Product positioning

Product type: Differential input active probe, model 702928 (PBD0200), needs to be used in conjunction with an oscilloscope for observing and measuring electrical signals, and cannot be used for other purposes.

Core advantages: Bandwidth coverage from DC to 200MHz, excellent common mode rejection capability, and support for direct observation of differential signals; Equipped with a Yokogawa dedicated probe interface, it can automatically detect and supply power through the interface when connected to a compatible oscilloscope.

Applicable scenario: It needs to be used with an oscilloscope with a Yokogawa probe interface (specific compatible oscilloscope models can be consulted with Yokogawa distributors), suitable for signal measurement in industrial environments, and belongs to Class A products (may cause radio interference when used in residential areas, users need to solve it themselves)

Packaging content and accessories

1. Standard Packaging List

Core equipment: differential probe unit (702928), portable case, supporting manual (see the “Supporting Manual” table above).

Standard accessories: The quantity and type of accessories are fixed, and standard accessories are not covered by the warranty of this instrument.

Number, accessory name, quantity

1 10cm wire pair (red/black) 2 sets

2 sets of crocodile clip wires (red/black)

3 micro clips (red,+) 1 piece

4 micro clips (black, -) 2 pieces

5 spring type straight needles, 4 pieces

6 spring type bent needles, 4 pieces

7 grounding extension wires, 2 pieces

2. Optional accessories (sold separately)

Additional accessories such as wires, pins, and fixed covers can be purchased. Some popular accessory information is as follows:

Number, accessory name, part number, quantity (single purchase specification)

1 10cm wire pair (red/black) B8099KU 5 sets

8 5cm wire pair (red/black) B8099KV 5 sets

9 straight needles B8099DL, 10 pieces

13 fixed covers B8099KY 2 pieces

Safety operation standards

1. Core Warning

Usage restrictions: Can only be used with oscilloscopes with Yokogawa probe interfaces, and it is necessary to confirm that the oscilloscope is labeled as “can connect to this probe”; Only use standard or official separately sold accessories.

Voltage limit: The maximum voltage between input and ground is ± 60V DC, ± 42V ACpeak; When the signal frequency increases, it needs to be derated for use (such as ACpeak maximum 30V at 200MHz, see “Product Specifications – Input Voltage derating” for details); The upper limit of non-destructive voltage for short-term (<5s) is ± 100V (DC+ACpeak), and normal use must comply with safety standard restrictions.

Connection sequence: When using, connect the oscilloscope first, and then connect the device under test; After use, disconnect the device under test first, then disconnect the oscilloscope, and ensure that the device under test is powered off when disconnecting.

Anti electric shock measures: Do not operate with wet hands or use the probe when it is damp; Avoid contact with exposed circuits and remove metal jewelry such as watches and rings before operation; Prohibited for use in flammable/explosive gas environments.

Troubleshooting: Stop using the probe immediately if suspected of damage (such as damaged signal lines or exposed metal), and contact the Yokogawa dealer; Disassembling or modifying the probe is prohibited, otherwise Yokogawa will not be held responsible.

2. Precautions (CAUTION)

Product features: Non dustproof and waterproof design, not suitable for use in dusty or near water environments; Not designed for long-term high reliability scenarios and not suitable for fields with extremely high stability requirements.

Environmental requirements: The operating/storage environment must comply with specifications (operating: 5-40 ℃, 20%~80% RH non condensing, altitude ≤ 2000m; storage: -30~60 ℃, 20%~80% RH non condensing, altitude ≤ 3000m), avoid direct sunlight, high temperature and humidity, or condensation to prevent deformation and insulation degradation.

Operation details: Wipe with a soft cloth during cleaning. Do not immerse the probe in liquids, and do not use abrasives or volatile solvents such as benzene; Avoid vibration, impact, and static electricity during operation, and do not excessively bend/pull cables.

Grounding requirements: The oscilloscope protection grounding terminal must be grounded; When measuring floating circuits, grounding terminals should not be used, only common grounding should be used, otherwise it may damage the measurement system or the tested equipment.

Usage method

1. Operation process

Prepare the probe and compatible oscilloscope, match accessories (such as wires and pins) according to the tested device and environment, and connect them to the probe head signal input terminal.

Insert the probe output connector into the oscilloscope input terminal and install it in place upon hearing the locking sound; The oscilloscope will automatically detect the probe and set the input coupling. If it is not set automatically, it will be manually adjusted.

Connect the probe head to the device under test, preheat for at least 30 minutes after powering on (the probe’s own heating can cause offset voltage drift, which stabilizes after preheating), and adjust the offset voltage if necessary.

2. Key points for using accessories

Wire selection: A 10cm wire pair (including a 150 Ω damping resistor) is suitable for low-frequency signals, while a 5cm wire pair (including a 100 Ω damping resistor, sold separately) is more suitable for high-frequency signals; The crocodile clamp wire pair can directly clamp the measured point.

Pin selection: Spring type straight/bent pin (standard accessory), straight/bent pin (sold separately) suitable for high-frequency signals, need to be selected according to the pin position and status of the tested device.

Grounding extension cable: Only when measuring low-frequency signals, connect the probe grounding terminal to the common grounding of the tested equipment to reduce noise. It can be directly connected to a 0.64mm square or a Φ 0.65mm round pin.

3. Offset voltage adjustment

Adjustment timing: Adjust when there is still residual offset voltage after preheating, using an appropriate screwdriver (thickness 0.2-0.35mm, width 1.3-1.5mm, flat or cross).

Operation precautions: Do not apply excessive force to avoid damaging the internal variable resistor; Only used to adjust residual offset voltage, cannot be deliberately changed for other purposes, otherwise it may cause the probe to not meet specifications; Environmental temperature changes can affect offset voltage, and temperature should be taken into account during continuous measurements.

4. Custom extension cord production

Material preparation: Contact points, heat shrink tubing, flanged pins, fixed covers, and user provided wires (recommended AWG 24-26, maximum diameter 2.0mm) and damping resistors (optional) need to be purchased separately.

Production steps:

Thread the wire into the contact heat shrink tube, crimp/weld the wire core to the contact (connect in series when inserting the resistor), and heat the heat shrink tube to fix it.

The other end of the wire is threaded into the user’s own heat shrink tubing and welded to the flanged pin. The heat shrink tubing is fixed (note that the tip of the pin cannot be welded within 4mm, and the diameter after heat shrink is ≤ 2.0mm).

Thread the flanges of the two input pins through the center hole of the fixed cover, align the probe head with the “+/-” mark, and install the fixed cover to ensure that the buckle is locked; Do not use the probe grounding terminal when using a fixed cover.

Product specifications

1. Electrical specifications (for use with a 50 Ω input resistance oscilloscope)

Project specifications

Frequency bandwidth (-3dB) DC to 200MHz

Attenuation ratio 10:1

DC gain accuracy (23 ± 5 ℃, preheating for 30 minutes+) ± 1% (when single ended input is 0V); Dual ended input without specifications due to CMRR characteristics

Differential input voltage range (+/- between terminals) ± 20V (DC+ACpeak)

Common mode rejection ratio (CMRR) DC: -80dB; <60Hz：-80dB； <100kHz：-70dB； <10MHz：-50dB； <100MHz: -20dB (typical value)

Input equivalent noise ≤ 4mVrms (typical value)

Input capacitance (to ground) 2pF (typical value)

Input resistance (to ground) 500k Ω (typical value)

Output resistance 50 Ω (typical value)

Rise/fall time 1.75ns (typical value)

Delay time 8.4ns

Preheating time ≥ 30 minutes

2. Input voltage derating (by frequency)

When the signal frequency increases, the maximum input voltage needs to be reduced, and the derating requirements of DC+ACpeak and ACpeak need to be met simultaneously:

Frequency maximum input voltage (DC+ACpeak) maximum input voltage (ACpeak)

DC~10MHz 60V 42V

10~151.6MHz decreases from 60V to 30V with increasing frequency, from 42V to 30V with increasing frequency

151.6~200MHz 30V 30V

3. General specifications and compliance

General specifications:

Project specifications

Power supply voltage ± (12.0 ± 0.6) V (powered by compatible oscilloscope interface pins)

Power consumption ≤ 200mA

Recommended calibration cycle of 1 year

Output connector type Yokogawa dedicated probe interface

Dimensions of the head unit: 26 (H) × 89.5 (W) × 12.6 (D) mm; Interface unit: 29 (H) × 108.1 (W) × 24 (D) mm

Weight approximately 90g

Compliance standards:

EMC standard: emission complies with EN 61326-1 Class A Group 1; The anti-interference degree complies with Table 2 of EN 61326-1 (note: strong electromagnetic field environments such as transformers, high current circuits, and near wireless devices may affect measurement accuracy).

Environmental standards: compliant with the EU RoHS directive; Environmental regulations in other regions require consultation with the local Yokogawa office.

Disposal: It is necessary to comply with the laws and regulations of the country/region where the product is disposed of; EU/UK must handle according to the WEEE directive and cannot mix with household waste. Contact the local Yokogawa office.

Basic Information and Security Standards

1. Document scope and supporting materials

Applicable equipment: AXW series electromagnetic flowmeter (integrated+remote sensor), paired with AXW4A/AXG1A/AXFA11G remote transmitters, supporting multiple communication protocols such as BRAN, HART, Modbus, FOUNDATION Fieldbus, PROFIBUS PA, EtherNet/IP, etc.

2. Core security principles

The document clearly identifies risks through four levels of Warning, Caution, Important Notice, and NOTE, and the key safety requirements are as follows:

Personnel qualifications: Installation, wiring, and maintenance must be carried out by professional engineers or skilled personnel, and ordinary operators are prohibited from participating.

Electrical safety: Power off and wait for at least 20 minutes before wiring; The power supply voltage needs to match the rated value of the equipment (AC 100-240V/24V, DC 100-120V/24V); Unused cable entrances need to be sealed with dedicated plugs to avoid failure of protection level.

Explosion proof requirements: Explosion proof equipment requires additional reading of the corresponding explosion-proof manual (such as ATEX/IECEx/NEPSI certified version), and grounding must comply with the requirements of the explosion-proof system to avoid the generation of mechanical sparks.

Static electricity protection: Equipment components are susceptible to static electricity damage, and anti-static wristbands should be used during operation. Direct contact with circuit components is prohibited.

Environmental restrictions: ambient temperature -10~60 ℃ (refer to special manual for explosion-proof type), humidity 0~100% (avoid long-term high humidity of 95% or more); Avoid corrosive gases (such as H ₂ S, SO ₓ), strong vibrations, and direct sunlight.

Reception and Storage

1. Arrival inspection

Appearance and accessory verification: Upon arrival, visual inspection of transportation damage is required to confirm the standard accessories according to the model (as shown in the table below). If missing, please contact Yokogawa in a timely manner.

|Equipment type | Standard accessories (example) | Quantity|

|Integrated flowmeter | centering device, plug, cable sealing sleeve | 1 set/0-2 pieces/0-3 pieces|

|Remote Sensor | Centering Device, Cable Sealing Sleeve, Special Double Headed Bolt (Specific Model) | 1 set/0-2 pieces/2 pieces|

|Remote transmitter (such as AXW4A) | Installation bracket, plug, cable sealing sleeve | 1 set/0-2 pieces/0-5 pieces|

Model and specification confirmation: Verify the model, serial number, instrument coefficient, fluid specifications, etc. through the equipment nameplate (as shown in Figure 2.1-2.5) to ensure consistency with the order; The nameplate information can also be viewed through the parameter menu (refer to the corresponding communication type manual).

2. Storage requirements

Packaging: The original packaging should be retained for long-term storage, and the PTFE lining model should retain the accompanying particle board until it is removed before installation.

Environment: Storage temperature -10~70 ℃, humidity 5~80% RH (non condensing), preferably 25 ℃, 65% RH environment; Avoid exposure to rain, vibration, and impact, and install as soon as possible after transportation to the installation site to prevent rainwater infiltration.

Installation process and requirements

1. Preparation before installation: pipeline design principles

Requirements for straight pipe section: It must meet JIS B 7554 standard. The length of the upstream straight pipe section should be 5D~10D (D is the sensor diameter) depending on the upstream pipe fittings, and 2D~3D (as shown in Figure 3.1.1) downstream to avoid uneven flow distribution affecting measurement.

Fluid conditions: The pipeline should always be filled with liquid (when installed vertically, the fluid flows from bottom to top) to avoid bubbles (valves should be installed downstream first to prevent negative pressure from generating bubbles); The injection point of chemical agents should be downstream of the flow meter. If it is necessary to reserve a straight pipe section of more than 50D upstream to ensure uniform mixing.

Anti interference: Keep away from power equipment such as motors and transformers; The distance between multiple electromagnetic flow meters should be ≥ 5D (taking the larger diameter D); To avoid pipeline misalignment and tilting (as shown in Figure 3.2.2), new pipelines need to be flushed to remove foreign objects such as welding slag and sawdust.

2. Installation of sensors and transmitters

(1) Integrated/remote sensor installation

Classification installation:

**Wafer type (25-200mm) * *: It is necessary to use a centering device to ensure concentricity, and the bolt torque should be based on the flange grade (such as JIS 10K, ASME Class 150) according to Table 3.3.2; 50mm/2-inch submersible JIS 20K wafer requires special double headed bolts.

Flange type (25-450mm): The gasket needs to be provided by the user (except in special circumstances), and the use of wrapped gaskets is prohibited; Attention should be paid to avoiding negative pressure for PTFE lining models, and uneven force on the lining should be prevented during installation (refer to Table 3.3.6-3.3.7 for torque values).

Grounding requirements: The protective grounding resistance should be ≤ 100 Ω (Class D), and the lightning protection requirement should be ≤ 10 Ω (Class C); Metal pipelines should be connected to sensor flanges through grounding rings or grounding wires first, while plastic pipelines must use grounding rings.

(2) Remote transmitter installation

Installation location: Avoid direct sunlight and ensure that the environment meets temperature/humidity requirements; AXW4A can be installed vertically/horizontally on 2-inch pipes, while AXG1A/AXFA11G supports surface mounting, 2-inch pipe mounting, and panel mounting (must meet load-bearing requirements: AXG1A 3.5kg, AXFA11G 3.4kg, and the bracket needs to withstand 4 times the weight).

Direction adjustment: The cable entry direction (non submersible/DHC type) can be rotated by -90 °/+90 °/+180 °, and the display screen direction can be rotated clockwise by 90 ° (the cover plate needs to be removed, pay attention to protecting the threads and O-ring).

3. Gasket selection and size

Core requirement: The inner and outer diameters of the gasket must not extend into the pipeline to avoid fluid leakage or affect measurement; Different linings (such as natural hard rubber, PTFE, polyurethane rubber) need to be matched with corresponding hardness gaskets (such as non asbestos gaskets, PTFE coated gaskets), with thickness reference to Tables 3.3.1/3.3.4.

Size inquiry: The user’s pipeline gasket size should refer to Table 3.3.8, specifying the effective sealing inner diameter (ø A) and recommended gasket inner diameter (ø C/ø D) corresponding to different linings and connection types (wafer/flange).

Wiring specifications

1. Preparation before wiring

Cable requirements:

Excitation/power/IO cables: JIS C 3401 control cables and JIS C 3312 power cables are recommended, with a wire diameter of 0.5~2.5mm ² (single strand)/0.5~1.5mm ² (multiple strands), and the outer diameter needs to match the cable sealing sleeve (such as waterproof sealing sleeve compatible with 7.5~12mm).

Special signal cable (AX01C): Double shielded structure, with a maximum length of 200m when paired with AXG1A/AXFA11 and 100m when paired with AXW4A. Cutting or splicing is prohibited, and excess length must be cut off.

Protective measures: When the ambient temperature is above 50 ℃, cables with a temperature resistance of 70 ℃ or above are required; Power and signal cables need to be separately threaded through steel conduits (excluding 24V power supply and 4-core cables); Explosion proof wiring must comply with the corresponding explosion-proof standards.

2. Wiring operation

Power wiring: DC power supply should pay attention to the positive and negative poles (L/+connected to the positive pole, N/- connected to the negative pole), and 24V models should not be connected to 100-240V power supply; 15A external switch/circuit breaker needs to be installed and labeled as “power-off equipment”.

Grounding Wiring: The protective grounding wire requires a 600V ethylene insulated cable, and the terminals require circular crimping terminals (M4 screws) with insulation covers to ensure reliable connection; Remote type requires separate grounding sensors and transmitters.

Cable entrance sealing: Unused entrances need to be sealed with dedicated plugs, waterproof sealing sleeves need to be evenly tightened (to avoid damaging the cable due to over tightening), and vertical conduits need to be equipped with drainage valves at the low end and regularly drained.

3. Communication and IO wiring

Communication protocol wiring: Modbus requires 3-core shielded wire (AWG24 or above), FOUNDATION Fieldbus/PROFIBUS PA requires Type A cable, EtherNet/IP requires CAT5e or above shielded twisted pair (without protective cover).

IO signal wiring: current output (4-20mA), pulse output (maximum 10000 pulses/second), status input (no voltage contacts), etc. need to be wired according to the terminal configuration table (such as 4.4.4/4.5.2) to ensure galvanic isolation (input/output/power circuits are isolated from each other).

Basic operations and parameter settings

1. Operation method

Display screen operation: Operated through three infrared (IR) buttons ([SET], [SHIFT], [▼]), supporting parameter viewing/modification, zero point adjustment, etc; The default display language is English, which can be switched through “Device setup ► Language” (supports multiple languages such as Chinese, French, German, etc., depending on the display code).

Operation level: divided into three levels: Operator (no password required, only basic display settings), Maintenance (maintenance personnel, password required, including zero adjustment), Specialist (expert, password required, full parameter settings), default password “0000”.

2. Key operational procedures

(1) Mode switching: Display mode → Set mode

Long press [SET] for a few seconds, touch [FFT]+[INC];

Select “Yes” with [INC], double-click [SET] to confirm;

Select the operation level, enter the corresponding password (Maintenance/Specialist requires password), and enter the “Device setup” menu.

(2) Example of Parameter Setting

Flow unit setting (optional parameter): Path “Device setup ► Detailed setup ► Pro var ► Volume ► Unit/Time Unit”. If setting “l/min”, select “l (lite)” (physical unit) and “/min” (time unit) respectively.

Flow range setting (numerical parameter): Path “Device setup ► Detailed setup ► Pro var ► Volume ► Span”, the unit needs to be set first, and the range value will be automatically converted with the unit.

Tag number setting (alphanumeric parameter): Path “Device setup ► Detailed setup ► Device info ► Order info ► Tag No.”, maximum input of 8 ASCII characters.

(3) Pre operation Zero Adjustment

Prerequisite: The sensor is filled with fluid and the flow rate is 0 (with the valve closed). For the FILDVUE/PROFIBUS PA type, all sensor blocks must first be set to “O/S” mode.

Operation path: “Device setup ► Diag/Service ► Autozero ► Execute”. Double click [SET] to start, taking about 30 seconds. After completion, check the “Result ► Zero value” to confirm the result (exceeding 10cm/s will trigger a warning “092: AZ warning”).

3. Use of configuration tools

BRAN/HART: Connected through BT200 or FieldMate, it needs to be parallel in a 4-20mA circuit, with load resistance ≥ 250 Ω/230 Ω respectively.

Modbus/FOUNDATION Fieldbus/PROFIBUS PA: Corresponding DTM (such as AXW4A Modbus DTM 1.1.4.0 or above) is required, and FieldMate needs to be upgraded to the corresponding version.

EtherNet/IP: Supports web configuration (requires IE8+/Chrome/Edge browser), requires installation of corresponding EDS file (supplier ID 250, product code 206).

Operation and maintenance

1. Hardware switch settings

Burnout switch: When the CPU fails, the current output direction defaults to a high value (>21.6mA), and when C1/C2 is installed, a low value (<2.4mA) is set.

Write Protect: To prevent parameter tampering, rewriting is prohibited when the hardware switch is set to “ON” (in conjunction with software write protection).

Address switch: Modbus (1-127), PROFIBUS PA (0-126), EtherNet/IP (set IP segment 4) need to be set through 8-bit dialing, and priority is controlled by the SW3-1 switch.

Terminal resistor switch (SW2): A 150 Ω terminal resistor (SW2-1/SW2-2 both “ON”) is required at both ends of the Modbus bus.

2. Correction factor setting (for specific flanges)

Applicable scenarios: When using 40-125mm wafer type and specific linings (such as polyurethane rubber U, natural hard rubber H) with carbon steel flanges, a correction factor (CFL/CFH: double-sided carbon steel) needs to be set; CF1L/CF1H: single-sided carbon steel), the coefficient is marked on the nameplate or on the Yokogawa official website for reference.

Set path: such as the display screen “Device setup ► Detailed setup ► Sensors ► Low MF/High MF”, Modbus address 40321 (Low MF)/40323 (High MF).

3. Fault handling

Chapter 7 of the document provides a detailed list of four types of faults: system alarms (equipment failures, such as “010: Main CPU FAIL” requiring contact with the service center), process alarms (process issues, such as “051: Empty detect” requiring fluid filling), set alarms (parameter errors, such as “060: Span cfg ERR” requiring range adjustment), and warnings (such as “087: Adhesion lv 3” requiring electrode cleaning). Each fault includes NE107 status (F/C/S/M/N), description, and countermeasures. Examples are as follows:

NE107 status error code/information reason countermeasures

F 010: Main CPU FAIL Mainboard CPU failure Contact Yokogawa Service Center

S 051: Empty detect sensor fills the pipeline with liquid through the empty tube

C 060: Span cfg ERR flow range setting error (requires 0.05<Span<16m/s) Check and correct range parameters

M 087: Adhesion lv 3 electrode adhesion insulation (resistance exceeding level 3). It is recommended to clean the electrode

Equipment Fundamentals and Safety Standards

1. Equipment positioning and scope of application

The AXW electromagnetic flowmeter is a pipeline type electromagnetic flow measurement device suitable for continuous measurement of fluid flow with a diameter of 25-1800mm (1-72 inches). It is divided into integrated flowmeter (sensor and transmitter integrated) and split type device (remote sensor+remote transmitter, such as AXW4A, AXG1A, AXFA11), and needs to be used with Yokogawa designated analyzer/communication tools (such as Modbus, PROFIBUS PA, EtherNet/IP and other communication protocols).

2. Core security principles

(1) Maintain operational safety

Personnel qualifications: Only authorized personnel from Yokogawa can carry out repairs, and wiring and maintenance must be carried out by professional engineers; Two or more people are required to cooperate in using the trolley during transportation (the equipment is heavy to avoid falling and injuring people).

Power supply and anti-static: Power off and wait for more than 20 minutes before maintenance (to prevent residual electric shock caused by capacitors); Wear an anti-static wristband when touching the circuit board to avoid damaging components due to static electricity.

Environment and fluid protection: The surface of the equipment may be hot to the touch under high-temperature fluid conditions, and it is necessary to prevent burns; Avoid contact with fluids and residual gases during maintenance of toxic fluids; Do not open the cover in damp environments (loss of protection level).

(2) Equipment protection requirements

Cover and sealing: When opening/closing the cover, check the threads and O-ring for damage/foreign objects. The O-ring should be regularly coated with silicone grease, and any damage should be replaced in a timely manner; Unused cable entrances need to be sealed with Yokogawa specific plugs (otherwise the protection level will be lost).

Grounding and power supply: protective grounding terminals are required (functional grounding terminals cannot be used as substitutes); An external 15A circuit breaker (compliant with IEC60947 standard) should be installed and labeled as a “power-off device”.

Routine inspection and model confirmation

1. Regular inspection items

Key Points for Periodic Inspection of Inspection Content

Check for condensation and moisture inside the terminal box once a year to prevent short circuits in the circuit

Tighten the pipeline joint screws twice a year to prevent fluid leakage or equipment loosening from affecting the measurement

Electrode and lining inspection should be set as needed (such as for viscous/abrasive fluids) to check for electrode scaling and lining wear (to avoid measurement errors)

2. Model and specification confirmation

Identification location: The model, suffix code, serial number, instrument coefficient, and other information are marked on the nameplate of the equipment casing (the nameplate styles of integrated flow meters, remote sensors, and remote transmitters are different, as shown in Figure 2.1-2.6 of the manual).

Key information: Confirm that the model is consistent with the order, and provide the model and serial number during repair; Device information (such as sensor serial number and software version) can be viewed through device parameters (refer to the corresponding communication manual).

Equipment adjustment and maintenance operations

1. Adjustment of cable entry direction

Depending on the type of device, there may be differences in the adjustment method, and power off is required first. The core steps are as follows:

Equipment type, caliber range, tool requirements, adjustment angle range, key considerations

Integrated flow meter+small caliber remote sensor 25-450mm (1-18 inches) No. 5 hex wrench -90 °,+90 °,+180 ° (one step every 90 °). It is forbidden to loosen the screws on the opposite side of the cable inlet; Tighten 4 bolts diagonally after adjustment

Large caliber remote sensor (Style S1) 500-1800mm (20-72 inches) with 1.5 hex wrench and 46 hex wrench -140 ° to+180 °. First loosen the hex nut, then loosen the neck screw, adjust and tighten in sequence

Large caliber remote sensor (Style S2) 500-1800mm (20-72 inches) 5 # hex wrench -90 °,+90 °,+180 ° (one step every 90 °) integrated flowmeter, do not loosen the screws on the opposite side

Note: The cable entry direction cannot be adjusted for submersible and district heating/anti condensation types (optional code DHC).

2. Maintenance of transmitter

(1) Display unit adjustment (only supported by AXW4A, not supported by AXG1A)

Direction adjustment: After power off, use a No. 3 hex wrench to open the cover, loosen the 2 fixing screws of the display unit, rotate clockwise 90 ° (do not remove the connector), re tighten the screws, close the cover and lock it.

Display board replacement: After opening the cover, loosen the screws of the display board, unlock the connector according to the “UNLOCK” mark and pull it out. When installing the new board, align the interfaces to avoid cable entanglement, and torque the screws to 0.6 ± 0.05 N · m.

(2) Parameter backup and recovery

Backup location: Parameters can be backed up to the built-in memory of the display board, supporting “backup restore” (same device) and “copy” (same model/specification/software and hardware version device).

Matching requirements: When restoring/copying, it is necessary to ensure that the device model, communication code, motherboard/sensor board/display board software version, etc. are consistent (see Table 4.4 in the manual). For split type, sensor device information should be synchronized with transmitter parameters.

3. Hardware switch settings

According to the device type (integrated, AXW4A, AXG1A), the switch functions are different, and the core settings are as follows:

(1) Integrated and AXW4A remote transmitter

The switch is located below the display panel, including address switch, burn switch, write protection switch, etc. Key settings:

Key points for setting switch type functions

When the CPU of the burn switch (SW1-1) fails, the default current output direction is high output (>21.6mA); Option C1/C2 low output (<2.4mA)

Write protection switch (SW1-2) to prevent parameter overwrite ON: prohibit modification; OFF: Allow modification (effective in combination with software write protection)

Address switch (Address) device address (Modbus/PROFIBUS PA/EtherNet/IP) Modbus: 1-127 (0 automatically converted to 1); EtherNet/IP: Set IP segment 4 (1-244, all OFF/ON automatically converted to 210)

The line terminal switch (SW2) for Modbus bus terminal matching should be set to “Bus end” at both ends of the bus (SW2-1/2 both ON, 150 Ω resistor); Set the intermediate device to ‘Not bus end’

(2) AXG1A remote transmitter

Only includes burn out switch (SW1-1) and write protect switch (SW1-2), with the same logic as AXW4A. It needs to be operated after opening the cover (using the corresponding tool) to avoid touching unrelated circuits.

Sensor inspection and health diagnosis

1. Excitation coil and insulation resistance inspection (only for remote sensors)

(1) Coil inspection

Step: After power off, disconnect the sensor terminal cable and use a multimeter to measure the continuity of the “EX1” and “EX2” terminals. If there is no continuity, the coil will be disconnected; Resistance ≥ 150 Ω is considered abnormal and requires contact with Yokogawa for maintenance.

(2) Insulation resistance inspection

The split coil circuit and signal circuit require a 500V DC insulation tester, with the following standards:

Precautions for Circuit Type Test Terminal Requirements

Coil circuit EX1 (excitation terminal) – C (common terminal) ≥ 1 M Ω. Fluid inside the pipeline can also be tested

Signal circuits C-A and C-B (signal terminals) ≥ 100 M Ω require emptying the pipeline and drying. Explosion proof type testing is prohibited

Note: The submersible and DHC types need to be measured at the cable terminal, not the sensor terminal.

2. Verification function (device health diagnosis)

(1) Functional positioning

Diagnosis of magnetic circuit, excitation circuit, calculation circuit, equipment status, and wiring connections can be done without dismantling the equipment, taking about 15 minutes to complete. It is recommended to perform it once every 1-2 years and operate it under full capacity (air traffic control may cause diagnostic abnormalities).

(2) Operation process

Parameter setting: Enter “Device setup ► Diag/Service ► Verification” through the display unit or communication tool, and set “Mode” (No flow/Flow) and “Execute” (execute/not execute).

Result judgment: After diagnosis, check the “Result”, “Passed” is normal, and “Failed” needs to be checked according to the manual flowchart (if the magnetic circuit is abnormal, check the grounding, and if the wiring is abnormal, rewire); Cancelled “may be caused by alarms (such as air traffic control, signal overflow) or flow noise, and the alarm needs to be resolved first.

Troubleshooting

The manual provides troubleshooting flowcharts for three types of core faults, with the following key steps:

1. No display

First, confirm if there are any error prompts (through display or communication tools). If there are no errors, check if the sensor arrow is consistent with the flow direction (can be reinstalled or set with reverse flow parameters), if the sensor is full, and if the electrode adhesion detection function is enabled (wait for 4 minutes after enabling).

If the electrode resistance is greater than 4M Ω, the sensor needs to be removed to clean the electrode/grounding ring of foreign objects; If the verification function is still abnormal, the insulation resistance needs to be checked. If it is invalid, contact Yokogawa.

2. Zero point instability

Priority should be given to confirming that the pipeline is full, free of bubbles, and has no leaks; Check the grounding (the grounding ring is not corroded, the grounding wire is not broken), and perform the no current state verification function.

The conductivity of the fluid must meet the specifications (if unstable, control the temperature/flow rate); Equipment close to motors, transformers, etc. needs to be shielded or kept away from interference sources.

3. The displayed traffic does not match the actual amount

Check whether the parameters (instrument coefficient, caliber, etc.) are correct, whether the pipe is full, and whether the zero adjustment is performed in a no flow state; The signal cable needs to be insulated (to avoid contact between the shielding layer and the conductor).

The upstream straight pipe section must meet the installation requirements (refer to the installation manual); Insufficient conductivity or fluid fouling require cleaning of electrodes/liners. If ineffective, check insulation resistance or use a calibrator to determine transmitter/sensor failure.

Equipment Overview and Adaptation System

The core positioning of DO30G dissolved oxygen sensor is based on the principle of primary battery method, used for continuous measurement of dissolved oxygen concentration in water, suitable for environmental protection, water treatment and other scenarios. It needs to be combined with a supporting analyzer/converter to form a complete system and cannot be used alone.

Model coding rules

Standard model format: DO30G-NN-50-XX-YY, the meanings of each part are as follows:

-NN: Fixed suffix, no special meaning

-50: Permeable membrane thickness, fixed at 50 μ m

-XX: Cable length, optional -03 (3m), -05 (5m), -10 (10m), -15 (15m), -20 (20m)

-YY: Cable terminal types, – PN (pin type), – FK (fork type), – FL (M4 ring type), – FM (M3 ring type)

Key technical specifications

Specification category specific parameter remarks

Measurement parameter measurement range: 0-20 ppm, 0-20 mg/L, 0-100% (saturation). Specific ranges need to be set in the converter

Repeatability: 0.1 mg/L or 3% FS (whichever is greater) with sensor error included

Temperature compensation error: ± 3% FS (± 5 ℃ variation within 0-40 ℃) including sensor error

Response time: ≤ 2 minutes (90% response) including sensor error

Environmental requirements for measuring solution temperature: 0-40 ℃ (maximum value) Exceeding the range affects accuracy

Measure solution pressure: conventional 0-30 kPa, maximum 100 kPa, depth not exceeding 3m

Measure solution flow rate: ≥ 20 cm/s to prevent errors caused by bubble retention

Structural Material Sensor Unit: Hard PVC, Stainless Steel Resistant to Conventional Corrosion

Permeable membrane: Fluororesin (FEP) with a thickness of 50 μ m, requiring regular inspection

O-ring: Nitrile rubber sealing function, it needs to be replaced synchronously when replacing the membrane

Cable: heat-resistant flexible PVC, shielding design length 3-20m, terminal type selected according to requirements

Temperature compensation built-in RTD: PT1000 has a resistance of approximately 1097 Ω at 25 ℃, used to correct the effect of temperature on dissolved oxygen

The basic weight is 0.3 kg+0.12 × N kg (N is the length of the cable), and the total weight of a 5m cable is approximately 0.9 kg

Installation process and precautions

Pre-installation preparation

Remove protective cap: There is a black rubber protective cap on the tip of the sensor. It is forbidden to forcefully pull or twist it to remove it (which may cause the film to stretch/break). The correct way is to insert a 0.1-0.2mm thin rod and leave an air gap before pulling it out, or slowly rotate it clockwise to remove it (see Appendix 1 for details).

Check the permeable membrane: visually confirm that the membrane is not wrinkled or damaged, and that the membrane component lock nut is not loose (looseness can cause electrolyte leakage and affect measurement).

Principles for selecting measurement points

Uniform solution composition: avoid areas with frequent bubbles and stagnant water (to prevent fluctuations in measurement values).

Stay away from high velocity sand containing solutions: prevent sand particles from wearing down the permeable membrane.

Depth ≤ 3m: meets the pressure tolerance range (maximum 100 kPa).

Bracket selection and installation | Bracket type | Material/structure | Applicable scenarios | Installation points | 

| Sensor tilted installation (anti bubble attachment), cleaning tube connected to water/air source for automatic cleaning|

cable connection

Match the converter according to the terminal number, taking FLXA402 as an example:

Temperature sensor (Pt1000): Connect terminal 11 (T1) and terminal 12 (T2) of the cable to the corresponding temperature terminals of the converter.

Electrode signal: Connect the 13 terminal (IE, anode) and 15 terminal (RE, cathode) of the cable to the corresponding electrode terminals of the converter.

Shielded wire: Connect to the shielded terminal of the converter to reduce interference.

Attention: Cable terminals must not be contaminated with water, and protection should be taken when not connected temporarily.

Maintenance and troubleshooting

Daily maintenance (regular inspection)

Permeation membrane cleaning: During each calibration, rinse the membrane surface with clean water, and wipe stubborn dirt with neutral detergent (do not scrape with hard objects to avoid membrane damage).

Membrane module lock nut inspection: Each calibration confirms that the lock nut is not loose, and if it is loose, it needs to be tightened; If there is still an abnormal display after tightening (such as extremely low measurement values), the electrolyte needs to be replaced.

Fault handling process

Troubleshooting steps and solutions

Abnormal measurement values (low/fluctuating) 1. Check if the membrane is damaged/wrinkled; 2. Check if the lock nut is loose; 3. Check if the electrolyte has deteriorated. 1. Replace the membrane module and electrolyte; 2. Tighten the nut lock; 3. Replace the electrolyte

If the temperature compensation fails and the resistance between terminals 11-12 of the measurement cable (standard value of 1097 Ω at 25 ℃) is abnormal, replace the sensor

Unable to zero/span 1. Replace membrane module+electrolyte and retry; 2. If the corrosion of the lead electrode is still ineffective, replace the sensor (lead electrode has a lifespan of 3-4 years)

Steps for replacing electrolyte and membrane components

Safety reminder: The electrolyte is KOH alkaline solution. If it comes into contact with the skin/eyes, rinse immediately with water and do not leave any residue in the syringe.

Steps:

Remove the sensor and clean the wet area;

Release the lock nut and remove the membrane component and old O-ring;

Empty the old electrolyte (tilt sensor, use a syringe to blow air from the injection port to assist in emptying);

Polishing silver electrode: Dip a damp gauze into aluminum oxide powder and gently wipe it (to avoid excessive polishing and prevent damage to the epoxy material), then clean the remaining powder;

Install a new O-ring, inject 8ml of new electrolyte (Yokogawa specific, model K9171DN), and reserve 1ml of air;

Install a new membrane component: Drop 1 drop of electrolyte on the surface of the silver electrode to prevent bubbles, lightly press the membrane component and tighten the locking nut (do not rotate the membrane component);

Rest: After replacement, it is necessary to rest for more than half a day before adjusting the zero/span (negative values may be displayed in the initial 10 minutes, which is a normal phenomenon).

Core spare parts list

DOX8A Maintenance Kit (Style B): Designed specifically for DO30G, it includes the following items:

Item Name Specification/Quantity Usage

Replace 50mL of electrolyte (model K9171DN) with 8ml each time

Replace damaged/contaminated membranes with 3 sets of membrane components and O-rings (model K9171HM)

500g of zero calibration reagent (sodium sulfite) (model L9920BR) is used to prepare a zero calibration solution (50g is required for 1L)

Inject 5ml (with needle, model L9827NH/L9827NG) of electrolyte into the syringe

200mL beaker (model L9825AF) for draining electrolyte/calibration purposes

30g of silver electrode polishing powder (model K9088PE) is used to polish silver electrodes, with approximately 0.5g used each time

Spare parts: membrane module lock nut (model K9171CH), spare sensor (to avoid measurement interruption caused by sudden failure).

Key issue

Question 1: How long does it take to replace the permeation membrane and electrolyte of DO30G sensor? What safety and operational details should be paid attention to when replacing?

answer:

Replacement cycle: It is recommended to replace the electrolyte every 6-8 months or immediately when the sensor cannot be adjusted for span; The permeable membrane and electrolyte should be replaced synchronously. If the membrane is damaged, wrinkled, or severely contaminated, it needs to be replaced in advance.

Safety details: The electrolyte is KOH alkaline solution. If it comes into contact with the skin, rinse immediately with clean water. If it enters the eyes, rinse and seek medical attention. Do not leave any residue in the syringe;

Operation details: When injecting electrolyte, add 8ml (Yokogawa specific model K9171DN) and reserve 1ml of air to prevent abnormal pressure; Before installing the membrane module, one drop of electrolyte should be dropped on the surface of the silver electrode to avoid the formation of bubbles between the membrane and the electrode; Do not rotate the membrane component when tightening the nut to prevent membrane wrinkling.

Question 2: There are three commonly used mounting brackets for DO30G sensors (PH8HG, PB350G, DOX8HS). How to choose according to the actual scenario? What are the core advantages and installation requirements of each bracket?

answer:

Selection of bracket type scene based on core advantages and installation requirements

PH8HG catheter measurement solution has no bubbles or pollutants (such as clear water tank), PVC material is corrosion-resistant, simple structure, low cost, and needs to be fixed on a pipeline with an outer diameter of 60.5mm. The sensor is suspended in a 2m long catheter

The PB350G floating ball bracket measures the solution level with large fluctuations and a small amount of flocculent substances (such as sedimentation tanks). The floating ball changes with the liquid level, and the sensor is always immersed in the solution; The wet part is smooth and not easy to hang flocs. The bracket is fixed on the 50A pipeline (outer diameter 60.5mm) or horizontal plane, and the float does not deviate from the measurement point

The DOX8HS immersion bracket measurement solution is prone to contamination (such as industrial wastewater) and needs to be regularly cleaned and installed at a 45 ° angle to prevent bubble adhesion; Support automatic cleaning with water/air spray to reduce the need for manual maintenance by connecting to a clean water/air source. The sensor is tilted and fixed to ensure that the cleaning spray port is aligned with the membrane surface

Question 3: When the DO30G sensor displays abnormal measurement values (such as continuous low or large fluctuations), how to gradually investigate the cause of the fault and solve it?

Answer: Troubleshooting should be carried out according to the following steps, with priority given to handling simple faults:

Check the condition of the permeable membrane: visually inspect the membrane for any damage, wrinkles, or severe contamination (such as oil stains or sediment). If there is, replace the membrane module (model K9171HM)+electrolyte; If the pollution is minor, clean with clean water and neutral detergent and try again;

Check the locking nut of the membrane module: confirm whether the locking nut is loose (looseness can cause electrolyte leakage, and the measured value is low). If it is loose, tighten it. If it is still abnormal after tightening, replace the electrolyte;

Check the status of the electrolyte: observe whether the electrolyte is turbid or discolored (normally clear), and replace it if it deteriorates;

Check temperature compensation: Use a multimeter to measure the resistance between terminals 11-12 of the cable (standard value of 1097 Ω at 25 ℃). If the resistance is abnormal, the sensor RTD is faulty and needs to be replaced;

Check the lead electrode: If the above steps are ineffective, it may be due to long-term corrosion failure of the lead electrode (with a lifespan of 3-4 years), and the sensor needs to be replaced as a whole.

Equipment foundation and adaptation system

1. Core positioning and application scenarios

SC4AJ is a compact sensor designed specifically for low conductivity solutions, suitable for industries such as semiconductors, power, and pharmaceuticals that require high purity (such as ultrapure water detection). It needs to be paired with a specific analyzer/converter to form a complete detection system. The compatible equipment and corresponding manual information are as follows:

Corresponding manual number for supporting equipment type

FLXA202, FLXA21 2-wire analyzer IM 12A01A02-01E

FLXA402 4-wire converter IM 12A01F01-02EN, IM 12A01F03-01EN, etc

SC450G Conductivity Converter IM 12D08N05-01E

SA11 Smart Adapter IM 12A06S01-00EN-P

2. Equipment core classification and parameters

SC4AJ is classified into models based on electrode material, installation method, and battery constant. The core differences focus on adaptation scenarios and measurement ranges. The specific classifications are as follows:

Classification dimensions, specific types, key parameters/characteristics

Electrode material titanium (- T) is only suitable for adapter installation type (- AD), with strong corrosion resistance

316L stainless steel material (- S) is compatible with all installation methods and has strong universality

Installation method: Adapter installation type (- AD) with 3/4NPT or R3/4 adapter (stainless steel/PVDF material), sensor length 9cm/15cm

Welding socket type (- SA) requires straight type (/SA1) or 15 ° angle type (/SA2) welding socket, with fixed sensor length

Welding clip type (- SB/- SC) – SB compatible 1/1.5 inch clip (/SB1//SB2), – SC compatible 2-inch clip (/SC1), including sealing ring

Battery constant 0.02 cm ⁻¹ (-002) measurement range 0-0.5 μ S/cm to 0-200 μ S/cm, suitable for extremely low conductivity solutions

0.1 cm ⁻¹ (-010) measurement range 0-5 μ S/cm to 1 mS/cm, suitable for low conductivity solutions

Cable terminal pin type/M4 ring type/M3 ring type/Variopin pin type compatible with multiple devices; M4 ring adapter FLXA202/FLXA21; M3 ring adapter FLXA402/SC450G; Variopin compatible with SA11

3. General technical specifications

Temperature and pressure: The electrode has a conventional temperature of 0-110 ℃ (can be steam sterilized at 135 ℃ for 30 minutes) and a pressure of 0-1 MPa; The tolerance range of the bracket varies with the material (stainless steel 316L has higher temperature resistance, PVDF has lower temperature resistance, please refer to the temperature pressure curve for details)

Contact fluid material: main body (316L stainless steel/titanium), O-ring (FKM fluororubber, EPDM EPDM EPDM), adapter (PVDF or 316L stainless steel)

Temperature compensation: Built in Pt1000 temperature sensor to calibrate the effect of temperature on conductivity

Protection restriction: The sensor mold and metal joint are not waterproof and cannot be immersed in process water

Safety regulations and usage restrictions

1. Core security principles

Prohibited unauthorized operation: Only use according to the instructions in the manual, unauthorized modification of the device will result in loss of protective function; Repairs require Yokogawa certified spare parts, unauthorized modifications are prohibited

Static electricity and explosion prevention: The flow of ultrapure water in plastic pipes may generate static electricity, and it is necessary to avoid the sensor conducting static electricity and damaging the converter circuit; Must comply with explosion-proof standards such as IEC 60079-11 and GB 3836.4-2010 (TIIS certified models cannot be connected), and if necessary, affix a “simple equipment” label

Temperature limit: The maximum process temperature needs to be determined based on the supporting analyzer (FLXA202/FLXA21) and temperature level (T1-T6). For example, under T6 level, the maximum process temperature at 40 ℃/60 ℃ ambient temperature is 49 ℃; At T5 level, the ambient temperature is 95 ℃ at 40 ℃ (note that the upper limit of T5 level is 100 ℃)

2. Manual usage guidelines

It needs to be handed over to the end user and properly stored, and unauthorized copying/dissemination is prohibited; Yokogawa reserves the right to improve manuals and equipment without prior notice

The manual only describes the device functions and does not guarantee adaptation to specific user scenarios; The equipment is provided as is, and Yokogawa is not responsible for unforeseeable direct/indirect losses

Installation and Wiring Guide

1. Core installation requirements

Installation principle: Ensure uniform composition and no dead zone when the solution flows through the sensor; The sensor needs to be submerged above the outlet to ensure continuous liquid flow between the electrodes; Reserve maintenance space for easy disassembly and release of process pressure; Confirm that the pressure at the installation site is within the tolerance range of the sensor and adapter

Steps for different installation methods:

Adapter installation type (- AD): Assemble in the order of “nut → adapter support (stainless steel adapter) → adapter → sealing ring → sensor body”, tighten the nut with a torque of about 190 N · m (tighten with fingers and then use a wrench to tighten 1.25 turns)

Welding socket type (- SA): First weld the welding socket to the process pipeline (cool to room temperature), insert the sensor into the socket after installing the O-ring, and fix it by hand tightening the nut

Welding clamp type (- SB/- SC): First weld the flange to the pipeline, insert the sensor into the flange after installing the sealing ring, and fix it with a special fixture

2. Wiring requirements

Wiring logic: Connect according to the cable end identification and the terminal number of the analyzer/converter, for example, connect the temperature sensor wire (brown/black/red) to the corresponding temperature terminal, and the electrode wire (green/yellow) to the corresponding electrode terminal; Variopin terminal (- VS) needs to be connected to SA11 adapter

Cable specifications: Cable length 3-20m (selected according to the order), avoid contact with high-temperature components, and ensure that the insulation resistance meets the requirements after wiring (such as 1000-1137 Ω between terminals 11-12 and>100 M Ω between terminals 11-13)

Operation and maintenance process

1. Preparation and calibration before operation

Pre operation inspection: Confirm that the cable connection is correct, the solution is leak free, the temperature/pressure is within the range, and the solution level reaches the outlet height

Battery constant setting: The factory calibrated battery constant on the cable label needs to be input into the matching analyzer/converter (refer to the corresponding equipment manual for operation steps)

Calibration requirements: Use a standard solution with known conductivity for calibration (the conductivity of the standard solution should be close to that of the test liquid). Before calibration, the sensor should be equilibrated with the temperature of the solution, and the temperature should be measured using a calibration thermometer

2. Core maintenance operations

(1) Sensor cleaning

Choose the cleaning method based on the type of pollutant, and prohibit mixing hydrochloric acid with chlorine containing solvents (to avoid producing toxic chlorine gas):

Scale and hydroxides: Clean with 5-10% hydrochloric acid solution

Organic dirt (oil, grease): Wipe with ethanol or acetone

Algae/bacteria: Clean with chlorine containing solution (household bleach)

Conventional pollution: cleaning with hot water and household detergent

After cleaning, visually inspect the sensor for any damage or deformation

(2) Abnormal judgment

After the sensor dries, measure the resistance between the terminals with a digital multimeter. If it exceeds the following range, it needs to be replaced:

Terminal combination (non VS) Variopin terminal combination (- VS) standard resistance at room temperature

11-12 E-F 1000-1137 Ω

11-13, 13-15, 12-15 E-C, C-A, F-A>100 M Ω

13-14, 15-16 C-D, A-B ＜ 10 Ω

3. Spare parts information

Core spare parts need to be matched according to the installation method, and common spare parts are as follows:

Type description corresponding to spare part number

K9670MA SA (non VS) O-ring

K9670VY SA (- VS) O-ring set

K9670MK-SB sealing ring (compatible/SB1//SB2)

K9670MP SC sealing ring (compatible/SC1)

K9670MT/MU-AD 3/4NPT stainless steel/PVDF adapter

K9670ME/MD-SA straight/angle welding socket and installation nut

Equipment foundation and system composition

1. Core positioning and adaptation system

SC210G is a conductivity detection unit that needs to be used in conjunction with a specific analyzer/converter to form a complete detection system. The compatible equipment and corresponding manual information are as follows:

Corresponding manual number for supporting equipment type

FLXA202, FLXA21 2-wire liquid analyzer IM 12A01A02-01E

FLXA402 4-wire converter IM 12A01F01-02EN, IM 12A01F03-01EN, etc

FLXA402T turbidity and chlorine liquid analyzer IM 12A01G01-02EN, IM 12A01G03-01EN, etc

SC450G 4-wire conductivity converter IM 12D08N05-01E

2. Equipment core classification and parameters

SC210G can be divided into two categories based on measurement range, with the core difference in electrode structure and conductivity range, suitable for different solution detection scenarios:

Model Measurement Type Electrode Structure Battery Constant Measurement Range Applicable Scenarios

SC210G-C low range 316 stainless steel 2-electrode coaxial type 0.05 cm ⁻¹ 0-200 µ S/cm low conductivity solution (such as ultrapure water)

SC210G-D medium range glass tube with equidistant 3-ring platinum electrodes (short circuited on both sides and forming a counter electrode in the middle) 5 cm ⁻¹ 200 µ S/cm-20 mS/cm medium high conductivity solution

3. General technical specifications

Temperature and pressure: Normal temperature 0-105 ℃ (polypropylene material bracket is limited to 0-100 ℃); Conventional pressure 0-1 MPa (polypropylene material support limit 0-500 kPa)

Contact fluid material: SC210G-C (sensor: 316 stainless steel, fluororubber O-ring, polytetrafluoroethylene; Main body: 316 stainless steel, polypropylene); SC210G-D (sensor: platinum, glass, fluororubber O-ring; Subject is the same as Type C)

Temperature compensation: Built in Pt1000 temperature sensor, used to calibrate the effect of temperature on conductivity

Protection level: JIS C0920 waterproof (equivalent to NEMA 4), suitable for humid environments in industrial sites

Safety regulations and usage restrictions

1. Core security principles

Prohibited unauthorized operation: Only use according to the instructions in the manual, unauthorized modification of the device will result in loss of protective function; Repairs require Yokogawa certified spare parts, unauthorized modifications are prohibited

Static electricity and explosion prevention: Non metallic components may carry static electricity, and it is necessary to avoid static electricity generation operations such as wiping with dry cloth; The junction box shell is made of aluminum, which can avoid impact, friction, and sparks; Must comply with explosion-proof standards such as IEC 60079-11 (TIIS certified models cannot be connected)

Temperature limit: The maximum process temperature needs to be determined based on the supporting analyzer (FLXA202/FLXA21/SC202S) and temperature level (T1-T6). For example, under T5 level, FLXA202/FLXA21 with SC210G-C has a maximum process temperature of 54 ℃ at an ambient temperature of 40 ℃, and with SC210G-D it is 95 ℃ (note that the upper limit of T5 level is 100 ℃)

2. Manual usage guidelines

It needs to be handed over to the end user and properly stored, and unauthorized copying/dissemination is prohibited; Yokogawa reserves the right to improve manuals and equipment without prior notice

The manual only describes the device functions and does not guarantee adaptation to specific user scenarios; The equipment is provided as is, and Yokogawa is not responsible for unforeseeable direct/indirect losses

Installation and Wiring Guide

1. Installation type and preparation

SC210G is divided into direct insertion type (installed in process pipelines) and flow type (sample introduced through sampling tubes). Before installation, it is necessary to:

Site selection requirements: easy maintenance, no bubbles in the solution (to avoid measurement deviation), stable liquid level, and away from high temperature (>50 ℃) pipelines

Preprocessing: For direct insertion type, corresponding thread holes (such as R1-1/2, 1-1/2 NPT) or flange holes (JIS 10K 50 RF, etc.) need to be reserved; The circulating polypropylene bracket needs to be equipped with a 50A pipe (outer diameter 60.5mm) and fixed with a bracket to prevent rupture

2. Installation steps

Direct insertion type: Threaded type requires sealing tape to be wrapped around the thread and screwed in; The flange type requires adding gaskets between the flange faces and evenly tightening 4 bolts

Flow type: fixed to the designated installation pipeline, adjustable solution inlet and outlet direction (stainless steel bracket can be adjusted horizontally, polypropylene bracket can be adjusted through the bracket direction)

Direction adjustment: Loosen the union nut of the junction box to rotate it for easy wiring (rotating without loosening the nut will damage the internal wiring)

3. Requirements for piping and wiring

Piping: Hard PVC pipes (JIS K9741, A16) for polypropylene supports, etc; 304/316 stainless steel pipes (JIS G3459, A15) are used for stainless steel brackets; Suggested flow rate<20 L/min (to prevent electrode wear caused by slurry solution), an overflow tank should be installed to remove bubbles, and a shut-off valve should be installed at the maintenance site to prevent leakage

Wiring: The cable length is provided according to the order (3/5/10/15/20m), and the terminals are divided into M4 ring type (compatible with FLXA202/FLXA21), M3 ring type (compatible with FLXA402/FLXA402T/SC450G), and pin type (compatible with multiple devices); The cable should avoid contact with high-temperature components, and the joint locking nut should be tightened for waterproofing after connection. The insulation resistance between the core wires should be ≥ 2 M Ω

Operation and maintenance process

1. Preparation before operation and steady-state operation

Inspection items: correctness of wiring, compatibility of piping materials, solution level (flow type needs to go to the outlet), no leakage; After startup, it is necessary to confirm that there is no bubble interference and no sudden temperature changes (to avoid affecting measurement accuracy)

Steady state maintenance: Conventional solutions (free of pollutants) can be maintained for 1 year without maintenance; Regular calibration with standard solution is required to ensure accuracy; If the analyzer outputs a FAIL signal, refer to the analyzer manual for troubleshooting

2. Core maintenance operations

(1) Electrode cleaning

Cleaning cycle: Low range (0.05 cm ⁻¹) electrodes require almost no cleaning due to minimal impurities in the solution; Medium range (5 cm ⁻¹) electrodes should be cleaned as needed (if the analyzer indicates abnormal electrode polarization)

Cleaning method: Type C (clean the inner and outer electrodes, only the inside of the hole needs to be cleaned externally); D-type (glass material requires a protective tube, gently wipe the platinum electrode on the inner wall of the glass tube with a thin rod wrapped in degreasing cotton)

(2) O-ring replacement

Replacement timing: O-ring damage can cause leakage, and regular inspections are required in high-temperature solution scenarios; Conventional O-ring (fluororubber, model K9050AT/K9050MR), with gate valve model requiring replacement with dedicated O-ring (K9050MS)

Replacement steps: For non gate valve types, simply loosen the union nut and remove the electrode to replace it; The gate valve type needs to first remove the external electrode and locking nut, remove the stop screw and replace the O-ring (recommended to replace in pairs), and calibrate the battery constant after reinstallation

(3) Electrode component replacement

Replacement condition: When the electrode is judged to be faulty (if there is still a large deviation after calibration)

Step: Power off → Remove the connection between the junction box and the electrode (use an Allen wrench to unscrew the electrode assembly) → Install a new component and wire it according to the color (green → C1, yellow → C2, red/black → T1/T2) → Update the battery constant label in the junction box → Enter the new battery constant in the analyzer

Product positioning and core series

1. Core positioning

PH4/OR4 series is a special electrochemical sensor designed for different severe working conditions. Through differentiated materials (such as HF resistant glass, perfluoroelastomer), electrolyte type (polymer electrolyte, high viscosity gel) and structure (built-in RTD, pressurized design), the PH4/OR4 series can solve the measurement stability problem of ordinary sensors under strong corrosion, high temperature, high viscosity and other scenarios. At the same time, it is compatible with mainstream transmitters in Yokogawa to meet industrial reliability requirements.

2. Series models and applicable scenarios

The series includes 9 sub models, classified according to measurement parameters (pH/ORP) and adaptability to working conditions. The core differences are as follows:

Model Series Type Core Features Applicable Scenarios

PH4P/PH4PT polymer electrolyte pH sensor with built-in polymer electrolyte (including KCl), no risk of liquid leakage; PH4PT with Pt1000 RTD (temperature compensation); General scenarios (such as municipal sewage and neutral solutions), without the need for frequent electrolyte replenishment;

The PH4F/PH4FT anti HF corrosion pH sensor is made of anti HF glass material, which can withstand low pH (2-11) and HF concentration (≤ 500 ppm at pH 2); PH4FT with RTD; Scenarios containing hydrofluoric acid (such as semiconductor cleaning, fluorine chemical industry);

PH4C/PH4CT special chemical pH sensor has a wide pH range (0~14) and built-in pressurized gel electrolyte (initial 250 kPa) to prevent medium infiltration; PH4CT with RTD; Strong acid-base and high viscosity media (such as chemical reaction vessels and acid-base neutralization processes);

OR4P/OR4C ORP sensor OR4P (polymer electrolyte, platinum wire electrode), OR4C (pressurized gel, platinum ring electrode); OR4P: Universal oxidation-reduction scenarios (such as wastewater treatment and disinfection); OR4C: Pollution prone scenarios (such as sulfide containing solutions);

PH4FE fermentation specific pH sensor long axis design (120/200mm), open electrolyte replenishment port, suitable for deep measurement in fermentation tanks; The biological fermentation process (such as pharmaceutical and food fermentation) requires regular replenishment of electrolytes;

Detailed explanation of technical specifications

1. Basic measurement parameters

Parameter category specification details (taking typical models as examples)

PH measurement range: PH4P/PH4CT 0~14 pH, PH4F 2~11 pH;

Accuracy: Slope ≥ 96% (25 ℃), asymmetric potential ± 15 mV;

Response time: t ₉₀<15 seconds (pH 7 → 4 step);

ORP measurement range: -1500~+1500 mV;

Electrode material: OR4P (platinum wire), OR4C (platinum ring);

Reference system: Ag/AgCl (containing KCl electrolyte);

Temperature adaptation without RTD model: -20~70 ℃ (ambient), process temperature varies from 0~105 ℃ depending on the model;

Model with RTD (such as PH4PT): Built in Pt1000 (-20~200 ℃) for temperature compensation;

Pressure adapted atmospheric pressure model (PH4P/PH4F): maximum immersion depth of 3m;

Pressure model (PH4C/OR4C): Initial pressure of 250 kPa, gradually decreasing with use, to avoid process pressure exceeding the internal pressure of the sensor;

Contact material body: borosilicate glass/HF resistant glass;

Electrolyte: PH4P (polymer), PH4C (high viscosity gel) PH4FE（3M KCl-LR）；

Sealing components: Fluororubber (FPM)/Perfluoroelastomer (FFKM, optional/PF);

There is no clear IP rating for protection and installation, and it is necessary to cooperate with brackets (such as PH8HS/PH8HF) to achieve waterproofing; The installation angle should be ≥ 15 ° (horizontal upward) to avoid residual bubbles; Prohibit outdoor or pipe hanging use;

2. Key operating condition limitations

Some models have strict operating conditions restrictions, and when selecting, special attention should be paid to:

PH4F/PH4FT (anti HF): The upper limit of HF concentration increases with pH (500 ppm at pH 2, 10000 ppm at pH 4), and the upper limit of temperature is 80 ℃;

PH4C/PH4CT/OR4C (pressurized): The process pressure should be ≤ the internal pressure of the sensor (initial 250 kPa), and the internal pressure can be determined by the “gas layer length” of the thin tube inside the sensor (the shorter the gas layer, the higher the internal pressure);

PH4FE (fermentation specific): Only compatible with customized brackets, prohibited from being paired with PH8HS/PH8HF universal brackets, and the electrolyte replenishment port should be regularly opened to check the liquid level;

Selection guide: Model and suffix code

1. Core selection dimensions

The selection should clarify the three dimensions of measurement parameters (pH/ORP), operating conditions (temperature/pressure/corrosiveness of the medium), and supporting equipment (transmitter/bracket). After prioritizing the matching model, the detailed configuration should be determined through suffix codes:

Example of key considerations for selection dimensions (such as chemical HF scenarios)

Choose PH4 series for pH measurement parameters and OR4 series for ORP measurement parameters; PH measurement with HF → PH4F;

If the temperature compensation fluctuates greatly (>5 ℃), choose the RTD model (such as PH4FT), otherwise choose the basic model (such as PH4F); Process temperature fluctuates between 20~80 ℃ → PH4FT;

For the installation bracket, choose PH8HS for immersion type and PH8HF for flow type, which require corresponding adapters (such as S3 stainless steel adapter); Pipeline installation → PH8HF bracket+PH4F+/S3 (stainless steel adapter, acid resistant);

Cable and terminal cable length (03=3m, 05=5m, etc.), terminal type matching transmitter (such as E-pin terminal compatible with FLXA202); Transmitter distance sensor 5m → PH4FT-05-E;

Choose FFKM (/PF) as the sealing material for organic solvents/high-temperature alkali, and fluororubber (default) for ordinary scenarios; Scenario containing ethanol → PH4F+/PF;

2. Meaning of suffix codes

The suffix code is used to determine the adapter material, cable length, terminal type, seal and other details of the sensor. The core code meaning is as follows:

Core options for suffix code classification

/S3//PP/PV adapter material/S3 (SUS316 stainless steel, acid resistant),/PP (polypropylene, neutral scenario),/PV (rigid polyvinyl chloride, low-cost);

/HPV//TN special adapter/HPV (heat-resistant polyvinyl chloride, upper limit of 80 ℃),/TN (titanium material, strong corrosion scenario);

/PF sealing material is perfluoroelastomer (FFKM), suitable for organic solvents and high-temperature alkalis (such as NaOH solution above 80 ℃);

-The cable length numbers such as 03/-05/-10 represent the length (unit: m), such as -03=3m, with a maximum length of 20m; -00 indicates no cable (terminal box required);

D/E/F/G terminal types D (fork shaped terminal, compatible with PH400G), E (pin terminal, compatible with FLXA202), F/G (ring terminal, compatible with FLXA21);

Installation and wiring process

1. Preparation before installation

(1) Unpacking and Inspection

Confirm that the appearance of the sensor is undamaged (glass body, cable without cracks), and the model and suffix code (such as PH4F-05-E/S3) are consistent with the order;

Check the integrity of attachments: storage cap (including protective liquid), O-ring (default fluororubber, optional/PF), adapter (such as/S3);

When removing the storage cap, use a screwdriver to unscrew the screw at the blue gasket to avoid damaging the glass electrode; Check the “gas layer length” of PH4C/OR4C (confirm that the internal pressure is normal).

(2) Installation site selection requirements

Avoid areas where bubbles gather (such as at the top of pipelines), dead zones, or locations with high flow rates (>2 m/s) to prevent response delays or electrode wear;

Anti HF models (PH4F/PH4FT) should be kept away from strong oxidizing media (such as concentrated nitric acid) to avoid accelerated glass corrosion;

The installation in hazardous areas must comply with the IEC 60079-14 standard, and as a “simple device”, it should be matched with an isolated transmitter (such as FLXA202) with a grounding resistance of ≤ 1 Ω.

2. Core installation steps (taking the flow bracket PH8HF as an example)

(1) Adapter and O-ring assembly

Select adapter: Choose the material based on the corrosiveness of the medium (such as S3 stainless steel adapter for acidic medium), and insert the O-ring (default FPM or optional/PF) into the adapter groove;

Pre installed sensor: Thread the sensor through the bracket fixing nut, insert the adapter, and ensure that the glass electrode is completely in contact with the medium channel (without air residue);

Tighten and fix: Tighten the nut clockwise to the O-ring compression seal (to avoid damaging the glass due to over tightening). For medium pressure models (PH4C/OR4C), it is necessary to confirm that the process pressure is ≤ the internal pressure of the sensor.

(2) Cable and terminal connection

The sensor cable contains 4-5 core wires (with an additional 1 core for RTD models), which need to be connected to the transmitter (such as FLXA202) according to the terminal definition. The wiring method is consistent for different terminal types:

Cable core function corresponding terminal (FLXA202 as an example) Remarks

The pH/ORP indicator electrode (GE) transmits measurement signals to terminal 15, ensuring that the wiring is secure and avoiding interference;

The reference electrode (RE) terminal 13 forms a circuit with the indicator electrode and needs to be grounded separately;

The grounding electrode (SE) terminal 14 must eliminate the grounding potential difference and be reliably grounded (grounding resistance ≤ 1 Ω);

RTD (T1/T2, with RTD model) terminals 11/12 are only available for PH4PT/PH4FT/PH4CT and are used for temperature compensation;

VP connector operation: Rotate the sensor connector to align the groove with the cable connector protrusion, gently insert and tighten the nut (only tighten the plastic part to avoid glass damage);

Terminal box usage: WTB10 terminal box is required for long-distance installation (>10m), with a total cable length of ≤ 20m to avoid signal attenuation.

Operations and Calibration

1. Daily maintenance

(1) Electrolyte replenishment and replacement

PH4P/PH4F/OR4P (polymer/gel type): there is no need to supplement electrolyte, and the sensor is replaced as a whole after its service life expires (usually 1-2 years);

PH4C/OR4C (pressurized type): The initial internal pressure is 250 kPa, which drops to about 125 kPa after 1 year of use. If the process pressure exceeds the internal pressure and the medium infiltrates, causing the sensor to fail, it needs to be replaced in advance;

PH4FE (fermentation specific): Regularly open the electrolyte replenishment port and replenish 3M KCl-LR solution to the liquid level line to avoid dry burning.

(2) Electrode cleaning

Choose the cleaning method based on the type of medium contamination, only clean the sensor tip (to avoid damaging the cable/connector):

Inorganic dirt (scale, salt): Use a soft cloth dipped in 1-2% dilute hydrochloric acid to wipe, and then rinse with pure water;

Organic dirt (oil, biofilm): Soak in neutral detergent solution (30 minutes to 2 hours), or use protease solution (such as hydrochloric acid solution containing gastric protease) in fermentation scenarios;

ORP electrode oxidation: Use a soft cloth dipped in toothpaste (mild abrasive) to wipe the platinum wire/platinum ring to remove the oxide layer.

2. Calibration process

(1) PH sensor calibration (two-point calibration method)

Prepare buffer solution: Select two points that are close to the process pH (such as pH 4.01+6.87, or pH 6.87+9.18), with the same temperature as the process;

Clean the sensor: Rinse the sensor with pure water to absorb surface moisture (avoid dilution with buffer solution);

First point calibration: Immerse in the first buffer solution (such as pH 6.87), wait for the reading to stabilize, and then follow the transmitter (such as FLXA202) prompts to perform “zero point calibration”;

Second point calibration: Rinse with pure water and immerse in a second buffer solution (such as pH 4.01), perform “slope calibration”, and ensure that the slope is ≥ 96%;

Verification: After calibration, return the first buffer solution with an error of ≤ 0.02 pH. Otherwise, clean and calibrate again.

(2) ORP Sensor Calibration (Quinone Hydroquinone Standard Method)

Prepare standard solution: Dissolve 1g of quinone hydroquinone powder in 200mL of pH 7.00 buffer solution and stir until saturated;

Calibration operation: Immerse the ORP sensor in a standard solution, wait for the reading to stabilize, and then enter the theoretical value according to the transmitter prompt (ORP=88 mV, rH=23.6 at pH 7);

Error allowance: Calibration error ≤ ± 10 mV. If it exceeds the tolerance, the platinum electrode needs to be cleaned and recalibrated.

3. Storage and regeneration

Short term storage (<1 month): Put on a storage cap and inject 1.5-2mL of 3.3M KCl solution to avoid electrode drying;

Long term storage (>1 month): It is recommended to replace the storage solution every 3 months to prevent electrolyte deterioration;

Sensor regeneration: If the sensor is dry or the response slows down, the pH sensor can be soaked in 0.1M NaOH (10 minutes) → 0.1M HCl (10 minutes) → 3.3M KCl (15 minutes); Clean the platinum surface of ORP sensor with abrasive.

Product positioning and core features

1. Core positioning

OR8EFG is a KCl filled ORP sensor based on metal electrode method, which achieves stable oxidation-reduction potential measurement (-1500~+1500 mV) by integrating platinum/gold indicator electrode and Ag/AgCl reference electrode, combined with KCl solution filling system. Its core advantage lies in its adaptability to multiple installation methods (immersion, flow, conduit suspension), and through pressure compensation design (medium pressure storage tank), it can be used under pressure conditions. It is also compatible with transmitters such as Yokogawa FLXA202/FLXA21, meeting the requirements of industrial measurement accuracy and reliability.

2. Core advantages

Wide working condition adaptation: supports a temperature range of -5~105 ℃ (slightly different depending on the material of the installation bracket), a pressure range of atmospheric pressure to 500 kPa (medium pressure storage tank), a medium flow rate of ≤ 2 m/s, and is suitable for various harsh processes;

Durable materials: PPS resin (main body), platinum/gold (indicator electrode), PTFE/ceramic (liquid interface), fluororubber/perfluoroelastomer (seal) are used for the contact medium components, which are acid and alkali resistant and corrosion-resistant;

Flexible installation: can be paired with PH8HS immersion bracket, PH8HF flow-through bracket, PH8HG catheter bracket, etc., or can be hung separately (maximum immersion depth of 3m) to adapt to different process layouts;

Compliance and Safety: Compliant with explosion-proof standards such as ANSI/ISA-60079 and IEC 60079, it can be used as a “simple device” in conjunction with isolated transmitters (such as FLXA202) for use in hazardous areas to avoid the risk of electrostatic ignition;

Low maintenance design: equipped with a KCl storage tank (universal type 250mL/medium pressure type), with low consumption of KCl solution (universal type ≤ 3 mL/day, PTFE liquid interface ≤ 20 mL/day), reducing the need for frequent fluid replenishment.

Detailed explanation of technical specifications

1. Basic measurement parameters

Parameter category specification details

ORP measurement range -1500~+1500 mV, measurement principle is metal electrode method, indicating electrode material can be platinum (- PT) or gold (- AU);

Environmental adaptability temperature: -5~105 ℃ (flow type bracket, stainless steel material), -5~80 ℃ (immersion bracket, PP material);

Pressure: normal pressure~500 kPa (medium pressure storage tank), normal pressure (universal storage tank);

Medium requirements: Conductivity is not mandatory, flow rate ≤ 2 m/s, maximum immersion depth 3m;

Contact material body: PPS resin (Ryton);

Indicator electrode: platinum glass/gold epoxy resin;

Liquid interface: ceramic/PTFE/fluororesin;

Sealing components: FKM/FFKM, suitable for organic solvents/high-temperature media;

KCl system storage tank: universal type (250mL, equipped with 2-inch pipe support), medium pressure type (requiring external pressure regulator);

Solution consumption: Under a pressure difference of 10 kPa, the universal liquid interface is ≤ 3 mL/day, and the PTFE liquid interface is ≤ 20 mL/day;

Cable: Chlorinated polyethylene rubber sheath, available in lengths of 3/5/7/10/15/20m;

The weight and protection of the sensor body are about 0.4kg, the general storage tank is about 0.3kg, and the medium pressure storage tank is about 1kg. There is no clear IP rating, but it can prevent liquid splashing through a sealed design (which needs to be used in conjunction with a bracket waterproof cap);

2. Model classification and suffix code

OR8EFG distinguishes core configurations through suffix codes, and the selection needs to specify electrode materials, cable lengths, storage tank types, and compatible transmitters. The specific meanings are as follows:

Core characteristics of suffix code classification

-PT/- AU indicator electrode PT: platinum electrode (universal scenario, oxidation resistant); -AU: Gold electrode (suitable for pollution prone scenarios such as sulfide);

-The numerical representation of the length of cables and KCl pipes, such as 03/-05/-10, is in meters. For example, -03 is 3m and supports a maximum length of 20m (100m can be customized);

-TT1/- TT2 storage tank type – TT1: universal type (250mL, normal pressure, equipped with pipeline support); -TT2: Medium pressure type (requires external air pressure, suitable for pressurized working conditions);

-TN1/- TN2 maintenance storage pipes only contain KCl supply pipes and do not include storage tanks (for pipeline replacement of existing storage tanks);

-E/- F/- G compatible transmitters – E: compatible with FLXA202/FLXA21/PH202 (pin terminals); -F: Compatible with FLXA202/FLXA21 (M3 ring terminal); -G: Compatible with FLXA402/PH450G (M4 ring terminal);

/TF//PF/FEP special options/TF: PTFE liquid interface (anti pollution); /PF: Perfluoroelastomer seal (resistant to organic solvents); /FEP: FEP material KCl tube (UV resistant);

3. Compliance and Explosion Protection Requirements

As a ‘simple device’, OR8EFG must meet the following compliance conditions before it can be used in hazardous areas:

Supporting equipment: It must be used in conjunction with transmitters with built-in isolation functions (such as FLXA202-D – □ – D-CB -…) or systems with isolation safety barriers to avoid risks introduced by non isolated circuits;

Temperature limit: Depending on the ambient temperature (Ta) and temperature level, the upper limit of the process temperature varies (for example, when T6 level Ta=40 ℃, FLXA202 can be used with an upper limit of 16 ℃); T3 level Ta=upper limit of 105 ℃ at 40 ℃);

Electrostatic protection: Avoid wiping the sensor with a dry cloth to prevent the accumulation of static electricity from causing explosions; The titanium material solution grounding terminal (- TN suffix) can eliminate the risk of impact friction sparks;

Installation and wiring process

1. Preparation before installation

(1) Unpacking and Inspection

After unpacking, confirm that the sensor body, indicator electrode, liquid interface, and KCl storage tank (if ordered) are not damaged, and verify that the model suffix matches the order (such as electrode material and cable length);

The indicator electrode and the liquid interface are packaged separately, and the liquid interface should be kept moist. After unpacking, it should not be taken out temporarily to avoid drying and affecting performance;

Check the integrity of attachments: installation bracket (such as PH8HS), KCl solution/powder (accessory OR8AX contains 3 bags of 250mL powder), cable sealing glass, etc.

(2) Installation site selection requirements

Avoid installing in dead zones, bubble accumulation areas, or locations with high flow rates (>2 m/s) to prevent measurement response delays or electrode wear;

If the medium contains corrosive gases (such as ammonia and hydrogen sulfide) or the temperature is greater than 80 ℃, a flow-through or immersion bracket must be used and cannot be suspended separately;

The installation in hazardous areas must comply with local electrical regulations (such as ANSI/ISA-RP12.06.01), ensure that the grounding resistance is ≤ 1 Ω, and avoid potential difference sparks.

2. Core installation steps (taking a flow-through bracket as an example)

(1) Assembly of electrode and liquid interface

Installation indicator electrode: Remove the sealing tape from the installation hole of the sensor body electrode, take out the platinum/gold electrode, check that the O-ring is not damaged, and then screw it clockwise into the installation hole until the O-ring is tightly sealed;

Pre installed liquid interface: Remove the sealing tape from the installation hole of the liquid interface, gently screw the liquid interface into 2-3 turns (not tightened temporarily), and reserve a channel for filling with KCl solution;

Connect KCl storage tank: If it is a universal type (- TT1), fix the storage tank on a 2-inch pipe through a bracket, connect the KCl supply pipe of the sensor, and use the accompanying needle to puncture the top of the storage tank (balance air pressure); If it is a medium pressure type (- TT2), an external air pressure regulator (slightly higher than the maximum process pressure) is required, and an air pipeline should be connected.

(2) KCl solution filling

Invert the sensor (below the height of the storage tank) to allow KCl solution to flow from the storage tank into the sensor body;

When the solution overflows from the installation hole of the liquid interface, tighten the liquid interface clockwise (to avoid residual air) to complete the filling;

The medium pressure storage tank needs to be replenished to a distance of 30-40 mm from the top to prevent the solution from overflowing during pressurization.

(3) Bracket assembly and fixation

Remove the protective foam of the circulating bracket (PH8HF), insert the sensor tip into the bracket, and tighten the fixing nut (ensure the O-ring compression seal);

Connect the process pipeline: first open the inlet valve, then open the outlet valve to avoid medium impact on the sensor; Under medium pressure conditions, the storage tank needs to be pressurized first before the process medium is introduced.

3. Wiring specifications

The OR8EFG cable contains 4-core wires and needs to be connected to the transmitter (such as FLXA202) according to the terminal definition. The wiring method may vary slightly depending on the terminal type (pin/ring):

Corresponding terminal for cable core color function (taking FLXA202 as an example) Remarks

The red indicator electrode (GE) at terminal 15 is transmitting ORP signals, and it is necessary to ensure that the wiring is secure to avoid signal interference;

The brown reference electrode (RE) terminal 13 forms a measurement circuit with the indicator electrode and needs to be grounded separately;

The black liquid interface/grounding (SE) terminal 14 is used to eliminate the grounding potential difference and must be reliably grounded;

Connect the green common terminal (G) 16 to the transmitter common terminal to ensure the integrity of the circuit;

Cable sealing: When passing through the transmitter cable inlet, a matching glass should be used, and the nut should be tightened to the seal (to avoid damaging the cable due to over tightening);

Explosion proof area: After wiring, it is necessary to confirm that the terminal box is sealed properly to prevent flammable gases from entering, and the grounding resistance should be ≤ 1 Ω.

Operations and Calibration

1. Daily maintenance

(1) KCl solution supplementation

Universal Liquid Storage Tank (- TT1): When the remaining solution is less than 1/4, replace with a new liquid storage tank (accessory K9084KQ), or supplement with a 3.3mol/L solution (246g KCl dissolved in 1L pure water) prepared with KCl powder (K9020XU) to avoid reference electrode failure caused by an empty liquid storage tank;

Medium pressure storage tank (- TT2): Close the process pipeline valve → Remove the pressure of the storage tank → Add KCl solution to the specified height → Re pressurize (slightly higher than the process pressure) → Open the process valve, and the replenishment cycle depends on the consumption (usually 1-2 months).

(2) Cleaning of electrode and liquid interface

Choose the cleaning method based on the type of medium contamination, only clean the sensor tip (to avoid damaging the cable/reservoir):

Suspended solids/viscous pollutants: Wipe with a soft tissue and rinse with pure water;

Oil/organic matter: Soak in neutral detergent solution (for tens of minutes to several hours), then rinse with pure water;

Metal adsorption/chemical stains: Soak in 1-2% dilute hydrochloric acid solution (several minutes), then rinse with pure water;

Liquid junction blockage: If the measurement response slows down, the liquid junction can be immersed in a 3mol/L KCl solution at 70 ℃ and naturally cooled to restore conductivity.

2. Calibration process

ORP sensors need to be calibrated regularly with quinone hydroquinone standard solution to ensure measurement accuracy. It is recommended to calibrate every 3-6 months (shortened for severe pollution scenarios):

(1) Calibration preparation

Prepare quinone hydroquinone powder (accessory K9024EC), pH buffer solution (such as pH 4.01/6.87), pure water, and clean the beaker;

Prepare standard solution: Dissolve 1g of quinone hydroquinone powder in 200mL of pH buffer and stir until saturated;

Clean the sensor: Follow the above cleaning method to clean the interface between the indicator electrode and the liquid, rinse with pure water, and dry dry.

(2) Two point calibration steps

First point calibration (pH 6.87 buffer solution):

Immerse the sensor in a quinone hydroquinone pH 6.87 standard solution and wait for the reading to stabilize (usually 5-10 minutes);

Enter the “ORP Calibration” mode according to the transmitter manual (such as FLXA202), and input the theoretical value (ORP=96 mV, rH=23.6 at pH 6.87);

Second point calibration (pH 4.01 or 9.18 buffer solution):

Rinse the sensor with pure water, immerse it in a quinone hydroquinone solution of another pH, and wait for it to stabilize before inputting the corresponding theoretical value (such as ORP=265 mV at pH 4.01);

Verification and reset: After calibration, immerse the sensor in pure water, confirm that the reading drift is ≤± 10 mV, and install it back into the process pipeline.

3. Replacement of vulnerable parts

(1) Liquid interface replacement

When the liquid interface is severely blocked (still unresponsive after cleaning) or damaged, it needs to be replaced (accessories K9142TH/TH, etc.):

Drain the KCl solution from the sensor and unscrew the old liquid interface counterclockwise;

Apply a small amount of KCl solution to the new liquid interface and gently screw it into the sensor body 2-3 times;

Refill the KCl solution until it overflows, tighten the liquid interface, and confirm that the solution seeps out from the liquid interface (visually or through a transmitter to detect impedance 2 ≤ 50 k Ω).

(2) Indicator electrode replacement

If the electrode surface is severely oxidized (with large reading drift and slow response), replace the platinum/gold electrode (accessory K9142TS/TT, etc.):

Remove the old electrodes from the sensor body and check if the O-ring is damaged (replace them together);

Apply silicone grease to the new electrode O-ring and screw it clockwise into the installation hole until it is sealed;

Refill KCl solution, calibrate and put into use.

Product positioning and core features

1. Core positioning

FU24 is a composite sensor that integrates pH, ORP (oxidation-reduction potential), rH (relative hydrogen activity), and temperature measurements. It uses a patented bellows system to achieve pressure compensation and maintain stable measurement in pressure fluctuation environments. It also supports full angle safety (including inversion) and is suitable for harsh industrial scenarios.

2. Core advantages

Pressure compensation: The patented bellows system can balance the internal and external pressures in real time, avoiding the impact of process pressure fluctuations on sensor life. It supports 0-10 bar (gauge pressure) and -0.99 bar (negative pressure), and there is no risk of liquid leakage during sudden pressure changes;

Multi parameter integration: achieve pH (0-14), ORP (-1500~+1500 mV), rH (0-100), and temperature (-10~105 ℃) measurement in a single installation, reducing installation space and cost;

Durable design: The main material is PPS 40GF (glass fiber reinforced polyphenylene sulfide), which is resistant to chemical corrosion; The measuring end adopts G-type glass (pH electrode) and AR type glass (reference tube), suitable for various harsh media;

Explosion proof safety: certified by multiple national explosion prevention certifications such as ATEX, IECEx, FM, NEPSI, etc., intrinsic safety type (Ex ia IIC T3~T6 Ga), can be used in hazardous areas such as Class I Div.1/Zone 0;

Intelligent adaptation: We offer models with fixed cables (5m/10m) or Vario Pin connectors (VP without ID chip/VS with ID chip). The VS model can be paired with the SA11-P1 intelligent adapter for data storage and quick replacement.

Detailed explanation of technical specifications

1. Basic measurement parameters

Parameter category specification details

The pH measurement range is 0-14 pH, the asymmetric potential is 8 ± 15 mV, the slope is ≥ 96% of the theoretical value (25 ℃), and the response time t ₉₀<15 seconds (pH 7 → 4 step);

ORP/rH measurement ORP range -1500~+1500 mV, rH range 0~100, using solid platinum electrode, reference system is Ag/AgCl (3.3M KCl);

Temperature measurement with built-in Pt1000 sensor (compliant with IEC 751), dome type -10~105 ℃ (response time t ₉₀<1 minute), flat type 15~105 ℃ (response time t ₉₀<4 minutes);

Environmental adaptability protection level IP67, process temperature -10~105 ℃ (dome type), 15~105 ℃ (flat type), medium conductivity needs to be greater than 10 μ S/cm;

The main material of the mechanical performance is PPS 40GF, and the contact medium components include Viton (O-ring/bellows), PTFE (reference junction), and platinum (grounding pin); The maximum tightening torque is 7.5 Nm, and the interface is a 1-inch NPT thread;

2. Explosion proof and compliance certification

FU24 has passed the global multi regional explosion-proof and safety certification, with the following core certification parameters:

Certification standard explosion-proof level key parameters applicable areas

ATEX/IECEx Ex ia IIC T3~T6 Ga Ui=18 VDC, Ii=170 mA, Pi=400 mW EU and IECEx member states

FM (US/Canada) Class I Div.1/Zone 0, Ex ia IIC Temperature Class T3 (-40~105 ℃)~T6 (-40~40 ℃) US, Canada

NEPSI (China) Ex ia IIC T3~T6 Ga Certificate No. GYJ21.2891X China

Other certifications PESO (India), KCs (South Korea), EAC Ex (Russia) based on ATEX/IECEx certification endorsement for India, South Korea, Russia, etc

3. Model classification

According to the differences in connection methods and functions, FU24 is divided into the following models, with clear suffix code meanings:

Core characteristics of model suffix classification

FU24-05/-10 fixed cable type cable length 5m/10m, directly connected to transmitter (such as FLX21/PH202S series), without ID chip;

FU24-VP Vario Pin 8-pin connector without ID chip, requires WU10/WE10 cable to connect analog transmitter, without sensor information storage function;

FU24-VS Vario Pin with ID chip 8-pin connector (including ID chip), can be paired with SA11-P1 smart adapter, stores sensor calibration data, supports hot swapping;

Suffix – T1/- GC temperature sensor and region-T1: Pt1000, compatible with global certifications such as ATEX/FM/NEPSI; -GC: Compatible with Korean KCs certification;

Suffix – NPT/- FSM measuring end type – NPT: dome type (wear-resistant, suitable for media containing particles); -FSM: Flat type (self-cleaning, suitable for viscous media);

Installation and wiring process

1. Installation preparation

(1) Site selection requirements

Ensure that the measurement points represent the true state of the process medium, avoiding dead zones, bubble accumulation, or low flow rates (recommended flow rate of 0.1~1 m/s);

The ambient temperature should meet the explosion-proof level requirements (such as T6 level -40~40 ℃, T3 level -40~105 ℃), and avoid direct sunlight or severe vibration;

If the conductivity of the medium is greater than 10 μ S/cm, an electrolyte (such as KCl) needs to be added to ensure measurement stability.

(2) Pre installation inspection

After unpacking, confirm that the sensor model and serial number are consistent with the order, check that the cables/connectors are not damaged, and that the measuring end’s “wet pocket” (transport protective fluid) is intact;

Remove the ‘wet pocket’ and rinse the measuring end with deionized water to avoid residual protective solution affecting the measurement; It is recommended to recalibrate before first use (factory calibration data can be found in the QIC certificate).

2. Installation steps

(1) Installation method

Support pipeline installation, immersion installation, and bypass circuit installation. The core steps are as follows:

Thread sealing: Wrap polytetrafluoroethylene tape around the 1-inch NPT thread end (to avoid covering the thread end and prevent contamination of the medium);

Fixed sensor: Use a wrench to clamp onto the flat surface of the sensor body and tighten with a maximum torque of 7.5 Nm to avoid over tightening and damaging the threads;

Angle adaptation: It can be installed at any angle (including inversion), and it is recommended that the medium flow direction be towards the measuring end to reduce bubble adhesion.

(2) Wiring specifications

According to the differences in models, the wiring methods are divided into two categories: fixed cables and Vario Pin connectors:

Wiring Type Wiring Requirements

Fixed cable – brown (core wire): pH signal;

-Brown (shielding layer): pH shielding;

-Black: reference electrode;

-Yellow: LE/ORP signal;

-Red/Blue: Pt1000 temperature sensor;

-The shielding layer needs to be grounded at one end (transmitter side) to avoid interference;

Vario Pin Connector – VP Type (No ID Chip): 8-pin interface, A-pH, B-reference, C-pH shielded D-LE/ORP、E/F-Pt1000；

-VS type (with ID chip): additional G-ID chip power supply, H-ID chip data, requires SA11-P1 adapter;

Calibration and maintenance

1. Calibration process

(1) PH calibration (two-point calibration method)

IEC standard buffer solutions (pH 4.01, 6.87, 9.18) are required, and the steps are as follows:

Cleaning the sensor: Soak it in a 5% hydrochloric acid solution for 5 minutes to remove surface dirt, and then rinse it clean with deionized water;

The first point of calibration: immerse the sensor in pH 6.87 buffer solution, wait for the reading to stabilize, and then perform “zero calibration” according to the transmitter manual;

Second point calibration: Select a buffer solution based on the pH range of the process (4.01 for acidity and 9.18 for alkalinity), repeat step 2 to perform “slope calibration”;

Verification and reset: After calibration, rinse with deionized water and immerse in buffer solution again to verify that the error is ≤ 0.02 pH. After confirmation, reinstall the process pipeline.

(2) ORP/rH calibration

Use Chinhydron standard solution (1g/200mL buffer), core steps:

Choose a buffer solution with a pH close to the process pH (such as pH 4.01 or 6.87), dissolve the quinone hydroquinone powder until saturated;

Immerse the sensor in a standard solution, wait for the reading to stabilize, and manually input the theoretical value according to the transmitter manual (such as ORP=96 mV, rH=23.6 at pH 6.87);

The calibration error should be ≤ ± 10 mV, otherwise the ORP electrode needs to be cleaned (wipe the platinum surface with a soft cloth) and recalibrated.

2. Daily maintenance

(1) Regular cleaning

Choose a cleaning solution based on the type of medium contamination, only clean the measuring end (to avoid damaging the cable/connector):

Scale/Hydroxide: Soak in 5% hydrochloric acid for 10 minutes and rinse with deionized water;

Oil stains/organic matter: Clean with hot water and neutral detergent. Stubborn stains can be gently wiped with a small amount of calcium carbonate powder;

Protein residue: Soak in hydrochloric acid solution containing gastric protease (10g gastric protease+8.5mL concentrated hydrochloric acid/1L water) for 30 minutes;

Reference end blockage: Immerse the sensor in 3M KCl solution at 70 ℃, cool naturally to room temperature, and restore the conductivity of the reference junction.

(2) Replacement of vulnerable parts

O-ring/bellows: Check every 6-12 months. If aging or cracking occurs, replace with Viton material spare parts to avoid leakage;

Cable/connector: If damaged, replace the original WU10/WE10 cable to ensure that the explosion-proof performance is not compromised.

Troubleshooting and spare parts

1. Common faults and solutions

Possible causes and solutions for the fault phenomenon

PH reading drift is large. 1. Reference junction blockage; 2. Electrode contamination; 3. The buffer solution has expired; 1. Use 3M KCl solution to regenerate the reference end; 2. Clean the electrodes according to the type of medium; 3. Replace with fresh buffer solution;

ORP reading unresponsive 1. Platinum electrode surface oxidation; 2. Poor cable contact; 3. The medium has no redox activity; 1. Gently sand the platinum surface with sandpaper; 2. Check if the cable wiring is loose; 3. Confirm whether the process medium is suitable for ORP measurement;

Abnormal temperature reading: 1. Pt1000 cable open circuit; 2. The temperature compensation setting of the transmitter is incorrect; 1. Use a multimeter to measure the resistance of Pt1000 (approximately 1000 Ω at 25 ℃), and replace the cable if there is a circuit break; 2. Confirm that the temperature sensor type of the transmitter is Pt1000;

Explosion proof certification failure: 1. Cable damage; 2. Replace non original spare parts; 3. Installation does not meet the requirements of the control diagram; 1. Replace the original factory cable; 2. Only use Yokogawa certified spare parts; 3. Reinstall according to the D&E 2020-023-A50/A51 control diagram;

2. Key spare parts list

Spare parts model, purpose, applicable scenarios

K1521JA/JB sensor installation bracket JA (stainless steel) JB（PVDF）， Compatible with FF20-S3/F3 series mounting components, 1-inch NPT interface;

K1520BA~BE pH buffer solutions BA (4.01+6.87+9.18, 3 × 0.5L), BC (4.01 separately), etc., comply with IEC standards;

WU10-V-D-XX Vario Pin cable XX is length (2/5/10m), suitable for VP/VS type sensors, connected to transmitters;

The SA11-P1 smart adapter is only compatible with VS type sensors, stores calibration data, and supports HART communication;

BA11 active junction box is used for remote installation of VS type sensors, achieving signal amplification and anti-interference;

Chemical compatibility and compliance

1. Material compatibility

The chemical compatibility of the sensor’s contact medium components needs to match the process medium, and the tolerance range of the core material is as follows:

Material resistant medium taboo medium

PPS 40GF (main body) mostly contains acid, alkali, salt solutions (such as 50% sulfuric acid, 40% sodium hydroxide), strong oxidizing media (such as fuming nitric acid), and halogenated hydrocarbons;

Viton (seal) mineral oil, most organic solvents ketones, amines, low molecular weight esters;

PTFE (reference end) has no significant contraindications for almost all chemical media (except for molten alkali metals);

Glass (measuring end) weak acid, neutral medium hydrofluoric acid (concentration>40%), concentrated alkali (>50%);

2. Compliance requirements

RoHS compliance: compliant with EU Directive 2011/65/EU, restricting harmful substances such as lead and cadmium;

WEEE compliance: As a component of industrial fixed equipment, it needs to be recycled and disposed of in accordance with national regulations (such as the EU WEEE Directive);

Installation compliance: Installation in hazardous areas must comply with local electrical codes (such as NFPA 70 in the United States and CEC CSA22.1 in Canada), with a grounding resistance of ≤ 1 Ω.

System positioning and core composition

1. System positioning

The SC200 system is an intelligent conductivity measurement solution based on microprocessors, which achieves continuous online measurement of solution conductivity through a combination of “transmitter+detector+distributor”. It can convert the measured value into conductivity at a reference temperature based on temperature compensation, and support fault diagnosis and signal output control, meeting the measurement needs of ordinary industrial environments and hazardous environments (including explosive gases).

2. Core components

The system consists of three core components, each with clear functions and classifications:

Component type, specific model/classification, core functions

Conductivity detector – SC210G (2-electrode type):

-SC210G-A (low range, electrode constant 0.05 cm ⁻¹)

-SC210G-B (medium range, electrode constant 5 cm ⁻¹)

-SC211G-C (4-electrode type, high range, electrode constant 10 cm ⁻¹) contact measurement solution conductivity, built-in temperature sensor (thermistor for SC210G, Pt1000 for SC211G) for temperature compensation; Supports direct insertion (screw/flange) and flow-through (pipe/flange) installation.

Intelligent Conductivity Transmitter – SC200G (Non Explosion proof Type)

-SC200S (intrinsic safety explosion-proof type) receives the conductivity and temperature signals of the detector, and outputs 4-20 mA DC analog signals after processing; Support digital display, parameter setting, and self diagnosis; Explosion proof type needs to be used in conjunction with safety barriers.

Distributor/Safety Barrier – Distributor: PH201G (supporting HOLD/fault contact output), SDBT/SDBS (universal type)

-Safety Barrier: BARD400 (for intrinsically safe explosion-proof systems) provides power to the transmitter, receives 4-20 mA signals, converts them to 1-5 V DC, and outputs them to the recorder; Safety barriers are used to limit the energy of circuits in hazardous environments and prevent explosions.

Detailed explanation of technical specifications

1. Specification of conductivity detector

(1) Basic parameters

Model measurement range electrode constant contact material (sensor) measurement temperature range measurement pressure range protection level

SC210G-A 0~200 μ S/cm 0.05 cm ⁻¹ SUS316, polytetrafluoroethylene resin, fluororubber 0~105 ℃ (PP bracket 100 ℃) 10 kgf/cm ² (PP bracket 5 kgf/cm ²) IP65 (NEMA 4)

SC210G-B 200 μ S/cm~20 mS/cm 5 cm ⁻¹ Platinum, glass SUS316、 Fluororubber with SC210G-A and SC210G-A IP65 (NEMA 4)

SC211G-C 1 mS/cm~1 S/cm 10 cm ⁻¹ Platinum, glass, polyvinylidene fluoride resin, fluororubber 0~80 ℃ 2 kgf/cm ² Rain proof (JIS C0920)

(2) Installation and Interface

Direct insertion type: supports Rc 1-1/2 (PT thread), 1-1/2 NPT thread, or JIS 10K-50-RF, ANSI CLASS 150-2-RF flange;

Flow type: The bracket material is divided into SCS14 (stainless steel) and PP (polypropylene), and the interface is Rc 1/2, 1/2 NPT thread, or JIS 10K-15-RF/FF, ANSI CLASS 150-1/2-RF/FF flange.

2. Smart transmitter specifications

(1) Basic parameters

Parameter category specification details

Measurement and output conductivity display range 0~1999 mS/cm, output signal 4~20 mA DC (linear/line approximation/reverse output), maximum cable length 2000m (non explosion proof)/700m (explosion proof);

The temperature compensation reference temperature is adjustable from 0 to 100 ℃, and the compensation coefficient is adjustable from -10% to+10%/℃. It supports NaCl solution characteristic compensation or custom solution characteristic compensation;

Environmental adaptability: working temperature -10~+55 ℃, storage temperature -30~+70 ℃, humidity 10~100% RH (non condensing); The shell material is cast aluminum (polyurethane baked paint) with a protection level of IP65;

Accuracy and repeatability of conductivity measurement accuracy ± 1% range (1 μ S/cm~2 S/cm), ± 0.02 μ S/cm (0~1 μ S/cm), repeatability ± 0.5% range;

The self diagnostic function supports diagnosis of temperature exceeding limits, conductivity exceeding limits, electrode contamination, temperature coefficient errors, circuit faults, etc. When a fault occurs, it outputs 22.0 mA (when the burnout function is turned on);

(2) Explosion proof specification (SC200S)

Explosion proof type: Intrinsic safety type (Ex ia IIC), to be used in conjunction with BARD400 safety barriers;

Environmental restrictions: Installation height ≤ 1000m, humidity 45~85% RH, prohibited from installation in Zone 0 hazardous environment;

Circuit parameters: Cable inductance ≤ 2.2 mH, capacitance ≤ 35 nF, ensuring no contact between intrinsic safety circuits and non intrinsic safety circuits.

Installation and wiring process

1. Installation of conductivity detector

(1) Preparation before installation

Site selection requirements: easy to maintain, measuring solution temperature/pressure in accordance with specifications, no bubbles, stable liquid level;

Interface preparation: Direct insertion type requires processing of threaded/flange holes that meet specifications (electrode insertion depth ≥ 60mm); The flow type (PP bracket) requires the installation of a nominal 50A (outer diameter 60.5mm) mounting pipe, which can be installed vertically or horizontally.

(2) Installation steps

Direct insertion type: thread type wrapped with sealing tape and screwed into the interface, flange type needs to add gaskets and evenly tighten 4 bolts;

Flow type: fixed to the installation pipe or wall, adjust the direction of the terminal connection port (can rotate by loosening the union nut);

Pipeline connection: Use rigid vinyl chloride pipes (nominal 16) or PP pipes for PP supports, and SUS304/316 pipes (nominal 15) for SCS14 supports. The recommended flow rate is ≤ 20 L/min to avoid the mixing of bubbles.

2. Installation and wiring of transmitters

(1) Installation method

Pipeline installation: fixed to a nominal 50A pipeline (vertical/horizontal) using a dedicated bracket;

Panel installation: The panel opening size is 156 × 121 mm (tolerance+1.1mm), fixed with panel brackets;

Wall installation: Process 3 M8 threaded holes on the wall with a spacing of 70mm, and fix them with wall brackets.

(2) Wiring specifications

Requirements and steps for wiring types

Detector specific cable – SC210G (2 electrodes): 3/5/10m dedicated cable, connecting transmitter terminals 11 (T1), 12 (T2), 13 (C1), 14 (C2);

-SC211G (4 electrodes): 5.5/10m cable with connector, directly inserted into the detector interface, with the other end connected to transmitter terminals 11-16;

2-core shielded cable (outer diameter 6-12mm) is used for transmitting signal cables, with a maximum length of 2000m for non explosion proof systems and 700m for explosion proof systems. The shielding layer is connected to the safety barrier grounding terminal (explosion-proof) or the transmitter grounding terminal (non explosion-proof), with a grounding resistance of ≤ 10 Ω;

Grounding Wiring Non Explosion proof System: The M4 grounding terminal at the bottom of the transmitter is grounded with a wire of ≥ 2 mm ² (JIS Class 1 grounding, resistance ≤ 100 Ω); Explosion proof system: Only grounded through safety barriers, the transmitter is not grounded separately.

Operation and parameter settings

1. Operational hierarchy and mode

The system operation is divided into three levels, with clear functions and permissions at each level:

Operational hierarchy, permission scope, core mode/function

Operational level daily monitoring and basic operations (no need to open the cover) – Measurement mode: display conductivity, temperature, output current;

-Calibration mode: Perform standard solution calibration;

-Display selection: Switch auxiliary data such as temperature, output value, electrode constant, etc;

-Signal Hold: Turn on/off signal hold (requires setting level permission).

Parameter configuration for level adaptation measurement scenarios (requires lid opening operation) – Output range: Set the conductivity range corresponding to 4mA/20mA (4mA value should be less than 60% x 20mA value);

-Maintain parameters: choose to maintain “previous value” or “fixed value” (fixed value 4~20mA adjustable);

-Temperature compensation: Choose NaCl characteristics or custom compensation (input conductivity at reference temperature).

Service level system underlying configuration (password required, only for initial startup or maintenance) – CODE 01: Select temperature sensor type (Pt1000/Ni100/NTC) and temperature unit (℃/℉);

-CODE 02: Set reference temperature (0~100 ℃);

-CODE 03: Select output characteristics (linear/polyline);

-CODE 05: Input electrode constant (including fine adjustment ± 19.99%);

-CODE 07: Select electrode type (2 electrodes/4 electrodes);

-CODE 09: Enable/disable fault burnout function (output 22mA in case of fault).

2. Key operational procedures

(1) Standard solution calibration (operational level)

Enter calibration mode (MEASURE → CAL → YES), immerse the detector electrode in a NaCl standard solution with known conductivity (concentration close to the upper limit of the range, temperature close to the reference temperature);

After the display stabilizes, press the YES key to record the current measurement value;

Enter the actual conductivity of the standard solution at the reference temperature and press the ENT key to complete the calibration;

If the deviation between the calibrated electrode constant and the input value of service level CODE 05 is greater than 20%, Err.3 will be displayed, and the concentration of the standard solution needs to be checked or the electrode needs to be replaced.

(2) Temperature compensation setting (setting level)

Enter temperature compensation mode (Setting → Temperature → YES);

Choose compensation method: NaCl characteristics (default) or custom characteristics (*%);

If customized, adjust the solution temperature to the reference temperature, read the current conductivity and input it, and the system will automatically calculate the compensation coefficient (-10~+10%/℃);

If the compensation coefficient is known, it can be directly input in the service level CODE 14, with priority higher than the calculated value at the setting level.

Maintenance and troubleshooting

1. Regular maintenance

(1) Detector maintenance

Electrode cleaning:

Low/medium range (SC210G): Wipe the electrode surface with a thin rod wrapped in degreasing cotton to avoid scratches;

High range (SC211G): Hot water+detergent is used for ordinary pollution, 5-10% dilute hydrochloric acid is used for lime/hydroxide, and sodium hypochlorite solution is used for algae (mixing hydrochloric acid with sodium hypochlorite is prohibited);

Cleaning cycle: Determine based on the degree of solution contamination. Low range (<200 μ S/cm) may not be cleaned for a long time, while high range (>200 μ S/cm) requires regular inspection.

O-ring replacement: The sealing O-ring (located at the union nut/fixing screw) needs to be checked regularly, and it is recommended to replace it every 6 months in high-temperature solution scenarios to avoid solution leakage.

(2) Transmitter maintenance

Transparent window (polycarbonate material): Clean with a soft cloth or neutral detergent, and do not use organic solvents;

Data backup: After setting the parameters, it is recommended to record key data (electrode constant, reference temperature, compensation coefficient) to avoid power loss.

2. Troubleshooting

The system outputs error codes through self diagnosis. Common faults and their solutions are as follows:

Error code, fault cause, solution measures

Err.1 electrode polarization (pollution, wear, corrosion) cleaning electrode; If the error persists after cleaning, replace the electrode assembly.

Err.2 temperature coefficient calculation abnormality (incorrect reference temperature conductivity input by setting stage). Re measure the solution conductivity at the reference temperature and recalculate after inputting correctly.

Err.3 standard solution calibration deviation>20% (standard solution concentration error or electrode failure). Confirm the standard solution concentration and recalibrate; If there are repeated errors, replace the electrode.

Err.5 conductivity exceeds the limit (the selected detector range does not match). Select a new detector based on the solution conductivity (low range → SC210G-A, medium range → SC210G-B, high range → SC211G-C).

Err.7/8 temperature exceeds the limit (solution temperature is too high/too low) or temperature sensor malfunction. Check the solution temperature and wait for it to recover to the allowable range; If the temperature is normal, check the sensor wiring or replace the sensor.

Err.10 EEPROM malfunction (abnormal internal storage of transmitter), power outage and restart; If it is ineffective, contact after-sales maintenance.

Err.17 output range setting error (4mA corresponds to conductivity ≥ 60% × 20mA value) Reset the range to ensure that 4mA value<60% × 20mA value.

Spare parts and compliance

1. Key spare parts list

Component spare parts model/specification usage

Replace the faulty electrode components of SC210G electrodes K9208EA (SC210G-A) and K9208JA (SC210G-B) to ensure electrode constant matching.

SC211G electrode K9208BD (electrode constant 10 cm ⁻¹) high range detector dedicated electrode replacement.

Seal O-ring K9050AT to prevent detector interface leakage, and replace regularly in high temperature scenarios.

Replace the scratched or contaminated transparent window of transmitter window K9311JN to ensure clear display.

Install brackets K9149SA (pipeline), K9149SB (wall), K9311KA (panel) for transmitter installation and fixation, suitable for different installation scenarios.

2. Compliance Statement

Explosion proof certification: SC200S intrinsic safety type complies with IECEx and ATEX standards and needs to be used in conjunction with designated safety barriers (BARD400);

Grounding requirements: Non explosion proof systems must comply with JIS Class 1 grounding, while explosion proof systems must be separately equipped with intrinsic safety circuit grounding (resistance ≤ 10 Ω);

Cable specifications: Explosion proof system cable inductance ≤ 2.2 mH, capacitance ≤ 35 nF. It is recommended to use CEV-S cable (up to 700m) or CVV-S cable (up to 350m).