Swann AMI INSPECTOR pH Operator's Manual

AMI INSPECTOR pH
Version 6.00 and higher
A-96.250.761 / 161017
Operator’
s Manual
© 2016, SWAN ANALYTISCHE INSTRUMENTE AG, Switzerland, all rights reserved
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:
AMI INSPECTOR pH Operator’s Manual
ID:
A-96.250.761
Revision Issue
00 June 2012 First Edition
01 Sept. 2013 Main board V2.4
02 Jan. 2016 AMI Inspector Version 2-A (with AMIAKKU main-
board) and Firmware version 6.00
AMI INSPECTOR pH
A-96.250.761 / 161017 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1. Installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2. Connecting Sample Inlet and Outlet. . . . . . . . . . . . . . . . . . . . . . . 13
3.2.1 Swagelok Fitting Stainless Steel at Sample Inlet . . . . . . . . . . . 13
3.2.2 Connect the Sample Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3. Install Swansensor pH SI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4. Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5.1 Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5.2 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.6. Relay Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.6.1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.6.2 Alarm Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.6.3 Relay 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.7. Signal Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4. Instrument Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1. Establish Sample Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2. Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5. Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1. Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2. Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3. Software Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4. Changing Parameters and values . . . . . . . . . . . . . . . . . . . . . . . . 28
6. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1. Maintenance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2. Stop of Operation for Maintenance. . . . . . . . . . . . . . . . . . . . . . . . 29
6.3. Maintenance of Electrode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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AMI INSPECTOR pH
6.3.1 Clean pHSI Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.4. Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.5. Quality Assurance of the Instrument. . . . . . . . . . . . . . . . . . . . . . . 33
6.5.1 Activate SWAN Quality assurance procedure. . . . . . . . . . . . . . 34
6.5.2 Pre-test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.5.3 Connect instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.5.4 Carry out comparison measurement . . . . . . . . . . . . . . . . . . . . . 37
6.5.5 Completion of the measurement . . . . . . . . . . . . . . . . . . . . . . . . 38
6.6. Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.7. Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.8. Longer Stop of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7. Error List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8. Program Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.1. Messages (Main Menu 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.2. Diagnostics (Main Menu 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.3. Maintenance (Main Menu 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.4. Operation (Main Menu 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.5. Installation (Main Menu 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9. Program List and Explanations . . . . . . . . . . . . . . . . . . . . . . . . . 50
1 Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10. Material Safety Data sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
10.1. Reagents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11. Default Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
12. Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
13. Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
AMI INSPECTOR pH
Safety Instructions
A-96.250.761 / 161017 3
AMI INSPECTOR pH - 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.
Target
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 Keep the AMI Operator’s Manual in proximity of the instrument.
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-96.250.761 / 161017
AMI INSPECTOR pH
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 pH
Safety Instructions
A-96.250.761 / 161017 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-96.250.761 / 161017
AMI INSPECTOR pH
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 pH
Product Description
A-96.250.761 / 161017 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.
pH Measuring
Principle
(simplified)
The pH measurement is based on a voltage measurement. A volt­age can only be measured between two different potentials, there­fore, the pH measuring chain contains a measuring electrode and a reference electrode. The reference electrode maintains a constant potential whereas the potential of the measuring electrode changes with the pH value. The voltage which results from this potential dif­ference is measured and displayed on the transmitter as pH value. The measuring chain is designed so that the voltage is zero at pH 7.
pH Electrode The Swansensor pH SI is a combined electrode with liquid electro-
lyte (KCl) for the measurement of pH.
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 hoursControlled 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, S. 19 regarding power supply and charging of the battery.
8 A-96.250.761 / 161017
AMI INSPECTOR pH
Product Description
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.
Temper ature
compensation
The pH value depends on the sample temperature. To compensate temperature fluctuations a temperature sensor is installed in the flow cell
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 One input for potential-free contact to freeze the measuring value
or to interrupt control in automated installations (hold function or re-
mote-off).
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).
Relays Two potential-free contacts programmable as limit switches for
measuring values, controllers or timer for system cleaning with au­tomatic hold function.
Rated load: 100 mA/ 50 VAC
Signal Output One programmable signal output for measured values (freely scal-
able, linear, bilinear or logarithmic) or as continuous control output (control parameters programmable).
Current loop: 0/4–20 mA Maximum burden: 510
Flow Cell Flow cell QV-Flow IS1000 made of stainless steel SS316L with
built-in temperature sensor (Pt1000), flow adjustment valve, digital sample flow meter, quick release vessel for easy sensor access and calibration.
AMI INSPECTOR pH
Product Description
A-96.250.761 / 161017 9
Fluidics The flow cell (QV-Flow) consists of the flow cell block [E] and the
vessel [G]. The pH sensor [A] and the temperature sensor [B] are screwed into
the flow cell block [E]. The sample enters at the sample inlet [C]. It flows through the flow
regulating valve [D], where the flow rate can be adjusted. Then the sample flows via the flow sensor [F] and the flow cell block [E] into the vessel [G], were the pH of the sample is measured. The pH val­ue depends on the sample temperature. The measuring value of the temperature sensor [B] is used to recalculate the pH measuring value to a predefined average sample temperature.
The sample leaves the vessel via flow cell block through the sam­ple outlet [H] and flows into the drain [I].
A B C D E
pH Sensor Temperature sensor Sample inlet Flow regulating valve Flow cell block
F G H I
Flow sensor Vessel Sample outlet Drain
A
B
CD E
F
G
H
I
10 A-96.250.761 / 161017
AMI INSPECTOR pH
Product Description
2.2. Instrument Overview
A B C D
KCl reservoir Temperature sensor (cable) pH sensor Flow cell
E F
G H
Flow sensor Flow regulating valve Sample inlet AMI Transmitter
A
B
C
D
E
F
G
H
AMI INSPECTOR pH
Product Description
A-96.250.761 / 161017 11
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).
Measuring
Range
pH: Resolution:
1 to 12 pH
0.01 pH
Temperature
Input
for Pt1000 type sensor Measuring range: Resolution:
- 30 to +130 °C
0.1 °C
Sample
conditions
Flow Rate: Temperature: Inlet pressure:
5–10 l/h up to 50 °C
0.2–2 bar
Temperature
monitoring
Alarm if the transmitter temperature is higher than + 65 °C or lower than 0 °C.
12 A-96.250.761 / 161017
AMI INSPECTOR pH
Installation
3. Installation
3.1. Installation Checklist
Check
Instrument’s specification must conform to your AC power
ratings. See External power adapter, p. 20.
Check if the battery is fully charged.
Installation
Connect sample inlet and outlet to the flow cell.
pH electrode
Install the sensor (see Install Swansensor pH SI, p. 14).Connect sensor cables.Store the protective caps for later use.
Power-up
Turn on the sample flow and wait until the flow cell is
completely filled.
Switch on power.
Instrument set-up
Adjust sample flow.Program all parameters for sensor.Program all parameters for instrument operation (limits,
alarms).
Run-in period
Let the instrument run continuously for 1 h.
AMI INSPECTOR pH
Installation
A-96.250.761 / 161017 13
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 Connect the Sample Outlet
Connect the 1/2” tube to the waste funnel of the AMI INSPECTOR pH.
A B C
Tube Union nut Compression ferrule
D E F
Compression cone Body Tightened connection
ABCDE
F
14 A-96.250.761 / 161017
AMI INSPECTOR pH
Installation
3.3. Install Swansensor pH SI
The pH electrode SI is packed separately and protected with a cap filled with KCl. After the AMI INSPECTOR pH has been installed and connected to the sample line, install the pH electrode SI as fol­lows:
CAUTION
Fragile parts.
The pH electrode is fragile.
Handle with care.Do not spill KCL when removing the protection cap.
Prepare the
KCl Reservoir
The KCl supply to the reference electrode is ensured by a syringe [A] with a volume of 10ml. The syringe is connected to the refer­ence electrode with a Luer-Lock connector [D].
To ensure a continuous flow of KCl to the reference electrode, pull the plunger of the syringe over the punched hole [B].
1 Remove the Luer-Lock seal cone [C] from the tip of the syringe
[A].
2 Insert the Luer-Lock connector [D] into the tip of the syringe.
A B C D
Syringe Punched hole Luer-Lock seal cone Luer-Lock connector
A
B
C
D
AMI INSPECTOR pH
Installation
A-96.250.761 / 161017 15
Install the
Electrode
1 Carefully remove the protective cap [G] from the electrode tip.
Turn it clockwise only.
2 Rinse the electrode tip with clean water.
3 Insert the electrode through the flow cell block [F] into the cali-
bration vessel [H].
4 Tighten it hand-tight.
5 Remove the connector cap [B].
6 Screw the connector [D] marked with pH onto the sensor.
7 Keep the protective caps on a secure place for later use.
A B C D
Syringe (KCl reservoir) Connector cap KCl supply tube Connector
E F G H
Electrode Flow cell block QV-Flow Protective cap Calibration vessel
B
A
E
F
H
G
D
C
16 A-96.250.761 / 161017
AMI INSPECTOR pH
Installation
1 Fill the KCl supply tube [D] of the electrode completely with
electrolyte.
Ensure that no air bubbles remain in the tube.
2 Fill the syringe completely with electrolyte by pulling the plunger
just below the punch hole [B].
3 Connect the syringe to the KCl supply tube (Luer-Lock) and clip
it to the holder [C].
4 Pull the plunger slightly over the air hole.
3.4. Temperature Sensor
The temperature sensor is permanently glued to the flow cell block. Screw the connector marked with T onto the temperature sensor.
ABPlunger
Punch hole
CDHolder
KCl supply tube
A
B
C
D
AMI INSPECTOR pH
Installation
A-96.250.761 / 161017 17
3.5. Electrical Connections
WARNING
Always turn off DC power before manipulating electric parts. Make sure the power specification of the wall mount adapter 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 mm
2
/ 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 resuming 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
18 A-96.250.761 / 161017
AMI INSPECTOR pH
Installation
3.5.1 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.
AMI INSPECTOR pH
Installation
A-96.250.761 / 161017 19
3.5.2 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 stand-alone operating time of at least 24h is guaran-
teed:
>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.
20 A-96.250.761 / 161017
AMI INSPECTOR pH
Installation
External
power adapter
Universal input range
85 - 265 VAC
Continuous short circuit protectionOver voltage protectionLED indicator for power on2-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
AMI INSPECTOR pH
Installation
A-96.250.761 / 161017 21
3.6. Relay Contacts
Programming of the relay contacts see 5.3 Relay Contacts, p. 59.
3.6.1 Input
NOTICE: Use only potential-free (dry) contacts.
Terminals 13 /14 If signal output is set to hold, measurement is interrupted if input is
active. For programming see menu 5.3.4, p. 65.
3.6.2 Alarm Relay
NOTICE: For resistive loads only; do not use with capacitive or inductive loads. Max. load 1 A/250 VAC.
Alarm output for system errors. Error codes see Error List, p. 42. Programming see 5.3.1, p. 59
NOTICE: With certain alarms and certain settings of the AMI transmitter the alarm relay does not switch. The error, however, is shown on the display.
1) usual use
Terminals Description Relay connection
NC
1)
Normally Closed
5/4 Active (opened) during normal
operation. Inactive (closed) on error and loss of power.
NO
Normally Open
5/3 Active (closed) during normal
operation. Inactive (opened) on error and loss of power.
4
3
5
0V
1)
4
3
5
0V
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