iCON TB800 Series Turbidity Controller

Product Usage Instructions

Dimensions and Installation
The product dimensions are as follows: 144mm x 144mm x 118mm. Follow the instructions for cabinet or wall mount installation provided in the manual.

Wiring Instructions
Connect the instrument to the sensor and power supply as per the wiring diagram provided in the manual. Ensure proper connections for sensor input, output signals, relay alarms, and power supply.

Keypad Operation         
Use the keypad to enter calibration mode, check calibration status, navigate menu settings, and confirm options. Short press or long press buttons as per the instructions provided.

Display Descriptions
Check all pipe and electrical connections before powering on the unit. The display will show relevant information once powered on.

Frequently Asked Questions (FAQ)

• Q: How do I recalibrate the Turbidity Controller?
  A: To recalibrate the controller, press ENT to enter calibration mode, then follow the on-screen instructions to recalibrate.
• Q: Can the Turbidity Controller be used in high humidity conditions? 
  A: The Turbidity Controller is designed to work in relative humidity conditions of up to 90%.

Features

• Large Color LCD Display
• Data Recording/Trend Chart/Data Upload Function
• Multiple Automatic Calibration to Ensure the Accuracy
• Differential Signal Mode
• Three Relay Control Switches
• High & Low Alarm and Hysteresis Control
• 4-20mA | RS485 Multiple Output Modes
• Password Protection

Technical Specifications

Dimensions

Cabinet Installation

Wall Mount Installation

Schematic of Installation

• Install a mounting bracket for the instrument
• Wall screw fixation

Wiring

Electrical Connection
The connection between the instrument and the sensor: The power supply, output signal, relay alarm contact and the connection between the sensor and the instrument are all inside the instrument, and the wiring is as shown above. The length of the cable lead is usually 5-10 Meters. Insert the line with corresponding label or color wire on the sensor into the corresponding terminal inside the instrument and tighten it.

Keypad Description

Keypad Operation

• Short Press: Release the key immediately after pressing (Default to short presses if not specified above).
• Long Press: Press the button for 3 seconds and then release it.

Display Descriptions

All pipe connections and electrical connections should be checked before use. After the power is switched on, the meter will display as follows.

Menu Structure

Menu Description

Measurement

Filling Solution for Calibration (TB800 Turbidity Sensor)

Calibration (Unit is Factory Calibrated)

Alarm

Current Settings (mA Output)

Communication (MODBUS)

System

Maintenance

Graphic Trend (Trend Chart)

Press the [ /TREND] button in the measurement mode to view the trend chart of the saved data directly. Pressing the [ESC] button returns to the measurement screen. There are 480 sets of data record per page.

• In the current screen, press the [CAL] key to move the data display line to the left and [ /TREND] key to move towardsright. Press [INFO] to change the chart display range.
• Data Recording Interval : Users can select the recording interval here. Once selected, the instrument will save the data at the specified interval.
• Data Query : Enter the number of records to query here, then press [ENT] to retrieve the historical data. 24-

MODBUS RTU

• The hardware version number of this document is V2.0; the software version number is V5.9 and above. This document describes the MODBUS RTU interface in details and the target object is a software programmer.

MODBUS Command Structure

• Data format description in this document;
• Binary display, suffix B, for example: 10001B – decimal display, without any prefix or suffix, for example: 256 Hexadecimal display, prefix 0x, for example: 0x2A
• ASCII character or ASCII string display, for example: “YL0114010022”

Command Structure
The MODBUS application protocol defines the Simple Protocol Data Unit (PDU), which is independent of the underlying communication layer.
MODBUS protocol mapping on a specific bus or network introduces additional fields of protocol data units. The client that initiates the MODBUS exchange creates the MODBUS PDU, and then adds the domain to establish the correct communication PDU.

On the MODBUS serial line, the address domain contains only the slave instrument address. Tips: The device address range is 1…247 Set the device address of the slave in the address field of the request frame sent by the host. When the slave instrument responds, it places its instrument address in the address area of the response frame so that the master station knows which slave is responding.

Function codes indicate the type of operation performed by the server. CRC domain is the result of the “ redundancy check” calculation, which is executed according to the information content.

MODBUS RTU Transmission Mode
When the instrument uses RTU (Remote Terminal Unit) mode for MODBUS serial communication, each 8-bit byte of information contains two 4-bit hexadecimal characters. The main advantages of this mode are greater character density and better data throughput than the ASCII mode with the same baud rate. Each message must be transmitted as a continuous string.

The format of each byte in RTU mode (11 bits):

• Coding system: 8-bit binary
• Each 8-bit byte in a message contains two 4-bit hexadecimal characters (0-9, A-F)
• Bits in each byte: 1 starting bit
• 8 data bits, the first minimum valid bits without parity check bits
• 2 stop bits]
• Baud rate: 9600 BPS

How characters are transmitted serially:
Each character or byte is sent in this order (from left to right) the least significant bit (LSB)… Maximum Significant Bit (MSB)

Check Domain Structure: Cyclic Redundancy Check (CRC16)

Structure description:

Fig.4 : RTU Information Structure
The maximum frame size of MODBUS is 256 bytes

MODBUS RTU Information Frame
In RTU mode, message frames are distinguished by idle intervals of at least 3.5 character times, which are called t3.5 in subsequent sections.

Fig.6 : MODBUS RTU CRC Check
The RTU mode contains an error-detection domain based on a cyclic redundancy check (CRC) algorithm that performs on all message contents. The CRC domain checks the contents of the entire message and performs this check regard-less of whether the message has a random parity check. The CRC domain contains a 16-bit value consisting of two 8-bit bytes. CRC16 check is adopted. Low bytes precede, high bytes precede.

Implementation of MODBUS RTU in Instrument
According to the official MODBUS definition, the command starts with a 3.5 character interval triggering command, and the end of the command is also represented by a 3.5 character interval. The device address and MODBUS function code have 8 bits. The data string contains n*8 bits, and the data string contains the starting address of the register and the number of read/write registers. CRC check is 16 bits.

Fig.7 : MODBUS definition of Data Transmission

Instrument MODBUS RTU Function Code

The instrument only uses two MODBUS function codes:

• 0x03: Read-and-hold register
• 0x10: Write multiple registers
• MODBUS Function Code 0x03: Read-and-hold Register

This function code is used to read the continuous block content of the holding register of the remote device. Request the PDU to specify the start register address and the number of registers. Address registers from zero. Therefore, the addressing register 1-16 is 0-15. The register data in the response information is packaged in two bytes per register. For each register, the first byte contains high bits and the second byte contains low bits.

Request:

Fig.8 : Read and hold register request frame

Response:

N = Register Number

Figure 9 : Read and hold register response frame
The following illustrates the request frame and response frame with the read and hold register 108-110 as an example. (The contents of register 108 are read-only, with two byte values of 0X022B, and the contents of register 109-110 are 0X0000 and 0X0064)

Figure 10 : Examples of read and hold register request and response frames

MODBUS Function Code 0x10 : Write Multiple Registers
This function code is used to write continuous registers to remote devices (1… 123 registers) block that specifies the value of the registers written in the request data frame. Data is packaged in two bytes per register. Response frame return function code, start address and number of registers written.

Request:

Fig.11 : Write Multiple Register Request Frames

Response:

N = Register Number
Figure 12 : Write Multiple Register Response Frames
The request frame and response frame are illustrated below in two registers that write the values 0x000A and 0x0102 to the start address of 2.

Figure 13 : Examples of writing multiple register request and response frames

Data Format in Instrument

Floating Point
Definition: Floating point, conforming to IEEE 754 (single precision)

Figure 14 : Floating Point Single Precision Definition (4 bytes, 2 MODBUS Registers)
Example: Compile decimal 17.625 to binary

Step 1:

• Converting 17.625 in decimal form to a floating-point number in binary form, first finding the binary representation of the integer part
• 17decimal= 16 + 1 = 1×24 + 0×23 + 0×22 + 0×21 + 1×20
• The binary representation of integer part 17 is 10001B then the binary representation of decimal part is obtained 0.625= 0.5 + 0.125 = 1×2−1 + 0×2−2 + 1×2−3
• The binary representation of decimal part 0.625 is 0.101B.
• So the binary floating point number of 17.625 in decimal form is 10001.101B

Step 2:

• Shift to find the exponent.
• Move 10001.101B to the left until there is only one decimal point, resulting in 1.0001101B, and
• 10001.101B = 1.0001101 B× 24 . So the exponential part is 4, plus 127, it becomes 131, and its binary representation is 10000011B.

Step 3:
Calculate the tail number

After removing 1 before the decimal point of 1.0001101B, the final number is 0001101B (because before the decimal point must be 1, so IEEE stipulates that only the decimal point behind can be recorded). For the important explanation of 23- bit mantissa, the first (i.e. hidden bit) is not compiled. Hidden bits are bits on the left side of the separator, which are usually set to 1 and suppressed.

Step 4:
Symbol bit definition
The sign bit of positive number is 0, and the sign bit of negative number is 1, so the sign bit of 17.625 is 0.

Step 5:
Convert to floating point number

• 1 bit symbol + 8 bit index + 23-bit mantissa
• 0 10000011 00011010000000000000000B (the hexadecimal system is shown as 0 x418d0000 )

Reference code:
If the compiler used by the user has a library function that implements this function, the library function can be called directly, for example, using C language, then you can directly call the C library function memcpy to obtain an integer representation of the floating-point storage format in memory.

For example: float floatdata; // converted floating point number

• void* outdata; memcpy(outdata,&floatdata,4);
• Suppose floatdata = 17.625
• If it is a small-end storage mode, after executing the above statement, the data stored in the address unit outdata is 0x00.
• address unit (outdata + 1) stores data as 0x00
• address unit (outdata + 2) stores data as 0x8D
• address unit (outdata + 3) stores data as 0x41
• If it is large-end storage mode, after executing the above statement, the data stored in outdata of address unit is 0x41 address unit (outdata + 1) stores data as 0x8D
• address unit (outdata + 2) stores data as 0x00
• address unit (outdata + 3) stores data as 0x00
• If the compiler used by the user does not implement the library function of this function, the following functions can be used to achieve this function:
  void memcpy(void *dest,void *src,int n)
• {
• char *pd = (char *)dest; char *ps = (char *)src;
• for(int i=0;i<n;i++) *pd++ = *ps++;
• }
• And then make a call to the above memcpy(outdata,&floatdata,4);

Example: Compile binary floating-point number 0100 0010 0111 1011 0110 0110 0110 10B to decimal number
Step 1: Divide the binary floating-point number 0100 0010 0111 1011 0110 0110 0110B into symbol bit, exponential bit and mantissa bit.

0 10000100  11110110110011001100110B

• 1-bit sign + 8-bit index + 23-bit tail sign bit S: 0 denotes positive number
• Index position E: 10000100B =1×27+0×26+0×25+0×24 + 0 × 23+1×22+0×21+0×20
• =128+0+0+0+0+4+0+0=132
• Mantissa bits M: 11110110110011001100110B =8087142
• Step 2: Calculate the decimal number
• D = (−1)×(1.0 + M/223)×2E−127
• = (−1)0×(1.0 + 8087142/223)×2132−127
• = 1×1.964062452316284×32
• = 62.85
• Reference Code:
• float floatTOdecimal(long int byte0, long int byte1, long int byte2, long int byte3){
• long int realbyte0,realbyte1,realbyte2,realbyte3; char S;
• long int E,M;
• float D; realbyte0 = byte3; realbyte1 = byte2; realbyte2 = byte1; realbyte3 = byte0;
• if((realbyte0&0x80)==0)
• {
• S = 0;//positive number
• }
• else
• {
• S = 1;//negative number
• }
• E = ((realbyte0<<1)|(realbyte1&0x80)>>7)-127;
• M = ((realbyte1&0x7f) << 16) | (realbyte2<< 8)| realbyte3;
• D = pow(-1,S)*(1.0 + M/pow(2,23))* pow(2,E);
• return D;
• }

Function description: parameters byte0, byte1, byte2, byte3 represent 4 bytes of binary floating point number.

The decimal number converted from the return value. For example, the user sends the command to get the temperature value and dissolved oxygen value to the probe. The 4 bytes representing the temperature value in the received response frame are 0x00, 0x00, 0x8d and 0x41. Then the user can get the decimal number of the corresponding temperature value through the following call statement. That is temperature = 17.625. float temperature = floatTOdecimal( 0x00, 0x00, 0x8d, 0x41)

Read Instruction Mode
The communication protocol uses MODBUS (RTU), and both the communication content and address can be customized based on customer requirements. The default configuration is network address 1, baud rate 9600, no parity check, and 1 stop bit. Users can modify these settings.

Function Code 0x03:
This function allows the host to retrieve real-time measurement values from the slave device, which are defined as single-precision floating-point values (i.e., occupying two consecutive register addresses). The received order is abcd, and the analytical order is cdab. Different parameters are marked with distinct register addresses.

The communication register address is as follows:
0000-0001: Main Value | 0002-0003: Temperature Value

Communication Example:

• Examples of function code 03 instructions:
• Address = 1, Main Value = 7.00, Temp Value = 24.00
• Host Send: 01 03 00 00 00 04 XX XX | Slave Reply: 01 03 08 00 00 40 E0 00 00 41 C0 XX XX

Note:

• [01] Represents the instrument communication address;
• [03] Represents function code 03;
• [08] represents 16 bytes data;
• [00 00 40 E0] = 7.00; | Main value ; Parse Order: 40 E0 00 00
• [00 00 41 C0]= 24.00; | Temperature Value ; Parse Order: 41 C0 00 00
• [XX XX] Represents the CRC 16 Check Code

Maintenance
According to the requirements of use, the installation position and working condition of the instrument are relatively complex. In order to ensure that the instrument is working normally, maintenance personnel should carry out regular maintenance on the instrument. Please pay attention to the following during maintenance:

• Check the working environment of the instrument. If the temperature exceeds the rated range of the instrument, please take appropriate measures; otherwise, the instrument may be damaged or its service life may be reduced;
• When cleaning the plastic body of the instrument, please use a soft cloth and a soft cleaner to clean.
• Check to ensure the wiring on the terminal of the instrument is firm. Pay attention to disconnect the AC or DC power before removing the wiring cover.
• Check to determine display data of the instrument is normal or not.

Warranty, Returns and Limitations

Warranty
Icon Process Controls Ltd warrants to the original purchaser of its products that such products will be free from defects in material and workmanship under normal use and service in accordance with instructions furnished by Icon Process Controls Ltd for a period of one year from the date of sale of such products. Icon Process Controls Ltd obligation under this warranty is solely and exclusively limited to the repair or replacement, at Icon Process Controls Ltd option, of the products or components, which Icon Process Controls Ltd examination determines to its satisfaction to be defective in material or workmanship within the warranty period. Icon Process Controls Ltd must be notified pursuant to the instructions below of any claim under this warranty within thirty (30) days of any claimed lack of conformity of the product. Any product repaired under this warranty will be warranted only for the remainder of the original warranty period. Any product provided as a replacement under this warranty will be warranted for the one year from the date of replacement.

Returns
Products cannot be returned to Icon Process Controls Ltd without prior authorization. To return a product that is thought to be defective, go to www.iconprocon.com, and submit a customer return (MRA) request form and follow the instructions therein. All warranty and non-warranty product returns to Icon Process Controls Ltd must be shipped prepaid and insured. Icon Process Controls Ltd will not be responsible for any products lost or damaged in shipment.

Limitations
This warranty does not apply to products which: 1) are beyond the warranty period or are products for which the original purchaser does not follow the warranty procedures outlined above; 2) have been subjected to electrical, mechanical or chemical damage due to improper, accidental or negligent use; 3) have been modified or altered; 4) anyone other than service personnel authorized by Icon Process Controls Ltd have attempted to repair; 5) have been involved in accidents or natural disasters; or 6) are damaged during return shipment to Icon Process Controls Ltd reserves the right to unilaterally waive this warranty and dispose of any product returned to Icon Process Controls Ltd where: 1) there is evidence of a potentially hazardous material present with the product; or 2) the product has remained unclaimed at Icon Process Controls Ltd for more than 30 days after Icon Process Controls Ltd has dutifully requested disposition. This warranty contains the sole express warranty made by Icon Process Controls Ltd in connection with its products. ALL IMPLIED WARRANTIES, INCLUDING WITHOUT LIMITATION, THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE EXPRESSLY DISCLAIMED. The remedies of repair or replacement as stated above are the exclusive remedies for the breach of this warranty. IN NO EVENT SHALL Icon Process Controls Ltd BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND INCLUDING PERSONAL OR REAL PROPERTY OR FOR INJURY TO ANY PERSON. THIS WARRANTY CONSTITUTES THE FINAL, COMPLETE AND EXCLUSIVE STATEMENT OF WARRANTY TERMS AND NO PERSON IS AUTHORIZED TO MAKE ANY OTHER WARRANTIES OR REPRESENTATIONS ON BEHALF OF Icon Process Controls Ltd. This warranty will be interpreted pursuant to the laws of the province of Ontario, Canada.

• If any portion of this warranty is held to be invalid or unenforceable for any reason, such finding will not invalidate any other provision of this warranty. For additional product documentation and technical support
• visit: www.iconprocon.com
• e-mail: sales@iconprocon.com or support@iconprocon.com
• Ph: 905.469.9283

Documents / Resources

iCON TB800 Series Turbidity Controller [pdf] Owner's Manual TB800 Series, TB800 Series Turbidity Controller, Turbidity Controller, Controller

References

• User Manual