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Swann AMI CACE Manual

Swann AMI CACE Manual

Version 6.20 and higher
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AMI CACE
Version 6.20 and higher
A-96.250.871 / 120417

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Summary of Contents for Swann AMI CACE

  • Page 1 AMI CACE Version 6.20 and higher A-96.250.871 / 120417...
  • Page 2 SWAN representative, or the manufacturer: SWAN ANALYTISCHE INSTRUMENTE AG Studbachstrasse 13 8340 Hinwil Switzerland Internet: www.swan.ch E-mail: support@swan.ch Document Status Monitor AMI CACE Operator’s Manual Title: A-96.250.871 Revision Issue Oct. 2016 First edition © 2016, SWAN ANALYTISCHE INSTRUMENTE AG, Switzerland, all rights reserved...

  • Page 3: Table Of Contents

    AMI CACE Table of Contents Safety Instructions ........
  • Page 4 AMI CACE Maintenance ........

  • Page 5: Safety Instructions

    AMI CACE Safety Instructions AMI CACE - Operator’s Manual This document describes the main steps for instrument setup, oper- ation and maintenance. Safety Instructions General The instructions included in this section explain the potential risks associated with instrument operation and provide important safety practices designed to minimize these risks.

  • Page 6: Warning Notices

    AMI CACE Safety Instructions 1.1. Warning Notices The symbols used for safety-related notices have the following sig- nificance: DANGER Your life or physical wellbeing are in serious danger if such warnings are ignored.  Follow the prevention instructions carefully. WARNING Severe injuries or damage to the equipment can occur if such warnings are ignored.
  • Page 7 AMI CACE Safety Instructions Warning Signs The importance of the warning signs in this manual. Electrical shock hazard Corrosive Harmful to health Flammable Warning general Attention general A-96.250.871 / 120417...

  • Page 8: General Safety Regulations

    AMI CACE Safety Instructions 1.2. General Safety Regulations Legal The user is responsible for proper system operation. All precautions must be followed to ensure safe operation Requirements of the instrument. Spare Parts Use only official SWAN spare parts and disposables. If other parts are used during the normal warranty period, the manufacturer’s...

  • Page 9: Restriction For Use

    AMI CACE Safety Instructions 1.3. Restriction for use The AMI CACE is designed for determination of:  specific (total) conductivity  cation (acid) conductivity after the cation exchanger (CACE) in power plant water. It calculates the pH value and the concentration of the alkaline sub- stance (NH , morpholine, etc.) if an alkaline substance is present in...

  • Page 10: Product Description

    AMI CACE Product Description Product Description 2.1. Description of the System Application Complete monitoring system for the automatic, continuous mea- surement of the specific (total) conductivity before a cation ex- Range changer and the cation (acid) conductivity after a cation exchanger (CACE).
  • Page 11 AMI CACE Product Description Alarm Relay One potential free contact. Alternatively:  Open during normal operation, closed on error and loss of power.  Closed during normal operation, open on error and loss of power. Summary alarm indication for programmable alarm values and in- strument faults.
  • Page 12 AMI CACE Product Description Temperature The mobility of ions in water increases with higher temperature, which enlarges the conductivity. Therefore, the temperature is mea- compensation sured simultaneously by an integrated Pt1000 temperature sensor and the conductivity is compensated to 25 °C. Several temperature compensation curves designed for different water compositions can be chosen.
  • Page 13 AMI CACE Product Description NOTICE: To visualize the sample flow more clearly, the EDI module is shown only schematically. Lateral view X shows the correct positions of the chambers and electrodes. First conductivity sensor Sample chamber Second conductivity sensor Anode chamber...

  • Page 14: Instrument Specification

    AMI CACE Product Description 2.2. Instrument Specification Power Supply Voltage: 100–240 VAC (± 10%) 50/60 Hz (± 5%) or 24 VDC (± 10%) Power consumption: max. 30 VA Sample Flow rate: 3–4 l/h Temperature: up to 50 °C requirements Inlet pressure: up to 0.5 bar...
  • Page 15 AMI CACE Product Description 280 mm / 11” 254 mm / 10” 13 mm / ½” A-96.250.871 / 120417...

  • Page 16: Instrument Overview

    AMI CACE Product Description 2.3. Instrument Overview Panel Flow cell Transmitter Flow meter Specific conductivity sensor Electrodeionization (EDI) Cation conductivity sensor module A-96.250.871 / 120417...

  • Page 17: Installation

    AMI CACE Installation Installation 3.1. Installation Checklist Monitors Check Instrument’s specification must conform to your AC power ratings. Do not turn on power until instructed to do so. On site require- 100–240 VAC (± 10%), 50/60 Hz (± 5%) or 24 VDC, isolated ments (±10%) power outlet with ground connection and 30 VA...

  • Page 18: Mounting Of Instrument Panel

    AMI CACE Installation 3.2. Mounting of Instrument Panel The first part of this chapter describes the preparing and placing of the system for use.  The instrument must only be installed by trained personnel.  Mount the instrument in vertical position.

  • Page 19: Edi Module Tubing

    AMI CACE Installation Stainless steel tube Compression cone Union nut Body Compression ferrule Tightened connection 3.3.2 EDI module tubing Remove the end caps [A] from tubes 1, 2, 3, 5 and 10 and connect the tubes according to Tube numbering, p.

  • Page 20: Electrical Connections

    AMI CACE Installation 3.4. Electrical Connections WARNING Electrical hazard.  Always turn off AC power before manipulating electric parts.  Grounding requirements: Only operate the instrument from an power outlet which has a ground connection.  Make sure the power specification of the instrument corre- sponds to the power on site.
  • Page 21 AMI CACE Installation WARNING External Voltage. External supplied devices connected to relay 1 or 2 or to the alarm relay can cause electrical shocks  Make sure that the devices connected to the following contacts are disconnected from the power before resum- ing installation.

  • Page 22: Connection Diagram

    AMI CACE Installation 3.5. Connection Diagram CAUTION Use only the terminals shown in this diagram, and only for the mentioned purpose. Use of any other terminals will cause short circuits with possible corresponding consequences to material and personnel. A-96.250.871 / 120417...
  • Page 23  Mains cable to comply with standards IEC 60227 or IEC 60245; flammable rating FV1  Mains equipped with an external switch or circuit-breaker – near the instrument – easily accessible to the operator – marked as interrupter for AMI CACE A-96.250.871 / 120417...

  • Page 24: Relay Contacts

    AMI CACE Installation 3.6. Relay Contacts 3.6.1 Input NOTICE: Use only potential-free (dry) contacts. The total resistance (sum of cable resistance and resistance of the relay contact) must be less than 50 Ω. Terminals 16/42 For programming see Program Overview, p.

  • Page 25: Relay 1 And 2

    AMI CACE Installation 3.6.3 Relay 1 and 2 NOTICE: Max. load: 1 A/250 VAC Relay 1 and 2 can be configured as normally open or as normally closed. Standard for both relays is normally open. To configure a re- lay as normally closed, set the jumper in the upper position.
  • Page 26 AMI CACE Installation CAUTION Risk of damage of the relays in the AMI Transmitter due to heavy inductive load. Heavy inductive or directly controlled loads (solenoid valves, dosing pumps) may destroy the relay contacts.  To switch inductive loads > 0.1 A use an AMI relay box available as an option or suitable external power relays.

  • Page 27: Signal Outputs

    AMI CACE Installation 3.7. Signal Outputs 3.7.1 Signal Output 1 and 2 (current outputs)  NOTICE: Max. burden 510 If signals are sent to two different receivers, use signal isolator (loop isolator). Signal output 1: Terminals 14 (+) and 13 (-)

  • Page 28: Signal Output 3

    AMI CACE Installation 3.8.1 Signal Output 3 Terminals 38 (+) and 37 (-). Requires the additional board for the third signal output 0/4–20 mA. The third signal output can be operated as a current source or as a current sink (switchable via switch [A]). For detailed information see the corresponding installation instruction.

  • Page 29: Hart Interface

    AMI CACE Installation 3.8.3 HART Interface Terminals 38 (+) and 37 (-). The HART interface PCB allows for communication via the HART protocol. For detailed information, consult the HART manual. HART Interface PCB 3.8.4 USB Interface The USB Interface is used to store Logger data and for Firmware upload.

  • Page 30: Instrument Setup

    AMI CACE Instrument Setup Instrument Setup After the analyzer is installed according to the previous instructions, connect the power cord. Do not switch on power, yet! 4.1. Establish sample flow 1 Open the sample tap 2 Check inlet pressure 3 Wait until the system has been completely filled...
  • Page 31 AMI CACE Instrument Setup Calculations Menu 5.1.1.1 Set <Calculations> to “Yes” if you want to have pH and alkalization agent calculated and displayed. Measuring unit Menu 5.1.1.2 Set the <Measuring unit> according to your requirements:  S/cm  S/m Display Menu 4.4.1, Screen 1...

  • Page 32: Operation

    AMI CACE Operation Operation 5.1. Keys Exit Enter to exit a menu or command (rejecting any changes) to move back to the previous menu level to move DOWN in a menu list and to decrease digits to move UP in a menu list and to increase digits...
  • Page 33 AMI CACE Operation Example of Display 2 15:20:18 8.79 µS 0.178 µS 22.1°C 4.0 l/h 21.8°C normal operation HOLD input closed or cal delay: Instrument on hold (shows status of signal outputs). input closed: control/limit is interrupted (shows status of signal outputs).

  • Page 34: Software Structure

    AMI CACE Operation 5.3. Software Structure Main Menu Messages Diagnostics Maintenance Operation Installation Menu Messages 1 Messages Reveals pending errors as well as an event history Pending Errors (time and state of events that have occurred at an Maintenance List earlier point of time).

  • Page 35: Changing Parameters And Values

    AMI CACE Operation 5.4. Changing Parameters and values Changing The following example shows how to change the logger interval: parameters 1 Select the parameter you want to Sensors Logger 5.1.2 4.4.1 change. Sensor type FOME Log interval 30 min 2 Press [Enter] Disinf.

  • Page 36: Maintenance

    AMI CACE Maintenance Maintenance WARNING Stop operation before maintenance.  Stop sample flow.  Shut off power of the instrument. 6.1. Maintenance Schedule Monthly  Check sample flow.  Check inlet pressure. If required  Clean conductivity sensors.  Replace inlet filter (if installed).

  • Page 37: Maintenance Of The Sensor

    AMI CACE Maintenance 6.3. Maintenance of the Sensor Conductivity sensor Locking pin unlocked Locking screw open Locking pin locked Alignment marks Locking screw closed 6.3.1 Remove the Sensor from the Flow Cell The sensors are fixed in the flow cell with Swan’s slot lock system.

  • Page 38: Replacing Fuses

    AMI CACE Maintenance 6.4. Replacing Fuses WARNING External Voltage External supplied devices connected to relay 1 or 2 or to the alarm relay can cause electrical shocks  Make sure that the devices connected to the following contacts are disconnected from the power before resum- ing installation.

  • Page 39: Longer Stop Of Operation

    AMI CACE Maintenance 6.5. Longer Stop of Operation If the instrument is not used for a longer period of time (2 months or more), drain the EDI module and seal the tube fittings marked in red using the end caps [A] supplied with the instrument.

  • Page 40: Troubleshooting

    AMI CACE Troubleshooting Troubleshooting This chapter provides some hints to make troubleshooting easier. For any detailed information on how to handle/clean parts please see chapter Maintenance, p. For any detailed information on how to program the instrument please see chapter Program List and Explanations, p.

  • Page 41: Error List

    AMI CACE Troubleshooting 7.1. Error List Error Non-fatal Error. Indicates an alarm if a programmed value is ex- ceeded. Such Errors are marked E0xx (bold and black). Fatal Error (blinking symbol) Control of dosing devices is interrupted. The indicated measured values are possibly incorrect.
  • Page 42 AMI CACE Troubleshooting Error Description Corrective action Cond. 1 Alarm high – check process E001 – check programmed value, see 5.3.1.1, p. 62 Cond. 1 Alarm low – check process E002 – check programmed value, see 5.3.1.1, p. 62 Cond. 2 Alarm high –...
  • Page 43 AMI CACE Troubleshooting Error Description Corrective action – check case/environment temperature E014 Case Temp. low – check programmed value, see 5.3.1.4.2, p. 65 – Calculated pH value < 7.5 or > 11.5 E015 pH Calculation undef. – Check control device or programming...
  • Page 44 AMI CACE Troubleshooting Error Description Corrective action – check process E038 Temp. 2 Alarm low – check programmed value, see 5.3.1.2.2.25, p. 64 – check sample inlet pressure and E043 EDI out of range acknowledge this error message – If the problem persists, stop sample flow and call service –...

  • Page 45: Tube Numbering

    AMI CACE Troubleshooting 7.2. Tube numbering To replace tube no. 10, the EDI module needs to be unmounted. Proceed according to Replacing the EDI module, p. 44 (select <no> at the end of the procedure). Tube no. Length 440 mm...

  • Page 46: Replacing The Edi Module

    AMI CACE Troubleshooting 7.3. Replacing the EDI module Select Menu 3.3 (Maintenance/Exchange EDI) and follow the in- structions on the display. Status of relays and signal outputs during the procedure:  Signal outputs are on hold  All limits are switched off...

  • Page 47: Program Overview

    AMI CACE Program Overview Program Overview For explanations about each parameter of the menus see Program List and Explanations, p. 50  Menu 1 Messages informs about pending errors and mainte- nance tasks and shows the error history. Password protection possible.

  • Page 48: Diagnostics (Main Menu 2)

    AMI CACE Program Overview 8.2. Diagnostics (Main Menu 2) Identification Designation AMI CACE * Menu numbers 2.1* Version V6.20-10/16 Factory Test Instrument 2.1.4.1* 2.1.4* Motherboard Front End Operating Time Years / Days / Hours / Minutes / Seconds 2.1.5.1* 2.1.5*...

  • Page 49: Maintenance (Main Menu 3)

    AMI CACE Program Overview 8.3. Maintenance (Main Menu 3) Simulation Alarm Relay 3.1.1* *Menu numbers 3.1* Relay 1 3.1.2* Relay 2 3.1.3* Signal Output 1 3.1.4* Signal Output 2 3.1.5* Exchange EDI 3.2* Set time (Date), (Time) 3.3* 8.4. Operation (Main Menu 4) Sensors Filter Time Const.

  • Page 50: Installation (Main Menu 5)

    AMI CACE Program Overview 8.5. Installation (Main Menu 5) Sensors Miscellaneous Calculations 5.1.1.1* 5.1* 5.1.1* Maes. unit 5.1.1.2* Sensor parameters Sensor 1 Cell Constant 5.1.2.1.1* 5.1.2* 5.1.2.1* Temp. Corr. 5.1.2.1.2* Cable length 5.1.2.1.3* Temp. comp. Comp. 5.1.2.1.5* 5.1.2.1.5.1* Sensor 2 Cell Constant 5.1.2.2.1*...

  • Page 51: Installation

    AMI CACE Program Overview Relay 1/2 Function 5.3.2.1/ 5.3.3.1* 5.3.2/5.3.3* Parameter 5.3.2.20/ 5.3.3.20* Setpoint 5.3.2.300 / 5.3.3.301* Hysteresis 5.3.2.400/ 5.3.3.401* Delay 5.3.2.50/ 5.3.3.50* Input Active 5.3.4.1* 5.3.4* Signal Outputs 5.3.4.2* Output/Control 5.3.4.3* Fault 5.3.4.4* Delay 5.3.4.5* Miscellaneous Language 5.4.1* * Menu numbers 5.4*...

  • Page 52: Program List And Explanations

    AMI CACE Program List and Explanations Program List and Explanations 1 Messages 1.1 Pending Errors 1.1.5 Provides the list of active errors with their status (active, acknowl- edged). If an active error is acknowledged, the alarm relay is active again. Cleared errors are moved to the Message list.

  • Page 53: Signal Output 1/2

    AMI CACE Program List and Explanations 2.2.2 Miscellaneous: 2.2.2.1 Case Temp: Shows the current temperature in [°C] inside the trans- mitter. 2.2.3 EDI: 2.2.3.1 Actual current: Current in mA applied to the EDI module. Actual voltage: Resulting voltage in mV.

  • Page 54: Maintenance

    AMI CACE Program List and Explanations 3 Maintenance 3.1 Simulation To simulate a value or a relay state, select  alarm relay  relay 1/2  signal output 1/2 with the [ ] or [ ] key. Press the <Enter> key.

  • Page 55: Operation

    AMI CACE Program List and Explanations 4 Operation 4.1 Sensors 4.1.1 Filter Time Constant: Used to damp noisy signals. The higher the filter time constant, the slower the system reacts to changes of the measured value. Range: 5–300 Sec 4.1.2 Hold after Cal.: Delay permitting the instrument to stabilize again af-...
  • Page 56 AMI CACE Program List and Explanations 4.4 Display Process values are displayed on two screens. Toggle screens with the [ ] key. Each screen displays max. 3 process values. 4.4.1 Screen 1 4.4.1.1 Row 1 4.4.1.2 Row 2 4.4.1.3 Row 3 Possible settings for all rows are: ...

  • Page 57: Installation

    AMI CACE Program List and Explanations 5 Installation 5.1 Sensors 5.1.1 Miscellaneous 5.1.1.1 Calculations: Select “yes” if pH and ammonia concentrations should be calculated. pH and ammonia are now available on screen 1 or 2, on the signal outputs and as alarm or limit values.
  • Page 58 AMI CACE Program List and Explanations 5.1.2.2.5 Temp. comp: 5.1.2.2.5.1 Comp.: Available compensation models:  Strong acids 5.2 Signal Outputs NOTICE: The navigation in the menu <Signal Output 1> and <Signal Output 2> is equal. For reason of simplicity only the menu numbers of Signal Output 1 are used in the following.
  • Page 59 AMI CACE Program List and Explanations As process The process value can be represented in 3 ways: linear, bilinear or logarithmic. See graphs below. values [mA] 0 / 4 linear X Measured value bilinear [mA] 0 / 4 1’000 10’000 X Measured value (logarithmic) A-96.250.871 / 120417...
  • Page 60 AMI CACE Program List and Explanations 5.2.1.40 Scaling: Enter beginning and end point (Range low & high) of the linear or logarithmic scale. In addition, the midpoint for the bilinear scale. Parameter Cond. 1(sc): Range low: 0.000–3000 S 5.2.1.40.10 Range high: 0.000–3000 S 5.2.1.40.20...
  • Page 61 AMI CACE Program List and Explanations As control Signal outputs can be used for driving control units. We distinguish different kinds of controls: output  P-controller: The controller action is proportional to the devia- tion from the setpoint. The controller is characterized by the P-Band.
  • Page 62 AMI CACE Program List and Explanations Control upwards or downwards Setpoint: User-defined process value for the selected parameter. P-Band: Range below (upwards control) or above (downwards con- trol) the set-point, within the dosing intensity is reduced from 100% to 0% to reach the setpoint without overshooting.
  • Page 63 AMI CACE Program List and Explanations 5.2.1.40 Control Parameters: if Parameters = pH 5.2.1.40.18 Setpoint Range: 0.00–14 pH 5.2.1.40.28 P-Band: Range: 0.00–14 pH 5.2.1.40 Control Parameters: if Parameters = Ammonia 5.2.1.40.19 Setpoint Range: 0.00–500 ppm 5.2.1.40.29 P-Band: Range: 0.00–500 ppm 5.2.1.40.3...
  • Page 64 AMI CACE Program List and Explanations 5.3 Relay Contacts 5.3.1 Alarm Relay: The alarm relay is used as cumulative error indicator. Under normal operating conditions the contact is active. The contact is inactive at:  Power loss  Detection of system faults like defective sensors or electronic parts ...
  • Page 65 AMI CACE Program List and Explanations 5.3.1.1.2 Cond. 2 (cc) 5.3.1.1.2.1 Alarm High: If the measured value rises above the alarm high val- ue, the alarm relay is activated and E003, is displayed in the mes- sage list. Range: 0.000 –3000 S 5.3.1.1.2.25...
  • Page 66 AMI CACE Program List and Explanations 5.3.1.1.5 Ammonia (if Calculations = yes) 5.3.1.1.5.1 Alarm High: If the measured value rises above the alarm high val- ue, the alarm relay is activated and E035 is displayed in the mes- sage list.
  • Page 67 AMI CACE Program List and Explanations 5.3.1.4 Case Temp. 5.3.1.4.1 Alarm high: Set the alarm high value for temperature of electronics housing. If the value rises above the programmed value E013 is is- sued. Range: 30–75 °C 5.3.1.4.2 Alarm low: Set the alarm low value for temperature of electronics housing.

  • Page 68: Parameter

    AMI CACE Program List and Explanations 5.3.2 and 5.3.3 Relay 1 and 2: The contacts can be set as normally open or nor- mally closed with a jumper. See Relay 1 and 2, p. The function of relay contacts 1 or 2 is defined by the user.
  • Page 69 AMI CACE Program List and Explanations 5.3.2.400 Hysteresis: within the hysteresis range, the relay does not switch. This prevents damage of relay contacts when the measured value fluctuates around the alarm value. Parameter Range 0–3000 S Cond. 1 (sc) 0–3000 S Cond.
  • Page 70 AMI CACE Program List and Explanations 5.3.2.32.1 Actuator = Time proportional Examples of metering devices that are driven time proportional are solenoid valves, peristaltic pumps. Dosing is controlled by the operating time. 5.3.2.32.20 Cycle time: duration of one control cycle (on/off change).

  • Page 71: Signal Output

    AMI CACE Program List and Explanations 5.3.2.1 Function = Timer: The relay will be activated repetitively depending on the pro- grammed time scheme. 5.3.2.24 Mode: Operating mode (interval, daily, weekly) 5.3.2.340 Interval/Start time/Calendar: Dependent on options operating mode. 5.3.2.44 Run time: time the relay stays active.

  • Page 72: Function

    AMI CACE Program List and Explanations 5.3.4 Input: The functions of the relays and signal outputs can be de- fined depending on the position of the input contact, i.e. no function, closed or open. 5.3.4.1 Active: Define when the input should be active: Input is never active.
  • Page 73 AMI CACE Program List and Explanations 5.4 Miscellaneous 5.4.1 Language: Set the desired language. Available settings: German /English/French/Spanish/Italian 5.4.2 Set defaults: Reset the instrument to factory default values in three different ways:  Calibration: Sets calibration values back to default. All other values are kept in memory.
  • Page 74 AMI CACE Program List and Explanations 5.5 Interface Select one of the following communication protocols. Depending on your selection, different parameters must be defined. 5.5.1 Protocol: Profibus 5.5.20 Device address: Range: 0–126 5.5.30 ID No.: Range: Analyzer; Manufacturer; Multivariable 5.5.40...

  • Page 75: Default Values

    AMI CACE Default Values Default Values Operation: Sensors: Filter Time Const.: ..............20 Sec Hold after Cal.:................. 0 sec Relay Contacts Alarm Relay ..........same as in Installation Relay 1/2............same as in Installation Input.............. same as in Installation Logger: Logger Interval:..............

  • Page 76: Hysteresis

    AMI CACE Default Values Case temp. high:..............65 °C Case temp. low: .................0 °C Relay 1/2 Function: ................limit upper Parameter: ...... Relay 1: Cond 1(sc), Relay 2: Cond 2(cc) Setpoint:................1000 µS Hysteresis: ................10 µS Delay:..................30 Sec If Function = Control upw. or dnw: Parameter: ......
  • Page 77 AMI CACE Default Values Miscellaneous Language:................English Set default: ................... no Load firmware:................no Password:............for all modes 0000 Sample ID:.............. - - - - - - - - - - - - Line break detection ..............no Interface Protocol: ........depending on installed interface...

  • Page 78: Index

    AMI CACE Index Index ....Alarm Relay Measuring principle ....
  • Page 79 AMI CACE Index ..– Terminals ..USB Interface ....Wire A-96.250.871 / 120417...

  • Page 80: Notes

    AMI CACE Notes Notes A-96.250.871 / 120417...
  • Page 81 AMI CACE Notes A-96.250.871 / 120417...
  • Page 82 AMI CACE SWAN is represented worldwide by subsidiary companies and distributors. cooperates with independent representatives all over the world. SWAN Products Analytical Instruments for: High Purity Water Feedwater, Steam and Condensate Potable Water Pool and Sanitary Water Cooling Water Waste Water and Effluents Made in Switzerland A-96.250.871 / 120417...

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