WG-602 Water Quality Analyzer

WG-602 Water Quality Analyzer
WG-602
Water Quality Analyzer
Version 5.13
March 2011
1 Preface
1.1 Intended Use
This manual is for qualified and trained service te chnicians who will install and service the WaterGuard
WG-602 Water Quality Analyzer. It provides instruct ions on how to install the WaterGuard system, how to
integrate it with external chemical dosing systems, as well as how to calibrate, operate, and maintain the
system.
Safety Precautions
Warning: Only properly trained and licensed electricians sho uld attempt to wire or service the electronic
components of the analyzer. There is an Electrical Shock Hazard when servicing this system. Always
verify that all electrical power source(s) are off before opening the analyzer unit or attempting to service
electronic components or wiring.
Caution: Extreme caution should be used when installing, op erating, and maintaining the WaterGuard
WG-602 Water Quality Analyzer and Controller. Only properly trained technicians are authorized to install
and maintain the analyzer. Only properly trained and licensed electricians should attempt any change to
the system’s electrical components. Only properly trained and licensed operators should attempt to make
any changes to chemical dosing levels.
Always follow local health and safety regulations when performing any service on the WaterGuard unit or
changing chemical dosing settings.
No part of this publication may be reproduced, trans mitted, trans cribed, s tored in a retrieval s ys tem,
or trans lated into any language or any computer language, in any form or by any third party, without
the prior written permis s ion of Acromet (Aust) Pty Ltd.
Dis claimer
Acromet (Aust) Pty Ltd does not accept any responsibiltiy for any damage caused to its products by
unauthorised personnel. Use of non Acromet (Aust) Pty Ltd replacement parts will void all warranties.
2
Table of Contents
1 Preface .................................................................................... 2
1.1 Intended Use ........................................................................2
1.2 Overview of Chapters ...........................................................5
2 Overview .................................................................................. 5
2.1 Measurements and Features ................................................5
2.1.1 Wireless Management Package .....................................6
2.2 System Components ............................................................6
3 Installation ................................................................................ 7
3.1 Selecting a Location .............................................................7
3.2 Site Requirements and Installation .......................................7
3.2.1 Mechanical Installation ...................................................7
3.3 Plumbing Requirements and Installation ...............................8
3.3.1 Water Supply ..................................................................8
3.3.2 Drainage .........................................................................9
3.4 Electrical Requirements and Installation ...............................9
3.4.1 Connecting the Main Electrical Power Source ................9
3.4.2 Input Switches ................................................................9
4 First Time Operation and Calibration...................................... 10
4.1 Installing additional Sensors and Meters.............................10
4.2 First Time Menu Setup .......................................................10
4.2.1 WaterGuard Control Panel............................................10
4.2.2 Menus...........................................................................11
4.2.3 Configuring Settings in the Operator Menu ...................13
4.3 Calibration ..........................................................................13
4.3.1 Example Calibration - Chlorine .....................................13
4.3.2 Calibrating other Sensors and Meters ...........................14
4.4 Technician Menu Setup ......................................................14
4.4.1 Configuring Settings in the Technician Menu ................17
4.5 Calibration and Initial Operation Checklist ..........................17
5 Routine Operation and Maintenance ...................................... 17
5.1 Monitoring WaterGuard Alarms...........................................18
5.2 Shut-Down and Winterizing ................................................18
5.3 Troubleshooting ..................................................................19
5.4 Replacing Components ......................................................19
5.4.1 Replacing Flow Switch..................................................20
5.4.2 Replacing Control Panel Module (electronics card) ......20
5.4.3 Replacing I/O Module ...................................................20
5.4.4 Module Software Update ..............................................21
3
Table of Contents
6 Additional Features ................................................................ 21
6.1 Cl, pH and Temperature Measurements .............................21
6.1.1 Installation ....................................................................21
6.1.2 Software Set-up ............................................................22
6.1.3 Routine Maintenance ....................................................23
6.1.4 Shut-down and Winterizing ...........................................24
6.1.5 Replacing Sensors........................................................24
6.1.6 Troubleshooting ............................................................25
6.2 Turbidity Measurements .....................................................25
6.2.1 Installation ....................................................................25
6.2.2 Relay Wiring and Use ...................................................27
6.2.3 First Time Set-up and General Operation .....................28
6.2.4 Routine Maintenance ....................................................29
6.2.5 Cleaning the Turbidity Sensor.......................................29
6.2.6 Shut-down and Winterizing ...........................................29
6.2.7 Replacing Components ................................................30
6.3 Conductivity Measurements ................................................30
6.3.1 Installation ....................................................................30
6.3.2 First Time Set-up and General Operation .....................31
6.3.3 Routine Maintenance ....................................................31
6.3.4 Cleaning the Conductivity Meter ...................................31
6.3.5 Shut-down and Winterizing ...........................................31
6.3.6 Replacing Components ................................................32
6.3.7 Replacing the Conductivity Meter .................................32
6.4 Flow Meter ..........................................................................32
6.4.1 Installation ....................................................................32
6.4.2 Routine Maintenance and Troubleshooting...................33
6.5 Communication Options......................................................33
6.5.1 External 4 to 20mA Outputs ..........................................33
6.5.2 Internal 4 to 20mA Output .............................................36
7 Appendix A: Relays and Closed-Loop Control ....................... 38
7.1 Connecting external equipment to the Relays .....................38
7.1.1 Wiring to Dosing Systems .............................................38
7.1.2 Proportional Control Overview ......................................39
7.1.3 Setting Proportional Factor ...........................................40
7.1.4 Setting Pump Period .....................................................40
7.1.5 Step By Step Proportional Settings ...............................40
8 Appendix B: Technical Specifications..................................... 41
4
1.2 Overview of Chapters
This document is divided into functional sections according to the various steps involved in installing and
operating the WaterGuard system.
Section 1:
Manual Overview
Section 2:
Analyzer Overview
Section 3:
Installation
Section 4:
First Time Set up and Operation
Section 5:
Routine Operation and Maintenance
Section 6:
Measurement Options
Appendix A:
Relays and Closed Loop Control
Appendix B:
Technical Information
Short Overview of manual layout and general
precaution information.
General description of how WaterGuard automatically
monitors water quality.
Instructions on WaterGuard installation and how to
integrate WG analyzers with water quality systems.
Instructions to configure, calibrate, and operate the
WaterGuard system immediately after installation.
Instructions on responding to alarms and
troubleshooting issues.
Additional components that may be preinstalled or
upgraded in the field.
Description of WaterGuard’s direct control
components and operation.
Table summary of technical data for WG-602.
2 Overview
The WaterGuard WG-602 Water Quality Analyzer continuously monitors chemical levels in a process
water application. WaterGuard automates free chlorine, total chlorine, pH, ORP (Redox), temperature,
turbidity, conductivity and/or flow rate, administering chemicals as required, according to the results of
these tests (closed loop).
2.1 Measurements and Features
The WaterGuard unit can be configured to measures any combination of the following water quality
parameters:
•
•
•
•
•
Free Chlorine – Amperometric
Turbidity
Conductivity
pH and Temperature
Flow Rate
Several communication options are also available:
•
•
•
•
Internal 4 to 20 mA Outputs (up to 4 channels)
External 4 to 20 mA Outputs (up to 8 channels + dry contact alarms)
HydroSoft - Direct Connection
Wireless Communication Package*
Optional Module – See supplemental manual for more information
5
2.1.1 Wireless Management Package
An advanced and unique WaterGuard option is the cellular communication package which provides webbased monitoring of up to 5 analyzers. The cellular communicator accepts WaterGuard's alarms and
readings and transmits them to a web-based application server.
The information is easily accessible
remotely through the Internet or mobile telephone.
Caution: Remote control of water chemistry is potentially dangerous; therefore, the WaterGuard remote
monitoring and control service is set by default to monitoring and reporting only.
2.2 System Components
WaterGuard has two primary units: the analyzing unit and the control unit. The analyzing unit performs
the actual measurements and the control units includes all electronics, the user interface and the software
that controls the measurements performed in the analyzing unit. Together, they contain the following
components:
Flow Cell - contains the sensors, including the pH, Redox (ORP), and temperature sensors.
I/O Module (Input/Output) – Power Supply to the analyzer and contains the dry-contact relays for direct
control of external dosing systems.
Control Panel Module – Calculates the measurement results and determines the required chemical
dosing to maintain an appropriate chemical balance in closed-loop systems, and provides data to external
communication devices such as 4 to 20mA Outputs or the wireless communication package.
Keyboard Panel - mounted on the cover of the control module, it functions as WaterGuard’s user
interface. The control panel displays current measurements and indicates alarms. All settings and
adjustments are performed through the control panel.
pH, Redox, Temp Module* – receives the signal from the pH, Redox, and temperature probes.
Internal 4-20 Input Module* - Contains Connections for Turbidity, Conductivity meter, and 4-20 Flow
Meter.
Internal 4 to 20 Output Module* – Provides up to 4, 4 to 20mA outputs for any measured variable.
External 4 to 20 Module* – Provides up to 8, 4 to 20mA outputs for any measured variable. Contains
dry contacts for alarms not related to measured values including: low reagents, no reagents, no flow, etc.
*Optional Module
6
3 Installation
3.1 Selecting a Location
Take extra time in selecting a location since the installation location will determine the ease of the
installation and future operation and maintenance. The location where WaterGuard is installed is
dependent on various considerations:
Convenient Access - WaterGuard should be installed where it can easily be viewed and operated.
Dry Area – WaterGuard handles electricity and includes electronic circuitry that is susceptible to shortcircuiting and/or corrosion when exposed to water or high ambient moisture levels.
Away from Chemicals - Many water treatment chemicals can be corrosive to WaterGuard’s electronic
circuitry. It is highly recommended that WaterGuard is not installed adjacent to the chemicals storage
area or the dosing systems themselves.
Minimum Distance from Supply Pipe - The water sampling line that is connected to the main pipe,
feeding the WaterGuard should be as short as possible. A long sample line from the main pipe to
WaterGuard creates an unnecessary delay between supply, measurement, analysis, and chemical
dosing.
Freezing Temperatures – The analyzer should be installed in a location that is not susceptible to
freezing temperatures. The reagents will freeze, preventing accurate readings (even when thawed) and
parts may be damaged due to expansion when ice forms.
3.2 Site Requirements and Installation
The WaterGuard assembly is wall mounted. It should be located on a wall where operators and service
technicians can easily access it for normal operation and maintenance. It is also advisable to install it
where the operators can easily view the readings and alarms. Finally, the unit weighs approximately 6 lbs.
(3 kg), so, it must be mounted securely onto a stable wall. The WaterGuard unit measures 26.3” x 13.1”
(66.8 cm x 33.2 cm). The base of the complete WaterGuard assembly should be mounted at least 24” (60
cm) above the floor (preferably at eye level).
The WaterGuard unit and its mounting panel are not shipped with mounting screws or anchors. The
installer must provide screws and anchors that can hold the weight of the WaterGuard unit, mounting
panel, intake filter, and electrical outlets and junction boxes. The screws and anchors must be compatible
with the wall where it will be installed.
3.2.1 Mechanical Installation
1) WaterGuard is shipped pre-mounted on a mounting panel, along with a water filter. The mounting
panel includes four screw holes, one in each corner.
2) Determine the location of one hole on the WaterGuard unit or on the mounting panel.
3) Secure one corner of the WaterGuard unit or mounting panel to the wall.
4) Level the WaterGuard unit or mounting panel and mark the remaining three (3) screw holes.
5) Secure the remaining corners to the wall using 5/16” (8 mm) screws.
7
Figure 1: WaterGuard 602 Mounting Panel
3.3 Plumbing Requirements and Installation
3.3.1 Water Supply
WaterGuard requires a pressurized water supply to tthe
he flow cell, a zero pressure (gravity) water return
retur
from the colorimeter and a pressurized (or gravity) return from the flow cell. An isolating valve must be
installed in the main line and the pipe (or tube) ffrom
rom the main pipe should be as short as possible, in
i order
to minimize the delay time between the water being sampled and WaterGuard testing the water and
adjustiQJ GRVLQJ OHYHOV VHH
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3.1). The inlet pressure should not exceed 36 psi (2.5
(
bar) and
should be adjusted to 7 psi (0.5 bar) using a press
pressure
ure regulator attached to the outlet of the pre-filter.
pre
Figure 2
2: Flow cell and Colorimeter Inlet and Outlet
8
3.3.2 Drainage
A pressurized, vacuum, or gravity connection is required from the outlet of the flow cell. The flow cell may
be pressurized up to 7 psi (0.5 bar) and a ¼” FNPT fitting is supplied for the flow cell drain connection.
3.4 Electrical Requirements and Installation
WaterGuard requires a 90-120 or 180-240 VAC, 50/60 Hz electrical power source on a separate 16A
circuit in the plant room’s electrical board. The main WaterGuard power supply should be connected to a
non-dependent power supply, so that the unit remains powered constantly. The active relays should be
connected to a (pump) dependent power supply (interlocked power supply) to provide an additional layer
of prevention against chemical addition and equipment operation when the main water supply is not
operating.
3.4.1 Connecting the Main Electrical Power Source
The Main Power Supply may be connected to either 90-120 or 180-240VAC 50/60Hz. Switching between
voltages is accomplished by changing two (2) jumpers located above the main power connection, to the
left of the transformer. For 90-120VAC, a 1amp fuse should be use; for 180-240VAC, a 0.5amp fuse
should be used. These changes must be completed prior to wiring.
Caution: Before making a connection to a power source, confirm that both jumpers are located on the
correct voltage and that the appropriate fuse is in place.
6)
7)
8)
9)
10)
11)
Verify that the power switch or circuit breaker to the non-dependent power source is off.
Connect the line (live) wire to the I/O board connector marked Line.
Connect the neutral wire to the I/O board connector marked Neutral.
Connect the earth wire to the I/O Module connector marked Ground.
Continue with the other electrical connections.
Turn on electrical power only after all electrical connections have been completed.
For information on wiring and using the relays as dry contact or for control, see Appendix A.
3.4.2 Input Switches
Flow input switch terminal blocks on the I/O module allow for three input switches to be connected to the
system as additional layers of security against accidental chemical additions when there is no flow. If a
connection is expected but not detected at each input, the analyzer/controller will indicate an alarm and
will close all relays (and open the alarm relay). Therefore, if a safety switch (flow, level, etc.) will not be
installed, a fixed connection (jumper wire) is required to allow the controller to operate.
Two flow switches and one flow meter may be connected:
•
Flow Switch (internal): Flow switch connected to flow cell of analyzer. Supports both 2 and 3 wire
flow switches.
o If a 2 wire switch is used, it should be connected to the “In” and “Gnd” connections. If a 3
wire switch is used, the “VCC” connection will also be used.
o If a rotating flow switch is used, the J25 jumper should be in place; if a float-type or other
on/off flow switch is used, the J25 jumper should be removed (to be used with the open
cell analyzer models).
•
External Flow Switch: Connection for external 2-wire flow switch. If an external switch is not
connected, a jumper must be installed for the analyzer to operate properly.
9
•
Flow Meter: Connection for 2 or 3 wire flow Meter. The analyzer will not look for the flow meter
connection unless the option is turned ON in technician menu; therefore, no jumper is required if
a meter is not installed.
Caution: Electrical connections in this section are ONLY recommendations. All electrical
connections should comply with National Electrical code (NEC) and all local regulations.
First Time Operation and Calibration
3.5 Installing additional Sensors and Meters
Install all additional sensors and meters and connect to the WG-602 main system, following the
supplemental manuals for each sensor or meter.
3.6 First Time Menu Setup
This section describes how to configure the settings (set points, alarms, and calibrations) through the
WaterGuard control panel.
Caution: WaterGuard's control board unit should not be opened except for initial installation and
troubleshooting and should only be opened by a trained and approved technician.
3.6.1 WaterGuard Control Panel
The WaterGuard control panel is a simple, intuitive interface for monitoring and controlling water quality
with the following components:
When an alarm is issued, the bottom row of the LCD displays the alarm.
Pressing the up and down arrows together will display the Langelier index for approximately five (5)
seconds, and then returns to the previous display mode.
3.6.2 Menus
WaterGuard has two menu levels: Operator and Technician. The Operator menu includes settings that
may be controlled by on-site operators. The Technician menu includes settings and calibrations that
should be restricted to specially trained WaterGuard maintenance technicians. Each menu has a
separate password. The technician level password may be used whenever a password is required,
however the operator password will only be accepted in the operator menu.
Table 1 displays the operator menu functions and their description and Table 2 displays the menu
functions with the minimum and maximum values for each.
10
Table 1: Operator Menu Functions and Descriptions
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Table 2: Operator Menu and Variable Limits
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3.6.3 Configuring Settings in the Operator Menu
Each of the parameters in the operator menu is configured in the same way. The following procedure
describes how to configure a typical setting:
12) Locate the desired parameter in the menu:
a) Press Menu until the desired parameter name appears in the LCD display.
13) Press OK. Enter Password 100 appears in the LCD display.
14) Enter the Operator password (or technician password; both are accepted)
15) Press the up arrow or down arrow until the password number is reached.
Note: Holding Menu why pressing up or down will advance the first digit. Holding up or down for an
extended period of time will proceed through the numbers more quickly.
The factory-set operator password is 123. The operator password can only be changed by
entering
the current operator or technician password (see Technician Menu Setup).
16) Press Enter to accept the password. The parameter name and current setting appear in the LCD
display.
17) Press Enter, again. The LCD display shows the parameter and the current setting.
18) Enter the new parameter setting:
a) Press the up arrow or down arrow until the desired value is reached.
b) The second row of the menu display, below the value that is being changed, shows the current
value.
19) Press Enter to save the new setting or Esc to abort without saving the new setting.
To change the settings of additional parameters, press Menu until the desired parameter appears in the
LCD display and repeat steps 6-8 above to set the new parameter.
Note: The Menu button displays the next parameter in the list, so that the operator can check every
parameter in the menu. There is no scroll-back option. To view or change a previous parameter in the
menu, you must exit the menu by pressing Esc, and start the above procedure from the beginning.
3.7 Calibration
Parameters must be calibrated with measurements taken with external testing devices. Always use digital
calibration devices, not the less accurate visual test kits. Alternatively, standard solutions may be used.
Make sure the standard solution is not expired or contaminated prior to using. Follow the procedures
below EXACTLY as instructed.
ALWAYS take water for calibration from the sampling valve, NOT from the process line directly. The
analyzer should always be calibrated with water from the same source.
Following calibration directions for each sensor as indicated in the sensor manual; however chlorine is
listed below as an example.
3.7.1 Example Calibration - Chlorine
20)
21)
22)
23)
Open the water sampling valve.
Fill the sampling container.
Test the water sample for chlorine using a digital photometer.
Press Menu until “Cl Calibrated to” appears in the LCD display.
13
The top line will display “Cl Calibrated to” and a number. The number displayed is the last value
someone entered for the calibration. The bottom line will display “Cl Sensor was” and a number. This
number is the sensor reading without any calibration at the time of the last calibration. If there is a large
discrepancy between these two numbers, the sensor was calibrated improperly or there is a problem with
the analyzer. The value displayed normally on the main screen and the value the analyzer uses to
determine dosing rates is the calibrated value.
24)
25)
26)
27)
Press OK.
Enter the password. Press the up arrow or down arrow until the password is reached.
Press OK.
Press OK again.
The display will now show “Calibrate Cl to” on the top line and “Sensor Reading” on the bottom line. The
“Sensor Reading” is the current reading of the sensor with no calibration. The “Calibrate Cl to” value is
the new value which you want to set.
28) Press the up arrow or down arrow until the value is the same as the value given by the digital
photometer.
29) Press OK to save the new calibration or Esc to abort without saving.
30) Press Esc to return to the main display.
3.7.2 Calibrating other Sensors and Meters
Calibration of other sensors and meters is similar to the chlorine calibration and requires the use of a
reliable external testing device or standard solution. See the supplemental manuals for each sensor or
meter for specific information on calibration.
3.8 Technician Menu Setup
The Technician menu includes advanced parameter settings that are accessible separately from the
Operator menu. Anyone can view the settings, but only someone with technician password can change.
This has been done to allow only those who are qualified to change the advanced analyzer settings.
These are also settings that should not require frequent changes after the initial installation and set-up.
14
Table 3: Technician Menu Functions and Descriptions
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16
3.8.1 Configuring Settings in the Technician Menu
Navigation within in the Technician Menu is identical to the operator menu.
1) To enter the Technician menu, press Menu to enter the operator menu and then the up arrow and
down arrow together simultaneously until the menu display changes.
2) Locate the desired parameter in the menu:
a) Press Menu until the desired parameter name appears in the LCD display.
b) Press OK. Enter Password 100 appears in the LCD display.
3) Enter the Technician menu password:
a) Press the up arrow or down arrow until the password number is reached.
b) Press OK. The parameter name and current setting appear in the LCD display.
Note: Technician menu password is different from the Operator menu password. The default
Technician menu password is 456 and if lost, can only be reset by replacing the chipset.
4) Continue changing the parameter setting, as described in the Operator menu.
3.9 Calibration and Initial Operation Checklist
Before leaving the site, perform the procedure in this section and record the requested values.
Calibrate the following WaterGuard parameters and enter the information into the table below. If pH is
reading slightly low, do not calibrate as it will continue to increase for the first 24-48 hours.
4 Routine Operation and Maintenance
Once installed by a qualified technician, WaterGuard can begin monitoring and controlling water quality.
WaterGuard is specifically designed for easy operation; however some periodic maintenance is still
required.
•
Basic Operation: involves setting the desired parameters and monitoring the system for alarms.
When operating normally, WaterGuard demands very little operator involvement.
•
Calibration: Sensor sensitivity and accuracy can degrade or drift over time. For this reason,
WaterGuard settings must be periodically recalibrated and compared with measurements from
other measuring devices, such as electronic photometers, pH sensors, and thermometers or
compared to standard solutions like pH buffers.
17
•
Shut-down and Winterizing: If the analyzer will not be operating for an extended period of time
or in areas where temperatures drop below freezing, all water must be removed from the analyzer
to prevent components from breaking and the probes must be removed and stored in a warm
area and kept wet at all times.
•
Troubleshooting: Occasionally problems will occur with the analyzer readings or chemical
dosing. These problems are most often simple to correct. The troubleshooting section provides
an outline to follow to help correct the problems easily.
4.1 Monitoring WaterGuard Alarms
WaterGuard issues alarms when it detects chemical levels that are above or below the allowed range.
Every alarm is automatically displayed in the LCD status display and logged in the data logger. Most
deviations in chemical levels, however, are automatically corrected. Thus, the internal alarms do not
immediately activate an external alarm. A delay mechanism prevents false alarms from minor deviations
that were automatically corrected. The external alarm is only activated after an internal alarm has been
continuously active for a certain period of time, as defined by the operator.
The Alarm Delay command in the Operator menu sets the number of seconds WaterGuard waits before
closing Relay 5, the relay that operates the external alarm. Only one alarm is shown on the screen at a
time based on importance and the order in which it should be fixed. For example, if the pH is high and
the ORP is low, only the pH alarm will be indicated since lowering the pH will likely also correct the low
ORP. All of the alarms are presented in Table 5 along with a description and resulting action of the
analyzer/controller.
Table 5: Alarm Description and Result
4.2 Shut-Down and Winterizing
The WaterGuard analyzer is designed to keep the probes submerged even if there is no flow to the
analyzer. However, if the analyzer is going to be offline for an extended period of time and/or exposed to
freezing temperatures, it must be winterized to prevent damage to the analyzer and the probes.
1) Store all probes following directions in the supplemental manuals for each sensor.
2) Drain the flow cell completely by opening the sampling valve on the bottom. Leave the valve in the
open position to allow air to completely dry the cell.
3) Check the security of the analyzer doors to ensure a weatherproof seal.
18
4.3 Troubleshooting
The following procedures instruct how to locate, evaluate, and fix a problem when WaterGuard issues an
alarm or indicates suspect chemical levels.
4.4 Replacing Components
The following procedures describe how to replace certain WaterGuard components.
Caution: The following procedures should only be performed by properly qualified and trained
WaterGuard analyzer technicians.
Warning: Disconnect all power supplies to the WaterGuard analyzer before opening the control unit door.
Replacing any parts of WaterGuard without the expressed written authorization of Chemical Injection
Technologies, Inc., or the qualified representative who supplied the product may void the warranty.
Chemical Injection Technologies, Inc., takes no responsibility, written or implied, for installation or
maintenance of WaterGuard that is not performed by a properly trained and certified WaterGuard
technician.
19
4.4.1 Replacing Flow Switch
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
Turn off the inlet and outlet water to the flow cel
cell and the power to the analyzer.
Open the doors of both the analyzing module and the control module.
Locate the flow switch attached to the flow cell.
Disconnect the flow switch wires from the I/O modul
module.
Remove the inlet connection to the old flow switch.
Remove the flow switch from the flow cell.
Pull the flow switch wires gently to completely remove from the analyzer
Insert the new flow switch on the flow cell
Insert the inlet connection on the flow switch
Route the flow switch wires back to the connection on the I/O module and connect the wires to the
input switch terminal block.
11) Close the analyzer doors and turn on the water and power and ensure proper operation.
4.4.2 Replacing Control Panel Module (electronics card)
Disconnect the power supply to the unit before open
opening the control unit.
1) Disconnect the flat cable plug fr
from the card.
2) Unscrew the four (4) mounting screws.
3) Put in the new card and tighten the 4 mounting scre
screws.
4) Connect the flat cable plug to the card.
Figure 3: Replacing all types of electronic modules (cards)
4.4.3 Replacing I/O Module
Disconnect the power supply to the unit before open
opening the control unit.
1) Disconnect the flat cable plug from the card.
2) Unscrew the four (4) mounting screws.
3) Put in the new card and tighten the 4 mounting scre
screws.
4) Connect the flat cable plug to the card.
20
4.4.4 Module Software Update
Each electronic module (card) has a microcontroller chip (IC) with its own unique software. Whenever a
module’s software is updated, its chip must be repl
replaced
aced by a new version with the new software.
1) Turn OFF the power to WaterGuard.
terGuard.
2) Locate the chip that needs to be replaced
3) Remove the chip carefully by prying up each end a llittle
ittle at a time with a thin screwdriver.
4) Install the new chip in the same location. Please n
note
ote in the figure that the chip and the board each
have a directional
ectional mark. The chip must be positioned so that these directional marks are aligned.
* The control panel has no IC, it is necessary to rreplace the module (electronics card).
Warning: Installing the chip in the
wrong direction will damage the
system and can create an electrical
fire hazard.
Figure 4: Installing New Chipset
5 Additional Features
5.1 Cl, pH and Temperature Measurements
5.1.1 Installation
If the WaterGuard system was ordered with these com
components some steps in this process will have been
completed in the factory and may be skipped.
Required Components
•
•
•
•
•
Amperometric, pH, Temp Module (electronics card)
150 mm flat cable
Amperometric probe
pH probe
Temperature probe
Note: the system may be operated with on
only
ly pH or only Amperometric but must always have the
temperature probe as this provides additional groun
grounding
ding to ensure reliable measurements. Likewise, the
th
integrated pH compensation for the Amperometric mea
measurement
surement will only operate if the pH probe is
installed.
The following procedure describes how to install th
the
e Amperometric and pH sensors in the WaterGuard
unit. The installation of all the sensors in the flflow
ow cell is similar, expect for the connecting wires.
wires
21
Caution: Make sure the amperometric and pH sensors have plastic or rubber plugs covering their ends.
Use another sensor if the plug of any sensor is missing or has fallen off.
Make sure to connect the appropriate wire to the appropriate sensors. Labels are located on the wires
near the probe connection and on the connection on the amperometric, pH, Temp Module.
Hardware Installation
1) Turn off all power and water supplies to the analyzer
2) Install the amp, pH, Temp module (electronics card) in the control module on the top left using the 4
supplied screws.
3) Connect the flat cable to the amp, pH, Temp module to an open connector on the I/O module
4) Install the temperature probe
a) Thread the 3/8” compression connector into the back of the flow cell.
b) Place the probe into the connector until and hand tighten the connector.
c) Route the temperature probe wires into the electronics box and connect to the bottom of the amp,
pH, Temp module following the color codes listed on the module.
5) Install the amperometric probe
a) Remove the sensor from its packing box and remove the plastic cover or plug from the end of the
sensor and drain the solution from the tube. Keep the plastic cover in a safe place for winterizing
or storage of probes.
b) Hold the sensor by its connector, with the tube pointing down.
c) If not already installed, install the threaded adaptor on the probe.
d) Insert the sensor into the largest opening on the top of the transparent flow cell and thread in
securely. DO NOT OVERTIGHTEN.
e) Route the cable to the electronics box and connect to the middle of the amp, pH, Temp module
following the color codes listed on the module.
f) Connect the one remaining wire to the grounding connector on the module.
6) Install the pH probe
a) Remove the sensor from its packing box and remove the plastic cover or plug from the end of the
sensor and drain the solution from the tube. Keep the plastic cover in a safe place for winterizing
or storage of probes.
b) Hold the sensor by its connector, with the glass tube pointing down.
c) Insert the sensor into ½” connector on the top of the transparent flow cell and thread in securely.
DO NOT OVERTIGHTEN.
d) Route the pH cables to the electronics box and connect to top of the amp, pH, Temp module.
e) Connect the cable to the pH sensor.
7) If the pH sensor is not installed:
a) install a jumper between the inputs for pH
b) In the menu, set the low and high alarm limits at the minimum and maximum values respectively
to prevent a false alarm for pH.
8) Turn the flow on to the analyzer and confirm that no connections are leaking. If the flow is not turned
on immediately, at least add water to the flow cell to keep the probes wet.
5.1.2 Software Set-up
1) Turn the analyzer ON
2) Enter the operator menu and set the alarms and set-points (if using relays) levels as appropriate.
3) Enter the technician menu and turn on the display for Free Cl and ph (temperature is automatically
displayed)
4) Perform a system reset and verify that Cl, pH and temperature appear on the display.
5) Observe the Cl and pH levels and wait several minutes until both readings stabilize.
6) If either one or both indicators do not display a proper reading or are not stable confirm proper
installation and then see Troubleshooting.
22
Note: the Cl readings should fully stabilize within 1 hour and the pH within 24 hours; however the
readings should not be erratic.
5.1.3 Routine Maintenance
Calibration
pH Calibration
pH is calibrated using an Phenol Red or Buffer 7 solution.
1) Shut off the water inlet and outlet from the flow cell
2) Remove the pH sensor and temperature probe from the flow cell.
3) Wipe sensor probe with a dry cloth and submerge it and the (PT-100) temperature probe into a cup
with the Phenol Red or Buffer 7 solution and wait for the reading to stabilize.
Note: The reading will not stabilize if the temperature probe is not also in the buffer solution
4)
5)
6)
7)
8)
9)
Press Menu until pH Calibrated to appears in the LCD display.
Press OK.
Enter the password. Press the up arrow or down arrow until the password is reached.
Press OK.
Press OK again.
Press the up arrow or down arrow until the value is the same as the value printed on the label of the
Phenol Red or Buffer 7 Solution.
10) Press OK to save the new calibration or Esc to abort without saving.
11) Press Esc to return to the main display.
Cl Calibration
1)
2)
3)
4)
Open the water sampling valve.
Fill the sampling container.
Test the water sample for chlorine using a digital photometer.
Press Menu until “Cl Calibrated to” appears in the LCD display.
The top line will display “Cl Calibrated to” and a number. The number displayed is the last value
someone entered for the calibration. The bottom line will display “Cl Sensor was” and a number. This
number is the sensor reading without any calibration at the time of the last calibration. If there is a large
discrepancy between these two numbers, the sensor was calibrated improperly or there is a problem with
the analyzer. The value displayed normally on the main screen and the value the analyzer uses to
determine dosing rates is the calibrated value.
5)
6)
7)
8)
Press OK.
Enter the password. Press the up arrow or down arrow until the password is reached.
Press OK.
Press OK again.
The display will now show “Calibrate Cl to” on the top line and “Sensor Reading” on the bottom line. The
“Sensor Reading” is the current reading of the sensor with no calibration. The “Calibrate Cl to” value is
the new value which you want to set.
23
9) Press the up arrow or down arrow until the value is the same as the value given by the digital
photometer.
10) Press OK to save the new calibration or Esc to abort without saving.
11) Press Esc to return to the main display.
Note: When the WaterGuard is initially turned on, the pH readings will continue to rise for the first 24-48
hours. If calibration is required, it is best to wait until the readings have stabilized or recalibrate when the
readings have stabilized.
Temperature Calibration
Take a sample of water from the flow cell
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
Insert a digital thermometer into the sample
Wait for the thermometer reading to stabilize
Press Menu until Temperature Calibrated to appears in the LCD display.
Press OK.
Enter the password. Press the up arrow or down arrow until the password is reached.
Press OK.
The value that appears is the last calibrated value.
Press OK again.
Press the up arrow or down arrow until the value is the same as the independent digital thermometer.
Press OK to save the new calibration or Esc to abort without saving.
Press Esc to return to the main display.
5.1.4 Shut-down and Winterizing
1) Remove the probe from the flow cell
2) Fill the rubber caps (that were on the new probes) with tap water or preferably KCl (potassium
chloride) solution and insert over the end of each probe (DO NOT use DI water).
3) Screw the plastic cap over the top of each probe to protect the connector.
4) Store in a safe location that will not drop below freezing, preferably in the original probe box for
additional protection.
5.1.5 Replacing Sensors
Replacing the Amperometric sensor
1) Turn off the inlet and outlet water to the flow cell and the power to the analyzer.
2) Open the doors of both the analyzing module and the control module.
3) Remove old sensor from flow cell
a) Disconnect the wires from the amperometric, pH, temp module.
b) Unscrew the sensor from the flow cell
c) Pull the sensor up until its tube clears the hole.
4) Install new Sensor
a) Open the replacement sensor's box, and remove the sensor cable connector.
b) Remove the plastic cap on the end of the probe
c) Hold the sensor by its connector, with the tube pointing down, and insert into the flow cell.
d) Thread the probe into place. DO NOT OVERTIGHTEN
e) Attach the sensor’s wire on the amp, pH, temp module following the color coding on the module.
Replacing the pH sensor
1) Turn off the inlet and outlet water to the flow cell and the power to the analyzer.
24
2) Open the doors of both the analyzing module and the control module.
3) Remove old sensor from flow cell
a) Unplug the sensor's wires from the sensor, by grabbing the connector at the top end of the
sensor and unscrewing the connector.
b) Unscrew the sensor from the flow cell
c) Pull the sensor up until its glass tube clears the hole.
4) Install new Sensor
a) Open the replacement sensor's box, and remove the sensor by the metal connector.
b) Remove the plastic cap on the glass end of the probe
c) Hold the sensor by its metal connector, with the glass tube pointing down, and insert the glass
tube into the flow cell.
d) Screw the probe into place. DO NOT OVERTIGHTEN
e) Attach the sensor wire onto the probe.
Replacing the Temperature Probe
1)
2)
3)
4)
Turn off the inlet and outlet water to the flow cell and the power to the analyzer.
Open the doors of both the analyzing module and the control module.
Remove the four (4) wires from the temperature probe in the control module.
Remove old sensor from reading cell:
a) Unscrew the compression fitting from the temperature probe
b) Pull the probe up until it clears the fitting.
5) Install new sensor:
a) Insert the temperature probe into the fitting
b) Screw the compression fitting around the probe.
c) Connect wires to amp, pH, Temp module following color coding
5.1.6 Troubleshooting
5.2 Turbidity Measurements
5.2.1 Installation
If the WaterGuard system was ordered with the Turbidity pre-installed some of these steps may have
been completed in the factory.
Supplied Components
25
•
•
•
•
•
Turbidity Input Module (electronics card)
250 mm flat cable
Turbidity Sensor (wiper optional)
Turbidity Flow Cell (bubble remover optional)
Flow Cell Mounting Bracket
Caution: Prior to opening the analyzer or installing any electrical components, turn off all power supplies
to the analyzer
There are five (5) wires, contained in a single cord, from the sensor that must be connected to the
analyzer. The standard wire length is 22 ft (7m), and may be cut or extended up to 650 ft (200m) as
needed. The turbidity flow cell and sensor must be securely mounted using appropriate hardware for the
mounting location. Unfiltered water will need to be supplied to the turbidity flow cell at a flow between
0.25 to 1 GPM and less than 30 psi (2 bar).
Hardware and Plumbing Installation
1) Mount the Turbidity Flow Cell, using the supplied bracket (or other mounting hardware as
appropriate) such that the inlet and outlet ports are horizontal and the flow tube extends down.
2) Insert the sensor into the opening of the flow tube, ensuring that the notch in the top of the opening
matches the rod on the sensor.
3) Hand-tighten the connector to secure the sensor and seal the turbidity flow cell.
4) Connect the water supply to the turbidity flow cell. Follow the flow indicated by the arrow on the flow
cell.
A
Figure 5:
B
A. Turbidity Sensor and Flow Cell without bubble remover
B. Flow Cell with bubble remover
The flow rate should be between 0.25 and 1 GPM (15-60 gal/hr or 50-225 L/hr) and the pressure should
not exceed 30psi (2 bar). The inlet and outlet connections are ¼” FNPT.
26
Electrical Installation
1) Install the Turbidity Module (electronics card) on the inside, bottom of the control panel door using the
supplied screws.
2) Connect the turbidity module to the I/O module using the supplied ribbon cable and any open
connector (the connectors on both boards operate in parallel).
3) Pass the sensor cable through an open glad on the bottom of the analyzer.
4) Connect the wires from the sensor cable to the terminal block on the lower left corner of the Turbidity
Module, following the color order indicated on the module.
Figure 6: Connecting Turbidity Sensor to Turbidity Module
The sensor cable may be cut or extended up to a maximum distance of 650 feet (200m) as needed.
If the turbidity relay is not going to be connected to any external equipment, the installation is complete. If
the relay will be used to operate equipment based on the turbidity set point, the following steps will need
to be followed:
5.2.2 Relay Wiring and Use
Wiring of the Turbidity Relay (NTU relay) is identical to wiring of all other relays and should be connected
to a dependent (interlocked) power supply to prevent operation of equipment when the water supply is not
active. Likewise, it operates based on closed-loop control.
The line (live) wire of the pump-dependent power source connects to the connection labeled Common (C)
on the NTU relay. The line wire of the controlled external turbidity equipment is connected to the normally
open (NO) or normally closed (NC) connection of each relay as appropriate. Normally Open means that
the relay will be open (i.e. no power from the relay) until the analyzer calls for power; Normally Closed
means that the relay will be closed (i.e. power from the relay) until the analyzer calls to stop power.
1) Turn OFF all power sources to the analyzer.
2) Connect the earth ground wire of the power supply to the ground return wire from the controlled
external turbidity equipment.
3) Connect the neutral wire of the power supply to the neutral wire from the controlled external turbidity
equipment.
4) Connect the line (live) wire of the power supply to the connector marked ‘C’ (common) on the NTU
terminal block.
27
5) Connect the line (live) wire of the controlled external turbidity equipment to the normally open (NO) or
normally closed (NC) connection on the NTU terminal block.
Caution: Each relay connection is limited to 4 amps, to prevent overheating. The relays may show a
higher rating but do not connect equipment exceeding 4 amps.
Relay and External Equipment Operation
The relay will operate in an ON/OFF mode. Whenever the measured turbidity is below the set point, the
relay will remain open (no power to normally open connection). Whenever the measured turbidity is
above the turbidity set point, the relay will close (power will be supplied to the normally open connection).
If the measured turbidity is above the turbidity high alarm, the alarm on the analyzer will be activated.
The NTU relay will remain closed (power to the normally open connection) even during alarm.
5.2.3 First Time Set-up and General Operation
Although the turbidity unit is connected, it will not operate until it is set-up in the analyzer menu.
Operator Menu
If the NTU relay is connected to external equipment:
1) Press Menu until “Turbidity Set Point” appears on the display and press OK
2) Enter the operator or technician password and press OK
3) Enter the turbidity set point value and press OK
With or without the NTU relay connected to external equipment:
4) Press Menu until “Turbidity High Alarm” appears on the display and press OK
5) Enter the operator or technician password and press OK
6) Enter the turbidity high alarm value and press OK
Technical Menu
1) Press Menu to enter the Operator Menu and then Press up and down together to enter the technical
menu
2) Press Menu until “Turbidity ON/OFF” appears in the display and press OK
3) Enter the technician password and press OK
4) Press up to turn the turbidity sensor ON and press OK
5) Press Menu until “Turbidity Wiper Interval” appears in the display and press OK
6) Enter the technician password and press OK
7) Enter the wiper interval (2 minutes is recommended) and press OK
The turbidity unit should now be active. Confirm that the turbidity value appears on the LCD display. If it
is not active, perform a system reset.
28
5.2.4 Routine Maintenance
Turbidity Calibration
1) Take a sample of water from the flow cell
2) Test the sample using an accurate digital turbidly meter
3) Press Menu until NTUl Calibrated to or NTUh Calibrated to appears in the LCD display.
If calibrating below 1.0 NTU use NTUl (low) if calibrating above 1.0 NTU use NTUh (high).
4)
5)
6)
7)
8)
9)
Press OK.
Enter the password. Press the up arrow or down arrow until the password is reached.
Press OK.
The value that appears is the last calibrated value.
Press OK again.
Press the up arrow or down arrow until the value is the same as the independent digital turbidity
meter.
10) Press OK to save the new calibration or Esc to abort without saving.
11) Press Esc to return to the main display.
Note: Only 1 Turbidity calibration will be active. If the measured Turbidity is less than 1.0, only the
NTUl calibration will be active; if the turbidity is greater than 1.0, only the NTUh calibration will be active.
5.2.5 Cleaning the Turbidity Sensor
The turbidity meter will need to be periodically cleaned to ensure proper operation and reliability. The
cleaning frequency will depend on the water source being tested. The meter should be cleaned
whenever the measurement accuracy is questionable and before calibration.
1) Turn off power to the analyzer.
2) Shut off the flow to the turbidity flow cell and remove the turbidity meter.
3) Rinse out the flow assembly with clean water to remove any sediment that may have been trapped in
the flow cell.
4) Wash the turbidity meter under clean water and a cloth to remove any debris and oil. Be careful not
to scratch the sensor covers.
5) If installed, inspect the wiper for signs of wear and replace if necessary.
6) Reinstall the meter and turn the flow back to the meter.
7) Confirm that the meter is operating properly and that the flow cell is sealed.
5.2.6 Shut-down and Winterizing
1) Disable the Turbidity measurement in the technician menu
2) Shut off the flow of water to the turbidity flow cell
3) Open the drain at the bottom of the flow cell to drain all water
4) If temperatures will drop below freezing, remove the turbidity sensor and store in a safe location
where temperatures will not drop below freezing.
29
5.2.7 Replacing Components
Replacing the Turbidity Meter
1)
2)
3)
4)
5)
6)
Turn off the inlet and outlet water to the flow cell and the power to the analyzer.
Open the door of the control module.
Remove the 5 wires from the bottom of the Turbidity input module
Remove the meter from the flow cell by unscrewing the cap and pulling gently
Install the new meter in the flow cell
Route the wires back to the turbidity module and reconnect the 5 wires following the color coding on
the module.
7) Restart the flow and turn the power on
8) Confirm that proper operation has been restored
Replacing Turbidity Input Module
Disconnect the power supply to the unit before opening the control unit.
1) Disconnect the flat cable plug from the card.
2) Disconnect all terminal blocks
3) Unscrew the four (4) mounting screws.
4) Put in the new card and tighten the 4 mounting screws.
5) Connect the flat cable plug to the card
6) Reconnect the terminal blocks
5.3 Conductivity Measurements
5.3.1 Installation
If the WaterGuard system was ordered with the Conductivity pre-installed some of these steps will have
been completed in the factory.
Supplied Components
•
•
•
•
Conductivity 4-20 input Module (electronics card)
150mm Flat Cable (ribbon cable)
Conductivity meter
Conductivity flow cell
Caution: Prior to opening the analyzer or installing any electrical components, turn off all power supplies
to the analyzer
1) Attach the module to the inside of the control panel door below the control panel module using the 4
supplied screws.
2) Attach the ribbon cable from the conductivity module to any open connector on the I/O module.
3) Mount the conductivity flow cell and meter on a solid wall or surface using appropriate hardware (not
supplied). Make sure that the distance is less than 15m (45 feet) from the WaterGuard analyzer.
4) Connect a water supply of no greater than 2 bar (30 psi) to the inlet fitting using 6mm tubing. It may
be a new separate water supply or a line tapped from the main analyzer water supply before the prefilter. Larger tubing may be used if the fitting is replaced to accept the new tubing.
5) Connect a 6mm water outline line to the outlet fitting and connect to:
a. The main water system at least 5 psi (0.3 bar) lower than the inlet water supply or
b. The pre-filter of the WaterGuard analyzer.
30
6)
7)
8)
9)
10)
Route the conductivity meter wire through an open gland on the bottom of the analyzer
Connect the wires to an open 4-20mA input on the bottom of the 4-20 module
Connect 24V from the meter to 24V on the module
Connect mS from the meter to IN on the module
Connect GND from the meter to ground (symbol) on the module
5.3.2 First Time Set-up and General Operation
For Output of the conductivity measurement, see internal or external 4-20mA module sections to
configure the output in your specific WaterGuard analyzer.
5.3.3 Routine Maintenance
Conductivity Calibration
Must be conducted when process is stable, specifically temperature should be within normal operating
range.
1) Test a sample of water with an accurate external conductivity meter
2) Use the calibration adjustment screw to increase or decrease the conductivity, making very small
changes
3) Wait for the adjustment to take effect before making additional changes
5.3.4 Cleaning the Conductivity Meter
Routine cleaning of the conductivity meter will ensure long-term reliability. The frequency of cleaning will
depend on the water source being tested and should be conducted whenever there is significant visible
dirt, the measurement accuracy is affected, or before the meter is calibrated.
1)
2)
3)
4)
Shut off the flow of water to the conductivity flow cell and remove the meter.
Wash the meter under a jet of water to remove the debris.
Use a soft cloth to remove any additional debris and oil.
Replace the meter and restore flow to the flow cell.
5.3.5 Shut-down and Winterizing
1) Shut off the flow of water to the conductivity flow cell
2) Drain the water from the flow cell
3) If temperatures will drop below freezing, remove the conductivity sensor and store in a safe location
where temperatures will not drop below freezing.
31
5.3.6 Replacing Components
5.3.7 Replacing the Conductivity Meter
1)
2)
3)
4)
5)
6)
7)
8)
Turn off the inlet and outlet water to the flow cell and the power to the analyzer.
Open the door of the control module.
Remove the wires from the bottom of the Conductivity input module
Remove the meter from the flow cell by unscrewing the cap and pulling gently
Install the new meter in the flow cell
Route the wires back to the conductivity module and reconnect the wires to the 4-20 input module.
Restart the flow and turn the power on
Confirm that proper operation has been restored
Replacing Conductivity Input Module
Disconnect the power supply to the unit before opening the control unit.
1) Disconnect the flat cable plug from the card.
2) Disconnect all terminal blocks
3) Unscrew the four (4) mounting screws.
4) Put in the new card and tighten the 4 mounting screws.
5) Connect the flat cable plug to the card.
6) Reconnect the terminal blocks
5.4 Flow Meter
Chemical Injection Technologies, Inc., can supply flow meters; but WaterGuard WG-602, itself, provides
only input connections and display.
5.4.1 Installation
Required Components
•
•
•
Flow meter – frequency or 4-20
4-20 input module if using 4-20 flow meter
150 mm flat cable if using 4-20 input module
Prior to opening the analyzer or installing any electrical components, turn off all power supplies to the
analyzer
Frequency Output Flow Meter
A flow meter with either two (2) or three (3) wires for a frequency output can be connected to the input
switch section on the I/O module.
Installation
1) Install the flow meter following the manufacturer directions. Be sure to install close enough to
WaterGuard that the wires will reach.
2) Pass the flow sensor cable through an open glad on the bottom of the analyzer.
3) Connect the two or three wires from the sensor cable to the input switch terminal block on the lower
right corner of the I/O Module.
32
Although the flow meter is connected, it will not operate until it is set-up in the analyzer menu.
4) Press Menu until “Flow Low Limit” appears and enter the low flow value (the flow value which will
cause an alarm and will disable any direct chemical dosing).
5) Press Menu again and “K-factor” appears. Enter the k-factor for the flow meter being used (should be
on paperwork with flow meter).
6) Press Up + Down arrows together and then press Menu until “Flow Rate m3/hr” appears and select
the flow units of m3/hr or GPM.
4-20 Output Flow Meter
Any flow meter with a 4-20mA output can be connected to the analyzer’s internal 4-20 input module
1) Install the flow meter as per the manufacturer directions.
2) Pass the flow sensor cable through an open glad on the bottom of the analyzer.
3) Connect the 4-20mA output wires from the flow meter to the middle 4-20mA Input connection on the
input module.
Although the flow meter is connected, it will not operate until it is set-up in the analyzer menu.
4) Press Menu until “Flow Low Limit” appears and enter the low flow value (the flow value which will
cause an alarm and will disable any direct chemical dosing).
5) Press Up + Down arrows together and then press Menu until “Flow Rate m3/hr” appears and select
the flow units of m3/hr or GPM.
6) Press Menu until “Max flow Range” appears and enter the maximum flow rate (flow rate at 20mA
output). The minimum flow rate (flow rate at 4mA output) is assumed to be zero.
The flow meter should now be active. Confirm that the flow rate appears on the LCD display. If it is not
active, perform a system reset.
5.4.2 Routine Maintenance and Troubleshooting
Follow manufacture’s recommendations for maintenance procedures and any troubleshooting issues.
5.5 Communication Options
5.5.1 External 4 to 20mA Outputs
Overview
The 4 to 20 mA output provides a connection of the WaterGuard water quality analyzer to any external
monitoring or control system. For each parameter, an output signal is transmitted and the strength of the
signal (in mA) can be simply correlated to the actual parameter value. Likewise, specific alarm
information may also be transmitted to alert personnel of a problem not related to the output parameters.
33
Installation
Required Parts
The 4 to 20mA module upgrade includes two (2) main components that are supplied with the upgrade:
•
•
External 4 to 20 module case
4 to 20 module (electronics card)
To complete the installation a few additional components, not supplied with the upgrade will be needed:
•
•
•
•
Hardware to attach the external module case to a wall or other secure structure.
110-115 or 220-230V AC power supply with 3 wires
A 2-wire cable for connection between the module and analyzer
A 2-wire cable for each output channel/parameter
Hardware Installation
1) The external case has 4 mounting brackets on the back. All 4 should be used to securely attach to
the wall.
2) Mark the location of each screw hole and drill a hole for a screw anchor.
3) Thread the screws almost completely into the anchor leaving about ¼” (6 mm) of thread exposed.
4) Attach the external case to the screws
5) Adjust the screw depth to securely fasten to the wall
Electrical Installation
The 4 to 20 mA module requires a separate power supply in order to operate. The 2-wire connection to
the analyzer is for communication only and does not supply any power.
The Module Power Supply may be connected to either 110-120 or 220-240VAC 50/60Hz. Switching
between voltages is accomplished by changing two (2) jumpers located above the main power
connection, to the left of the transformer. For 110-120VAC, a 1amp fuse should be used; for 220240VAC, a 0.5amp fuse should be used. These changes must be completed prior to wiring.
Caution: Before making a connection to a power source, confirm that both jumpers are located on the
correct voltage and that the appropriate fuse is in place.
Connecting Main Power and Analyzer Communication
1)
2)
3)
4)
5)
6)
Verify that the power switch or circuit breaker to the non-dependent power source is off.
Locate the power supply connection.
Connect the line (live) wire to the electronic board connector marked Line.
Connect the neutral wire to the electronic board connector marked Neutral.
Connect the earth wire to the electronic board connector marked Ground.
Locate the RS485 connections on the analyzer control panel (electronics card on the analyzer door)
and the 4 to 20 mA module.
7) Connect the 2-wire cable from the RS485 connection on the analyzer to the RS485 connection on the
4 to 20 mA module.
a) Connect the ‘+’ wire from the analyzer to the ‘A’ connection on the module
b) Connect the ‘-‘ wire from the analyzer to the ‘B’ connection on the module
8) Turn on electrical power only after all electrical connections have been completed.
Confirming Operation and Communication
34
Prior to connecting to the external monitoring or control system, it is best to confirm that all desired
outputs are working properly using a digital multi-meter. This must be done without output wires
connected to an external system.
1) Set the multi-meter to measure current and connect the multi-meter to an active output (an output is
inactive if it does not have a chipset installed next to the terminal block).
2) Record the current in mA.
3) Confirm that the value is accurate using, Equation 1.
4) Repeat for each active output.
MeasuredValue =
(mA) ∗ ( Fullscale)
+ MinimumValue
16
or
mA =
(16) ∗ (MeasuredValue ) + 4
FullScale
mA = milliamp output value
Full Scale = Max Value - Min Value (in case of Min is zero, it's the max value)
Equation 1: Determining Parameter Value from mA output
Connecting to External Monitoring System
1) Connect two wires from the active output to the appropriate connection on the external system
2) Repeat for each active output
3) If an active output (output with a chipset installed) is not to be used, place a jumper wire between the
contacts.
4) For alarm notification
a) Connect two wires to the appropriate dry contact
i) Connection between C and Nc will have contact unless alarm
ii) Connection between C and No will only have contact during alarm
b) Repeat for each alarm
Connections on an optional, external 4 to 20mA Module
Figure 7: Optional External 4 to 20 mA Output Module Electrical connections
1. Power Input 110-115 or 220-230VAC 50/60 Hz
Alarm (Dry Contacts)
2. No Flow
3. Unclean Cell
35
Alarm (Dry Contacts), continued
4. No Communication with the Colorimeter
5. Reagents Close to completion
6. No Reagents
7. External Disconnected
Communication Connection
8. RS485 Communication Terminal Block
17. RS 232 Communication Terminal Block
Communication Connection
9. Free Cl
4mA = 0
10. pH
4mA = 0
11. ORP
4mA = 0
12. Temp
4mA = 0
13. NTU
4mA = 0
14. Flow Rate
4mA = 0
15. Total Cl
4mA = 0
16. Conductivity
4mA = 0
20mA = 9.99
20mA = 9.99
20mA = 999
20mA = 50°C or 212°F
20mA = 9.99
3
20mA = 200 m /hr
20mA = 9.99
20mA = 2000 uS
Troubleshooting
There are a few indicator lights on the 4 to 20 mA module to aid in troubleshooting. The following
conditions are possible:
Green Light
ON – 4 to 20 mA module is powered
OFF – 4 to 20 mA module is not powered
Red Light
ON – One or more of the outputs is not connected (use jumper wire on unused outputs)
Flashing – No communication between 4 to 20 mA module and analyzer
OFF – Communication and Outputs are working properly
5.5.2 Internal 4 to 20mA Output
Installation
Required Parts
•
•
Internal 4-20mA Module (electronics card)
250mm Flat Cable (ribbon cable)
To complete the installation a 2-wire cable for each output channel/parameter will also be required.
Hardware Installation
1) Attach the 4 to 20 module to the inside of the control panel door below the control panel module using
the 4 supplied screws.
2) Attach the ribbon cable from the 4 to 20 module to any open connector on the I/O module.
36
Electrical Installation
The 4 to 20 mA module is powered through the ribbon cable and does not require a separate electrical
supply as the external module.
Software Set-up
1)
2)
3)
4)
5)
6)
7)
Go to “4-20mA Output Settings” menu and press OK
Enter the technician password and press OK
Select the channel (1 to 4) and press
Press OK and Select the parameter for that channel (Free Cl, Total Cl, pH, etc.)
Press Menu and then OK to set the minimum range (4mA value)
Press Menu and then OK to set the maximum range (20mA value)
Optional: Press Menu and then OK to set the test value (to be used for troubleshooting purposes or
initial tests)
8) Press Escape to return to the set-up menu and repeat above for remaining channels
9) Press Menu to go to “On Alarm go to” menu and then OK to set the error value (output value in case
of measurement or communication error) from the following options:
• 2 mA
• 4 mA
• 20 mA
• Hold Last Value
This is the 4-20mA output value that will indicated whenever an alarm condition exists or communication
between the analyzer and 4-20 module is interrupted.
Confirming Operation and Communication
Prior to connecting to the external monitoring or control system, it is best to confirm that all desired
outputs are working properly using a digital multi-meter. This must be done without output wires
connected to an external system.
1) Set the multi-meter to measure current and connect the multi-meter to an active output (an output is
inactive if it does not have a chipset installed next to the terminal block).
2) Record the current in mA.
3) Confirm that the value is accurate using, Equation 1.
4) Repeat for each active output.
MeasuredValue =
(mA) ∗ ( Fullscale)
+ MinimumValue
16
or
mA =
(16) ∗ (MeasuredValue ) + 4
FullScale
mA = milliamp output value
Full Scale = Max Value - Min Value (in case of Min is zero, it's the max value)
Equation 1: Determining Parameter Value from mA output
37
Connecting to External Monitoring System
1) Connect two wires from the active output to the appropriate connection on the external system
2) Repeat for each active output
3) If an active output (output with a chipset installed) is not to be used, place a jumper wire between the
contacts.
6 Appendix A: Relays and Closed-Loop Control
There are 6 dry-contact relays on the I/O module. Five of the relays may be used for direct control of
closed loop systems. All of the relays may be used as dry-contacts, and will operate based on the
settings, specifically the set-points, selected in the operator menu.
6.1 Connecting external equipment to the Relays
This is only required if the relays are being used to power and control external dosing equipment. The
relays will act as dry contacts if no power is supplied. A dependent power supply should be used such
that no equipment will be activated unless the process line has flow.
6.1.1 Wiring to Dosing Systems
WaterGuard controls chemical dosing systems using a series of electronic relays that start and stop the
dosing pumps. Each relay opens and closes a switch that activates a separate pump or piece of
equipment.
The line (live) wire of the dependent power source connects to the connection labeled Common on each
relay. The line wire of each controlled system is connected to the normally open (NO) or normally closed
(NC) connection of each relay as appropriate. Normally Open means that the relay will be open (i.e. no
power from the relay) until the controller calls for power; Normally Closed means that the relay will be
closed (i.e. power from the relay) until the controller calls to stop power.
1)
2)
3)
4)
Verify that the power switch or circuit breaker to the dependent power source is off.
Connect the earth wire to the ground return wire from each of the external dosing systems.
Connect the neutral wire to the return wire from each of the external dosing systems.
Connect the line (live) wire to the connector marked Common of each active relay.
Caution: Each relay connection is limited to 4 amps, to prevent overheating. The relays may show a
higher rating but do not connect equipment exceeding 4 amps.
The following table lists the relays and the dosing systems they control:
38
6.1.2 Proportional Control Overview
WaterGuard controls dosing proportionally. This met
method
hod sets dosing rates in relation to how far current
curren
chemical levels are from the set point. The dosing rates gradually decrease as chemical
chemica levels get closer
to the set point.
8: Proportional Control of Chemical Dosing
Figure 8
If water chemical levels are far below the set poin
point,
t, WaterGuard will operate the dosing systems to
operate at full speed (100%).
0%). As the controller senses chemical levels risin
rising
g and getting closer to the set
point, it will control the dosing systems to slow d
down
own to a lower speed (i.e. 60%). As chemical levels get
even closer to the set point, the dosing system wil
will slow down even
n more (i.e. 30%), and so on, until the
chemical level gets to the set point.
The % of the time on is explained by the following equation with chlorine as an example:
point and measured values are:
In this example, the Cl set-point
Cl Set Point
2.0
Cl Measured
1.8
factor is changed, the percentage of the pump cycle that will be on (% time on) changes as
If the P-factor
follows:
P factor
0.1
0.5
1
5
10
% Time ON
1%
5%
10%
50%
100%
The range for P-factor
factor for Cl and pH are presented in the table bel
below.
39
6.1.3 Setting Proportional Factor
Proportional control of chemical dosing requires configuration according to various factors. The primary
factors are the ratio between the system size and the rate the chemical dosing systems can feed
chemicals, and the delay time between when the chemical level changes and when it is sensed by the
controller.
In large systems, changes in chemical levels occur slowly. The dosing systems must feed large amounts
of chemicals for a long period of time in order for a change to be noticed. The chemicals also disperse
slowly in larger systems. Smaller systems, on the other hand, react much more quickly.
The length of time between the change and when the controller identifies the change also affects
proportional control. The controller can only identify water chemical levels after they have been distributed
throughout the system and have returned to the analyzer. This may be a long time after the chemicals
were released into the water. The controller, therefore, recognizes the chemical levels from dosing
settings in the past. The dosing systems continue feeding chemicals during this delay, causing chemical
levels to pass the set point, resulting in fluctuations.
To prevent these fluctuations, the controller must reduce chemical dosing rates as it senses that chemical
levels are approaching the set point, taking the delay into account. The controller should also not
overcompensate for the delay, which would cause chemical levels.
In short, the larger the water system, the higher the p-factor.
6.1.4 Setting Pump Period
Pump period is a single cycle during which the dosing pump operates and then rests. Proportional control
divides the pump period into two distinct phases: active and at rest.
In general it is recommended to operate in a short cycle, i.e., 00:30 Sec. For large systems, or if you
activate solenoid valves, you may consider longer pump periods.
6.1.5 Step By Step Proportional Settings
1)
2)
3)
4)
Finish the installation of all controllers (electrical, water, feeding systems, and electrodes).
Calibrate the controller to the water chemical values at the sample point.
Set the proportional factor and the pump period of the chlorine and the pH at an initial setting.
Let the controller operate the chlorinator and the pH correction devices and make sure that chemicals
are injected into the water.
5) Watch the chlorine and pH as they change. We recommend that you record the values frequently so
that the process is closely monitored.
a) If the values greatly exceed the set point, you need to decrease the proportional factor.
b) If it takes too long to get to the set point, you need to increase the proportional factor.
Note: In large systems the delay time between injection of the chemicals and receiving the change in
the controller can be very long (30 minutes or more).
40
7 Appendix B: Technical Specifications
41
APPENDIX 1
Background:
Based on feedback from the field, several changes have been made to the software for the WG 602/702. This
document explains only these new features.
Changes:
Two standard on-board 4-20mA outputs:
The control panel (electronics card with the LCD display) will now come standard with two 4-20mA outputs. Up to 4
additional internal outputs may be added using the 4-20mA outputs card.
Software-based conductivity calibration:
A conductivity calibration menu has been added, allowing for calibration of conductivity from the software instead of
requiring adjustment of the calibration screw on the conductivity sensor.
Optional two-point pH calibration:
pH may be calibrated using the standard single-point calibration or a two-point calibration.
Description:
On-board 4-20mA outputs:
There are two 4-20mA output channels on the control panel electronics card. These are connected the same as all of
the other 4-20mA outputs using a (+) and (-) connection.
Configuring the outputs is done through the “4-20mA Settings” menu in the technical menu section. The output
channels now include:
•
•
•
•
•
•
Built-In Ch. #1
Built-In Ch. #2
4-20/NTU Ch. #1
4-20/NTU Ch. #2
4-20/NTU Ch. #2
4-20/NTU Ch. #2
Please make sure that you are configuring the correct output.
Conductivity Calibration:
A conductivity calibration menu is now part of the software and is located in the operator menu. Conductivity may be
calibrated like all other parameters and there is no need to use the adjustment screw on the conductivity meter.
pH Calibration:
There are two pH calibration menus:
•
pH 7 Calibrated to
Sensor Value was
#.##
#.##
•
pH 4,10 calibrated to
Sensor Value was
#.##
#.##
Single-Point Calibration (same as previous versions).
1.
Use only the first ph calibration menu (pH 7 calibrated to), to calibrate the pH at any level using a buffer or
external testing device.
Two-Point Calibration:
1.
Use the pH 7 calibration menu and a pH 7 buffer to calibrate pH = 7.
2.
Use the pH 4,10 calibration menu and a pH 4 or pH 10 buffer to calibrate pH = 4 or 10.
Note: for 2-point calibration, pH 7 must be calibrated first and buffers must be used to ensure accuracy.
APPENDIX 2
Maintenance
Check the measurement at regular intervals; depending on the respective conditions at
least once a month.
Perform the following tasks:
• If the membrane is visibly soiled, clean the sensor (see section "Cleaning the sensor").
• Refill the sensor with electrolyte once per season or every 12 months. Depending on the
chlorine content on site, this period can be reduced or extended (see section "Refilling the
electrolyte").
• Calibrate the sensor when necessary (see "Calibration").
Cleaning the sensor
Caution!
• Do not use chemicals reducing the surface tension.
• When using hydrochloric acid, observe the safety regulations.
If the membrane is visibly soiled, proceed as follows:
1. Remove the sensor from the flow assembly.
2. Clean the membrane mechanically with a gentle water jet or put it for some minutes in
1 to 5 % hydrochloric acid without chemical additives.
Replacing the membrane
1. Unscrew the measuring chamber (pos. 1)
from the shaft.
2. Unscrew the front screw cap (pos. 3).
3. Remove the membrane cap (pos. 2) and replace it by a
replacement cartridge.
4. Refill the measuring chamber with electrolyte
(see section "Refilling the electrolyte").
1
Refilling the electrolyte
Warning !
Do not swallow the electrolyte! Avoid contact of the electrolyte with skin or eyes. Otherwise
wash with a lot of cold water! In case of eye inflammation, contact a doctor!
Wear gloves when refilling the electrolyte.
Caution !
• Do not touch or damage the electrodes!
• The electrolyte is sensitive to oxidation: Always keep the electrolyte bottle closed after
use.
Do not transfer the electrolyte into other containers!
• The electrolyte should not be stored for more than 1 year and not yellow (use by date, see
label).
• Avoid forming air bubbles when pouring the electrolyte into the measuring chamber!
Proceed as follows to fill in the electrolyte:
1. Unscrew the measuring chamber from the sensor shaft.
2. Hold the measuring chamber at an angle and fill in about 7 to 8 ml (0.24 to 0.27 fl.oz)
electrolyte, up to the internal thread of the measuring chamber.
3. Tap the filled measuring chamber several times on a flat surface so that adherent air
bubbles can detach and rise.
4. Insert the sensor shaft vertically from above into the measuring chamber.
5. Slowly tighten the measuring chamber to the stop. Excess electrolyte is pressed out at
the sensor bottom during the tightening.
Reconditioning the sensor
Long-term operation (> 1 week) in chlorine-free media, i.e. with very low sensor currents,
leads to a deactivation of the sensor.
This deactivation is a continuous process that results in a lower slope and longer response
times.
After long-term operation in a chlorine-free medium, the sensor must be reconditioned.
You need the following materials for reconditioning:
• Demineralized water (or electrolyte)
• Polishing sheet (see "Accessories")
• Beaker
• Approx. 100 ml (3.381 fl.oz) of chlorine bleach liquor NaOCl approx. 13 %,
pharmaceutical
quality (available at chemical stores or pharmacies)
Proceed as follows:
1. Close the medium inlet and outlet and make sure that no medium can squirt out of
the assembly.
2. Remove the sensor from the assembly.
3. Unscrew the measuring chamber and put it aside.
4. Polish the gold cathode of the sensor using the polishing sheet:
– Place a wetted strip of the sheet in your hand.
– Polish the gold cathode by moving it circularly on the strip.
2
– Rinse the sensor with demineralized water (or electrolyte).
5. Top up the electrolyte if required (see chapter "Refilling the electrolyte") and screw
the measuring chamber back into place.
6. Fill the beaker with chlorine bleach liquor to about 10 mm (0.39") and position it
safely.
7. " Caution!
The sensor must not touch the liquid.
Place the sensor in the gaseous phase about 5 to 10
mm (0.2" to 0.39") above the chlorine bleach liquor.
8. The sensor current will now increase. The absolute
value and the speed of increase depend on the
temperature of the chlorine bleach liquor.
– When the sensor has reached a high value CL
reading, leave the sensor under these conditions
over a period of 20 min.
– If the chlorine value is not increasing, cover the
beaker to avoid quick air change.
9. After the 20 min. have elapsed, re-install the sensor in
the assembly.
10. Re-establish the medium flow. The sensor current will
normalize.
11. After sufficient settling time (no noticeable drift),
calibrate the measuring chain.
3
A c ro me t (A us t) P ty L td
14 Winterton Road, Clayton, Victoria 3168
(P O Box 1105, Clayton South, Victoria 3169)
Ph: (03) 9544 7333
t Fax: (03) 9543 6706
Email: [email protected]
www.acromet.com.au
42
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