Manual
Manual
Manual
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Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Safety Precautions 5
1.1.1 Warnings used in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.2 Qualification and Training of Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.3 Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.4 Safe Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
I Analyser
2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Safety Precautions 10
2.1.1 Installation, Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1.2 Unauthorised Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1.3 Impermissible Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1.4 Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Technical Data 10
2.3 Installation 11
2.3.1 Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3.3 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.4 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Operation 15
2.4.1 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4.2 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4.3 Home Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4.4 User Authentication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.5 Analyser Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.6 Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
II Options
3 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 OzoSense (Ozone) Sensor 31
3.1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.1.3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1.4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.1.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1 Analogue Outputs 45
4.1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1.3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1.4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.2 Relay Output 51
4.2.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.2.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.2.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
III Accessories
5 Flow Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.1 Single Overflow Cell 65
5.1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.1.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
IV Documentation
6 RoHS and WEEE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.1 Compliance statement WEEE 69
6.2 Compliance statement RoHS 70
7 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8 Returns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.1 Contact Details 73
1. Introduction
This manual has been generated to accompany the serial number of the instrument as recorded
on the front of this manual. It is specific to that serial number. Information regarding options or
accessories that do not apply to this instrument do not appear in this manual. If you upgrade your
firmware or your hardware please ask for a new manual to be generated for you.
This manual contains basic information to be noted during installation, operation and main-
tenance. It is therefore essential that this manual be read by the contractor before installing and
commissioning the CRIUS® , as well as by the relevant operating personnel/owner of the unit. It
must remain available for reference at all times.
In addition to the general safety instructions under the main heading Safety Precautions, the
special safety precautions outlined in other sections must also be observed.
This manual has been supplied electronically. A hard copy is available on request from
support@processinstruments.net.
Draws attention to supplementary information to make the work easier and ensure
trouble-free operation. May also appear in conjunction with safety instructions which
may endanger the analyser and its operation if disregarded.
To reduce the risk of injury, do not permit children to use this product.
Risk of electric shock. Connect only to a suitable isolated, hard wired electrical outlet.
It is recommended that the outlet is protected by an RCD (Residual Current Detector)
or is in any event in compliance with all local electrical regulations. Do not bury the
electrical supply cable.
To reduce the risk of electric shock, replace damaged electrical cable immediately.
To reduce the risk of electric shock, do not use an extension cable to connect the unit
to an electric supply; provide a properly located outlet.
2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Safety Precautions
2.2 Technical Data
2.3 Installation
2.4 Operation
2. Overview
The CRIUS® is a compact electronic communication and control system. It is designed for use
with many different measuring sensors. Any use other than the one described here compromises
the safety of persons and the entire measuring system and is, therefore, not permitted. The
manufacturer is not liable for damage caused by improper or non-designated use.
Every analyser is carefully checked before leaving the factory. If for any reason you are unhappy
with your purchase, please contact the organisation that you purchased the analyser from or
Process Instruments (UK) Ltd directly.
CRIUS® Overview
1. Front panel screws (×4)
2. Display
3. Up button
4. Down button
5. Right button
6. Left button
7. Enter/Select button
8. Soft keys
9. Cable glands
10. Micro SD access
11. Power lamp
12. Indication lamp
10 Chapter 2. Overview
2.1.4 Chemicals
Should the sensors attached to the CRIUS® be in contact with hazardous chemicals, great care
must be taken when handling the sensors.
Fire hazard. No parts are suitable for use in a hazardous rated area.
When working with this equipment, the accident prevention regulations applicable on
site must be observed and the specified personal protective equipment worn.
Please unpack the equipment and ordered accessories carefully in order not to miss
small parts. Immediately compare the scope of delivery to the delivery note. If there are
any discrepancies, contact your supplier.
CRIUS® Dimensions
1. 103mm
2. 309mm
3. 230mm
2.3 Installation
As with all instrumentation the installation and commissioning of this instrument is
crucial to its safe and effective operation. This instrument must only be used for its pur-
pose as outlined in this manual. It must be installed and commissioned in accordance
with this manual and by trained, qualified personnel.
2.3.2 Unpacking
Please have a copy of your order with you when you unpack your instrument. All orders are checked
when they leave the factory. Please check that you have all the parts that were ordered as soon as
you open the box. If anything is missing, or damaged, please contact your supplier immediately. If
12 Chapter 2. Overview
the instrument needs to be returned for any reason please follow the return instructions given in
this manual (refer to section 8).
2.3.3 Mounting
The CRIUS® enclosure is very versatile and can be wall mounted, panel mounted or mounted on a
handrail or pole2 . The CRIUS® electronics should be mounted so that:
The analyser enclosure can be screwed directly onto the wall. Mark and drill the holes as per the
drawing below. Insert wall plugs and secure with appropriate screws (not supplied).
The analyser enclosure can be panel mounted using the optional panel mount kit. The support
bracket can be used as a template for cutting and drilling the panel.
2 For panel or handrail mounting the enclosure requires optional mounting kits that can be ordered from Pi.
2.3 Installation 13
A - CRIUS® front section, B - Four M5 bolts, C - CRIUS® rear section, D - Rubber gasket,
E - Panel, F - Support bracket, G - Four M5 washers, H - Four M5 nuts.
The analyser enclosure can be handrail mounted using the optional handrail mount kit. By
turning the brackets through 90° the analyser can also be pole mounted.
14 Chapter 2. Overview
The connections are made via press to open connectors or screw terminals. An insulated
screwdriver can be used to operate the connector. Each instrument has a large number of possible
wiring combinations depending on which sensors, inputs, outputs or communications are selected
at the time of purchase. This is achieved by the use of expansion electronics cards specific to each
role. These expansion cards are fitted to “Slots”.
The connections for sensors, inputs, outputs and communication cards are detailed in Part II of
this manual.
2.4 Operation
2.4.1 User Interface
The CRIUS® display is a 4.3“, 480 × 272, 24-bit colour display and is best viewed from directly in
front. The user interface is accessed via nine buttons embedded in the membrane overlay. There
are also two status LEDs, showing power and alarm status, and an audible buzzer.
The buttons all have a tactile feedback response. Holding the buttons in will inject multiple
key presses of increasing speed until the button is released. In some cases holding a button will
provide access to a different function. These are highlighted in the manual. The four buttons
along the bottom of the screen, are defined for each screen by the legend above the button. The
navigation and Select buttons below the display are always for navigation of the display. The Up
and Down, Left and Right buttons are used for moving the “Select” target around the display.
The screen displayed once the system is started is either the default “Home” screen (see
section 2.4.3), if configured, or the Main Menu.
The Menu screen is a standard display in your CRIUS® and is a tile based display of all the
different parts or “devices” that make up your analyser. By using the Up, Down, Left, Right and
Select button it is possible to navigate to any part of the analyser by highlighting the icon and
16 Chapter 2. Overview
selecting it. Devices are firmware modules that control a physical device, such as a sensor, or a
purely software construct, such as a PID control calculation. Some hardware devices have multiple
device tiles associated with them. For example, an Ethernet communications card will add an
“Ethernet” tile which allows a physical interface to be configured and a “Modbus TCP” tile allowing
access to the main communications protocol used on the interface.
There are two standard device tiles available on all analysers, regardless of configuration. The
“Analyser” tile gives access to information and configuration options for the unit, e.g., selecting the
language and setting the time and date. The “Logs” tile allows access to the status and data logs
stored on the unit.
Selecting a device tile from the menu will open an overview or set up screen. The overview
display gives the user key information for that device and may allow the entering of commonly
changed variables. For example, an overview for a chlorine sensor will display the chlorine reading
and sensor maintenance information, and offer the user a shortcut to calibrate the sensor.
Many screens will have an “Options” button. Pressing this button will produce a pop-up menu
on the display. Some of the items on this menu will have a I next to them indicating that there are
further menus accessible by highlighting the menu item and either pressing the Select button or
the Right button.
For details of how home screens are defined and configured see section 2.4.5.3.
2.4 Operation 17
The analyser is preconfigured with a default user called “user1” who has full access to the
analyser, with the default password of:
1, 1, 1, 1, 1, 1
Analyser Overview
Name & ID The Name and ID details allows the user to name the instrument in various ways.
These tags are used to identify the instrument, e.g., when an instrument sends a text alarm,
the Name and ID details are used to inform the recipient as to which instrument is in alarm.
The Name would typically be the site name and the ID would typically refer to a specific
analyser.
Language The user interface of the CRIUS® can be set to any supported language. Use the drop
down list to select the language of choice.
Time Zone Select the required time zone. The internal clock stores the time in UTC format.
Therefore changing the time zone will change the current time. Daylight savings, if applicable
for the selected time zone, will automatically be followed.
Time Set the required time by modifying the values using the up/down buttons
Date Select the date using the calendar widget that will appear when the date entry box is selected.
Buzzer The buzzer will sound when a key is pressed or to indicate that the analyser is in alarm.
Use the checkbox to enable or disable the buzzer sounding.
Backlight Timeout In order to extend the life of the display a timeout can be set. At the end of
the timeout the display will go dark. Any button press will turn the screen back on. Use the
checkbox to enable or disable the backlight timeout and set the desired timeout using the
up/down buttons. The timeout is in HH:MM:SS format.
Home Button On most displays the left button under the display can be set to take the user to the
“Home” screen or the “Menu” screen.
Blink highlighted If this option is enabled, the element the user needs to look at blinks between
two colours to attract attention.
2.4.5.2.1 Menu
Analyser tile If the checkbox is ticked then the Analyser tile will be hidden as default on the main
menu.
Logs tile If the checkbox is ticked then the Logs tile will be hidden as default on the main menu.
The CRIUS® has the capability to have multiple home screens which give the user options as to
how the display provides information (see section 2.4.3). To set up a new home screen, edit or
delete an existing home screen, select:
To delete a home screen highlight the home screen name with the up/down buttons and press
“Delete”. Pressing and holding the “Delete” key will make the “Delete All” function available. A
confirmation message box will appear before all home screens are deleted. To edit the home
screen, again select the name, and press the select button. To create a new home screen, select
“Create Home Screen” and press select.
Select the home screen type from the drop down list. Generic home screens allow up to 4
devices to be displayed in a variety of formats. Other home screen types are application-dependent
and are described below, if applicable. For this example, select “Generic” and press “Create”.
Editing an existing Generic home screen or creating a new Generic home screen will display
the above form. Select the desired layout as shown in the diagram below the layout selection
box. The layout is made up of a series of windows that display selected information. The possible
window arrangements for the layouts are as follows:
2.4 Operation 21
Layout 1 Layout 2
1 1
3
2 3 2
4
Layout 3 Layout 4
1 2 1 2
3 4 3
Layout 5 Layout 6
Each window can display information about a device or a data log graph. To select what is
displayed in each window of a particular layout, move the selection to highlight the window and
press the select button.
Type Select the type of information to display in the selected window. Options are “Device” or
“Data Log”.
Data Log If “Data Log” is selected in the type field, this option will be available. Select the data
log to display.
22 Chapter 2. Overview
Device If “Device” is selected in the Type field above, this option will be available. Select the
device to display in the selected window.
Window If the device selected above has multiple types of display possible for this type of window,
then this option will be available. Select the type of information to display.
2.4.5.4 Security
To access the security setup options, select:
Login Timeout If no user activity is detected within this given time period while the main menu or
home screen is displayed, then the current user will be logged out. The time is in HH:MM:SS
format.
Default Access If enabled, then no user authentication will be attempted when accessing a device
tile or using a quick access function from the home screen. Instead the user will be allowed
access at the security level set out in the boxes below it.
With each of these areas, operations have been assigned to four security levels:
None No access to the assigned area is enabled.
Basic Users with this access level can see information and perform basic maintenance tasks.
Users generally can not change any settings with this access level.
Intermediate Users with this access level can perform routine maintenance tasks and change
common settings.
Advanced Users with this access level can perform all available actions.
Using this security model it is possible to assign specific tasks to individual users. For example,
It is possible to allow a user to calibrate sensors (intermediate access for sensors), but not change
PID settings (no access for controls). Access to restricted functions will require the entry of the
operator’s security password.
2.4.5.5 Users
To add, remove users or modify access rights, select:
To add a user, highlight “<+ Add User>” and press the select button. Enter the desired user
name and access rights. To set the password, press “Password” and follow the on screen prompts.
To delete a user, highlight the user name and press “Delete”3 . To modify a user account, highlight
the user name and press the select button. The user name and security access rights will then be
editable.
A user can change their own password by selecting the following and following the on screen
prompts.
Information given for each Node4 includes board number, board type, firmware version number
and unique serial number. Each enclosure in a system contains a base board. These boards are
numbered 1, 5, 9 and 13. Board 1 is the master board with the screen and keypad attached. Each
base board has three slots for communication boards, whose node number increments from the
base board they are installed on. For example, the master board, or node 1, has communication
slots with nodes numbered 2, 3 and 4.
Highlighting a base board and pressing the “Select” key will open a further information screen
showing the I/O plugin cards installed, their location and hardware and software version numbers.
3 A user can not delete their own user account. This prevents the possibility of having no privileged user accounts and
The CRIUS® makes use of several internal read-only file systems as well as the micro SD card.
Information regarding the file system usage can be viewed by selecting:
Options → Information → File Systems
All entries other than “/mnt” are internal read-only file systems and the information may be
useful for technical support enquiries. The “/mnt” file system refers to the micro SD card and a
total size of 0.00MB indicates that the card is missing or not detected.
The device list shows which software modules are installed and active on the anlayser. To
access this information, select:
Options → Information → Device List
Each installed device is listed. Use the Up and Down keys to scroll through the list.
The “re-alarm” feature can be enabled and the timeout set. If the analyser is in alarm and
that alarm is acknowledged (see below), then the analyser will return to the alarm state after the
timeout has expired if the error condition has not been rectified. The exact reason for the active
alarm is shown by selecting:
When the analyser is in alarm, the message shows the time and date of when the message was
updated and an “Ack” button silences the alarm and prevents any further alarm SMS messages5
being generated. The alarm message will change to indicate the alarm has been acknowledged.
Select an existing file to overwrite or select “+New File” and select “Next”. If creating a new file,
enter the desired filename (by default the date is included in the filename). Then select “Next”.
When notified that the backup file has been created select “OK”.
2.4.5.10.2 Restore/Clone
To begin a restore/clone operation navigate to:
Select the file to restore/clone from and select “Next” and then “OK”. If this is the analyser on
which the backup file was created a restore operation will occur. If this is a different analyser a
clone operation will occur.
2.4.6 Logs
Selecting the log tile from the main menu will display a secondary logs menu. These available
options are; Backup Logs, Status Log and Create Data Log.
If any data logs are defined, each will be displayed as its own file.
Use the arrow keys to scroll up, down, left and right. Press “Clear” to delete the current status
log messages and truncate the status log. Press “Download” to save the status log to SD card.
Enter the name to identify the data log and the log interval. Available options are 1, 2, 5, 10, 15,
20, 30 minutes or 1 hour. Press “Next” to continue.
Select from a list of available parameters, signal inputs and control outputs to populate the data
log. Highlight the desired measurements or press “All” to highlight all available measurements. Up
to the first 4 measurements selected will be displayed on the data log graph. Press “Done” when
finished. The data log will be created and data collected.
The overview allows the renaming of the log and changing of the log interval. The “Delete”
button will remove the log completely and prevent any further data logs being collected. Please
note that deleting a data log will cause the analyser to reset. The “Clear” button will truncate the
data log and remove any historic data. The "Download" button allows the data log to be saved to
SD card as comma-separated values.
28 Chapter 2. Overview
To view the data log values collected, press the “Data” button. A table of recorded values will
be displayed. Use the arrow keys to scroll up, down, left and right.
To view the data log graph, press the “Graph” button. The legend shows the line style for each
measurement and axis.
II
Options
3 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 OzoSense (Ozone) Sensor
4 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1 Analogue Outputs
4.2 Relay Output
3. Sensors
Do not touch the electrode finger. Do not remove the surface layer on the electrode
finger.
Risk of electric shock. Disconnect electrical supply before making or breaking electrical
contacts.
The OzoSense (Ozone) Sensor is designed to measure ozone in water. When handling
the sensor please wear the appropriate PPE.
During operation, ozone diffuses out of the sample water, through the membrane and, with the
help of the electrolyte, causes an electrical signal at the working electrode. The electrical signal
at the working electrode is proportional to the concentration of the ozone and is amplified by the
electronics of the sensor. The measuring signal is independent from the temperature of the sample
water due to an integrated temperature compensation. Surfactants (e.g. tensides) are partially
tolerated.
3.1.2 Installation
The sensor can be mounted in a single, double, or triple overflow cell, a single pressure cell, a
single autoflush or a double autoflush. In all cases the sensor should be mounted such that:
• The sensor must be operated in an upright position, so that the incoming flow comes from
the bottom up to the membrane.
• During unpressurised operation with free outflow of the sample water, air bubbles have no
detrimental effect unless they cover the membrane. Air bubbles on the membrane obstruct
the inflow of the disinfectant which leads to incorrect measured values.
• The flow rate must be constant.
• The membrane life is typically one year, but can vary considerably depending on the water
quality. Heavy contamination of the membrane should be avoided.
• During interval operation of the measuring system or plant the sensor is not allowed to be
disconnected from the power supply. The sensor must be connected to the power supply all
the time.
1 Depending on sample water quality.
3.1 OzoSense (Ozone) Sensor 33
3.1.3 Commissioning
Some electrolytes contain diluted acids. Please heed the warnings on the electrolyte
bottle. Do not ingest the electrolyte. Avoid contact of the electrolyte with skin and eyes.
Wash with lots of water in case of contact. In case of eye inflammation, contact a doctor.
Open the membrane cap container, empty out the liquid and
take out the membrane cap. Make sure that only one band is
in the groove and covers the vent (A). Fill the empty membrane
cap up to the top edge with the electrolyte supplied. If there are
air bubbles on or near the membrane, please perform the “knock
method” described below.
Hold the electrode finger upright and place it onto the filled mem-
brane cap. Turn it anticlockwise until the thread engages, then
screw the electrode shaft clockwise slowly onto the membrane
cap. Excess electrolyte will escape through a vent (A) in the
membrane cap. Do not close this vent with your finger. Take
care as the electrolyte may spurt from the vent. Wipe off the
excess electrolyte with a paper towel.
Push the second band into the groove over the first. Make sure
that the bands do not crease.
3.1.3.3 Calibration
If the sensor is connected via Modbus and a calibration indication is required, the
sensor will need to be placed into hold during calibration. To do this press the hold
button found on the sensor overview screen. Once calibration is completed the sensor
will need to be taken out of hold by going back to the overview screen and pressing the
hold button again. If the hold button is not pressed again the real time sensor values
will not be output.
The calibration function can be accessed either from sensor overview page using the “Calibra-
tion” shortcut button or by selecting:
1. Follow the instructions by pressing “Next” when the sensor readings are stable.
2. The CRIUS® will count down from 30 seconds. During this countdown, calibration data is
collected.
3. At the same time as the CRIUS® is counting down, a sample of the water being measured by
the OzoSense (Ozone) Sensor sensor should be taken from the sample point at the sensor
and measured using a device for calibration.
4. At the end of the countdown the current value being read from the sensor is displayed. To
calibrate the sensor change the value to the value given by the calibration device. To do this
press the “Select/Enter” button and using the Up, Down, Left and Right arrows change each
digit to the correct number. Press “Next”.
2 The OzoSense (Ozone) Sensor should not be calibrated at less than 10% of maximum range. This is to reduce
when the chemical reaction in the sensor has reached equilibrium for the level of Ozone in the water.
36 Chapter 3. Sensors
5. If the calibration is successful, the analyser may ask various maintenance questions4 . Select
“Yes” or “No” to answer the maintenance questions.
3.1.4 Operation
When selecting the OzoSense (Ozone) Sensor tile from main menu, the sensor overview screen
will be displayed. This shows the current reading, alarm state and maintenance information. The
buttons allow access to the sensor options, quick access to the calibration functions and manual
control of the sensor hold feature.
The following sections describe the functionality found in the pop-up menu that appears when
selecting “Options”.
4 The CRIUS® asks whether maintenance was done at the same time as calibration. This provides a review of recent
Name Edit the sensor name used to identify the sensor. Up to 25 characters.
Display Options are “Show” or “Hide”. This relates to whether the tile for this sensor will show on
the Menu screen.
Enabled Options are “Yes” or “No”. If “No” is selected the sensor will not update and will not
generate alarms.
Flow Signal Allows a flow switch to be associated with a sensor. Options are “Disabled” or
selectable from a list of available digital inputs.
Flush Signal Allows an external flush signal to be associated with a specific sensor. The flush
signal will notify the sensor that an automatic cleaning operation is underway. Options are
“Disabled” or selectable from a list of available digital inputs.
Process Signal Allows an external process signal to be associated with a specific sensor and
allows the external signal to enable or disable a sensor. Options are “Disabled” or selectable
from a list of available digital inputs.
Hold Delay The Sensor hold delay is used following a flush event to allow the sensor reading to
recover. Time entered in HH:MM:SS format.
3.1.4.2 Ozone
Parameter settings are accessed by selecting:
Type A selectable list of parameter types. The selection made here will affect what options are
available below.
Units Select from an appropriate list of units for the parameter type.
Precision Select the number of digits following the decimal point to display. This should be
appropriate for the measurement. Options are 0 to 5.
Range Set the range values for the parameter. Options are restricted to those appropriate to the
parameter.
Offline Value This is the value reported by the parameter when in ‘Offline’ mode, for example, if
the sensor is in alarm. Options are within the range of the parameter.
Averaging Enables or disables a rolling average for the parameter to smooth the reading. Options
are “Enabled” or “Disabled”. Selecting “Enabled” will allow editing of the following two form
fields.
Length Enter the number of data points in the rolling average buffer. Options are 2..60.
Delay Enter the delay between collecting data points for the rolling average5 . Options are
200..5000ms.
taken every 2 seconds. If averaging is enabled it will apply to all aspects of the parameter value, e.g., it will apply to the
value displayed, logged and outputted.
38 Chapter 3. Sensors
a visible bar across the top of the screen and sound a buzzer. One flow alarm per sensor and two
data alarms per parameter are available.
Thresholds are similar to alarms except that they are events that are supposed to occur and
therefore will not cause the instrument to go into “Alarm”. Thresholds are most frequently used to
trigger relays to cause something to happen when a parameter reaches a value.
To access the alarm and threshold configuration select:
The display has a tab for each alarm and threshold. Navigate to the tab using the right and left
buttons indicated on the bottom of the display or navigate through the settings using the up and
down arrows. Options are:
Enabled Selecting this option turns the alarm/threshold on or off.
Set The Value is used to trigger the alarm or threshold6 . The Delay is the amount of time the
value has to exceed the set value before the alarm/threshold is triggered.
Reset The Value is used to clear the alarm or threshold. The Delay is the amount of time the
value has to exceed the reset value before the alarm/threshold is cleared.
3.1.4.5 Calibration
The calibration procedure is described in section 3.1.3.3.
The graph shows the current calibration slope. The health of the sensor and/or quality of
calibration can be assessed using this information. If required, the calibration can be reset to
factory settings by pressing the “Reset” button.
Flags that are active are shown in black text on a white background, those that are not active
are greyed out. Available flags are:
Display on main menu When active the device tile is displayed on the main menu. If inactive, the
tile is hidden in the default view.
Sensor enabled This flag is enabled if the sensor is enabled.
Sensor on-line This flag is enabled if the sensor is on-line.
Sensor reading in warm up If the sensor reports that the current reading is not ready, then this
flag is set.
Sensor reading in hold This flag is enabled when the sensor output value is held, usually during,
or just after, self-cleaning or periods of maintenance.
Sensor process stopped If the sensor is off-line due to a process stop signal, this flag is set.
Sensor flush active This flag is set when the sensor is self-cleaning.
Sensor calibration warning reached If the calibration is due and the maintenance warning is
enabled, then this flag is set
Sensor maintenance period x warning reached If the maintenance warning is enabled and the
due date has passed, then this flag is set. The exact type of maintenance is sensor-specific.
See section 3.1.4.4 for details.
Flags that are active are shown in black text on a white background, those that are not active
are greyed out. Available flags are:
I/O card fault detected If set, this flag indicates that a low-level hardware fault has occurred.
Report to your supplier.
Incorrect I/O card found If set, this flag indicates that the I/O card fitted is of the wrong type.
I/O card in use This flag is set when two devices are attempting to use the same I/O card.
Sensor connection error This flag is set when the sensor hardware detects a physical connection
fault.
Sensor failed to read input signal If set, the sensor has failed to read the state of the flow, flush
or process signal.
40 Chapter 3. Sensors
Sensor flow alarm active This flag is set if a low/no flow condition is reported by the flow signal.
Sensor data alarm active When the sensor readings trigger a data alarm, this flag is set.
I/O card configuration failed This flag is set if the I/O plugin card fails to respond correctly.
Contact your supplier for advice.
Sensor conversion failed This flag is set if the analyser fails to read sensor values from the I/O
plugin card. Contact your supplier for advice.
Flags that are active are shown in black text on a white background, those that are not active
are greyed out. Available flags are:
Alarm 1 active The first parameter data alarm is active and triggered.
Alarm 2 active The second parameter data alarm is active and triggered.
Averaging enabled The value displayed for this parameter is averaged.
Threshold 1 active The first parameter threshold is active and triggered.
Threshold 2 active The second parameter threshold is active and triggered.
3.1.4.10 Diagnostics
To view raw sensor conversion data and calibration settings for live sensor values, select:
Options → Diagnostics
Conversion Raw sensor output readings converted by hardware. Values are either in mA or mV,
depending on the exact type of sensor.
Offset The zero offset applied to the calibration.
Slope The slope calculated by performing a span calibration.
Value The value of Ozone as determined by the conversion value and calibration variables. The
value is calculated as:
Conversion − Offset
Value =
Slope
3.1.4.11 Connections
As the CRIUS® is a modular system the exact wiring details will be specific to each order. Electrical
connections required can be viewed by selecting:
Options → Connections
3.1 OzoSense (Ozone) Sensor 41
In the image above, the left side shows the position of the connector. The right side shows the
connections required on the marked connectors.
3.1.5 Maintenance
The coating of the electrode finger must not be polished. Do not unscrew the metallic
membrane holder from the cap as this will damage the membrane.
The use of warm water is recommended to rinse the residual electrolyte from the elec-
trode finger and the membrane cap.
Check the sensor regularly for dirt, biofilm and bubbles. As far as possible avoid contamination
of the membrane with solid particles, deposits, etc. Bubbles on the outside of the membrane can
be removed by increasing the flow rate temporarily. A calibration must be performed after a change
of the membrane cap or the electrolyte once the sensor has had sufficient time to settle.
On the membrane cap, lift the two elastic seals that covers the
vent (A) so that the vent opening is free. Unscrew the membrane
cap to allow air into the uncovered vent.
If the sensor still displays values that are too low or unstable, a new membrane cap
must be used.
When changing the membrane cap, it usually takes an hour for the readings to stabilise
before calibration is possible.
3.1.5.3 Storage
To store the sensor the membrane cap is unscrewed. Membrane cap and electrode finger are
rinsed in clean water and dried in a place free of dust. Do not wipe the electrode finger as this
may damage the surface. The dry membrane cap is then loosely screwed onto the electrode shaft
to protect the electrode finger. The membrane must not rest against the electrode finger. When
putting the sensor back into use after storage, the electrode tip must be cleaned with the abrasive
paper, as in section 3.1.5.1, and a new membrane cap must be used. Used membrane caps which
have been in operation for at least 1 day can not be stored and reused.
3.1.6 Troubleshooting
If the electrode finger turns shiny silver or white the sensor must be reconditioned by
the manufacturer. Brown-grey coloration is normal. Contact your supplier for technical
support if this occurs.
3.1.6.1 Sensor can not be calibrated or there is an unexpected deviation of the measuring value
from calibration measurement.
Outputs are the means by which values from measuring sensors, control outputs or system status
are transmitted to another device, for example to a SCADA1 for data acquisition or to a pump for
dosing control. The two types of output used by CRIUS® are the analogue output2 and relay3 .
In order to utilise the full capability of the instrument it is necessary to link the signal/value and
an output device, such as an alarm, threshold or control options for the relays or analogue outputs.
Pi utilises the latest in firmware and electronic innovations and as such analogue outputs and
relays are extremely flexible, and are not tied to individual sensors. In the past outputs were
typically fixed to a specific sensor or control and the range was also the same as the range of the
sensor. More recently the capability of the analogue output to be more flexible has come about
with advances in electronics.
4.1.3 Commissioning
When cables are attached to the analogue outputs, these add additional resistance through which
the signal must be passed. This can result in the analogue output range being affected. For
1 Supervisory Control and Data Acquisition, a central data logging and control system
2A current or voltage output, proportional to a signal generated in the instrument
3 A mechanical or electronic device mounted on the electronics within the instrument that can switch. The number and
example a 4-20 mA output at the analyser could end up being 3.95 mA to 19.9 mA at the end of
the cable. The CRIUS has the capability to supply more current to account for this resistance so
the analogue output at the end of the cable is of the required value. To enable this the offset (range
minimum) and span (range maximum) of the analogue output are calibrated.
Select the slider and then use the Left and Right buttons to adjust the zero.
Select the slider and then use the Left and Right buttons to adjust the span.
4.1.4 Operation
To access the analogue output setup and maintenance options, select the relevant device tile in
the main menu and press “Select”. The output setup screen will be displayed initially, though other
functions are available by pressing the “Options” button.
4.1.4.1 Setup
The setup of the analogue output is split into three sections. Later sections can be accessed
separately from the menu or by selecting “Next” from any of the previous pages. To access the
analogue output setup:
Name Device name to identify the control in menus. Text can be up to 25 characters long.
Display Options are to “Show” or “Hide” the device tile on the menu screen.
Enabled Options are “Yes” or “No”.
Mode Options Options are “Manual” which allows the user to manually set an output value; “Data
Output” which maps the output to an analogue data source such as a parameter; and “Control
Output” which maps the output to an analyser generated control signal.
The “Next” button is a shortcut to the following configuration screen.
4.1.4.2.2 Configuration
This configuration screen is accessed by pressing “Next” from the Map Output above screen or
navigating via the Options Menu.
Type Choose the type of analogue output from the drop down box. See technical data for a list of
supported output types. See section 4.1.2.
Manual Value Enter the manual value of the output as a percentage. For example if 4..20mA
output type is selected a manual value of 50% will force the current output to 12mA.
Sensor Select the appropriate sensor from the drop down list.
Parameter Choose the appropriate parameter from the drop down list. If the selected sensor has
only one parameter this option may not be available.
The “Next” button is a shortcut to the following configuration screen.
Type Choose the type of analogue output from the drop down box. See the technical data in
section 4.1.2 for a list of supported outputs.
Minimum Enter the parameter value that translates to a minimum output of e.g. 4mA if “type” is
set to 4..20mA.
Maximum Enter the parameter value that translates to a maximum output of e.g. 20mA if “type” is
set to 4..20mA.
The minimum and maximum values can be anywhere within the range of a parameter. For
example the data output for a chlorine sensor with a range of 0..10ppm, the output could be ranged
0..10ppm (common) but could be ranged, for example 2.4..5.3ppm.
4.1.4.4.2 Configuration
This configuration screen is accessed by pressing “Next” from the Map Output screen or navigating
via the Options Menu.
Type Choose the type of analogue output from the drop down box. See the technical data in
section 4.1.2 for a list of supported outputs.
Flags that are active are shown in black text on a white background, those that are not active
are greyed out. Available flags are:
Display on main menu When active the device tile is displayed on the main menu. If inactive, the
tile is hidden in the default view.
Output enabled This flag is set if the output is enable.
Output calibrating offset This flag is set when calibrating the analogue output offset.
Output calibrating span This flag is set when calibrating the analogue output span.
Flags that are active are shown in black text on a white background, those that are not active
are greyed out. Available flags are:
Output mapping error This indicates that one of the outputs is mapped incorrectly e.g., mapped
to a sensor or control that no longer exists.
I/O card fault detected If set, this flag indicates that a low-level hardware fault has occurred.
Report to Pi.
Incorrect I/O card found If set, this flag indicates that the I/O card fitted is of the wrong type.
I/O card in use This flag is set when two devices are attempting to use the same I/O card.
I/O card configuration failed This flag is set if the I/O plugin card fails to respond correctly.
Contact Pi for advice.
4.1.4.7 Connections
This screen is accessed by navigating via the Options Menu:
Options → Connections
4.2 Relay Output 51
The image above is for an output with the types selected as 0..20mA or 4..20mA. The connections
will reflect the configuration of the device and differ between current and voltage outputs.
4.2.3 Operation
To access the relay output setup and maintenance options, select the relevant device tile in the
main menu and press “Select”. The output setup screen will be displayed initially, though other
functions are available by pressing the “Options” button.
4.2.3.1 Setup
The setup of the relay output is split into three sections. Later sections can be accessed separately
from the options or by selecting “Next” from any of the previous sections.
To access the relay output setup:
4 This describes the link between a signal/value generated by the instrument and an output device (relay or analogue).
52 Chapter 4. Outputs
Name Device name to identify control in menus. Text can be up to 25 characters long.
Display Options are “Show” or “Hide” the device tile on the menu screen.
Enabled Options are “Yes” or “No”. This option must be enabled for the option to function.
Mode Options Options are “Manual” which sets a relay to manual output; “Control Output” which
maps a relay to a control output and allows the setup of either pulse width modulation or
pulse frequency modulation; “Data Output” which outputs a pulse for each set increment
of a sensor parameter value; “Device Status Flags” which allows the mapping of a relay to
activate if the status of a device changes; “Device Error Flags” which allows the mapping of a
relay to activate if a device goes into error; “Parameter Flags” which allows the mapping of a
relay to activate on selected parameter flags and “System Flags” which allows the mapping
of a relay to activate on a system alarm state.
4.2.3.2.2 Configuration
This configuration screen is accessed by pressing “Next” from the Map Output screen or navigating
via the Options Menu.
Control Choose from a list of available controls to output the control value.
The “Next” button is a shortcut to the following configuration screen.
4.2.3.3.2 Configuration
This configuration screen is accessed by pressing “Next” from the Map Output configuration screen
or navigating via the Options Menu.
In all cases the polarity and output mode of the relay will need to be configured. Pulse width
modulation outputs a repeated pulse with a fixed width. The control signal is output by increasing
the proportion of time the relay is active in any pulse as the value increases. Pulse frequency
modulation outputs pulses of a fixed activated width, but increases the frequency of the pulses in
respect of the control output value.
Polarity Options are “Normally Open” and “Normally Closed”.
Mode Options are “Pulse Width Modulation” or “Pulse Frequency Modulation”.
When "Pulse Width Modulation" is selected further options are:
Pulse Width Define the maximum pulse width in MM:SS. The relay will energise for a proportion
of this time based on the control output value.
Deadband Defines the minimum pulse width that would be output. This can be used to avoid relay
chatter due to a small control output value.
54 Chapter 4. Outputs
Sensor Select the appropriate sensor from the drop down list.
Parameter Choose the appropriate parameter from the drop down list. If the selected sensor has
only one parameter this option may not be available.
The “Next” button is a shortcut to the following configuration screen.
4.2.3.5.2 Configuration
This configuration screen is accessed by pressing “Next” from the Map Output configuration screen
or navigating via the Options Menu.
Polarity Options are “Normally Open” and “Normally Closed”. The device status flags available
depend on the device mapped above. See the status flag descriptions for that device for
details.
Press the “Next” button to select the device status flags used to activate the relay.
4.2.3.6.2 Configuration
This configuration screen is accessed by pressing “Next” from the Map Output screen or navigating
via the Options Menu.
Polarity Options are “Normally Open” and “Normally Closed”. The device error flags available will
depend on the device mapped above. See that device description for details.
Press the “Next” button to select the device error flags used to activate the relay.
Sensor Choose the appropriate sensor from the drop down list.
Parameter Choose the appropriate parameter from the drop down list.
The “Next” button is a shortcut to the following configuration screen.
4.2.3.7.2 Configuration
This configuration screen is accessed by pressing “Next” from the Map Output screen or navigating
via the Options Menu.
Flags that are active are shown in black text on a white background, those that are not active
are greyed out. Selecting the flag will cause the relay to activate if that parameter flag becomes
active.
4.2.3.8.2 Configuration
This configuration screen is accessed by pressing “Next” from the Output Setup configuration or
navigating via the Options Menu.
Polarity Options are “Normally Open” and “Normally Closed”. The “Next” button is a shortcut to
the following configuration screen.
Flags that are active are shown in black text on a white background, those that are not active
are greyed out. Available flags are:
Display on main menu When active the device tile is displayed on the main menu. If inactive, the
tile is hidden in the default view.
Output enabled This flag is set if the output is enable.
Relay polarity This reflects the relay polarity, if set the relay is normally closed.
Relay output state This reflects the relay activation state. Taken together with the relay polarity
above, it is possible to determine if the relay is open or closed.
60 Chapter 4. Outputs
The error flags show any problems causing an error for a device. These flags can either be active
or not. To see the state of these error flags, select:
Flags that are active are shown in black text on a white background, those that are not active
are greyed out. Available flags are:
Output mapping error This indicates that one of the outputs is mapped incorrectly e.g., mapped
to a sensor or control that no longer exists.
Incorrect I/O card found If set, this flag indicates that the I/O card fitted is of the wrong type.
I/O card in use This flag is set when two devices are attempting to use the same I/O card.
I/O card fault detected If set, this flag indicates that a low-level hardware fault has occurred.
Report to Pi.
I/O card configuration failed This flag is set if the I/O plugin card fails to respond correctly.
Contact your supplier for advice.
Modbus communications error This flag is set when a Modbus exception, timeout or checksum
failure occurs. If clear, communication with the sensor is normal.
Device identifier mismatch If set, this flag indicates that the sensor connected to the Modbus
input is not responding as expected. Check that the correct sensor is connected.
Pump fault detected This flag is set if a fault is signalled by the pump.
It is possible to test a relay. The relays polarity and active state can be manually changed. Leaving
this configuration screen will return the relay to its previous state. To do this navigate to:
Options are
Polarity Options are “Normally Open” or “Normally Closed”
Active Options are “No” or “Yes”
4.2.3.12 Connections
Options → Connections
4.2 Relay Output 61
This screen identifies the terminals to use for electrical connections for this relay. The left hand
pane identifies the terminal block and the right hand pane the connectors on the terminal block.
III
Accessories
5 Flow Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.1 Single Overflow Cell
5. Flow Cells
Dimensions
(A) 100mm
(B) 60mm
(C) 128mm
5.1.2 Installation
Please choose a suitable location for the installation of the flow cell. The choice of installation point
on any site is a compromise and is best undertaken by an experienced installation engineer. The
following is a list of the factors that need to be taken into consideration. The list is not intended as
a checklist neither is it implied that the list is complete.
• Vertical mounting.
• If water overflows due to overpressure on the inlet ensure it does not run on to electrical
equipment or equipment that can be damaged.
• The outlet can run to drain or a recycling system without causing air locks or a back pressure.
• The installation should be stable, secure and free from vibration.
• Ensure there is sufficient room above the flow cell to insert and remove the sensor.
IV
Documentation
7 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8 Returns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.1 Contact Details
6. RoHS and WEEE Compliance
Process Instruments (UK) Ltd is committed to meeting all requirements of the European Union’s
WEEE (Waste electrical and electronic equipment) and RoHS (Restriction of the use of certain
hazardous substances in electrical and electronic equipment) Directives. These directives require
strategies for waste management and product design for the environment for electrical and
electronic equipment sold into EU countries.
then any WEEE can be recycled via your local collection facilities. Details of these should be
obtained from your local authority.
7. WEEE from users other than Private Households. Pi will ensure the proper recycling
of waste resulting from those products arising at the customer’s location within the United
Kingdom.
8. Treatment. In accordance with UK legislation, Pi confirm that treatments and recycling of
WEEE done on behalf of Pi, either by a collective scheme or individually, will be carried out in
accordance with the requirement of the WEEE Directive, including requirements in respect of
special treatment for specific parts and overall recovery rates.
9. Information. Pi will provide information on reuse and treatment of each new type of WEEE
placed on the market within one year.
10. Legal. The information contained herein is subject to change without notice. Nothing herein
should be construed as constituting an additional warranty. Pi shall not be liable for technical
or editorial errors or omissions contained herein.
Process Instruments (UK) Ltd warrants its product to be free of defects in material and workmanship
for a period of one year from date of shipment to the original customer unless specifically agreed
elsewhere. Upon receipt of written notice from the customer, Pi shall issue a returns form for the
defective product and, upon its receipt, shall repair or replace (at the discretion of Pi) the defective
equipment or components. Pi assumes no responsibility for equipment damage or failure caused
by:
1. Improper installation, operation, or maintenance of the equipment.
2. Abnormal wear and tear on moving parts caused by some processes.
3. Acts of nature (i.e. lightning, flooding, etc.).
This warranty represents the exclusive remedy of damage or failure of the equipment. Under
no circumstances shall Pi be liable for any special, incidental, or consequential damage, such as
loss of production, profits or product quality. The warranty cannot be guaranteed if the customer
fails to service and maintain the equipment in accordance with Pi written instructions and policies,
as stated in the Operations Manual.
Any costs associated with this warranty, such as the cost of returning the products to Pi or the
cost of returning a repaired unit to the customer lies with the customer. Any warranty replacements
will be covered by the warranty, with the same terms and conditions as the original.
8. Returns
If the analyser has to be repaired, please return it cleaned to your local service organisation or
Process Instruments (UK) Ltd at the address below. To return your equipment for repair:
• Contact Pi support, open a service ticket and request a returns form.
• Complete the returns form, including the contaminant declaration.
• Enclose the completed returns form with the packaging and shipping documents.
• Address the package to “The Service Department” at the address below and mark the box
with the service ticket number to ensure the package is dealt with as efficiently as possible.
• Please use the original packaging, if possible.
No repair can be undertaken without a returns form with a completed contaminant de-
claration. This is required to comply with our Health and Safety responsibilities.
Email support@processinstruments.net
Phone +44 1282 422835