correct polarity and themaximum load (600 ).

4.5.2.4. Serial OutputThis port is for Henkel use only. NO access is currently available.

4.6. 1739319 LG97 Relay Output Module

If two or three measurement (control) modules with relay outputs are being used, anadditional relay module can be installed in the Lineguard 97 Controller. This relay moduleprovides additional switching outputs.

Image to right is the electrical connections to the relay module.

20 21 21aRELAY 4

22 23 23aRELAY 5

24 25 25aRELAY 6

26 27 27aRELAY 7


4.6.1. Relay Module Outputs

Relay No. Signal Description Terminal Position Contact type

4 Measurement (control) Module 2(Switching Point 1)


5 NOT USED22 & 23 Normally Open




7 NOT USED26 & 27 Normally Open


All E-CO Lineguard 97 relay connections have a spark-quenching circuit through which aminimal residual current can flow, even if the contact is open.

4.7. Sensor Information and Connections

Module Sensor Wiring

1598683Meas. ModuleConductivityind.

689734SensorElectrodelessConductivity

1598685Meas. ModuleConductivitycond.

1997904Sensor ContactConductivity

1598684Meas. ModulepH

1598681Meas. Probe0-10pH HF res.

2028846Measuringmodule ORP0-1000mV

2028843ORP/RedoxCombinationElectrode


4.7.1. Sensor Immersion Installation Requirements

All Sensors

Locate a suitable location to measure representative sample of the bath. For immersionassembly, the location should be in the top of the process tank where the sensor immersionassembly can be placed without interference from piping or other obstacles. The immersionassembly must be capable of being lifted out of the process tank for maintenance. The sensorcable must not touch heated piping, nor may it be allowed to drape onto the top of the tankwhere it may be in contact with standing fluids. The location must not be near chemicaladditions, water additions, or heating coils; all of which will adversely affect both the quality ofthe control and the physical well-being of the sensor assembly. Do not mount on a removablelid, because the sensors must be moved as little as possible for the longest sensor life.

Drill a hole for the sensor to fit through in the top of the process tank at the chosenlocation.

Install the sensor in the process tank through the hole. Use the round stainless steel disk toadjust the depth of the sensor immersion.

Run the cable to the bottom of the Lineguard 97 controller and through it’s strain relief.

Tie the excess sensor cable into a loose loop with plastic cable ties and attach to anyconvenient, cool piping or brackets to hold the cable out of the way of maintenanceactivity on the tank.

Never cut or modify the sensor cable!

Attach the cable wires to the respective function module using the wiring diagrams shownin the section 4.7.1 “Sensor Electrical Connections to Each Style”.

If required, calibrate the sensor.

Do not use a new system to control a process until the system has been verified for properoperation to the chemical operator’s satisfaction, and then commence automatic control.

Electrodeless & Contact Conductivity

Immersion sensors must be located a minimum of 150mm off the bottom of the process tank.

Sensors typically fail after extended service or improper handling causing cracking and allowingsolution to enter the sensor housing and internal wiring. This requires replacement of entiresensor.

pH

pH sensors will degrade in normal service and periodic replacement of the pH sensor isrequired. 6 to 12 months is the expected life span for pH sensors in normal operation. Life spanis dependent on proper sensor care and operating conditions.

ORP

Platinum ORP sensors will degrade in normal service and require periodic replacement of etherthe electrode, filling solution, or both.

4.8. Start up

Before switching on the main voltage, check that the voltage matches the Lineguard 97Controller nameplate.


Once the operating voltage has been applied the Lineguard 97 Controller requires around5 seconds for the transient phase. Stable measured values can only be displayed after thetransient phase.

4.8.1. Typical Start-Up for measurement type

Electrodeless Conductivity

Adjust the bath to the required process titration.

Insert the sensor into the bath and adjust the set-point to the current value that thecontroller is reading.

Adjust the alarm limits to the desired values for High alarm (L+) and Low alarm (L-).Typically, alarms are set to ±10 mS from the set point.

Contact Conductivity

Adjust the bath to the required process titration.

Insert the sensor into the bath and adjust the set-point to the current value that thecontroller is reading.

Adjust the alarm limits to the desired values for High alarm (L+) and Low alarm (L-).Typically, alarms are set to ±1 uS from the set point.

pH

Insert the sensor into the bath and adjust the set-point to the desired pH value.

Adjust the alarm limits to the desired High alarm (L+) and Low alarm (L-). Typically, alarmsare set to ±2 pH from the set point.

ORP

Insert the sensor into the bath and adjust the set-point to the desired value.

Adjust the alarm limits to the desired High alarm (L+) and Low alarm (L-). Typically, alarmsare set to ±20 mV from the set point.

Initial operation / change or repositioning of measurement (control) modules will requiresystem configuration.

4.8.2. Configuration

Once the operational voltage has been applied, the 97 logowith the program version is displayed for 5 seconds.

4.8.3. Configuration Error

Upon the initial operation of the Lineguard 97 Controller orwhen measurement (control) modules are repositioned, thesystem displays a configuration error instead of themeasurement screen. Press ENTER key to acknowledge theerror.


4.8.4. Configuration Menu

Once the Message “Configuration Error” has beenacknowledged, the configuration menu opens. The E- COLineguard 97 Controller is configured from this menu (seesection 5.6). Choose “operator level” from the menu toreturn to the initial menu for the controller.

4.8.5. Initiation

Once the operation voltage has been applied, the MeasCon97 logo with the program version is displayed for 5 seconds.

4.8.6. Measurement Screen

Example when equipped with two measuring modules

Once 5 seconds have elapsed, the unit switches to theoperating level and the measurement screen appears(example to left).


5. Operation5.1. General notes for Operation

All configuration data, measurement and controller parameters can be accessed with the-key from the operator’s screen.

The last line in the respective setting menu shows the keys that effect the respectivecursor position.

Every set value can be changed directly at its position in the setting menu. The cursor mustbe positioned on the corresponding selection and can then be moved to the set value withthe -key. The keys are used to set one value from between specific limits. The valueis changed by one digit through pressing one of the two keys once. The value changescontinuously if the key is pressed for a longer period; the value at which point thecorresponding arrow key is released is the one that remains. The value is adopted throughoperating the ENTER key. The -key is used to cancel the respective setting.

If set values have changed, these are saved during the change to the operating level(measurement screen). Only the changed values are adopted.

All the controllers are turned off when adjusting the values in the configuration menu, i.e.fast processes can result in significant set point deviations during the adjustment phase.The effects of significant set point deviations must therefore be determined in advanceand suitable counter measures should be implemented if required.

The same applies when operating the device using "manual functions". Here too all controlsystem functions are switched off. The effects of manually operated pumps, valves etc. onthe process must be considered whatever the circumstances

5.2. Operating Flow Chart


5.3. Operating Level

Appears once operating voltage is applied

Display of current measured values

Display of Controller type

Display of Controller set point

Display of Controller status

Display of error messages

5.4. Main Menu

Accessed from the measurement level with the - key.

Access to the measurement parameter settings menu.

Access to the controller parameter settings menu.

Access to the Calibration menu.

Access to the Configuration menu.

Access to the manual functions.

5.5. Settings

5.5.1. Main Menu

The main menu for the adjustment of the MeasCon 97 isopened through operating the -key in the measurementmask (screen).

5.5.2. Measurement Parameter Settings

Adjustment of the module specific measurement parameters.

For a more detailed description, see Measurement Parameters – in the supplementmanual of the relevant measurement module.

5.5.3. Controller Parameter Settings

Adjustment of the module specific controller parameters.


5.5.4. Calibration

Module specific calibration routines.



5.6. Configuration

Select System Configuration through placing the cursor ontothe selected item “system” and operating the ENTER key.The system configuration menu is displayed on 2 pages.

5.6.1. Configuration System PAGE 1

The language in which the menus are to be displayed isselected through the language option.

Value range: German / English / French

language is active once it has been selected and acknowledged by pressing the ENTER key.The menu will be displayed in the selected language.

accesscode - function is used to safeguard write access to the settings. Value range:off / on

When acknowledging the on setting, the access code entry screen is activated. Seereference (access code Section 7.1.2).

temp. f. comp. - function (temperature path for temperature compensation) is used tospecify which module is to be supply the temperature for the automatic temperaturecompensation.

value range - individual / measuring module 1 / measuring module 2 / measuring module3. Individual setting means that every module carries out its own temperaturemeasurement for the respective temperature compensation of the measured value.

comparative pH – setting made for pH measurement is responsible for self-monitoring pHmeasurements.

value range - no comparison / 2 comparisons / 3 comparisons. The pH module on plug-inconnection 1 must have a controller identifier since only the controller from module 1 isused.

alarmrel inv - use alarmrel inv. (inverted) to change the mode of operation of the alarmrelay. If the mode of operation is not inverted (setting OFF), the alarm relay is activated inan alarm scenario; contacts 1 and 2 are closed. If the mode of operation is inverted (settingON), the alarm relay is deactivated in an alarm scenario; contacts 1 and 2a are closed. Withthis setting, a network failure on the unit can be detected (intrinsic safety).

config. Menu - opens the configuration menu.

Page 2 – function opens the second page of the system configuration menu.

5.6.2. Configuration System PAGE 2

The idle time function is used to specify the time that maypass between operating two keys before the measurementscreen is automatically opened again.


Value range: 1 min to 60 min

limit alarm delay - specifies the time (adjustable) at which an alarm message is issued aftera limit condition has been reached. Value range - 0 sec to 600 sec

limit alarm repetition - function is used to specify the time at which an acknowledged limitalarm message is issued again without leaving the limit condition area. Value range 0 minto 240 min, with off-option (no alarm repetition)

show control variable - used to enable the control variable of the selected PID controllersto be displayed in % instead of the relay line in the measurement mask.

Value range: Off / On

control variable indication - only active for PID controllers. The setting is not savedpermanently (The relay status line becomes active again after system rest or restart). Thedisplayed percentage can be used to adjust the PID parameters more accurately.

internal clock - set through the date/time option. The format of the date ismonth/day/year in two digits. After confirmation, the date/time it lasts about 2 sec. totake over the setting. After takeover of the date/time the input-cursor will be positionedon the date/time selection.

Value ranges: Date: 01/01/00 to 12/31/99 Time: 00:00 to 23:59

Initial operation / change or repositioning of measurement (control) modules will requiresystem configuration.

config.-menu – Opens the configuration menu.

Page 1 – function opens the first page of the system configuration menu.

5.6.3. Configuration Module

Select Modul configuration through placing the cursor ontothe selected item “modul” and pressing the ENTER key.

For a more detailed description, see Measurement Parameters in the supplement manualof the relevant measurement module.

5.6.4. Manual Functions

Before Activating an output, it must be ensured that no danger is posed to other personsthrough activation of pumps, valves, etc.

Relay output test functions.

Current output test functions.

The following manual functions can be selected from the main menu to inspect theoutputs of the E-CO Lineguard 97 Controller and downstream units.


Main Menu

The following screen appears:

To activated relay outputs, position the cursor on the corresponding point of the relay numberin the relay output line; start left with relay 1. The output can be activated or deactivated bypressing the ENTER key. The activated state is indicated by the display of the relay number.The output remains activated until it is deactivated via the ENTER key or until the cursor isplaced on the relay output selection.

To inspect the current outputs, the corresponding current output number in the currentoutput line must be selected. The maximum output current of this current output is switchedthrough operating the ENTER key. It remains activated as long as the ENTER key is operated.The minimum current of this current output can also be selected on this screen. The status ofthe active current output value is displayed.

Current Output

The return function selection option is used toopen the manual function selection screen.


6. Control Operation6.1. General

Each individual measuring module can be assigned a unique control response in theconfiguration level. In the fully assembled version it is possible to support up to 3 differentcontrollers on a single unit.

It is recommended to enter a value unequal 0 (zero) for all adjustable values to reduce theswitching frequency of the corresponding control relay.

6.2. Signal Unit

The signal unit is a so-called “Set-point controller” which switches exactly at the set-point (orat the hysteresis value), opposite to the 2-state controller which operates by clocking.

The control state is directly dependent of the variable being measured. There is thus only aproportional behavior.

The second switching point is entered relative to the first. For each switching point it ispossible to enter a hysteresis.

6.3. Parameters Setpoint

Set-point (W): Set-point value lies within the measuring range (including switchingpoint 1).

Switch difference (XSd): Switching hysteresis around the set-point value; the percentagerelates to the set-point value (Note Not used see Switch Delay Times).

Set-point difference (LW): Distance between switching point 2 and the set-point value.Given in positive and negative values; can also be given as absolute values. (Note Not usedsee).

Switch difference (X2Sd): Switching hysteresis of switching point 2; percentage relates tothe absolute value of switching point 2. (Note Not used).

Switch- delay time on: The relevant relay is switched on when the actual value falls below(positive control direction) or exceeds (negative control direction) the set-point value.(Note Used as hysteresis parameter).

Switch- delay time off: The relevant relay is switched off when the actual value exceeds(positive control direction) or falls below (negative control direction) the set-point value.(Note Used as hysteresis parameter).


6.4. Switching Performance

When the switching point interval is negative (LW), switching point 2 comes to rest at the leftof the set-point value.

6.5. Limit-Contact

The “limit contact” function is not a control function, but a means of monitoring statedeviation.

The alarm message resulting from a too large state deviation is displayed via the relayoutput 1 (terminals 1 and 2) and is shown on the display as plain text.

The switching points, L- (lower limit) and L+ (upper limit) must be set independently of theset-point value of the feedback control (absolute values).

In addition to this, the switching points are assigned a hysteresis characteristic which itselfare independent of the control.

6.6. Parameters Limit

Limit contact (L-): Lower alarm limit - adjustable as an absolute value within the measuringrange.

Limit contact (L+): Upper alarm limit - adjustable as an absolute value within themeasuring range.

It is essential to ensure that L- is adjusted smaller than L+.

Switch difference (X2Sd): To be adjusted in %. The difference is calculated as a function ofthe switching points, L- and L+.

The display will show the type of alarm used. The alarm output can be switched off bypressing the “ENTER” button or, depending on the setting, can be acknowledgedautomatically if the relevant measured value has moved out of the limit area again.

Switching performance


7. Additional Operation Functions7.1. Access Protection

The access code function can be used to protect the set configuration data and parameters ofthe E-CO Lineguard 97 Controller against unauthorized

changes. The access code is a four-digit, alphanumerical string of characters that are requestedevery time the setting menu is accessed.

The settings for the access code are in the system configuration.

7.1.1. System Configuration PAGE 1

SettingsOFF: The setting menus are not protected by accesscode.ON: The settings menus are protected by accesscode.ON (no cal.): The settings menus are protected byaccess code apart from the calibration.

The access code can be entered once the “on” setting in the system configuration has beenacknowledged. The input screen for the access code is displayed automatically.

7.1.2. Access Code Input

The last access code that has been assigned isautomatically displayed. This access code can bechanged. The values of the respective positions canbe changed with the keys.

The position that is to be changed can be accessed with the cursor through operating the keys.

Once the set access code has been adopted through operating ENTER, the systemconfiguration menu is displayed again.

7.1.3. Protective Mechanism

Every setting menu is protected if the access codeoption is used. If for example, the measurementparameters of module 1 are to be changed, theaccess code is requested after selecting module 1 inthe measurement parameter module selectionmenu.

0000 - is the standard display of the access code. The access code can be changed. The orcan be used to change the value of the corresponding position. The keys are used to

access the position that is to be changed with the cursor. The entered access code is comparedto the saved value through operating ENTER. The menus can be accessed without restrictions ifthe two passwords match. If additional changes in other modules are required, the password is


not required anymore for this level. The access code is only requested again when theparameter level is changed

7.1.4. Password Error Message

The following message is displayed on the screen ifdifferences between the entered and the savedaccess code have been established when a passwordhas been requested.

7.1.5. Measurement Parameters

Although the next setting menu can be viewedthrough operating ENTER it is protected againstchanges. The status of protected pages is signaledthrough a little lock in the left-hand top corner.

While working in this mode, the access code is constantly requested, even when working onone and the same level.

The configuration data and the reset functions are also protected with access codes per thesame principle.

A calibration cannot be carried out without an access code.

7.1.6. Use of Master Code

If access protection is cancelled using the mastercode, this lack of protection is indicated by a key andexplanation mark in the last row of the displayscreen.

The lack of protection icon can only be removed by confirming the original access code.

7.1.7. Reset

Performing a reset will reset all configuration parameters for all channels. Insure that youknow all configuration parameters for this controller before performing a reset.

The reset function can be used to rectify possible sporadic malfunctions of the E-CO Lineguard97 Controller through restarting the E-CO Lineguard 97 Controller or resetting measuringmodules to their initial state.

The key combination , , and ENTER in the measuring screen must be operated for 5seconds in order access the reset menu. The following options are then displayed.


7.1.7.1. Reset Option Menu

To reset the standard values of a correspondingmodule, the module must be selected from theoptions and the selection must be acknowledgedwith ENTER.

The standard data is then adopted by the module and saved.

7.1.8. Adoption of Standard Values for Measuring Module X

The MeasCon 97 logo appears after a short periodand operating can commence again.

The MeasCon 97 restarts once the saving process iscompleted.

To trigger only one restart of the MeasCon 97 while operating (warm start) the menu itemsystem in the reset options must be operated.

7.1.9. Multiple pH Measurement

This option is not utilized with this controller and this configuration.

7.1.9.1. System Configuration PAGE 1

Settings

No comparison: every pH measurement individually(Default setting).


8. TroubleshootingOnly qualified personal shall be carrying out repair and maintenance work.

Always wear required personal protection equipment.

Opening covers or removing parts may expose live (electrical) connections.

8.1. Display Blank After Turning ON Power

POSSIBLE CAUSE REPAIRBlown Fuse Locate cause and perform necessary correctiveactions.

Then Replace Fuse.No Supply Power Measure input power and trace tosource.Ribbon Cable Connection Loose Remove and reseat connector.Contrast of LCD display toodark or light

Adjust contrast potentiometer on processor board located onrear of lid.

Defective Power Supply Unit Return entire unit to Henkel for repair.Processor PC-board defective

8.2. Configuration Error After Turning ON Power

POSSIBLE CAUSE REPAIRExisting modules andconfiguration do not match

Check configuration and modules. Press to reconfigure.

8.3. Display Value Remains Zero Despite Altered Conductivity Value

POSSIBLE CAUSE REPAIRConductivity cable connectionto sensor not correct or broken

Inspect cables and establish connection.

8.4. Display Value Unstable

POSSIBLE CAUSE REPAIRConductivity – air in water Move sensor to location without air bubbles. Position

sensor so that it doesn’t trap air.pH/ORP – Defective Sensor orCables

Replace sensor or cables

All Sensors – faulty shieldconnection

Replace cable or improve shield connection.

8.5. Error Message “Plausibility Error” During Calibration.

POSSIBLE CAUSE REPAIRWrong calibration solutions Use correct buffer or standard solutions.Measurement system toosluggish – times out

See error description “Display Too Sluggish”


8.6. Error Message “Timeout” During Calibration

POSSIBLE CAUSE REPAIRCalibration procedurefollowed too slowly

Increase speed following procedure.

Measurement system toosluggish – times out

See error description “Display Too Sluggish”

8.7. Display Value Fails to go to Value of pH Buffer Solution WhenCalibrating

POSSIBLE CAUSE REPAIRpH electrode has degraded Replace pH electrode.Reference electrode hasdegraded

Replace reference electrode.

8.8. Display OK in Buffer Solution; Measured Value Changes inMeasured Solution

POSSIBLE CAUSE REPAIRSignal output circuit (4-20 mA) Check signal output for ground loops.

8.9. Display Remains Constant Despite Altered pH Value

POSSIBLE CAUSE REPAIRIf pH ~7, short circuit inelectrode lead or moisturetrapped in the plug-inconnections

Inspect Electrode connectors and cable for moisture.Replace if necessary.

If pH = 5 and unchanging, glasselectrode may be broken

Replace glass pH electrode.

8.10.Display Remains Constant Despite Altered Conductivity Value

POSSIBLE CAUSE REPAIRIf pH = 5 and unchanging, glasselectrode may be brokenReplace glass pH electrode.

Inspect cable at connectors and check for moisture. Clean,dry and reconnect.

8.11.Display Too Sluggish

POSSIBLE CAUSE REPAIRMeasuring lead too long If possible, reduce sensor cable length.


9. Care and MaintenanceOnly qualified personal shall be carrying out repair and maintenance work.

Always wear required personal protection equipment.

Opening covers or removing parts may expose live (electrical) connections.

9.1. Sensor & Module Service

For detailed maintenance and repair work on probes, follow separate sensor instructions inthe supplement packages.

9.2. Setting the Display Contrast

The contrast of the back-lit display depends on the viewing angle and the operatingtemperature. In very poor conditions it is possible that there is very little contrast (highoperating temperature, flat viewing angle). In these cases, it is possible to adjust the contrastusing a potentiometer on the display board.

The Unit is connected to power.

Loosen the 4 cover screws and open the housing.

Adjust contrast potentiometer (P1) on the display board.

Close and fasten housing cover.

For following operations, the power must be disconnected from the unit. Strictly followall safety requirements.

9.3. Replacing the Main Power Fuse (F1)

The main power fuse (F1) is located on the mother board left side above the power terminals.

Disconnect power


Replace fuse (F1), see section 4.5.


Connect power.

When closing the housing, ensure that the seal is not damaged and that it is sitting exactlyin the seal groove.

9.4. Replacing a Module

When inserting a new module, take care to ensure that all the pins are lined up with the socketpositions

Disconnect power


Loosen and remove the fastening screw in the center of the module.

Remove the module.


Insert the new module. Make sure pins line up with socket positions.

Insert and tighten the module fastening screw.


Connect power.

Perform configuration, parameter assignment and calibration steps.

9.5. Replacing the Door

Disconnect power


Unplug the ribbon cable to the base board (door). (Note: remove the relay board to getaccess to the ribbon cable plug).

Carefully lift the hinge pins from the base unit.

Remove the door stop strap.

Insert new door (Note: carefully push the hinge pins into the base unit).

Install the door stop strap.

Plug in the ribbon cable to the main board.

Replace the relay board (make sure the pins line up and insert with socket positions).

Insert and tighten the relay board fastening screws.


Connect power.

Perform configuration, parameter assignment and calibration steps as needed.

9.6. Replacing the Base Board

Disconnect power


Remove the measuring module(s) (see section 9.4).

Unplug the ribbon cable to the door assembly.

Remove the base board fastening screws.

Remove the board.

Insert the new board.

Replace and tighten the bas board fastening screws.

Plug in the ribbon cable to the door assembly.

Insert measuring module(s) (see section 9.4)


Connect power.

Perform configuration, parameter assignment and calibration steps as needed.


10. Accessories and Spare Components10.1. Accessories

Part No. Description694706 Sensor Electrodeless Conductivity Immersion1598681 Meas. Probe 0-10pH HF res.1598677 Calibration box Cond. probes1598678 Calibration box Induct. probes689742 Coaxial cable mt. 15689734 Sensor Electrodeless Conductivity2028843 ORP/Redox Combination Electrode1598682 Conductivity probe PVC f.f.2028841 Temperature sensor Pt 100694708 Flow probe P.P.1786902 Contact cond. immersion probe

10.2. Measurement Modules

Part No. Description1598685 Meas. Module Conductivity cond.1598683 Meas. Module Conductivity ind.1598684 Meas. Module pH1598681 Meas. Probe 0-10pH HF res.2028846 Measuring module ORP 0-1000mV2028847 Temperature Measurement Module


11. LG97 Wiring Diagram


12. WarrantyHenkel expressly warrants that all products referred to in this Instruction Manual for(IDH # Bonderite® process controller) (hereafter called “Products”) shall be free fromdefects in materials and workmanship.Liability for Henkel shall be limited, as its option,to replacing those Products which are shown to bedefective in either materials orworkmanship or to credit the purchaser the amount of the purchase price thereof (plusfreight and insurance charges paid therefor by the user). The purchaser s sole and exclusiveremedy for breach of warranty shall be such replacement or credit.

A claim of defect in materials or workmanship in any Products shall be allowed only whenit is submittedin writing within one month after discovery of the defect or after thetime the defect should reasonablyhave been discovered and in any event, within (12)months after the delivery of the Products to thepurchaser. This warranty does notapply to perishable items, such as (indicate items: fuses, filters, lights,etc.). No such claimshall be allowed in respect of products which have been neglected or improperlystored, transported, handled, installed, connected, operated, used or maintained. In theevent ofunauthorized modification of the Products including, where products, parts orattachments for use inconnection with the Products are available from Henkel, the useof products, parts or attachments whichare not manufactured by Henkel, no claim shallbe allowed.

No Products shall be returned to Henkel for any reason without prior written approvalfrom Henkel.Products shall be returned freight prepaid, in accordance with instructionsfrom Henkel.

NO WARRANTY IS EXTENDED TO ANY EQUIPMENT WHICH HAS BEEN ALTERED, MISUSED,NEGLECTED, OR DAMAGED BY ACCIDENT.

EXCEPT FOR THE EXPRESS WARRANTY CONTAINED IN THIS SECTION, HENKEL MAKES NOWARRANTY OF ANY KIND WHATSOEVER, EXPRESS OR IMPLIED, WITH RESPECT TO THEPRODUCTS.

ALL WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, ANDOTHER WARRANTIES OF WHATEVER KIND (INCLUDING AGAINST PATENT OR TRADEMARKINFRINGEMENT) ARE HEREBY DISCLAIMED BY HENKEL AND WAIVED BY THE PURCHASER.

THIS SECTION SETS FORTH EXCLUSIVELY ALL OF LIABILITY FOR HENKEL TO THE PURCHASER INCONTRACT, IN TORT OR OTHERWISE IN THE EVENT OF DEFECTIVE PRODUCTS.

WITHOUT LIMITATION OF THE FOREGOING, TO THE FULLEST EXTENT POSSIBLE UNDERAPPLICABLE LAWS, HENKEL EXPRESSLY DISCLAIMS ANY LIABILITY WHATSOEVER FOR ANYDAMAGES INCURRED DIRECTLY OR INDIRECTLY IN CONNECTION WITH THE SALE OR USE OF, OROTHERWISE IN CONNECTION WITH, THE PRODUCTS, INCLUDING, WITHOUT LIMITATION, LOSSOF PROFITS AND SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, WHETHER CAUSED BYNEGLIGENCE FROM HENKEL OR OTHERWISE.

Documents

Operating Manual - en · Operating Manual Page 8 2. Description Lineguard 97 Controller is a stand-alone process control unit designed for the control and monitoring of cleaners,