YSI 3017M User Manual

3017M Chlorine Analyzer

DPD CHLORINE ANALYZER

USER MANUAL

332100_Rev A

General Information

The information contained in this manual is subject to change without notice.

Effort has been made to make the information in this manual complete, accurate, and current.

The manufacturer shall not be held responsible for errors or omissions in this manual, or for incidental or consequential damages in connection with the furnishing, performance, or use of this material.

No part of this document may be reproduced, photocopied, or translated to another language without the prior written consent of YSI.

Consult YSI.com for the most up-to-date version of this manual.

Warranty

YSI warrants each YSI manufactured product against defects in materials and workmanship under normal use and service for a period of two years. Equipment installed by YSI is warranted from the installation date; all other equipment is warrantied from the ship date. If purchaser schedules or delays installation more than 90 days after delivery, then the warranty period starts on the 91st day from date of shipment. This warranty extends only to the original purchaser. YSI will, at its option, repair or replace equipment that proves to be defective during the warranty period, provided the equipment is returned to YSI at the expense of the purchaser.

Consumables, expendables, and parts are warranted for 30 days and are not covered under extended warranties or service contracts.

YSI warrants for a period of one year from the date of delivery: (i) the software, when installed and used with an YSI recommended hardware conﬁguration, will perform in substantial conformance with the documentation supplied with the software; and (ii) the physical media on which the software is furnished will be free from defects in materials and workmanship under normal use.

This warranty shall not apply to defects originating from, but not limited to, the following:

• Improper maintenance or operation by the purchaser;

• Purchaser-supplied accessories or consumables;

• Modiﬁcation or misuse by the purchaser;

• Operation outside the product’s environmental and electrical speciﬁcations;

• Software, interfacing, parts, or supplies not supplied by YSI;

• Improper or inadequate site preparation;

• Purchaser-induced contamination or leaks.

THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY, FITNESS, OR ADEQUACY FOR ANY PARTICULAR PURPOSE OR USE. YSI SHALL NOT BE LIABLE FOR ANY SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, WHETHER IN CONTRACT, TORT, OR OTHERWISE.

Any service requests or questions should be directed to the YSI Customer Support Center at (937) 767-7241.

Safety Information

Please read this entire manual before unpacking, installing and operating this instrument. Ensure that the protection provided by the instrument is not impaired. Do not install or use this instrument in any manner other than that speciﬁed in this manual. For operator safety, pay attention to DANGER, WARNING and CAUTION statements throughout the manual.

Safety Hazard Information

DANGER indicates a potentially or imminently hazardous situation which, if not

avoided, will result in serious injury or death.

WARNING indicates a condition or possible situation that could result in physical

injury to the operator.

CAUTION indicates a condition or possible situation that could damage or destroy the product or the operator’s work.

NOTE: Information that is supplemental to the point in the main text.

Follow warnings and precautions in this manual or on the instrument during operation, service and repair. Failure to follow these warnings and precautions violates the safety design standards and intended use of the instrument. YSI is not liable for the operator’s failure to comply with these warnings and precautions.

Precautionary labels

Please read all labels and tags attached to the instrument. Personal injury or damage to the instrument could occur if not observed.

Electrical equipment marked with this symbol may not be disposed of in the European public disposal systems after 12 August 2005. In conformity with European local and national regulations (EU Directive 2002/96/EC), European electrical equipment users must now return old or end-of-life equipment to the Producer for disposal at no charge to the user.

NOTE: For return for recycling, please contact the equipment producer or supplier for instructions on how to return end-of-life equipment, producer-supplied electrical accessories, and all auxiliary items for proper disposal.

TABLE OF CONTENTS

1. General Product Information..........................................4

1.1 Instrument Description...........................................4

1.2 Instrument Speciﬁcations.......................................5

1.3 Method of Analysis..................................................6

1.4 Theory of Operation................................................6

2. Installation...........................................................................7

2.1 Unpack the Analyzer................................................7

2.2 Environmental Considerations..............................7

2.3 Analyzer Mounting..................................................7

2.4 Plumbing Connections.........................................10

2.5 Sample Line...........................................................10

2.6 Sample Inlet Device............................................10

2.7 Optional In-Line Filter.........................................13

2.8 Sample Inlet Devices and Systems......................13

2.9 Electrical Connections........................................13

2.9.1 Power Connections.................................13

2.9.2 Wiring the Analyzer.................................14

2.9.3 RS 485.......................................................15

2.9.4 Analog Output (4-20 mA)......................15

2.9.5 Alarm (Relay) Connections.....................15

2.9.6 AC Connections.......................................16

2.9.7 Reagent Preparation................................16

2.10 Pump Tubes..........................................................17

2.10.1 Sample Pump Tube...............................18

2.10.2 Reagent Pump Tubes............................19

3. Analyzer Startup...............................................................20

3.1 Supply the Sample..............................................20

3.2 Supply Power to the Analyzer............................20

3.3 Language Selection............................................21

3.4 Powerup Mode....................................................21

4. Analyzer Operation..........................................................22

4.1 User Interface.......................................................22

4.2 Display...................................................................23

4.3 Touchpad..............................................................23

4.4 Firmware Structure & Operation.......................23

4.5 Unlocking/Locking the Analyzer.......................32

4.6 Method Settings..................................................33

4.7 Setting the 4-20mA Output...............................33

4.8 Setting the Alarm/Timed Event Relays.............33

4.8.1 Setting Alarm Relays with Keypad........33

4.8.2 Setting Alarm Relays w/ MODBUS........34

THIS IS AN INTERACTIVE ADOBETM PDF DOCUMENT

4.9 Calibration............................................................34

4.9.1 Calibration with Known Standard.........34

4.9.2 Calibration by Comparison....................35

5. Default Conﬁguration & Method Settings..................36

5.1 Method Settings..................................................36

5.1.1 Times.........................................................36

5.1.2 Pumps........................................................37

5.1.3 LEDs..........................................................37

5.2 Setup.....................................................................37

5.2.1 Communications......................................37

5.2.2 4-20 mA Setup.........................................38

5.3 Status......................................................................38

5.4 Linearization.........................................................38

5.5 Maintenance.........................................................38

6. Maintenance......................................................................39

6.1 Regularly Scheduled Maintenance...................39

6.1.1 Reagent Replacement.............................39

6.1.2 Pump & Reagent Tube Replacement....39

6.1.3 Flowcell Cleaning....................................41

6.2 Unscheduled Maintenance................................41

6.2.1 Fuse Replacement...................................41

6.2.2 Linearization.............................................42

6.2.3 Field Linearization Procedure................42

7. Troubleshooting...............................................................45

7.1 Troubleshooting Guide......................................45

7.2 Using Manual Controls & STATUS Screen.......46

7.3 UsingTier 3 Selections & STATUS Screen........47

7.3.1 Main STATUS Screen...............................48

7.3.2 Liquid Level Sensor & Error Levels.......49

7.3.3 Firmware & PCA Revision Levels...........51

8. Parts & Accessories...........................................................52

9. Declaration of Conformity..............................................59

10. Appendix A: MODBUS Manual...................................60

1. General Product Information

1.1 Instrument Description

DANGER Chemical or biological hazards: If this instrument is used to monitor a treatment process and/or chemical feed system for which there are regulatory limits and monitoring requirements related to public health, public safety, food or beverage manufacture or processing, it is the responsibility of the user of this instrument to know and abide by any applicable regulation and to have sufﬁcient and appropriate mechanism in place for compliance with applicable regulations in the event of malfunction of the instrument.

The 3017M Chlorine Analyzer is a microprocessor-controlled process analyzer. It is designed to continuously monitor an aqueous sample for chlorine content. Either free or total chlorine, in the range of 0 – 5 mg/L can be monitored. Indicator and buffer solutions are used for the determination of chlorine content. Speciﬁc buffer solutions are used for free or total chlorine.

WARNING Fire hazard: This analyzer is intended to be used for aqueous samples only.

The 3017M Chlorine Analyzer enclosure is rated for IP 66 per IEC 529. The enclosure is dust tight and drip resistant and is designed for outdoor use. However, a three-sided covering that prevents direct exposure to sunlight, dripping water, rain, sleet, or snow should be used.

The 3017M Chlorine Analyzer is an on-line photometric analyzer that uses N,N-diethyl-p-phenylene diamine (DPD) indicator and a buffer to determine chlorine content. The system has two peristaltic pumps that deliver sample and reagents to the ﬂowcell. The sample pump continually delivers sample to the ﬂowcell. The reagent pump is activated at a predetermined time to deliver buffer and DPD reagent to the sample stream.

The ﬂowcell consists of a sample inlet, reagent inlets, a static mixer and sample drain. Either a green, blue, or red LED can be selected to provide the appropriate wavelength of light. Light is transmitted through ﬁber optic cables through the ﬂowcell and back to a dual-channel detector. One channel is used for the analysis of the colored complex while the other channel is used as a reference to monitor the LED source, and thereby, maintain stability of the system.

The reagents are dispensed from two replaceable bottles. One bottle has a buffer to control the pH; the second bottle has the DPD reagent that produces a magenta color when chlorine is present in the sample. The degree of color change is proportional to the amount of chlorine in the sample water. Chlorine concentration is displayed on the front panel by three-digit LCD readout in mg/L chlorine.

The system accepts commands and sends data over RS-485 using Modbus RTU/ASCII protocols, or through the touchpad, if the instrument is not operated under Modbus control. A 4-20 mA output is available for connection to an external datalogger, Programmable Logic Controller (PLC) or Distributive Control System (DCS). Concentration minimum and maximum values in mg/L chlorine are set by the operator at the analyzer touchpad.

Programmable alarm circuits provide relay closures, both normally open and normally closed, for two selectable chlorine level set points. Set points can be programmed by the operator anywhere in the overall range. System warning and system alarm features provide automatic, self-testing diagnostics that detect a number of possible malfunctions, and provide alarm relay closures indicating a need for operator intervention.

Indicator and buffer reagent containers (500-mL each) are placed in the instrument enclosure. Reagents are replenished once a month when operating in the 0 – 5 mg/L chlorine range. A clear front cover allows for viewing of reagent bottles, and other critical components without the need for opening the analyzer enclosure.

General Product Information

1.2 Instrument Speciﬁcations

Performance

Measurement Method N, N-Diethyl-p-phenylenediamine (DPD)

Measurement Range 0-5 mg/L free or total chlorine, reagent dependent

Measurement Interval Programmable; 2.5 to 60 minutes

Accuracy ±0.03 mg/L or ±5%, whichever is greater

Limit of Detection 0.03 mg/L

Calibration Factory calibrated, 1-point if required

Resolution 0.01 mg/L

General

Display 2.8 x 6 cm backlit LCD

Enclosure IP66 (with door latched)

Instrument Dimensions 17.6 x 14.7 x 7.9 inches (44.6 x 37.3 x 18.8 cm)

Mounting 4 mounting struts bolted to back of unit

Instrument Shipping Weight <18 lbs ; 8 kg

Warranty 2 year warranty

Regulatory Compliance US EPA regulations 40 CFR 141.74 and 40 CFR 136.3; Standard method

4500-CL-G; US EPA method 334.0; ISO method 7393-2

Certiﬁcation CE, cETLus

Language English, French, German, Italian, Spanish

Sample Requirements

Sample Flow Rate to Sample Inlet Device 50 to 1,000 mL/min when using Sample Inlet Device

Inlet pressure 1 to 20 psig with Sample Inlet Device

Sample Temperature Range 41 to 113 °F (5 to 45 °C)

R  R

Reagent Sets 330006 - Reagent set for measuring total chlorine

330007 - Reagent set for measuring free chlorine

Reagent Consumption ~30 days per bottle at a 2.5 minute measurement interval

Reagent Storage Life (before hydration) Buffer and indicator: 5 years

DPD powder: 1 year

Reagent Storage Life (after hydration) ~30-40 days

Power & Communication

Power 115-230 VAC , 50-60 Hz, 70VA

Relays Two relays rated at 6A, 30VDC

Analog Output One 4-20 mA conﬁgurable output

Digital Output RS-485 Modbus RTU

Optical

Light Source Class 1 LED; wavelength centered at 525 nm

Light Path Length >1 cm

Environmental

Storage Temperature Range 41 to 158 °F (5 to 70 °C)

Operating Temperature Range 41 to 131 °F (5 to 55 °C)

Relative Humidity 90% at 40°C non-condensing

General Product Information

1.3 Method of Analysis

Free available chlorine (hypochlorous acid and hypochlorite ions) oxidizes the DPD indicator reagent at a pH between

6.3 and 6.6 to form a magenta-colored compound (Würster dye). The intensity of the resulting color is proportional to the concentration of chlorine in the sample. A buffer solution speciﬁcally for free chlorine maintains the proper pH.

Total available chlorine (free chlorine and combined chloramines) is determined by adding potassium iodide to the reaction. Chloramines in the sample oxidize iodide to iodine, which, along with any free available chlorine, oxidizes DPD indicator to form the magenta color at a pH of 6.5 – 8.5. A different buffer solution containing potassium iodide maintains the reaction pH. After the chemical reaction is complete, the optical absorbance at the selected wavelength is compared to the absorbance measured through the ﬂowcell before the reagents are added. Chlorine concentration is calculated from the difference in absorbance.

1.4 Theory of Operation

The sample continuously ﬂows through the ﬂowcell. Prior to the addition of reagents, the blank absorbance is measured. Measurement of the sample blank allows for compensation for any turbidity or natural color in the sample and provides an automatic zero reference point. Reagents are added after the measurement of the blank sample and develop the magenta color if chlorine is present in the sample. Absorbance is measured and compared to the blank reference value.

Peristaltic pumps control the ﬂow of sample and reagents. The sample ﬂows continuously and the reagent pump delivers a metered amount of buffer and indicator in a 2.5-minute cycle. The cycle operates as follows:

1. The sample is continuously ﬂowing through the ﬂowcell.

2. At a preset time, the absorbance of the blank sample is measured.

3. After the blank absorbance is measured, the indicator and buffer reagents are injected into the ﬂowing stream of sample.

4. The sample and reagents are allowed to thoroughly mix for the full development of the magenta color. The measurement of the treated sample is taken to determine the chlorine content.

5. The sample pump increases the ﬂow rate to thoroughly evacuate the ﬂow cell in preparation for the start of the next cycle.

General Product Information

2. Installation

DANGER Electrocution and ﬁre hazard. Only qualiﬁed personnel should conduct the tasks described in this section of manual.

WARNING Electrocution hazard. Install a 10A circuit breaker for main power. Identify the circuit breaker with a label, as a local disconnect for this equipment.

2.1 Unpack the analyzer

Remove the analyzer from the box and inspect it for damage. Verify that all of the parts are contained in the shipment. If any items are missing or damaged, contact Technical Support, or the local representative.

2.2 Environmental Considerations

The analyzer enclosure is designed for indoor or outdoor installation with an ambient temperature range of 5 – 55 °C (18 – 131 °F). The enclosure environmental rating is IP 66 with the door closed and latched. For outdoor installation, the analyzer should be covered by a three-sided cover to protect it from direct sunlight, dripping water, rain, sleet or snow.

2.3 Analyzer Mounting

The enclosure is designed for wall mounting. Refer to Figures 2.1, 2.2, 2.3 and 2.4 for critical dimensions and other installation information.

The 3017M has four mounting tabs that must be installed on the enclosure refer to Figure 2.2. These mounting tabs can be found in a package of mounting hardware that is included with the enclosure. Connect the mounting tabs to the enclosure using the four (4) #10-32 x 3/8-inch Phillips Drive ﬂat head machine screws found in the mounting hardware kit.

Use ¼-inch screws, or bolts, depending on mounting location/surface. The analyzer should be mounted at a height at which it can be safely operated. Mount the analyzer as close as practical to the sampling point to ensure complete purging of the sample line during each cycle. Leave adequate clearance at the sides and bottom of the analyzer enclosure for wiring and plumbing connections.

The most common installation approach is the use of Unistrut® frame. Unistrut frame with ¼-inch spring nuts would be used for mounting the 3017M. The mounting tabs on the 3017M are designed for ¼-inch bolts.

NOTE: The sample pump in the analyzer pulls sample into the ﬂowcell. The maximum distance between the analyzer and the sample point should not exceed 3.28 ft (1 m).

Installation

14.674”

(37.27 cm)

7.891”

(20.04 cm)

17.582”

(44.66 cm)

Figure 2.1 3017M overall dimensions

16.172”

(41.08 cm)

9.625”

(24.45 cm)

4X .250” MOUNTING HOLE (.635 cm)

Figure 2.2 3017M mounting dimensions showing the mounting tabs connected to the enclosure

Installation

7.361”

(18.70 cm)

2.393”

(6.08 cm)

POWER CONNECTIONS

RELAY/ALARM & NETWORK CONNECTIONS

7.000”

(17.78 cm)

1.736”

(44.08 cm)

5.745”

(14.59 cm)

Figure 2.3 3017M electrical connections

Installation

2.988”

(75.88 cm)

3.475”

(88.26 cm)

Figure 2.4 3017M plumbing connections

2.4 Plumbing Connections

NOTE: The waste line contains analysis waste, which include both sample and chemical reagents. The chemicals used for the analysis are of very low concentrations. Adhere to local codes for the proper disposal of this waste.

Sample inlet and waste connections are made on the bottom of the analyzer. The sample inlet is a quick connect ﬁtting for a 1/8-inch (3.175-mm) OD tubing. The waste line is a barb ﬁtting for ½-inch (12.7-mm) ID ﬂexible tubing. See Figure

2.4. Connect the 1/8-inch (3.175 mm) OD Teﬂon® by pushing it into the ﬁtting. A stop will be felt when the tubing is properly seated in the ﬁtting. Connect the waste line by pushing, and gently twisting, the tubing over the barb on the ﬁtting. Ensure that the tubing completely covers the barb.

NOTE: No pressure, positive or negative, should be applied to the waste line. Never plug the waste line.

CAUTION Fire hazard. This analyzer is intended for water samples only.

2.5 Sample Line

The selection of a representative sample is important for optimal performance of the analyzer and analytical results. The sample must be representative of the condition of the entire process. Erratic reading will be realized if the sample is drawn from a location that is too close to the point of chemical injection, if mixing is incomplete, or if the chemical reaction is incomplete.

Install sample line taps into the side or center of larger process pipes to minimize the chance of ingestion of sediment or air bubbles. A tap projecting into the center of a pipe is an ideal conﬁguration. Opaque tubing is recommended if the tubing is exposed to sunlight in order to prevent algae growth.

2.6 Sample Inlet Device

The Sample Inlet Device, part number 327114, is shown in Figure 2.5. It is a simple, easy-to-use device that serves as the interface between the sample tap and the 3017M. It consists of inlet and outlet ports, a 60-micron ﬁlter for ﬁltration of ﬁne particles, if necessary, and a 20-psig pressure relief valve. The Sample Inlet Device is rated for line pressure in the range of 1 – 20 psig (0.069 to 1.38 bar). It may be necessary to install an in-line pressure regulator, or shut-off valve upstream of the Sample Inlet Device.

These instructions cover the plumbing connections for the Sample Inlet Device, part number 327114. See Figure 2.5. Other sampling schemes can be used with the 3017M. The critical point is that the sample inlet line from the 3017M is always immersed in sample that is representative of the process that is being monitored.

The instrument is designed to require very little head pressure to operate. If the Sample Inlet Device is being used the pressure range is 1 psi (0.069 bar) to 20 psi (1.38 bar). The maximum allowable ﬂuid temperature is 50°C (122°F).

Opaque tubing is recommended if the tubing is exposed to sunlight in order to prevent algae growth. Note that the sample inlet and outlet connectors are compatible with ¼-inch (6.35-mm) O.D. ﬂexible tubing. The outlet port of the Sample Inlet Device has a pressure relief valve that will open if the sample pressure through the device exceeds 20-psi (1.38 bar).

The 1/8-inch (3.175-mm) sample inlet line from the analyzer to the Sample Inlet Device will be connected to sample inlet side of the Sample Inlet Device through a bored-through, Swagelok® ﬁtting with a Teﬂon® ferrule.

Installation

The analyzer has a separate drain for the ﬂow from the sample and reagent pumps onboard the analyzer. The drain tubing is ½-inch (12.7-mm) ﬂexible tubing.

NOTE: The analyzer drain must be open to the atmosphere. No pressure, positive or negative, must be applied to the drain tube.

NOTE: The waste from the drain connection of the instrument contains reagents diluted with large quantities of water. Route the drain line from the analyzer to the appropriate point in accordance with local codes or regulations.

The ideal location for the Sample Inlet Device is below the 3017M and as close as practical to the 1/8-inch (3.175 mm) quick connect ﬁtting at the bottom of the analyzer. The installation location of the Sample Inlet Device should not exceed 3.28 ft. (1 m) from the analyzer. See Figure 2.6.

1/4” NPT to 1/8” TUBE

BRASS FITTING

POLY FILTER 60U

SAMPLE INLET

DEVICE ASSEMBLY

INSERT POLY FILTER ON END

OF 1/8” TUBE TO MIDDLE OF

CLEAR INLET TUBE

1/2” ID URETHANE

TUBING TO DRAIN

1/8” X 1X16” ID TEFLON TUBING

1/2” TO 1/4” PVC REDUCING BUSHING

1/4” TO 1/4” TUBE BRASS FITTING

Installation

1/4” POLY TUBING FROM FLOW PRESSURE REGULATED SAMPLE STREAM TAP

Figure 2.5 Sample Inlet Device (part #327114)

Figure 2.6 Recommended position of the Sample Inlet Device with 3017M

The Sample Inlet Device is supplied with quick connect ﬁttings for ¼-inch (6.35-mm) OD tubing. Other ﬁttings may be substituted depending on the application, but these are not supplied with the device.

Secure the Sample Inlet Device to the wall, panel, or other structure. Push the ¼-inch OD tubing into the inlet ﬁtting. A stop will be felt when the tubing is properly seated in the ﬁtting. Repeat this process for the outlet ﬁtting. Route the outlet tubing to an atmospheric drain, or sump.

Remove the 1/8-inch NPT to 1/8-inch Tube ﬁtting at the top of the Sample Inlet Device. This ﬁtting has Teﬂon® twopiece ferrule. Take care not to lose it, or over-tighten. It can be reused numerous times if not over-tightened.

Insert the sample pick-up line into the ﬁtting and attach the 60 micron ﬁlter to the end of the sample line. Secure the ﬁtting to the Sample Inlet Device. Position the sample pick-up line/ﬁlter at approximately mid-way in the Sample Inlet Device. Gently tighten (do not overtighten) the 1/8-inch nut on the ﬁtting.

Apply sample to the system and check for leaks. Ensure that the sample from the outlet of the Sample Inlet Device is ﬂowing freely to the drain.

Installation

2.7 Optional In-Line Filter

In some applications, the addition of ﬁrst-stage ﬁltration may be necessary before the Sample Inlet Device. A 40-mesh strainer is available, but not included with the analyzer.

The 40-mesh strainer may be installed at any point in the sample line prior to the inlet of the Sample Inlet Device. However, a position in close proximity to the inlet of the Sample Inlet Device is recommended to prevent the build-up of contamination in the sample line after the strainer.

2.8 Optional Sample Inlet Devices and Systems

The 3017M Chlorine Analyzer is not absolutely dependent upon a pressurized stream of water. For instance, a sample may be placed in a container and the sample inlet tube submerged in it. As long as the sample inlet tube shown in Figure 2.6 is submersed in a representative sample, the Sample Pump on the instrument will draw the sample into the instrument. Therefore, any number of different sample devices can be used on the 3017M.

The sample inlet tube may be inserted into a ﬂowing stream of water. As long as the recommended distances from the instrument to the sample point are followed and the sample tube is always fully submersed in water, and steps are taken to prevent clogging, the Sample Pump should draw water into the analyzer.

2.9 Electrical Connections

The cable glands on the left-hand-side of the analyzer will accept cable diameters from 0.23 in (5.8 mm) to 0.53 in (13.5 mm). All terminals are designed to accept wires in the range of 14-28 AWG. All wires should be stripped to a length of 1/4- inch (6.35 mm). Wire ferrules have been found to be particularly useful with the terminal block in the analyzer.

The power and RS 485/4-20 mA connections are made through the cable glands that are supplied with the analyzer. The power and RS 48/4-20 mA cable glands can be found on the left-hand-side of the analyzer. See Figure 2.3.

If alternate cable glands are desired, use sealing-type conduit ﬁttings to maintain IEC 529 IP 66 rating. Alternatively, hard conduit and conduit seals may be used for power and RS 485/4-20 mA connections.

2.9.1 Power Connections

DANGER Electrocution hazard. Only qualiﬁed personnel should conduct the tasks described in this section of the manual. Connect equipment in accordance with national, state and local electrical codes. When working inside of the enclosure power should be disconnected prior

to entry.

Power, signal, relay and alarm connections are made at the terminal block inside the enclosure on the left-hand-side of the analyzer. For industrial applications, the national electrical codes of most countries may require that AC service be hard-wired and contained in rigid conduit systems. The 3017M has been designed to conform to that requirement. Refer to Figure 2.3.

Additionally, electrical and instrumentation standards require a local means of removing power from a device. The

3017M does not have a power on/off switch. However, a fusible link on the terminal block can be used to remove power from the analyzer. An external means of removing power from the analyzer may be necessary.

Installation

External Power Switch (optional)

1 2 3

5 6 7 8

9 10 11 12 13 14 15 16

Figure 2.7 3017M showing terminal block and external power switch

In applications where power cords are allowed by local electrical code and power surges and transients are not a concern, a power cord with three 18 gauge wires can be used. The cable gland on the left-hand-side of the analyzer is compatible with most, standard power AC power cords.

2.9.2 Wiring the Analyzer

DANGER Electrocution hazard. Ensure that the power cord is not connected to outlet, or other power source.

NOTE: The 3017M can accept either 115 VAC or 230 VAC. There is no voltage selector switch.

The 3017M uses WAGO® connectors for power, signal, and alarm connections. See Figure 2.8 and Tables 1 and 2. The individual connector blades are opened by inserting the tip of a narrow, ﬂat-blade screwdriver into the square opening of the connector. Insert the screwdriver tip until it bottoms-out in the connector. Insert the stripped wire and remove the screwdriver. Gently pull on the wire to ensure that the blades of the connector have secured the wire.

Installation

Position Connection/Purpose Wire Color

1 AC Earth Green/Green Yellow

2 AC Neutral (Line 2) White/Blue

3 AC Line (Line 1) Black/Brown

4 Fusible Link (0.5A) Brown

5 RS 485-A White

6 RS 485-B Grey

7 RS 485 RTN Purple

8 4-20 mA (+) Blue

9 4-20 mA (-) Green

10 ALARM 1 (NC) Yellow

11 ALARM 1 (COM) Orange

12 ALARM 1 (NO) Red

13 ALARM 2 (NC) Brown

14 ALARM 2 (COM) Black

15 ALARM 2 (NO) Pink

16 SPARE

Figure 2.8 3017M terminal block

Table 1 Position and purpose for each

wire on the 3017M terminal block

2.9.3 RS 485

The RS-485 full-duplex (3-wire) digital interface operates with differential levels that are not susceptible to electrical interferences. This is why cable lengths up to 3,000 ft. can be implemented. The last device on each bus may require terminating with a 120 ohm resistor to eliminate signal reﬂection on the line. Do not run RS-485 cables in the same conduit as mains power. Reference Appendix A: MODBUS Manual.

2.9.4 Analog Output (4-20 mA)

The 4-20 mA output is driven by a 12 VDC power source or may be driven by an external power source by changing the jumper position on the Main Control PCA. The 4-20 mA output will drive loads from 0 to 600 Ohms. Transformer isolation is provided on the analyzer. Do not run 4-20 mA cables in the same conduit as mains power.

2.9.5 Alarm (Relay) Connections

CAUTION Fire hazard. Current to the relay contacts must be limited to 6A resistive. A method to remove power from the relays locally must be available in case of an emergency or for servicing the analyzer.

The analyzer has two potential-free, single pole-double throw Alarm Relays. The relays are rated at 30 V, 6A. The Alarm connections are labeled Normally Open (NO), Normally Closed (NC) and Common (C). The alarm is conﬁgured failsafe; the normal condition is with power applied to the analyzer and in a non-alarm condition.

Installation

2.9.6 AC Connections (if applicable)

Connect the unpowered, AC power wires to the terminal block as follows:

1. If using a power cord, strip the outer sheath back 4 inches. Strip each individual wire back 1/4 inch (6.35 mm). If using individual wires, strip each wire back 1/4 inch.

2. Remove the nut from the cable gland and route the power cord through the nut and cable gland into the enclosure.

3. Pull the power cord back so that the end of the sheath aligns with the inside edge of the cable gland in the enclosure. This ensures that the nut will tighten on the sheath and seal the connection.

4. Connect the three wires to the proper connector using the information in Table 1, Table 2 and Figure 2.8.

Regional Wire Color Earth Ground Line 1 (Hot) Line 2 (Neutral)

North America Green Black White

IEC Green with yellow tracer Brown Blue

Table 2 Main Power Terminal Wiring

2.9.7 Reagent Preparation

The 3017M requires two reagents; a buffer solution and an indicator solution that contains the DPD powder. These reagents must be mixed and installed in the analyzer enclosure. The buffer and indicator solutions are mixed in 500-mL bottles that can be found in either: KIT-FREE CHLORINE, part number 330007, or KIT-TOTAL CHLORINE, part number

330006. Each kit will contain the items below. The containers in the respective kits are clearly marked. The buffer and indicator bottles are installed on the right-hand side of the analyzer enclosure with the BUFFER in the farthest, righthand position closes to the right side of the enclosure.

1. Diphenylenediamine (DPD) reagent in a small amber glass bottle

2. The 500 mL buffer reagent pre-charged with dry powder and a ﬁll line

3. The 500 mL indicator reagent pre-charged with dry powder and a ﬁll line

4. Instructions for use

NOTE: 1 liter of deionized water (not included) is needed to prepare the reagents. If deionized water is not available, then use water that is known to be chlorine free. If necessary, test this water with a handheld meter, or other laboratory test to verify that the water is free of chlorine.

CAUTION The DPD powder must be mixed in the indicator container.

Installation

Preparing the reagents

1. First prepare the buffer by adding approximately half of the required DI water to the buffer bottle, capping the bottle, and shaking vigorously until the dry powder inside has completely dissolved.

2. Once solids are no longer visible, carefully ﬁll the bottle to the ﬁll line, recap it, and mix it again by shaking vigorously for approximately 1 minute. Then let stand until the bubbles clear. The buffer is ready for use.

WARNING Indicator reagent is corrosive. handle with care.

3. Carefully add approximately 1/3 of the required water to the indicator reagent bottle, cap the bottle securely, and mix it by shaking for approximately 1 to 2 minutes. It is likely there will still be solid material in the bottle. Add a second one-third of the required water and mix again for 1 to 2 minutes. There should be little-to-no solid material left in the bottle. If necessary, mix for an additional 1 to 2 minutes, or until all solid material is in the solution.

4. Transfer the contents of the DPD (brown glass) bottle into the indicator reagent bottle, minimizing the amount of material left in the brown bottle. Cap securely and shake the indicator bottle, at which time the color should begin to darken slightly.

5. Carefully add the ﬁnal amount of water to reach the ﬁll line of the indicator reagent bottle, cap securely and mix again, then let stand until bubbles clear. The indicator reagent is ready for use.

6. After mixing, the reagents have a shelf life of 30 days at room temperature and 90 days refrigerated at 77° F (25° C).

Installing the reagents

1. Replace the plain bottle cap with the buffer reagent bottle cap (with siphon tube and barbed ﬁtting) and place the prepared, colorless buffer in the right bottle bay of the 3017M.

2. Replace the plain bottle cap with the indicator reagent bottle cap (with siphon tube and barbed ﬁtting) and place the prepared, slightly-colored indicator in the left bottle bay of the 3017M.

3. Carefully connect the pump tubing from the rear reagent pump cassette to the barb on the indicator reagent bottle and do the same for the front cassette tube with the buffer bottle.

4. Replace the bottle retaining plate to secure the bottles.

2.10 Pump Tubes

WARNING Pinch Point Hazard – While pumps are running it may be possible to become entangled in them while they rotate. Operators should not attempt to replace tubing while the pumps are in operation.

WARNING Leak Hazard – A leak detector is advised to be installed into the analyzer to ensure any leaks will be noticed before causing damage to the analyzer. All barbed connections should utilize cable ties in order to protect from disconnection.

Installation

2.10.1 Sample Pump Tube

The analyzer is shipped with the sample pump tube and the reagent pump tubes in place. However, the sample pump tube must be installed on the sample pump rollers.

1. Refer to Figure 2.9.

2. Remove the cover from the sample pump by placing your ﬁnger under the bottom of the cover and gently pulling outward. Take care to not allow the pump roller to fall out of the assembly.

3. A small package of silicone lubricant, part #331121, will be located on top of the rollers. This will be used to lubricate the sample pump tube before assembly.

4. Locate the package of silicone lubricant and cut a small opening across one corner of the package.

5. Apply a thin layer of the silicone lubricant to the section of the tube that will mount on the roller in the pump. A small bead of approximately 3-mm in diameter should be sufﬁcient. Spread the lubricant along the section of the tube that will contact the pump tube rollers. Do not apply the lubricant in excess. There is sufﬁcient lubricant in the startup kit for multiple pump tube installations. Remove any excess.

6. Hold the pump tube over the roller, and gently push the roller onto the drive shaft of the pump motor. Your ﬁngers should be all that is necessary to insert the sample pump tube onto the rollers of the pump. Do not use

any type of sharp tool to position the tube. Damage may result.

7. Position the tube so that it connects so that the barb ﬁtting connections on each end are as even as possible. Adjust the tube by gently moving back and forth on the rollers.

8. Install the cover.

Figure 2.9 Installation of the sample pump tube

Installation

2.10.2 Reagent Pump Tubes

1. The reagent pump tubes are installed in the proper position in the reagent pump. They were connected to the ﬂowcell at the factory. During the preparation of the reagents, the other ends of the pump tubes were connected to their respective reagents..

2. Tension the platens by pushing down on the tensioners. The tensioners will make an audible “click”. Typically, three “clicks” is sufﬁcient tension on the pump tube. Do not overtighten as this may result in premature failure of the tubes.

3. See Figure 2.10.

4. Installation complete.

Installation

Figure 2.10 Complete reagent tube installation and platen tube tensioning

3. Analyzer Startup

3.1 Supply the Sample

NOTE: Double-check all ﬁttings to ensure security before applying pressure to the Sample Inlet Device (if used).

Start the sample ﬂowing through the device to which the sample line from the analyzer is attached, or inserted. If this is the Sample Inlet Device, part #327114, adjust the pressure/ﬂow so that liquid is ﬂowing through the device. Nominally, the ﬂow rate will be in the range of 500 – 1,000 ml/min.

It is not absolutely necessary to have process sample available to start the instrument. If process sample is not available, the sample line from the analyzer may be inserted into a container of water. Fill a container with water that contains some known level of chlorine. This could be checked prior to startup with a handheld meter. Position the container in a convenient location under, or near, the analyzer and insert the sample line into the container.

3.2 Supply Power to the Analyzer

Ensure that the fusible link on the terminal block is open. If an external power switch is installed, close it at this time. Once power is available, close the fusible link. The instrument will proceed to the analyzer self-check and come to the STARTUP mode as shown below. See Figure 3.1.

The analyzer will be in a LOCKED state. This means that the user will only have access to the commands in Tier 1 of the ﬁrmware. For more information on these commands, and the procedure to UNLOCK the analyzer, refer to Section 4.7.

BACK

ENTER

Chlorine 3017M Chlorine 0.00 mg/L STATUS: STARTUP

STATUS: STARTUP

Figure 3.1 3017M STARTUP screen

Analyzer Startup

3.3 Language Selection

English is the default language. Spanish, French, German and Italian are available. If one of these languages is desired, take the following steps.

From the touchpad, select MENU > SETUP > LANGUAGE. Use the UP/DOWN arrows to select the language of your choice. Use the BACK arrow to exit from this menu. All of the text should now be in the language of your choice.

3.4 POWERUP Mode

The default POWERUP mode is STARTUP. The POWERUP MODE is user-selectable; refer to Section 4.5. Every time the power is cycled on the analyzer, the STARTUP sequence will occur. There are other options for the POWERUP MODE. These are: STANDBY and SHUTDOWN.

In STANDBY, when power is applied, the analyzer will come to the STANDBY mode. The sample and reagent pumps will occasionally rotate to prevent the tubes from taking a set due to prolonged periods of idleness.

In SHUTDOWN, when power is applied, the analyzer will come to the SHUTDOWN mode. Power will remain ON; however, the sample and reagent pumps will not periodically turn.

The STARTUP state consists of the following sequence of events. Each event, or state, will be displayed on the screen.

• PRIME: The sample and reagent pumps will turn at a high speed to prime the lines with liquid.

• RINSE: The reagent pump will stop, and the sample pump will continue to turn and rinse the ﬂowcell with sample.

• RUN: The sample pump will return to the speed for normal operation.

• SET AUTOGAIN: The zero point, sample without reagent, is determined.

• INJECT REAGENT: The reagent pump will start and run for the predetermined amount of time.

• INTEGRATE: The analyzer measures the absorption of light that corresponds to the concentration of the sample

ﬂowing through the ﬂowcell.

• CALCULATE VALUE: The concentration of the sample is calculated against the calibration curve stored on

the analyzer.

• DISPLAY VALUE: The concentration of the sample is displayed on the screen.

Observe the outlet of the ﬂowcell. As liquid start to ﬁll the tubes, air will be displaced in the tubes. Since there should be chlorine in the sample, the waste from the ﬂowcell will turn a magenta color during the PRIME state.

Two, or three, cycles may be necessary to obtain a stable reading. If bubbles persist after several cycles, ensure all tubes are submersed in liquid, and check all ﬁttings for tightness. The analyzer will continue to measure the sample in the normal operation until a new command is entered, such as, STANDBY. STANDBY state is the preferred state if the analyzer is not actively monitoring a sample stream.

If normal operation is not desired at this point in time, select: MENU > STANDBY and place the instrument in the STANDBY mode.

After the analyzer is set up to run, the cover should be secured using the 8-32 screws that are included with the mounting hardware in order to prevent unauthorized access to the analyzer by untrained personnel.

Analyzer Startup

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