Home

876-25 User Manual

1. YES PASSWORD 2 ENTERED NO YES PASSWORD 1 ENTERED YES 0000 ENTERED ACCESS ACCESS ACCESS ACCESS LEVEL O LEVELO LEVEL 1 LEVEL 2 VIEW ONLY VIEW ONLY OPERATOR COMPLETE DISPLAY DISPLAY DISPLAY DISPLAY bAd good l good acc o Lace 3 acc 2 Page 60 www iccontrols com um 876 211 IC CONTROLS APPENDIX A Enabling Security PASSWORD EXAMPLE A QUICK TOUR With security disabled select CONF PAS 2 from the menu Set the level 2 password to 0002 Select CONF PAS 1 from the menu Set the level 1 password to 001 Security is now enabled Select PASS from the main menu Press ENTER with 0000 displayed The analyzer will display ACC 0 to indicate we are now at access level 0 Try changing the output 1 low setting Select out out1 LO from the menu The current value will display Press ENTER to go into edit mode The analyzer will display PASS for 2 seconds because we need to enter a password first Level 1 security is needed to change this setting Select PASS from the main menu again Change the displayed value to 0001 which is the level 1 password Press ENTER The analyzer will display good followed by ACC 1 indicating that the password is valid and that we now have level 1 access Try changing the output 1 low setting again You will find that this time we can go into edit mode unhindered
2. eee INDUSTRIAL PRODUCTS WARRANTY INDEX Copyright 2005 IC Controls Ltd All rights reserved Page 2 www iccontrols com um 876 211 IC CONTROLS 876 25 Menus display home base SAMPLE 876 25 Menus EFF 100 0 Efficiency main menu Lea cE Ce LoLa _0 90 pom do SEt pH pH C Auto te SEt C F Auto SLOP 100 0 Er pH OFFS O00 mv CALIBRATE pH pur caL bur2 HOLd 7 50 pH te SEt 25 0 c Auto See list of d i Err eg g error and caution iLoe See Internal Data Log Menu tECI list of Lin HOC available en inputs LS out out C__ display units out2 unit F used by output on ONOF OFF HI 5 00 LO 0 00 cur 12 02 mA AL See Alarm Menu SEr conr See Serial Menu See Configuration Menu PASS 0000 j H See Timer Menu Illustration 1 Menu overview um 876 211 www iccontrols com Menus are context sensitive Accessible only when function is activated Page 3 876 25 Menus IC CONTROLS Init ALL do unc timer feature AL alarm contact ALA OPEN AL Nonce ro Sa Func
3. 3 Now adjust the pump stroke length and or speed frequency to a range approximately 2596 higher than you would normally want for the process 4 Slowly rotate bleed adjustment screw counter clockwise until just a small amount of solution begins to trickle down inside the bleed return tubing A small amount of solution pumped back to the tank with each stroke of the pump will allow gas and air to escape without air or gas locking in the pump head C DEPRESSURIZING DISCHARGE LINE 1 It is possible to depressurize discharge line and pump head without removal of tubing or loosening of fittings Be sure injection check valve is properly installed and is operating Ifa gate valve or globe valve has been installed downstream of injection check valve it should be closed Be certain bleed return tubing is connected and run to solution supply tank 2 Withascrewdriver rotate bleed adjustment screw counter clockwise two 2 full turns A small amount of solution in discharge line should drain back to the supply tank 3 The discharge line is now depressurized 4 If injection check valve is of higher elevation than pump head disconnecting tubing at injection check valve end will allow air to enter and cause solution to drain back to tank Page 73 APPENDIX D OPTION 51 53 TIMER ELECTRODE CLEANER IC CONTROLS Instruction Supplement Series PO Electronic Metering Pump INJECTION CHECK VALVE COUP
4. Al Messages for pH Input A Caution Messages for Alarms 43 DISPLAY PROMPTS dd GLOSSARY eeereeeeeeeeeeeenttntnnnnnn 46 CONFIGURATION OF PROGRAM eerte 47 OUTPUT SIGNALS cereis eee eese tn eene estne tn senso udl 49 Reversing the 4 mA to 20 mA Output 49 Simulated 4 mA to 20 mA Output A0 Units for Oupmuts eee 149 ALARM FUNCTIONS eese eese eene entente sensns tnn 50 Use of Relay Contacts 90 Alarm Indication 150 Manual Alarm Override esee 51 Delayed Relay Actvatton esee sedi Unt Selection rer Re EP 51 Wiring and NO NC Contacts ol High or Low Alarm eene 52 Deviation Alarm 52 Fault Alarm Using Alarms for On Off Control TROUBLESHOOTING csccscssssssssssccssssssesssnssseseoees Analyzer Electronic Hardware Alignment 5 Chlorine Sensor ssi iin hanasu e eS PH EE APPENDIX A Enabling Securit APPENDIX B Default Settings eee APPENDIX C Installation eren APPENDIX D OPTION 51 53 TIMER ELECTRODE CLEANER eerie entente ee enened APPENDIX E PARTS LIST eeeeeeeeeeenee DIEN D4040081 Outline and Mounting Dimensions D5030269 Main Board Component Location D5980176 Display Board Component Location D5040276 Wiring Diagram
5. Galvanic technology for better calibration with absolute zero Galvanic technology does not attract iron to the sensor tip therefore the sensor requires less cleaning and maintenance Automatic chemical cleaning option available Easy to replace membrane pH measurement and compensation for better accuracy Intuitive user friendly program that is easy to use e Grab sample calibration for chlorine Self and sensor diagnostics Two programmable 4 mA to 20 mA outputs Two programmable alarms Serial digital output and remote operation Three level security to protect settings um 876 211 www iccontrols com Page 7 INTRODUCTION Specifications Analyzer 876 PROPERTY Display Display Ranges Keypad LED s Analyzer Dimensions Panel Dimensions Weight Shipping Weight Shipping Dimensions PROPERTY Temperature Environment Ratings Electrical Ratings Electrical Requirements Page 8 IC CONTROLS Physical Data CHARACTERISTIC Four LCD digits 1 5 cm 0 6 in displays for total free available chlorine tFC1 and free available chlorine HOCI pH temperature efficiency error codes prompts and diagnostic information back lit display optional Total free available chlorine tFC1 0 00 mg L to 5 00 mg L Free available chlorine HOCI 0 00 mg L to 2 00 mg L pH 0 pH to 14 pH units Temperature 5 0 C to 105 C 23 0 F to 221 F 8 pushbutton entry keys 2 alarms A an
6. Ar dedicated alarm contact Laub OPEN ON zm Gi ana noci ben sample ae 00 01 Le Loge L oa Gs input damping sec _ _ E23 59 5vpc 0 17 chlorine input V Membrane Compensation Factor StAt 10 00 In NONE No membrane compensation Let sta Standard membrane HOLd 10 PH onor Illustration 3 Timer menu dA 5 input damping sec CALIBRATE car E c Lorrs o Oftset c L a Input damping sec Ce metric or imperial E See A Lyear aa onth 12 SEt t 0 10 dAtE 31 a m Lin L 59 Lo SEC 59 Func ni bas Cue TUN D pas a 0000 Illustration 2 Configuration menu m e AL A in x AL b EEN ONOF dEv 0 60 diFF 0 10 dLAY 30 Illustration 4 Alarm menu Page 4 www iccontrols com list of available inputs display units used by alarm alarm activation delay sec um 876 211 IC CONTROLS internal data log menu when not logging StAr FrE FULL I stop cnt i CLr internal data log menu while StOP do in tFCl FrE 10 Cont LOG uL o o ki cnt 626 asa 2 start data logging list of available inputs frequency of log update in seconds continue logging overwriting oldest data stop logging when buffer full number of data points currently in buffer Clear the buffer deleting all data points Send ASCII serial output when logging No ASCII
7. NOTE A video presentation of this procedure can be Illustration 19 Memb toolkit viewed at the IC CONTROLS website www iccontrols com Mic eres a The membrane replacement toolkit P N A2104035 consists of two pieces which fit together into one unit separate the toolkit into it s individual components refer to illustration 19 One piece will be a cylindrical shape A and the other will resemble a T B b Place the membrane retainer tapered side up into the larger diameter hole of the cylindrical component of the membrane replacement toolkit c Place one membrane from P N A2104036 shiny Illustration 20 side up over the membrane retainer Membrane retainer d Place the narrow end of the second component from the membrane toolkit onto the membrane containing component refer to illustration 21 Press firmly on top of the second component until the two components fit together securely Illustration 21 Step d of membrane replacement procedure um 876 211 www iccontrols com Page 25 CHLORINE SENSOR INSTRUCTIONS IC CONTROLS e Take the sensor and rinse the fill solution cavity with fresh fill solution P N A1100239 Hold the sensor in an upright position with the fill solution cavity facing upwards and fill with P N A1100239 so that the gold tip is completely covered with liquid Ensure that there are no air bubbles in the solution f Take the assembled toolkit with the larger diameter hole and place over t
8. Select PASS from the main menu again Enter the level 2 password which is 0002 We are going to set the level 2 password to 0000 again to disable password security Password 2 is found in the configuration menu and therefore requires level 2 access before it can be accessed Select CONF PAS 2 from the menu Press ENTER with 0000 displayed Both passwords are set to 0000 again and password security is disabled um 876 211 www iccontrols com Page 61 APPENDIX B Default Settings IC CONTROLS APPENDIX B Default Settings The following program settings are the default settings for the analyzer New analyzers will have these settings unless the setup has already been customized for your application Outputs Output 1 Output 2 Input to be transmitted tFCI C Low setting 0 00 0 0 High setting 2 00 100 0 ON OFF switch ON ON Alarms Alarm A Alarm B Input for alarm tFCI tFCI Alarm function HI LO ON OFF switch ON ON Set point 0 60 ppm 0 20 ppm Differential 0 10 ppm 0 10 ppm Unit 1E 6 ppm 1E 6 ppm Delay Os Os Global Units Metric units temperature in degrees Celsius chlorine concentration in parts per million ppm Alarm Contacts Configured normally open Security Not enabled pH and Temperature Compensation Method for Chlorine Automatic TC using temperature input automatic pH compensation using pH input Membrane Compensation Enabled Timer Feature Not enabled Page 62 www iccontrols com um 876
9. Aquassy Bursnoy S90d SS0d Gnod SEOd S20d WN AOZ es Aiquassy Buisnoy S90d SS0d GEO NIG A0 z Aquessy Dueno 90d S0d v0d 80d 620d NIG MOES gesing Aquassy Bulsnoy 90d end EpOd Sn Agee Aquassy Susnoy 290d 250d nd End 220d SN A0 z eem Ajquiassy Buisnoy 290d S0d 20d i i i j ASHI Aquiessy Bulsnoyy 190d IS0d LrOd LE0d Leod AGLL tesing m Aiquassy BuisnoH 190d 1S0d Let 190d 290d 2P0d 280d z0d 990d 990d 90d 9E0d 920d S90d end GOd SE0d Gen SSIMS MOES jesindjw Alquessy Bursnoy 2 0d 220d sn A0Sz iesing m fjquiessy Busnoy 9 0d 920d YN Are Jasingym Ajquiassy Buisnoy S 0d Sc d NIG AOEZ 1esng m Mossen Buisno 0d Eed SN A0 z Jasing m Mussen Dueno 200d 220d ASLL Leed Aiquiassy Buisnoy L 0d 120d 81 5isig Ada 290d 990d 890d 9od 290d gL ASIAM nd3 190d 6 0 Wem nd3 290d gend SS0d S0d es0d 6 0 Om Nd LS0d Sp Melu nd3 Zv0d 9v0d ShOd CEO Zrod F O Weu nd3 Ltd 6 0 ASIAM Nd 180d 9 0d S 0d 0d End BO SON nd3 1 0d SO
10. Error messages are numbered Errors 1 through 5 are identified as En e Chlorine 1 where n is the input number and e is the error number Messages 6 through Input Source Input Number for Error Caution Messages Temperature 2 cx 9 are less serious and are identified as pH 3 cautions instead eg CAn e Alarm A T Off scale errors for chlorine are not Alarm B 8 numbered and are identified as Err and Err depending on whether the Table 2 Input number designation for error messages input is at the top or the bottom of the scale The off scale error is displayed instead of the sample reading and does not show up in the error menu with the numbered error messages if any Error message indicators can be annoying when one has already been made aware of them A method has been provided to turn off the error LED and the fault alarm for a particular error message Refer to Acknowledging an Error Message below for the exact procedure The error LED will remain on as long as there is an unacknowledged error or caution message or as long as any input is off scale Each source of error must be removed or acknowledged before the error LED will go off Acknowledging an Error Message Select Err from the main menu Use the Up or Down arrow key until the error message to be acknowledged is displayed Errors are displayed with either a positive sign or a negative sign in front The sign is used to indicate an active or unacknowle
11. then press ENTER to have the change go into effect Example The timer cycle is set for 24 hours the off cycle for 23 59 and the on cycle for 1 minute 00 01 so that the timer will clean the electrode once a day for one minute To turn the timer on for 2 minutes i Ensure the on off switch is set to ON ii Select StAt from the timer menu and press ENTER to go into edit mode iii Change the time to read 00 02 and the sign to a sign iv Press ENTER to accept the changes The timer will now stay on for 2 minutes When the 2 minute on cycle is completed the timer will start it s 23 59 off cycle Timer Menu Reference onor L OFF Lt Kee NN 23 59 StAt 10 00 nora E Illustration 3 Timer menu EE Display Prompts Defined ON OF Turning the timer off causes the timer clock to stop updating The alarm contact will be turned off if the timer is in it s on cycle Set the length of the on cycle in hours minutes The longest on cycle is 99 99 Set the length of the off cycle in hours minutes The longest off cycle is 99 99 StAt Display the current status of the timer The sign shows whether the timer is in it s on cycle or in it s off cycle The timer clock is displayed in hours minutes Go into edit mode to change the timer status If the timer is turned on the sign can be changed to switch between on cycle and off cycle Hold Specify the output hold time in seconds When the on c
12. INSTALLING INJECTION CHECK VALVE 1 The purpose of the injection check valve is to prevent backflow from the treated line 2 A1 2 NPT female fitting with sufficient depth will accept the injection check valve 3 To insure correct seating of the ball inside the injection check valve the injection check valve should be installed upwards vertically into bottom of the pipe B CONNECTING DISCHARGE TUBING Note Cut tubing to length needed for discharge line 1 Route tubing from the injection check valve to the meter ing pump making sure it does not touch hot or sharp surfaces or is bent so sharply that it kinks 2 Slide the small end of the coupling nut onto tubing then slide on the clamp ring 3 Push tubing on the valve housing nozzle so that tubing flares out and butts up against valve housing and will not go any further 4 Slide the clamp ring and coupling nut to the threads and engage While pushing the tubing on to the valve housing nozzle tighten the coupling nut by hand until tubing is held securely in place Excessive force will crack or distort fittings DO NOT USE PIPE WRENCH C CONNECTING SUCTION TUBING Cut suction tubing to a length so that the foot valve hangs just above the bottom of the solution container Maximum recommended vertical suction lift is 5 ft 1 5 m 2 Follow same procedure in connecting suction tubing to suction valve and foot valve see B Connecting Discharge Tubin
13. Run a zero calibration 7 pH is equivalent to 0 0 mV so use pH 7 buffer 10 Run a span calibration by placing the sensor in pH 4 buffer The display should read approximately 4 01 0 05 pH 11 To check for general performance place the pH sensor in pH 7 buffer again It should now read approximately 7 0 0 05 pH 12 The sensor is now ready for field installation 13 If the application will be in the caustic region repeat steps 10 amp 11 using pH 10 buffer so that the sensor is tested in the region of use 14 Before placing the 876 analyzer into operation verify the settings to ensure that they agree with the intended setup Factory defaults are listed in Appendix B For the 4 mA to 20 mA output set high limit and low limit e 15 Set preference for temperature units C or F in O CONF unit default is C 16 Set desired input signal damping if known default is 5 O seconds 17 The analyzer is now ready for field installation C Illustration 8 Pin location for chlorine sensor shorting jack Page 14 www iccontrols com um 876 211 IC CONTROLS STARTUP STARTUP If the analyzer is new and has not been installed follow the procedures described in Installation and Configuration of Program before mounting Mounting and wiring procedures for new installations vary with equipment options see drawing section for instructions If the analyzer has been previously installed all that is
14. The analyzers inputs tFCl HOCI pH and temperature are arranged underneath each other at the left hand side of the menu Use the Up or Down arrow key to display each of the readings in turn Main Menu Display Features o 5 ila ITI out of Program section for further details Illustration 10 Main menu Page 16 www iccontrols com IC CONTROLS SAMPLE home base HOCIL oa tFCI oe pH i 7 51 ec 1 250 Illustration 9 Home base 1 The analyzer has a built in timer which returns the program to displaying tFCI if no key is pressed for 15 minutes This time out has the same effect as pressing the SAMPLE key If security has been enabled then the time out will change the access level back to 0 or 1 automatically which gives the user read only access The user will have to enter an appropriate password to go to a higher access level 2 When the sample value is displayed pressing the Left arrow key will show which of tFCL HOCI pH or temperature is displayed Pressing Right arrow key displays the sample reading again 3 The main sample ie the input that is displayed first when the SAMPLE key is pressed can be changed By default the main input is tFCI Change the default in CONF in dFLt Refer to the Configuration um 876 211 IC CONTROLS STARTUP Arrow Keys The four arrow keys on the keypad are used to move around in the menu Example Press SAMPLE
15. 15 minutes the 15 minute timeout will return the alarms to N AUTO moda AUTO mode s s Illustration 40 Alarm override status AUTO LED Delayed Relay Activation Alarm relay activation by default is immediate upon alarm condition Alarm relay activation may be delayed Activation delay gives the operator a chance to correct alarm situations before the relay contacts activate or can eliminate alarms based on temporary or spurious changes in the process The delay time is programmable by the operator To change or view the delay time select ALAY from the alarm menu The default value of O seconds is for immediate contact activation The delay time can be set from 0 s to 9999 s Unit Selection The alarm module will be using different units for it s settings depending on the input selected Select unit from the alarm menu to display the units in use for this alarm The unit setting affects the set point differential and deviation settings for the alarm The temperature input will use different units depending on whether metric or imperial units are selected For temperature the unit selection can be viewed only The choice between metric or imperial units is made in the configuration menu Refer to the Configuration of Program section for further details Wiring and NO NC Contacts The alarm contacts for alarms A and B may be wired as normally open or normally closed By default the analyzer assumes the alarm contacts
16. For further details on the timer refer to Appendix D If desired install password security um 876 211 www iccontrols com Page 63 APPENDIX D OPTION 51 53 TIMER ELECTRODE CLEANER IC CONTROLS APPENDIX D OPTION 51 53 TIMER ELECTRODE CLEANER Overview A timer function is provided in the IC CONTROLS 876 program The timer is designed to control a cleaner for the electrode Options 51 and 53 provide the necessary cleaning accessories which can be retrofitted to the 876 25 system after initial purchase and setup The only difference between these options is that option 51 provides a 115 V pump P N A2100082 and option 53 provides a 220 V pump P N A2100083 Options 51 and 53 do not include the cleaning solution the user must supply cleaner IC CONTROLS suggests using a mild hydrochloric acid 5 HCl solution The timer is a program option only and does not require any modifications to be made to the analyzer electronics The timer will use the contact for alarm A While the timer is in use only the contact for alarm B is available for remote alarm indication Alarm A will continue to function but if there is an alarm condition then only the LED will come on The instruction manual was written without reference to the timer function All the changes and additions to the menu and the program are documented in this appendix Configuration of Alarm Contacts Go to the configuration section of the menu press SAMPLE to dis
17. MU CANCEL Illustration 13 Edit keys Page 18 www iccontrols com um 876 211 IC CONTROLS STARTUP Temperature C or F By default the analyzer will use metric units This means that temperature will be displayed using degrees Celsius and that the prompt for the temperature input will be C The analyzer can also use imperial units For imperial units temperature will be displayed using degrees Fahrenheit and the prompt for the first temperature input will be F instead of C In this instruction manual the temperature input is always identified as C throughout the menus To select imperial units for the analyzer select unit from the configuration menu then go into edit mode and change the C setting to F Real Time Clock The analyzer clock is used for internal date time stamping of system events and the internal data log Both the system events and the internal data log are accessed using the IC Net Intelligent Access Program which is available as option 35 Analyzers purchased with option 34 have a real time clock which will maintain the correct time and date even when the analyzer power is turned off Input Damping The chlorine pH and temperature measurements can be damped to provide the user with a means to stabilize rapidly varying or noisy signals Damping range is 3 s to 99 s With O seconds there would be no damping and each reading the analyzer made would be used to directly update the display
18. NC Normally Closed NO Normally Open Normally Closed Each of the alarm contacts can be wired and configured as normally open or normally closed A circuit which is wired normally closed will be closed ie the external device wired to it is turned on when the analyzer is not powered Normally Open A circuit which is wired normally open will be open ie the external device wired to it is turned off when the analyzer is not powered On off Control Control response in which the contact is either fully on or fully off ppm Parts per Million 1 ppm 1 mg L Unit of concentration for chlorine measurement RAM Random Access Memory Memory in a RAM chip can be both written to and read from The contents of RAM will disappear as soon as the RAM chip loses power The RAM chip has a battery backup device which preserves the contents of the RAM chip for a considerable time even if the analyzer is turned off All settings are stored in RAM TC Temperature Compensator Temperature Compensation Correction for the influence of temperature on the sensing electrode The analyzer reads out concentration as if the process were at 25 C regardless of actual solution temperature Total Free Available Chlorine Sum of the hypochlorous acid HOCI and hypochlorite ion OCI forms of chlorine Page 46 www iccontrols com um 876 211 IC CONTROLS CONFIGURATION OF PROGRAM CONFIGURATION OF PROGRAM The 876 analyzer has been designed with ease of
19. Xsiq nd3 220d 920d Sc d End Send Te pe le leie le ele pete ele le La ie Le jie e lela S 0 Weu Nda 0d uonduoseq O Hed L AOSZ 0EZ Aiquessy JosueA 2290 90d End Et0d EE0d ez d i SN A0EZ Aquiessy jojsueA SSZLE 290d Send r d e 0d 220d L ASL Aiquiessy jojsueA 9290 190d IG0d LrOd Le0d 120d I Dudel rees 0d l Jop Gust eM L 89601 0d L desing vSzoE 0d L Aiquassy M 26462 0d 20d L 1eqgng IeuSeM Leem 0d L UoKN usw Coeez 0d L Bury Buurieg zzrot 0d Beld eure L am 1 020652 0d L eju jeuture eJIM L 28101 Od L Duo 99404 Od ON E S uonduoseg L t Seg A quisssy aAug Od sees BDO trols com WWw iccon Page 76 APPENDIX D OPTION 51 53 TIMER ELECTRODE CLEANER IC CONTROLS gojou noum eBuetuo o Lelong suoneoyiroeds YSN ut pejuug penjese SUBH tly oH UO HINT 2661 AI8W3SSV Idi DAME HO NU9 TANNY HO NB GON IHOULS WSN 02210 WW NOLOW Jee E 18 HO LHM AINO 0d 20d webera BULIAA Od seues u ied jeUeY jo43u02 Od seues www iccontrols com Page 77 um 876 211 APPENDIX E PARTS LIST APPENDIX E PARTS LIST PART NUMBER A2500033 6 A9051009 OS A905 1063 A9141007 A9201014 A9160024 A9160029 A9201046 A2104023 A7300011 A7300013 A7300014 A2100082 A
20. acid plus hypochlorite ion unit Display of units used for analog outputs and alarms YEAr Year Real time clock setting um 876 211 www iccontrols com Page 45 GLOSSARY IC CONTROLS GLOSSARY Electrode Both a sensing and a reference electrode are needed for the analyzer to measure the process Commonly these are combined into one and referred to as a combination electrode The temperature sensor may be built into the electrode as well EPROM Erasable Programmable Read Only Memory The EPROM chip holds the program which determines the functioning of 876 25 analyzer Replacing the EPROM chip with a chip containing a new or an updated program changes the way the analyzer functions The EPROM chip is programmed by the manufacturer Free Available Chlorine The hypochlorous acid form of chlorine HOCI Hysteresis The reading at which an alarm is turned on is not the same reading at which the alarm is turned off again This phenomenon is referred to as the hysteresis LED Light Emitting Diode LEDs are used as on off indicators on the front panel of the 876 25 Menu The series of prompts which determine the layout of the program used by the analyzer Microprocessor An integrated circuit chip which executes the program on the EPROM chip and controls all the input output functions Nernst Equation Equation which relates the voltage signal produced by the electrodes to the pH of the sample The equation is temperature dependent
21. and 4 mA to 20 mA output The factory default of 5 seconds adds the next four seconds of readings to the first and divides by five this gives fast response Selecting 99 seconds adds the readings for 99 seconds and divides by 99 providing smooth damping out of turbulent readings Any selection between 3 s and 99 s can be made Select CONF in from the menu Use the Up or Down arrow key to select the input to be adjusted then select the dA frame Press ENTER then change the input damping to the new number of seconds Press ENTER again to leave edit mode um 876 211 www iccontrols com Page 19 APPLICATION INFORMATION IC CONTROLS APPLICATION INFORMATION Chlorine Chemistry When chlorine gas is dissolved in water it hydrolyzes rapidly according to equation 1 This reaction occurs very rapidly in only a few tenths of a second at 18 C 1 Clare H Oag HOC lag HClag Since HCl hydrochloric acid is a strong acid the addition of gaseous chlorine to water results in a lowering of the pH due to the acidic HCl by product The important product of reaction 1 is HOCI or hypochlorous acid Hypochlorous acid is the disinfectant form of chlorine in water Hypochlorous acid is unstable because the chlorine molecule is weakly bonded and as a result will react quickly Hypochlorous acid is also referred to as free available chlorine or free chlorine lt is taste free and aggressive against germs and organic compounds Chlorin
22. are wired normally open A normally open alarm contact will be inactive if there is no alarm condition and will be active when there is an alarm condition If the program configuration and the wiring for each alarm do not match then the incorrectly configured alarm contact will generate an alarm when there is no alarm condition and vice versa um 876 211 www iccontrols com Page 51 ALARM FUNCTIONS IC CONTROLS High or Low Alarm A high alarm is set when the value of the chlorine pH or temperature rises above the set point and is cleared when that value drops to below the set point minus the differential refer to Illustration 41 A low alarm is set when the value of the chlorine pH or temperature drops below the set point and is cleared when that value rises to above the set point plus the differential refer to Illustration 42 The differential has the effect of setting the sensitivity of the alarm The differential provides a digital equivalent of a hysteresis A two stage alarm can be implemented by choosing the same alarm function ie high or low alarm for both alarms but selecting different set points Example The HOCI of a critical process may not drop to below 0 5 ppm Use alarm A as a low alarm set at 0 5 ppm and use alarm B as an advance warning device by configuring it as a low alarm set at 0 75 ppm When alarm B is activated there is still time left to take corrective action HIGH ALARM LOW AL
23. functions 18 numeric values 18 Electrode 46 Electronic calibration of inputs 48 Er 94 44 Er 95 44 Error messages 40 Err 40 43 sign 40 acknowledging 40 CA3 6 42 CA3 7 42 clearing 40 ELO 41 E12 41 E13 41 E14 41 E15 41 E2 1 41 E22 41 E3 1 42 E3 2 42 E3 3 42 E3 4 42 B35 42 Fahrenheit 19 Fault alarm 53 Free available chlorine 21 46 Galvanic cell 23 Galvanic chlorine sensor 23 INDEX Home Base 16 Hypochlorite ion 20 Hypochlorous acid 20 Hysteresis 46 iLOG 44 Input damping 19 Installation 12 63 Installation analyzer mounting 12 analyzer wiring 13 sensor mounting 13 sensor wiring 13 shop test startup 14 Keypad arrow keys 17 AUTO key 17 CANCEL key 18 ENTER key 18 functions 18 MANUAL key 17 SAMPLE key 16 SELECT key 18 LED 46 Manual pH compensation 32 Manual temperature compensation 32 Membrane replacement toolkit 25 Menu 3pp 16 46 Nernst equation 46 Normally closed 46 Normally open 46 Output hold 17 Output signals 49 Password 59pp pH buffers 37 calibration 36pp 55 compensation 32 Nernst equation 46 Nernstian response 39 offset 36 38p output hold 17 slope 36 39 standardizing 38 pH compensation 32 pH Sensor um 876 211 www iccontrols com Page 85 INDEX cleaning 34p insertion into flow fitting 33 maintenance 33 Mounting 13 preparation for use 33 removal from flow fitting 33 specifications 10 storage 33 troubleshooting 57p wiring 13 ppm 46 Pr
24. is of higher elevation than pump head disconnecting tubing at injection check valve end will allow air to enter and cause solution to drain back to tank um 876 211 IC CONTROLS IC CONTROLS APPENDIX D OPTION 51 53 TIMER ELECTRODE CLEANER 39071 390s 390B1 39171 39181 39181 39271 392si 3928 aal 39351 3938 1 1 H 1 3 1 8 3 3 53 1 Inj Ck Valve PVDF 3FV PGC 3 8 3FV PVDF 3 8 4FV PGC 3 8 4FV PVDF 3 8 B4FV PGC 3 8 B4FV PVDF 3 8 CV 375 PGC Polyprel CV 375 PVDF Polyprel 3 3 3 36306 CV 375 PVDF PTFE 3 3 36351 Suction Valve PGC 1 1 1 1 Suction Valve PVDF 1 1 1 36354 Suction Valve PVDF 1 1 Foot Valve PGC 1 1 1 1 Foot Valve PVDF 1 1 1 Foot Valve PVDF 1 1 Head Acrylic 0 9 1 1 Head PGC 0 9 1 1 Head PVDF 0 9 1 1 1 1 Liquifram 0 9 1 1 1 1 1 1 1 1 1 Inj Fitting PGC 1 1 1 1 1 Inj Fitting PVDF 1 1 1 1 1 1 Valve Housing PGC 3 3 3 3 3 Valve Housing PVDF 3 3 3 3 3 3 Clamp Ring 3 3 3 3 3 3 3 3 3 3 3 3 Coupling Nut 4 4 4 4 4 4 4 4 4 4 4 4 Tubing 375 P E 1 1 1 1 1 1 1 1 1 1 1 1 Tubing 375 U V P E Black UV resistant tubing change I to U for example 391SI to 39
25. mA value to display the desired output needed for testing the output signal Press ENTER to select the displayed value The output signal will be adjusted to put out the desired current This process can be repeated as often as necessary The output signal is held at the displayed level until the program leaves this part of the menu Units for Outputs The output menu will be using different units for its settings depending on the input selected Select unit from the output menu to display the units in use for this output um 876 211 www iccontrols com Page 49 ALARM FUNCTIONS IC CONTROLS ALARM FUNCTIONS Two alarms alarm A and alarm B are a standard feature Each alarm has an alarm contact associated with it which can be used for remote alarm indication or for control functions The two alarms function independently of each other Either alarm can independently monitor any of the inputs Each alarm features an adjustable set point user selectable alarm type and adjustable differential also called hysteresis The alarm types which are available are no chlorine high low deviation and fault Alarms can be set anywhere between 0 ppm and 2 ppm for HOCI 0 x mmm ppm to 5 ppm for tFCI 0 pH to 14 pH for aca pH and 5 C to 105 C for temperature He Use of Relay Contacts By default the relay contacts will be used E list of to indicate alarm conditions Alarm ALA im e PH ora conditions ar
26. of pressure gradually stretching the chlorine sensor membrane which is getting thinner The membrane will soon fail Correct by lowering pressure at the sensor Change membrane if required Page 56 www iccontrols com um 876 211 IC CONTROLS TROUBLESHOOTING pH Sensor IC CONTROLS manufactures a portable pH analyzer and pH calibrator model 659 for this purpose The calibrator can be used to prove the portable pH analyzer before use or it can be used to prove the process pH analyzer in this case the 876 where a problem has been exhibited Before testing the pH sensor be sure the test analyzer is known to be good FIRST Inspect electrodes and if dirty or scaled gt Clean with a soft cloth gt Acid clean to remove scale as per Chemical Clean procedure SECOND Run buffer tests in but do not adjust analyzer gt pH 7 buffer write down reading and response time gt pH 4 buffer write down reading and response time Slow response Clean again or acid clean overnight in electrode wash solution P N A1100091 Make sure that after cleaning response is not longer than 3 minutes REFERENCE If pH 7 reads between 6 pH and 8 pH then the reference is good If pH reading is outside pH 6 or pH 8 then the reference is poor or has failed pH GLASS Subtract pH 4 reading from pH 7 reading gt if result is 2 5 to 3 the glass is good gt if result is less than 2 5 then pH electrode is failing and should be replaced Less responsive
27. or over scale still occur when the analyzer and sensor are hooked up and placed in service then the most likely cause is a ground loop short forming not actually a pH sensor problem Refer to the model 659 user manual troubleshooting procedures to resolve this pH loop plant site interaction problem The above symptoms cover most difficulties associated with pH sensors The key to isolating problems in the pH sensor or analyzer is being able to separate the two Restoring Electrode Response Used electrodes which are mechanically intact but low efficiency or slow responding can often be restored to full response by one of the following procedures 1 Scale deposits Dissolve the deposit by immersion of the electrode tip overnight or over weekend in electrode wash solution P N A1100091 followed by rinse in tap water Soak in electrode storage solution P N A1100090 for 1 to 2 hours Difficult cases Repeat substituting gentle scale remover P N A1100093 then 15 minute rinse 2 Oil or grease films Wash electrode tip with detergent and water If film is known to be soluble in a particular organic solvent wash with this solvent Rinse electrode tip with tap water Let sit in demin water P N A1100015 for 2 to 4 hours followed by 2 to 4 hours in electrode storage solution P N A1100090 Difficult cases Repeat using wash in sodium hypochlorite Javex Bleach in water solution adjusted to pH 6 5 0 5 using vinegar or acid
28. serial output logging input being logged frequency of log update in seconds continue logging overwriting oldest data stop logging when buffer full number of data points currently in buffer Send ASCII serial output when logging No ASCII serial output Illustration 5 Internal data log menu um 876 211 i i i ch N eo e eh ZS D N M Gelb 5 e e O fe IN 876 25 Menus i Illustration 6 Serial menu www iccontrols com Page 5 INTRODUCTION IC CONTROLS INTRODUCTION The model 876 25 is IC CONTROLS industrial quality remote operational total free chlorine and pH analyzer designed to provide maximum flexibility reliability and ease of use The model 876 25 analyzer has been designed to include a pH input to measure sample pH for continual pH compensation ideal for samples with fluctuating pH values Temperature compensation is obtained via a temperature sensor in the chlorine sensor The chlorine sensor used with the 876 25 is a galvanic cell that is separated from the process by a chlorine permeable membrane As the hypochlorous acid HOCI in the process diffuses through the membrane a galvanic reaction occurs which produces a current that is proportional to the free available chlorine concentration An advantage of the galvanic cell is that an absolute zero measurement can be obtained no chlorine present equals no chlorine produced Many manufacturers use amperometric techn
29. the offset is known to be greater than 77 mV or if the analyzer selected the wrong buffer using automatic buffer recognition then it is necessary to specify which buffer is being used This is done by selecting 4 01 7 00 or 10 0 then an offset of 4 pH units is allowed and temperature compensated values are still used Other Buffer Values or Custom Buffers If a buffer with a pH value other than pH 4 pH 7 or pH 10 is to be used select cuSt custom value then enter a value between 0 pH and 14 pH Buffer values entered this way are not temperature compensated the buffer is assumed to have the specified pH value at the current temperature Offsets of up to 4 pH units are allowed pH Buffer Use and Maintenance pH CALIBRATION Illustration 32 Temperature compensated pH 7 buffer Illustration 33 Temperature compensated pH 10 buffer A pH measurement is only as good as the calibration and the calibration is only as good as the buffers The following guidelines for buffer maintenance will ensure accurate pH calibration and thus accurate pH measurement e Buffers have a limited shelf life IC CONTROLS suggests a one 1 year shelf life for unopened pH buffers Store buffers at room temperature e Discard used buffer do not return used buffer to the stock bottle e Protect buffers from exposure to air as atmospheric carbon dioxide lowers the pH value of alkaline buffers Other trace gases found in industrial en
30. to the pH Calibration section 1 Press SAMPLE to display the tFCI reading Press SELECT to reach the first menu then use the Up or Down arrow key to display tFCI 2 Press SELECT then the Up or Down arrow key to display CAL 3 Press SELECT then the Up or Down arrow key to Get Then press SELECT again to display a flashing do LEAVE ANALYZER FLASHING 4 From the analyzer outlet obtain a representative grab sample cup full of water then immediately go and press ENTER on the analyzer Illustration 26 Chlorine calibration kit P N A7010001 5 Take an ampoule from the kit and place the ampoule s tapered tip into one of the four depressions in the bottom of the sample cup Snap the tip by pressing the ampoule towards the side of the cup The sample will fill the ampoule and begin to mix with the reagent A small bubble of inert gas will remain in the ampoule to facilitate mixing CAUTION Do not break the tip of the ampoule unless it is completely immersed in your sample Accidentally breaking the tip in the atmosphere may produce a jack hammer effect shattering the ampoule Wear eye protection when working with these ampoules Illustration 27 Method for breaking the ampoule Page 30 www iccontrols com um 876 211 IC CONTROLS CHLORINE CALIBRATION 6 Remove the fluid filled ampoule from the cup Mix the contents of the ampoule by inverting it several times allowing the bubble to travel from end to end each tim
31. will contain acid b wm First remove the pH sensor from the process and examine it for deposits Use the sensor cleaning brush and tap water to loosen and flush away any deposits within the measurement area Detergent can be added to remove oil films and non tenacious deposits Hard scales and other tenacious deposits may require chemical cleaning c CHEMICAL CLEANING Fill a beaker full of pH electrode wash solution P N A1100091 d e Allow the sensor to sit in this solution for a few minutes and then check to see if the pH electrode and reference junction appear clean If not entirely clean allow sensor to sit in solution until clean Stubborn deposits can be removed with the brush and syringe to squirt wash solution into hard to reach areas Lower the pH sensor into the center of the beaker until the entire tip is submerged CAUTION Use great care when brushing and squirting acid Wear rubber gloves and facial protection f Rinse the cleaned sensor thoroughly in tap water and then with demineralized water for a second rinse prior to calibration g Check the sensor against a pH buffer close to the application pH If the sensor is still not reading properly 0 5 pH in the buffer clean again using gentle scale remover P N A1100094 following steps h to 1 h CHEMICAL DESCALING Fill a beaker full with gentle scale remover P N A1100094 i Lower the pH sensor into the center of the beaker until the entire tip is s
32. wrench to turn the sensor The plastic components of the chlorine sensor could be broken or deformed Removing Chlorine Sensor from Flow Fitting 1 Stop the sample flow and allow system to drain Remove the pH sensor as per instructions on page 33 Removing the pH sensor will reduce the vacuum effect within the flow cell CAUTION Removal of the chlorine sensor from a sealed flow cell will vacuum stretch the thin sensing membrane Stretching the membrane will cause slow response and higher readings at low levels Parting the membrane will cause chlorine sensor failure 2 By hand turn the union nut until free For higher pressures it may be necessary to use a wrench to start turning the nut 3 Gently rock and pull the chlorine sensor back and forth to ease the O ring seals back up the compression throat 4 When the chlorine sensor has been fully removed wipe the sensor clean and then proceed to the calibration procedure or monthly yearly maintenance as necessary Zero Test Technique The best way to zero check at the point of use where all water and even the air contains some chlorine is to use a zero chlorine solution available from IC CONTROLS as P N A1100225 in a 500 mL bottle CAUTION If zero standard gets on hands wash with running water Protective eye wear and gloves are suggested 1 Pour some of the zero chlorine solution P N A1100225 into a clean beaker 2 Immerse the chlorine sensor into the beaker so that it i
33. 104034 Component Identification eee np erts 24 Assembly of the Chlorine Sensor Inserting Chlorine Sensor in the Flow Fitting 27 Removing Chlorine Sensor from Flow Fitting 27 Zero Test Technique o Monthly Maintenance esee 28 Semi Annual Maintenance esee 28 Chemical Cleaning Automatic Chemical OCleanmng 29 Sensor Stora ES CHLORINE CALIBRATION Standardizing Chlorine sees pH and Temperature impact on Chlorine 32 Manual Temperature Compensation Se Manual pH Compensation esee PH SENSOR INSTRUCTIONS eerie eerte 33 Inserting pH Sensor into Flow Fitting 33 IC CONTROLS Removing pH Sensor from Flow Fitting 33 Electrode Matntenance 33 Sensor Storage treten ennt eere Monthly Maintenance Yearly Maintenance essent When to Clean Sensors 34 pH CALIBRATION 36 Selecting a pH Buffer 136 pH Buffer Use and Maintenance BS Standardizing Single Buffer Calibration 138 Calibrating Two Buffer Calibration i39 Manual Adjustment of Offset and Slope 39 ERROR MESSAGES eene 40 Acknowledging an Error Message 40 Messages for Chlorine Input eese 41 Messages for Temperature Input
34. 1SU Foot Valve Coupling 1 1 1 1 1 1 1 1 1 1 1 1 Strainer 1 1 1 1 1 1 1 1 1 1 1 1 Screw Head 4 4 4 4 4 4 4 4 4 4 4 4 P R Cap Asm 1 1 1 1 1 1 1 1 AEN Body PGC 1 1 1 1 4FV Body PVDF 1 1 1 1 36280 A S Cap Asm 1 1 1 1 1 1 1 1 22 25628 Nut 4 4 4 4 4 4 4 4 4 4 4 23 25631 1 1 1 1 1 1 1 1 1 1 1 1 24 Tubing 250 P E 1 1 1 1 1 1 1 1 1 1 1 1 28636 10 Tubing 250 U V P E Black UV resistant tubing change I to U for example 391SI to 391SU 25 37228 3FV Body PGC 1 1 SFV Body PVDF 1 1 26 Screw 3FV 4 4 4 4 25627 Screw 4FV 4 4 4 4 4 4 4 4 Screw B 4FV 1 1 1 1 29 32171 Cap 1 1 1 1 30 34868 Dss i 1 1 1 31 32173 Diaphragm 1 1 1 1 32 32175 O Ring 1 1 1 1 33 32176 O Ring 1 1 1 1 34 27352 Flapper Valve 1 1 1 1 1 1 1 1 1 1 1 1 37349 Inj Ck Valve Kit 1 1 1 1 1 1 1 1 1 1 1 1 10322 Weight not shown 1 1 1 1 1 1 1 1 1 T l4 1 um 876 211 www iccontrols com Page 71 APPENDIX D OPTION 51 53 TIMER ELECTRODE CLEANER ONT ig a 090 Washer on Bottom SE 24 Install 3 piece cartridge X valve as shown in direction of flow arrow Lh 4 FUNCTION BLEED VALVE B 4FV Page 72 www iccontrols com IC CONTROLS Washer on Top Install 3 piece cartridge valve as shown in d direction of flow arrow um 876 211 IC CONTROLS APPENDIX D OPTION 51 53 TIMER ELECTRODE CLEANER METHOD OF OPERATION tive pressure um 876 211 N at discharge
35. 2100083 A2104034 A9201047 A2104033 A7010001 A7010002 A7010004 A7010005 A2104035 A2104036 A1100239 A1100225 A1100227 100051 100052 100053 1100054 100091 100092 A A A A A1100090 A A A1100094 Page 78 IC CONTROLS DESCRIPTION REFERENCE DRAWING 876 25 Free Available Chlorine Analyzer pH preamp D5040276 Assembly 876 Micro display board D5980176 Assembly 876 Main board D5030269 Assembly M55 case complete 16 wire interconnector cable two end 0 25 A microfuse 0 10 A microfuse 5 pin adapter for chlorine sensor 876 dual sensor manifold 0 psi to 30 psi inch NPT pressure regulator 0 psi to 100 psi 2 inch pressure guage Brass shut off needle valve 115 VAC metering pump and accessories for automatic cleaning option 51 220 VAC metering pump and accessories for automatic cleaning option 53 Chlorine Sensor Chlorine sensor with TC 5 pin shorting plug for chlorine sensor pH Sensor pH sensor no TC Chlorine Consumables Chlorine calibration kit Chlorine calibration ampoules qty 30 for A7010001 Precision 0 001 ppm portable chlorine calibrator Chlorine calibration ampoules qty 30 for A7010004 Membrane replacement toolkit Membranes qty 5 Chlorine sensor fill solution 100 mL Zero chlorine solution 500 mL Chlorine renew solution 30 mL pH Consumables 4 buffer red 500 mL A1100051 6P for 6 pack 7 buffer green 500 mL A1100052 6P for 6 pack 10 buffer blue 500 mL A1100053 6P for 6
36. 211 IC CONTROLS APPENDIX C Installation APPENDIX C Installation Electrical The analyzer requires 115 230 VAC power to be hooked up to TB400 found on drawing D5040276 Connect the two alarm contacts Alarm A contact TB300 Alarm B contact TB301 Connect the two isolated 4 mA to 20 mA outputs Output 1 TB303 Output 2 TB304 Connect the inputs Chlorine direct connect to analyzer via 5 pin DIN connector pH direct connect to analyzer via BNC connector Mechanical Refer to sections entitled Chlorine Sensor Instructions and pH Sensor Instructions of this instruction manual Program Refer to Appendix B for default settings Prior to putting the analyzer into operation verify the settings to ensure that they agree with the intended setup For a more detailed description of any program setting refer to the appropriate section of this instruction manual Change defaults for the alarms Set alarm function high low deviation fault input chlorine pH temperature differential set point and on off switch Change defaults for the 4 mA to 20 mA outputs Set input high limit low limit and on off switch Set preference for metric imperial units in CONF unit Set the normally open normally closed configuration of the alarm contacts in CONF AL The program setting must reflect the actual NO NC wiring If using automatic cleaning system enable timer option Select _ _ ON OF and change setting to ON
37. 3 Plugged or dry reference junction Remove the contaminant with one of the above procedures then soak in electrode storage solution P N A1100090 for 24 hours to one week Difficult cases Repeat but heat almost to boiling for 2 hour first then soak in electrode storage solution P N A1100090 for 24 hours to one week Biological growths Wash electrode tip with detergent and water Difficult cases Wash with Sodium hypochlorite Javex Bleach in water solution adjusted to pH 6 5 0 5 using vinegar or acid Use rubber gloves and wash until deposits fall off or turn white Rinse tip with tap water Let sit in demin water P N A1100015 for 2 to 4 hours then 2 to 4 hours in electrode storage solution P N A1100090 Clean but slow and with less than 85 efficiency Wash electrode tip with electrode renew solution P N A1100092 for 15 minutes Rinse electrode tip using tap water for 15 minutes Let sit in demin water P N A1100015 for 2 to 4 hours followed by 2 to 4 hours in electrode storage solution P N A1100090 4 2 wa Note Jr none of the above procedures succeed in restoring electrode response it is near the end of the useful life of that sensor and should be replaced Page 58 www iccontrols com um 876 211 IC CONTROLS APPENDIX A Enabling Security APPENDIX A Enabling Security The analyzer has a built in password protection system This security system is disabled by default and does not need
38. ARM 4 E 4 E differential E 8 differential E Y SS v 4 ES a y e 7 E raids uel isc ai sa ae i a a T time time Illustration 41 High alarm Illustration 42 Low alarm Deviation Alarm A deviation alarm is practical when the process is expected to stay within a certain range An alarm will be set if the input deviates too far from a set point Note that the dEv frame only shows up in the menu after the alarm function has been changed to deviation alarm it would have no effect for a high low or fault alarm Example If the total free chlorine concentration is expected to stay between 0 2 ppm and 1 0 ppm then we would set in to tFCl Func to dEv SEt to 0 6 and dEv to 0 4 Effectively a high alarm at 1 0 ppm and a low alarm at 0 2 ppm has been set The differential setting will continue to function as for high and low alarms Page 52 www iccontrols com um 876 211 IC CONTROLS ALARM FUNCTIONS Fault Alarm A fault alarm for an input will be set when anything goes wrong with that input Something is wrong with an input if the input is off scale or an unacknowledged error message exists for that input Caution messages do not cause a fault alarm To use an alarm as a fault alarm select FUNC from the alarm menu then select Flt To enable the alarm make sure the on off switch is set to on Also set the input in the alarm menu to the desired input either chlorine pH or temperature The set point a
39. C CONTROLS INTRODUCTION Specifications Chlorine Sensor A2104034 Measurement Range Free Available Chlorine HOCH 0 00 mg L to 2 00 mg L Total Free Available Chlorine HOCI OCT 0 00 mg L to 5 00 mg L Minimum Temperature 0 C 32 F Maximum Temperature 80 C 176 F Maximum Pressure 621 kPa 90 psi Principle of Operationh nante n aga c ca he Er Eau c Galvanic Electrode Materials Cathod PP Gold Luet Silver Minimum Flow Velocity cece aaa aeaiee 15 cm s 0 5 ft s Wetted Materials ie etd Seele bet ein CPVC PTFE Viton Electrode Dimensions EE 2 3 cm 0 9 in Eengthi uet er et teg o inea eq Gail intet ee oees 16 5 cm 6 5 in Process Conpnechon uk fixed in the flow cell via a 1 in MNPT CPVC quick connect insertion fitting Sensor Cable ane e Aida ea eee 4 conductor 1 5 m 5 ft in length with 5 pin DIN connector D EE 0 5 kg 1 1 Ib Shipping UE LUS 0 9 kg 2 0 Ib Shipping Dimensions sse 30 cm x 23 cm x 23 cm 12 in x 9 in x 9 in es A2104034 1 0 um 876 211 www iccontrols com Page 11 INSTALLATION IC CONTROLS INSTALLATION Analyzer Mounting The model 876 25 comes as a complete sample conditioning system The analyzer is mounted on a CPVC panel with a dual flow cell containing the pH and chlorine sensors The sample conditioning system includes a pressure regulator valve sample point and atmospheric drain The only installation requirement of the user is
40. EANER Setting the Timer The timer menu is selected from the main menu as __ __ The following adjustments can be made to the timer Prompt Stands for Description Default ON OF on off switch turn timer feature on or off OFF on time length of on cycle in hour minute 00 01 IL off time length of off cycle in hour minute 23 59 HOLd output hold duration of output hold in seconds 10 StAt status displays on cycle or off cycle and time remaining 10 00 The on off status is shown by the sign After the timer is turned on the contact can be turned on or off by changing the sign using the Up or Down arrow key The default setting for the timer is an off cycle of 24 hours followed by one minute of cleaning so that the analyzer will turn on the contact for one minute at the same time each day Interaction with Other Analyzer Functions Automatic Output Hold The 4 mA to 20 mA outputs will not change and the alarms will be off temporarily as long as the timer is in it s on cycle After the analyzer has completed it s on cycle the analyzer program will give the electrode some additional time to stabilize before updating the output levels and enabling the alarms again The user specifies the length of the additional hold time in seconds in the HOLd selection of the timer menu Timer Interaction With Calibration Main Menu The timer will not start an on cycle while a calibration is in progress nor can a calibration be st
41. H inputs adjustments This makes it possible for c example to transmit both HOCI and outi CT signals each using separate high out c display units and low adjustments out2 F used by output To adjust the output span or output on window for chlorine pH or temperature ONOF OFF signals set LO to correspond to the low end of the scale or 4 mA output and HI 5 00 set HI to correspond to the high end of LO 0 00 the scale or 20 mA output The analyzer cur 32702 mA wil automatically scale the output according to the new settings Illustration 37 Output menu Reversing the 4 mA to 20 mA Output The low scale setting will normally be lower than the high scale setting It is possible to reverse the output or flip the window by reversing the settings of the low and high scale Simulated 4 mA to 20 mA Output Select cur from the menu to display the output current in mA that is presently being transmitted The display will be updated as the output signal changes based on the input signal and the program settings From here one can watch the output respond to the change in the input signal This is useful for verifying program settings and for testing the hardware calibration In addition the 876 25 output can be used to calibrate downstream receivers such as 4 mA to 20 mA recorders or data acquisition systems To simulate a different 4 mA to 20 mA output signal press ENTER to access edit mode Edit the displayed
42. LING NUT DISCHARGE TUBING 4 FUNCTION VALVE SPACER E P METERING PUMP PUMP HEAD HOUSING RETURN LINE PRESSURE RELIEF SUCTION FITTING POWER CORD H FOOT VALVE m et Ee Metering Pump Component Diagram Page 74 www iccontrols com um 876 211 APPENDIX D OPTION 51 53 TIMER ELECTRODE CLEANER IC CONTROLS BST erer as SS 1 1 0409 93404 i NDOHO NYO weibelg erA pepordxa Ajquessy Aud Od sees www iccontrols com Page 75 um 876 211 IC CONTROLS APPENDIX D OPTION 51 53 TIMER ELECTRODE CLEANER fda 290d 990d s90d 90d 290d fid3 190d 290d 990d SS0d S0d 250d um 876 211 Ida Lt0d Ibd SP0d EPOd Zrod fid3 190d Lie nda 1 0d 960d SEOd E 0d GE J 0d 920d S20d EZOd 220d Nda 1 0d 20d eas Od RK 90d K N S d 0d Meng Od qouy ex01IS 0d etd 340S 90d eld exons SOd b0d eig exons 0d eld exon 20d Kl id 20d SSIMS MOES Aiquessy Buisnog 90d 490d ZP0d Z 0d 220d SSIMS A0E2 Jasin g m Alquessy Bulsnoy 490d 250d 20d ASN Ae Mousse Buisnoy 990d 990d 970d 9 0d 920d ASIV A062 asing m Ajquassy Bulsnoy 990d 950d GEO 3n Adve
43. OD discharge tube D inch OD return vent line E inch OD suction tube F Chemical cleaner supplied by user Note Jt is recommended that the pump be primed using demineralized water prior to using with chemical cleaner This is to check for any leaks and for pump function Illustration 8 Pump assembly Chemical Cleaning Solution The chemical cleaning solution is supplied by the user IC CONTROLS suggests that a mild hydrochloric acid 596 HCI solution be used Page 68 www iccontrols com um 876 211 IC CONTROLS APPENDIX D OPTION 51 53 TIMER ELECTRODE CLEANER Wiring the Pump to Analyzer The pump is available as 115 VAC P N A2100082 selectable by option 51 or 220 VAC P N A2100083 selectable by option 53 Capacity range of pump is 0 20 to 1 0 gal hr or 0 76 L hr to 3 8 L hr at 110 psi 7 6 bar Tu Geeren mee KK oni Oza w w G t Ate Illustration 9 Wiring the cleaner option to the analyzer um 876 211 www iccontrols com Page 69 APPENDIX D OPTION 51 53 TIMER ELECTRODE CLEANER Liquid End Sheet LE 390 Series 0 9 IN When pumping solutions make certain that all tubing is securely attached to the fittings It is recommended that tubing or pipe lines be shielded to prevent possible injury in case of rupture or accidental damage Always wear protective clothing and face shield when working on or near your metering pump Note See parts list for materials of construction A
44. USER MANUAL MODEL 876 25 TOTAL FREE CHLORINE amp pH ANALYZER um 876 211 ID CONTROLS Contents Contents um 876 211 Conte nts sescccssesssserssrssccerseesessssesesersesssseeessesessesesessesesees 2 876 25 Menus 3 INTRODUCTION 6 General e Beat tes EES 7 Specifications sx ie aem t 8 INSTALLATION eee essen eene ente nersini 12 Analyzer Mounting x12 876 25 Component Identification 212 Analyzer Wiring Ee none eee 13 Sensor Mounting PE 13 Sensor Wiring esses NER 13 Instrument Shop Test Startup 14 STARTUP csccsscsssosssessessssenes 15 Analyzer Startup Tests rrr gt Easy to use Menn 16 Remembers Where You Were 16 Home Base Press Sample 16 Display Features 16 Arrow Keys XN AUTO and MANUAL Keys SN Standby Mode PN T Output Hold fel Edit Mode tet 18 Temperature C or F ld Real Time Clock ld Input Damping 19 APPLICATION INFORMATION 20 Chlorine Chemistry detentus 20 Chlorine and the effect of pH 20 Disinfectant Properties of Chlorine 22 876 25 CHLORINE MEASUREMENT 23 Introducti n 5 t entere EE 23 Galvanic Measuring Cell 23 CHLORINE SENSOR INSTRUCTIONS 24 Chlorine Sensor P N A2
45. ain the correct time and date even with the power turned off To check if your analyzer has a real time clock select CONF rtc CHIP from the menu If the display shows YES then there is a real time clock If the display shows no you can still set the date time clock but the time and date will need to be adjusted each time the analyzer loses power To set the real time clock select CONF rtc from the menu Set the year month day of the month hour minute and second Electronic Calibration of Inputs Adjustments to the input circuits of chlorine pH and temperature can be made both electronically and by making software adjustments The program adjustments are made using the configuration section of the menu ie by selecting CONF in and then the appropriate input from the menu The procedures are described in detail in the Electronic Hardware Alignment section Page 48 www iccontrols com um 876 211 IC CONTROLS OUTPUT SIGNALS OUTPUT SIGNALS Two assignable 4 mA to 20 mA output channels are provided The user may configure the analyzer to determine which input signal will be transmitted by each 4 mA to 20 mA output channel Each output channel can be independently configured to transmit a chlorine pH or temperature signal The output channels function independent of each other Each output Lee list of channel has a separate on off switch and Hoc ee adjustable low and high span or scale in P
46. alibration specifying correct buffer Perform electrode maintenance Check connections redo calibration Calibrate using buF1 for first buffer then go to buF2 to calibrate for slope Select buffers which are further apart to allow for more accurate slope calculation Perform buF1 calibration only and use default slope Redo calibration with correct buffer Check TC connections or use manual TC Redo calibration within TC operating range or use manual temperature compensation Check electrode service or replace as required Use fresh buffer Check both the reference and the glass pH electrode The glass may need to be etched or cleaned Use fresh buffer Use buffers which are further apart Allow more time for the analyzer to stabilize repeat calibration if necessary Use buffer closest to pH 7 as first buffer um 876 211 IC CONTROLS ERROR MESSAGES Error Description Causes Solutions Err pH reading off scale Process too caustic for accurate Verify process pH gt 14 measurement Large electrode offset Service or replace electrode Err pH reading off scale Electrode not connected Connect electrode or check pH 0 connections Electrode not responding Etch glass electrode Clean reference electrode Process too acidic to be measured Verify process Caution Messages for Alarms Caution Number Description CAT 5 Alarm A No Chlorine alarm CA7 6 Alarm A HIGH ala
47. anty of merchantability or fitness for a particular purpose and all warranties arising from the course of dealing or usage of trade The buyer s sole and exclusive remedy is for repair or replacement of the non conforming product or part thereof or refund of the purchase price but in no event shall IC CONTROLS its contractors and suppliers of any tier be liable to the buyer or any person for any special indirect incidental or consequential damages whether the claims are based in contract in tort including negligence or otherwise with respect to or arising out of the product furnished hereunder Representations and warranties made by any person including its authorized dealers distributors representatives and employees of IC CONTROLS which are inconsistent or in addition to the terms of this warranty shall not be binding upon IC CONTROLS unless in writing and signed by one of its officers um 876 211 www iccontrols com Page 83 INDEX INDEX Acknowledging error messages 40 Alarms 50 caution messages 43 default settings 62 delay activation 51 deviation 50 52 differential 50 53 fault 50 53 function 50 high 52 indication of 50 low 52 manual override 51 relay contacts 50 sensitivity of 52 set point 50 two stage 52 units 51 Ampoules 30 Analyzer electronic alignment 54pp mounting 12 specifications 8p startup tests 15 troubleshooting 54 wiring 13 Automatic chemical cleaning 20 Bleach 20 Buffers automatic r
48. arted while the timer is in it s on cycle The timer is generally connected to an electrode cleaner The analyzer cannot clean and calibrate an electrode at the same time Ele ss o 4 2 ila me When Cleaning H8 During the on cycle of the timer a calibration cannot be started If a E T calibration is attempted the analyzer will flash __ __ twice to show that out the timer is now in it s on cycle When Calibrating aL SEr If the off cycle is completed during a calibration then the on cycle will not start until after the calibration has finished Also as a safety and process integrity feature the timer will wait at least 5 minutes after a calibration has been completed before starting the on cycle automatically To avoid having the cleaning cycle start soon after a calibration it is good practice to turn the timer off temporarily or to increase the time of the current off cycle in the timer status selection ell 5 8 Sill Wala Le WK i Illustration 2 Main menu with timer option enabled um 876 211 Www iccontrols com Page 65 APPENDIX D OPTION 51 53 TIMER ELECTRODE CLEANER IC CONTROLS Manual Operation The timer can be operated manually by changing the timer status Changing the timer status does not affect the programmed on cycle and off cycle times To change the on off status of the timer the timer must be turned on In edit mode use the Up or Down arrow key to toggle the sign between and
49. ation menu but all other settings are unprotected Effectively the user will always have at least level 1 access um 876 211 www iccontrols com Page 59 APPENDIX A Enabling Security IC CONTROLS Level 1 At this point password 1 is still O00 You may optionally enable operator access control or level 1 security by changing the level 1 password from 000 to a non zero value Change the password by selecting CONF PAS 1 from the menu then entering an appropriate 3 digit password RECORDING YOUR PASSWORDS You may want to write down the passwords you set and store them in a secure place Once a password has been set there is no way to redisplay it Since passwords are set in the configuration menu level 2 access is required to change either password If you have forgotten the level 2 password there is no simple way to regain access to the analyzer Contact the factory if you find yourself locked out of the analyzer DISABLING PASSWORD SECURITY Password security can be disabled by setting the level 2 password to 0000 In order to change the password you must first have level 2 access to the program Select CONF PAS 2 from the menu then press ENTER when the program displays 0000 Both passwords 1 and 2 are set to 0000 and security is now disabled The main menu will be changed to exclude the PASS frame and the configuration menu will no longer have the PAS 1 frame ENTER PASSWORD Password Validation
50. ature calibration necessary not attached Temperature is greater than 105 C Electronic temperature calibration necessary WWW iccontrols com Temperature is less than Temperature compensator is ERROR MESSAGES Solutions The analyzer is at the limit of it s measuring capability Check the sensor setup to ensure that the sensor is operating properly Service or replace the sensor if necessary The analyzer needs electronic adjustments Arrange for servicing Set up electrode then redo calibration Also refer to Troubleshooting section Check electrode connection then redo calibration Also refer to Troubleshooting section Check pH sensor connections and or select manual pH compensation Check TC connections or install TC Use manual temperature compensation Solutions Verify process and sensor location Follow procedure in Hardware Alignment section Attach temperature compensator Connect resistor to TC terminals to simulate a constant temperature Refer to Hardware Alignment section Verify process and sensor location Follow procedure in Hardware Alignment section Page 41 ERROR MESSAGES Messages for pH Input Error E3 1 Description minutes of calibration E3 2 gt 1 3 pH units This error generated by auto detection of pH 4 pH 7 and pH 10 buffers only Previous offset is retained E3 3 gt 4 pH units Previous offset retained E3 4 or greater than 110 N
51. b sample calibration reference reading HI High alarm high limit 20 mA for 4 mA to 20 mA output window HOCI HOCI hypochlorous acid free available chlorine input HOLd Output hold hour Hour Real time clock setting hund Hundredth of a second Real time clock setting GLOG Internal data log menu refer to IC Net section in Input OR Minute for real time clock setting init Initialize all program settings to factory defaults LO Low alarm low limit 4 mA for 4 mA to 20 mA output window no Cl No chlorine alarm NodE Node number NO NC Normally Open Normally Closed NONE No membrane compensation OFF Off OFFS Offset Page 44 www iccontrols com um 876 211 IC CONTROLS DISPLAY PROMPTS OLd Old The grab sample calibration old reading ON On ON OF On off switch onth Month Real time clock setting OPEN Normally open alarm contact out 4 mA to 20 mA analog output channel out1 Output 1 out2 Output 2 PH pH input pH C pH compensation rtc Real time clock SEC Second Real time clock setting SEr Serial menu refer to IC Net section SEt Set point select manual compensation value set grab sample calibration SLOP Calculated slope for pH input given as Nernstian response StAr Start StAt Current status of timer Stby Standby mode Std Standard membrane tc Temperature compensation tFCI Total free available chlorine input HOCI OCT hypochlorous
52. calibration of the temperature input Select CONF in C OFFS from the menu and edit the offset to read 0 0 2 Set up a precision multimeter Fluke 8051A or equivalent to read VDC 3 Use TB200 terminal 3 as common See wiring diagram Place a 1000 Q 1 resistor across T and T Adjust blue trimpot VR202 located at the top left side of TB201 for a reading of 0 225 V at TP202 Refer to wiring diagram and drawing D5030269 for component locations 4 Place a 1 385 Q 1 resistor across T and T Adjust blue trimpot VR203 located at top right side of U201 for a reading of 4 80 V at TP202 Refer to drawing D5030269 for component locations 5 Close case and press SAMPLE key followed by the Down arrow key to display the temperature reading 6 Re insert the 1000 Q 1 resistor and adjust VR202 until the display reads 0 0 0 1 C 7 Re insert the 1 385 1 resistor and adjust VR203 until the display reads 100 0 0 1 C Calibration of pH Input Input for measurement circuit zero 0 00 V at high impedance BNC connector normally found on preamp refer to drawing D5030269 876 main board component locations Measured voltage at TP201 Pin 1 of U201 should be 2 50 VDC Adjust voltage using blue trimpot VR204 Note There is no span adjustment because the chemical calibration always varies it to suit the electrode Calibration of 4 mA to 20 mA Outputs Use one of the following two approaches to get the analyzer to output the de
53. chlorine or acid pump valve Best practice uses a separate circuit to isolate the sensitive sensing circuits from any pump or solenoid inductive surges however as a convenience for light loads a 3 A circuit fuse P N A9160035 can be installed at F402 to feed the 876 L1 HOT to COM on relay A Alarm A contact TB300 closest to AC lines Alarm B contact TB301 3 If required connect the two isolated 4 mA to 20 mA outputs these are 24 VDC Output 1 TB303 closest to the relays Output 2 TB304 4 Connect the inputs Chlorine sensor is direct connected to the analyzer via a 5 pin DIN connector pH sensor is direct connected to the analyzer via a BNC connector Sensor Mounting Optimum sensor performance with minimum user effort is provided through the use of the factory integrated sample system 35 5 cm x 66 0 cm 14 in x 26 in CPVC sample panel with pressure regulating valve flow setting valve atmospheric break grab sample point drain plus dual flow cell housing the chlorine and pH sensors The chlorine sensor and pH sensor are fixed in the flow cell via a 1 in MNPT CPVC quick connect insertion fitting The sensors are mounted within the sensor lead length as near as possible to the chlorine analyzer The flow cell is arranged so that the sensors are mounted on a 45 degree rising line with the sensor s tip down at an angle anywhere from 15 degrees above horizontal to 15 degrees vertical 45 degrees above horizontal is best because ai
54. closes diaphragm and prevents syphoning Anti Syphon Knob Pump discharge stroke f ifts diaphragm to allow for fluid flow A PRIMING with B 4FV see page 1 for 3FV 4FV 1 Connect bleed return tubing to bleed relief port 2 Route tubing to solution tank Be sure the end of tubing is above the maximum solution level Do not submerge tubing in solution 3 Set pump at 8096 speed and 10046 stroke Start pump With screwdriver rotate bleed adjustment screw counter clockwise two 2 full turns When solution begins to flow through translucent bleed return tubing the pump is primed 4 Stop pump Note a Pumpisnormally self priming if suction lift is no more than 5 ft 1 5 m valves in the pump are wet with water pump is shipped from factory with water in pump head and the above steps A1 thru A3 are followed b If the pump does not self prime remove Bleed 4 Function Valve and Discharge Cartridge and pour water or solution slowly into discharge port until it is filled Replace Cartridge and follow steps Al thru A3 thereafter B BLEED ADJUSTMENT 1 Start pump and let pump inject solution into the discharge line 2 Close the bleed adjustment screw by rotating it clockwise C with a screwdriver Rotate clockwise C to close Bleed SSS Adjustment Screw SSSSS vi www iccontrols com Ie Ze at Pon j KC Space open UM to drain
55. ct with test solutions 4 If air bubbles are visible inside the pH bulb shake the electrode downward to fill the bulb with solution 5 IC CONTROLS electrodes are shipped in a pH electrode storage solution buffered to approximately 7 pH These electrodes are often ready for use immediately with typical accuracy of 0 2 pH without buffering however it is strongly recommended that buffered calibration be performed 6 The pH sensor is ready to be placed in service Inserting pH Sensor into Flow Fitting Insertion sensors should be examined for good clean sealing surfaces and installed carefully Clean seals such as O rings should be lubricated with silicone grease to ensure liquid tight performance Remove the storage cap then carefully push the sensor into the insertion fitting until it is seated against the stop Tighten the retainer nut to hold the sensor firmly in place Let the vessel fill with liquid The pH sensor should now read the liquid pH Removing pH Sensor from Flow Fitting Simply turn off the sample flow and allow the pressure to drop to zero then undo the retaining nut and carefully remove the pH sensor from the flow cell Electrode Maintenance The pH sensor needs to be calibrated periodically to maintain accurate measurements IC CONTROLS recommends that the electrode be calibrated every 30 days Depending on the process it may need to be calibrated more frequently eg weekly or even daily Frequent calibration is
56. d B 1 auto 1 error 12 0 cm H x 20 0 cm W x 7 5 cm D 4 7 1n H x 7 9 in W x 3 0 in D 36 cm W x 66 cm H 14 in W x 26 in H 9 kg 20 0 Ib 11 4 kg 25 0 Ib 71 cm x 41 cm x 20 cm 28 in x 16 in x 8 in Environmental Data CHARACTERISTIC Operational 5 0 C to 45 C 41 0 F to 113 F Storage 10 0 C to 55 C 14 0 F to 131 F Relative Humidity 95 maximum non condensing Housing IP65 Nema 4X Pollution Degree 2 Installation Category I 115 230 VAC 0 25 A 50 60 Hz 115 230 VAC 10 50 W es 876 1 5 www iccontrols com um 876 211 IC CONTROLS Specifications Analyzer 876 PROPERTY Accuracy Precision Response Time Temperature Compensation Sample Conditions Sample Inlet Sample Outlet Security Alarms Outputs Communication um 876 211 INTRODUCTION Operational Data CHARACTERISTIC Chlorine 0 02 mg L pH 0 04 pH units Temperature 0 1 C Chlorine 0 01 mg L pH 0 02 pH units Temperature 0 1 C 90 96 within 5 s default function of flow and temperature Damping adjustment 3 s to 99 s Automatic temperature compensation via 1000 Q Pt RTD Auto 5 0 C to 105 C 23 0 F to 221 F Manual 5 0 C to 105 C 23 0 F to 221 F Flow 50 mL min to 500 mL min Temperature 2 C to 45 C 35 0 F to 113 F Pressure lt 400 kPa 60 psi 4 bar Drain Atmospheric 1 2 in barb fitting 1 2 in barb fitting 3 access
57. d up The hypochlorite ion OCI form of chlorine is a relatively poor disinfectant because of it s inability to diffuse through the cell wall of microorganisms The obstacle is the negative electrical charge Page 22 www iccontrols com um 876 211 IC CONTROLS 876 25 CHLORINE MEASUREMENT 876 25 CHLORINE MEASUREMENT Introduction Chlorine in water is a measure of the amount of chlorine usually thought of as a gas that is dissolved in the liquid Chlorine is widely respected as a leading chemical for the treatment of water to make it potable or safe to drink In addition free available chlorine is often used to control biological agent growth in water filled industrial systems The 876 25 directly measures free available chlorine using a model 876 S3 P N A2104034 galvanic chlorine sensor Galvanic Measuring Cell The chlorine measuring sensor P N A2104034 is an electrochemical cell similar to a battery that produces a current when chlorine is present By using carefully selected electrodes in contact with an appropriate electrolyte a chemical reaction occurs that uses electrons gained from chlorine molecules to produce a galvanic current directly proportional to the concentration of chlorine present Illustration 16 shows how such an electrode system works in a simple laboratory test Illustration 17 shows how these scientific principles can be implemented into a working chlorine electrode Also unlike an electrolytic cell in which a
58. dged error the sign indicates an inactive or acknowledged error Acknowledging the error will change the sign from to Press ENTER to go into edit mode The or sign will be flashing Use the Up or Down arrow key to change the sign then press ENTER again An acknowledged error message is cleared for one occurrence of the error only If the error reappears the sign changes from to and the error message must be acknowledged again Page 40 www iccontrols com um 876 211 IC CONTROLS Messages for Chlorine Input Error E1 0 E1 3 E1 4 E1 5 Description Reading is off scale Display shows Err Electrode efficiency would be less than 20 Previous setting retained Sensor efficiency would be more than 300 Previous setting retained Causes The internal A D converter is at the top of the scale The analyzer cannot measure higher chlorine values Improper electrode setup or electrode failure No chlorine signal or signal from sensor very weak pH compensator is pH sensor is not connected off scale Temperature compensator is off scale TC is not connected Process is outside of TC operating range of 5 C to 105 C Messages for Temperature Input Error E2 1 E2 2 Temperature reading is off scale Temperature is greater than 105 C um 876 211 Description Temperature reading is off scale Temperature is less than 5 C Causes zer Electronic temper
59. e 7 Wipe all liquid from the exterior of the ampoule and wait 1 minute 8 After 1 minute use the appropriate comparator to determine the level of chlorine in the sample Write down the chlorine value Low range Comparator High range Comparator 0 ppm to 1 ppm 1 ppm to 5 ppm The ampoule is placed in the center tube flat The comparator should be illuminated by a end downward The top of the cylinder is then strong white light directly above the directed toward a source of bright light while comparator The filled ampoule should be viewing from the bottom Hold the placed between the color standards for comparator in a nearly horizontal position and viewing It is very important that the ampoule rotate it until the standard below the ampoule be compared by placing it on both sides of the shows the closest match standard tube before concluding that it is darker lighter or equal to the standard Illustration 28 Using the low Illustration 29 Using the high range comparator range comparator Table 1 How to use the comparators 9 Install the chlorine calibration value determined in step 8 into the 876 as follows Press SAMPLE then SELECT to display tFCl Press SELECT to display CAL then press SELECT to display Get then press Up arrow to display SEt Press SELECT to display numeric value then press ENTER to get the numeric value to flash Edit the numeric value to the new value determined from step 8 When the flashin
60. e indicated using both the AEB c LED and the relay contact This usage of Ce the relay contacts is selected by setting unit display units used by alarm CONF AL AL A FUNC and Ea CONF AL AL b FUNC to AL If ONOF OFF some other use is selected for the relay dey contacts then the alarm cannot dIFF L 7088 simultaneously use the contact however dLAY SU alarm activation delay sec the alarm function continues using the LED display messages and serial Illustration 38 Alarm menu Re communication Alarm Indication The A and B LEDs on the front panel show the current state of each alarm and alarm contact In addition an alarm condition for an input will cause the sample display for that input to alternate with the alarm function no Cl LO HI dEv or FLt An LED that is blinking or on shows that the alarm has an alarm condition The status of the alarm contact can also be determined at a glance the corresponding alarm contact is activated when the LED is on and is deactivated while the LED is blinking or off Note that the alarm LED will blink while the alarm is in MANUAL because this also deactivates the alarm contacts Each alarm will generate a caution number in the error OFF D no alarm condition menu Refer to Caution Messages for Alarms in the i Error Messages section for the meaning of each alarm P alarm condition caution The alarm cautions will not cause the error LINK L eontact na
61. e supplied as sodium hypochlorite calcium hypochlorite or bleach is in a basic form When a base is present a different reaction sequence occurs 2 NaOClaj HO gt HOClag Nat OH 3 Ca OCDu 2H O aq gt 2HOCI A Ca 20H In any hypochlorite solution the active ingredient is always hypochlorous acid Then once HOCI and OH are formed an additional reaction occurs 4 HOClaj OH lt gt OCT H2O aq The proportion of chlorine hypochlorous acid and hypochlorite ion in solution depends primarily on pH and somewhat on temperature The different forms of chlorine are named as follows Ch chlorine HOCI hypochlorous acid OCI hypochlorite ion At atmospheric pressure and 20 C the maximum solubility of chlorine is about 7 395 mg per liter or 7 395 ppm Chlorine and the effect of pH 100 The most important reaction in the chlorination of D an aqueous solution is the formation of hypochlorous acid The hypochlorous acid form of chlorine is very effective for killing germs 3 Hypochlorous acid is a weak acid meaning that it tends to undergo partial dissociation to form a 20 hydrogen ion and a hypochlorite ion Once in a water environment HOCI tends to dissociate into o 2 H Cl HgO HOC H C107 H c Hoc V i m 15 10 12 14 6 8 7 i Solution pH H and OCI 10ns i Percent Fraction ofi Chlorine Hypochlorous Acid and Hypochlorite vs Solution p
62. ecognition of 36 custom 37 selecting 39 temperature dependence of 37 Calcium hypochlorite 20 Calibration chlorine 30p electronic 54pp outputs 55p pH 36pp temperature 54 Celsius 19 Chemical cleaning solution 68 Chlorine Page 84 www iccontrols com IC CONTROLS alignment of detection circuit automatic chemical cleaning 29 calibration 30p calibration kit 30 chemistry 20p combined chlorine 21 disinfectant properties 22 effect of pH 20 32 free available chlorine 21 grab sample standardization 30 measurement 23 measuring cell 23 pH compensation 32 sensor 24pp standardizing 30 temperature compensation 32 temperature effect of 32 total free chlorine 21 total residual chlorine 21 zero test 27 Chlorine calibration kit 30 Chlorine sensor automatic chemical cleaning 29 chemical cleaning 28 insertion into flow fitting 27 maintenance 28 membrane replacement 25p mounting 13 removal from flow fitting 27 specifications 11 storage 29 troubleshooting 56 wiring 13 zero check 27 Combined chlorine 21 Configuration 47 63 Configuration clock 48 input damping 48 normally closed 47 51 normally open 47 51 program 47 63 units 48 54 um 876 211 IC CONTROLS Current output 49 default settings 62 output hold 17 reversing 49 settings 49 simulating 49 standby mode 17 units 49 Damping of inputs 19 Default settings 62 Deviation Alarm 52 Display prompts 44 Display prompts 45 Edit Mode change settings 18 key
63. er Plug the meter into a different outlet so that the meter and receiver are on different branch circuits If necessary the user should consult the dealer or an experienced radio television technician for additional suggestions The user may find the following booklet prepared by the Federal Communications Commission helpful How to Identify and Resolve Radio TV Interference Problems This booklet is available from the U S Government Printing Office Washington D C 20402 Stock No 004 000 00345 4 CANADA This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications Le present appareil num rique n met pas de bruits radio lectriques depassant les limites applicables aux appareils num riques de la class A prescrites dans le R glement sur le brouillage radio lectrique dict par le minist re des Communications du Canada Page 6 www iccontrols com um 876 211 IC CONTROLS INTRODUCTION General The 876 25 is one of a series of 115 230 VAC process analyzers supplied in a corrosion resistant IP65 NEMA 4X watertight dustite case These analyzers are also available for pH ORP dissolved oxygen and conductivity and are also available in two wire versions with an optional explosion proof rating In the case of CHLORINE the analyzer measures the sensor signal corresponding to the actual chlori
64. ernstian response slope is too flat or too steep Previous calibration is retained E3 5 scale CA3 6 Offset 1 3 pH units CA3 7 greater than 102 Nernstian response Page 42 Electrode has not stabilized after 5 Electrode has stabilized but offset Electrode has stabilized but offset Electrode efficiency less than 60 Temperature compensator is off Slope efficiency less than 85 or Causes Poor electrode performance Large offset in electrode Wrong buffer used for calibration Only pH 4 pH 7 and pH 10 buffers can be detected automatically Wrong buffer used for calibration Bad electrode Electrode not connected buF2 calibration done before buF1 calibration Buffers used in buF1 and buF2 are too close together or are the same buffer Wrong buffer specified TC is not connected Process is outside of TC operating range of 5 C to 105 C Large offset in reference electrode or electrode depleted Bad buffer used for calibration Poor electrode pair performance Bad buffer used for calibration Buffers were too close together Electrodes did not stabilize www iccontrols com IC CONTROLS Solutions Check electrode redo calibration Calibrate specifying custom pH 4 pH 7 or pH 10 buffer to allow for offsets of up to 4 pH units Perform electrode maintenance Specify the correct pH value for the standard and redo the calibration Redo c
65. es into effect as soon as SELECT is pressed when CAL is displayed The output hold feature avoids false alarms and erratic signal output that would be caused by a routine calibration Output hold is not necessary for the chlorine input as chlorine calibration is performed by grab sample calibration only Output hold for the pH input has the following effect 4 mA to 20 mA output signal for pH is frozen at it s current level e alarms for pH are temporarily disabled If the output signal for pH is not acceptable at the value found it can be changed for the duration of the calibration Select Hold from the pH menu to display the pH value used by the analyzer to determine the output signal Use the normal editing procedure to change the pH value used for output hold The output hold remains in effect for the duration of the calibration that is the output hold is disabled when the CAL prompt is displayed the SAMPLE key is pressed or after no key has been pressed for 15 minutes um 876 211 www iccontrols com Page 17 STARTUP IC CONTROLS Edit Mode Edit mode is used to change a numeric value or to select between different options Values and settings which can be edited are identified by the darker shading in the menu Any frame which has a white background cannot be modified Editing by Selecting a Setting Editing a value is like picking an option from a list only one item on the list can be seen at a time To change the setting pr
66. especially important if accurate measurements are required Over time electrode performance will degrade The glass bulb becomes less responsive to pH and the reference electrode becomes depleted The electrodes will need to be replaced after several years of use or depending on the harshness of the process after several months Sensor Storage Short Term Rinse the pH sensor in demineralized water then store in a plastic shipping cap of 4 0 pH buffer solution Long term Clean the pH sensor in pH electrode wash solution P N A1100091 rinse in demineralized water then store in a plastic shipping cap of pH electrode storage solution P N A1100090 um 876 211 www iccontrols com Page 33 pH SENSOR INSTRUCTIONS IC CONTROLS Monthly Maintenance Remove the sensor from the flow cell rinse in water remove any significant deposits and then check by calibration in 7 pH for offset and then 4 pH or 10 pH buffer for slope If the calibration turns up a caution or error message in the 876 analyzer then follow the appropriate solution Also refer to Troubleshooting section If the calibration is good keep a log of the pH offset and slope at each monthly calibration The pH sensor is now ready to return to service Yearly Maintenance Check the pH offset log If the pH offset has changed more than 30 mV over the past year it may need to be chemically cleaned follow the Chemical Cleaning of Sensor procedure Check the pH slope eff
67. ess ENTER to go into edit mode The display will start blinking Use the Up or Down arrow key to switch between the possible options and then press ENTER again to accept the new setting and leave edit mode Example Turn alarm A off From the menu select AL AL A ON OF The analyzer will now display either ON or OFF which are the two choices To change the setting press ENTER to go into edit mode The display will start blinking Use the Up or Down arrow key to switch between the possible options When ON is displayed press ENTER again to accept the new setting and leave edit mode Summary of Key Functions in Edit Mode Enters edit mode The entire display or a single digit will blink to indicate that the analyzer ENTER Us in edit mode Press the ENTER key again to leave edit mode and accept the new value Adjusts blinking digit upward or selects the previous item from the list If a 9 is displayed then the digit will loop around to show 0 Adjusts blinking digit downward or selects the next item from the list If a 0 is displayed then the digit will loop around to show 9 Numeric values only move to the right one digit If blinking is already at last digit the display will loop to the sign on the left SELECT Numeric values move left one digit If blinking is at the sign then blinking goes to last character Settings restore the initial value if it was changed Otherwise leaves edit mode without doing anything
68. flow of current produces the chemical reaction there is no zero current as galvanic current is naturally zero when zero chlorine is present The chlorine sensor uses a galvanic cell separated from the sample by a chlorine permeable PTFE membrane The cell has a gold cathode in close contact with the PTFE membrane where chlorine gains electrons is reduced to become chloride ions and a silver anode that produces a fixed potential and completes the reaction with the chloride to form silver chloride The chemical reactions within the cell are At the cathode Cb42e 2CF S t At the anode 2Ag 2Ag 2e Overall Cl 2Ag 2AgCl Gold athode 7 Talon Membrame Silver Anode KCL Fill Solution Sensor Body Insul ator Illustration 17 Galvanic chlorine sensor um 876 211 Www iccontrols com Page 23 CHLORINE SENSOR INSTRUCTIONS IC CONTROLS CHLORINE SENSOR INSTRUCTIONS The chlorine sensor is designed for simple maintenance The sensor is robust and will withstand difficult applications when properly applied and maintained Follow the instructions in this section to promote proper operation Chlorine Sensor P N A2104034 Component Identification CE A Membrane B Retainer ring C O ring D Sensor body E Sensor cable F Silver coils Illustration 18 Chlorine sensor P N A2104034 component identification Page 24 www iccontrols com um 876 211 IC CONTROLS CHLORINE SENSOR INSTRUCTIONS Assembl
69. g www iccontrols com D PRIMING with 3FV 4FV see page 4 for B 4FV 1 Connect pressure relief tubing to pressure relief port on the discharge valve 2 Route tubing to solution reservoir and anchor with a plastic tie Do not submerge tubing in solution 3 Start pump Set at 80 speed and 100 stroke 4 Turn Pressure Relief knob black knob 1 4 turn Let pump run until solution is visible through translucent return tubing 5 Turn Pressure Relief knob back 1 4 turn The pump is now primed Note a Pump isnormally self priming if suction lift is not more than 5 ft 1 5 m valves in the pump are wet with water pump is shipped from factory with water in pump head and the above steps D Priming are followed b Ifthepump does not self prime remove cartridge valve and pour water or solution slowly into discharge port until head is filled Follow step D Priming thereafter E DEPRESSURIZING DISCHARGE LINE 1 It is possible to depressurize the discharge line and pump head without removal of tubing or loosening of fittings Be sure injection check valve is properly installed and is operating If a gate valve or globe valve has been installed downstream of injection check valve it should be closed Be certain relief tubing from the four function valve is connected and run to solution reservoir 2 Turn Pressure Relief knob 1 4 turn 3 The discharge line is now depressurized 4 If injection check valve
70. g value is the chlorine value from step 8 press ENTER to get the analyzer to accept the value then press SELECT to display flashing do Press ENTER to get the 876 to accept the chlorine calibration by displaying Done 10 Press SAMPLE to display the tFCI or total available chlorine reading in mg L or ppm Write down this value 11 Press Down arrow key to display HOCI or free available chlorine in mg L or ppm Write down this value 12 Press SELECT to display tFCI then press SELECT then the Up arrow key to display EFF Press SELECT to display the sensor efficiency in percent Write down this value Note Keeping a written calibration record will show how your unit trends over time The 876 analyzer is now reading chlorine and tracking chlorine changes in the water sample um 876 211 www iccontrols com Page 31 CHLORINE CALIBRATION IC CONTROLS pH and Temperature impact on Chlorine The measurement of the chlorine concentration is done by the galvanic sensing electrode However the chlorine chemistry of the sample will change with both temperature and pH Illustration 15 shows how the relative concentrations of hypochlorous acid and hypochlorite ion shift with a change in the water pH This same relationship is also dependent on the temperature of the solution as the curves will shift with changes in the temperature The 876 25 includes a temperature input and pH input to compensate for these changes A pH sensor is provided
71. h Recharge with fresh electrolyte Calibrate and return the sensor to service Semi Annual Maintenance Replace the membrane P N A2104036 and electrolyte solution P N A1100239 following the appropriate membrane replacement procedure in Assembly of the Chlorine Sensor section in Chlorine Sensor Instructions Examine the coils for any discoloration or heavy coating Such coatings should be removed for best performance caution the silver coils are soft metal never use force in cleaning To clean the coils refer to the Chemical Cleaning section for further instructions Remove the old membrane from the cell and replace with a new one Re assemble the cell calibrate check efficiency and if above 50 percent place in service Chemical Cleaning Chlorine sensors can be refreshed with IC CONTROLS P N A1100227 chlorine sensor renew solution This solution is only available in 30 mL bottles Due to the acidic nature of this solution the 30 mL bottle is packaged in a baking soda packer for non hazardous shipment Note This procedure should be done over a sink Wear plastic or rubber gloves and protective eye wear as the solution is acidic Wash hands thoroughly with lots of water if the solution comes in contact with the skin 1 Disassemble the chlorine sensor to expose the silver coils and gold tip 2 Immerse in cleaning solution as shown in illustration 24 for about 10 minutes or until deposits disappear 3 Remove and rinse in dis
72. iciency log If the efficiency has dropped below 8546 it may need to be chemically cleaned and restored see Chemical Cleaning of Sensor and or Restoring Electrode Response in the Troubleshooting section After all the above checks plus chemical cleaning and or restoring procedures follow the monthly maintenance procedure Start a new log with the improved values When to Clean Sensors Various factors can affect the pH reading scale biological growth oil wax gum etc all reduce the area for hydrogen ion to react with the glass Biological microbe growths can also produce local pH environments inside their growth deposit which can be quite different from the true process pH Periodic cleaning of pH sensors will remove these deposits restore the pH glass surface reference junction and thus the pH accuracy Mechanical Cleaning of Sensor The sensor will require cleaning if sludge slime or other deposits build up in the internal cavities of the sensor Wherever possible clean with a soft brush and detergents General debris oils films biological growths and non tenacious deposits can be removed in this way Use a soft flat brush and a beaker or bucket of water with a good liquid detergent Take care not to scratch the pH electrode glass surface it is thin fragile and easily broken All the wetted surfaces of plastic body sensors should be washed with a soft cloth This will return their appearance to like new condition a
73. in menu to see what errors have been detected by the analyzer Calibration Settings Retained If the analyzer was calibrated previously then the analyzer will use the calibration settings from the last successful calibration otherwise default settings are used Error and caution messages generated during the last calibration will remain in effect IC CONTROLS recommends a full chemical calibration of chlorine after initial startup Refer to the Chlorine Calibration section Analyzer settings and parameters can be viewed and or changed at any time Refer to the menus on pages 3 to 5 the areas shaded in dark gray indicate program settings um 876 211 www iccontrols com Page 15 STARTUP Easy to use Menu The layout of the program is shown in the menus starting on page 3 Remembers Where You Were The analyzer remembers where SAMPLE is The sample display is home base for the program The program also remembers which menu selections were used last and loops around the columns The menu can be accessed using the arrow keys to find any parameter then press SAMPLE to return to the displayed reading Then using the Right arrow key return to exactly where you were Home Base Press Sample From anywhere in the menu the SAMPLE key can be used to return to displaying tFCl The program will safely abort whatever it was doing at the time and return to displaying the tFCI reading The tFC1 display is the default sample display for the analyzer
74. is the same security as the other calibration procedures When the offset or slope are adjusted directly there is no way for the analyzer to verify the accuracy of the adjustments made However slope and offset warnings are given whenever the adjustments fall outside the preset safe regions Unlike a normal calibration the manual adjustments will allow slope adjustments outside 60 to 110 slope efficiency or offset adjustments greater than 4 pH units about 240 mV The usual error messages will come up but the specified new values will be installed nonetheless An alternate calibration method grab sample may be performed as follows 1 Take a pH reading using a different method eg portable meter 2 Go to PH CAL buF1 cuSt and edit the value to the pH value obtained in step 1 IC CONTROLS advises that the operator use one of the regular calibration procedures whenever possible um 876 211 www iccontrols com Page 39 ERROR MESSAGES IC CONTROLS ERROR MESSAGES Detected errors and or cautions can be displayed by the analyzer From the main menu select Err If there are no error or caution messages NONE will be displayed otherwise scroll through the error list using the Up and Down arrow keys Errors and cautions cannot be removed from this list directly each error or caution will be removed automatically when appropriate eg errors associated with improper calibration will be cleared after a successful calibration
75. it is able to kill living matter in water such as bacteria cysts and spores Exactly how chlorine works to kill is not known Studies do agree however that certain forms of chlorine are more effective disinfectants than others Whatever the chemical reaction it is also generally agreed that the relative efficiency of various disinfecting compounds is a function of the rate of diffusion of the active agent through the cell wall Factors which affect the efficiency of destruction are e Nature of disinfectant type of chlorine residual fraction Concentration of disinfectant Length of contact time with disinfectant Temperature Type and concentration of organisms pH HOCI is the most effective disinfectant of all the chlorine forms and is similar in structure to water The germicidal efficiency of HOCI is due to the relative ease with which it can penetrate cell walls This penetration is comparable to that of water and can be attributed to both it s modest size and to it s electrical neutrality The concentration of hypochlorous acid is dependent on the pH which establishes the amount of dissociation of HOCI to H and OCI ions Lowering the temperature of the reacting solution suppresses the dissociation conversely raising the temperature increases the amount of dissociation The rate of dissociation of HOCI is so rapid that equilibrium between HOCI and the OCT ion is maintained even though the HOCI is being continuously use
76. l 5 HOC ag lt gt H OCI Hiustration 14 Chlorine species change vs pH Page 20 www iccontrols com um 876 211 IC CONTROLS APPLICATION INFORMATION In waters between 5 pH and 8 5 pH the reaction is incomplete and both species are present to some degree Since H is one of the ions that is formed and it s concentration is expressed as pH it follows that changing pH levels will influence the balance of this reaction and with it the availability of hypochlorous acid for reaction In a water environment the water pH will affect the chemistry of chlorine due to it s pH sensitivity This becomes important as pH rises 6 HO lt H OH preference is right to left Three things follow from this form of ionization 1 Since the tendency of these two ions to react and form H20 is much stronger than the tendency of water to break down into the ions it follows that as the pH rises there are fewer H ions and more OH ions 2 The H released by the breakdown of HOCI equation 5 react to form water equation 6 and leave behind residual OCI hypochlorite ions Hypochlorite does not react readily so the chlorine is weaker 3 If the pH goes down and H ions become readily available again the OCI ions revert to HOCI which is the killing form of chlorine This pH change has been J k known to cause surprise downstream fish kills BE cio rb abe sio ai pH Illustration 15 Chlorine concentration vs pH Terminology I
77. l PH C At this point either Auto for automatic pH compensation or SEt for manual pH compensation set point will be displayed To change the setting from Auto to SEt press ENTER to edit the current setting The display will start blinking indicating that a selection needs to be made Use the Up or Down arrow key to display SEt Press ENTER to select manual pH compensation With SEt as the current display press SELECT to display the pH setting for manual pH compensation If the current value needs to be changed press ENTER to edit the current setting The display will start blinking Use the Up or Down arrow keys to display the desired pH value for manual pH compensation Press ENTER to accept the currently displayed value Page 32 www iccontrols com um 876 211 IC CONTROLS pH SENSOR INSTRUCTIONS pH SENSOR INSTRUCTIONS Preparation for Use 1 Moisten the pH sensor body with tap water and carefully remove the tape and orange plastic storage cap Caution should be used in removing this cap pull straight down Do not bend the body of the pH sensor This can result in damage to the internal element Note Save the lower cap for later use in storage of the pH sensor 2 Rinse away any deposits on the exposed pH bulb and junction area with tap water 3 For first time use or after long term storage immerse the pH electrode in 4 pH buffer for 30 minutes This hydrates the pH bulb and prepares the reference junction for conta
78. l 2 password then press ENTER The program will display good followed by your access level before returning to the main menu If an incorrect password was entered the program displays bAd instead Refer to Password Validation flow chart to determine how the program validates a password You will now have level 1 or level 2 access for as long as you are working with the analyzer The access level will automatically be restored to level 0 after no key has been pressed for 15 minutes This 15 minute timeout will also return to display the main sample It is good practice to return the analyzer to level 0 access or level 1 access if password 1 is set to 000 when you have finished using the analyzer This is accomplished by selecting PASS from the main menu then pressing ENTER with 0000 displayed ENABLING PASSWORD SECURITY When security is disabled both password 1 and password 2 are set to 0000 Security is enabled by setting password 2 to a non zero value Level 2 Select CONF PAS 2 from the menu The analyzer will display 0000 Use the arrow keys to change the display to the desired password for level 2 You can press SAMPLE at any time to safely cancel password entry Press ENTER to enter the password into memory and to enable password security The analyzer program automatically returns to the configuration menu With only password 2 set to a non zero value level 2 access is required to make changes in the configur
79. level security partial and or all settings may be protected via 3 and or 4 digit security code Two independent assignable programmable configurable failsafe NO NC alarm relays SPDT Form C rated 10 A 115 V 5 A 230 V Two continuous assignable programmable 4 mA to 20 mA or 0 mA to 20 mA outputs isolated max load 600 Q Convertible from 1 VDC to 5 VDC or 0 VDC to 5 VDC Via RS485 bidirectional serial data port require IC Net 2000 software es 876 1 5 www iccontrols com Page 9 INTRODUCTION IC CONTROLS Specifications pH Sensor A2104033 Measurement Range 0 pH to 14 pH units Minimum Temperature 0 C 32 F Maximum Temperature 100 C 212 F Maximum Pressure 689 kPa 100 psi Minimum Flow Velocty A 15 cm s 0 5 ft s Wetted Materials eire dicet cir irte ES tat o e eel CPVC PTFE Viton Glass Electrode Dimensions BI IMISCI Em 2 3 cm 0 9 in e LE 16 5 cm 6 5 in Process Connechon posiesie iaiia fixed in the flow cell via a 1 in MNPT CPVC quick connect insertion fitting Sensor EE 2 conductor 1 5 m 5 ft in length with BNC connector Preamplifier ected eh cds aen ierat ae e atem ree Remote Weight deat or adenine ae desea ana ee Rode oet 0 5 kg 1 1 Ib Shipping Weight 5 cree gt inti tea eec need eet Ia qne Rena d deba nc 0 9 kg 2 0 Ib Shipping Dimensions enne 30 cm x 23 cm x 23 cm 12 in x 9 in x 9 in es A2104033 1 0 Page 10 www iccontrols com um 876 211 I
80. lled with electrolyte and not connected to a powered analyzer um 876 211 www iccontrols com Page 29 CHLORINE CALIBRATION IC CONTROLS CHLORINE CALIBRATION The 876 25 chlorine system is calibrated by grab sample an easy method of standardizing the chlorine measurement without taking the electrode out of the sample Grab sample standardization method requires the user to determine the actual total free chlorine concentration of the sample using an alternative method When grab sample calibration is used it EFF 1 100 0 Efficiency is the responsibility of the user to ensure that the grab sample taken and the total spgj Get ge GEt free chlorine value recorded for it are CAL LoLa T1 0 99 ppm Et j accurate Le A chlorine calibration kit P N A7010001 is supplied with the model 876 25 The calibration kit uses a H C reagent which develops a violet color which is proportional to the amount of total free chlorine in the sample The tc kit contains 30 ampoules sample cup and low amp high range comparators to measure total free chlorine in the 0 ppm to 1 ppm and 1 ppm to 5 ppm concentration ranges respectively o S SEt Auto FE Illustration 25 Chlorine menu Note Keep the kit closed when not in use The comparators need to be stored in the dark Standardizing Chlorine NOTE The pH input should be calibrated first prior to chlorine standardization Refer
81. must be used or performance warranty is void Accessories not manufactured by IC CONTROLS are subject to the manufacturer s warranty terms and conditions Limitations and exclusions Industrial electrodes and replacement parts are warranted to be free from defects in material and workmanship for a period of three 3 months from the date of installation or eighteen 18 months from the date of shipment when used under normal operating conditions and in accordance with the operating limitations and maintenance procedures given in the instruction manual and when not having been subjected to accident alteration misuse abuse freezing scale coating or poisoning ions Chemical solutions standards or buffers carry an out of box warranty Should they be unusable when first out of box contact IC CONTROLS immediately for replacement To be considered for warranty the product shall have an RA Return Authorization number issued by IC CONTROLS service department for identification and shall be shipped prepaid to IC CONTROLS at the above address In the event of failure within the warranty period IC CONTROLS or its authorized dealer will at IC CONTROLS option repair or replace the product non conforming to the above warranty or will refund the purchase price of the unit The warranty described above is exclusive and in lieu of all other warranties whether statutory express or implied including but not limited to any implied warr
82. n demineralized water to remove drops of process OFFS liquid Lp Note Although pH buffers are formulated to resist pH change mixing in strong foreign ions can cause pH shift and resultant calibration to incorrect pH value Dirt deposits biological growths and any other contaminants should be removed from the pH sensor body and tip prior to calibration ELEC 5 Place the electrode in the selected buffer solution then press SELECT to start the calibration process The display will show a flashing pH reading to indicate that the analyzer is reading pH and is testing for stability buF2 buF1 Y ERE FERRE R The calibration procedure is fully automatic from here on As soon as the HOLd electrode has stabilized the display will stop flashing the electrode offset will be calculated and the new offset will be entered in memory It is however possible to override the analyzer The ENTER key may be pressed before the electrode has stabilized forcing the analyzer to calibrate using the current pH input Also the calibration may be redone or started over at any time Press CANCEL to display the selected buffer eg Auto then SELECT to restart the calibration i r e BEER If the analyzer detects or suspects any problems during calibration an error and or caution message will appear Refer to Error Messages for a description of each message m o o If an error has occurred
83. n the industry there are a number of terms used to indicate the various forms of chlorine that are of interest These terms tend to be used rather loosely and not necessarily consistently For that reason IC CONTROLS will define the following terms for purposes of this instruction manual and the 876 25 system FREE AVAILABLE CHLORINE refers to the hypochlorous acid HOCI form of chlorine only It is said to be free available because it is the free uncombined form of chlorine that is effective for killing TOTAL FREE CHLORINE refers to the sum of hypochlorous acid HOCI and hypochlorite ion OCI The hypochlorite ion is not effective for killing but it is in a free form All of the total free chlorine would be in the form of hypochlorous acid if the pH is low enough COMBINED CHLORINE refers to chlorine which is not readily available is not an effective disinfectant and will not readily convert to hypochlorous acid or hypochlorite ion For example chlorine combined as chloramines or organic nitrogen TOTAL RESIDUAL CHLORINE refers to the sum of total free chlorine and combined chlorine In environmental studies low total residual chlorine is of particular interest to ensure no downstream consequences for aquatic life Total residual chlorine is commonly monitored for final effluent um 876 211 www iccontrols com Page 21 APPLICATION INFORMATION IC CONTROLS Disinfectant Properties of Chlorine Chlorine is known to be a good disinfectant
84. nd 4 20mA LOOP IREDI T ME 18T 4 20mA LOOP RED 418101 RELAY B ItPowi RELAYA 115VAC 50 60 HZ e dr chk CO E P 301 E ET n 1980849195082 e H ovdi zor 410 CG B 2 Coen S IOM1NO 9I J0 29STH ord men Nsom qeon O mee CONTROLS 10 14 04 Orangeville Ontario Canada a LE MODEL 876 WIRING DIAGRAM code dwg no D5040e76 RE V sheet of 1 0 scale Page 82 www iccontrols com um 876 211 IC CONTROLS INDUSTRIAL PRODUCTS WARRANTY IR CONTROLS wr H 29 Centennial Road Orangeville Ontario LOW 1R1 Canada Tel 619 941 8161 Fax 519 941 8164 INDUSTRIAL PRODUCTS WARRANTY Industrial instruments are warranted to be free from defects in material and workmanship for a period of twelve 12 months from the date of installation or eighteen 18 months from the date of shipment from IC CONTROLS whichever is earlier when used under normal operating conditions and in accordance with the operating limitations and maintenance procedures in the instruction manual and when not having been subjected to accident alteration misuse or abuse This warranty is also conditioned upon calibration and consumable items electrodes and all solutions being stored at temperatures between 5 C and 45 C 40 F and 110 F in a non corrosive atmosphere IC CONTROLS consumables or approved reagents
85. nd differential for the alarm have no effect when the alarm is used as a fault alarm Using Alarms for On Off Control The alarms can also be used for process control the alarm contacts will then function as on off signals for switches controlling a valve pump or motor The set point determines the control point of the system and the setting of the differential controls the amount of corrective action before a controlled shut off occurs um 876 211 www iccontrols com Page 53 TROUBLESHOOTING IC CONTROLS TROUBLESHOOTING Analyzer Electronic Hardware Alignment Devices referred to in the following descriptions are shown on component location drawings D5030269 and D5980176 Proper field wiring for hookup is shown on drawing D5040276 These instructions assume 115 230 VAC power is hooked up the calibration of input electronics are operable and field wiring is in place Alignment of Chlorine Detection Circuit 1 Set up a precision multimeter Fluke 8051A or equivalent to read VDC 2 Use the CL2 sensor connection TB201 1 and COM sensor TB200 3 as common Refer to wiring diagram 3 Set the chlorine efficiency constant to 100 by selecting tFCI EFF from the menu and editing the value to read 100 0 4 Adjust the electronic standardize with blue trimpot VR200 located mid board above the terminal block marked D O see drawing D5020269 Adjust the trimpot to a reading of 2 50 V at TP200 while inputting 0 250 VDC thro
86. nd remove sites for buildups to occur When to Chemical Cleaning After mechanical cleaning as above check the sensor against a pH buffer If the sensor is still not developing the pH reading properly in the pH buffer proceed to the Chemical Cleaning procedure otherwise return the sensor to the process Page 34 www iccontrols com um 876 211 IC CONTROLS pH SENSOR INSTRUCTIONS Chemical Cleaning of Sensor IC CONTROLS offers a pH sensor chemical cleaning kit containing solutions and necessary cleaning items as P N A1600054 Note 1 A suitable place to do chemical cleaning is at a counter or bench with a laboratory sink with a chemical drain where waste is contained and treated before release Note 2 IC CONTROLS kits are kept small and portable so that they can be taken to installation sites together with a plastic bucket of water for rinsing and a rag towel for drying Waste materials particularly acid leftovers should be returned to the laboratory for disposal CAUTION Use extra care when handling the cleaning solution as it contains acid Wear rubber gloves and adequate facial protection when handling acid Follow all P N A1100091 amp P N A1100094 MSDS safety procedures a Set up the cleaning supplies where cleaning is to be performed Lay out the sensor cleaning brush syringe cleaning solutions and rinse solutions plus the beakers and sensor Note Ensure your cleaning solution beaker is on a firm flat surface since it
87. ne with respect to the sample pH and temperature The analyzer digitizes the signal for maximum accuracy conditions it and then sends it out as a digital output and or on 4 mA to 20 mA outputs The model 876 25 comes as a complete sample conditioning system The analyzer is mounted on a CPVC panel with a dual flow cell containing the pH and chlorine sensors The sample conditioning system includes a pressure regulator valve head tank sample point and atmospheric drain The only installation requirement of the user is to mount the panel and supply plumbing to the inlet and from the outlet A chlorine and pH calibration kit are supplied with the unit Features The model 876 25 total free chlorine and pH analyzer has the following features No reagents required reagent based analysis typically require a separate waste outlet Added reagents also require time for reaction therefore there is usually a lag time in response No reagents allow for reduced stock and maintenance costs No mechanical parts since direct measurement does not require reagents to be added and sample mixing there is no need for additional pumps tubing etc which also reduces the maintenance required Immediate response without lag time the direct measurement method used with the model 876 25 gives instantaneous results By comparison systems that use reagents require time for the sample to react with the reagent in the sample chamber thus introducing a lag time
88. ne sensor in air the 876 analyzer should come up reading 0 0 ppm 0 05 ppm Run an air zero check use wires to be field installed and allow 30 minutes warm up time for the electronics to stabilize Runa span check In the tFCI menu change to these settings tc SEt 25 0 and pH C SEt 7 50 A fairly accurate 1 ppm chlorine standard can be made from commercially available bleach use a fresh 5 2596 solution Pipet 0 1 mL of bleach into a 1 0 L volumetric flask Fill to mark with demineralized water This will produce a 5 ppm standardizing solution Pipet 20 mL of the 5 ppm solution into a 100 mL volumetric flask Fill to mark with demineralized water This solution should be used immediately after prepared and then discarded after 2 hours e Fill a plastic beaker with the 1 ppm chlorine standard and place the chlorine sensor into the beaker and stir f Wait 10 minutes the 876 should read 1 0 ppm 0 3 ppm aoa fe Return the tc and pH C settings back to Auto To check for general performance place the chlorine sensor in running tap water chlorinated tap water should be between 0 2 ppm and 1 0 ppm The display should read in that range Hook up the pH sensor via the BNC connector on the underside of the 876 analyzer and remove orange protective cap from sensor tip Keep the cap for future use With the pH sensor in pH 7 buffer the pH analyzer should display a reading of 7 0 0 5 pH
89. ocess control 53 Prompts 45 Real time clock 19 Relays testing 56 Security access level 59 disabling 60 enabling 59 password 59pp password 1 59 password 2 59 time out 16 SEr 45 Sodium hypochlorite 20 Specifications 8pp Standby mode 17 IC CONTROLS Start up analyzer tests 15 instrument shop test 14 program initialization 47 Temperature 19 calibration 54 compensation 32 current output 49 default settings 62 units 19 48 Temperature compensation 32 46 Terminology combined chlorine 21 free available chlorine 21 total free chlorine 21 total residual chlorine 21 Timer 15 minute time out 16 automatic cleaner 64pp security time out 16 Total free available chlorine 46 Total free chlorine 21 Total residual chlorine 21 Troubleshooting 54 analyzer 54 chlorine sensor 56 pH sensor 57 Page 86 www iccontrols com um 876 211
90. ology as opposed to galvanic Amperometric cells rely on an induced voltage to produce a current Since this residual current is always present an absolute measurement cannot be obtained and the HOCI concentration measured may be artificially high Another disadvantage of the amperometric method that does not affect galvanic measurement pertains to iron coating Polarization attracts iron ions that may be in the process water which can cause coating of the membrane iron deposits on the membrane can skew the chlorine readings NOTICE OF COMPLIANCE US This meter may generate radio frequency energy and if not installed and used properly that is in strict accordance with the manufacturer s instructions may cause interference to radio and television reception It has been type tested and found to comply with the limits for a Class A computing device in accordance with specifications in Part 15 of FCC Rules which are designed to provide reasonable protection against such interference in an industrial installation However there is no guarantee that interference will not occur in a particular installation If the meter does cause interference to radio or television reception which can be determined by turning the unit off and on the user is encouraged to try to correct the interference by one or more of the following measures Reorient the receiving antenna Relocate the meter with respect to the receiver Move the meter away from the receiv
91. op of the fluid filled sensor tip refer to illustration 22 Press down firmly until a stop is felt and a click is heard Some fluid will escape this is normal and to be expected wa g Remove the toolkit from sensor tip h Dry the chlorine sensor and blot the tip Examine the tip the membrane should be smooth with no wrinkles or cuts and the surface contours of the gold electrode should be clear There should be no lines from trapped bubbles between the membrane and the gold electrode If there are no visible problems as described here then the chlorine sensor is ready to be put into service Illustration 22 Step f of membrane replacement procedure B Assembly without Membrane Replacement Toolkit Required Materials 1 P N A2104036 Membrane kit ii P N A1100239 Chlorine sensor fill solution Membrane Replacement Procedure NOTE Successful membrane replacement without toolkit P N A2104035 can be difficult It is strongly suggested that the toolkit be purchased for ease of use a Take the sensor and rinse the fill solution cavity with fresh fill solution P N A1100239 Hold the sensor in an upright position with the fill solution cavity facing upwards and fill with P N A1100239 so that the gold tip is completely covered with liquid Ensure that there are no air bubbles in the solution b Place one membrane from P N A2104036 centered and shiny side down over the filled sensor tip c Take the membrane retaine
92. ot to be Le used unless you are absolutely sure that coNE PTN Redu you want to restore the analyzer to factory chlorine input V default configuration Membrane Compensation Factor In Le No membrane compensation After the analyzer program has been Ler seas sanant membrane initialized you will need to re enter the a le output signal settings alarm settings as E well as the program configuration if it aA S input damping sec was different from the factory default oa SN settings Lorrs 0 9 ofteet c Mess L aa Ge input damping sec Select CONF init ALL do from the menu The display will flash do Zeg Len Nothing will happen if you press DI Fes SAMPLE or CANCEL The analyzer will Let L GZ re initialize only if you press ENTER eo LS The analyzer will then go through it s start up sequence Year Lem 12 Laate Sr Lee aav thu hour 23 Lin_ _ 39 Lsec isa nuna 1 99 seca a ane PAS 2 0000 Illustration 36 Configuration menu um 876 211 www iccontrols com Page 47 CONFIGURATION OF PROGRAM IC CONTROLS Metric or Imperial Units By default the analyzer will use metric units This means that temperature will be displayed using degrees Celsius and that the prompt for the temperature input will be C The analyzer can also be made to use imperial units as the preferred unit Using imperial units temperature will be displayed using degrees Fahrenheit in the sample menu and the p
93. pH 10 gives a large enough span relative to the pH 7 buffer that a good slope can be calculated When performing the two point calibration a percent value will be given in microprocessor based pH analyzers The closer to 100 the slope is the better the efficiency and thus the performance of the electrode The model 876 25 has been programmed to recognize the three buffers most commonly used for calibration pH 4 pH 7 and pH 10 To achieve greater accuracy the temperature compensated values for these buffers are calculated by the analyzer Simply place the electrodes in the buffer solution and the analyzer will select the correct buffer value allowing for an offset of up to 1 3 pH units Note Auto must be selected in the calibration menu for this feature to work Page 36 www iccontrols com um 876 211 IC CONTROLS Temperature Dependence of Buffers The pH of a solution is dependent on temperature To achieve greater accuracy the temperature compensated values for the 4 pH 7 pH and 10 pH buffers are calculated by IC CONTROLS analyzers The graphs show the temperature dependence of the standard buffers The TC curves have been programmed into the IC CONTROLS analyzer The actual pH value of each of the three standard buffers will be used Example Calibrate using the pH 4 01 buffer at 25 C The temperature of the buffer is 50 C The analyzer will use the pH value of 4 05 Incorrect Buffer Selection by the Analyzer If
94. pH electrodes can sometimes be regenerated with P N A1100092 electrode renew solution Refer to Restoring Electrode Response THIRD If pH sensor passes the above tests then it is good Place electrode back in the loop and then run a 2 buffer calibration following the instructions in this manual FOURTH If the sensor fails tests gt Replace the pH sensor Troubleshooting Tips for pH Reading spike characteristic of bubbles in the sample line passing through the sensor or sticking to the pH sensor Also characteristic of pickup from interference pulses generated from AC lines when AC loads go off line Readings gradually drifting away the pH sensor can no longer be calibrated This problem is typical of scale or sludge slime deposits on the pH glass The sensor may need to be cleaned Readings at maximum under all conditions Either the sensor is in air or there is a problem with the wiring analyzer setup Test for shorts by disconnecting BNC and checking impedance between center pin and outside housing with sensor in air Insulation value should exceed 100 MO If the sensor is OK use the model 659 portable calibrator analyzer to test the preamp wiring and the analyzer If the problem persists with the 659 in place then it is an analyzer problem um 876 211 www iccontrols com Page 57 TROUBLESHOOTING IC CONTROLS If the sensor tests as still good and the analyzer and wiring works with the model 659 but the ERR
95. pack Buffer 6 pack 4 pH 7 pH 10 pH Electrode storage solution 500 mL A1100090 6P for 6 pack Electrode wash solution 500 mL A1100091 6P for 6 pack Deionized rinse water 500 mL A1100092 6P for 6 pack Gentle scale remover 500 mL A1100094 6P for 6 pack WWW iccontrols com NUMBER um 876 211 DRAWINGS IC CONTROLS DRAWINGS D4040081 Outline and Mounting Dimensions 0 T 40 uys 23j 02S A3s T800v see per SNDISN3WIG ONTLNAGW 8 ANTTILAN 9 8 7300W 31111 0pouoj olaogug anm e8uvug STOHLNOD 9 S50V1d v VIG S 0 S330H ONILNNOW ssyxg 383V8 En LIINI SSvad 383V8 S 0 NIV3IG D N 3Ad 0000 92 00G2 v2 www iccontrols com Page 79 um 876 211 IC CONTROLS Main Board Component Location DRAWINGS D5030269 ALARMI A SIG D P TENP SIG D P pH L1 MODEL 876 MAIN BOARD REV 1 0 1260874 dP 301 184 12808 W o w e GA el o er NV JI ID 00 1 i S c47 8 oC TB304 TB303 TB301 TB300 TB400 S i 6 CONTROLS Orangeville Ontario Canada TITLE 876 MAIN BOARD COMPONENT LOCATION um 876 211 www iccon
96. play measured reading Press SELECT to access main menu Use LI timer feature Up or Down arrow key to display eure 1 AL alarm contact CONF ALA Ges From the configuration menu select AL AL A which refers to Alarm dedicated alarm contact A Contact Select whether the OPEN program uses the alarm A contact for CLSd alarm A or for the timer The options Illustration 1 Configuration of alarms menu are AL alarm function timer function The normally open normally closed configuration for the alarm A contact will be used regardless of whether the contact is used by alarm A or by the timer Follow the same procedure to configure Alarm B Contact AL b With Alarm Function The alarm A contact is owned by alarm A The alarm A contact will be on if there is an alarm condition for alarm A otherwise the contact will be off The LED for alarm A will show the status of the alarm and it s contact The timer menu is not accessible from the main menu The frame is not available unless the timer option is enabled With Timer Function The alarm A contact is owned by the timer Alarm A will continue to function as before The alarm A LED will come on when there is an alarm condition however the alarm does not have an external contact The timer menu is accessed by selecting __ __ from the main menu Page 64 www iccontrols com um 876 211 IC CONTROLS APPENDIX D OPTION 51 53 TIMER ELECTRODE CL
97. r refer to illustration 20 and carefully slide down over the membrane until a stop is felt Some fluid will escape this is normal and to be expected d Dry the chlorine sensor and blot the tip Examine the tip the membrane should be smooth with no wrinkles or cuts and the surface contours of the gold electrode should be clear There should be no lines from trapped bubbles between the membrane and the gold electrode If there are no visible problems as described here then the chlorine sensor is ready to be put into service Page 26 www iccontrols com um 876 211 IC CONTROLS CHLORINE SENSOR INSTRUCTIONS Inserting Chlorine Sensor in the Flow Fitting 1 Inspect the inside of the quick union fitting for any foreign matter and wipe out any dirt which may be inside It should appear clean shiny and bright 2 Install the union ring nut and push sleeve on the assembled chlorine sensor by sliding it down the lead wire 3 Check that the sealing O ring is on the electrode body on the sensing tip side of the ledge or in the O ring groove of the flow cell 4 Insert the chlorine sensor into the fitting Rock the sensor back and forth to pass the O ring and press firmly all the way down so that the O ring firmly seats in its groove 5 By hand turn the union nut until finger tight For higher pressures it may be necessary to use a wrench however the components are plastic and care is needed to avoid breakage CAUTION Do not use a large
98. r bubbles will rise to the top and grit will sink both bypassing the sensor The pressure regulating valve installed before the flow cell functions to control and stabilize flow The atmospheric drain allows for the collection of representative samples without disturbing sample conditions and acts as a vent for bubbles The drain line should be larger than the sample line to allow for purging of sediments bubbles biologicals and other debris Sensor Wiring The basic wiring scheme for IC CONTROLS chlorine sensor and pH sensor is shown in drawing D5040276 This wiring scheme is intended for cable lengths less than 20 meters 65 feet where electrical interference is low The chlorine sensor has a 5 pin DIN connector and the pH sensor has a BNC connector This allows the sensors to be connected and disconnected easily at the analyzer Take care to route all signal wiring away from AC power lines to minimize unwanted electrical interference Avoid twisting the sensor lead to minimize possibilities for broken wire Make sure that the sensor connections are clean and tight um 876 211 www iccontrols com Page 13 INSTALLATION IC CONTROLS Instrument Shop Test Startup 1 2 8 9 Apply 115 230 VAC power to the analyzer Hook up the chlorine sensor to bottom of analyzer via 5 pin DIN connector Ensure that the shorting strap on the sensor connector is removed refer to illustration 8 Keep shorting jack for future use With the chlori
99. required is to attach the electrode to the analyzer and then to turn on the power The analyzer will go through its automatic startup procedure any time power to the analyzer was lost for more than a few seconds The startup procedure initializes the analyzer program performs error checking and then proceeds to display the chlorine and operate the analyzer normally All program settings calibration settings and defaults will have been remembered by the analyzer as the memory is none volatile Analyzer Startup Tests The startup procedure will begin by alternately flashing tESt and and blinking the top LED while performing the memory tests The analyzer will then display in sequence the analyzer number in this case 876 any software option numbers and the program version number eg 2 10 The program then proceeds to the display test which will light each of the implemented display segments in turn At the same time each of the LEDs will be lighted If the analyzer passes all the tests then the hardware is functioning properly and the analyzer will proceed to display total free chlorine If the analyzer displays Err or Err this indicates that the input is off scale The error LED will be lighted as long as any input is off scale An off scale error can indicate that the electrode is not in solution is off scale or is not connected properly If the error LED remains lighted go to the error display section select Err from ma
100. rm CA7 7 Alarm A LOW alarm CA7 8 Alarm A DEVIATION alarm CA7 9 Alarm A FAULT alarm CA8 5 Alarm B No Chlorine alarm CA8 6 Alarm B HIGH alarm CA8 7 Alarm B LOW alarm CA8 8 Alarm B DEVIATION alarm CA8 9 Alarm B FAULT alarm um 876 211 www iccontrols com Page 43 DISPLAY PROMPTS IC CONTROLS DISPLAY PROMPTS Timer menu _ _ Set time for on cycle _ _ Set time for off cycle AL Alarms AL A Alarm A AL b Alarm B Auto Automatic compensation bAud Baud rate buF1 Buffer for standardizing or first buffer for calibration buF2 Second buffer for calibration C Temperature in degrees Celsius temperature input use metric units CAL Calibrate CHIP Chip Is this analyzer equipped with a real time clock chip CF Membrane compensation factor CLSd Normally closed alarm contact CONF Configuration cur Signal output in mA or current cuSt Custom buffer value for calibration dA Input damping time in seconds dAtE Date Real time clock setting for day of month dEv Deviation alarm dFLt Default dLAY Alarm activation delay do Do press to do reset clear action donE Done reset clear action has been accepted EFF Efficiency Err Error Er 94 RAM checksum failed Some settings may be lost Er 95 EPROM checksum failed F Temperature in degrees Fahrenheit temperature input use imperial units FLt Fault alarm selectable function for alarm B GEt Get the gra
101. rode stability and performs many diagnostic tests during calibration SE t 125 0 C Automatic stability testing Auto takes most of the guesswork out of deciding whether a reading is acceptable or not The internal diagnostic tests will activate caution or error messages if faulty operation is suspected or detected Errors detected during calibration will not cause the analyzer to lock up pH Illustration 30 pH menu Buffers automatically recognized by the 876 are Buffer Part Number 500 mL bottle Part Number 6 pack 4 01 pH red A1100051 A1100051 6P 7 00 pH green A1100052 A1100052 6P 10 0 pH blue A1100053 A1100053 6P Selecting a pH Buffer pH buffers provide the simplest and most accurate method of calibrating the pH sensor and analyzer First Buffer The first step is to use 7 pH buffer to calculate the mV offset of the electrode from the theoretically perfect 0 mV pH 7 buffer is used because it simulates 0 mV thus making it the best standard since the electronics are also at this 0 mV reference point Second Buffer The next step in the calibration is to use a second buffer usually 4 pH or 10 pH When choosing which buffers to use in calibration it is best to select buffers that fall on both sides of the normal operating pH range By using these two buffers the slope calculation will encompass the normal pH thus giving the most accurate pH measurement Either of these buffers pH 4 or
102. rompt for the temperature input will be F instead of C throughout the program For practical reasons the temperature input is identified as C throughout this instruction manual and in the menus To select imperial units for the analyzer select unit from the configuration menu then go into edit mode and change the C prompt to F Input Damping The chlorine pH and temperature measurements can be damped to deal with rapidly varying or noisy signals Damping range is selectable between 3 s to 99 s With 0 seconds each reading is used to directly update the display and 4 mA to 20 mA output The factory default of 5 seconds adds the next 4 seconds of readings to the first and divides by five this gives fast response Selecting 99 seconds provides a smooth damping out of turbulent readings Any selection between 3 s and 99 s can be made Select CONF in from the menu Using Up or Down arrow key find the desired input and press SELECT Using Up or Down arrow key find dA and press SELECT Press ENTER to get into edit mode and change the damping value to the new value Press ENTER to accept the change and leave edit mode Real Time Clock All IC CONTROLS analyzers have an internal clock used for date time stamping of system events and the internal data log On power outage the clock stops then it continues where it left off when power returns When the 876 25 is purchased with option 34 a real time clock will maint
103. s ENTER to go into edit mode then press the Up or Down arrow key to change the normally open normally closed configuration from open to closed Press ENTER again to accept the new value A closed contact should open an open contact should close 2 Repeat step 1 for for the Alarm B contact 3 If so desired all software settings can be returned to factory default condition by following the procedure in Re initializing All Settings in the Configuration of Program section Chlorine Sensor Slow Response typically due to excessive sample line length and low flow thus producing long sample transport lags Resolve by adding a fast flow loop with the sensor in a short side stream or by shortening the line Slow response can also be caused by growth of biologicals in the sample line In this case the problem may be alleviated by changing the take off point Readings consistently low or spike low characteristic of wiring problems between the analyzer and the chlorine sensor an open circuit in the field wiring will result in zero cell current and a very low reading Review the installation instructions Readings gradually falling the analyzer can no longer be calibrated properly This problem is typical of sludge slime deposits on the face of the chlorine sensor The sensor will need to be cleaned Refer to the Monthly Maintenance and or Semi Annual Maintenance procedure in this manual Readings trend higher this problem is typical
104. s about 3 inches below the surface of the zero check liquid refer to illustration 23 Provide slow gentle movement to ensure the chlorine present is consumed The chlorine sensor should rapidly fall below 0 1 ppm thus confirming operation of the sensor Make sure that the zero check solution is used within 8 hours because the scavenger will be used up with exposure to air by also absorbing oxygen The remaining zero check solution should be stored tightly capped in it s bottle The zero solution is single use so discard the used zero solution Illustration 23 Zero check um 876 211 www iccontrols com Page 27 CHLORINE SENSOR INSTRUCTIONS IC CONTROLS Monthly Maintenance Certain applications may require occasional sensor cleaning A monthly maintenance check is recommended by visual examination of the sensor cell area If needed a soft wipe can be used to blot plus detergent and water to remove any deposits Rinse thoroughly after cleaning with water Run a calibration and return to service if sensor efficiency is above 50 percent Note Option 51 offers accessories for automatic chemical cleaning that can be retrofitted to the 876 25 Refer to Appendix D for details White silt inside the sensor cap may not cause problems However if after calibration the sensor response is slow replace the electrolyte and wipe the coils and surface lightly using a soft wipe or a little more vigorous cleaning can be done using a toothbrus
105. sired current level and then make electronic adjustments to calibrate the output Approach 1 Simulated 4 mA to 20 mA Output Self Calibration 1 Select cur from the output 1 menu to display the present output current in mA The display will be updated as the output current 2 To simulate a different 4 mA to 20 mA output signal press ENTER to enter edit mode Use the arrow keys to display the desired output signal Press ENTER to select the displayed value The output signal will be adjusted to put out the desired current This process can be repeated as often as necessary to output different signal levels 3 The output signal is held at the displayed level until the program leaves this menu selection Make calibration adjustments while the analyzer shows the output at 20 00 mA 4 Repeat the above steps for output 2 Approach 2 Use Voltage Source to Adjust Input This faster calibration approach requires a voltage source for the input 1 To calibrate output 1 set in C input a low enough signal to cause analyzer to indicate Err the analyzer will output 4 00 mA Reverse the polarity or input a high enough signal to cause the analyzer to indicate 4 Err analyzer will output 20 00 mA 2 Repeat step 1 for output 2 Tip Both outputs can be simultaneously calibrated if you set in C for both inputs um 876 211 www iccontrols com Page 55 TROUBLESHOOTING IC CONTROLS Adjusting Electronic Calibration 1 Outpu
106. t 2 pH units higher or lower than the buffer used for the standardize procedure Refer to the section entitled Selecting a Buffer for an explanation of the buffer selection process Y D E j N 3 Rinse the pH sensor in demineralized water to remove drops of pH 7 buffer Note Carryover of old buffer into different fresh buffer will decrease the pH difference between the buffers producing an efficiency calibration error Y 4 01 4 Place the rinsed sensor into the second buffer and press SELECT to start the calibration process N o o The calibration with the second buffer works similar to a standardization except that additional error checking is possible and the electrode efficiency will be calculated indicated as SLOP in the PH menu If an error occurs at this point the settings from the standardization buF1 selection will be kept Either retry the calibration with a second buffer buF2 or resume normal operation with the settings from the standardization Note Discard used buffer after calibration Used buffer usually picked up carryover buffer and or contaminants that cause pH error if re used ENTER o c lr D ilo ZS ilo m Illustration 35 Buffer 2 calibration Manual Adjustment of Offset and Slope It is possible to bypass the regular calibration procedure and edit the slope or offset directly Offset and slope are protected by level 1 security which
107. t activated LED to come on because the error LED only comes on if there are any errors To view alarm caution s using ON EI alarm condition the error menu select Err from the main menu then contact activated use the Up or Down arrow key to scroll through the list of errors and cautions if any Illustration 39 Alarm status indication alarm LEDs Each alarm situation also causes an event tag to be written into an internal log which can be accessed using the IC Net Intelligent Access Program The IC Net program uses the analyzer s serial communication port to read and display this information Page 50 www iccontrols com um 876 211 IC CONTROLS ALARM FUNCTIONS Manual Alarm Override For normal alarm operation the alarms are said to operate in auto mode If the operator wishes to intervene and switch off the alarm contacts temporarily while attending to a problem the alarms can be switched to manual override using the MANUAL key In AUTO mode the green AUTO LED is on and the analyzer alarms will activate and deactivate the relay contact as programmed Press the MANUAL key to temporarily deactivate the alarm contacts In MANUAL mode the green AUTO LED will blink The relay contacts are deactivated but OFF O alarms OFF or the alarm LEDs continue to indicate alarm analyzer in STANDE Y mode condition s Press the AUTO key to return to AUTO mode immediately and reactivate the BLINK 9 MANUAL mode relays If no key is pressed for
108. the standardization was not successful The analyzer SE has kept the value from the last successful calibration Press any key to pH acknowledge the error The analyzer will return to the buffer selection menu and display the selected buffer eg Auto Take corrective action and retry the calibration If a potential problem has been detected seen by a caution message then the analyzer has successfully completed calibration The caution message simply informs the user that poor performance is suspected ijt ENTER Press any key to resume normal operation after a caution or error message has appeared Illustration 34 pH standardization Page 38 www iccontrols com um 876 211 IC CONTROLS pH CALIBRATION Calibrating Two Buffer Calibration Calibrating the analyzer involves calculating both the offset and the slope electrode efficiency for a particular electrode pair The electrode slope will be calculated as a percentage of Nernstian response 1 Calibrate the offset with 7 pH buffer as buF1 buffer 1 by following the procedure for Standardizing Single Buffer Calibration Return to the calibration menu and display buF2 Press SELECT to reach the buffer selection menu SLOP OFFS cr Q E FERE F 2 Use the Up and Down arrow keys to select either automatic detection Auto a custom value cuSt or one of the standard buffers 4 01 7 00 or 10 0 The second buffer should be at leas
109. tilled or demineralized water use a small toothbrush to scrub coils to speed removal if necessary 4 Repeat steps 2 and 3 until coils and tip look clean and have a shine re assemble chlorine sensor with new membrane and fill solution calibrate and verify efficiency is above 50 5 Repeat steps 2 to 4 as necessary to get at least 50 efficiency If not possible the chlorine sensor should be replaced Illustration 24 Chemical cleaning Page 28 www iccontrols com um 876 211 IC CONTROLS CHLORINE SENSOR INSTRUCTIONS Automatic Chemical Cleaning The model 876 25 offers the option of automatic chemical cleaning Please refer to Appendix D Option 51 Timer Electrode Cleaner for complete details Sensor Storage Short Term Immerse the sensor tip in tap water Wet storage can be used up to two weeks If the sensor is not connected to the analyzer the sensor needs to be shorted Place the shorting strap across the appropriate pins of the sensor connector refer to illustration 8 CAUTION f a wet sensor dries out in storage it may become damaged beyond repair Long Term Disassemble the chlorine sensor tip and pour out the fill solution Rinse the coils gold tip and membrane retainer with demineralized water and blot dry with a paper towel Re assemble the chlorine sensor dry and store dry with the tip covered Dry storage can be used for a year or more NOTE The sensor needs to be shorted only when it is charged fi
110. to be enabled if no password protection is necessary If you choose not to enable the password protection system then the user will have unrestricted access to all analyzer settings available through the menu as described in this manual Having security disabled gives the user the same access to the program as being at access level 2 at all times With security enabled anyone can view settings anywhere in the program When you do not have Bective ER proper access rights the program will display 0 View only access to all settings PASS for 2 seconds indicating that a proper 1 Access to all settings except for password must be entered before being allowed to configuration menu Usage operator proceed access no changes can be made to configuration and passwords cannot This appendix contains instructions for setting be changed passwords in the configuration section of the menu 2 Access to all settings This gives the Daily usage of the analyzer by the operator does not same program access as when require knowledge of setting passwords in the password security is not enabled Passwords can be changed Usage configuration section since all passwords are installation management entered by selecting PASS directly from the main menu Table 1 Security access levels ENTERING A PASSWORD With security enabled select PASS from the main menu The analyzer will display 0000 Use the arrow keys to display your level 1 or leve
111. to make sure that display is at home base Press the Right arrow key One of the prompts in the column starting with out will be displayed Use A the Up or Down arrow keys to display the prompt MANUAL ENTER SAMPLE above or below If the prompt at the top or the bottom is displayed the program will loop around Press the Up or Down key until AL is displayed Press the Left 4 key to return to the sample display Press the Right key AUTO CANCEL SELECT again and AL will be displayed AUTO and MANUAL Keys The AUTO and MANUAL keys are used to implement the alarm override feature Refer to the heading Manual Alarm Override in the Alarm Functions section Standby Mode Standby mode can be selected from the main menu In standby mode the alarms will not function and the 4 mA to 20 mA outputs will go to 4 00 mA When SAMPLE is pressed all the inputs will show StbY instead of the normal input measurement Illustration 11 Analyzer keypad The analyzer will not resume normal operation until the analyzer is taken out of standby mode While in standby mode the entire YES menu and all of the settings are accessible to the operator as before StbY None of the settings will take effect until the analyzer is returned to no normal operation Illustration 12 Standby menu The standby feature is protected by security level 2 Output Hold The 876 features an automatic output hold for the pH input only Output hold go
112. to measure the pH of the sample and temperature compensation is provided via a temperature sensor in the chlorine electrode A method has been provided in the analyzer program to change the compensation method for temperature compensation and pH compensation from automatic to manual Providing a method of manual temperature compensation and or manual pH compensation allows the analyzer to continue measuring free available chlorine and total free chlorine in the event that the temperature sensor and or pH sensor are malfunctioning or absent Manual Temperature Compensation From the main menu select tFCl tc At this point either Auto for automatic temperature compensation or SEt for manual temperature compensation set point will be displayed To change the setting from Auto to SEt press ENTER to edit the current setting The display will start blinking indicating that a selection needs to be made Use the Up or Down arrow key to display SEt Press ENTER to select manual temperature compensation With SEt as the current display press SELECT to display the temperature setting for manual temperature compensation If the current value needs to be changed press ENTER to edit the current setting The display will start blinking Use the Up or Down arrow keys to display the desired temperature for manual temperature compensation Press ENTER to accept the currently displayed value Manual pH Compensation From the menu select tFC
113. to mount the panel and supply plumbing to the inlet and from the outlet The panel mounts on a wall via four 7s inch bolts at 12 inch x 24 inch centers refer to drawing D4040081 for mounting dimensions Sample inlet and outlet plumbing hookup is via a in barb fitting 876 25 Component Identification A Identification label indicates complete model number and serial number B Analyzer model 876 C pH sensor P N A2104033 D Chlorine sensor P N A2104034 E Atmospheric drain F Flow cell a cleaning injection port is located on the underside of the chlorine sensor flow cell housing hidden from view by the pressure guage G Pressure guage H Pressure regulator D Flow control shut off valve J Inlet K Outlet Illustration 7 876 25 component identification Page 12 www iccontrols com um 876 211 IC CONTROLS INSTALLATION Analyzer Wiring Please refer to drawing D5040276 and perform the following 1 The 876 25 requires 115 V or 230 VAC power to be hooked up to TB400 Power consumed is less than 1 A so generally 16 guage wire is OK consult local electrical codes for verification For stable operation the microprocessor needs a good earth ground CAUTION Confirm that the 115 230 VAC switch is correctly set for your feed 2 If required connect the two relay contacts as supplied they are not powered They are typically used as L1 HOT circuit ON OFF switches in NO normally open configuration to control the
114. trols com Page 80 DRAWINGS IC CONTROLS ion lay Board Component Locati isp D D5980176 EEN Adel 94108690 Gump po gt 2 ul pesn NOILVOO 1 LNANOdWOO OO AVIdSId SSW ddo j LII UD opouoj or103up en eBuoag Eo CLel Fal Up STOULNOD 9j sop xa Be cat 9010p O ps 14 SOT E R68 P d 3 i p Ze POS e o Lera CO LeSeL CR is MMS432N 9 OvdSIC on 8S02E06W ELESTHL 99L23WN N O ES A3H 620LG8 N quvoa Av idSIG SSW 1330N VOTSWIW 0 D P o 2 a 9en OOOOOOOOOOOOOOOO E Tt NId OT NId AQT Hd 0 0 OND3 S 0d HDIH Hd v 0d dW31 9 0d 2 dW31 0d Y ae 3ONVa 8 ND12313S 39Nv3 Hd d U SIS dW3L do SIS v Walvnv 8 Waviv A8 DAS WOO DO DWD2 19 www iccontrols com Page 81 um 876 211 DRAWINGS D5040276 Wiring Diagram IC CONTROLS 1 TID Ese IGRNI DIN CONNECTOR 5 PIN CLR cL2 WHT SENSOR F ag s t S z 2933 GE eceeeeeeooe PREAMP BNC IGRANI Esc IREDI IBLKI pH IWHTI SENSOR TP 3000 cats Pil d Es Nx Kess Se veeni 98 DOEN zoen BK 2
115. ts are isolated from main circuit therefore measurements are made with common at the output 2 terminal TB304 2 Measure output 1 zero at TP301 pin 8 of U304 while output 1 is outputting 4 00 mA Reading should be between 0 870 V and 1 250 V Adjust 2 voltage with VR300 3 Change analyzer output to 20 00 mA switch meter to mA and measure Terminal terminal of O P 1 and adjust VR301 so that the current reads 20 00 mA Return analyzer output to 4 00 mA and trim actual output to 4 00 mA using VR300 Check again at 20 00 mA and repeat adjustments until satisfied 4 Measure output 2 zero at TP300 pin 7 of U304 while output 2 is outputting 4 00 mA The test point should read between 0 870 V and 1 250 V Adjust 2 zero voltage with VR302 5 Change output at output 2 to 20 00 mA switch meter to mA at TB304 terminal of output 2 and adjust VR303 span pot until the current reads 20 00 mA Note Zero and span are very wide range adjustments which show small interactions Recheck zero and span to confirm good calibration 6 If so desired all software settings can be returned to factory default condition by performing a reinitialization Refer to heading Initializing All Program Settings in Configuration of Program section Testing Relay Outputs 1 Relay output operation can be verified by testing for contact closure or continuity at each relay To activate a relay select CONF NO NC AL A from the menu Pres
116. ubmerged j Allow the sensor to sit in this solution for a few minutes and then check to see if the pH electrode and reference junction appear clean If not entirely clean allow sensor to sit in solution until clean Stubborn deposits can be removed with the brush and syringe to squirt scale remover into hard to reach areas CAUTION Use great care when brushing and squirting acid Wear rubber gloves and facial protection k Rinse the cleaned sensor thoroughly in tap water and then with demineralized water for a second rinse before calibrating D Check the sensor against a pH buffer solution close to the application pH m A clean and rinsed pH sensor should read near 7 in pH 7 buffer If it does not troubleshoot the pH sensor wiring and analyzer um 876 211 www iccontrols com Page 35 pH CALIBRATION IC CONTROLS pH CALIBRATION The pH input is calibrated using one of two methods A one point standardization adjusts the electrode offset while maintaining the previous slope The two point calibration combines the results of the standardization with the results of the buffer 2 calibration and calculates the slope as well as the offset SLOT eeng A calibration is easily 1100 0 TEE cust accomplished by selecting OFFS EH Auto CALIBRATE an appropriate buffer placing the electrode in buF1 I 7 00 the buffer solution and buF2 letting the analyzer do the can rest The analyzer tests HOLd so for elect
117. ugh a 1 MQ 1 resistor 0 250 VDC simulates 1 0 ppm HOCI at approximately 100 efficiency under above conditions Calibration of Temperature Input The temperature input can be adjusted both by making electronic adjustments and or by having the program compensate for differences in offset By default the analyzer is shipped with a 1 07 kQ 1 resistor across the TC terminals A 1 07 kQ resistor across the TC terminals will simulate a temperature of approximately 18 C or 65 F Software Calibration To do a software calibration of the temperature input the correct temperature needs to be known 1 Select CONF in C CAL from the menu The actual temperature as measured by the temperature sensor will be shown Edit the displayed value to the known correct temperature Press ENTER to leave edit mode then SELECT to start the calibration 2 The current temperature will be shown using a flashing display When it looks like the input is stable press ENTER to set the new temperature The software offset for the temperature input will be adjusted automatically 3 The calculated offset in degrees Celsius can be viewed by selecting CONF in C OFFS from the menu Whenever the hardware alignment is correct the offset will be 0 0 The displayed offset can be edited Page 54 www iccontrols com um 876 211 IC CONTROLS TROUBLESHOOTING Adjusting Electronic Calibration 1 Remove any offset calculated by a previous software
118. use in mind In most cases the analyzer has been configured to ordered specifications at the factory and no configuration of the analyzer is necessary However several hardware options are available and if they are changed the program configuration settings need to be set accordingly for the program to function properly Other program adjustments which are normally made infrequently or when installing the analyzer are located in the configuration menu Normally Open or Normally Closed Alarm Contacts The 876 program assumes the alarm contacts are wired normally open A normally open alarm contact will be open inactive if there is no alarm condition and will be closed active when there is an alarm condition If the program configuration and the wiring for each alarm do not match then the incorrectly configured alarm contact will generate an alarm when there is no alarm condition and vice versa Initializing All Program Settings Int ALL do Occasionally it may be desirable to rune timer tecture reinitialize all of the program s settings to LJ aem contact bring them back to default Executing the ALA Ge initialization procedure will cause the analyzer to reset all the program De variables settings preferences and input Die Nong Loren calibrations to factory default and then Cre proceed with the normal startup display Les Sege The initialization procedure is n
119. vironments may also affect the buffer pH Molds resulting from airborne spores may accumulate in neutral and acidic buffers and change the pH value as well e Rinse sensor with demineralized water before placing in buffer to prevent carryover contamination A few drops of demineralized water will not visibly alter the pH Do not wipe the sensor dry as wiping may induce a static charge which could result in noisy readings um 876 211 www iccontrols com Page 37 pH CALIBRATION IC CONTROLS Standardizing Single Buffer Calibration Standardizing the analyzer causes the analyzer to calculate the offset for the pH electrode indicated as OFFS in the PH menu The electrode slope value determined during the last buffer 2 calibration will be maintained indicated as SLOP in PH menu 1 Press SAMPLE to display the tFCI reading Press SELECT to reach the main menu then use the Up or Down arrow keys to display PH Press SELECT then use the Up or Down arrow keys to display CAL 2 Press SELECT again then use the Up or Down arrow keys to display buF1 3 Press SELECT again to reach the next menu A buffer value needs to be determined with which to calibrate the analyzer Use either automatic detection Auto a custom value cuSt or one of the standard buffers 4 01 7 00 or 10 0 For further details see Selecting a Buffer for an explanation of the buffer selection process SLOP 4 Rinse the pH sensor i
120. y of the Chlorine Sensor This procedure should be done over a sink Protective eye wear and plastic or rubber gloves are recommended when handling the electrolyte a salt solution Wash hands with water if the electrolyte comes in contact with the skin 1 Galvanic chlorine sensors should have a current drain at all times Assemble sensor while powered to analyzer OR with a short coax center to shield The chlorine sensor has a 5 pin DIN connector and the sensor is shipped with a shorting strap across two pins refer to illustration 8 Remove this shorting strap prior to connecting to analyzer Note the location of the pins requiring short for future sensor storage 2 Disassemble the chlorine sensor by removing the CPVC membrane retainer see illustration 20 at the sensor tip Pull straight down on the retainer The retainer holds the membrane in place and removing the retainer will release the fill solution and expose the silver coils and gold sensing tip The fill solution is not hazardous so if any gets on the skin simply rinse with water 3 Discard the used membrane and rinse the retainer and fill solution cavity thoroughly with demineralized water 4 Replace the membrane using one of the following procedures A Assembly with Membrane Replacement Toolkit Required Materials i P N A2104035 Membrane replacement toolkit ii P N A2104036 Membrane kit iii P N A1100239 Chlorine sensor fill solution Membrane Replacement Procedure
121. ycle is completed the output hold for the 4 mA to 20 mA output signals and alarms will not be updated immediately The additional hold time gives the electrodes time to stabilize after they have been cleaned Page 66 www iccontrols com um 876 211 IC CONTROLS APPENDIX D OPTION 51 53 TIMER ELECTRODE CLEANER Option 51 53 Chemical Cleaning Accessories Pump Sub Assembly Part Identification A Metering pump B Foot valve C Tubing weight D 4 function valve E inch OD suction discharge tube F inch OD return vent line Illustration 4 Pump sub assembly part identification Cleaner Assembly Part Identification A inch tube to inch tube reducing fitting B inch NPT to 4 tube elbow C 10 foot 3 meter inch OD poly tube Illustration 5 Cleaner assembly part identification Chemical Cleaner Injection Port The injection port is a standard feature on the flow cell The injection port requires a inch NPT connection Illustration 6 Cleaner injection port location um 876 211 www iccontrols com Page 67 APPENDIX D OPTION 51 53 TIMER ELECTRODE CLEANER IC CONTROLS Cleaning Equipment Setup Chemical Cleaner Connection at the Flow Cell A inch NPT to 4 tube elbow B 10 foot 3 meter inch OD poly tube Illustration 7 Chemical cleaner connection at flow cell Pump Assembly A 10 foot 3 meter inch OD poly tube B 6 inch tube to inch tube reducing fitting C inch

876-25 User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents