Monitor AMI Codes Operator’s Manual

Customer Support SWAN and its representatives maintain a fully trained staff of technical specialists around the world. For any technical question, contact your nearest SWAN representative, or the manufacturer: SWAN ANALYTISCHE INSTRUMENTE AG Turicaphonstrasse 29 8616 Riedikon Switzerland Internet: www.swan.ch E-mail: [email protected]

Document Status Title:

Monitor AMI Codes Operator’s Manual

ID:

A-96.250.161

Revision

Issue

02

December 2005

© 2005, SWAN ANALYTISCHE INSTRUMENTE AG, Switzerland, all rights reserved Information contained in this document is subject to change without notice.

AMI Codes Preface

AMI Codes Preface The operator’s manual provides thorough information about the installation, operation and the maintenance of the instrument for the user and service technician. This document also contains the Profibus instructions and the Material Safety Data Sheets.

Qualification, Training

To be qualified for instrument installation and operation, you must: Š read and understand the instructions in this manual as well as the Material Safety Data Sheets Š know the relevant safety rules and regulations.

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1

AMI Codes Table of Contents

Table of Contents

2

1. 1.1 1.2

Safety Instructions... General Safety Regulations... Warning Notices...

4 4 5

2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

Product Description... Description of the System... Technical Data... Instrument Overview... Dimensions... Display, Keys... Software Structure... Program Overview... Changing parameters and values...

6 6 6 8 9 10 11 12 15

3. 3.1 3.2

Installation... Installation Checklist... Electrical Connections Diagram...

16 16 17

4. 4.1 4.2 4.3 4.4

Setup... Establish sample flow... Fill/flush reagent system... Application example... Check Outputs and Relays...

18 18 19 20 24

5.

Calibration...

25

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AMI Codes Table of Contents

6. 6.1 6.2

Maintenance... Fill reagents... Reagents for Measuring Free Chlorine, Chlorine Dioxide, Bromine, Iodine... Reagents for Measuring Monochloramine and Ozone Cleaning... Replacing Parts...

27 28 29 30

7.

Troubleshooting... Error list...

31 32

A. A.1 A.2 A.3

Material Safety Data Sheets for Reagents... Oxycon On-line Buffer... Oxycon On-line DPD... Oxycon On-line KJ...

34 34 37 41

B. Profibus Communication (option)... B.1 Introduction... B.2 Cyclic Data Telegram... B.3 Data Formats... B.4 DP Diagnostics... B.4.1 Diagnosis... B.4.2 Diagnosis Extension... B.5 Acyclic Data Communication...

45 45 46 47 49 50 51 52

C.

53

6.3 6.4 6.5

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Index...

26 26

3

AMI Codes Safety Instructions

1.

Safety Instructions This chapter contains general information assuring safe operation of the instrument. More safety instructions are given throughout this manual, at the respective locations where observation is most important. Strictly follow all safety instructions in this publication.

1.1 General Safety Regulations The instructions included in this section explain the potential risks associated with the instrument operation and provide important safety practices designed to minimize these risks. If you carefully follow the information contained in this section, you can protect yourself from hazards and create a safer work environment. Legal Requirements

The user is responsible for proper operating according to all local, state and federal laws that may apply. All precautions must be followed to ensure safe operation of the instrument.

Modifications

Modifications and instrument upgrades shall only be carried out by an authorized Service Technician. SWAN will not accept responsibility for any claim resulting from unauthorized modification or alteration.

Operator’s Manual Location

The AMI Codes Operator’s Manual shall be kept in proximity of the instrument.

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AMI Codes Safety Instructions

1.2 Warning Notices The symbols used for safety-related notices have the following significance: WARNING Symbols

WARNING Generally, the triangular warning symbol indicates the possibility of personal injury or even loss of life if instructions are not followed, e.g.

electrical shock hazard

corrosive

harmful to health

ATTENTION The attention symbol indicates the possibility of equipment damage, malfunctions or incorrect process results, if instructions are not followed.

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5

AMI Codes

Product Description

2.

Product Description

2.1 Description of the System Application Range

The AMI Codes is a complete monitoring system for the automatic, continuous measurement and dosing control of chlorine and other disinfectants. It can be used for measuring disinfectants in: Š potable water Š swimming pools Š cooling water Š effluent Š seawater It is also applicable for water containing additives like corrosion inhibitors, cyanuric acid and antiscalants.

Measuring Principle

The Analyzer AMI Codes is used for the continuous in-line determination of disinfectants based on the colorimetric measurement principle according to EN ISO 7393-2. Free chlorine, chlorine dioxide, bromine and iodine are determined with the DPD photometric method. The measurement of monochloramine and ozone requires an additional reagent.

2.2 Technical Data Power Supply

Voltage: 85 - 265 VAC, 47 - 63 Hz or 24 VDC, isolated, ± 15 % Power consumption: max. 20 VA

Signal Outputs

Two signal outputs programmable for measured values (freely scaleable, linear or bilinear) or as continuous control output (control parameters programmable). Current loop: 0/4 - 20 mA Maximal burden: 510 Ω Third signal output with the same specifications as option. (Only possible if no communication interface is used.)

Relays

Two potential-free contacts programmable as limit switches for measuring values, controllers or timer for system cleaning with automatic hold function. Maximum load: 1 A / 250 VAC

6

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AMI Codes

Product Description

Alarm Relay

One potential free contact. Open during normal operation, cloesd on error and loss of power. Summary alarm indication for programmable alarm values and instrument faults.

Input

For potential-free contact to freeze the measuring value or to interrupt control in automated installations (hold function or remote-off).

Communication interface (optional)

RS232 for logger download with HyperTerminal or RS485 with Fieldbus protocol Modbus or Profibus DP. Webserver connection via Modbus.

Disinfectant Measurement

Disinfectant

Accuracy

Measuring range

Ozone

± 0.005 ppm

0.000 - 1.000 ppm

HOCl / free Chlorine / Monochloramine

± 0.01 ppm ± 0.06 ppm ± 0.2 ppm

0.00 - 1.00 ppm 1.00 - 3.00 ppm 3.00 - 5.00 ppm

Chlorine dioxide / Iodine / Bromine

± 0.02 ppm ± 0.12 ppm

0.00 - 2.00 ppm 2.00 - 6.00 ppm

Electronics housing

Aluminum with a protection degree of IP 66 / NEMA 4X Ambient temperature: Limit range of operation: Storage and transport: Humidity: Display:

Safety Features

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-10 to +50 °C -25 to +65 °C -30 to +85 °C 10 to 90 % relative non condensing backlit LCD, 75 mm x 45 mm

No data loss after power failure. All data is saved in non-volatile memory. Over voltage protection of in- and outputs. Galvanic separation of measuring inputs and signal outputs. The analyzer is factory tested and ready for installation and operation.

7

AMI Codes

Product Description

2.3 Instrument Overview Transmitter with backlit LCD display pH sensor (optional) Temperature sensor (optional) Mounting panel Flow cell Flow control valve Reagent pumps Protection filter Photometer Air bubble detector Sample intake Reagent-level detector Full mark Overflow from flow cell Drainage of treated sample Reagent Oxycon on-line DPD Reagent Oxycon on-line Buffer

8

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AMI Codes

Product Description

2.4 Dimensions 374 mm / 14¾”

Mounting holes View from the side

850 mm / 33½“

412 mm / 16¼” 30 mm / 1 3⁄16”

824 mm / 32 7⁄16”

6 x dia. 6.5 mm / ¼”

100 mm / 4” min. free space for removing/inserting pH sensor

13 mm / ½“

13 mm ½“

400 mm / 15¾”

Weight:

9.0 kg / 20 lbs without reagents and sample water 18.0 kg / 40 lbs with reagents and sample water Panel material: PVC

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9

AMI Codes

Product Description

2.5 Display, Keys Measured Values Display

RUN normal operation HOLD Input closed: Signal Outputs frozen OFF

Contact closed: Signal Outputs are set to 0 (0/4 mA)

RUN

14:10:27

0.42 ppm 7.04 pH

R1 R2

Sample flow (bubbles per sec.)

60

52 B/s

27.5 °C

60 Reagent low indicates for how many more hours the reagent lasts Sample temperature

Status Relay Contacts: upper / lower limit reached upper / lower limit not yet reached control upwards/ downwards: no action control upwards/ downwards: active, dark bar indicates control intensity Error; blinking symbol: fatal Error

Timer

Keys Exit

to exit a menu or command (without accepting) to move back to the previous menu level to move DOWN in a menu list and to decrease digits to move UP in a menu list and to increase digits

Enter

10

to open a selected sub-menu to accept an entry

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AMI Codes

Product Description

2.6 Software Structure Main Menu Messages Diagnostics Maintenance Operation Installation

1

Messages Pending Errors Maintenance List Message List

1.1

Diagnostics Identification Sensors Sample I/O State Interface

2.1

3.1 Maintenance Calibration Simulation Set Time 01.06.04 16:30:00 Fill System Cleaning

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Operation Sensors Signal Outputs Relay Contacts Logger

4.1

Installation Sensors Signal Outputs Relay Contacts Miscellaneous Interface

5.1

Menu Messages 1 Reveals pending errors as well as an event history (time and state of events that have occurred at an earlier point of time. It contains user relevant data. Menu Diagnostics 2 Provides user relevant instrument and sample data.

Menu Maintenance 3 For instrument calibration, relay and signal output simulation, to set the instrument time and fill/ flush the reagent system. It is used by the service personnel. Menu Operation 4 User relevant parameters that might need to be modified during daily routine. Normally password protected and used by the process-operator. Subset of menu 5 Installation, but processrelated. Menu Installation 5 For initial instrument set up by SWAN authorized person, to set all instrument parameters. Can be protected by means of password.

11

AMI Codes

Product Description

2.7 Program Overview Messages (Main Menu 1)

Pending Errors 1.1* Maintenance List 1.2* Message List 1.3*

Designation AMI Codes Version 3.32-11/05

Identification

Factory Test

Operating Time

Diagnostics

2.1.3.1*

Years Days Hours :

2.1.4.1*

(Fotometer)

Current Value Raw Value Absorbance Cal. History

2.2.1.5*

Miscellaneous

Case Temp.

2.2.3.1*

Sample ID Temperature Nt5k Sample Flow Raw Value

2.3.1*

Alarm Relay Relay 1/2

2.4.1*

FOME Sensor Sensor

Instrument Motherboard

(Main Menu 2)

Sample

I/O State Input Signal Output 1/2

Interface

Protocol Baud rate

(only with optional additional board for 3rd signal output)

* Menu numbers

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AMI Codes

Product Description

Calibration

Maintenance (Main Menu 3)

Simulation

Set Time Fill System

Sensors

Process DIS.

3.1.1*

Alarm Relay Relay 1/2 Signal Output 1/2 Magnetic Valve

3.2.1*

3.3* 3.4*

Filter Time Const. Hold after Cal. Meas. Interval Default pH

4.1.1* 4.1.2* 4.1.3* 4.1.4*

Signal Output 1

Range Low Range High

4.2.1.100* 4.2.1.200*

Signal Output 2

Range High Range Low

4.2.2.102* 4.2.2.202*

Alarm Relay

Alarm DIS.

Signal Outputs

Operation (Main Menu 4) acc. Installation Relay Contacts

Relay 1/2 Input

Logger

Log Interval Clear Logger

4.4.1* 4.4.2*

* Menu numbers

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13

AMI Codes

Product Description

Sensor Type

FOME

Disinf.

Free Chlorine Hypochloric Acid Ozone Chlorine dioxide Bromine Iodine Monochloramine

Temperature

NT5K

Standards

Standard 1 Standard 2

5.1.5.1* 5.1.5.2*

Parameter

DIS pH Temperature Sample Flow FM Frequency

Sensors

Signal Outputs

Signal Output 1/2

Alarm DIS. Sample Flow Case Temp. high Case Temp. low

Alarm Relay

Installation (Main Menu 5) Relay Contacts

Interface

Active Signal Outputs Output/Control Fault Delay

Language Set defaults Load Firmware Password Sample ID

Protocol Baud Rate

5.3.1.1* 5.3.1.3* 5.3.1.4* 5.3.1.51*

Function Parameter Limit/settings (dep. on Function)

Relay 1/2

Input

Miscellaneous

Current Loop (0/4 – 20 mA) Function Scaling (depends on Function)

5.3.4.1* 5.3.4.2* 5.3.4.3* 5.3.4.4* 5.3.4.5*

5.4.1* 5.4.2* 5.4.3* 5.4.4* 5.4.5*

(only with optional additional board for 3rd signal output)

* Menu numbers

14

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AMI Codes

Product Description

2.8 Changing parameters

Changing parameters and values The following example shows how to change the disinfectant from Free chlorine to Chlorine dioxide: Sensors Sensor type Disinf. Temperature Standards

5.1.2

FOME Free chlorine NT5K

5.1.2 Sensors Sensor type Disinf. FOME Free chlorine Disinf Hypochloric acid Free chlorine Ozone Temperature Standards Chlorine dioxide

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Press Enter .

Press or to highlight the required parameter. Press Enter to confirm the selection (or [Exit] to keep the previous parameter).

5.1.2 Sensors Sensor type FOME Disinf. Chlorine dioxide

The selected parameter is indicated (but not saved yet).

Temperature Standards

Press

NT5K

5.1.2 Sensors Sensor type FOME Save ? Disinf. Chlorine dioxide Yes No Temperature NT5K Standards

Changing values

Highlight the menu item indicating the parameter you want to change.

Alarm DIS. Alarm High Alarm Low Hysteresis Delay DIS. Alarm Alarm High Alarm Low Hysteresis Delay

5.3.1.1.1

5.00 ppm 0.00 ppm 0.10 ppm 5 Sec 5.3.1.1.1 1.00 ppm 0.00 ppm 0.10 ppm 5 Sec

Exit

.

Yes highlighted, press Enter to save the new parameter. The system reboots, the new parameter is set.

Select value and press Enter . to set required value. Enter

to confirm new value.

Exit

to exit the menu.

15

AMI Codes Installation

3.

Installation ATTENTION If a solenoid dosing pump is controlled by means of power on/off (by opening/closing the relays 1 and/or 2), connect it via an external power relay ≥ 30 A. Otherwise the starting current peak will destroy the relay(s) in the AMI Codes. The optional AMI Relaybox can be used for the direct power supply of dosing devices which are controlled with an AMI transmitter. It protects the AMI transmitter electronics from power peaks which occur when pumps are switched. For details, see the corresponding manual.

3.1 Installation Checklist Check

Check if mains voltage corresponds with voltage indicated on the type plate. Drainage: Assure appropriate slope of drain tubes.

Location

Outdoor installations: Protect instrument from weather.

Connections

Š Š Š

Monitor

Power supply, grounded, 85 - 265 VAC, 47 - 63 Hz or 24 VDC. Sample supply (tube 6x8 mm) of min. 10 l/h. 2 drains 15x20 mm (½”).

Mount with 6 screws M5 or M6 (3⁄16“ or ¼“). Install outer flow cell cylinder and (optional) pH sensor.

Sample tubing

Connect sample intake and drainage tubes.

Electrical connections

Power controlled pump: Note the ATTENTION on 16 . Connect external devices. Connect power supply cable to the instrument. Do not yet connect the power supply cable to the mains!

Reagents

Prepare reagents and fill containers, see 26 .

Sample flow

Establish sample flow, p. 18, see 18 .

Setup

Connect the instrument to the power. Fill reagent system, see 19 .

Programming

16

Setup instrument according to customer specifications. See 4.3“Application example”,  20.

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AMI Codes Installation

3.2 Electrical Connections Diagram

Use only the terminals shown in this diagram, and only for the mentioned purpose. Use of any other terminals will cause short circuits with possible corresponding consequences to material and personnel.

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17

AMI Codes Setup

4.

Setup Install the outer flow cell cylinder and the (optional) pH sensor as well as the sample intake and the drainage tubes. (see also Installation Checklist, p. 16) After that, establish the sample flow.

4.1 Establish sample flow 1

Open flow control valve.

2

Regulate the sample flow so that enough water flows over the brim of the longer of the two inner tubes (approx. 15 l/h).

3

Connect the instrument to the power.

4

Fill reagent system, see 4.2“Fill/flush reagent system”,  19.

5

Check tubing connections and flow cell for leaks and remedy if necessary.

WARNING As the sample water (the water flowing out of the photometer) contains reagents, DO NOT lead it back into the system! Make sure it flows into the sewage drains.

18

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