Water Quality Analyzer Operating Manual for S/W Version 2 ... · Residual Chlorine Analyzer Residual Ozone Analyzer pH/ORP Analyzer Revised 01/07/10 JE CRA3500 OZA4800 PHO6300 CPO7600

Water Quality Analyzer Operating Manual for S/W Version 2.2.6 And Later

Manual date 7 January 2010 Page 1 of 88

OPERATIONS MANUAL

Residual Chlorine Analyzer Residual Ozone Analyzer

pH/ORP Analyzer

Revised 01/07/10 JE

CRA3500 OZA4800 PHO6300 CPO7600





TABLE OF CONTENTS Page No.

1.0 OVERVIEW 5 1.1 Theory of operation 6

1.1.1 Free Chlorine 1.1.2 Total Chlorine 7 1.1.3 Chlorine Dioxide 1.1.4 Dissolved Ozone 1.1.5 pH 1.1.6 ORP 8

1.2 Specifications 9 1.2.1 Analyzer 1.2.2 Residual Chlorine sensor probes (Free or Total) 1.2.3 Chlorine Dioxide sensor probe 10 1.2.4 Dissolved Ozone sensor probe 1.2.5 pH sensor probe 11 1.2.6 ORP sensor probe 1.2.7 GSM/GPRS Modem 1.2.8 Flow cells 12

1.3 System Components 1.3.1 User interface unit 1.3.2 Sensor 1.3.3 Overflow cell 1.3.4 Electrochemical Probe Simulator 1.3.5 GSM/GPRS Modem unit 1.3.6 Autoflush 1.3.7 Autocalibrators

2.0 INSTALLATION AND COMMISSIONING 13 2.1 Site selection 2.2 Unpacking 2.3 Mounting 14 2.4 Water connections 15 2.5 Electrical connections 16

2.5.1 Power 2.5.2 RS 485 17 2.5.3 Relays 2.5.4 Probe(s) 2.5.5 TCP/IP 2.5.6 4-20mA Inputs and Outputs 18 2.5.6.1 Inputs 2.5.6.2 Outputs 2.5.7 USB 2.5.8 Digital Inputs and Outputs 19

2.5.8.1 Inputs 2.5.8.2 Outputs 2.5.8.3 Flowswitch 2.5.9 PI-ANIO Board 20 2.5.10 PI-PHIN Board 2.5.11 PI-SERIAL

3.0 OPERATION (Instrument) 21

3.0.1 Display, Buttons and Menu 3.0.2 Time and date 22 3.0.3 Menu overview 23

3.1 Sensor Configuration 24 3.1.1 Calibration

3.1.1.1 Manual Calibration 3.1.1.2 Automatic Calibration

3.1.2 Averaging 3.1.2.1 Display 3.1.2.2 Output 3.1.2.3 Data Log 3.1.2.4 Sample Time

3.1.3 Log Intervals 3.1.4 Units



3.2 Output Configuration 25 3.2.1 Hold Channel 3.2.2 Scale Output 3.2.3 Map Output 3.2.4 Proportional Control

3.2.4.1 Setup 3.2.4.2 Controller 1 26 3.2.4.3 Controller 2

3.2.5 PID Control 27 3.3 Alarm Configuration 30

3.3.1 Alarms 3.3.2 Setpoints 3.3.3 Relays 3.3.4 Digital Outputs 3.3.5 Flow Alarms

3.4 Communications Configuration 31 3.4.1 Setup

3.4.1.1 Serial 3.4.1.2 Ethernet 3.4.1.3 GPRS

3.4.2 SMS Alerts 3.4.2.1 Off/On 3.4.2.2 Phonebook 3.4.2.3 Ack. Timeout

3.4.3 Modbus TCP 32 3.4.3.1 Ethernet 3.4.3.2 GPRS 3.4.3.3 Password

3.5 Settings 33 3.5.1 Time and date 3.5.2 LCD/Keypad

3.5.2.1 Keypad Tone 3.5.2.2 Backlight 3.5.2.3 Contrast

3.5.3 Tag 3.5.3.1 Tag Name 3.5.3.2 Tag ID

3.5.4 Password 4.0 SENSORS 34 4.1 Free Chlorine

4.1.1 Installation 36 4.1.2 Setup 37 4.1.3 Maintenance 38

4.1.3.1 Routine maintenance 4.1.3.2 Diagnostic maintenance 39

4.1.4 Storage 4.1.5 Spares 4.1.6 Single flowcell 40

4.1.6.1 Insertion 41 4.1.7 Double flowcell 42

4.2 Total Chlorine 43 4.2.1 Installation 44 4.2.2 Setup 45 4.2.3 Maintenance 47

4.2.3.1 Routine maintenance 4.2.3.2 Diagnostic maintenance

4.2.4 Storage 4.2.5 Spares 4.2.6 Single flowcell

4.2.6.1 Insertion 4.2.7 Double flowcell

4.3 Chlorine Dioxide 48 4.3.1 Installation 49 4.3.2 Setup 50 4.3.3 Maintenance 52

4.3.3.1 Routine maintenance



4.3.3.2 Diagnostic maintenance 53 4.3.4 Storage 4.3.5 Spares 4.3.6 Single flowcell


4.4 Dissolved Ozone 54 4.4.1 Installation 56 4.4.2 Setup 4.4.3 Maintenance 4.4.4 Storage 4.4.5 Spares 4.4.6 Single flowcell


4.5 pH 57 4.5.1 Installation 58 4.5.2 Setup 4.5.3 Maintenance 4.5.4 Storage 4.5.5 Spares 4.5.6 Single flowcell 59

4.5.6.1 Insertion 4.5.7 Double flowcell 60

4.6 ORP 61 4.6.1 Installation 4.6.2 Setup 62 4.6.3 Maintenance 4.6.4 Storage 4.6.5 Spares 4.6.6 Single flowcell


5.0 GSM Modem unit 63 5.1 General 5.2 Installation 64 5.3 Setup 5.4 Electrical connections 65 6.0 Commissioning 66 7.0 Troubleshooting guide 67 7.1 Electronics

7.1.1 Fault codes 7.2 Sensors 68 7.3 Further help APPENDICES A General layout drawings 69 B Electrical layout drawing 71 C Certificates and approval statements 72 D Part numbers for spares ordering 73 E Returns Procedure and ‘Free of Contamination Sheet’ 74 F Warranty 76 G MSDS safety data sheets for : Free Chlorine Electrolyte (ECS2.1/GEL) 77 Total Chlorine Electrolyte (ECP1.3/GEL) 80 Chlorine Dioxide Electrolyte (ECD7/W) 83

Ozone Electrolyte (EOZ7/W) 86



1.0 Overview Thank you for purchasing your Chemtrac Water Quality Analyzer. The analyzer is a compact electronic communication and control system. It is designed for use with many different measuring probes. Any other use 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. This manual reviews the installation, operation, and maintenance of the following models CRA3500 - One or two sensors, measuring Free Chlorine, Total

Chlorine or Chlorine Dioxide

OZA4800 - One or two sensors, measuring Dissolved Ozone

PHO6300 - One or two sensors, measuring pH or ORP

CPO7600 - Two sensors, one measuring pH or ORP and one measuring Dissolved Ozone, Free Chlorine, Total Chlorine or Chlorine Dioxide

Nearly all functions in this manual are common to all instruments. Ancillary items, such as the Autocalibrator and the Autoflush, for the CRA3500, and the Autocalibrator for the PHO6300, have their own separate manuals.



1.1 Theory of Operation 1.1.1 Free Chlorine The free chlorine sensor has been designed to measure the concentration of dissolved free residual chlorine. It does this using a 3-electrode amperometric sensor insulated from the water supply by a hydrophilic membrane. The free chlorine diffuses through the membrane and is reduced at the cathode generating a small current that is proportional to the concentration of free chlorine. In potable, process, or swimming pool water this means HOCl (hypochlorous acid) and OCl- (hypochlorite ion). The relative amount of these two species is dependent on the pH of the solution. At low pH’s the predominant species will be HOCl. At higher pH's the predominant species will be OCl-. Traditional amperometric measurement systems need to be buffered to an exact pH in order that changes in the pH of the sample water do not affect the Free Chlorine measurement. The probe supplied for Free Chlorine measurement with this instrument is not affected by changes in pH to the same degree. This means that on many plants it will not be necessary to buffer the sample water at all. If pH is both high and variable, it is recommended to use the CPO7600 with both a Free Chlorine sensor and a pH sensor. The CPO7600, in this configuration, will automatically adjust the chlorine reading to compensate for changes in pH. The probes are available for a variety of ranges which are specified at the time of purchase. The sensor incorporates automatic temperature compensation (ATC).

Typical Probe Response to pH

(Unbuffered)

0

20

40

60

80

100

120

6 6.5 7 7.5 8 8.5 9 9.5 10

Chlorine Probe Response Typical Amperometric Probe Response



1.1.2 Total Chlorine The total chlorine probe measures free chlorine and chlorine that is combined as chloramines. It does this using a 3-electrode amperometric sensor insulated from the water supply by a hydrophilic membrane. The total chlorine diffuses through the membrane and is reduced at the cathode generating a small current that is proportional to the concentration of total chlorine. The sensor is held at an offset potential which negates the need for a zero routine. The probes are available for a variety of ranges which are specified at the time of purchase. The sensor incorporates automatic temperature compensation (ATC). 1.1.3 Chlorine Dioxide The chlorine dioxide sensor has been designed to measure the concentration of dissolved chlorine dioxide. It does this using a 2-electrode amperometric sensor insulated from the water supply by a hydrophilic membrane. The chlorine dioxide diffuses through the membrane and is reduced at the cathode generating a small current that is proportional to the concentration of chlorine dioxide. The sensor is held at an offset potential which negates the need for a zero routine. Due to the membrane used and the design of the sensor the measurement has no interference from free chlorine in the water and is largely unaffected by surfactants present in the water. The chlorine dioxide sensor is particularly sensitive and is designed specifically for use at low levels of chlorine dioxide. The sensor incorporates automatic temperature compensation (ATC). 1.1.4 Dissolved Ozone The dissolved ozone sensor has been designed to measure the concentration of dissolved ozone. It does this using a 2-electrode amperometric sensor insulated from the water supply by a hydrophilic membrane. The ozone diffused through the membrane and is reduced at the cathode generating a small current that is proportional to the concentration of ozone. The sensor is held at an offset potential which negates the need for a zero routine. Due to the membrane used and the design of the sensor the measurement has no interference from free chlorine in the water and is largely unaffected by surfactants present in the water. The ozone sensor is particularly stable and drifts less than many of its competitors, thereby reducing maintenance costs. The sensor incorporates automatic temperature compensation (ATC). 1.1.5 pH pH was invented in early 1920’s as a shorthand way of writing hydrogen ion concentration. pH is the negative logarithm of the hydrogen ion activity and a measure of the acidity or alkalinity of a solution. Each pH unit is a factor of 10 hydrogen ions pH 7 is neutral. Pure water is pH 7. pH = –log A[H+] pH is normally measured using a glass electrode and a reference electrode. The glass electrode acts as a transducer, converting chemical energy (the hydrogen ion activity) into an electrical energy (measured in millivolts). The reaction is balanced and the electrical circuit is completed by the flow of ions from the reference solution to the solution under test. For every unit change in pH (or decade change in ion concentration) the emf of the electrode pair changes by 59.16 mV at 25 °C. This value is known as the Nernstian Slope of the electrode. The pH electrode pair is calibrated using solutions of known and constant hydrogen ion concentration, called buffer solutions. The buffer solutions are used to calibrate both the electrode isopotential and slope. The k-series pH electrode is a high quality superior electrode with smaller drift and longer life. The patented electrode design incorporates a polymeric gel which cannot leak and provides a very stable signal. The sensor incorporates automatic temperature compensation (ATC).



1.1.6 ORP ORP (also known as redox potential, oxidation / reduction potential). In aqueous solutions, the reduction potential is the tendency of the solution to either gain or lose Hydrogen electrons when it is subject to change by introduction of a new species. A solution with a higher reduction potential will have a tendency to gain Hydrogen electrons from the new species (i.e. oxidize them) and a solution with a lower reduction potential will have a tendency to lose Hydrogen electrons to the new species (i.e. reduce them). The measurement is quoted in mV. Like the pH sensor, the k-series ORP series is a high quality superior electrode with smaller drift and longer life. The patented electrode design incorporates a polymeric gel which cannot leak and provides a very stable signal. The sensor incorporates automatic temperature compensation (ATC).



1.2 Specifications 1.2.1 ANALYZER Power: 100-240VAC (12VDC & 24VDC versions are available as an option)

Warning - if using optional modules, their power requirements override those stated above, and must be matched.

Fuse: 1A (100-240VAC), 2A (9-36VDC) Display: LCD Backlit 128x64 graphical Outputs: 4 configurable alarms (relays), 250VAC, 6A 2 x 4-20mA outputs standard, further 2 optional 4 digital outputs Inputs: Up to 2 sensors standard, further 2 optional 1 x low flow alarm, 3 further digital inputs Comms: RS485 TCP/IP (Optional) Datalogging: 4096 Data Points (42 days at 15 min intervals) System Eventlogging: 500 events Weight: 2kg IP Rating: IP65 1.2.2 RESIDUAL CHLORINE SENSOR PROBES (Free or Total) Type: Membrane covered amperometric three-electrode system Measurand: Free Residual Chlorine or Total Residual Chlorine Range: 0.01-2, 0.01-5, 0.01-10mg/l (ppm) Resolution: 0.01mg/l (ppm) Reproducibility: ±5 % Stability: -2 % per month (without calibration) Working electrode: Cathode made of gold Counter electrode: Anode made of stainless steel Reference electrode: Silver / silver halide Membrane material: Micro-porous hydrophilic membrane Flow rate: 0.5 to 1.0 l/min Temperature range: >0 up to 45 °C Temperature compensation: Automatically by an integrated thermistor (ATC) pH-range: pH 4 up to pH 9.5 Permissible overpressure: 0.5 bar (7.25 psi) First-polarization time: 120 min Re-polarization time: 30 min Response time: T90: approx. 2 min Zero-point adjustment: Not necessary Zero running: Running at zero de-polarizes the probe Calibration: Manual using DPD or Automatic (Autocal) Housing material: PVC, silicone, polycarbonate, stainless steel, perspex Dimensions: Diameter approx. 25mm (1”), length 175mm (7”) Maintenance intervals:

Calibration: Recommend to calibrate once a week for control and/or reporting applications, otherwise acceptable to calibrate once a month.

Electrolyte: Replace every 3 to 6 months Calibration reagent: Replace every 6 months (Autocal unit only) Membrane: Replace yearly

Interferences: High levels of other oxidants such as Ozone and Chlorine Dioxide



1.2.3 CHLORINE DIOXIDE SENSOR PROBE Type: Membrane covered amperometric two-electrode system Measurand: Chlorine dioxide Range: 0.01-0.5, 0.01-2, 0.01-5, 0.01-10, 0.01-20mg/l(ppm) Resolution: 0.001mg/l (ppm) for 0.5 range, all others 0.01mg/l (ppm) Reproducibility: ±2 % Stability: -1 % Working electrode: Cathode made of gold Counter electrode: Anode: combined reference and counter electrode of silver / silver halogenide Reference electrode: see Counter electrode Membrane material: Non-porous, elastic material Flow rate: 0.5 to 1.0 l/min Temperature range: >0 up to 55 °C Temperature compensation: Automatically by an integrated thermistor (ATC) pH-range: pH 1 up to pH 11 Permissible overpressure: 1 bar (14.5 psi) First-polarization time: 60 min Re-polarization time: 30 min Response time: T90: approx. 20 sec Zero-point adjustment: Not necessary Zero running: Running at zero de-polarizes the probe Calibration: Manual using analytic determination Housing material: PVC, silicone, polycarbonate, stainless steel Dimensions: diameter approx. 25mm (1”), length 175mm (7”) Maintenance intervals:

Calibration: Recommend to calibrate once a week for control and/or reporting applications, otherwise acceptable to calibrate once a month.

Electrolyte: Replace every 3 to 6 months Membrane: Replace yearly

Interferences: Ozone. Chlorine has no interfering effect Conductivity interference: 1% sulphuric acid or 1% nitric acid in water have no interfering effect 1.2.4 DISSOLVED OZONE SENSOR PROBE Type: Membrane covered amperometric two-electrode system Measurand: Residual Ozone O3 Range: 0.01-0.5, 0.01-2, 0.01-5mg/l (ppm) Resolution: 0.001mg/l (ppm) for 0.5 range, all others 0.01mg/l (ppm) Reproducibility: ±5 % Stability: -1 % per month (without calibration) Working electrode: Cathode made of gold Counter electrode: Silver / silver halide Membrane material: Micro-porous hydrophilic membrane Flow rate: 0.5 l/min (0.13 gallon/minute [US]) Temperature range: >0 up to 40 °C Temperature compensation: Automatically by an integrated thermistor (ATC) pH-range: pH 4 up to pH 9.5 Permissible overpressure: 0.5 bar (7.25 psi) First-polarization time: 120 min Re-polarization time: 30 min Zero-point adjustment: Not necessary Zero running: Running at zero de-polarizes the probe Calibration: Manual using a suitable ozone test kit Housing material: PVC, silicone, polycarbonate, stainless steel Dimensions: Diameter approx. 25mm, length 175mm Maintenance intervals:

Calibration: 1 week to 1 month Recommend to calibrate once a week for control and/or reporting applications, otherwise acceptable to calibrate once a month.

Electrolyte: Replace every 3 to 6 months Membrane: Replace yearly



1.2.5 pH SENSOR PROBE Type: W-Type Rod membrane pH electrode Reference Type: Patented pH Range: 0-14 Slope: 95-102% Pressure range: 0-3Bar (0 – 42 Bar) Long Term Stability (drift): <0.01 pH/Hour Reproducibility: <0.01 pH EO: -25mV to +25mV Electrode Resistance: 100-500 Mega Ohms Response Time: 95% of step pH2 to pH12 <5s Temperature Range: 0-40 °C Cable length: 6m (any length optional) Shelf Life: 12 Months Temperature compensation: Automatically by an integrated thermistor PT100 (ATC) Estimated life: 12-18 months application dependent Maintenance intervals:

Calibration: On control applications it is 2 weeks to 1 month and on non-control it is 1 to 2 months.

Calibration reagent: Replace every 6 months (Autocal unit only) 1.2.6 ORP SENSOR PROBE Type: Platinum Ball Reference Type: Patented ORP Range: -1999 to 1999mV Slope: 95-102% Pressure range: 0-3Bar (0 – 42 Bar) Long Term Stability (drift): <0.1 mV/Hour Reproducibility: <0.1m Electrode Resistance: <2 Mega Ohms Response Time: 95% of step pH2 to pH12 <5s Temperature Range: 0-40 °C Cable length: 6m (any length optional) Shelf Life: 12 Months Temperature compensation: Automatically by an integrated thermistor PT100 (ATC) Estimated life: 12-18 months application dependent Maintenance intervals:

Calibration: On control applications it is 2 weeks to 1 month and on non-control it is 1 to 2 months.

1.2.7 GSM/GPRS Modem Power: 100-240VAC (12/24VDC optional) Power consumption: 25W Sim card: User supply Region: Quad band Weight: 1kg IP Rating: IP65 *Modem does not work with carriers that utilize CDMA technology ** SIM cards are not supplied with the modem. SIM cards must be purchased by the customer through a local GSM/GPRS cell phone service provider. ** For “Remote Access” monitoring capability, a Fixed IP SIM card is required. Fixed IP SIM cards are available through cellular providers like AT&T (contact Chemtrac Systems for details).



1.2.8 FLOW CELL Inlet: ¼” or 6mm barb fitting, or 8mm pipe push-fitting Outlet: ½” or 12mm barb fitting No. of probes: Single and double flow cells available Service isolation: Ball valve Flow: 0-1.4 l/min (preferred flow rate 0.5 l/min) Inlet pressure: 0.5 bar (7.25 psi) Flow cell pressure: Effectively zero, cell open to atmosphere Weight: 1kg (single), 1.5kg (double) 1.3 System Components A Chemtrac water quality analyzer is made up of distinct parts that are chosen as options when the unit is ordered. These are: 1.3.1 User interface unit This houses the main electronics and is the main user interface. 1.3.2 Sensor This is the device that measures the water quality measurand of interest and is used with the user interface unit. 1.3.3 Overflow cell These are available in single or double flow cells. These will take a flow from 0-1.0 l/min, but a minimum of 0.5 l/min preferred. A flow switch is available as an option to give a low flow alarm if flow should be lost. 1.3.4 Electrochemical Probe Simulator Supplied with your instrument, if ordered. It simulates a constant output from a chlorine or ozone sensor and allows for easier troubleshooting. 1.3.5 GSM/GPRS Modem unit Supplied with your instrument, if ordered. This allows remote communication with the analyzer, such as texting alarms to mobile phones, or full internet access (internet access requires Fixed IP SIM card). 1.3.6 Autoflush In some applications, such as the backwater of a paper machine, solids may build up on the sensors and an Autoflush unit keeps the sensors clean. This unit is only available with the CRA3500, OZA4800 and PHO6300. The Autoflush module comes with its own manual. 1.3.7 Autocalibrators The PHO6300 and CRA3500 are available with an auto calibrator option. These units come with their own manuals.



2.0 Installation and Commissioning As with all instrumentation the installation and commissioning of this instrument is crucial to its safe and accurate function. This instrument must be used only for its purpose as outlined in this manual and must be installed and commissioned in accordance with this manual and by trained and qualified personnel. 2.1 Site Selection Please choose a suitable location for the installation of the probe and the electronics. The choice of installation point on any site is a compromise and is best undertaken by experienced installation personnel. The following is a list of the factors that need to be taken into consideration. This list is not intended as a checklist neither is it implied that the list is complete. Ensure that the mounting allows access to all serviceable parts. Try to mount the electronics in a position where they are not habitually hosed down in a cleaning process. Consider the length of wiring runs when mounting the instrument. Try to keep the electronics away from substations or other large emi emitters. Consider whether the sample will be representative and well mixed. Consider sample return points. In a plastic run, with a low conductivity sample consider earthing the sample. 2.2 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 double check that you have all the parts that were ordered as soon as you open the box. This may include (but not necessarily); Analyzer (Display & Interface Unit) Probe(s) Probe mounting overflow cell. Electrolyte Membrane(s) Abrasive paper (blue) Manual CO2 Buffer kit (Optional) Acid buffer unit (Optional) Autocalibrator (Optional) GSM Modem unit (Optional) Autoflush unit (Optional) If anything is missing, or damaged, please contact your sales outlet immediately. If the instrument needs to be returned for any reason please follow the instructions given in Appendix E of this manual.



2.3 Mounting Mounting the ANALYZER. Please refer to the drawings below and in Appendix A.



The instrument electronics enclosure should be mounted away from sources of heat or direct sunlight. For mounting of optional parts, please refer to the manual supplied with that unit. For mounting of the GSM/GPRS modem, please refer to section 5.2. For mounting of the flow cell (single or double), with its backplate (9mm thick), please refer to the drawings below.

2.4 Water connections The incoming water sample connection on a Chemtrac Analyzer is to the flowcell lower barb fitting. In all cases the incoming water sample should be regulated to 0.5 to 1.0 l/min. The flow cell is open to atmosphere, and so large changes in water pressure or flow rate can cause water to leak out the topside of the flow cell. If this occurs, reduce flow using the valve located on the bottom of the flow cell. Avoid connecting long drain lines to the overflow port on the flow cell as this will restrict the flow. If a long drain line is required, have the overflow fitting dump into a drain funnel that is open to atmosphere. Avoiding drain line restrictions is important as higher flow rates closer to 1 l/min are sometimes needed to prevent the accumulation of air bubbles on the membrane. The incoming fitting is a ¼” or 6mm barb fitting, or an 8mm pipe push-fitting. The outlet fitting is a ½” or 12mm barb fitting.



2.5 Electrical connections

2.5.1 Power Please note the warnings in Section 1.2. Please refer also to the above drawing, red area’s, and below. Cable type and rating – 18 AWG, 3 conductor, current rating 6A, 300V rated. The power switch (SW3, up-ON, down-OFF) is between the power connector (J10) and the fuse (F1, AC 1A). Note: DC powered units use a 2A fuse.

AC or DC power



2.5.2 RS 485 Please refer to the drawing in section 2.5, green area, and below. Cable type and rating – one pair, 22awg conductors, 120Ω impedance, 300V rated.

2.5.3 Relays Please refer to the drawing in section 2.5, green area, and below. The unit has normally open (NO) contacts. Cable type and rating – 18 AWG, current rating 6A, 300V rated.

2.5.4 Probe(s) The probes connect via a 4 pin IP65 connector at the base of the Analyzer (or via an interconnect cable for the Auto-calibrator option). The pH / ORP sensors use a female connector on the lead, while the ozone / chlorine sensors (all types) use a male connector on the lead. Cable type and rating – 4mm overall diameter, 2 x 0.25mm2 conductors [ozone / chlorine sensors (all types)], or multicore (co-axial cable together with multiple stranded cores) [for pH / ORP sensors]. 2.5.5 TCP/IP Please refer to the drawing in section 2.5, dark blue area, labelled ‘Ethernet’, and below. There is an RJ45 Ethernet socket (Cat 5) housed within the electronics. If this socket is used, please be sure to use a suitable cable gland to maintain the IP rating of the enclosure.



2.5.6 4-20mA Inputs and Outputs Please refer to the drawing in section 2.5, dark blue area, labelled ‘Analogue I/O’. Please refer to the drawing in section 2.5.6.1. AI0 and AO0 are instrument channel 0, AI1 and AO1 are instrument channel 1, (AI is Analogue Input, AO is Analogue Output). Cable type and rating – 2 x 24awg conductors (7 strands), 300V rated, PVC outer sheath. 2.5.6.1 Inputs The 4-20mA inputs are set at the factory for powered input. The powered input supplies +15Vdc @ 50mA max. If connecting external devices that don’t require power, the inputs can be switched to a non-powered mode by changing the switch (SW1 & SW2) position. SW1 and SW2 factory “powered” positions are shown below.

NOTE: incorrect use of the input can cause failure to the board. 2.5.6.2 Outputs Maximum loop loading is 700Ω, at 14Vdc. 2.5.7 USB Please refer to the drawing in section 2.5, light blue area, and below. There is an USB type B socket housed within the electronics. If this socket is used, please be sure to use a suitable cable gland to maintain the IP rating of the enclosure.



2.5.8 Digital Inputs and Outputs Please refer to the drawing in section 2.5, light blue area, and below.

2.5.8.1 Inputs 0/5Vdc 2.5.8.2 Outputs Capable of switching 40Vdc 2.5.8.3 Flowswitch Low flow fail indication, below 0.2 lpm. General assembly

Wiring diagram



2.5.9 PI-ANIO Board Please refer to the drawing below. Note statement at base of page.

This board is used in the 3500+ and 4800+ units. The board is a copy of section 2.5.6 above, AI0 and AO0 becoming instrument channel 2, AI1 and AO1 becoming instrument channel 3. 2.5.10 PI-PHIN Board Please refer to the drawing below. Note statement at base of page.

This board is used in the PHO6300 and CPO7600 units. The PHO6300+ uses 2 of these boards. The board is the input for the pH and ORP probes. Jumpers J4 and J5 have links fitted. 2.5.11 PI-SERIAL Board Please refer to the drawing below. Note statement at base of page.

This board is used to communicate with the GSM modem. Jumpers LK1 and LK2 have links fitted, as shown in red. Note: Please note that the use of expansion boards within the Analyzer means that some connectors can be difficult to access. This is a compromise to ensure that all possible functionality is available at a reasonable price inside a compact electronics unit. In order to access the connections it is permissible to remove the expansion boards. This is done by:

1. remove the power from the unit 2. open both the lower and upper covers 3. remove the central aluminium bar 4. remove the mounting screws from the expansion board 5. lift the expansion board (allowing access to connectors below)

Reverse the above to replace the expansion card. Do not reconnect power before expansion cards have been replaced.



3.0 OPERATION (Instrument) The ANALYZER is a complex set of electronics that may be controlled in a variety of ways. This section deals with controlling the instrument via the buttons on the front panel. 3.0.1 Display, Buttons and Menu The display is a backlit LCD display with variable contrast. The buttons are inductive and do not need to be pressed to activate. An extremely light touch or even hovering a finger over the button will activate it. Touching the button for an extended period will have the same effect as holding a key down on a PC keyboard. The up and down buttons on the right hand side of the display are always up and down. The remaining four buttons along the bottom are defined for each screen by the legend above the button on the display. For example, on the main display only three of the four buttons are active and the right hand button is used to take the user to the alarm display. The main display will look like:

By pressing the ‘menu’ button you will be taken to the main menu where configuration of the instrument is performed, refer to section 3.0.3. By pressing the ‘cal’ button you will be taken to the calibration section, for the probe that was being displayed. Refer to section 3.1, calibration. Note: The ‘cal’ shortcut button will not be shown on the main screen as shown above when certain options like PID control function are installed. If more than one sensor is fitted, then pressing the up or down arrow buttons will scroll around the sensors. By pressing the ‘logs’ button you will be taken to a log of system events and datalogs. Use the up or down arrow buttons to scroll through the log. By pressing the ‘alrm’ button you will be taken to a page that shows the current status of the alarms. In the alarm screen, the ‘rlys’ button will display the allocation of the relay outputs. When an alarm is active, the alarm screen will also have a button marked ‘ack.’. Pressing this button will acknowledge the alarm and silence the buzzer. To return to the main menu at any time, simply press the button marked ‘quit’ on any of the screens shown. Setting the time and date will be used to explain how to navigate around the instrument menus and enter configuration values.



3.0.2 Time and date To set the time and date press the menu key. This will take you to the main menu from where all parameters are set. Scroll up and down using the up and down arrows until the word ‘Settings’ is highlighted. Press the button under the word ‘entr’.

Scroll until the words ‘Time/Date’ are highlighted and then press ‘entr’. Select the word ‘Time’ and press ‘entr’. Use the up and down arrows to highlight the hours (24 hour clock), press ‘entr’ when you have selected the correct time in hours. This will take you to the number of minutes past the hour. Use the up and down buttons to display the correct number of minutes and press ‘entr’. This will take you back to the Time and Date menu. Highlight the word ‘Date’ using the up and down buttons, select the date, day, month and year, in the same way as above and amend it in the same way as above.



3.0.3 Menu Overview

* See Sections 3.2.4 And 3.2.5 For OtherController Configuration / PID Setup Options Not Listed Here.



3.1 Sensor Configuration 3.1.1 Calibration 3.1.1.1 Manual Calibration In order to perform a span of the sensor it is necessary to have an independent method of determining the level of the measurand, e.g. a DPD test kit to measure free or total chlorine, chlorine dioxide or ozone in the sample water, or buffers for pH or ORP. To span the sensor, press the button under the word ‘Cal’, If the instrument is multi-channel a menu will appear to select the channel to calibrate. Scroll through the menu and highlight the channel the probe is attached to. Press the button under the word ‘entr’. If the instrument has only one probe this menu will be skipped. This will take you to the ‘Span’ setting screen, which will show the raw value measured by the probe. At this point it will be necessary to test the water, from the sample line feeding the probe flow cell, using the necessary test kit. Once the concentration has been determined, use the up and down arrows to adjust the raw reading of the probe to equal that of the measured value. At this point press the button under the word ‘entr’ to set the span for the probe. Only set the span when the value is constant. Note: If it is no longer possible to adjust the span of the probe to the value measured i.e. the screen shows ‘MAX LIMIT’ or ‘MIN LIMIT’, consider performing the probe maintenance procedure. Press the button under the word ‘exit’ to exit to the main menu at any time. 3.1.1.2 Automatic Calibration Please refer to the Autocalibrator manuals. 3.1.2 Averaging This option allows you to turn on the rolling average function. It takes the last 60 readings and produces an average. 3.1.2.1 Display This menu allows you to turn this feature on/off for the data displayed on the instrument. On multi-channel instruments this can be set for each channel independently. 3.1.2.2 Output This menu allows you to turn this feature on/off for the alarms, setpoints and 4-20mA output. On multi-channel instruments this can be set for each channel independently. 3.1.2.3 Data Log This menu allows you to turn this feature on/off for the data log. On multi-channel instruments this can be set for each channel independently. 3.1.2.4 Sample Time The sample time option allows you to set how often a sample is taken – the default is 0.5s giving an average time of 30s. Other options are 1s, 2s, 3s & 5s. 3.1.3 Log Intervals Allows you to set the interval between logging data points. It the above option is turned on the rolling average is logged otherwise the current reading is logged. The default is 15 mins with other options of 1, 5, 10, 30 & 60 mins. 3.1.4 Units Allows you to choose between mg/l & ppm for certain measurements.



3.2 Output Configuration 3.2.1 Hold Channel Each channel can have its output value placed on hold. This will maintain the output signal and alarm state in their current state for the selected period of time. On a multi-channel instrument you will be asked to select the channel to hold. The hold delay is set by highlighting the desired time using the up and down arrow keys and pressing the button under ‘entr’. The available settings are:

• Off • 5 minutes • 10 minutes • 15 minutes • 30 minutes • 1 hour

3.2.2 Scale Output The 4-20mA output of each channel can be scaled within a user-defined range. The default output range is the same as the input range. On a multi-channel instrument you will be asked to select the channel to set the scale of the output. Use the up and down arrow keys to set the minimum value and press the button under ‘entr’. Set the maximum value in the same manor. 3.2.3 Map Output The 4-20mA output channels can be mapped to one of the input channels. To set up a mapping select the output channel on the first screen. When you press ‘entr’ you will be prompted to select whether the output channel is on or off. If you selected ‘on’ a further screen will ask you to select the input channel to output. Finally, a message will be displayed confirming your choice. 3.2.4 Proportional Control Setup Menu only available with Controller option. The Proportional Control is one of two available control options, the other is PID Control. The proportional control methodology is suitable for most dosing applications. The proportional control allows for either a pulsed output (relay) or a 4-20mA signal. The PID control feature (discussed in Section 3.2.5) is available for applications where process changes are more complex and a tighter band of control is needed. The preferred type of control must be specified at the time of ordering. The settings for Proportional Control are located under the Output Config menu.

3.2.4.1 Setup Input Select the sensor channel of the parameter reading to control. Output



First select the output method: • Continuous – Controller output as a 4-20mA signal. If this option is chosen select the output

channel connected to pump. • Pulse Frequency – Controller output is a normally open relay. The controller will close relay

in pulses in order to control dosing. If this option is chosen select the relay connected to the pump, valve, etc.

• Actuator – Controller is an actuator valve driven by two relay outputs and limit signals provided to two digital inputs. The controller will set the valve position depending on the dosing requirements. If this option is chosen select the relays connected to the valve. The first relay chosen will open the valve and the second close the valve. The corresponding digital inputs act as limit sensors. For example, if the option “Relays 1 & 2” is chosen, Relay 1 should be wired so as to open the valve when active and Relay 2 should close the valve. Digital input 1 (DI1+/-) should be wired to the open limit switch and Digital input 2 (DI2+/-) to the closed limit switch. 5V provided the J13 connector on the lower left hand corner of the analyzer board can be used as the power source for these switched signals.

3.2.4.2 Controller 1 Off/On Turns the controller loop on or off. Setpoint Sets the setpoint of the controller loop. This is the value of the parameter to be maintained. Control Mode Direct or reverse. Select direct when dosing increases the parameter value and reverse when dosing decreases the parameter value. Prop. Band Proportional Band. The size of the proportional band. If the setpoint is 1.00, the proportional band set to 0.25 and the control mode direct, the proportional band would effectively be 1.00. Prop. Gain Proportional Gain. The gain of the controller output in percent over the proportional band. Max. Output The maximum output of the controller in percent. Int. Time Interval Time. Only available for pulse frequency & actuator outputs. Pulse Frequency Output – This is the loop output time, default 60 seconds. If the controller loop calculates an output of 10% is required and the Interval Time is set to 60 seconds, the relay output will be closed for 6 seconds and open for 54 seconds. Actuator Output – This is the time taken for the valve to move from fully closed to fully open or visa versa. This time is used by the controller to calculate the valve position during dosing. 3.2.4.3 Controller 2 Only available in two channel PID controllers. Refer to section 3.2.4.2. 3.2.5 PID Control Setup Menu only available with Controller option. The PID Control is one of two available control options, the other is Proportional Control (discussed in section 3.2.4). The PID control methodology is recommended when the requirements for control are more complex and it is felt a simple proportional control would not be adequate. The PID control signal is a 4-20mA signal. The preferred type of control must be specified at the time of ordering.



Note: When the analyzer is equipped with the PID Control function, the shortcut key on the main screen for Calibration is replaced with a shortcut key for viewing the Setpoint and Control Output along with the measured reading. From this screen, the user can also quickly change the Control Mode, Setpoint, and Manual Output value.

3.2.5.1 Control Config Off/On Enables and Disables the PID Control functions. This function must be turned “ON” to use PID functionality. PID Settings

• Control Mode – The Controller’s pump output control has two mode of operation; AUTO or MANUAL (MAN). In AUTO mode, the pump output percent will increased or decreased automatically in response to deviations from the setpoint. In MAN mode, the pump output percent can be increased or decreased manually by setting the Man Output.

• Manual Value – The Manual Output value can be changed from 0 to 100% at 0.1% increment. When running in Automatic mode, the Manual Value setting is ignored. However, when switching from AUTO to MAN, it is important to understand that the Pump Output value will go to the Manual Value. Therefore, it is recommended to change the Man Output value to match the AUTO pump output value prior to switching mode. Failing to do so can result in a significant change in the pump output when switching from AUTO to MAN.

• Setpoint –The Setpoint is the value that the controller is programmed to maintain when in AUTO mode.

• Prop. Band – The Proportional Band setting determines the level of response, or amount of change to the control output signal, when the reading deviates from the setpoint. The Proportional Band value can be changed from 1 to 1000. The higher the value, the smaller the change the PID will make to the control output signal. A basic rule for setting the Proportional Band is that if a small change in the control output produces a large response in the reading, then you will need to use a higher Proportional Band value.

• Int. Time – The Integral Time setting determines how much adjustment is made to the control output signal while the reading is not at the setpoint. The Integral Time value can be changed from 1 to 1000. The higher the value, the smaller the change the PID will make to the control output signal. A basic rule for setting the Integral Time constant setting is that the longer the lag time, the higher the integral time constant will need to be.

• PID Rate – The PID Rate function serves to improve the controller’s response when higher Proportional Band and Integral Time settings appear to still be too responsive for the



application. The PID Rate setting is usually left at 1 for most applications since proper setting of Proportional Band and Integral Time are usually capable of providing proper response. Higher PID Rate settings will slow down the PID control. The PID Rate value can be changed from 1 to 20.

• Action – The Action function determines whether the control output will increase or decrease when the reading deviates from the setpoint. When set for Reverse acting, the PID will increase the control signal (e.g. go from 10% to 11%) when the reading decreases. When set for Direct acting, the PID will decrease the control signal (e.g. go from 10% to 9%) when the reading decreases. As an example, Reverse acting would be used when controlling pH with a base, and Direct would be used when controlling pH with an acid.

• Min. Output – The minimum output limit defines the minimum value of the control output signal when the control mode is set for Auto . The minimum output percent (%) value can be changed from 0 to 100%

• Max. Output – The maximum output limit defines the maximum value of the control output signal when the control mode is set for Auto . The maximum output percent (%) value can be changed from 0 to 100%

Flow Control* Flow Control should not be enabled in units with firmware versions of 2.2.6 or earlier. Information The Information screen shows a basic summary of the PID settings, including the current reading and control output value.



3.3 Alarm Configuration 3.3.1 Alarms This menu allows you to setup two alarms per channel, for either rising or falling levels. It is found under the ‘Alarm Config’ menu. If the “set” value is lower than the “reset” value then the alarm is a falling alarm. If the “set” value is higher than the “reset” value then the alarm is a rising alarm. Use the up and down arrow keys to highlight the alarm to configure and press the button under ‘entr’. Highlight either ‘Off’ or ‘On’ and press the button under ‘entr’ to set the state of the alarm. If ‘On’ was selected then the set and reset points can be entered using the up and down arrow keys followed by pressing the button under ‘entr’. 3.3.2 Setpoints Setpoints are used to activate relays or digital outputs based on parameter readings but without generating alarms. This menu allows you to setup two setpoints per channel, for either rising or falling levels and is configured as alarms in 3.3.1. 3.3.3 Relays This menu allows you to allocate relay outputs to alarms and setpoints. Relays can be allocated to system alarms, analogue alarms set in section 3.3.1 or setpoints set in section 3.3.2. Some optional extras, such as the Auto Calibrator and Auto Flush options, will reserve relays for system use. To allocate a relay, highlight the desired relay using the up and down arrow keys and press the button under ‘entr’. In the next menu select if the alarm is a system alarm or an analogue alarm and press the button under ‘entr’. If system alarm was chosen a further menu will ask you to select if the relay is normally open or normally closed. If an analogue alarm or setpoint was chosen a further menu will ask you to allocate the relay to a specific alarm. 3.3.4 Digital Outputs This menu allows you to allocate digital outputs to alarms and setpoints. Digital outputs are configured as relays in section 3.3.3. 3.3.5 Flow Alarms Allows you to set the digital in which is connected to the flow switch to monitor flow/no (v. low) flow condition. Generates a system alarm if tripped and an appropriate message in the system log. Default disabled.



3.4 Communications Configuration 3.4.1 Setup 3.4.1.1 Serial Modbus Address Sets the device address for the Modbus protocol transmitted over RS-485 and USB. RS485 Baud Sets the RS485 baud rate. Options are:

• 9600 (Default) • 19200 • 38400 • 57600 • 115200

RS232 Baud Sets the RS232 baud rate if a RS232 expansion card is fitted. Options are:

• 9600 • 4800 • 2400 • 1200 (Default) • 600

3.4.1.2 Ethernet This menu is only available if the Remote Access option is purchased. The sub-menus within allow the IP address, subnet mask, gateway address and DNS server for the Ethernet connection to be set. 3.4.1.3 GPRS This menu is only available if the Remote Access option and GSM/GPRS modem is purchased. The sub-menus within allow the GPRS communications to be turned on or off and the username, password and access point authentication data to be set. The username, password and access point (APN) will be provided by your SIM card provider. These must be set before enabling the GPRS communications. 3.4.2 SMS Alerts 3.4.2.1 Off/On Using the up and down arrow keys, select ‘Off’ or ‘On’ and press the button under the word ‘entr’. 3.4.2.2 Phonebook Up to 5 numbers can be entered with a maximum of 15 digits each. To edit a number use the up and down arrow keys to select the phone number and press the button under the word ‘entr’. Each digit can be edited in turn by using the up and down arrow keys. Press the button under the word ‘entr’ to move to the next digit. Phone numbers that are all 0 will be ignored, as will spaces within each phone number. 3.4.2.3 Ack Timeout This menu will select the acknowledgement timeout – the time the Analyzer waits to notify the next person in the phonebook if no reply is received when an alarm is active. The available options are:

• 5 minutes • 10 minutes • 30 minutes • 1 hour



Using the up and down arrow keys to select the desired timeout and press the button under the word ‘entr’. 3.4.3 Modbus TCP The Modbus TCP protocol is used to provide the remote access functionality. It is disabled by default and must be configured to allow access. 3.4.3.1 Ethernet Off/On Turns Modbus TCP on or off on the Ethernet interface. Off by default. Auth. Off/On Turns on or off a basic authentication extension to the Modbus TCP protocol for the Ethernet interface. Clients must provide the password set in section 3.4.3.3 to access the service. Off by default. 3.4.3.2 GPRS As section 3.4.3.1 but applies to the GPRS interface. 3.4.3.3 Password This menu allows the password to be set for the authentication extension to the Modbus TCP protocol.



3.5 Settings 3.5.1 Time and Date See section 3.0.2. 3.5.2 LCD/Keypad Navigate to LCD/Keypad under the Settings menu. You will find three submenus of ‘Keypad tone’, ‘Backlight’ and ‘Contrast’. 3.5.2.1 Keypad Tone This can be selected on or off. It is a quiet audible confirmation that a button has been pressed. 3.5.2.2 Backlight This can be set to ‘on’, ‘off’ or ‘auto’ where ‘auto’ turns the backlight on when a button is pressed. It will leave the backlight on for ten seconds after the last key press. 3.5.2.3 Contrast This can be set using the up and down arrows between 0 and 9 to allow for changes in the ambient lighting conditions. 3.5.3 Tag Each instrument can be identified by a custom name and identification code called Tag Name and Tag ID, respectively. These are used in all communication protocols. 3.5.3.1 Tag Name Navigate to ‘Tag Name’ via the Tag menu. Press ‘entr’ and use the up and down keys to select the letters and numbers required. The alphanumeric Tag field will accept 11 characters including spaces. To move onto the next character press the button under the word ‘entr’. To delete a character press the button under the word ‘back’. To store the tag name all 11 characters must be entered. 3.5.3.2 Tag ID Navigate to ‘Tag ID’ via the Tag menu. Press ‘entr’ and use the up and down keys to select the letters and numbers required as above. Again, Tag ID will accept 11 characters. 3.5.4 Password The Analyzer provides password protection to prevent unauthorised users from tampering with the instrument settings. When password protected, the Analyzer will not allow access to the main menu until an administrator password has been entered. To enter a password use the up and down arrow keys along with the button under the word ‘entr’. A time delay facility has been incorporated into the password protection. The time delay facility re-activates password protection (if enabled) 60 seconds after the last key press of an authorised user. Note: Access to the alarm status and stored data is still possible without a password. Password protection is turned off as the default setting. To turn password protection on or off scroll through the ‘Settings’ menu until the word ‘Password’ is highlighted. Press the button under the word ‘entr’. In the menu that follows highlight the ‘Off/On’ menu item and press the button under the word ‘entr’. In the menu that follows highlight the ‘On’ or ‘Off’ menu item and press the button under the word ‘entr’ to turn the password protection on or off respectively. The default password for the Analyzer is ‘1234’. It is possible to change the default password to any 4 character password using the letters A-Z and the numbers 0-9. To change the password, navigate to the ‘Password’ menu as described above and select the ‘ADMIN’ menu item. The Analyzer will prompt the user to enter a password. This will be the current user defined password or default password if the password has not previously been changed. If a correct password is entered the user will then be prompted to enter a new password. Once the new password has been entered the Analyzer will prompt the user to re-enter the new password to confirm the change.



4.0 Sensors 4.1 Free Chlorine

WARNING! WARNING! WARNING! WARNING! PLEASE READ THE INSTRUCTIONS BELOW BEFORE DOING ANYTHING WITH THIS PROBE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN DAMAGE TO THE MEMBRANE CAP AND WARRANTIES FOR THIS DEVICE MAY BE VOIDED. You will find a membrane cap that is loosely screwed onto the end of your probe. DO NOT REMOVE OR TIGHTEN THIS MEMBRANE CAP UNTIL YOU HAVE READ THESE INSTRUCTIONS! There is an elastic seal around the membrane cap which is used to seal the vent hole on the membrane cap during normal operation. Prior to servicing the probe the elastic seal must be slid down to expose this vent hole. Do not loosen the membrane cap without having the vent hole exposed and unobstructed. If the vent hole is blocked off when the membrane cap is removed, then the membrane may rupture (i.e. develop a tiny tear) and the probe may not produce accurate readings. When the membrane cap is filled with electrolyte and fastened onto the probe (in accordance with instructions in the operations manual), you will notice some electrolyte bleed out from the vent hole. This is normal. NOTE: DO NOT INSERT THE PROBE INTO THE FLOW CELL, OR GET IT WET, WITHOUT HAVING THE VENT HOLE COVERED WITH THE ELASTIC SEAL! The purpose of the vent hole is to protect the membrane from being exposed to internal pressure or vacuum when the membrane cap is screwed onto or off of the probe tip. For further assistance please contact your sales and service centre.

IPBI08 – Probe Warning

Vent Hole This vent hole must be exposed prior to unscrewing the membrane cap from the probe tip.

Elastic Seal This is the position the seal should be in when the probe is inserted into the flow cell.



The chlorine sensor is a membrane covered potentiostatic 3-electrode system. The measuring electrode is membrane covered and is in the electrolyte area together with the reference electrode. This electrolyte area contains a special electrolyte and is separated by a second membrane from the sample water. In this measuring method chlorine diffuses out of the sample water, through the membranes and causes an electrical signal at the measuring electrode. The electrical signal at the measuring electrode is proportional to the chlorine concentration and is amplified by the electronics in the sensor. The measuring signal is independent from the temperature of the measuring water due to an integrated temperature compensator.

4.1.1 Installation Please refer to Site Selection, section 2.1. Ensure the probe housing is mounted vertically, to ensure correct water flow over the sensor. Ensure the installation is stable, secure and away from vibration. Ensure the sample is free from bubbles and is well mixed.



4.1.2 Setup

Caution: When you unscrew the filled (or unfilled) membrane cap, ensure the vent band has been removed from the vent hole, to allow air to enter, otherwise the membrane will be destroyed by the vacuum.

Unscrew the membrane cap from the electrode shaft. Place the membrane cap and the G-holder onto a clean and non-absorptive bench.

Caution: When Caution: never polish this area of the probe.

Fill the membrane cap up to the edge with the enclosed electrolyte. Be careful so that there are hardly any bubbles. Then replace it onto the bench.

Note: Read the electrolyte MSDS sheet.



Fill up the G-holder with electrolyte. Be careful that there are no bubbles.

Hold the electrode shaft upright and push the electrode finger carefully into the filled G-holder.

Hold the electrode shaft (with the G-holder) upright and put it on the filled membrane cap. Then screw the membrane cap onto the electrode shaft. Turn it anticlockwise until the thread engages, then screw slowly the electrode shaft clockwise (by hand) onto the membrane cap. Excess electrolyte will escape through the vent hole in the membrane cap. Do not close this vent with your finger.

Warning: Electrolyte may spurt from the vent hole. Excess electrolyte, or electrolyte on your skin or in your eye, should be washed off immediately with water. The electrolyte contains potassium halide.



Check that the membrane cap is completely screwed in up to the stop. There is initial resistance from the o-ring, continue past this to the electrode body. Then ensure the vent band is seated correctly. Wash off the excess electrolyte with water. Initial run-in is 1 hour prior to calibration. Calibration should be repeated after 24 hours. Routine calibration should be weekly.

Caution: When you unscrew the filled membrane cap, ensure the vent band has been removed from the vent hole, to allow air to enter, otherwise the membrane will be destroyed by the vacuum.

4.1.3 Maintenance Caution: The coating of the electrode finger must not be emeried! Do not unscrew the metal end ring of the membrane cap, as this will destroy the membrane. 4.1.3.1 Routine maintenance The electrolyte should be changed every three months, although it may be possible to extend the period if low levels of chlorine are measured. It may be necessary to use a new membrane cap when changing the electrolyte. In any event, the membrane cap should be changed every 12 months. If your unit has been ordered with the auto calibrator then the calibration reagent should be changed every six months.



4.1.3.2 Diagnostic maintenance If calibration is impossible due to unstable or low output, remove the sensor, displace the vent seal so that the vent hole opening is free. The membrane cap can then be unscrewed. The electrode finger is cleaned with a clean, dry, soft paper towel. With the special abrasive paper supplied (blue) just the tip of the dry electrode (the working electrode) is cleaned. Place the special abrasive paper on a paper towel (on a flat, dry surface), hold it at the corners and rub the electrode tip of the perpendicularly held probe two or three times across the abrasive paper. Then replace the vent seal onto the vent hole and fill with electrolyte (see section 4.1.2). If necessary, use a new membrane cap. Recommendation: change the electrolyte every 3 months.

4.1.4 Storage To store the probe the membrane cap is unscrewed (note previous warning). The membrane G-holder must be removed and discarded. The membrane cap and electrode finger should be rinsed in clean water and dried in a place free of dust with a soft paper towel (do not damage the electrode areas). The dry membrane cap is then loosely screwed onto the electrode shaft. The membrane must not rest against the measuring electrode. Do not fully tighten the membrane cap. When putting the probe back into use after storage, the electrode tip must be cleaned with the special abrasive paper supplied (see 4.1.3.2) and a new membrane cap and G-holder must be used (follow 4.1.2). 4.1.5 Spares Free Chlorine Membrane cap M48 G Free Chlorine Electrolyte ECS2.1/GEL



4.1.6 Single flowcell The o-ring is first inserted in the 1” opening of the adaptor followed by the PVC shim. Then the 1” PVC threaded end cap is screwed in loosely. The probe is inserted into this prepared probe housing. Then the probe is fixed in place by tightening (hand tight only) the threaded end cap, so the probe cannot move away from its position.



4.1.6.1 Insertion There should be 25mm (1”) of clear space between the tip of the sensor and the conical base of the flowcell tube.



4.1.7 Double flowcell The sensor fits into the right-hand entry. The o-ring is first inserted in the 1” opening of the adaptor followed by the PVC shim. Then the 1” PVC threaded end cap is screwed in loosely. The probe is inserted into this prepared probe housing. Then the probe is fixed in place by tightening (hand tight only) the threaded end cap, so the probe cannot move away from its position.

As with the single flowcell, there should be 25mm (1”) of clear space between the tip of the sensors and the conical base of the flowcell tubes (refer to 4.1.6.1).



4.2 Total Chlorine

WARNING! WARNING! WARNING! WARNING! PLEASE READ THE INSTRUCTIONS BELOW BEFORE DOING ANYTHING WITH THIS PROBE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN DAMAGE TO THE MEMBRANE CAP AND WARRANTIES FOR THIS DEVICE MAY BE VOIDED. You will find a membrane cap that is loosely screwed onto the end of your probe. DO NOT REMOVE OR TIGHTEN THIS MEMBRANE CAP UNTIL YOU HAVE READ THESE INSTRUCTIONS! There is an elastic seal around the membrane cap which is used to seal the vent hole on the membrane cap during normal operation. Prior to servicing the probe the elastic seal must be slid down to expose this vent hole. Do not loosen the membrane cap without having the vent hole exposed and unobstructed. If the vent hole is blocked off when the membrane cap is removed, then the membrane may rupture (i.e. develop a tiny tear) and the probe may not produce accurate readings. When the membrane cap is filled with electrolyte and fastened onto the probe (in accordance with instructions in the operations manual), you will notice some electrolyte bleed out from the vent hole. This is normal. NOTE: DO NOT INSERT THE PROBE INTO THE FLOW CELL, OR GET IT WET, WITHOUT HAVING THE VENT HOLE COVERED WITH THE ELASTIC SEAL! The purpose of the vent hole is to protect the membrane from being exposed to internal pressure or vacuum when the membrane cap is screwed onto or off of the probe tip. For further assistance please contact your sales and service centre.

IPBI08 – Probe Warning


Elastic Seal This is the position the seal should be in when the probe is inserted into the flow cell.



The chlorine sensor is a membrane covered potentiostatic 3-electrode system. The measuring electrode is membrane covered and is in the electrolyte area together with the reference electrode. This electrolyte area contains a special electrolyte and is separated by a membrane from the sample water. In this measuring method chlorine diffuses out of the sample water, through the membrane and causes an electrical signal at the measuring electrode. The electrical signal at the measuring electrode is proportional to the chlorine concentration and is amplified by the electronics in the sensor. The measuring signal is independent from the temperature of the measuring water due to an integrated temperature compensator.




4.2.2 Setup

Caution: When you unscrew the filled (or unfilled) membrane cap, ensure the vent band has been removed from the vent hole, to allow air to enter, otherwise the membrane will be destroyed by the vacuum.

Unscrew the membrane cap from the electrode shaft. Place the membrane cap onto a clean and non-absorptive bench.

Caution: When Caution: never polish this area of the probe.

Fill the membrane cap up to the edge with the enclosed electrolyte. Be careful so that there are hardly any bubbles. Then replace it onto the bench.




Hold the electrode shaft upright and put it on the filled membrane cap. Then screw the membrane cap onto the electrode shaft. Turn it anticlockwise until the thread engages, then screw slowly the electrode shaft clockwise (by hand) onto the membrane cap. Excess electrolyte will escape through a valve (located above the type marking, under the vent band seal) in the membrane cap. Do not close this vent with your finger.

Warning: Electrolyte may spurt from the vent hole. Excess electrolyte, or electrolyte on your skin or in your eye, should be washed off immediately with water.

Check that the membrane cap is completely screwed in up to the stop. There is initial resistance from the o-ring, continue past this to the electrode body. Then ensure the vent band is seated correctly. Wash off the excess electrolyte with water. Initial run-in is 1 hour prior to calibration. Calibration should be repeated after 24 hours. Routine calibration should be weekly.

Caution: When you unscrew the filled membrane cap, ensure the vent band has been removed from the vent hole, to allow air to enter, otherwise the membrane will be destroyed by the vacuum.



4.2.3 Maintenance Caution: The coating of the electrode finger must not be emeried! Do not unscrew the metal end ring of the membrane cap, as this will destroy the membrane. 4.2.3.1 Routine maintenance The electrolyte should be changed every three months, although it may be possible to extend the period if low levels of chlorine are measured. It may be necessary to use a new membrane cap when changing the electrolyte. In any event, the membrane cap should be changed every 12 months. If your unit has been ordered with the auto calibrator then the calibration reagent should be changed every six months. 4.2.3.2 Diagnostic maintenance

If calibration is impossible due to unstable or low output, remove the sensor, displace the vent seal so that the vent hole opening is free. The membrane cap can then be unscrewed. The electrode finger is cleaned with a clean, dry, soft paper towel. With the special abrasive paper supplied (blue) just the tip of the dry electrode (the working electrode) is cleaned. Place the special abrasive paper on a paper towel (on a flat, dry surface), hold it at the corners and rub the electrode tip of the perpendicularly held probe two or three times across the abrasive paper. Then replace the vent seal onto the vent hole and fill with electrolyte (see section 4.2.2). If necessary, use a new membrane cap. Recommendation: change the electrolyte every 3 months.

4.2.4 Storage To store the probe the membrane cap is unscrewed (note previous warning). The membrane cap and electrode finger should be rinsed in clean water and dried in a place free of dust with a soft paper towel (do not damage the electrode area). The dry membrane cap is then loosely screwed onto the electrode shaft. The membrane must not rest against the measuring electrode. Do not fully tighten the membrane cap. When putting the probe back into use after storage, the electrode tip must be cleaned with the special abrasive paper supplied (see 4.2.3.2) and a new membrane cap must be used (follow 4.2.2). 4.2.5 Spares Total Chlorine Membrane cap M48 Total Chlorine Electrolyte ECP1.3/GEL 4.2.6 Single flowcell Refer to section 4.1.6 4.2.6.1 Insertion Refer to section 4.1.6.1 4.2.7 Double flowcell Refer to section 4.1.7



4.3 Chlorine Dioxide

WARNING! 2 seals! WARNING! 2 seals! PLEASE READ THE INSTRUCTIONS BELOW BEFORE DOING ANYTHING WITH THIS PROBE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN DAMAGE TO THE MEMBRANE CAP AND WARRANTIES FOR THIS DEVICE MAY BE VOIDED. You will find a membrane cap that is contained in a tub of liquid. DO NOT REMOVE FROM THE TUB, OR DO ANYTHING WITH THE MEMBRANE CAP UNTIL YOU HAVE READ THESE INSTRUCTIONS! There are two elastic seals around the membrane cap which is used to seal the vent hole on the membrane cap during normal operation. Prior to servicing the probe the elastic seals must be slid down to expose this vent hole. Do not loosen the membrane cap without having the vent hole exposed and unobstructed. If the vent hole is blocked off when the membrane cap is removed, then the membrane may rupture (i.e. develop a tiny tear) and the probe may not produce accurate readings. When the membrane cap is filled with electrolyte and fastened onto the probe (in accordance with instructions in the operations manual), you will notice some electrolyte bleed out from the vent hole. This is normal. NOTE: DO NOT INSERT THE PROBE INTO THE FLOW CELL, OR GET IT WET, WITHOUT HAVING THE VENT HOLE COVERED WITH BOTH ELASTIC SEALS! The purpose of the vent hole is to protect the membrane from being exposed to internal pressure or vacuum when the membrane cap is screwed onto or off of the probe tip. For further assistance please contact your sales and service centre.

IPBI09 – Probe Warning 2 seals


Elastic Seals This is the position the seals should be in when the probe is inserted into the flow cell.



The chlorine dioxide sensor is a membrane covered amperometric 2-electrode system. The measuring electrode is in the electrolyte area together with the reference electrode. This electrolyte area contains a special electrolyte and is separated from the sample water by a membrane. In this measuring method chlorine dioxide diffuses out of the sample water, through the membrane and causes an electrical signal at the measuring electrode. The electrical signal at the measuring electrode is proportional to the chlorine dioxide concentration and is amplified by the electronics in the sensor. The measuring signal is independent from the temperature of the measuring water due to an integrated temperature compensator.




4.3.2 Setup

Remove the black protection tube from the electrode.

Use the special abrasive blue paper supplied to clean only the tip of the dry electrode. Firmly hold the soft pad (supplied), with the special abrasive paper on it, and rub the probe electrode tip of the slightly inclined probe over the abrasive paper. Then turn the probe a bit around its axis and rub again over the abrasive paper. Repeat this procedure several times.

Caution: The coating of the electrode finger must not be e emeried!

Do not allow the probe finger to touch the membrane cap when assembling or disassembling.

Caution: never polish this area of the probe.



Open the tub with the membrane cap and empty out the water.

Note: The water contains a small amount of methanol.

Move one rubber ring (vent ring) from the channel, leaving the second vent ring in place, covering the vent hole. Fill the membrane cap up to the edge with the electrolyte. Be careful so that there are hardly any bubbles.


Hold the electrode shaft upright and put it on the filled membrane cap. Then screw the membrane cap onto the electrode shaft. Turn it counter clockwise until the thread engages, then screw slowly the electrode shaft clockwise (by hand) onto the membrane cap. Excess electrolyte will escape through a hole (located above the type marking, under the single vent band seal remaining) in the membrane cap. Do not close this vent with your finger, as this will destroy the membrane (due to pressure).

Warning: Electrolyte may spurt from the vent hole. Excess electrolyte, or electrolyte on your skin or in your eye, should be washed off immediately with water.



Check that the membrane cap is completely screwed in up to the stop. There is initial resistance from the o-ring, continue past this to the electrode body. Then replace the second vent band, ensuring both vent bands are seated correctly. Initial run-in is between 1 and 3 hours prior to calibration. Calibration should be repeated after 24 hours. Routine calibration should be weekly.

Caution: When you unscrew the filled membrane cap, ensure both the vent bands have been removed from the vent hole, to allow air to enter, otherwise the membrane will be destroyed by the vacuum.

4.3.3 Maintenance Caution: The coating of the electrode finger must not be emeried! Do not unscrew the metal end ring of the membrane cap, as this will destroy the membrane. 4.3.3.1 Routine maintenance The electrolyte should be changed every six months. It may be necessary to use a new membrane cap when changing the electrolyte. In any event, the membrane cap should be changed every 12 months.



4.3.3.2 Diagnostic maintenance If calibration is impossible due to unstable or low output, remove the sensor, displace the vent seals so that the vent hole opening is free. The membrane cap can then be unscrewed. The electrode finger is cleaned with a clean, dry, soft paper towel. Use the special abrasive paper supplied to clean only the tip of the dry electrode. Firmly hold the soft pad (supplied), with the special abrasive paper on it, and rub the probe electrode tip of the slightly inclined probe over the abrasive paper. Then turn the probe a bit around its axis and rub again over the abrasive paper. Repeat this procedure several times. Then replace one vent seal onto the vent hole and fill with electrolyte (see section 4.3.2). If necessary, use a new membrane cap. Recommendation: change the electrolyte every 6 months.

4.3.4 Storage To store the probe the membrane cap is unscrewed (note previous warning). The membrane cap and electrode finger should be rinsed in clean water and dried in a place free of dust with a soft paper towel (do not damage the electrode areas). The dry membrane cap is then loosely screwed onto the electrode shaft. The membrane must not rest against the measuring electrode. When putting the probe back into use after storage, the electrode tip must be cleaned with the special abrasive paper supplied (see 4.3.3.2) and a new membrane cap must be used (follow 4.3.2). 4.3.5 Spares Chlorine dioxide Membrane cap M7N Chlorine dioxide Electrolyte ECD7/W 4.3.6 Single flowcell Refer to section 4.1.6 4.3.6.1 Insertion Refer to section 4.1.6.1 4.3.7 Double flowcell Refer to section 4.1.7



4.4 Dissolved Ozone

WARNING! 2 seals! WARNING! 2 seals! PLEASE READ THE INSTRUCTIONS BELOW BEFORE DOING ANYTHING WITH THIS PROBE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN DAMAGE TO THE MEMBRANE CAP AND WARRANTIES FOR THIS DEVICE MAY BE VOIDED. You will find a membrane cap that is contained in a tub of liquid. DO NOT REMOVE FROM THE TUB, OR DO ANYTHING WITH THE MEMBRANE CAP UNTIL YOU HAVE READ THESE INSTRUCTIONS! There are two elastic seals around the membrane cap which is used to seal the vent hole on the membrane cap during normal operation. Prior to servicing the probe the elastic seals must be slid down to expose this vent hole. Do not loosen the membrane cap without having the vent hole exposed and unobstructed. If the vent hole is blocked off when the membrane cap is removed, then the membrane may rupture (i.e. develop a tiny tear) and the probe may not produce accurate readings. When the membrane cap is filled with electrolyte and fastened onto the probe (in accordance with instructions in the operations manual), you will notice some electrolyte bleed out from the vent hole. This is normal. NOTE: DO NOT INSERT THE PROBE INTO THE FLOW CELL, OR GET IT WET, WITHOUT HAVING THE VENT HOLE COVERED WITH BOTH ELASTIC SEALS! The purpose of the vent hole is to protect the membrane from being exposed to internal pressure or vacuum when the membrane cap is screwed onto or off of the probe tip. For further assistance please contact your sales and service centre.

IPBI09 – Probe Warning 2 seals


Elastic Seals This is the position the seals should be in when the probe is inserted into the flow cell.



The ozone sensor is a membrane covered amperometric 2-electrode system. The measuring electrode is in the electrolyte area together with the reference electrode. This electrolyte area contains a special electrolyte and is separated from the sample water by a membrane. In this measuring method ozone diffuses out of the sample water, through the membrane and causes an electrical signal at the measuring electrode. The electrical signal at the measuring electrode is proportional to the ozone concentration and is amplified by the electronics in the sensor. The measuring signal is independent from the temperature of the measuring water due to an integrated temperature compensator.



4.4.1 Installation Please refer to section 4.3.1. 4.4.2 Setup Please refer to section 4.3.2. 4.4.3 Maintenance Please refer to sections 4.3.3, 4.3.3.1 and 4.3.3.2. 4.4.4 Storage Please refer to section 4.3.4. 4.4.5 Spares Ozone Membrane cap M7N O3 stating range (eg 0-2ppm) Ozone Electrolyte EOZ7/W 4.4.6 Single flowcell Refer to section 4.1.6 4.4.6.1 Insertion Refer to section 4.1.6.1 4.4.7 Double flowcell Refer to section 4.1.7



4.5 pH The measurement of solution pH involves the use of two half cells; a pH glass cell and the reference cell. A combination pH electrode contains these two half cells within a single body. The internal half cell consists of a high resistance glass tube which has a pH sensitive glass membrane at the lower end. Within this tube is an internal reference system which remains constant. This cell is referred to as the glass half cell. The reference cell is housed concentrically between the outer body of the electrode and the glass half cell. It comprises of a reference element (silver/silver chloride or a caromel type) and an electrolyte solution (gel) which seeps through a porous liquid junction to make the necessary electrical connection with the sample. The cell generates a small voltage which provides the glass half cell with a stable reference voltage against which all measurements can be made.



4.5.1 Installation Please refer to Site Selection, section 2.1. Ensure the probe housing is mounted vertically, to ensure correct water flow over the sensor. Ensure the installation is stable, secure and away from vibration. Ensure the sample is free from bubbles and is well mixed. 4.5.2 Setup Remove the storage teat from the pH sensitive membrane (spill caution, teat contains liquid). Wash the membrane and liquid junction area in distilled water to remove any salt deposits from the exterior of the electrode. Check that the pH sensitive membrane is full of electrolyte (gel). If air bubbles are present these can easily be removed by shaking the electrode in a downward motion. 4.5.3 Maintenance Cleaning procedure. Soak the electrode in 0.1 molar HCl for 30 minutes followed by soaking in pH7 buffer for 2 hours. Always keep the pH sensitive membrane wet. Always use freshly prepared pH buffers. When not in use pH buffers should be stored in sealed containers. It is not recommended that pH buffers should be stored in this way for more than one week. Care should be taken to avoid handling the membrane. Any damage to the surface, such as abrasion, may cause inaccuracies and result in a slow response time. The electrical connections, terminations, etc. must be kept clean and dry. Failure to do so will result in a loss of insulation – producing inaccurate results or total failure. 4.5.4 Storage To store the sensor overnight (short term). Leave the sensor electrode tip soaking in pH7 buffer. To store the sensor long term. Replace the electrode storage teat containing pH7 buffer/0.1 molar KCl. 4.5.5 Spares Replacement pH probe KDI9/PT100/PI



4.5.6 Single flowcell The o-ring is first inserted in the 1 ¼” opening of the flowcell followed by the PVC shim. Then the 1 ¼” PVC threaded end cap is screwed in loosely. The probe is inserted into this prepared probe housing. Then the probe is fixed in place by tightening (hand tight only) the threaded end cap, so the probe cannot move away from its position.

4.5.6.1 Insertion Refer to section 4.1.6.1



4.5.7 Double flowcell The sensor fits into the left-hand entry. The o-ring is first inserted in the 1 ¼” opening of the flowcell followed by the PVC shim. Then the 1 ¼” PVC threaded end cap is screwed in loosely. The probe is inserted into this prepared probe housing. Then the probe is fixed in place by tightening (hand tight only) the threaded end cap, so the probe cannot move away from its position.

As with the single flowcell, there should be 25mm (1”) of clear space between the tip of the sensors and the conical base of the flowcell tubes (refer to 4.1.6.1).



4.6 ORP The measurement of ORP, redox potential or oxidation / reduction potential is achieved using a platinum ball mV measuring sensor. The probe contains a reference cell and a measurement cell. The measument unit is volts, millivolts or Eh (1Eh = 1mV). ORP/redox values are determined by measuring the potential difference between an inert indicator electrode in contact with the sample solution and a stable reference electrode connected to the solution by a salt bridge. The indicator electrode acts as a platform for electron transfer to or from the reference half cell. This is the platinum ball.




4.6.2 Setup Remove the storage teat from the ORP sensitive membrane (spill caution, teat contains liquid). Wash the membrane and liquid junction area in distilled water to remove any salt deposits from the exterior of the electrode. Check that the ORP sensitive membrane is full of electrolyte (gel). If air bubbles are present these can easily be removed by shaking the electrode in a downward motion. 4.6.3 Maintenance Cleaning procedure. Soak the electrode in 0.1 molar HCl for 30 minutes followed by soaking in pH7 buffer for 2 hours. Always keep the ORP sensitive membrane wet. Always use freshly prepared ORP buffers. Care should be taken to avoid handling the membrane. Any damage to the surface, such as abrasion, may cause inaccuracies and result in a slow response time. The electrical connections, terminations, etc. must be kept clean and dry. Failure to do so will result in a loss of insulation – producing inaccurate results or total failure. 4.6.4 Storage To store the sensor overnight (short term). Leave the sensor electrode tip soaking in pH7 buffer. To store the sensor long term. Replace the electrode storage teat containing pH7 buffer/0.1 molar KCl. 4.6.5 Spares Replacement ORP probe KDIPt9/PT100/PI 4.6.6 Single flowcell Refer to section 4.5.6 4.6.6.1 Insertion Refer to section 4.1.6.1 4.6.7 Double flowcell Refer to section 4.5.7



5.0 GSM Modem Unit 5.1 General This device will send SMS alerts to warn users when the Analyzer is in alarm. The modem aerial is contained within the housing.



5.2 Installation Please refer to the attached drawings for installation and connection information. A site with reception for your SIM card supplier is needed.

5.3 Setup Please refer to section 3.4.4, SMS Alerts.



5.4 Electrical connections Please refer to the attached drawing for electrical connections (ac or dc).



6.0 COMMISSIONING It is recommended that the ANALYZER is commissioned by a trained commissioning engineer. During the commissioning the engineer can train the operators in the correct operation of the ANALYZER. The installation and commissioning should proceed in the following manner:

1) Install the unit. 2) Check the sensor(s) for damage (as per the manual). 3) Make up the sensors as per the manual. 4) Ensure that water flows through the flowcell and passes the sensor(s). 5) Calibrate the temperature and then the pH sensor and or after the Cl2 / ClO2 / O3 sensor(s)

have completely polarized (from 2-12 hours of water flow with the electronics turned on and chlorine / chlorine dioxide / ozone in the water). Calibrate the instrument using a suitable test kit (eg DPD for Cl2) and the instrument is fully commissioned.



7.0 Troubleshooting guide 7.1 Electronics

Symptom Possible cause Possible solution Check power is getting to the instrument No power and check connections No display or Open the unit and check the ON/OFF LEDs switch and fuse Ribbon cable disconnected Turn off the power using the ON/OFF switch, then push ribbon cable onto board LEDs light up, Display fault Return unit for repair no display Not selected in software Map output 4-20mA output Dip switch in wrong Check the position of the DIP switch not working position (section 2.5.6 or 2.5.8) Add on board problem Check PI-ANIO board fitted and connected correctly pH/temp. Add on board problem Check PI-PHIN board fitted and connectedincorrect correctly Relays not Not assigned in software Check assignment of relays (see working section 3.3.2)

7.1.1 Fault codes The following table gives the error codes and explanation of them:

Error Reason

Sx Error. Check Sx connection Wiring problem with probe. Check connection (eg. where S1 is channel CH0)

CHx Flow Error. Low flow Check water flow through flowcell

Battery Error. Check Backup Battery RTC backup battery has failed

4-20mA CHx. Report to supplier Analogue input failure



7.2 Sensors Sensor faults will usually show themselves as unexpected readings. Unexpected readings can also be caused by the electronics, so when troubleshooting it is important to determine the cause of the variable readings. All analyzers (except the PHO6300 and CPO7600 [pH/ORP sensors]) can be supplied with an electrochemical probe simulator. If the instrument displays unexpected readings, unplug the probe and plug in the probe simulator. This supplies a fixed constant reading to the analyzer. If the reading is not constant, please contact your supplier.

Symptom Possible cause Possible solution Sensor disconnected Check sensor connected pH/temp. incorrect Sensor misconnected Check sensor connected to correct (100+ or pHybrid) channel Sensor disconnected Check sensor connected Chlorine/ozone Probe depolarized after Probe will repolarize after 2-12 hours incorrect extended zero period Sensor misconnected Check sensor connected to correct channel

7.3 Further help For more troubleshooting, please contact Chemtrac Systems customer support at 800-442-8722, or send an email to [email protected].



Appendix A General Layout Drawing - Instrument



General Layout Drawing - Flowcell



Appendix B Electrical Layout Drawing



Appendix C Certificates and approvals CE approval Declaration of conformity The product meets the legal requirements of the harmonised European standards. Chemtrac Systems confirms compliance with the standards by affixing the CE symbol.



Appendix D Part Numbers for Spares Ordering Free Chlorine Free Chlorine Membrane cap 17410 (M48 G) Free Chlorine Electrolyte 17415 (ECS2.1/GEL) Free Chlorine Electrolyte (Seawater) 17417 Autocal - Calibrant bag for probes upto 2mg/l 17235 (FCLB1) Autocal - Calibrant bag for probes over 2mg/l 17237 (FCLB2) Total Chlorine Total Chlorine Membrane cap 17420 (M48) Total Chlorine Electrolyte 17425 (ECP1.3/GEL) Total Chlorine Electrolyte (Seawater) 17427 Autocal - Calibrant bag for probes upto 2mg/l 17240 (TCLB1) Autocal - Calibrant bag for probes over 2mg/l 17242 (TCLB2) Autocal Tubing for the peristaltic pump 17232 Activated carbon filters 17234 Chlorine Dioxide Chlorine dioxide Membrane cap 17430 (M7N) Chlorine dioxide Electrolyte 17435 (ECD7/W) Dissolved Ozone Ozone Membrane cap 17450 (M7N O3)*

*State range (eg 0-2ppm) Ozone Electrolyte 17455 (EOZ7/W) pH Replacement pH probe 17600 (KDI9/PT100/PI) ORP Replacement ORP probe 17300 (KDIPt9/PT100/PI) Please contact your local sales organisation regarding any other spares.



Appendix E Returns Procedure and ‘Free of Contamination Sheet’ If the analyzer has to be repaired, please return it cleaned.. Please use the original packaging, if possible. Please enclose the completed Contaminant sheet (copy the Contaminants page, on the following page) with the packaging and shipping documents. No repair will be undertaken without a completed Contaminant sheet!



Contamination sheet Dear customer Because of legal requirements and for the safety of our employees, we need this “Contamination sheet” filled in (with your signature) before your instrument can be handled. Please put the completely filled in declaration with the instrument and the shipping documents. Add any safety data sheets (MSDS) and/or specific handling instructions if necessary. Type of instrument / sensor: __________________________________ Serial number: _______________________ Medium / concentration: __________________________________ Temperature: ______ pressure: _______ conductivity: ______ viscosity: _______ Cleaned with: __________________________________ Please mark the appropriate warnings. Radioactive ___ Explosive ___ Caustic ___ Poisonous ___ Harmful to health ___ Biologically hazardous ___ Inflammable ___ Safe ___ Company: ______________________________ Contact name: ______________________________ Address: ______________________________ Telephone/fax no: ______________________________ e-mail: ______________________________ Order no.: ______________________________ I hereby certify that the returned equipment has been cleaned and decontaminated according to good practices and is in compliance with all regulations. This equipment poses no health or safety risks due to contamination. ______________________________ Company stamp (if available) and legally binding signature Date _______________



Appendix F Warranty Chemtrac Systems warrants its product to be free of defects in material and workmanship for a period of one (1) year from date of shipment to the original customer. Upon receipt of written notice from the customer, Chemtrac Systems, Inc shall repair or replace (at Chemtrac Systems discretion) the defective equipment or components. Chemtrac Systems, Inc assumes no responsibility for equipment damage or failure caused by: A. Improper installation, operation, or maintenance of the equipment. B. Abnormal wear and tear on moving parts caused by some processes. C. 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 Chemtrac Systems, Inc 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 Chemtrac Systems, Inc written instructions and policies, as stated in the Operations Manual.



Appendix G























Documents

Water Quality Analyzer Operating Manual for S/W Version 2 ... · Residual Chlorine Analyzer Residual Ozone Analyzer pH/ORP Analyzer Revised 01/07/10 JE CRA3500 OZA4800 PHO6300 CPO7600