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The content of this document is entirely a non-binding external opinion. Neither AppliTek NV
nor any of its employees can be held liable for damages to people, third parties, goods and
assets that may result from implementing the content.
CONTENTS
Preface – Documents and safety..........................................................................................10
Installation of the analyzer – Overview .............................................................................11
1. Installation of the analyzer ........................................................................................12
1.1 Dimensions of the analyzer ...............................................................................12
1.2 Location and ambient conditions .......................................................................13
1.3 Mounting instructions ........................................................................................13
2. Power and signals ....................................................................................................14
2.1 Power................................................................................................................14
2.2 Signals ..............................................................................................................14
3. Utilities ......................................................................................................................15
3.1 Overview ...........................................................................................................15
3.2 Sample feed ......................................................................................................15
3.3 Drain .................................................................................................................16
3.4 Overflow............................................................................................................16
3.5 Reagents & Calibration/validation solutions feed ...............................................16
3.6 Instrument air ....................................................................................................16
4. Power up & components test ....................................................................................17
4.1 Analyzer design ................................................................................................17
4.2 Wet chemical components ................................................................................18
4.3 Analog output ....................................................................................................21
4.4 Analog input ......................................................................................................21
5. Analyser method .......................................................................................................22
5.1 Specifications ....................................................................................................22
5.2 Analysis ............................................................................................................22
5.3 Calibration .........................................................................................................22
5.4 Validation ..........................................................................................................23
5.5 Cleaning ............................................................................................................23
5.6 Prime ................................................................................................................23
6. Reagent preparation .................................................................................................24
6.1 Reagent consumption .......................................................................................24
6.2 Storage and quality of chemicals and solutions .................................................24
6.3 Acid solution (0.5 M) .........................................................................................25
6.4 Buffer Ca Mg solution ........................................................................................25
6.5 Buffer Ca solution (NaOH 1M)...........................................................................26
6.6 Color solution ....................................................................................................26
6.5 EDTA solution (0.01 M) .....................................................................................27
6.6 Calibration standard solution .............................................................................28
6.7 Validation standard solution ..............................................................................28
6.8 Cleaning solution...............................................................................................29
7. Start-up of the analyser.............................................................................................30
7.1 Access ..............................................................................................................30
7.2 Reagents ..........................................................................................................30
7.3 Analysis procedure............................................................................................31
7.4 Calibration .........................................................................................................35
7.5 Cleaning ............................................................................................................36
7.6 Time List ...........................................................................................................36
7.7 Data and results ................................................................................................37
7.8 Analyzer settings ...............................................................................................38
7.9 Start-up the analyser for on-line measurement..................................................40
8. Maintenance .............................................................................................................41
8.1 Check for leaks and abnormal conditions ..........................................................41
8.2 Check for alarms ...............................................................................................41
8.3 Prepare reagents and fill the reagent containers ...............................................41
8.4 Run the calibration program ..............................................................................42
8.5 Run the cleaning program .................................................................................42
8.6 Replacement of the micropump’s duckbills .......................................................42
8.7 Replacement of the peristaltic pump tubing .......................................................42
8.8 Shutdown of the analyzer for a longer period ....................................................43
9. Troubleshooting ........................................................................................................43
10. Spare Parts ...........................................................................................................43
Addendum ........................................................................................................................44
Addendum 1: Analysis Procedure.....................................................................................44
1.1 Main Method – Analysis ....................................................................................44
1.2 Main Method – Cleaning (optional) ....................................................................44
1.3 Main Method – Priming (optional)......................................................................45
1.4 Ca Hardness Method – Analysis .......................................................................45
1.5 Total Hardness Method – Analysis ....................................................................46
Addendum 2: Analyzer Configuration ...............................................................................48
2.1 Digital Outputs ..................................................................................................48
2.2 Digital Inputs .....................................................................................................48
2.3 Analog Inputs ....................................................................................................48
2.4 Analog Outputs .................................................................................................49
2.5 Communication ports ........................................................................................49
2.6 Results ..............................................................................................................49
2.7 Results Calibration ............................................................................................49
2.8 Results Calculation ...........................................................................................49
2.9 Results Analog output .......................................................................................51
2.10 Result Alarms....................................................................................................51
2.11 Results Graph ...................................................................................................51
2.12 Algorithms .........................................................................................................51
2.13 Alarm and message table..................................................................................53
2.14 Group DO .........................................................................................................53
Addendum 3: Alarms and signals .....................................................................................54
Preface – Documents and safety
Thank you for purchasing this high quality analytical instrument. The analyzer is designed for
installation in industrial environments and intended for professional use. On delivery the
analyzer does not offer readily available end-user functionality. The analyzer needs to be
installed and configured by competent staff prior to use by the end user. Information about
the exact specifications, necessary connections, utilities and maintenance schedules is given
in the accompanying GENERAL SAFETY BOOK (8 languages).
• Knowledge of the basic safety regulations is essential for the safe handling and
disruption-free operation of the unit. Therefore, please read the entire manual before
setting up the analyzer. Pay attention to danger and caution statements;
• These operating instructions contain the most important guidelines necessary in order
to safely oversee the unit’s operation;
• All persons working on the unit should take note of these operation instructions, and
especially those relevant to safety;
• Protect the analyzer from impacts causing corrosion or preventing components from
working properly;
• Have faulty parts of the analyzer replaced immediately;
• Spare parts must comply with the technical requirements determined by AppliTek;
• When malfunctioning, take the analyzer out of operation. Repair the malfunctions
immediately. Failure to do so could result in serious injury to persons or damage to
the equipment;
• On top of this, all rules and regulations pertinent to accident prevention, which are
applicable at the measuring site, are to be followed.
• It is the operator’s responsibility to allow only those persons to work on the unit who
are familiar with the regulations concerning safe handling and have been informed
how to work with the instrument;
Safety devices
Before any initialization of the unit, all safety devices must be properly mounted and
functional. Safety devices can only be removed:
• During maintenance and repair work by trained personnel or when the unit has been
disconnected from the electrical mains.
• After the unit has been safeguarded against renewed operation.
Electrical dangers
Work on the unit’s power supply and electronics can only be carried out by a qualified
electrician. The mains switch must be switched off during work on electrical components.
10
Installation of the analyzer – Overview
11
1. Installation of the analyzer
12
1.2 Location and ambient conditions
The analyzer is designed for installation at indoor environmental conditions. Install the
analyzer where the temperature is maintained as stable as possible between 10 and 30 °C
(range 4°C) and is not subject to sudden temperature changes.
The analyzer should be installed as close as possible near the sampling point. If this is not
the case, a fast loop sampling system has to be installed because a long distance between
the analyzer and the sampling point will increase the response time of the analyzer.
Do not mount the analyzer in direct sunlight! This can affect the visibility of the screen
and the analyzer, its components and reagents.
Variation of these conditions can seriously affect the analyzer results and damage the
analyzer and its components!
The analyzer is designed for wall mounting and intended for permanent installation. Make
sure the location is easy accessible. The dimensions of the analyzer are given on the
previous page. The indicated footprint is a strict minimum and doesn’t take into account the
space needed for tubing and cables.
The analyzer has four mounting holes for screws M8x10mm at the back of the cabinet.
These bolts are fastened into/onto the supporting structure from the inside of the electrical
cabinet at the back.
13
2. Power and signals
2.1 Power
First open the electrical cabinet door by pulling the two levers and unhook them. Make
provisions for removing power to the analyzer during servicing. The AC power cable enters
on the left side of the cabinet at the back through the upper left cable gland. The terminals for
the power and ground are located at the upper left hand corner of the cabinet at the back, as
you face the unit. Connect your wiring to the upper side of the terminals. Connect the AC
feed as follows:
2.2 Signals
Note: If additional AO, DI or DO connections are required, extra terminals will be present.
Connections:
INP1-INP4: INPut
(digital input)
24VDC, to trigger with external
potential free contact
14
CONTACT INPUT/OUTPUT NAME
AO1 AO1 Result Tot Hard STR1
AO2 AO2 Result Ca Hard STR1
AO3 AO3 Result Tot Hard STR2
AO4 AO4 Result Ca Hard STR2
FCT1 DO25 Malfunction
FCT2 DO26
FCT3 DO27
FCT4 DO28
FCT5 DO29
PCT1 DO21 EXT SV STR1
PCT2 DO22 EXT SV STR2
PCT3 DO23
PCT4 DO24
INP1 DI1
INP2 DI2
INP3 DI3
INP4 DI4
3. Utilities
3.1 Overview
The sample feed to the analyzer must be at atmospheric pressure if the analyzer uses a
peristaltic pump for sampling. The sample feed to the analyzer must be higher than the
sample flow in the analyzer. It is recommended to use a small overflow vessel (next to the
analyzer) from which the analyzer will take fresh sample. Thus the sample in the overflow
vessel should be continuously refreshed. If the size of the solids present in the sample is too
high, it is recommended to filter the sample.
The analyzer is not designed for use with samples that are explosive or flammable. If a
solution other than water is used, this solution should be tested to test the
compatibility with the instrument!
15
3.3 Drain
The analyzer needs a drain to discharge both sample and reagents after analysis. A floor or
sink drain is satisfactory, but it must be unrestricted and located at a lower level than the
analyzer so that gravity will carry away the liquid. The drain must have a vent to the
atmosphere and the drain tube from the analyzer must not be submerged. Pay attention that
the drain line is never blocked. A water connection is also recommended so that the drain
sink and piping is regularly flushed with clean water in order to avoid clogging due to
crystallization. Steepness of the draining pipe must be sufficient.
Although the chemical reagents are diluted, the user has to check that the external
drain/overflow system is appropriate for reagents and corrosive wastes! Used
reagents shall be treated for disposal according to national or local regulations!
3.4 Overflow
The analyzer needs an overflow tube in order to drain the analysis compartment in case of
leakage of sample fluids, reagent fluids (and combination of both) in the compartment. A floor
or sink drain is satisfactory, but it must be unrestricted and located at a lower level than the
analyzer so that gravity will carry away the liquid. The overflow tube from the analyzer must
not be submerged. Pay attention that the overflow line is never blocked. Steepness of the
overflow pipe must be sufficient.
Connections have to be made between the reagent containers and the dispensers, the micro
pumps and the cleaning valve. The calibration/validation solutions can be connected to the
REF1 or REF2 selection valve.
Although the chemical reagents are diluted, the user has to check that the external
drain/overflow system is appropriate for reagents and corrosive wastes! Used
reagents shall be treated for disposal according to national or local regulations!
The instrument air must be dry and dust free (according to ISA-S7.0.01-1996). The minimal
pressure of the instrument air necessary for the analyzer is 1 bar (100 kPa or 15.5 psi).
Instrument air is used for purging the analyzer in order to prevent corrosion by corrosive
gases such as chlorine gas from outside the analyzer.
16
4. Power up & components test
The analyzer and its components must be tested before the unit can be put into online
service. Make sure that all necessary connections were made before testing the following
components. Switch on the analyzer by means of the circuit breakers lever in the electrical
compartment and (if present) the external power switch.
When connecting the power of the analyzer, the software is started up. First, the initial
startup screen appears. While this screen is visible, the parameters are loaded (loading of
methods, configuration …) and the dispensers are initialized. Next, the MAIN screen (F1)
becomes visible automatically.
17
4.2 Wet chemical components
Menu path:
→ F2
In the Visualization (F2) submenu, the wet chemical components (reagent pumps, stirrer,
dispenser…) can be controlled manually. Press the icons on the screen to control the
components. A control panel appears on the right side of the screen. By use of this panel,
the chemical components can be controlled. Check if these components are working
properly.
1. Stirrer
2. Micropump
18
3. Drain pump and Drain/Level valve
4. Sample pump
19
When the sample enters because one or
more valves are switched, it is necessary to
switch these valves on before the sample
pump is started. Press the icon of the
corresponding valve. Switch the valve
ON/OFF by pressing the ‘ON/OFF’ button. It
is also possible to turn a valve ON for a
specified time. Fill in the time (in seconds)
and press the ‘Start’ button.
Components that are not visible on the visualization screen can be controlled in the DO
submenu.
Menu path:
20
4.3 Analog output
Menu path:
Menu path:
4.4.1 Photometer
21
5. Analyser method
5.1 Specifications
Specifications are subject to change without notice.
Wavelength: 610 nm
5.2 Analysis
The analysis vessel is cleaned and filled with fresh sample. After sampling, the acid, buffer
(buffer Ca Mg) and color solution are added to the sample. Next, the photometric titration
(610 nm) with EDTA is performed and the calcium and magnesium concentrations in the
sample are determined (Total Hardness as mg/L CaCO3).
When measuring the Ca hardness the buffer (buffer Ca) changes the pH to 12. The Mg
settles and when the EDTA is added, the calcium concentration in the sample is only
determined.
The acid solution is added to dissolve all carbonates (CaCO3 dissolves into Ca2+ and (CO3)2-
which is removed as CO2 in acidic environment). The buffer solution is added to reach an
alkaline pH in which the color solution forms a purplish-blue color. The color changes to red
when contacting free calcium or magnesium. The color changes to blue when EDTA is
added to the sample. The change from the red to blue color is measured.
5.3 Calibration
The calibration procedure measures a REF2 or 1000 mg/l CaCO3 solution (channel 10 –
REF2 valve) to correct for any deviation in the results by external influences (sample volume,
micropump volume, reagent concentration).
22
5.4 Validation
The validation method is used to verify the functioning of the analyzer with a standard
solution. The validation procedure measures a standard solution with a known CaCO3
concentration (channel 8 – REF2 valve) to validate the analyzer.
5.5 Cleaning
The cleaning procedure should prevent any build-up of chemicals in the analyzer. To obtain
an effective cleaning procedure one has to test the cleaning solution and the cleaning
interval for each application. Perform the cleaning procedure with the selected cleaning
solution and interval for a trial period, check then the effectiveness of the procedure and
change if necessary.
5.6 Prime
The prime procedure can be used when starting up the analyzer or after a shutdown of the
analyzer: the reagent tubings are flushed with fresh reagent solution and the sample tubing
and the analysis vessel are flushed with fresh sample.
23
6. Reagent preparation
Warning:
Some of the chemicals used are corrosive or harmful! All operating
! personnel should wear protective gloves, goggles and acid-proof
clothing! Check the MSDS before starting to handle the chemicals.
The information in this document is based on the present state of our knowledge and is
applicable to the products with regard to appropriate safety precautions. It does not guarantee
any of the properties of the products. AppliTek shall not behold liable for any damage resulting
from handling or from contact with any product described in this manual.
In the tables below, the products that are needed to prepare the reagents are listed. The
product name, the formula, the molecular weight, the CAS No. and the amount needed to
prepare 1 liter of the reagents is given. Check the consumption of the reagents (28 days) to
adapt the volumes needed.
Quality of chemicals:
All chemicals should be of ACS grade or better. We recommend the use of pro analysis
chemicals.
Quality of water:
Reagent grade, de-ionized water (calcium- and magnesium-free) must be used to prepare
the chemical solutions and for rinse purposes.
Laboratory equipment:
Reagent and solutions should be prepared and kept in plastic vessels. Avoid the use of
glassware.
24
6.3 Acid solution (0.5 M)
Hazard statement(s):
H290: May be corrosive to metals.
Precautionary statement(s):
None
Ammonium chloride
Hazard statement(s):
H302: Harmful if swallowed.
H319: Causes serious eye irritation.
Precautionary statement(s):
P305 + P351 + P338: IF IN EYES: Rinse cautiously with water for several minutes. Remove
contact lenses, if present and easy to do. Continue rinsing.
Hazard statement(s):
H302: Harmful if swallowed.
H314: Causes severe skin burns and eye damage.
H335: May cause respiratory irritation.
H400: Very toxic to aquatic life.
25
Precautionary statement(s):
P261: Avoid breathing vapours.
P273: Avoid release to the environment.
P280: Wear protective gloves/ protective clothing/ eye protection/ face protection.
P305 + P351 + P338: IF IN EYES: Rinse cautiously with water for several minutes. Remove
contact lenses, if present and easy to do. Continue rinsing.
P310: Immediately call a POISON CENTER or doctor/ physician.
Not a hazardous substance or mixture according to Regulation (EC) No. 1272/2008. This substance is
not classified as dangerous according to Directive 67/548/EEC.
Preparation:
Dissolve 54 g of ammonium chloride (NH4Cl) in de-ionized water using a volumetric flask of
1000 ml. Add 350 ml of 25% ammonium hydroxide solution (NH4OH). Add 5 g Mg-EDTA,
dissolve completely and fill up to 1 liter with de-ionized water.
Hazard statement(s)
H314: Causes severe skin burns and eye damage
Precautionary statement(s)
P280: Wear protective gloves/ protective clothing/ eye protection/ face protection.
P305 + P351 + P338: IF IN EYES: Rinse cautiously with water for several minutes.
Remove contact lenses, if present and easy to do. Continue rinsing.
P310: IF exposed or if you feel unwell: immediately call a POISON CENTER or
doctor/physician.
Preparation:
Dissolve 40 g of sodium hydroxide (NaOH p.a., > 99 %) in 500 ml of demineralized water and
dilute to 1 liter with demineralized water.
26
Calmagite
Hazard statement(s):
H315: Causes skin irritation.
H319: Causes serious eye irritation.
H335: May cause respiratory irritation.
Precautionary statement(s):
P261: Avoid breathing dust/ fume/ gas/ mist/ vapours/ spray.
P305 + P351 + P338: IF IN EYES: Rinse cautiously with water for several minutes. Remove
contact lenses, if present and easy to do. Continue rinsing.
Preparation:
Dissolve approximately 0.2 g Calmagite (HOC10H5[N=NC6H3(OH)CH3]SO3H) in 400 mL
degassed de-ionized water using a volumetric flask of 1L. Fill up to the grade mark with de-
ionized water.
Hazard statement(s)
H319: Causes serious eye irritation.
Precautionary statement(s)
P305 + P351 + P338: IF IN EYES: Rinse cautiously with water for several minutes. Remove
contact lenses, if present and easy to do. Continue rinsing.
Preparation:
Dissolve accurately 3.722 g ethylenediaminetetraacetic acid disodium salt dihydrate
(C10H14N2Na2O8.2H2O) in 500 ml degassed de-ionized water and fill up to 1000 ml.
27
OR
Dilute a 0.1 M EDTA stock solution by taking exactly 100 ml of the 0.1 M EDTA solution using
a volumetric flask of 1000 ml and adding de-ionized water up to the mark grade.
Hazard statement(s):
H319: Causes serious eye irritation
Precautionary statement(s):
P305 + P351 + P338: IF IN EYES: Rinse cautiously with water for several minutes.
Remove contact lenses, if present and easy to do. Continue rinsing.
Preparation:
1000 mg/L Ca stock solution
Prepare a stock solution of 1000 mg/L CaCO3: dissolve accurately 3.668 g calcium chloride
dihydrate (CaCl2.2H2O) in 200 ml degassed de-ionized water (DI water), using a volumetric
flask of 1000 ml. Add de-ionized water up to the mark grade.
Hazard statement(s):
28
H319: Causes serious eye irritation
Precautionary statement(s):
P305 + P351 + P338: IF IN EYES: Rinse cautiously with water for several minutes.
Remove contact lenses, if present and easy to do. Continue rinsing.
Preparation:
1000 mg/L Ca stock solution
Dissolve accurately 3.668 g calcium chloride dihydrate (CaCl2.2H2O) in 200 ml de-ionized
water, using a volumetric flask of 1000 ml. Add de-ionized water up to the mark grade.
This solution contains the equivalent of 100 mg/l Ca or 250 mg/l CaCO3.
The cleaning procedure should prevent any build-up of chemicals in the analyser. To obtain
an effective cleaning procedure one has to test the cleaning solution and the cleaning
interval for each application. Perform the selected cleaning solution and interval for a trial
period, check then the effectiveness of the procedure and change if necessary.
29
7. Start-up of the analyser
7.1 Access
Menu path:
→ F1 → User → Enter Access password
Press the black box next to ‘User:’ to change the userlevel by use of the corresponding
password.
Depending on the userlevel some menus are accessible and some are not. Normally, when
the analyzer is started up, the ‘Automatic’ userlevel appears. This level is also used in
online situations. The analyzer is locked, which means that the METHOD (F4) and CONFIG
(F5) menu are not accessible. If modifications of the software are needed, higher userlevels
can be used. The access to certain crucial parameters is only given if the ‘Administrator’
password is used. Enter the password by pressing the ‘Enter Access password’ button.
Default passwords:
User Password
Automatic -
User1 a
User2 b
7.2 Reagents
Menu path:
→ F1 → 1.Method → Priming
Select the method with the navigation buttons at the bottom of the MAIN (F1) screen. The
method screen appears.
If all wet chemical components are working properly, the reagents can be connected to the
analyser. Press the ‘Priming’ button to fill up all tubings to the analysis vessel with reagent
30
Make sure there is no air present in the tubings. Also, make sure there is no air present in
the dispenser, the tubing to the dispenser and the tubing from the dispenser to the analysis
vessel.
Follow the procedure below to start the method. It is recommended to run the method
several times and to make sure the measurements are stable before a calibration of the
analyzer is performed. Make sure all flushing times are set correctly before the analyzer is
started for on-line measurement.
Menu path:
→ F1 → 1.Method
Select the method with the navigation buttons at the bottom of the MAIN (F1) screen. The
method screen appears.
Menu path:
→ F1 → Method → Playlist → Automatic sequence
Press the Playlist button. Press the Automatic sequence button and insert the desired
module, channel and number of analysis. Press Accept to confirm. Press Back to quit the
window without saving the changes.
Start parameters:
31
7.3.1 Single stream analysis
For example:
- The third sample stream needs to be analyzed
- Insert ‘3’ as channel (CH) and 1 as #Runs
For example:
- There one streams that need to be analyzed. After 10 analysis, a cleaning is needed.
- Insert ‘Analysis’ as Module, ‘1’ as channel and ‘10’ as #runs
- Insert ‘Cleaning’ as Module, ‘1’ as channel and ‘1’ as #runs
(For cleaning, always use channel 1)
32
- Continuous analysis: insert 0 as #Runs in the method main screen
- Fixed number of analysis: insert the desired #Runs in the method main screen
For example:
- There are five streams that need to be analyzed.
- Insert ‘1’ as channel and 1 as # runs
- Insert ‘2’ as channel and 1 as # runs
- Insert ‘3’ as channel and 1 as # runs
- Insert ‘4’ as channel and 1 as # runs
- Insert ‘5’ as channel and 1 as # runs
For example:
- There are two streams that need to be analyzed. Next, a cleaning is needed.
- Insert ‘Analysis’ as Module, ‘1’ as channel and ‘1’ as #runs
- Insert ‘Analysis’ as Module, ‘2’ as channel and ‘1’ as #runs
- Insert ‘Cleaning’ as Module, ‘1’ as channel and ‘1’ as #runs
(For cleaning, always use channel 1)
33
7.3.5 Start the method
Menu path:
→ F1 → 1.Method1 → Playlist → Start
Menu path:
→ F1 → 1.Method1 → Stop
Press the ‘Stop’ button. The method will be finished and the analyzer will stop (status will
change from ‘Run’, to ‘Stopped’ and then ‘Ready’).
Menu path:
→ F1 → 1.Method1 → Abort
Press the ‘Abort’ button to stop the method immediately after confirmation.
Menu path:
→ E-Stop
In case of emergency, all methods can be stopped directly by pressing the E-STOP button
(SOFTWARE emergency stop) at the bottom of the screen.
34
7.3.7 Remote control
Menu path:
→ F1 → 1.Method1 → Is Master
Press the ‘Is Master’ button. The following instruction screen appears. Press ‘Toggle’ to put
the analyzer in ‘Is Slave’ position. If the method is in this position, it is impossible to start the
method manually. The method can only be started remotely i.e. by a digital input, by Modbus
communication, by a sequence…
Press Abort to stop the method. Press the ‘Is Slave’ button to put the analyzer in ‘Is Master’
position again.
7.4 Calibration
When the analysis results are stable, the analyzer can be calibrated.
Menu path:
→ F1 → Method → Calibrate
Press the ‘Calibrate’ button. The calibration procedure will start automatically after
confirmation. The calibration procedure consists of following steps:
The concentration of the REF1 and REF2 solution and the number of runs is programmable
in the Configuration (F5) menu (See Configuration Manual for more information).
Press the ‘Calibration history’ button to get an overview of the previous calibration data.
35
7.5 Cleaning
Menu path:
→ F1 → Method → Cleaning
To clean the analyzer (the analysis vessel) press the ‘Cleaning’ button. The cleaning
subroutine will be executed and the analyzer is stopped.
When the analyzer is on-line, the cleaning procedure starts after the Analysis subroutine is
finished. The analyzer is started again for on-line measurements after the Cleaning
subroutine is finished.
Menu path:
→ F1 → Method → Time list
Press the Time list button to configure the time list. An overview of the configured time tables
is displayed. Scroll through the list by use of the arrow keys.
Press the Edit (E) button to configure the selected time table. Every time table can be turned
ON or OFF by pressing the toggle (T) button.
Make sure the ‘Direct’ button is selected to guarantee the proper functioning of the Time list.
Press Back to quit the screen.
36
7.6.1 Configuration of the time list
Only a configured time list can be used. Make sure the time list is turned ‘ON’ and the
‘Direct’ button is selected.
Refer to the Configuration manual for additional information about the configuration of the
time list. Press Accept to confirm. Press Back to quit the screen.
Example:
An automatic calibration on stream 1 of
method 1 is needed, every day at 12 o’clock.
- HH: 12
- Channel: 1
- Start function: Calibration
- Index: Method1
Menu path:
→ F3 → Database
The analysis results of every method are displayed in the ‘Database’ submenu. A method
can be selected by use of the arrow keys at the right side of the screen. Press the Edit (E)
button to view the result for the selected method. The arrow keys on the right side of the
screen can be used to scroll through the list.
The file can be exported to a memory stick by pressing the ‘Export’ button. The data are
exported to a CSV-file that can be opened for example in EXCEL.
37
Menu path:
→ F6
The course of a titration can be followed in the F6 submenu. Select the titration algorithm by
use of the dropdown menu. The graph can be appointed by use of the alphanumeric
keyboard. The screen can be copied to an USB stick by pressing the Export button. Press
the orange arrow key to view the titration data table. The titration algorithm can be selected
by use of the dropdown menu.
Adjustments to the analyzer configuration are made in the Configuration (F5) menu. We
recommend you to read the instructions very carefully before making adjustments to the
analyzers configuration: the functioning of the analyzer may be disturbed!
For more information about the analyzer settings, refer to the Configuration Manual.
The time set in a channel interval is channel dependent. Change this time in order to
extend/reduce for example the flush time of the sample through the analysis vessel.
38
7.8.2 Adaptation of constant values
Menu path:
→ F5 → Software → Constants
Constant values are used in the calculation of the results. Change these values if necessary.
Group actions are implemented to run several actions simultaneously. Be careful when
changing the ‘group DO’ settings, the functioning of the analyzer may be disturbed.
Select the ‘group DO’ by use of the arrow keys and press the Edit button to change the
settings.
The times are entered in millisecond (ms). To avoid problems with analyzer functioning, only
change the time with the greatest value. Press Accept to save the settings. Test the changes
before starting the analyzer for on-line measurements.
39
7.8.4 Adaptation of algorithms
Menu path:
→ F5 → Software → Algorithms
Settings for algorithms are configured in the AppliTek lab with standard solutions.
Depending on the problems that occur in the field, other settings need to be adapted.
For more information about the algorithm settings, refer to the Configuration Manual.
The analyser is now set-up and ready to go online. Make sure all analyser components are
working properly and all settings are correct before the analyser is started.
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8. Maintenance
Task Daily Weekly Monthly Quarterly Annually
Check for leaks and abnormal
X X X X X
conditions
Check for alarms X X X X X
Prepare reagents and fill the
X X X
reagent containers
Run the calibration program (X) (X) X
Replace the duckbills X
Replace all peristaltic pump
X X
tubing
Replace all pinch valve tubing X
Replace all tubing X
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8.4 Run the calibration program
• Unfasten the wingnuts that fix the peristaltic pumps onto the electric motor coupler.
• Remove the pump head.
• Separate the front pump half from the back half. Hold the pump axle and the back pump
half together (1a).
• Remove the tubing. Keep in mind the length of both endings coming out of the pump head.
• Cut new tubing of the same size at the same length of the old one.
• Assemble the tube in the exact same way the old one was placed and push it down the
back pump half in front of the pump axle rollers. Then twist the pump axle a bit while you
keep pushing the tubing down so it is pressed between the pump housing and the pump
axle rollers (1b +1c).
• Join the two pump halves and make sure the tubing is not squeezed between the two
halves (1d).
• Place back the pump head and align the pump axle with the motor axle by pushing it
against the motor axle while turning the pump axle with a screwdriver.
• Fasten the wingnuts.
• Activate the pump and check if it is running properly.
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8.8 Shutdown of the analyzer for a longer period
If the analyzer is stopped for a longer period (more than 3 days), it is recommended to rinse
the sample tubing, the reagent tubing, the dispensers and the analysis vessel with de-
mineralized water or a cleaning solution. In order to increase the lifetime of the electrodes, it
is recommended to take out the electrodes and store them with the original electrode cap. To
prevent evaporation of the electrolyte in the electrode, the electrode cap has to be filled with
electrolyte. Storage of the electrodes in de-mineralized water will significantly decrease the
lifetime of the electrodes.
9. Troubleshooting
If analysis results are unstable the following items should be checked:
a) Micropumps: make sure the reagents are dosed correctly and that no air is present in the
tubings
b) Peristaltic pumps: check if the drain and sample pump are working correctly
d) Stirrer: check if there is a magnetic stirrer bar in the analysis vessel and if the solution is
stirred during analysis
f) Check the reagents. Prepare a new set of reagents when the reagent containers are
empty. Flush/Prime all tubing before performing a measurement.
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Addendum
Streamselection Channel DO
Channel 1 (sample) Sample (STR1)
Channel 2 (sample) Sample (STR2)
Channel 8 (validation) REF2
Channel 10 (calibration) REF2
44
1.3 Main Method – Priming (optional)
45
20 ABS Meas. 5s
21 ABS sample Calc. 1s
22 Sample Detection Calc. 1s
23 Waiting 15 s
24 Sub procedure 0 0s
25 Drain / Level OFF 50 ms
26 Stirrer ON 50 ms
27 Acid pulses 9s 9p
28 Waiting 60 s
29 Buffer Ca pulses 18 s 18p
30 Color pulses 12 s 12p
31 Waiting 5s
32 Hardness Algorithm 1200 s
33 Waiting 1s
34 Algorithm check Calc. 1s
35 ml. infl Ca Calc. 1s
36 Ca Hardness Calc. 1s
37 Write to database 1s
38 Drain Group 16000 ms
39 Streamselection ON 50 ms
40 Rinse Group 10000 ms
41 Drain Group 16000 ms
42 Rinse Group 10000 ms
43 Drain Group 16000 ms
44 Streamselection OFF 50 ms
45 Waiting Variable: Waiting
46 Sub procedure 1000 0s
47 Drain / Level OFF 50 ms
48 Ca Hardness Calc. 1s
49 Write to database 1s
50 Streamselection OFF 50 ms
51 Waiting 1s
46
10 SP CW OFF 50 ms
11 Waiting 5s
12 DP CCW OFF 50 ms
13 Sample Group 8000 ms
14 Drain Group 16000 ms
15 Sample Group 8000 ms
16 Drain Group 16000 ms
17 Sample Group 8000 ms
18 Level Group 11000 ms
19 Streamselection OFF 50 ms
20 ABS Meas. 5s
21 ABS sample Calc. 1s
22 Sample Detection Calc. 1s
23 Waiting 15 s
24 Sub procedure 0 0s
25 Drain / Level OFF 50 ms
26 Stirrer ON 50 ms
27 Acid pulses 9s 9p
28 Waiting 60 s
29 Buffer CaMg pulses 15 s 15p
30 Color pulses 12 s 12p
31 Waiting 5s
32 Hardness Algorithm 1200 s
33 Waiting 1s
34 Algorithm check Calc. 1s
35 ml. infl TH Calc. 1s
36 Total Hardness Calc. 1s
37 Write to database 1s
38 Drain Group 16000 ms
39 Streamselection ON 50 ms
40 Rinse Group 10000 ms
41 Drain Group 16000 ms
42 Rinse Group 10000 ms
43 Drain Group 16000 ms
44 Streamselection OFF 50 ms
45 Waiting Variable: Waiting
46 Sub procedure 1000 0s
47 Drain / Level OFF 50 ms
48 Total Hardness Calc. 1s
49 Write to database 1s
50 Streamselection OFF 50 ms
51 Waiting 1s
47
Addendum 2: Analyzer Configuration
See also ‘Material Date Sheet’ with corresponding analyzer serial number.
Nr Name
1 SP CW
2 SP CCW
3 DP CW
4 DP CCW
5 Drain / Level
6 Stirrer
7 Acid
8 Buffer Ca
9 Buffer CaMg
10 Color
11 EDTA
12 Spare
13 REF2
14 Clean
15 Rinse
16 Sample
21 EXT SV STR1
22 EXT SV STR2
25 Malfunction
Nr Name
1 INP1
2 INP2
3 INP3
4 INP4
Nr Name
1 ABS
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2.4 Analog Outputs
Nr Name
1 Result Tot Hard STR1
2 Result Ca Hard STR1
3 Result Tot Hard STR2
4 Result Ca Hard STR2
2.6 Results
Nr Name Unit
1 Sample Detection N.A.
2 ABS drain Ca mAU
3 ABS sample Ca mAU
4 ml. infl Ca ml
5 Algorithm check N.A.
6 Ca Hardness ppm
7 Total Hardness ppm
8 ABS mAU
9 ml. infl TH ml
10 ABS drain TH mAU
11 ABS sample TH mAU
Sample Detection
1 M1 - M2
2 IF R1 < 100 THEN Set alarm byte: 1 Value: 1
3 IF R1 >= 100 THEN Set alarm byte: 1 Value: 0
4 IF R1 < 100 THEN goto subprocedure 1000
5 IF R1 >= 100 THEN goto subprocedure 0
6 R1 End of calculation
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ABS drain Ca
1 M1 End of calculation
ABS sample Ca
1 M2 End of calculation
ml Infl. Ca
1 M3 End of calculation
Algorithm check
1 IF M-Alarm3 = 1 THEN GOTO R3
2 0 End of calculation
3 IF 0 = 0 THEN goto subprocedure 1000
4 1 End of calculation
Ca Hardness
1 M3 write to calibration
2 M3 / Factor a1
3 R2 * Conc. ref2
4 R3 End of calculation
Total Hardness
1 M6 write to calibration
2 M6 / Factor a1
3 R2 * Conc. ref2
4 R3 End of calculation
ABS
1 ABS End of calculation
ml Infl. TH
1 M6 End of calculation
ABS drain TH
1 M4 End of calculation
ABS sample TH
1 M5 End of calculation
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2.9 Results Analog output
Result Channel Low alarm DO High alarm DO Low value High value
Ca
0 0 1500
Hardness
Total
0 0 1500
Hardness
2.12 Algorithms
Name: Ca Hardness
Sensor: ABS
Pauze
Pauze drift: 0
Pauze Max time: 0
Pauze Min time: 0
Initial dosing
Init steps: 3
Init time: 5
Init Volume: 0,1
Init Speed: 30
Dynamic dosing
Dyn. slope: 5
Dyn. speed: 30
Dyn. refill speed: 60
Dyn. min step: 0.1
Dyn. max step: 0.2
Dyn. min time: 5
Dyn. max time: 6
Dyn. drift: 0
Dyn. nr of points: 5
EP minimum: 0,05
EP peak: 2
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EP filter: 6
EP threshold: 50
EP1
M-position: 3
Window-low: 0
Window-high: 2000
Threshold: 250
Stop
Stop volume (ml) 10
Stop at measured value: 2900
Drift: 0
Number of EP: 1
Dosed volume after EP: 0.1
Stop time: 1200
Graph
Graph Low: 0
Graph High: 2500
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Window-low: 0
Window-high: 2000
Threshold: 250
Stop
Stop volume (ml) 10
Stop at measured value: 2900
Drift: 0
Number of EP: 1
Dosed volume after EP: 0.1
Stop time: 1200
Graph
Graph Low: 0
Graph High: 2500
2.14 Group DO
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Addendum 3: Alarms and signals
3.1 Alarms
Introduction
Alarm list
• Malfunctioning alarm:
o Emergency stop
When the emergency stop is activated, the analyzer shall stop immediately.
o Leak detection
There is a sensor installed inside the analyzer cabinet to detect leaks. When a leak
is detected, the malfunctioning alarm is triggered and the analyzer is stopped
(optional). A message box appears on the main screen.
o Sensor
When there is a problem with one of the sensors, the malfunctioning alarm is
activated. A massage appears in the message or history submenu.
o Titration alarm
When there is a problem during the titration (titration out of time, no inflection
points detected…) the malfunctioning alarm is activated. A massage appears in
the message or history submenu.
• Maintenance alarm:
When the maintenance mode is active after pressing the MAINTENANCE ON/OFF
button, a digital output is activated (maintenance contact is opened) to indicate
remotely that the analyzer is not running on-line. When the maintenance mode is
active, the analyzer is always in the local control mode: the analyzer can only be
started manually.
3.2 Signals
The standard signal is an active 4-20 mA signal.
RS232/MODBUS are optional, but can be programmed and used if the proper remote IO is
installed.
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Warranty
1. Warranties
AppliTek NV/SA warrants that its products are free from defects in materials and workmanship (under
normal conditions of use and service) for a period one (1) year from date of shipment to original
purchaser.
• Operating the unit for reasons other than its designed purpose
• Improper assembly, initializing, operating or maintenance of the unit
• Operating the unit when any safety or protection devices are defect or non-functioning
• Non-adherence of any instruction in the operating manual
• Unauthorized constructional alterations to the measuring unit
• Unauthorized constructional alterations to the utilities (for example instrument air supply).
• Incorrect maintenance of unit components
• Maintenance and repair work improperly carried out
• Catastrophes caused by outside interference, natural disaster, labor unrest, acts of war,
terrorism, civil strife or acts of any governmental jurisdiction.
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