Swan Analytical Instruments AMI INSPECTOR Conductivity Operator's Manual
AMI INSPECTOR
Conductivity
Version 6.00 and higher
A-96.250.611 / 120617
Operator’s Manual
© 2016, SWAN ANALYTISCHE INSTRUMENTE AG, Switzerland, all rights reserved
subject to change without notice
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
Studbachstrasse 13
8340 Hinwil
Switzerland
Internet: www.swan.ch
E-mail: support@swan.ch
Document Status
Title:
Monitor AMI INSPECTOR Conductivity Operator’s Manual
ID:
A-96.250.611
Revision Issue
00 April 2010 First Edition
01 August 2014 New mainboard V 2.4, update to Firmware version
V5.30
02
January 2016
AMI Inspector Version 2-A (with AMIAKKU mainboard) and Firmware version 6.00
AMI INSPECTOR Conductivity
A-96.250.611 / 120617 1
Table of Contents
1. Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1. Warning Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2. General Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1. Description of the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2. Instrument Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1. Installation Check List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2. Connecting Sample Inlet and Outlet. . . . . . . . . . . . . . . . . . . . . . . 15
3.2.1 Swagelok Fitting Stainless Steel at Sample Inlet . . . . . . . . . . . 15
3.2.2 Sample Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4. Connection Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4.1 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5. Relay Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5.1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5.2 Alarm Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5.3 Relay Contacts 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.6. Signal Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4. Instrument Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.1. Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5. Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1. Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2. Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3. Software Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.4. Changing Parameters and values . . . . . . . . . . . . . . . . . . . . . . . . 26
6. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1. Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2. Stop of Operation for Maintenance. . . . . . . . . . . . . . . . . . . . . . . . 27
6.3. Maintenance of the Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.4. Quality Assurance of the Instrument . . . . . . . . . . . . . . . . . . . . . . 29
6.4.1 Activate SWAN Quality assurance procedure. . . . . . . . . . . . . . 30
6.4.2 Pre-test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.4.3 Connecting sample lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2 A-96.250.611 / 120617
AMI INSPECTOR Conductivity
6.4.4 Carry out comparison measurement . . . . . . . . . . . . . . . . . . . . . 33
6.4.5 Completion of the measurement . . . . . . . . . . . . . . . . . . . . . . . . 34
6.5. Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.6. Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.7. Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.8. Longer Stop of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7. Error List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8. Program Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.1. Messages (Main Menu 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.2. Diagnostics (Main Menu 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.3. Maintenance (Main Menu 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.4. Operation (Main Menu 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.5. Installation (Main Menu 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9. Program List and Explanations . . . . . . . . . . . . . . . . . . . . . . . . . 46
1 Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10. Default Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
11. Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
12. Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
AMI INSPECTOR Conductivity
Safety Instructions
A-96.250.611 / 120617 3
AMI INSPECTOR Conductivity Operator’s Manual
This document describes the main steps for instrument setup, operation and maintenance.
1. Safety Instructions
General The instructions included in this section explain the potential risks
associated with 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.
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.
Tar get
audience
Operator: Qualified person who uses the equipment
for its intended purpose.
Instrument operation requires thorough knowledge of applications,
instrument functions and software program as well as all applicable
safety rules and regulations.
OM Location The AMI Operator’s Manual shall be kept in proximity of the instru-
ment.
Qualification,
Training
To be qualified for instrument installation and operation, you must:
read and understand the instructions in this manual as well as
the Material Safety Data Sheets.
know the relevant safety rules and regulations.
4 A-96.250.611 / 120617
AMI INSPECTOR Conductivity
Safety Instructions
1.1. Warning Notices
The symbols used for safety-related notices have the following significance:
DANGER
Your life or physical wellbeing are in serious danger if such
warnings are ignored.
Follow the prevention instructions carefully.
WARNING
Severe injuries or damage to the equipment can occur if such
warnings are ignored.
Follow the prevention instructions carefully.
CAUTION
Damage to the equipment, minor injury, malfunctions or incorrect process can be the consequence if such warnings are ignored.
Follow the prevention instructions carefully.
Mandatory
Signs
The importance of the mandatory signs in this manual.
Safety goggles
Safety gloves
AMI INSPECTOR Conductivity
Safety Instructions
A-96.250.611 / 120617 5
Warning Signs The importance of the warning signs in this manual.
Electrical shock hazard
Corrosive
Harmful to health
Flammable
Warning general
Attention general
6 A-96.250.611 / 120617
AMI INSPECTOR Conductivity
Safety Instructions
1.2. General Safety Regulations
Legal
Requirements
The user is responsible for proper system operation.
All precautions must be followed to ensure safe operation
of the instrument.
Spare Parts
and
Disposables
Use only official SWAN spare parts and disposables. If other parts
are used during the normal warranty period, the manufacturer’s
warranty is voided.
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.
WARNING
Risk of Electrical Shock
If proper operation is no longer possible, the instrument must be
disconnected from all power lines, and measures must be taken
to prevent inadvertent operation.
To prevent from electrical shock, always make sure that the
ground wire is connected.
Service shall be performed by authorized personnel only.
Whenever electronic service is required, disconnect instru-
ment power and power of devices connected to.
–relay 1,
–relay 2,
– alarm relay
WARNING
For safe instrument installation and operation you must read
and understand the instructions in this manual.
WARNING
Only SWAN trained and authorized personnel shall perform the
tasks described in this document.
AMI INSPECTOR Conductivity
Product Description
A-96.250.611 / 120617 7
2. Product Description
This chapter contains technical data, requirements and performance data.
2.1. Description of the System
The portable AMI INSPECTOR instrument is a complete monitoring
system mounted on a small panel with supporting stand and a rechargeable battery for stand-alone operation (>24h), designed as
an inspection equipment for quality assurance of online process
monitors.
Application
Range
The conductivity is a parameter for the total quantity of ions present
in the solution. It can be used for the monitoring of:
the condition of waters
water purification
water hardness
completeness of ion analysis
Features General Features of AMI INSPECTORs are:
Battery life after full charge:
– >24h at full load (use of 3 relays, USB, signal output, logger)
– >36h at minimum load (use of logger only)
Charging time: approx. 6 hours
Controlled shut-down if battery is empty.
Display of remaining battery life in hours.
For longer battery life the back light of the LC Display is dis-
abled.
Continuous operation using power adapter. The battery
should be discharged at least once a month (normal usage
until the monitor automatically shuts down).
Battery The Li-Ion battery is located in the housing of the AMI transmitter.
See chapter Power Supply, p. 18 regarding power supply and
charging of the battery.
USB interface Built-in USB interface for logger download. Use the USB stick sup-
plied by Swan only (other USB sticks can dramatically reduce battery life).
8 A-96.250.611 / 120617
AMI INSPECTOR Conductivity
Product Description
Special
Features
Many temperature compensation curves for specific conductivity
measurement:
none
Coefficient
Neutral salts
High-purity water
Strong acids
Strong bases
Ammonia, Eth. am.
Morpholine
Signal Output
(optional)
One signal output 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
Relay Two potential-free contacts programmable as limit switches for
measuring values, controllers or timer for system cleaning with automatic hold function.
Maximum load: 100 mA/ 50 VAC
Alarm Relay One potential free contact.
Alternatively:
Open during normal operation, closed on error and loss of
power.
Closed during normal operation, open 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 inter-
rupt control in automated installations (hold function or remote-off)
Safety features 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.
Sensor Swansensor UP-Con1000 SL high precision two-wire electrode
made of stainless steel with integrated NTC temperature probe.
AMI INSPECTOR Conductivity
Product Description
A-96.250.611 / 120617 9
Measuring
Principle
The conductivity of high purity water is determined with a sensor
consisting of two metal electrodes. The characteristics of each sensor is expressed as cell constant. An alternating voltage (to minimize polarization effects) is applied to two electrodes. Depending
on the concentration of ions in the sample, a signal results between
the electrodes which is proportional to the conductivity of the water.
The measuring result is indicated as conductivity.
Temperature
compensation
The mobility of ions in water increase with higher temperature
which enlarges the conductivity. Therefore, the temperature is measured simultaneous by an integrated Pt1000 temperature sensor
and the conductivity is compensated to 25 °C. Several temperature
compensation curves, designed for different water compositions,
can be chosen.
After cation exchanger (cation conductivity), the temperature compensation curve strong acids has to be set.
For more information see: Influence of Temperature on Electrical
Conductivity, PPChem (2012)
Standard
Temperature
The displayed conductivity value is compensated to 25 °C standard
temperature.
10 A-96.250.611 / 120617
AMI INSPECTOR Conductivity
Product Description
Fluidics The flow cell QV-Flow UP-Con SL consists of the flow cell block [B],
the flow sensor [C] and the flow regulating valve [E].
The Swansensor UP-Con1000 SL [A] with integrated temperature
sensor is inserted into the flow cell block [B].
The sample enters at the sample inlet [F]. It flows through the flow
regulating valve [E], where the flow rate can be adjusted. Then the
sample flows through the flow cell block were the conductivity and
temperature of the sample is measured.
The sample leaves the flow cell block via flow meter through the
sample outlet [D].
A
B
C
Swansensor Up-Con1000 SL
Flow cell block
Flow sensor
D
E
F
Sample outlet
Flow regulating valve
Sample inlet
A
B
C
D
E
F
AMI INSPECTOR Conductivity
Product Description
A-96.250.611 / 120617 11
2.2. Instrument Overview
A
B
C
D
E
F
G
AMI Transmitter
Swansensor UP-Con1000 SL
Flow cell QV-Flow UP-Con SL
Sample outlet
Flow meter
Sample inlet
Flow regulating valve
A
B
C
D
E
F
G
12 A-96.250.611 / 120617
AMI INSPECTOR Conductivity
Product Description
2.3. Technical Data
Power Supply
Battery
Use original, supplied power adapter only.
Voltage:
Power consumption:
Charging time:
Battery type:
85–265 VAC, 50/60 Hz
max. 20 VA
6h
Li-Ion
During charging protect from heat impact and keep splash-proof
(not IP66).
Operating time
Stand-alone (Battery):
Connected adapter:
> 24h
continuous
Controlled shut-down when battery is empty, remaining time is displayed.
Electronics
Aluminium with a protection degree of IP 66 / NEMA 4X
housing
Ambient temperature:
Humidity:
Display:
-10 to +50 °C
10–90% rel., non condensing
backlit LCD, 75 x 45 mm
Sample
requirements
Flow rate:
Temperature:
Inlet pressure:
Outlet pressure:
5–20 l/h
up to 50 °C
up to 2 bar
pressure free
On-site
The analyzer site must permit connections to:
requirements
Sample inlet:
Sample outlet:
Max. Altitude:
1/4” Swagelok tube adapter
flexible tube 6x 8 mm
2000 m above sea level
Measuring
Range
Range:
0.055 to 0.999 s/cm
1.00 to 9.99 s/ cm
10.0 to 99.9 s/cm
100 to 1000 s/cm
Resolution
0.001 s/cm
0.01 s/cm
0.1 s/cm
1 s/cm
Accuracy
Automatic range switching.
±1% of measured value ±1 digit
Values for the cell constant 0.0415 cm
-1
Swansensor
UP-Con1000 SL.
AMI INSPECTOR Conductivity
Product Description
A-96.250.611 / 120617 13
Sensor
UP-Con1000 SL
The Swansensor UP-Con1000 SL is a 2-electrode conductivity
sensor for the continuous measurement of specific and acid conductivity with a built-in temperature sensor.
Sensor Cell Constant k:
Temperature sensor:
~ 0,04 cm
-1
Pt1000
Materials
Shaft:
Electrode:
Isolation:
SS 316L, stainless steel
Titanium
PEEK
Operating
Conditions
Continuous temperature:
Max. temperature:
Max. pressure:
100 °C at 6,5 bar
120 °C at 6,5 bar
30 bar at 25 °C
The cell constant (ZK) and the temperature
correction (DT) are written on the sensor label.
14 A-96.250.611 / 120617
AMI INSPECTOR Conductivity
Installation
3. Installation
3.1. Installation Check List
Check
Instrument’s specification must conform to your AC power
ratings. See External power adapter, p. 19.
Check if the battery is fully charged.
Site requirements
Sample line with sufficient flow and pressure, see Sample
requirements, p. 12
Installation
Connect the sample and waste line.
Electrical
connections
Connect all external devices like limit switches and current
loops, see Connection Diagram, p. 17.
Power-up
Turn on sample flow
Switch on power
Adjust the sample flow to 5 – 20 l/h
Instrument
Setup
Program all sensor specific parameters (cell constant, temp.
correction, cable length).
Program all parameters for external devices (interface,
recorders, etc.).
Program all parameters for instrument operation (limits,
alarms, etc.).
Run-in period
Let the instrument run continuously for 1 h.
NOTICE: If the conductivity value of the sample is very low,
the sensor might need some time until the correct reading is
displayed
AMI INSPECTOR Conductivity
Installation
A-96.250.611 / 120617 15
3.2. Connecting Sample Inlet and Outlet
3.2.1 Swagelok Fitting Stainless Steel at Sample Inlet
Preparation Cut the tube to length and deburr it. The tube must be straight and
free from blemishes for approximately 1,5 x tube diameter from the
end.
Lubrication with lubricating oil, MoS2, Teflon etc. is recommended
for the assembly and reassembly of bigger sized unions (thread,
compression cone).
Installation 1 Insert the compression ferrule [C] and the compression cone
[D] into the union nut [B].
2 Screw on the union nut onto the body, do not tighten it.
3 Push the stainless steel pipe through the union nut as far as it
reaches the stop of the body.
4 Tighten down the union nut 1¾ rotation using an open ended
spanner. Hold Body from turning with a second wrench.
3.2.2 Sample Outlet
Flexible tube 8x 6 mm. Connect the tube to the serto elbow union
and insert it into a pressure free drain of sufficient capacity.
A
B
C
D
E
F
Tube
Union nut
Compression
ferrule
Compression
cone
Body
Tightened
connection
ABCDE
F
A
B
C
D
Elbow union
Compression ferrule
Knurled nut
Flexible tube
B
C
D
A
16 A-96.250.611 / 120617
AMI INSPECTOR Conductivity
Installation
3.3. Electrical Connections
WARNING
Always turn off DC power before manipulating electric parts.
Make sure the power specification of the instrument corresponds to the power on site.
Cable
thicknesses
In order to comply with IP66, use the following cable thicknesses
NOTICE: Protect unused cable glands
Wire For Relays: Use max. 1.5 mm2 / AWG 14 stranded wire with
end sleeves.
For Signal Outputs and Input: Use 0.25 mm
2
/ AWG 23
stranded wire with end sleeves.
WARNING
External Voltage.
External supplied devices connected to relay 1 or 2 or to the
alarm relay can cause electrical shocks.
Make sure that the devices connected to the following con-
tacts are disconnected from the power before continuing the
installation.
–relay 1
–relay 2
– alarm relay
ABPG 9 cable gland: cable Ø
outer
4–8 mm
PG 7 cable gland: cable Ø
outer
3–6.5 mm
ON
OFF
AB
AMI INSPECTOR Conductivity
Installation
A-96.250.611 / 120617 17
3.4. Connection Diagram
CAUTION
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.
18 A-96.250.611 / 120617
AMI INSPECTOR Conductivity
Installation
3.4.1 Power Supply
Contrary to all other Swan online process monitors the AMI INSPECTOR transmitter is supplied with power by battery only. The
rechargeable battery (Li-Ion) enables a stand-alone operation for at
least 24 hours.
WARNING
Do not provide power directly to the transmitter as this will destroy the motherboard. All AMI INSPECTOR transmitters are
supplied with power by battery only.
Charging Use the original supplied power adapter to charge AMI INSPEC-
TOR only. Charging time: approx 6h.
Fully charged a stand-alone operating time of at least 24h is guar-
anteed:
>24h at full load (use of 3 relays, USB, signal output, logger)
>36h at minimal load (use of logger only)
In case that the battery is discharged completely the firmware will
automatically shut down.
Switch Power
ON - OFF
Switch the instrument ON or OFF using the toggle switch on the
transmitter.
Continuous
operation
For continuous operation use the power adapter as well.
CAUTION
If the AMI powers ON and then immediately shuts OFF, the
battery is empty. Do not hold the toggle switch in ON position,
as this can damage the battery.
CAUTION
During charging protect from heat impact and keep splash-
proof (plug of power adapter is not IP66).
Do not supply external devices, e.g. pumps, magnetic valves
or any other current consumers with AMI INSPECTOR
CAUTION
Use the original supplied power adapter to charge AMI IN-
SPECTOR only. Use of any other power adapter can damage
the battery or cause malfunction
AMI INSPECTOR Conductivity
Installation
A-96.250.611 / 120617 19
External
power adapter
Universal input range
85 - 265 VAC
Continuous short circuit protection
Over voltage protection
LED indicator for power on
2-pin AC inlet (IEC 320-C8) for
detachable country-specific power
cord
Power cords Two different power cords are supplied:
Power cord with type C plug (Europlug)
Power cord with type A plug (NEMA-1)
If a different plug type is needed, please purchase a suitable power
cord from your local supplier.
NOTICE: Do not use any plug adapters.
Dimensions
Unit: mm
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