YOKOGAWA PH450G, FLXA202, FLXA21, PH8SM3, PH8EFP User Manual

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User ’s Manual

Chemical Cleaning pH Measuring System

IM 12B07W01-04EN

1st Edition

u Introduction

n Chemical Cleaning pH Measuring System

Thank you for purchasing Chemical Cleaning pH Measuring System.

To have the system deliver its full capabilities, read this instruction manual thoroughly before you use it. For safety reasons or to avoid possible damage to your equipment, strictly adhere to every cautionary note that appears in this manual.

Chemical Cleaning pH Measuring System features automatic chemical cleaning of the pH sensor without removing pH sensor, while maintaining its performance in pH measurement.

System Conguration of Chemical Cleaning pH Measuring System is as below;

Chemical Cleaning pH Measuring System

pH/ORP Converter 2-wire Analyzer

Chemical Cleaning unit PH8SM3-E PH8SM3-G or PH8SM3-F

pH analyzer PH450G FLXA202 or FLXA21

Distributor ― PH201G pH sensor

Holder PH8HS3

(Note) You can select WTB10 Terminal Box, if necessary.

PH8EFP-□-TT2 (Note)

This document describes mainly PH8SM3 unit of the system and PH8HS3 Holder. For further information on other products, please read corresponding manual attached to each product.

The related documents to each product:

General Specications

Product Model Document Name Document number

PH8SM3, PH8HS3, PH201G Chemical Cleaning pH measuring System GS 12B7A1-E PH450G PH450G pH and Redox (ORP ) Converter GS 12B07C05-01E FLXA202 FLXA202 2-Wire Analyzer GS 12A01A03-01EN FLXA21 FLXA21 2-Wire Analyzer GS 12A01A02-01E PH8EFP, WTB10 pH and ORP Sensors GS 12B07B02-E

* the “E” or “EN” in the document number is a language code.

User’s Manual

Product Model Document Name Document number

PH8SM3, PH8HS3 Chemical Cleaning pH measuring System PH450G PH450G pH and ORP Converter IM 12B07C05-01E FLXA202, FLXA21 FLXA202/FLXA21 2-Wire Analyzer IM 12A01A02-01E PH201G PH201G Distributor IM 19B01E04-02E PH8EFP, PH8EFP, KCI Filling type pH sensor IM 12B7J1-01E WTB10 WTB10-PH□ Terminal Box IM 19D01B01-01E

* the “E” in the document number is the language code.

n Notes on Handling User’s Manuals

IM 12B07W01-04EN(this document)

• Please hand over the user’s manuals to your end users so that they can keep the user’s

manuals on hand for convenient reference.

• Please read the information thoroughly before using the product.

• The purpose of these user’s manuals is not to warrant that the product is well suited to any

particular purpose but rather to describe the functional details of the product.

IM 12B07W01-04EN 1st Edition : Nov. 11, 2016-00

• No part of the user’s manuals may be transferred or reproduced without prior written

consent from YOKOGAWA.

• YOKOGAWA reserves the right to make improvements in the user’s manuals and product at

any time, without notice or obligation.

• If you have any questions, or you nd mistakes or omissions in the user’s manuals, please

contact our sales representative or your local distributor.

n Drawing Conventions

Some drawings may be partially emphasized, simplied, or omitted, for the convenience of

description.

Some screen images depicted in the user’s manual may have different display positions or

character types (e.g., the upper / lower case). Also note that some of the images contained in this

user’s manual are display examples.

n Inspection on delivery

Each component of Chemical Cleaning pH Measuring Systems comes in a separate package. However, PH450G pH/ORP Converters (or FLXA202/FLXA21 2-Wire Analyzer ) are delivered with factory-installed in PH8SM3 Chemical Cleaning pH Measuring Unit ,

After the delivery, open the package carefully and inspect for damages caused during transport. Should there be any damage or breakage on the product, please contact YOKOGAWA immediately and keep all the packing materials, containers and boxes that came with the product.

After the unpacking, make sure the delivered products include all of the component equipment you ordered.

After completing the unpacking, make sure that the delivered component covers all of the

required specications. When conrming the specications, refer to the model and sufx codes

indicated on the nameplate on the instrument. The models are indicated on the name plates. Check also those of accessories. For further information on PH8SM3 or PH8HS3, please read subsection 1.2 of this document.

l Unpacking and handling

When unpacking, place the instrument on a level surface in the position in which the instrument will actually be installed, (Do not allow the package to undergo any intense mechanical shock by turning it over on its side.) Avoid applying any excess force to the pipes and cables. Otherwise, a defective pipe and / or cable connection may result

PH8SM3 Chemical Cleaning pH Measuring Unit weighs approximately 50 kg. It is recommended that the product be unpacked as near your installation location as possible.

IM 12B07W01-04EN 1st Edition : Nov.11, 2016-00

u Safety Precautions

n Safety, Protection, and Modication of the Product

• In order to protect the system controlled by the product and the product itself and ensure safe operation, observe the safety precautions described in this user’s manual. We assume

no liability for safety if users fail to observe these instructions when operating the product.

• If this instrument is used in a manner not specied in this user’s manual, the protection

provided by this instrument may be impaired.

• If any protection or safety circuit is required for the system controlled by the product or for

the product itself, prepare it separately.

• Be sure to use the spare parts approved by Yokogawa Electric Corporation (hereafter

simply referred to as YOKOGAWA) when replacing parts or consumables.

• Modication of the product is strictly prohibited.

• The following safety symbols are used on the product as well as in this manual.

WARNING

This symbol indicates that an operator must follow the instructions laid out in this manual in order to avoid the risks for the human body and health including risk of injury, electric shock, or fatalities. or the damages to instruments. The manual describes what special care the operator must take to avoid such risks.

iii

CAUTION

This symbol indicates that the operator must refer to the instructions in this manual in order to prevent the instrument (hardware) or software from being damaged, or a system failure from occurring.

The following are signal words to be found only in our instruction manuals.

CAUTION

This symbol gives information essential for understanding the operations and functions.

NOTE

This symbol indicates information that complements the present topic.

n Warning and Disclaimer

The product is provided on an “as is” basis. YOKOGAWA shall have neither liability nor responsibility to any person or entity with respect to any direct or indirect loss or damage arising from using the product or any defect of the product that YOKOGAWA can not predict in advance.

n Trademark policy

FLEXA, FLXA, SENCOM are the registered trade marks and trade names of Yokogawa’s

products. All other company and product and product names mentioned in this document are trade names, trademarks or registered trademarks of their representative companies. In this document, trademarks or trade names are not indicated with TM or ® as trademark symbols.

IM 12B07W01-04EN 1st Edition : Nov. 11, 2016-00

u After-sales Warranty

n Do not modify the product.

n During the warranty period, for repair under warranty, carry or send the product

to the local sales representative or service ofce. Yokogawa will replace or

repair any damaged parts and return the product to you. Before returning a product for repair under warranty, provide us with the model name and serial number and a description of the problem. Any diagrams or data explaining the problem would also be appreciated.

• If we replace the product with a new one, we won’t provide you with a repair report.

• Yokogawa warrants the product for the period stated in the pre-purchase quotation Yokogawa shall conduct dened warranty service based on its standard. When the

customer site is located outside of the service area, a fee for dispatching the maintenance engineer will be charged to the customer.

n In the following cases, customer will be charged repair fee regardless of

warranty period.

• Failure of components which are out of scope of warranty stated in instruction manual.

• Failure caused by usage of software, hardware or auxiliary equipment, which Yokogawa

Electric did not supply.

• Failure due to improper or insufcient maintenance by user.

• Failure due to modication, misuse or outside-of-specications operation which Yokogawa

does not authorize.

• Failure due to power supply (voltage, frequency) being outside specications or abnormal.

• Failure caused by any usage out of scope of recommended usage.

• Any damage from re, earthquake, storms and oods, lightning, disturbances, riots, warfare,

radiation and other natural changes.

n Yokogawa does not warrant conformance with the specic application at the

user site. Yokogawa will not bear direct/indirect responsibility for damage due to a specic application.

n Yokogawa Electric will not bear responsibility when the user congures the

product into systems or resells the product.

n Maintenance service and supplying repair parts will be covered for ve years

after the production ends. For repair for this product, please contact the

nearest sales ofce described in this instruction manual.

IM 12B07W01-04EN 1st Edition : Nov.11, 2016-00

Chemical Cleaning pH Measuring System

IM 12B07W01-04EN 1st Edition

CONTENTS

u Introduction ....................................................................................................i

u Safety Precautions ......................................................................................iii

1. General ...................................................................................................... 1-1

1.1 Standard Specications ................................................................................... 1-1

1.2 Model and Sufx Codes ................................................................................... 1-4

1.3 External Dimensions ........................................................................................ 1-6

2. Installation ................................................................................................. 2-1

2.1 Installing the PH8SM3 Chemical Cleaning Unit for a Chemical Cleaning Sys-

tem ...................................................................................................................... 2-1

2.1.1 Where to install the unit ...................................................................... 2-1

2.1.2 Installation Facilities ........................................................................... 2-2

2.1.3 Installing Chemical Cleaning Unit ...................................................... 2-2

2.2 Installing the PH8HS3 Holder .......................................................................... 2-3

2.2.1 Where to install the holder ................................................................. 2-3

2.2.2 Installation Facilities ........................................................................... 2-3

2.2.3 Installing the PH8HS3 Holder ............................................................ 2-4

Toc-1

3. Piping and Wiring ..................................................................................... 3-1

3.1 Piping ................................................................................................................. 3-1

3.1.1 Line for Connecting Air Source .......................................................... 3-2

3.1.2 Line for Actuating Cylinder to Drive Sensor Pneumatically (Upward) 3-2

3.1.3 Line for Actuating Cylinder to Drive Sensor Pneumatically (Downward) 3-2

3.1.4 Line for Forced Feeding of Chemical Solution and Air-bubbling ....... 3-2

3.1.5 Line for Pressurizing KCl Reserve Tank ............................................ 3-2

3.2 Wiring ................................................................................................................. 3-3

3.2.1 Wiring for Intelligent Two-wire pH Transmitter System ......................3-4

3.2.2 Wiring system with 2-Wire Analyzer .................................................. 3-6

4. Operation ................................................................................................... 4-1

4.1 Names and Functions of Components ........................................................... 4-1

4.2 How the Chemical Cleaning pH Measuring System Works ......................... 4-3

4.2.1 Operating Modes ............................................................................... 4-3

4.2.2 WASH (Cleaning) Command .............................................................4-3

4.2.3 Wash Sequence .................................................................................4-4

4.3 Startup ................................................................................................................ 4-5

4.3.1 Inspection of Piping and Wiring ......................................................... 4-5

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1st Edition : Nov. 11, 2016-00

Toc-2

4.3.2 Supplying Chemical Solution to Holding Tank ................................... 4-5

4.3.3 Supplying KCl Solution to Reserve Tank ........................................... 4-6

4.3.4 Adjustment of Pneumatic Pressure ................................................... 4-6

4.3.5 Setting Duration of Forced Feeding of Chemical Solution and Output of

CYLINDER FAIL Signal ..................................................................... 4-7

4.3.6 Supplying Power ................................................................................ 4-7

4.3.7 Entering Data Related to WASH Operation .......................................4-7

4.3.8 Verifying WASH Operation ................................................................ 4-8

4.3.9 Calibration with Standard Solution .................................................... 4-8

4.4 Regular Operation ............................................................................................. 4-8

4.4.1 Data Acquisition in Early Stages of Operation ................................... 4-8

4.4.2 Inspections During Regular Operation .............................................. 4-9

4.4.3 Behaviour During Power Failure/Restart ........................................... 4-9

4.4.4 Operation When Shutting Down the System ..................................... 4-9

4.4.5 Procedure When Restarting System Operation .............................. 4-10

5. Inspection and Maintenance ................................................................... 5-1

5.1 Inspection and Maintenance of Operating Unit for PH8SM3 Chemical Cleaning

System ............................................................................................................... 5-1

5.1.1 Inspection of Piping (between chemical cleaning chamber and holder) 5-1

5.1.2 Inspection of Solenoid Valves ............................................................ 5-1

5.1.3 Replacement of Fuses in the Power Supply Box .............................. 5-2

5.2 Inspection and Maintenance of PH8HS3 Holder ........................................... 5-2

5.2.1 Removing Foreign Matter from Wetted Part of Sensor Holder ......... 5-2

5.2.2 Inspecting Gasket on the Bottom Plate of Cleaning Chamber .......... 5-2

5.2.3 Cleaning and Lubricating Pneumatic Cylinder for Driving the Sensor

Holder ................................................................................................. 5-3

5.2.4 Inspecting O-rings on Sensor Holder ................................................ 5-4

5.2.5 Inspecting Terminal Block for Limit Switch .........................................5-4

6. Troubleshooting ....................................................................................... 6-1

6.1 More Than 100 ml of Chemical Solution at a Time Is Being Fed to Holder 6-1

6.2 A Smaller Quantity of Chemical Solution Is Fed to Holder .......................... 6-2

6.3 CYLINDER FAIL Signal Appears .....................................................................6-2

6.4 When Liquid keeps leaking from bottom plate of Cleaning Chamber ........ 6-2

6.5 Chemical Solution Cannot Be Fed into Cleaning Chamber ......................... 6-3

Customer Maintenance Parts List (PH8SM3).................. CMPL 12B07W01-13E

Customer Maintenance Parts List (PH8HS3)....................CMPL 12B07W01-23E

Revision Record .......................................................................................................i

IM 12B07W01-04EN 1st Edition : Nov. 11, 2016-00

<1. General>

1. General

Chemical Cleaning pH Measuring System is designed to automatically clean pH electrodes with a chemical solution while they remain in the system. The system is especially effective in restoring the performance of a pH electrode which has been deteriorated through repeated pH measurements of highly alkaline solutions. It is also effective in cleaning pH electrodes contaminated with calcium sulfate (CaSO

1.1 Standard Specications

Chemical Cleaning pH Measuring System are congured as the table shown below.

pH/ORP Converter 2-wire Analyzer

Chemical Cleaning unit PH8SM3-E PH8SM3-G or PH8SM3-F

pH analyzer PH450G FLXA202 or FLXA21

Distributor ― PH201G pH sensor

Holder PH8HS3

Note You can select WTB10 Terminal Box, if necessary.

The following are specication describing on PH8SM3 Chemical Cleaning Unit and PH8HS3

Holder. For more information on other products, please read corresponding instruction manuals attached to each product.

) scale or calcium carbonate (CaCO3) scale.

Chemical Cleaning pH Measuring System

PH8EFP-□-TT2 (Note)

1-1

n PH8SM3 Chemical Cleaning Unit

Cleaning Method:

Automatic chemical cleaning by air bubbling

Interval Time:

0.1 to 36.0 hours (To be set in the pH converter)

Wash Time:

0.1 to 10 min (factory setting: 4 min)(To be set in the pH converter)

Relaxation Time:

0.1 to 10 min. (factory setting: 0.5 min.)(To be set in the pH converter)

Bubbling (SV1: On) Time:

0 to 10 min. (factory setting: Approx. 2 min.)

Cylinder Failure Time:

0 to 1 min. (factory setting: Approx. 0.5 min.)

Structure:

Freestanding rack for indoor installation.(For the uv protection,when you install the unit

outdoors, specify tank cover and select Fluoropolymer (PTFE) tube, or specify hood if necessary.

Main Components:

Chemical solution tank, control box, air-pressure regulator, and power supply unit (for pH/

ORP Converter only)

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<1. General>

Chemicals for Cleaning:

Acid solution (e.g., hydrochloric acid or diluted sulfuric acid), or alkali solution. Organic

solvents are not allowed.

Note: Select appropriate solution for effective cleaning.

Material, Finish, and Color of Main Components:

Control Box (K9729AN)

Material: Aluminum alloy casting Colors:

Deep sea moss green (Munsell 0.6GY3.1/2.0) and frosty white (Munsell 2.5Y8.4/1.2)

Finish: Baked polyurethane resin coating

Power Supply Unit (for pH/ORP converter only)

Material: Carbon steel (body) Color: Deep sea moss green (Munsell 0.6GY3.1/2.0 or equivalent) Finish: Baked polyurethane resin coating

Mounting Rack

Material: Carbon steel Color: Deep sea moss green (Munsell 0.6GY3.1/2.0) Finish: Baked polyurethane resin coating

Chemical Solution Tank (20 L, 2 to 10 % diluted hydrochloric acid or diluted sulfuric acid.

Effective capacity; approximately 17 L, approximately 100 ml is used for each cleaning) Material: Polyethylene resin (for solution tank), and hard PVC resin (for internal tank)

Tubing for Solution, Air, or KCl

Material of tubes: Polyethylene or Fluoropolymer (PTFE)

Mateirial of tting (joint): polypropylene resin or Fluoropolymer (PTFE)

Ambient Temperature: 0 to 45°C (Note ; Freezing protection is required if necessary.)

1-2

Power Supply: 100 V AC ±10%, 50/60Hz ±5%

Power Consumption: Approx. 60 VA

Air Supply: 300 to 950 kPa {3 to 9.5 kg/cm

}

Max. Air Consumption: Approx. 10 Nl/min.

External Dimensions:

500 (W) x 600 (D) x 1630 mm (H)

Weight: Approx. 50 kg (when the chemical tank is empty)

Output Contact Signal: Cylinder failure

Contact State: Normally open (close on error )

Contact Capacity: 24 V DC, 1 A, 110 V AC 0.3 A (resistance load)

Output:

pH/ORP Converter : 4 to 20 mA DC 2 points (isolated transmission output; maximum load of

600 Ω)

2-Wire Analyzer : 1 to 5 V DC (minimum resistive load of 2 kΩ)

Cable Connection: G 1/2 gland packing is supplied.

Terminal Size: M4

Outside Cable Diameter: Φ9 to Φ12 mm

Piping Connection: Air for Instrumentation: Rc 1/4 female thread

Note 1: Install the KCl reserve tank in an appropriate place at the job site or attached to the stand for the

chemical cleaning unit.

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<1. General>

1-3

Note 2: The wiring and piping between the chemical cleaning unit, sensor, KCl reserve tank, and holder are to

Note 3: The wiring between the switch in the holder and the chemical cleaning unit is to be done by the user.

be done by the user.

The terminal size is M4.

EMC Compliance: Korea Electromagnetic Conformity Standard Class A

A급 기기　(업무용 방송통신기자재) 　이 기기는 업무용(A급) 전자파적합기기로서 판매자 또는 사용자는 이 점을 주의하시기 바라며, 가정외의 지역에서 사용하는 것을 목적으로 합니다.

n PH8SM3 Holder

Functions:

Moves the pH sensor up or down using a pneumatic cylinder (air cylinder), and provides

chemical cleaning.

Structure: Constructed for indoor use (

Max. External Dimensions:

190 (W) x 170 (D) x Approx. 830 to 2030 mm (H) (when the sensor is raised)

Mounting:

Mounted on a 2-inch (50A) vertical pipe (outside diameter: 60.5 mm). Two mounting

brackets are supplied.

pH Sensor Up/Down Movement (nominal):

한국 전자파적합성 기준

For outdoor installation, select Cylinder cover /SC as Option.)

300 mm, 600 mm, 1000 mm, 1500 mm

Weight:

Approx. 8 kg (holder with 300 mm movement)

Approx. 10 kg (holder with 600 mm movement)

Approx. 12 kg (holder with 1000 mm movement)

Approx. 15 kg (holder with 1500 mm movement)

Materials

Frame: Baking nish over staineless steel

Color: Deep sea moss green (Munsell 0.6GY3.1/2.0 or equivalent)

Bottom Cover Pull-up Mechanism: Rod (PPS resin) and screws (PEEK)

Mounting bracket: staineless steel

Holder: Polypropylene and hard PVC (for part of a holder)

Solution Chamber: Hard PVC

O-ring: Fluororubber

Gasket: EPDM

Solution Temperature Range: -5 to 80°C

Ambient Temperature: 0 to 45°C

Flow Speed: 2 m/s or less

Provide an adequate ventilation when using chemicals.

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<1. General>

1.2 Model and Sufx Codes

The name plate on product describes each specication of the product. The following are Model and Sufx Code and their details on PH8SM3 and PH8HS3.

n PH8SM3 Chemical Cleaning Unit

●Model and Sufx Codes

Model Sufx code

PH8SM3 - - - - - - - - - - - - - - - - - - Operating Unit for Chemical Cleaning System

(*1)

-E

-F

-G

-TT2 - - - - - - - - Medium-pressure reserve tank *2

-NN

-PR

-NP

pH measuring system

KCl reserve tank

Pressure regulator for KCl tank

Air connection -JP

Tubing for cleaning chemicals

Style code *C - - - - - - - - Style C Option /H

*1: The pH/ORP converter or 2-wire analyzer is attached to the chemical cleaning operating unit when shipped.

*2: For PH8EFP sensor, select KCl reserve tank (sufx code “-TT2”) with a medium-pressure.

*3: Polyethylene is susceptible to degradation upon UV radiation. Specify the Fluoropolymer (PTFE) (-T10) as tube

material, when you install PH8SM3 outdoors. Specify the Fluoropolymer (PTFE) when using PH8HS3 holder outdoors, even though you install PH8SM3 unit indoors.

*4: Specied at the outdoor installation. Hood is made of precoated SEHC. *5: Specied at the outdoor installation. The cover is made of non-coated stainless steel. *6: For FLXA21 or FLXA202 with the sufx code -F, or -G, specify the type -AG (for general purpose for KC

-L10

-T10

Option code

- - - - - - - -

/TC /KC

Specications

pH/ORP converter (PH450G) 2-wire Analyzer(FLXA21) 2-wire Analyzer(FLXA202)

None Attached to the stand

Rc1/4 1/4 NPT female thread

Polyethylene (Connections: Polypropylene) Fluoropolymer (PTFE)

(Connections: Fluoropolymer (PTFE))

With hood *4 With tank cover *5

for Korean Certicate *6

1-4

CAUTION

The system must undergo start-up service when the chemical cleaning pH measuring system is installed.

l Accessories

Description Qt'y Remarks

6 (OD) x 4 (ID) polyethylene Fitting (polyethylene resin or Fluoropolymer (PTFE)) 6 3 for joint, 3 for spare parts *2

*1: 1 tube for the control box-the chemical tank assembly 3 tubes for the PH8SM3-Ph8HS3 1 tube for the pressure valve-KCI reserve tank, if the operating unit has the pressure reducing valve for KCI. Cut the tube into an approriate length to use.

*2: If the operating unit has a pressure-reducing valve that lowers the pressure on the KCl reserve tank, one of

these spare ttings is to be used for the piping port of the valve.

resin or Fluoropolymer (PTFE) tube

40 m

For tubing *1

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<1. General>

l Spare Parts

Description P/N Remarks

Fuse for power supply box

Polyethylene tubing Fluoropolymer (PTFE)

tubing

Polypropylene tting

Fluoropolymer (PTFE)

tting

A1109EF Rating: 1A (for pH/ORP converter only)

L9901CA L9901LG

L9831NA L9831NE L9831JE

L9831TS L9831TT

Specied length by meters Specied length by meters

L-shape tting (R1/8) L-shape tting (R1/4)f I-shape tting (R1/4)

L-shape tting (R1/8) L-shape tting (R1/4)

n PH8HS3 Holder

●Model and Sufx Codes

Model Sufx

PH8HS3 - - - - - - - - - - - - - Holder for Chemical Cleaning

Material -PP - - - - - Polypropylene

Movement -03

pH measuring system

Cleaning system -YP - - - - - Acid or alkali solutions can be used.

Style code *C - - - - - Style C Option /SC Cylinder cover for outdoor use *1

*1: For outdoor installation, select Cylinder cover /SC as Option.

code

-06

-10

-15

-C

-T

Option

code

- - - - -

Specications

300 mm (with 2 mounting brackets) 600 mm (with 2 mounting brackets) 1000 mm (with 2 mounting brackets) 1500 mm (with 2 mounting brackets)

pH/ORP Converter 2-wire Analyzer

1-5

l Accessories

(other than mounting brackets and sensor holder)

Description Qt'y Remarks

M8 x 16 mm bolts and nut Washers

U bolts (M8) Washers and nuts

Rubber sheet (19 x 40 mm) Plate Clamp M4, 16mm screw

Piping tting (polypropylene) 3 Parts for PH8SM3 holder (used for piping port) Cable tie 5 For KCl supply tube/sensor cable Spare gaskets (P/N: K9729WJ) 1 Parts for cleaning chamber of PH8HS3 holder

4/pkg

Parts for mounting brackets (used to mount to the

holder) Parts for mounting brackets

(used to mount to 2-inch pipe)

4/pkg

Parts for sensor holder (used to x sensor cable)

1 1 1

l Spare Parts

Description P/N

Gasket K9729WJ O-rings K9729YK

Qt'y

1 2

Remarks

Material : EPDM 1p/pkg. Replace both of the two rings at the same time.

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<1. General>

1.3 External Dimensions

n PH8SM3 Chemical Cleaning Unit

l pH/ORP Converter (PH8SM3-E)

）

Option

（

Hood

）

KCl reserve tank *1

an be installed

（

）

PH450G

Separated Order

（

1-6

unit：mm

Control Box

*2 Pressure Regulator

for KCI reserve tank

Tank Cover

Option

（

(AS3)

）

Power

Supply Unit

Air Inlet *3 (Rc1/4 or 1/4NPT)

Tank cover

fixing screws

option

（

）

PVC plate

30 440

500 600

4-Φ15fixing holes

l 2-Wire Analyzer (PH8SM3-G, -F)

KCI reserve tank *1

(Can be installed)

(Separated Order

FLXA21

Control Box

*2 Pressure Regulator AS3

for KCI reserve tank

（

Tank Cover

(Option)

fixing screws

）

Tank cover

(Option)

(1540)

(1200)

(30)

30 540

FLXA202

(Separated order)

Air Inlet *3

Rc1/4

（

or 1/4NPT

）

(1200)

Stand

SEHC

（

Chemical Solution

tank (20 L)

Hood(Option)

(1540)

SEHC

（

Chemical Solution

Tank (20 L)

）

Stand

1630

1600

Power Cable Inlet

Cable O.D. （Φ9 ～ 11）

(30)

unit：mm

1630

1600

）

PVC plate

30 440

(30)

30 540

(30)

500 600

4-Φ15Fixing holes

*1: Mount the KCl solution reserve tank when necessary after installation. If the hood is specied, (Option code /H is specied) mount the tank on the hood.

*2: This is a pressure valve to regulate the air that increases the pressure in the reserve tank for the KCl solution.

This valve is added only when specied. *3: If no pressure valve is specied, there is no tube tting. Air inlet connects directly to piping port of the control

box.

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<1. General>

n PH8HS3 Holder

1-7

Cylinder Cover

(Option)

(130)

(126)

35 pitch

Grommet for external wiring

55485 max.

（

Approx.150

Mounting bracket with U-bolts

50A Pipe

provided by customer

2-Φ9 holes

Sensor cable

and KCI tube

Approx.110

）

Cylinder

Movement

247

(65)

300

230

Unit: mm

136

(95)

nominal movement

(170)

During

measurement

30mm or longer

Solution being measured

During Cleaning

30379

During

measurement

pH electrode

Tubing Connections A : Chemical solution inlet (Ø6/Ø4 tube joint) B : Lower air inlet of cylinder (Ø6/Ø4 tube joint) C : Upper air inlet of cylinder (Ø6/Ø4 tube joint)

Nominal

movement

300mm 340mm 1107 712 395 – – –

600mm 640mm 1707 1012 695 300 – – 1000mm 1040mm 2507 1412 1095 300 300 – 1500mm 1540mm 3507 1912 1595 300 300 300

Specify the nominal movement when ordering. L4, L5, and L6 designate the movable position for the pipe mounting bracket.

Note: ● Mounting bracket for holder will be shipped separately.

● Joint nipple will be attached with PH8SM3 Chemical Cleaning unit.

● For the outdoor installation, select /SC option of cylinder cover

Actual

movement

L1 L2 L3 L4 L5 L6

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<2. Installation>

2. Installation

The chemical cleaning pH measuring system can be installed indoor/outdoors. Choose an appropriate location (free from dust, sunlight, rain) for easy maintenance. Note that since the system uses water for washing and a chemical solution, care must be taken to ensure that these liquids are protected from freezing in winter.

Note: Install the PH201G distributor, which is required when using the 2-Wire Analyzer, in an

indoor location such as an instrument room.

This chapter explains the procedure for installing the component equipment, highlighting the PH8SM3 Chemical Cleaning Unit for the chemical cleaning system and the PH8HS3 holder.

2.1 Installing the PH8SM3 Chemical Cleaning Unit for a Chemical Cleaning System

2.1.1 Where to install the unit

Install the PH8SM3 operating unit for a chemical cleaning system in a location which meets the following requirements.

(1) Close to the pH measurement point (location where the PH8HS3 holder is installed)

2-1

The operating unit for the chemical cleaning system and the holder are connected via

electrical wiring as well as the piping through which the chemical solution is supplied. Keep the length of the tubing for supplying the chemical solution to a minimum (less than 10 m) in order to reduce piping resistance.

(2) The maximum tube length between the cleaning unit and the sensor holder is 10 m.

It is preferable to install the stand at the same level as the sensor holder. If this is impossible,

the stand can be installed a maximum of 2 m below the holder level. Installation above the holder level causes no problem.

(3) Easy access for maintenance work

The location must allow users to have an easy view of the display on the PH450G pH/ORP

Converter or 2-wire Analyzer FLXA202/FLXA21, and to operate the control box with ease

to set the pressure. Also, consider the ease of work required when relling the holding tank

with the chemical solution. Furthermore, secure the clearance for maintenance access shown in Figure 2.1.

Unit: mm

PH8SM3

Approx. 1150

Front view

Approx. 500

More than 900

Figure 2.1 Clearance for Maintenance Access

Ｆ2.1.ai

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<2. Installation>

(4) Ambient temperature is always maintained in the range of 0 to 45˚C

Check if there is any possibility that the cleaning chemical solution can freeze in winter or

if the pH/ORP Converter (or 2-Wire Analyzer) or the control box are subject to abnormal temperature rises from direct sunlight. A location exposed to constant high humidity is not desirable either.

(5) Free from vibration

The location must be free from such vibrations that might loosen piping connections.

(6) Free from corrosive gases

It is desirable that the location be free from any corrosive gas which may adversely affect

the components within the pH/ORP converter (or 2-Wire Analyzer) or the control box.

2.1.2 Installation Facilities

The PH8SM3 operating unit for the chemical cleaning system has a stand-alone construction and can be securely attached with nuts to anchor bolts set in a concrete base.

l Construction of concrete base to install operating unit for chemical cleaning system

The PH8SM3 operating unit of the chemical cleaning system weighs approximately 60 kg when

the tank is lled with the chemical solution. Consequently, the facilities must be strong enough to

hold the weight of the entire unit. The facilities must also provide good drainage, Prepare anchor bolts with M10 threads to secure the unit. Figure 2.2 shows how to set these anchor bolts in the installation site.

2-2

Unit: mm

Dimensions of vat for operating unit of

M10 thread

Concrete base

Note: The holes (four) for the anchor bolts on the operating unit of the chemical cleaning system are 15 mm in diameter.

Figure 2.2 Setup of Anchor Bolts for Attaching Operating Unit of Chemical Cleaning System

chemical cleaning system

Approx. 60

540 600

Position of anchor bolt

Front view

440

500

F2.2.ai

2.1.3 Installing Chemical Cleaning Unit

After completing construction of the installation facilities, install the operating unit of the chemical cleaning system. Tighten the nut securely (with nuts in all four locations.).

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<2. Installation>

2.2 Installing the PH8HS3 Holder

2.2.1 Where to install the holder

The PH8HS3 holder must be installed in a location which is appropriate for pH measurement and

control and satises the following requirements.

(1) Safe and easy access for maintenance work.

This requirement must be satised since the holder is raised and removed when attaching/

detaching the pH sensor.

(2) Even in winter, the temperature must remain above that temperature at which the

chemical solution freezes.

Also, any condensation on the moving parts of the PH8HS3 holder cannot be allowed to

freeze.

(3) Protected from excessive dust in the air.

The presence of excessive dust may lead to an increased need to clean (removal of dust

from the cylinder).

2.2.2 Installation Facilities

The PH8HS3 holder is mounted on a 50A (OD: 60.5 mm) pipe installed in an upright position. Provide the installation location with facilities to set the pipes and inserting sensors Special attention must be paid to the following points when constructing these facilities:

2-3

l Position of pH measurement point (position of pH sensor) in relation to the

mounting pipe

Mounting pipe

pH sensor

Approx. 150

pH sensor

485 maximum

(Can be shorted in length of 205 mm by 35 mm pitch)

Figure 2.3 Position of pH Sensor in Relation to Mounting Pipe with Dimensions of Opening for

Inserting pH sensor

110 or more

160 or more

Machining of opening for inserting pH sensor (for tanks with a covering)

60 or more

l Height (length) of mounting pipe

Position of upper mounting bracket

(Pitch: 300 mm)

Position of lower mounting bracket

More than 310

Covering (machined to provide an opening)

Measured solution

Figure 2.4 Length (Height) of Mounting Pipe

P L

Ground

Mounting pipe (OD: 60.5 mm)

Note: When employing a covering to prevent the chemical solution from spattering, refer to the dimensions of the opening for inserting the pH sensor shown in Figure 2.3.

Nominal Stroke L P H 300 mm 400 minimum 300 500 to 590

600 mm 700 minimum 300x2 500 to 890 1000 mm 1000 minimum 300x3 500 to 1290 1500 mm 1000 minimum 300x4 500 to 1790

Unit: mm

Ｆ2.3.ai

Unit: mm

F2.4.ai

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<2. Installation>

2.2.3 Installing the PH8HS3 Holder

Follow the procedure below to mount the PH8HS3 holder onto the pipe.

(1) Attach the mounting brackets (two pairs) to the holder by adjusting the position of the pH

sensor to satisfy the required distance to the pipe. To attach brackets, use the bolts (two each), washers (four each) and nuts (two each) that with the holder.

(2) Assemble the U bolts, washers and nuts into the brackets (see Figure 2.5).

Nut

(Pipe)

U bolt

Figure 2.5 Parts for Mounting Bracket (Included)

Washer

Mounting bracket

Washer

Nut

Bolt (M8)

Washer

Chassis

F2.5.ai

2-4

(3) Assemble the PH8EFP pH sensor onto the sensor holder.

a. First remove the rubber cap on the top end of the sensor holder. Then thread the cable of

the pH sensor and the KCI supply tube from the bottom end of the sensor holder and then pull them out from the top end.

b. Insert the pH sensor into the sensor holder so the sensor ange contacts the bottom end of

the sensor holder.

Note: Two O-rings are used to seal the openings of the sensor holder to prevent the

measured solution from leaking into the holder.

c. Using the supplied parts (plate, clamp, screw and rubber sheet), attach the given latch

mechanism to the sensor cable to prevent the sensor and sensor holder from coming apart (see Figure 2.6).

KCl supply tube

Plate

Note:

·Fasten only the sensor cable with the clamp.

·Make sure that there is no slack in the sensor cable inside the sensor holder.

Sensor cable

Rubber sheet (19 x 40 mm) [P/N K9729WE]

Attach the rubber sheet around the sensor cable with the 40 mm length parallel with the cable.

Clamp

Screw

Sensor holder

Figure 2.6 Treatment to Prevent the pH Sensor from Coming Apart

d. Replace the rubber cap on the sensor holder.

e. Using the cable tie (included), securely fasten the sensor cable and the KCl supply tube to

the sensor holder. ( Figure 2.7)

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<2. Installation>

Rubber cap

Sensor holder

Cable tie

Pass the cable tie through the opening of the metal fitting and then fasten the sensor cable and, the KCI supply tube together.

KCl supply tube

Figure 2.7 Fixing the Sensor Cable and KCI Supply Tube

Metal fitting

Sensor cable

F2.7.ai

(4) Fix the PH8HS3 holder to the pipe

CAUTION

When installing the holder, avoid any contamination or moist/wet on the tip of the sensor cable.

2-5

When xing the holder, make sure both of the following requirements are completely satised:

• During measurement, the tip of the pH sensor must be submerged in the measured

solution.

Carefully observe any changes in the liquid level.

• The bottom plate of the holder’s cleaning chamber must not become wet with the

measured solution.

Contamination of the gasket on the bottom plate by the solution will lead to a decrease in the

gasket’s sealing capability.

CAUTION

When the bottom plate of the holder’s cleaning chamber is open, good ventilation must attend its use

to prevent the holder from corrosive gas.

Figure 2.8 illustrates the PH8HS3 holder when it is installed.

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<2. Installation>

Install the holder so the tip of the pH sensor drops into the measured solution to a depth of 30 to 90 mm.

2-6

Do not allow the bottom plate of the cleaning chamber to become submerged in the measured solution.

Measured solution

Figure 2.8 Installed PHSHS3 Holder

Tank

Measured solution

F2.8.ai

l Installing the medium-pressure KCl reserve tank

The KCl reserve tank supplied with the PH8EFP KCl-lling type pH sensor can be installed in the

operating unit for the chemical cleaning system (see Figure 1.1).

Note: Use an appropriate length of KCI supply tube for PH8EFP KCI supply PH sensor.

If installing the KCl reserve tank in other locations, choose a location which is higher than where the cleaning chamber of the PH8HS3 holder is positioned.

Note This is important to maintain the normal position of liquid junction even when the supply of the pressurizing

air stops.

After completing installation of the KCl reserve tank, connect the KCl supply tube of the pH

sensor to the outlet of the KCI reserve tank.

l Submersion of pH sensor when the measured solution ows fast.

Rapid and continuous ow of measured solution can give the sensor holder distortion, which

hampers the ascent/descent motion of the holder, therefore the result of the measurement may be affected. Appropriate installation must be guaranteed without distortion of the sensor holder.

If the ow of measured solution gives the sensor holder distortion, install the holder so the tip of

the pH sensor drops in to the solution to a depth of 30 to 90 mm. If this method is not available,

reduce the ow speed so that the distortion never occurs. For the stability of the measurement result as well, the ow speed must be 2 m/sec or less at a measuring point.

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<3. Piping and Wiring>

3. Piping and Wiring

3.1 Piping

The following lines must be provided to the chemical cleaning pH measuring system.

Lines (2) through (4) are polyethylene resin tubing or joints supplied with the system. Always make sure that the length of each line is kept to a minimum (less than 10 m).

(1) Line for connecting air source (2) Line for actuating cylinder to drive sensor pneumatically (upward) (3) Line for actuating cylinder to drive sensor pneumatically (downward) (4) Line for forced feeding of chemical solution and air-bubbling (5) Line for pressurizing KCl reserve tank

Note: If you specify, polyethylene tube or Fluoropolymer (PTFE) tube of 40 m in length come with PH8SM3

with their corresponding tting.

If you do not use the piping materials that came with your system, refer to the notes given in

Subsection 5.1.1. Figure 3.1 shows the pipe lines in the system.

PH8SM3 Operating unit for chemical cleaning system

3-1

AS3

Internal tank

PG3

AS2

AS1

Air

Control box

PG2

PG1

SV1

B C D E

F G

Chemical solution Tank (20 l)

SV2

Purge

(purge air outlet)

KCl tank (medium pressure) (The KCl tank of the pH sensor is used)

Dedicated tube

Process liquid bath

PH8HS3 Holder

pH sensor

Pressure reduction valve

AS1:

for forced feeding of chemical solution Pressure reduction valve

AS2:

foe actuating cylinder

AS3:

Pressure reduction valve (optional) for pressurizing the KCl tank

PG1: PG2: PG3:

SV1:

SV2:

Figure 3.1 Piping Diagram

Pressure gauge Pressure gauge Pressure gauge (optional)

2-way solenoid valve (N, C)

4-way solenoid valve

Air source connection

Rc1/4 or 1/4NPT Pneumatic line

B - F:

for forced feeding of chemical solution Pneumatic line raise

C - J:

the sensor holder Pneumatic line to lower

D - K:

the sensor holder

Line for forced feeding

G - H:

of chemical solution

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<3. Piping and Wiring>

3.1.1 Line for Connecting Air Source

Air with a pressure of 300 to 950 kPa (3 to 9.5 kg/cm2) is supplied to the operating unit of the chemical cleaning system. Use a steel or stainless steel line with an inner diameter greater than 6 mm to connect the air source to piping port “A” (air) in the control box.

Note : The piping port is Rc1/4 thread or 1/4 NPT female-thread (as specied when ordering).

The maximum air consumption is approximately 10 normal litter/min.

3.1.2 Line for Actuating Cylinder to Drive Sensor

Pneumatically (Upward)

This line is provided to allow the pH sensor to be withdrawn from the measured solution during cleaning and then housed in the cleaning chamber. This line connects the holder (the piping port labelled “J”) with the control box (piping port “C” [the lower section of the cylinder] ). Use the tubing supplied with the system when connecting these ports.

3.1.3 Line for Actuating Cylinder to Drive Sensor

Pneumatically (Downward)

This line is provided to allow the pH sensor once housed in the cleaning chamber to be returned to a measurement position after cleaning. This line connects the holder (the piping port labelled “K”) with the control box (piping port “D” [the upper section of the cylinder]), Follow the same piping procedure as that discussed in Subsection 3.1.2.

3-2

3.1.4 Line for Forced Feeding of Chemical Solution and Air-

bubbling

This line is provided to supply air for forced feeding of approximately 100 ml of the chemical solution into the cleaning chamber during cleaning and then to bubble the chemical solution in the chamber. During piping, connect the control box (piping port “B” [forced feeding of chemical solution]) with the metering tank (piping port “F” [IN]) built in the holding tank for the chemical solution, Also, connect the metering tank (piping port “G” [OUT]) with the holder (piping port “H”). If the holding tank is positioned above the holder, always connect the tubing so at least a part of the tubing is positioned above the cleaning chamber. Failure to observe this instruction may

result in the chemical solution fed to the cleaning chamber owing back into the holding tank after

air bubbling.

Follow the same piping procedure as that discussed in Subsection 3.1.2.

3.1.5 Line for Pressurizing KCl Reserve Tank

An air pressure of approximately 10 kPa (0.1 kg/cm2) is applied to the KCI reserve tank for the pH sensor. Connect the outlet of the pressure reduction valve with the pneumatic connection

port of the KCI reserve tank. If so specied, the operating unit of the chemical cleaning system is

supplied with an “AS3” pressure reduction valve along with a polyethylene tube (10 m long) for piping

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<3. Piping and Wiring>

3.2 Wiring

The following six electrical connections must be provided to the chemical cleaning pH measuring system. Note that slightly different wiring procedures are used depending on the system

conguration, either the intelligent two-wire pH transmitter system or the intelligent four-wire pH

converter system.

(1) Connection for pH sensor cable

Connect the pH sensor cable assembled in the PH8HS3 holder with the terminals of the

PH450G pH/ORP converter or 2-wire analyzers’ (FLXA202/FLXA212) terminals.

NOTE

The standard pH sensor cable is 3 m or 20 m long. If the PH8HS3 holder is located away from the PH8SM3 operating unit at a distance greater than either of these lengths, it may become necessary for you to use the PH8TBG/WTB10 terminal box through which this connection is made.

(2) Connection for DETECT UPPER LIMIT signal (signal for detecting the upper limit of the

sensor holder’s position)

Connect the terminals of the PH8HS3 holder with the terminals of the control box in the PH8SM3 operating unit.

3-3

(3) Connection for power supply and ground

For the intelligent four-wire pH converter system, set up power-supply connections with the power supply box in the PH8SM3 operating unit. For the two-wire pH transmitter system, set up power-supply connections with the terminals of the control box in the PH8SM3 operating unit, Supply power to the PH201G distributor.

Note: The methods of power-supply connection (either a plug or terminal connection) differ

depending on the specications of the PH201G distributor. For further details, see the IM19B01E04-02E user’s manual.

(4) Connection for pH signal

For the intelligent four-wire pH converter system, set up wiring for signal output on the PH450G pH/ORP converter. For the two-wire pH transmitter system, set up connection (for a transmission signal) between the PH202G intelligent pH transmitter and the PH201G distributor, with the wiring for an output signal provided to the PH201G distributor.

(5) Connection for contact output of CYLINDER FAIL signal

Set up this connection with the control box in the PH8HS3 operating unit.

(6) Connection for contact input of WASH (cleaning) signal

This connection is essential for the two-wire pH transmitter system. Set up the connection between the control box and the PH201G distributor.

Note: For the four-wire pH converter system, connect the control box with the PH450G pH /

ORP converter (this connection is already made before shipment).

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<3. Piping and Wiring>

3.2.1 pH/ORP Converter System

Figure 3.2 illustrates electrical connections for pH/ORP converter system.

PH450G

Output signal

(4 to 20 mA DC, HART)

Output signal

(4 to 20 mA DC)

Remote

Contact input

Air Cylinder

21 22

Jumper

mA1

mA2

CONTACT

IMP.LOW

13 11 12 14 15 16

POWER

S4 (Failsafe)

1 2

3-4

pH Holder

1 2

pH Sensor

Position signal

PH8SM3 Control Box

Ground to earth

Cleaning signal

A1 A2

Power

supply unit

Cylinder failure signal

wiring by customer 100V AC

Figure 3.2 Wiring for pH/ORP Converter (PH8SM3-E)

(1) Connection for pH sensor cable

Connect the sensor cable so that the code on each core wire matches the corresponding

code on the PH450G pH/ORP Converter. For more information about sensor cable

connection, see the user’s manual “PH450G pH/ORP Converter.” Also refer to “WTB10 Relay Terminal Box” user’s manual if your system uses a relay terminal box.

CAUTION

The sensor cable and the KCI supply tube move up and down in synchronization with the sensor holder along the PH8HS3 holder. No slack in cable or tube is allowed. Provide an installation location to ensure that a smooth up-and-down motion takes place. The cable or tube may be damaged if, during the up-and-down motion, it comes into accidental contact with the PH8HS3 holder or other structures.

(2) Connection for DETECT UPPER LIMIT signal (signal for detecting the upper limit of

sensor holder’s position)

Use a two-core cable with an outer diameter of 9 to 12 mm for this connection. Treat both

ends of each cable core so they t M4 threads. Connect terminal 1 of the terminal block for

the limit switch of the PH8HS3 holder to terminal 8 of the control box, and terminal 2 with terminal 9.

Note: There will not be a problem if you connect terminal 1 with terminal 9 and terminal 2 with

terminal 8.

The cable inlet of the PH8HS3 holder is located on the right-hand side of the chassis’s upper

section. When wiring the cable, loosen the two screws and remove the cover (for protection against drips). After the completion of wiring, always make sure the cover is reinstalled in place.

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<3. Piping and Wiring>

(3) Connection for power supply and ground

A power supply voltage of 100 V AC ±10%, 50/60 Hz is applied to the power supply unit of

the chemical cleaning pH measuring system.

CAUTION

Chemical Cleaning pH Measuring System has no power switch. To avoid the possible hazard of electrical shock or damage to the instrument, always install a power switch (double-pole) in the power line.

NOTE

The fuse (1 A) in the power supply unit is installed for the pH/ORP converter. (The pH/ORP converter itself contains an additional power-line fuse (0.1 A)).

Use a two-core cable with an outer diameter of 9 to 12 mm for this connection. Treat both

ends of each core wire of the cable extending from the power supply so they t M-4 thread

and then connect them with terminals L1 and L2 of power supply unit.

3-5

The control box and pH/ORP Converter of the system must be grounded with a grounding

resistance of less than 100Ω). The grounding terminal of the control box can be found in the

bottom of the control box casing. The grounding terminal of the pH/ORP Converter can be found in the bottom of the control box casing.

(4) Connection for contact output of CYLINDER FAIL signal

PH8SM3 Chemical Cleaning System outputs a CYLINDER FAIL contact signal. This

contact signal is output to let the operator know that a failure has occurred in the upward movement of the pneumatic cylinder of the PH8HS3 holder. The system uses the DETECT

UPPER LIMIT signal (the signal for detecting the upper limit of the sensor holder’s position)

discussed in step 2 above for this purpose.

The CYLINDER FAIL contact signal is given if the DETECT UPPER LIMIT signal is not

present even if the setting for timer T1 in the control box is reached. This connection is applied when the above function is used. Use a two-core cable with an outer diameter of 9

to 12 mm for this connection. Treat both ends of each core wire of the cable so they t M4

threads and then connect terminals 6 and 7 of the control box with the instrument being used, such as an annunciator. For the contact capacity and other details, see subsection

1.1.

(5) Connection for pH signal

PH450G pH/ORP Converter sends two 4 to 20 mA signal (pH, temperature) and receives

the contact input for cleaning start. Use a two-core cable with a nished outer diameter

of 9 to 12 mm for this connection. For the output signal from pH/ORP Converter, connect the terminals “mA1 +” or “mA1 -” to those corresponding terminals at the receiving instrument. For the second output signal, connect the terminals “mA2 +” or “mA2 -” to those corresponding terminals at the receiving instrument.The terminal CONTACT on a pH/ORP Converter is for connection of remote contact input. For cable shield, connect a cable to the terminal SHLD.

CAUTION

Connect the cable shield to the grounding at pH/ORP converter.

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<3. Piping and Wiring>

(6) Connection for contact input of WASH (cleaning) signal

It is already been wired.

3.2.2 Wiring system with 2-Wire Analyzer

Figure 3.3 illustrates wiring the system with 2-Wire Analyzer.

3-6

PH201G

Distributor

A(+)

(+)C

(

-)D

Output signal (1-5V DC)

100V AC

pH Holder

1 2

pH sensor

Air Cylinder

Position signal

FLXA202 or FLXA21

PH8SM3 Control box

Cleaning Signal

Cylinder failure signal

Wiring by customer 100V AC

Figure 3.3 wiring for 2-Wire Analyzer (PH8SM3-G, -F)

(1) Connection for pH sensor cable

Connect the sensor cable so that the code on each core wire matches the corresponding

code on 2-Wire Analyzer; FLXA202 or FLXA21. For more information about sensor cable connection, see the user’s manual on “FLXA 202/FLXA21 ” Also refer to “WTB10 Relay Terminal Box” user’s manual if your system uses a relay terminal box.

CAUTION

The sensor cable and the KCI supply tube move up and down in synchronization with the sensor holder along the PH8HS3 holder. Give adequate consideration to any slack in the cable or tube and to the installation location to ensure that a smooth up-and-down motion takes place. The cable or tube may be damaged if, during the up-and-down motion, it comes into accidental contact with the PH8HS3 holder or other structures.

(2) Connection for DETECT UPPER LIMIT signal

Use a two-core cable with an outer diameter of 9 to 12 mm for this connection. Treat both

ends of each core wire of the cable so they t M4 threads and then connect terminal 1 of the

terminal block for the limit switch of the PH8HS3 holder with terminal 8 of the control box, terminal 2 with terminal 9.

Note: There will not be a problem if you connect terminal 1 with terminal 9 and terminal 2 with

terminal 8.

The cable inlet of the PH8HS3 holder is located on the right-hand side of the chassis’s upper

section. When wiring the cable, loosen the two screws and remove the cover (for protection against drips). After the completion of wiring, always make sure the cover is reinstalled in place.

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<3. Piping and Wiring>

(3) Connection for power supply and ground

A power supply voltage of 100V AC ±10%, 50/60 Hz is box of the PH8HS3 operating unit of

the chemical cleaning system.

CAUTION

The chemical cleaning pH measuring system has no power switch. To avoid the possible hazard of electrical shock or damage to the instrument, always install a power switch (double-pole) in the power line.

Use a two-core cable with an outer diameter of 9 to 12 mm for this connection. Treat both

ends of each core wire of the cable extending from the power supply so they t M4 thread

and then connect them with terminal1 and 2 on the control box. For information on the

distributor power supply, refer to the user’s manual “PH201G Distributor”.

Note Power voltage or connection varies depending on the specication of distributors.

The control box and pH transmitter of the chemical cleaning pH measuring system must

be grounded with a grounding resistance of less than 100Ω. The grounding terminal of

the control box can be found in the bottom of the control box casing. As for the grounding terminal of the 2-Wire Analyzer, refer to the corresponding instruction manual.

3-7

(4) Connection for contact output of CYLINDER FAIL signal

The chemical cleaning system outputs the CYLINDER FAIL contact signal. The contact

signal is output to let the operator know that a failure has occurred in the upward movement of the pneumatic cylinder of the PH8HS3 holder. The system uses the DETECT UPPER LIMIT signal discussed in step 2 above for this purpose.

The CYLINDER FAIL contact signal is given when DETECT UPPER LIMIT is not signaled

even if the setting for timer T1 in the control box is reached. This connection is applied when the above function is used. Follow the same procedure as for the two-wire pH

transmitter system. Use a two-core cable with a nished outer diameter of 9 to 12 mm for this connection. Treat both ends of each core wire of the cable so they t M4 threads and

then connect terminals 6 and 7 of the control box with the instrument being used, such as an annunciator.

Note: For the contact capacity and other details, see Subsection 1.1.

(5) Connection for pH signal

To PH201G distributor, 2-Wire Analyzer FLXA202 or FLXA21 sends a 4 to 20 mA output

signal and 2 mAp-p <WASH> signal which is superimposed on the 4 to 20 mA DC signal.

The distributor outputs 1 to 5 V DC signal. Use a double-core shielded cable with a nished

outer diameter of 9 to 12 mm for this connection. For wiring between 2-Wire Analyzer and the distributor, connect + terminal of 2-Wire Analyzer to terminal A of the distributor, and connect a minus terminal to terminal B. Shiled of cables must be connected to the ground terminal G of the 2-Wire Analyzer.

Connect output cables to each corresponding terminal on the distributor or receptor, such as

terminal C, or D. Shield of cables must be grounded on each receptor side.

(6) Connection for contact input of WASH (cleaning) signal

Use a double-core shielded cable with a nished outer diameter of 9 to 12 mm for this

connection. Treat both ends of each core wire of the cable so they t M4 threads and then

connect terminals 4 and 5 of the control box with the distributor terminal e and terminal f.

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4. Operation

This chapter gives an overview of the functions and operations of the components the system along with their names and explains the start-up procedure required implement optimum cleaning

4.1 Names and Functions of Components

n PH8SM3 Chemical Cleaning Unit

(Reserver tank for KCl solution)

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(pH/ORP converter) (2-Wire Analyzer)

Pressure reduction valve AS3

Sets the pressure of the air that pressurizes the KCl reserve tank. (Supplied when specified accordingly.)

Power supply box

(Supplied with the pH/ORP converter system for outdoor use.)

Holding tank for chemical solution

A tank (with an effective capacity of approximately 17 liters) to contain a chemical cleaning solution.

Awning hood

Protects against an abnormal temperature rise in the pH converter (or the pH transmitter) or the control box due to direct sunlight (Supplied when specified accordingly.)

Control box

Controls the operation sequence of the chemical cleaning pH measuring system.

Tank cover

Optional for outdoor use, to protect against UV rays.

Pressure gauge (PG1)

Indicates the air pressure for forced feeding of the chemical solution.

Pressure reduction valve (AS1)

Sets the air pressure for forced feeding of the chemical solution.

Timer (T2)

Sets the time required to air-bubble the chemical solution within the cleaning chamber during cleaning.

Control Box

Pressure gauge (PG2)

Indicates the air pressure for actuating the pneumatic cylinder.

Pressure reduction valve (AS2)

Sets the air pressure for actuating the pneumatic cylinder.

Manuel cleaning commend switch

When turned on, this switch initiates the cleaning sequence; when turned off, it shuts down the sequence.

Figure 4.1 Names and Functions of Components in PH8SM3 Chemical Cleaning System

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n PH8SM3 Holder

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Terminal block for limit switch

Limit switch

Senses that the upper limit of the sensor holder's position is reached.

Spring

helps the bottom plate of cleaning chamber to tightly close during cleaning.

Drip-proof cover protects against rain or dust.

Cable inlet

Allows the cable (for the signal which detects the upper limit of the sensor holder's position) to get through to the terminal block for the limit switch.

Optional pneumatic cylinder cover, to protect against dust.

Arm to support sensor holder

The sensor holder is installed by simply inserting it into this arm.

Air connection part for actuating pneumatic cylinder (downward)

Mounting bracket

Used to mount the PH8HS3 holder to a two-inch pipe.

Pneumatic cylinder

Slider of pneumatic cylinder

Goes up or down pneumatically.

Air connection part for actuating pneumatic cylinder (upward)

Bottom plate of cleaning chamber

Closes during cleaning to hold the chemical solution supplied from the tank within the cleaning chamber.

Cleaning chamber

Accommodates the pH sensor during cleaning and allows the sensor electrodes to be cleaned.

(pH sensor)

Piping port for forced feeding of chemical solution

Sensor holder

Holds the pH sensor.

The sensor holder goes up or down along with the slider of the pneumatic cylinder.

O-ring

Protects the holder from precipitation of solutions

Figure 4.2 Names and Functions of Components in PH8HS3 Holder

(Note) When you remove the sensor holder out of the unit during calibration or for some reasons, take off the cover on the upper chassis. However, put the cover back to where it was to maintain the isolation of limit switch terminals and prevent operation errors.

l How the slider of air cylinder moves

The slider of air cylinder moves up and down by the strength of magnet inside the pneumatic cylinder. Stain or dust around the air cylinder hampers a smooth sliding of the cylinder. We highly recommend the installation of cylinder be guaranteed in a clean environment.

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4.2 How the Chemical Cleaning pH Measuring System Works

4.2.1 Operating Modes

There are two operating modes in the chemical cleaning pH measuring system: the measurement mode and cleaning mode.

l Measurement mode

The system performs pH measurement. The sensor holder is in its lowest position, submerging the pH electrodes in the chemical solution.

l WASH (Cleaning)mode

The sensor holder begins rising from its lowest position by way of the wash command, performs cleaning of the pH electrodes and then goes into the measurement mode again. The cleaning mode includes the relaxation interval required after the washing sequence. In the wash mode, it is possible to hold the output signal as a certain value, such as the last value before the WASH mode starts.

4.2.2 WASH (Cleaning) Command

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WASH command in normal operation is issued from the pH/ORP converter or the 2-Wire analyzers at the intervals set in these instruments. For the pH measuring system for outdoor use, the WASH command can be issued on demand using a remote contact input. A WASH command sent from the pH/ORP converter or 2-wire analyzers consists of two time elements, i.e., the washing time and the relaxation interval.

Chemical cleaning can also be implemented using the MANUAL Wash (cleaning) switch in the control box. Turning on this switch causes the chemical cleaning pH measuring system to enter

the wash mode; turning off causes the system to exit from the wash sequence. Note that, when

washing is carried out using the MANUAL WASH switch, neither the pH/ORP converter nor the 2-Wire analyzer performs the functions (such as a holding of the output signal) available in the wash mode.

If there is a conict between a WASH command sent from the pH/ORP converter or 2-wire

analyzer and the same command issued with the MANUAL WASH switch in the control box, the sensor holder behaves according to the timing diagram shown in Figure 4.3.

pH/ORP Converter or 2-Wire Analyzer

WASH signal (automatic cleaning)

MANUAL WASH switch on

Sensor holder

Highest position

Lowest position

Power on

Washing time

Interval between wash

Relaxation interval

Interval between wash

Holding of pH output signal

(WASH mode)

Note: The interval between wash, washing cycle(time) and relaxation interval are set on the pH/ORP Converter or 2-Wire Analyzer. Hold of the pH output signal is implemented only in the washing sequence (WASH mode) initiated by a command issued from the pH/ORP converter or 2-Wire Analyzer. Hold can be off, too. Forced air feeding / Air bubbling of chemical solution continues for a determined length of time ( set in Timer T2) only after the sensor holder moves from Lowest position to Highest position.

Figure 4.3 Behaviour of the Sensor Holder If There Is a Conict Between the Automatic-

WASH Command and Manual-WASH Command

Air for forced feeding of chemical solution

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4.2.3 Wash Sequence

Figure 4.4 shows the actions that the system implements to clean the electrodes when it receives a WASH (cleaning) command from either PH450G or FLXA202/FLXA21.

Holding of pH output signal

WASH

Chemical cleaning system

SV2 solenoid valve for actuating cylinder

Sensor holder

Bottom plate of cleaning chamber

DETECT UPPER LIMIT signal

CYLINDER FAIL signal

SV1 solenoid valve for forced feeding of chemical solution and air bubbling

pH meter

Highest position

Lowest position

Closes

Opens

(Measurement mode) (Measurement mode)

Contact signal for WASH

Air is injected to raise the cylinder

t1≥

t1<

(WASH mode)

WASH

When can not reach the highest position.

Open (air is fed to the metering tank.)

Relaxation

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t1: Setting of timer T1 t2: Setting of timer T2

Figure 4.4 WASH Sequence

l Output of WASH (cleaning) signal

When the setting the interval between WASH (in pH/ORP Converter or 2-Wire Analyzer ) times out, the system enters the WASH sequence. The WASH signal is then output to the control box of the operating unit in the chemical cleaning system for the period equivalent to the value set in the timer.

l Actuation of SV2 solenoid valve

The SV2 solenoid valve in the control box is active while it is receiving the WASH signal. This causes a pneumatic pressure to be applied to the port that raises the cylinder on the PH8HS3 holder. Consequently, the sensor holder goes up in conjunction with the cylinder slider.

l Output of DETECT UPPER LIMIT signal and CYLINDER FAIL signal

When the sensor holder reaches the upper limit, the bottom plate of the cleaning chamber closes and the limit switch is turned on. The ON signal from the limit switch then starts timer T2 in the control box, causing solenoid valve SV1 to be actuated (the valve is opened). Solenoid valve SV1, when opened, causes a pneumatic pressure to be applied to the interior of the metering tank, resulting in an approximately 100 ml of the chemical solution being forced into the cleaning chamber of the holder. The air is kept supplied until timer T2 times out, bubbling the chemical solution within the cleaning chamber to enhance the cleaning of the pH sensor electrodes.

Note that if the sensor holder does not reach the upper limit when timer T1, which starts at the same time the WASH signal is output, is timed out, the CYLINDER FAIL signal is given. This signal stops (the contact opens) when the WASH contact signal is no longer present.

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l End of WASH sequence

When the WASH time elapses, the WASH contact signal stops. The air circuit for solenoid valve SV2 switches to apply a pneumatic pressure to the port that lowers the cylinder. The sensor holder goes down and the bottom plate of the cleaning chamber opens, causing the chemical solution within the cleaning chamber to drain out. The pH/ORP Converter (or 2-Wire Analyzer) then enters a relaxation interval after the WASH time has elapsed. The pH/ORP Converter or 2-Wire ajayzer still holds the output signal during that period (if HOLD OUTPUT SIGNAL is selected). The display indicates *WASH (blinking) meaning that the system is in the WASH sequence.

The sensor holder is in the lowest position, allowing the electrodes of the pH sensor to be submerged in the chemical solution and waiting for the relaxation interval to elapse so the system enters the measurement mode.

4.3 Startup

The following procedures must be observed before the chemical cleaning pH measuring system is put into regular operation.

4.3.1 Inspection of Piping and Wiring

Verify that all of the lines and cables are connected correctly (refer to Section 3, “Piping and Wiring.” Also make sure that there is no slack in piping couplings and that terminal covers in the control box are in place.

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4.3.2 Supplying Chemical Solution to Holding Tank

The system uses a chemical solution, such as a 2 to 10 % solution of diluted hydrochloric acid or diluted sulfuric acid, that can remove contaminants adhering to the pH sensor. The holding tank for the solution has an effective capacity of approximately 17 litters. Fill the tank with this amount of solution. When preparing a solution using concentrated hydrochloric acid (e.g., commercially available hydrochloric acid with a concentration of 37 %) or concentrated sulfuric acid (e.g., commercially available sulfuric acid with a concentration of 96 %), prepare the solution in a separate container and then transfer it to the tank.

WARNING

Hydrochloric and sulfuric acids are physically hazardous to the human body. In addition, these acids can corrode metallic parts if the acids come into contact with equipment. When using either of these acids in high concentrations to prepare a chemical solution, exercise the utmost care to avoid possible hazards. Follow proper handling procedures when diluting these acids.

When lling the holding tank with the chemical solution remove the metering tank.

After lling the tank, replace the metering tank.

l How the metering tank works

A certain volume (100 ml) of a chemical solution is measured by using the difference in height between two tubes: pressurized tube F and force-feeding tube G. A solution is introduced from the holding tank (TK) to the metering tank through the check valve (seat) at the bottom of the metering tank. The air in the tank is vented to the atmosphere through the air vent (bleed) on the top of tube F until the solution level reaches the bottom of tube F. When the instrument enters the WASH mode, force-feeding air pressure is added to tube F, the check valve closes, and the volume for one wash is approximately 100 ml, which is metered based on the difference in height

between the two tubes’ bottoms in the metering tank.

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Cap

Bleed

O-ring

Level of chemical solution in holding tank

Pressurized Tube (F)

Force-feeding Tube (G)

Level of solution in metering tank (Volume: approx. 100 ml)

Bottom

Gasket

Check Valve

(Seat)

4-6

Gasket

Figure 4.5 Metering Tank for constant quantity of chemical solution

Check Valve (Seat)

Chemical Solution Inlet

4.3.3 Supplying KCl Solution to Reserve Tank

Fill the KCl reserve tank for the pH sensor with a KCl solution. After lling the tank, follow the necessary procedures, such as removal of air from inside the sensor unit. Refer to user’s

manual, “PH8EFP KCl Filling type pH Sensor” to do the necessary work.

4.3.4 Adjustment of Pneumatic Pressure

(1) Rotate the knobs on the pressure reduction valves (two) in the control box fully counter

clockwise. Pull the red ring around the knob toward you to turn the knob. If the operating unit is equipped with an AS3 pressure reduction valve, also rotate the knob on this valve fully counter clockwise.

(2) Supply air (pressure: 300 to 950 kPa {3 to 9.5 kg/cm

valve located in the line for connecting the air source.

(3) Adjust the pressure of the air for forced feeding of the chemical solution (the air is also used

to purge the interior of the control box). Slowly rotate the knob on pressure reduction valve AS1 clockwise until pressure gauge PG1 in the control box indicates a reading of 20 to 50 kPa {0.2 to 0.5 kg/cm

}) to the control box. Open the stop

F4.5.ai

(4) Adjust the pressure of the air for actuating the cylinder. Slowly rotate the knob on pressure

reduction valve AS2 clockwise until pressure gauge PG2 in the control box indicates a reading of 300 kPa {3 kg/cm

}. A pneumatic pressure is then applied to the “Down” port of the cylinder in the PH8HS3 holder and forces the sensor holder to move down to the lower end together with the cylinder slider.

(5) Apply a pneumatic pressure of approximately 10 kPa {0.1 kg/cm

} to the KCl reserve tank. If the PH8HS3 holder is equipped with an AS3 pressure reduction valve, use the valve to do this. Slowly rotate the knob clockwise while observing the reading of the pressure gauge on the valve.

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4.3.5 Setting Duration of Forced Feeding of Chemical

Solution and Output of CYLINDER FAIL Signal

The timers in the control box are used to set the time for forced feeding of the chemical solution and output of the CYLINDER FAIL signal. Use timer T2 (setting range: 0 to 10 minutes) to set the

time for forced feeding of the chemical solution; use timer T1 (setting range: 0 to 2 minutes) to set

the time for output of the CYLINDER FAIL signal.

Note: The adjustment screw on timer T1 is hidden under the terminal cover.

Upon shipment, the time for forced feeding length of the chemical solution is set to approximately two minutes. Similarly, the time for output of the CYLINDER FAIL signal is set to approximately

30 seconds. Conrm these settings and change them, if necessary.

Note: Always make sure that the value set on timer T2 for forced feeding length of the chemical

solution is smaller than that for the WASH time (output of the WASH contact signal).

Note: that both of these timers have graduations which divide an angle of approximately 270°

(corresponding to the setting range) into ve identical segments as shown in Figure 4.6. Use a at-blade screwdriver to rotate the adjustment screw so the end of the slot on the screw

head (on the side painted in white) points to the desired time setting.

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Slot on the head of the adjustment screw

More time Less time

Figure 4.6 Graduations on Timer

When completing the verication and resetting of timer settings, close the door on the control

box. The interior of the control box is air purged. Keep the door closed as much as possible.

CAUTION

Conrm that the MANUAL WASH switch inside of the control box is OFF.

4.3.6 Supplying Power

Turn on power to the chemical cleaning pH measuring system.

pH/ORP converter system has the power on switch installed on the power line to the power supply box of Chemical Cleaning pH measuring unit. Startup the entire system can be put into operation simply by turning on this switch. If your system is the 2-Wire Analyzer system, turn on the switch installed on the power line to the control box and turn on the power to the distributor.

Turn the screw to the side painted in white is set at the desired time setting.

F4.6.ai

4.3.7 Entering Data Related to WASH Operation

Parameters related to WASH operation include, besides the data items discussed in Subsection

4.3.5, the interval between WASHs, WASH time and relaxation interval,

These parameters are set on the PH450G or FLXA202/FLXA21.

Upon shipment, these data settings are provided as shown in Table 4.1. Conrm these settings

before operation and change them as necessary.

For operation required to verify or change these settings, see the instruction manuals of PH450G or FLXA202/FLXA21.

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Table 4.1 Parameters Related to WASH Operation

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Parameter

Interval between WASHs 8 hours

(setting range: 0.1 to 36.0 hours)

WASH time 4 minutes

(setting range: 0.1 to 10 minutes)

Relaxation time 30 seconds

(setting range: 0.1 to 10 minutes)

Output signal Hold (the value immediately before) Hold (the value immediately before)

PH450G FLXA202 or FLXA21

4.3.8 Verifying WASH Operation

First conrm that the PH8HS3 holder is properly installed to ensure that:

(1) The tip of the pH sensor is always submerged in the measured solution in the measurement

mode even if the liquid level varies.

(2) The bottom plate of the cleaning chamber does not become submerged in the measured

solution.

Next turn on the MANUAL WASH switch in the control box and conrm that the chemical

cleaning system operates normally to ensure that:

(3) The sensor holder rises at the same time the switch is turned on and reaches the upper limit

smoothly without delay (before the CYLINDER FAIL signal is output).

Setting up on Shipment

8 hours (setting range: 0.1 to 36.0 hours)

4 minutes (setting range: 0.1 to 10 minutes)

30 seconds (setting range: 0.1 to 10 minutes)

Note: When the sensor holder reaches the upper limit, the DETECT UPPER LIMIT signal is

output.

(4) No chemical solution leaks from the gasket on the bottom plate of the cleaning chamber.

(5) The sensor holder descends smoothly without delay at the same time the switch is turned

off.

After completing verication of these operations, have the PH450G or the FLXA202/FLXA21

output the WASH contact signal to make sure that the WASH operation of the chemical cleaning pH measuring system is carried out properly.

Note: Shorten the preset interval between WASHs to approximately 30 minutes when

performing the WASH operation. Note that the pH converter system for outdoor use can also be put into the WASH operation by using a remote contact-input signal.

4.3.9 Calibration with Standard Solution

Before starting regular operation, apply calibration with a standard solution. Refer to the instruction manual supplied with PH450G or FLXA202/FLXA21.

4.4 Regular Operation

After completion of required startup procedures, you can put your system into regular operation. This section deals with items for routine inspection during regular operation and precautions that must be observed when shutting down the system.

4.4.1 Data Acquisition in Early Stages of Operation

Implementing WASH too often will lead to a waste of the chemical solution, making your system uneconomical. It is, therefore, often advantageous for the number of cleanings to be reduced,

provided that this ensures that the measurement error always falls within the specied range,

The settings for the parameters related to the cleaning operation are provided upon shipment, assuming that the system is used for a process under standard conditions. Consequently, it is

possible for you to perform more efcient cleaning depending on your process condition.

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The manufacturer recommends that, in the early stages of operation, you choose from the following parameters that can be changed and then change them at regular intervals to verify the

cleaning effect so you can nd the optimum conditions for cleaning.

• Concentration of chemical solution (No data is required to change.)

• Interval between WASHs

• WASH time

• Bubbling time

4.4.2 Inspections During Regular Operation

Routine inspection must be made according to the items shown in Table 4.2 to ensure that the chemical cleaning system is free from faults during regular operation. For inspection and maintenance implemented during a system shutdown to maintain system performance, see Chapter 5. For details on the items of inspection for the FLXA202/FLXA21, PH450G pH/ORP converter or PH8EFP pH sensor, refer to those corresponding manuals.

Table 4.2 Inspection During Regular Operation

4-9

Inspection Item

Amount of chemical solution remaining in holding tank

Amount of contaminants on the cylinder of PHSHS3 holder

Pneumatic pressure setting of pressure reduction valves in control box

Amount of contaminants on the wetted part of sensor holder

If your system requires immediate corrective actions as a result of inspection, perform the necessary maintenance work while observing safety precautions.

WARNING

There is a possibility of personal injury or equipment damage during maintenance of the holder. Exercise utmost care to ensure that no cleaning takes place during maintenance work.

(Corrective Action When Criterion Is Not Met)

Acceptance Criterion

The tank must holds not less than the required amount (the

level indicated on the tank). (Rell the tank if the liquid is below the specied level.)

The cylinder must be free of contaminants that would prevent it sliding properly. In addition, any applied lubricating grease must provide good 1ttbrication (the cylinder starts moving smoothly).

The PG1 and PG2 pressure gauges en the AS1 and AS2 pressure reduction valves must indicate their preset readings, respectively. (If they fail to indicate the preset readings, adjust them.)

The wetted part must be free of any contaminants that could get into the cleaning chamber while the sensor holder was rising or descending.

Recommended

Frequency of

Inspection

Approximately once a month

(100 ml per rell)

Approximately once a month

4.4.3 Behaviour During Power Failure/Restart

The sensor holder moves to its lowest position and stays there, whether the system is in the measurement mode or the WASH mode, if a power interruption lasts longer than the allowable time for a momentary power failure in which the system is able to maintain normal operation. The system resets to the measurement mode when restarted. It goes into the WASH mode, however, if the MANUAL WASH switch in the control box is left turned on.

4.4.4 Operation When Shutting Down the System

It is fundamental to system operation that the pH sensor be maintained in excellent working condition and that the system be able to resume normal pH measurement when it is restarted.

Follow the instructions given here before cutting off the power supply.

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(1) Turn on the MANUAL WASH switch in the control box to execute the WASH operation.

(2) Remove the sensor holder after the air bubbling in step 1 is completed.

Submerge the pH sensor in water. Leave the sensor in the water until the system is

restarted in order to prevent the glass lm on the sensor electrodes from drying out.

CAUTION

Always reinstall the cover which you have removed in order to remove the sensor holder from the chassis. Particular caution must be taken if the system is installed in a location exposed to rain. A wet terminal block of the limit switch will result in corroded cables.

(3) Turn off the MANUAL WASH switch and cut off the power supply.

(4) To prevent loss of the chemical solution in the KCl reserve tank during a system shutdown

over a prolonged period, close the pressure reduction valve for air that pressurizes the tank. lf you are also shutting down the air supply, you need not close the valve.

4.4.5 Procedure When Restarting System Operation

Follow the instructions below when restarting system operation. If the system is restarted after a

prolonged shutdown, conrm that the chemical cleaning system is free from problems.

(1) If the air supply has been cut off, supply air at the specied pressure,

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(2) Conrm the settings of each pressure reduction valve. Adjust them if they fail to indicate the

required readings.

(3) Attach the sensor holder to the cylinder of the PH8HS3 holder.

(4) Supply power to the chemical cleaning system.

(5) Turn on the MANUAL CLEANING switch in the control box to verify that the system

performs cleaning normally. Turn off the switch when you have completed verication.

(6) Calibrate the pH converter or the pH transmitter with a standard solution.

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5. Inspection and Maintenance

We recommend product inspection and maintenance be implemented once a year regularly. Annual inspection and maintenance requires system operation shut down , still it is highly valuable for the sustainable system performance. Refer to sub section 4.4.2 to check the

itemised inspection and maintenance, such as relling the tank with chemical solution, required

to maintain normal system operation. For inspection and maintenance of PH450G pH/ORP

Converter, FLXA202/FLXA21, and PH8EFP pH sensor, refer to the corresponding user’s

manuals supplied with each of these instrument.

5.1 Inspection and Maintenance of Operating Unit for PH8SM3 Chemical Cleaning System

5.1.1 Inspection of Piping (between chemical cleaning

chamber and holder)

Inspect the lines running from the chemical cleaning unit to the holder to ensure that they have no physical damage or no loosening in the couplings. If any defect, such as physical damage, is found, replace these lines. In addition, if the tubing for forced feeding of the chemical solution is

contaminated with dirt which may affect the ow of uid, replace the tubing.

Always use tubing Ø6 x Ø 4 mm in size for the tubing. Use same length of tubing even after the tube is replaced. For piping procedures to pipe between chemical solution tank and holder cleaning chamber, you need tubes with chemical resistance. For further information, see Subsection 3.1.

5-1

l Replacement and material of tubings.

Chemical Cleaning pH measuring system uses polyethylene or Fluoropolymer((PTFE)) tubing because thet have excellent chemical resistance and provide easy piping. These materials, however, show limited weather resistance. It is, therefore, recommended that you replace the

tubing including ttings, once every year or two even if you do not observe any anomaly (for

example, extensive deterioration in the material). If polyethylene tubing seems to be easily deteriorated due to its outdoor use, other material tubing such as Fluoropolymer((PTFE)) may be appropriate.

When piping your system with using materials other than polyethylene tubing, take note of the following:

• Use metal tubing with the size 6 (OD) x 4 (ID) mm even when installing a dedicated pneumatic line (between the control box and air cylinder). In that case, use a tting for metal

tubing (Rc l/4 connection).

• For piping for the forced feeding of a chemical solution, choose a resistant material such as Fluoropolymer (PTFE). When using Fluoropolymer (PTFE) tubing, select dedicated tting (Rc 1/4 connection). Using regular ttings may cause piping disconnected.

5.1.2 Inspection of Solenoid Valves

Conrm that air is not getting into the holding tank for the chemical solution while the SV1

solenoid valve in the control box for forced feeding of the solution remains closed.

The valve must be replaced if there is any air leakage.

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5.1.3 Replacement of Fuses in the Power Supply Box

This procedure applies only when your system is a pH/ORP Converter. The power supply box of the operating unit contains a fuse (1 A rating) for the power supply circuit of the pH converter. No pH measurement is possible if this fuse blows. It is, therefore, recommended that you replace the fuse once every two years even if you do not observe any anomaly with it.

Note: The PH450G pH/converter also contains a 0.1 A fuse. Refer to the maintenance parts list

of PH450G.

5.2 Inspection and Maintenance of PH8HS3 Holder

5.2.1 Removing Foreign Matter from Wetted Part of Sensor

Holder

Chemical cleaning can remove only such dirt that is on the pH sensor unit. If the sensor holder itself is also wetted with the measured solution, manually remove dirt if the dirt cannot be cleared by chemical cleaning function. An excessive amount of dirt on the holder may lead to anomaly of performance because the cleaning chamber or pneumatic cylinder are affected by their contamination which is made while the sensor holder is rising.

5.2.2 Inspecting Gasket on the Bottom Plate of Cleaning

Chamber

Put the PH8HS3 holder into the WASH mode (turn on the MANUAL WASH switch in the control box) to inspect the gasket for leaks. If there is any leaking of chemical solution, the following are the possible major causes:

• The sealing surface of the gasket is dirty.

• The gasket is slightly out of shape, resulting in its failure to maintain a proper seal with an

even force.

• The gasket is damaged due to deterioration of the material.

If solution is leaking from the seal because of a deteriorated gasket, replace the gasket. If an unevenness in the pressure applied to the seal is responsible for leakage (or if the gasket has been replaced), follow the procedure below to adjust the height of the stopper.

Make this adjustment with the system set in the cleaning mode.

(1) Loosen the locknut on the stopper.

(2) Adjust the height of the stopper so the solution stops leaking from the seal. (Adjust the

stopper to a height which ensures that the sealing surface of the gasket is level with the bottom surface of the cleaning chamber and the entire sealing surface comes into contact

with the bottom of the chamber with an even pressure.) If the chamber is empty, ll it with

approximately 100 ml of water to make this adjustment.

If the solution leaks signicantly even after you have adjusted the height of the stopper,

adjust (increase) the force of the spring that produces the pressure around the gasket.

a. Loosen the spring locknut above the spring (turn the locknut counter clockwise).

b. Turn the Spring-adjustment nut clockwise until the solution stops leaking.

Note: The typical force of the spring is 45 N {4.5 kgf} (where the spring contracts approximately

10 mm). If the solution does not stop leaking even when a pressure close to this value is applied, there may be another cause of the leak.

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<5. Inspection and Maintenance>

<Standard position of spring-adjustment nut> The standard position of the spring-adjustment nut is where it is when the spring contracts

9mm from the position of its upper end (free length) which is given when the gasket surface comes into slight contact with the bottom surface of the cleaning chamber.

c. Tighten the spring locknut.

(3) Tighten the locknut.

Spring locknut

Spring-adjustment nut

Spring

Cleaning chamber

Locknut

5-3

Stopper

Figure 5.1 Construction of PH8HS3 Holder

Gasket

Bottom plate

F5.1.ai

WARNING

When highly concentrated sulfuric acid or hydrochloric acid are used, remove those remaining solutions in the cleaning chamber before starting cleaning.

Sulfuric acid or hydrochloric acid at high-concentration level causes serious damage to human health and corrosive characteristics to metals. Use proper care to handle these solutions.

5.2.3 Cleaning and Lubricating Pneumatic Cylinder for

Driving the Sensor Holder

The slider on the pneumatic cylinder for driving the sensor holder slides along the cylinder barrel. Inspect the barrel to make sure that it is free from any foreign matter or dirt. If the barrel is contaminated with dust which will prevent the slider from moving properly, use a clean cloth to remove the dust. The slider may stay at its lowest position for a prolonged period depending on the interval between cleanings. If the slider has been in this position for a long time, it may fail to start moving smoothly at a preset pneumatic pressure. Wipe off any dust on the cylinder, if any.

If your system has the air cylinder cover, remove the cover to inspect and clean. How to remove the cover is as follows. When you restore the cover again go backward the procedure.

(1) Keep the sensor holder at the lowest position ( measuring position ).

(2) Remove all 4 screws that x the cover(up and down , 2 screws for each.)

(3) Slide the cover upward to take off.

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<5. Inspection and Maintenance>

5.2.4 Inspecting O-rings on Sensor Holder

There are two O-rings attached where the pH sensor is installed in the sensor holder to prevent the measured solution from getting inside the sensor holder (see Figure 4.2). Remove the pH

sensor from the holder and conrm that the chemical solution is not leaking into the holder. If the

solution is leaking into the holder, replace both of these O-rings.

When replacing the O-rings, completely wipe off any solution that has leaked into the sensor holder. Exercise extra care to remove dirt, which may impair the sealing capability of the O-rings, from where the O-rings are installed.

5.2.5 Inspecting Terminal Block for Limit Switch

Remove the cover at the upper section of the chassis. Make sure the terminal block for the limit switch is clean. If the terminal block is contaminated with dust or dirt, clean it.

Also check the conductors and terminals of the cable to ensure that there is no anomaly (such as corrosion) which may lead to broken wires. If there is any possibility of problems, eliminate such possibilities by restoring the terminal block to its normal state.

5-4

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<6. Troubleshooting>

6-1

6. Troubleshooting

This chapter deals with the corrective actions taken when the system fails to operate normally due to, for example, a failure in components. For malfunctions regarding the PH450G pH/ ORP Converter or FLXA202/FLXA21 2-Wire Analyzer and PH8EFP pH sensor, refer to the

correspondng user’s manual supplied with these instruments.

6.1 More Than 100 ml of Chemical Solution at a Time Is Being Fed to Holder

The primary reason is that air may be leaking from the O-ring in the metering tank. Since an excessive air leak allows the chemical solution to enter the metering tank up to the level of the surface of the liquid in the holding tank, more than the required quantity (approximately 100 ml) of the chemical solution is supplied.

l Corrective action

Tighten the cap fully. If the air leak still persists, check the cylinder barrel for possible cracks and the O-ring for possible defects. Replace defective components, if necessary.

O-ring

Level of liquid in holding tank

Pneumatic pressurizing tube

Tube for forced feeding

Gasket

Figure 6.1 Normal Level of Liquid in Metering Tank

If the holding tank is positioned below the cleaning chamber of the holder conrm that at least a

part of the tubing is positioned above the cleaning chamber. Failure to observe this instruction

may result in the chemical solution fed to the cleaning chamber owing back into the holding tank

after the air bubbling.

Note: If the chemical solution in the cleaning chamber ows back into the holding tank, clean

Cap

Bleed valve

Metering tank

Level of liquid in metering tank (capacity: approximately 100 ml)

Check Valve (Seat)

Fluid inlet

the bleed valve to prevent it from being clogged.

Holding tank for chemical solution

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<6. Troubleshooting>

6-2

6.2 A Smaller Quantity of Chemical Solution Is Fed to Holder

One of the reasons for this is that the thin covering in the bottom of the metering tank does not

serve as a check valve. Normally, the covering shuts off the uid inlet when the appropriate pneumatic pressure is applied to the metering tank, resulting in the liquid inside owing only into the holder. If the covering fails to shut off the uid inlet due to deterioration or damage, the liquid inside ows back into the holding tank, thus allowing a smaller quantity of the liquid to be sent to

the holder.

l Corrective action

Inspect the thin covering and replace it if deteriorated or damaged.

NOTE

lf no defects are found in the thin covering, check for possible leakage around the SV1 solenoid valve used for forced feeding of the chemical solution which is located in the control box. If air

ows through the valve while it remains closed, replace it with a new valve. Also, check the chemical solution in the cleaning chamber for traces that shows the chemical solution owed

back into the chemical tank. If the bleed valve (see Figure 6.1) has become clogged due to a

reverse ow of the solution, the system is no longer able to measure the specied quantity of

solution. If the bleed valve is clogged, clean it.

6.3 CYLINDER FAIL Signal Appears

Possible causes are:

• There is slack in the connections of the line for driving the cylinder.

• The specied pneumatic pressure is not possible.

• The cylinder barrel of the PH8HS3 is dirty.

• The capability of the lubricating grease applied to the cylinder barrel has degraded.

• Limit switch circuits have anomaly.

First conrm that the PG2 pressure gauge in the control box indicates the preset value (with

the system set in the cleaning mode). If the gauge reads smaller than the preset value, readjust

it after conrming that the connections are not loosened. When the slide of the cylinder is in a

upper position, refer to 6.5 and proceed along with it.

Next remove dirt from the cylinder barrel and then apply a thin lm of grease to the barrel.

6.4 When Liquid keeps leaking from bottom

plate of Cleaning Chamber

THe continuous leakage even after replacement of the gasket and adjustment of the height of the stopper (see Subsection 5.2.2) may be caused by the reduced pressure of the spring due to deterioration (corrosion) of its material. Inspect the spring visually and replace it if it is defective.

l How to replace spring

(1) Remove the two screws which secure the guide plate to the chassis.

(2) Remove the screw set at the tip of the rod.

(3) Remove the assembled components, such as the guide plate, from the rod.

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<6. Troubleshooting>

(4) Put a new spring in place. Also replace the washer, spring-adjustment nut, locknut and

guide plate removed in step (3) as well as the screw removed in step (2).

(5) Taking precautions against problems in vertical movement of the rod, secure the guide plate

to the chassis (with screws).

(6) Adjust the pressure of the spring.

First, x the bottom plate of the cleaning chamber (temporarily with tape) to where the

gasket makes slight contact with the bottom edge of the chamber.

Next, screw the spring-adjustment nut into the rod so the spring tightens as it contracts by

approximately 9 mm (pressure of spring: approximately 40 N {4 kgf}).

(7) Tighten the locknut.

Screw

Rod

Guide plate

Locknut

Spring-adjustment nut

Washer

Spring

6-3

Chassis

F6.2.ai

Figure 6.2 Assembly for Adjusting Pressure of Spring in Holder

6.5 Chemical Solution Cannot Be Fed into Cleaning Chamber

Timer T2 may fail to come into action although the slider on the cylinder has reached the top end of the cylinder barrel. Consequently, none of the chemical solution is forcibly fed into the cleaning chamber (i.e., solenoid valve SV1 does not open). One of the reasons is an erroneous DETECT UPPER LIMIT signal (or the signal is not present).

If this failure occurs, always proceed as follows: First make sure cleaning sequence is nished

and the slider on the cylinder is positioned at the bottom end. Then check the cable wired to the terminal block for the limit switch.

WARNING

Electrical shock hazards:

Short-circuited cable between terminal 1 and 2 on the terminal box for the limit switch, an electrical current of 24 VDC, 50 mA maximum passes.

lf any abnormality, such as a broken wire, is found, remedy it. lf you cannot point out any abnormality in the wiring or localize the cause of failure, contact our sales ofce.

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Blank Page

Customer Maintenance Parts List

Automatic Cleaning Type pH Metering System

PH8SM3 Operational Unit (Style C)

2 3

7 6

Item Part No. Qty Description

1 A1109EF 1 Fuse (1A) (Only PH8SM3-E) 2 K9729DB 1 Solenoid Valve Assembly (SV1) 3 K9729DC 1 Solenoid Valve Assembly (SV2) 4 K9731MA 1 Tank Assembly for polyethylene (Sufx Code : -L10)

K9731MB 1 Tank Assembly for PTFE (Sufx Code : -T10)

5 K9729BN 1 Tank 6 K9729CT 1 Cap 7 K9731MC 1 Metering Tank Assembly (Material: polyethylene)

K9731MD 1 Metering Tank Assembly (Material: PTFE)

8 L9831NE 2 Connector (Material: polyethylene)

9 10

11 12

L9831TT 2 Connector (Material: PTFE) 9 K9729BL 1 Cap Assembly 10 K9729YL 1 O-Ring 11 L9831JE 2 Connector (Material: polyethylene)

12 K9729BV 1 Pipe

13 K9729BX 1 Tube 14 K9729BY 1 Tube 15 K9729GA 1 Check Valve (Seat) 16 K9729GB 1 Gasket 17 K9729GC 1 Bottom

CMPL 12B07W01-13E

1st Edition: 1999 (YK)

4th Edition: Oct. 2016 (YK)

Customer Maintenance Parts List

Automatic Cleaning Type pH Metering System

PH8HS3 Holder (Style C)

Item Part No. Qty Description

1 K9729YK 2 O-Ring 2 K9729WJ 1 Gasket

CMPL 12B07W01-23E

1st Edition: 1999 (YK)

3rd Edition: Oct. 2016 (YK)

Revision Record

l Manual Title : Chemical Cleaning pH Measuring System l Manual No. : IM 12B07W01-04EN

Nov. 2016/1st Edition

Newly published. (IM 12B7W1-03E’s order is discontinued. Newly published for PH8SM3-E, -F, -G.)

Yokogawa Electric Corporation 2-9-32 Nakacho, Musashino-shi, Tokyo 180-8750, JAPAN http://www.yokogawa.com/

IM 12B07W01-04EN1st Edition : Non. 11, 2016-00

Blank Page

YOKOGAWA PH450G, FLXA202, FLXA21, PH8SM3, PH8EFP User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

u Introduction

u Safety Precautions

1. General

1.3 External Dimensions

2. Installation

2.1 Installing the PH8SM3 Chemical Cleaning Unit for a Chemical Cleaning System

2.1.1 Where to install the unit

2.1.2 Installation Facilities

2.1.3 Installing Chemical Cleaning Unit

2.2 Installing the PH8HS3 Holder

2.2.1 Where to install the holder

2.2.2 Installation Facilities

2.2.3 Installing the PH8HS3 Holder

3. Piping and Wiring

3.1 Piping

3.1.1 Line for Connecting Air Source

3.1.5 Line for Pressurizing KCl Reserve Tank

3.2 Wiring

3.2.2 Wiring system with 2-Wire Analyzer

4. Operation

4.1 Names and Functions of Components

4.2 How the Chemical Cleaning pH Measuring System Works

4.2.1 Operating Modes

4.2.2 WASH (Cleaning) Command

4.2.3 Wash Sequence

4.3 Startup

4.3.1 Inspection of Piping and Wiring

4.3.2 Supplying Chemical Solution to Holding Tank

4.3.3 Supplying KCl Solution to Reserve Tank

4.3.4 Adjustment of Pneumatic Pressure

4.3.6 Supplying Power

4.3.7 Entering Data Related to WASH Operation

4.3.8 Verifying WASH Operation

4.3.9 Calibration with Standard Solution

4.4 Regular Operation

4.4.1 Data Acquisition in Early Stages of Operation

4.4.2 Inspections During Regular Operation

4.4.3 Behaviour During Power Failure/Restart

4.4.4 Operation When Shutting Down the System

4.4.5 Procedure When Restarting System Operation

5. Inspection and Maintenance

5.1 Inspection and Maintenance of Operating Unit for PH8SM3 Chemical Cleaning System

5.1.2 Inspection of Solenoid Valves

5.1.3 Replacement of Fuses in the Power Supply Box

5.2 Inspection and Maintenance of PH8HS3 Holder

5.2.4 Inspecting O-rings on Sensor Holder

5.2.5 Inspecting Terminal Block for Limit Switch

6. Troubleshooting

6.1 More Than 100 ml of Chemical Solution at a Time Is Being Fed to Holder

6.2 A Smaller Quantity of Chemical Solution Is Fed to Holder

6.3 CYLINDER FAIL Signal Appears

6.5 Chemical Solution Cannot Be Fed into Cleaning Chamber

Revision Record