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Acromet WG-602 Manual

Water quality analyzer
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WG-602
Water Quality Analyzer
Version 5.13
March 2011

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Summary of Contents for Acromet WG-602

  • Page 1 WG-602 Water Quality Analyzer Version 5.13 March 2011...

  • Page 2: Preface

    This manual is for quali ed and trained service te chnicians who will install and service the WaterGuard WG-602 Water Quality Analyzer. It provides instruct ions on how to install the WaterGuard system, how to integrate it with external chemical dosing systems, as well as how to calibrate, operate, and maintain the system.

  • Page 3: Table Of Contents

    Table of Contents 1 Preface ..................2 1.1 Intended Use ................2 1.2 Overview of Chapters ............5 2 Overview .................. 5 2.1 Measurements and Features ..........5 2.1.1 Wireless Management Package ........6 2.2 System Components ............6 3 Installation ................7 3.1 Selecting a Location .............7 3.2 Site Requirements and Installation ........7 3.2.1 Mechanical Installation ...........7 3.3 Plumbing Requirements and Installation .......8...
  • Page 4 Table of Contents 6 Additional Features ..............21 6.1 Cl, pH and Temperature Measurements ......21 6.1.1 Installation ..............21 6.1.2 Software Set-up ............22 6.1.3 Routine Maintenance ............ 23 6.1.4 Shut-down and Winterizing ........... 24 6.1.5 Replacing Sensors............24 6.1.6 Troubleshooting ............

  • Page 5: Overview Of Chapters

    Technical Information 2 Overview The WaterGuard WG-602 Water Quality Analyzer continuously monitors chemical levels in a process water application. WaterGuard automates free chlorine, total chlorine, pH, ORP (Redox), temperature, turbidity, conductivity and/or flow rate, administering chemicals as required, according to the results of these tests (closed loop).

  • Page 6: Wireless Management Package

    2.1.1 Wireless Management Package An advanced and unique WaterGuard option is the cellular communication package which provides web- based monitoring of up to 5 analyzers. The cellular communicator accepts WaterGuard's alarms and readings and transmits them to a web-based application server. The information is easily accessible remotely through the Internet or mobile telephone.

  • Page 7: Installation

    3 Installation 3.1 Selecting a Location Take extra time in selecting a location since the installation location will determine the ease of the installation and future operation and maintenance. The location where WaterGuard is installed is dependent on various considerations: Convenient Access - WaterGuard should be installed where it can easily be viewed and operated.

  • Page 8: Plumbing Requirements And Installation

    Figure Figure 1: WaterGuard 602 Mounting Panel 3.3 Plumbing Requirements and Installation Plumbing Requirements and Installation 3.3.1 Water Supply WaterGuard requires a pressurized water supply to t WaterGuard requires a pressurized water supply to the flow cell, a zero pressure (gravity) water retur he flow cell, a zero pressure (gravity) water return from the colorimeter and a pressurized (or gravity) from the colorimeter and a pressurized (or gravity) return from the flow cell.

  • Page 9: Drainage

    3.3.2 Drainage A pressurized, vacuum, or gravity connection is required from the outlet of the flow cell. The flow cell may be pressurized up to 7 psi (0.5 bar) and a ¼” FNPT fitting is supplied for the flow cell drain connection. 3.4 Electrical Requirements and Installation WaterGuard requires a 90-120 or 180-240 VAC, 50/60 Hz electrical power source on a separate 16A circuit in the plant room’s electrical board.

  • Page 10: First Time Operation And Calibration

    National Electrical code (NEC) and all local regulations. First Time Operation and Calibration 3.5 Installing additional Sensors and Meters Install all additional sensors and meters and connect to the WG-602 main system, following the supplemental manuals for each sensor or meter. 3.6 First Time Menu Setup This section describes how to configure the settings (set points, alarms, and calibrations) through the WaterGuard control panel.
  • Page 11 Table 1: Operator Menu Functions and Descriptions 0(18 1$0( '(6&5,37,21 6KRFN &O 7XUQ &O 6KRFN 2Q2II 0HQX 5HOD\V 0DQXDO DFWLYDWLRQ RI 5HOD\V &O 6HWSRLQW  &RQWUROV &O 5HOD\   2Q2II RU 3URSRUWLRQDO &O 6KRFN 6HWSRLQW 6HWSRLQW IRU &O 6KRFN &O 6HWSRLQW  &RQWUROV &O...
  • Page 12 Table 2: Operator Menu and Variable Limits 0,1,080 0$;,080 0(18 1$0( 9$/8( 9$/8( '()$8/7 81,76 6KRFN &O 0HQX 5HOD\V  &O 6HW 3RLQW  6KRFN 6HW 3RLQW   &O  &O 6HW 3RLQW   &O &DOLEUDWHG 7R  &O 6HQVRU :DV ...

  • Page 13: Configuring Settings In The Operator Menu

    3.6.3 Configuring Settings in the Operator Menu Each of the parameters in the operator menu is configured in the same way. The following procedure describes how to configure a typical setting: 12) Locate the desired parameter in the menu: a) Press Menu until the desired parameter name appears in the LCD display. 13) Press OK.

  • Page 14: Calibrating Other Sensors And Meters

    The top line will display “Cl Calibrated to” and a number. The number displayed is the last value someone entered for the calibration. The bottom line will display “Cl Sensor was” and a number. This number is the sensor reading without any calibration at the time of the last calibration. If there is a large discrepancy between these two numbers, the sensor was calibrated improperly or there is a problem with the analyzer.
  • Page 15 Table 3: Technician Menu Functions and Descriptions 0(18 1$0( '(6&5,37,21 &O 3 )DFWRU 3URSRUWLRQDO )DFWRU IRU &O 5HOD\  &O 3XPS 3HULRG  3XPS F\FOH 2Q  2II WLPH IRU &O 5HOD\  &O 3XPS )UHTXHQF\ &O SXPS PD[ SXOVHVPLQ  IRU 2Q2II &O $YHUDJLQJ 'LVSOD\V DQ DYHUDJH RI WKH ODVW  &O...
  • Page 16 Table 4: Technician Menu and Variable Limits 0$;,080 0(18 1$0( 0,1,080 9$/8( 9$/8( '()$8/7 81,76 &O 3 )DFWRU  0LQXWHV &O 3XPS 3HULRG &O 3XPS   212)) 0D[LPXP )UHTXHQF\ SXPS SXOVHVPLQ &O $YHUDJLQJ &O 6HQVRU 7\SH S+ S )DFWRU S+ 3XPS 3HULRG  0LQXWHV...

  • Page 17: Configuring Settings In The Technician Menu

    3.8.1 Configuring Settings in the Technician Menu Navigation within in the Technician Menu is identical to the operator menu. 1) To enter the Technician menu, press Menu to enter the operator menu and then the up arrow and down arrow together simultaneously until the menu display changes. 2) Locate the desired parameter in the menu: a) Press Menu until the desired parameter name appears in the LCD display.

  • Page 18: Monitoring Waterguard Alarms

    Shut-down and Winterizing: If the analyzer will not be operating for an extended period of time • or in areas where temperatures drop below freezing, all water must be removed from the analyzer to prevent components from breaking and the probes must be removed and stored in a warm area and kept wet at all times.

  • Page 19: Troubleshooting

    4.3 Troubleshooting The following procedures instruct how to locate, evaluate, and fix a problem when WaterGuard issues an alarm or indicates suspect chemical levels. 4.4 Replacing Components The following procedures describe how to replace certain WaterGuard components. Caution: The following procedures should only be performed by properly qualified and trained WaterGuard analyzer technicians.

  • Page 20: Replacing Flow Switch

    4.4.1 Replacing Flow Switch Replacing Flow Switch 1) Turn off the inlet and outlet water to the flow cel Turn off the inlet and outlet water to the flow cell and the power to the analyzer. 2) Open the doors of both the analyzing Open the doors of both the analyzing module and the control module.

  • Page 21: Module Software Update

    4.4.4 Module Software Update Module Software Update Each electronic module (card) has a microcontroller Each electronic module (card) has a microcontroller chip (IC) with its own unique software. Whenever a chip (IC) with its own unique software. Whenever a module’s software is updated, its chip must be repl module’s software is updated, its chip must be replaced by a new version with the new software.

  • Page 22: Software Set-Up

    Caution: Make sure the amperometric and pH sensors have plastic or rubber plugs covering their ends. Use another sensor if the plug of any sensor is missing or has fallen off. Make sure to connect the appropriate wire to the appropriate sensors. Labels are located on the wires near the probe connection and on the connection on the amperometric, pH, Temp Module.

  • Page 23: Routine Maintenance

    Note: the Cl readings should fully stabilize within 1 hour and the pH within 24 hours; however the readings should not be erratic. 5.1.3 Routine Maintenance Calibration pH Calibration pH is calibrated using an Phenol Red or Buffer 7 solution. 1) Shut off the water inlet and outlet from the flow cell 2) Remove the pH sensor and temperature probe from the flow cell.

  • Page 24: Shut-Down And Winterizing

    9) Press the up arrow or down arrow until the value is the same as the value given by the digital photometer. 10) Press OK to save the new calibration or Esc to abort without saving. 11) Press Esc to return to the main display. Note: When the WaterGuard is initially turned on, the pH readings will continue to rise for the first 24-48 hours.

  • Page 25: Troubleshooting

    2) Open the doors of both the analyzing module and the control module. 3) Remove old sensor from flow cell a) Unplug the sensor's wires from the sensor, by grabbing the connector at the top end of the sensor and unscrewing the connector. b) Unscrew the sensor from the flow cell c) Pull the sensor up until its glass tube clears the hole.
  • Page 26 Turbidity Input Module (electronics card) • 250 mm flat cable • Turbidity Sensor (wiper optional) • Turbidity Flow Cell (bubble remover optional) • Flow Cell Mounting Bracket • Caution: Prior to opening the analyzer or installing any electrical components, turn off all power supplies to the analyzer There are five (5) wires, contained in a single cord, from the sensor that must be connected to the analyzer.

  • Page 27: Relay Wiring And Use

    Electrical Installation 1) Install the Turbidity Module (electronics card) on the inside, bottom of the control panel door using the supplied screws. 2) Connect the turbidity module to the I/O module using the supplied ribbon cable and any open connector (the connectors on both boards operate in parallel). 3) Pass the sensor cable through an open glad on the bottom of the analyzer.

  • Page 28: First Time Set-Up And General Operation

    5) Connect the line (live) wire of the controlled external turbidity equipment to the normally open (NO) or normally closed (NC) connection on the NTU terminal block. Caution: Each relay connection is limited to 4 amps, to prevent overheating. The relays may show a higher rating but do not connect equipment exceeding 4 amps.

  • Page 29: Routine Maintenance

    5.2.4 Routine Maintenance Turbidity Calibration 1) Take a sample of water from the flow cell 2) Test the sample using an accurate digital turbidly meter 3) Press Menu until NTUl Calibrated to or NTUh Calibrated to appears in the LCD display. If calibrating below 1.0 NTU use NTUl (low) if calibrating above 1.0 NTU use NTUh (high).

  • Page 30: Replacing Components

    5.2.7 Replacing Components Replacing the Turbidity Meter 1) Turn off the inlet and outlet water to the flow cell and the power to the analyzer. 2) Open the door of the control module. 3) Remove the 5 wires from the bottom of the Turbidity input module 4) Remove the meter from the flow cell by unscrewing the cap and pulling gently 5) Install the new meter in the flow cell 6) Route the wires back to the turbidity module and reconnect the 5 wires following the color coding on...

  • Page 31: First Time Set-Up And General Operation

    6) Route the conductivity meter wire through an open gland on the bottom of the analyzer 7) Connect the wires to an open 4-20mA input on the bottom of the 4-20 module 8) Connect 24V from the meter to 24V on the module 9) Connect mS from the meter to IN on the module 10) Connect GND from the meter to ground (symbol) on the module 5.3.2 First Time Set-up and General Operation...

  • Page 32: Replacing Components

    4) Put in the new card and tighten the 4 mounting screws. 5) Connect the flat cable plug to the card. 6) Reconnect the terminal blocks 5.4 Flow Meter Chemical Injection Technologies, Inc., can supply flow meters; but WaterGuard WG-602, itself, provides only input connections and display. 5.4.1 Installation Required Components Flow meter –...

  • Page 33: Routine Maintenance And Troubleshooting

    Although the flow meter is connected, it will not operate until it is set-up in the analyzer menu. 4) Press Menu until “Flow Low Limit” appears and enter the low flow value (the flow value which will cause an alarm and will disable any direct chemical dosing). 5) Press Menu again and “K-factor”...
  • Page 34 Installation Required Parts The 4 to 20mA module upgrade includes two (2) main components that are supplied with the upgrade: External 4 to 20 module case • 4 to 20 module (electronics card) • To complete the installation a few additional components, not supplied with the upgrade will be needed: Hardware to attach the external module case to a wall or other secure structure.
  • Page 35 Prior to connecting to the external monitoring or control system, it is best to confirm that all desired outputs are working properly using a digital multi-meter. This must be done without output wires connected to an external system. 1) Set the multi-meter to measure current and connect the multi-meter to an active output (an output is inactive if it does not have a chipset installed next to the terminal block).

  • Page 36: Internal 4 To 20Ma Output

    Alarm (Dry Contacts), continued 4. No Communication with the Colorimeter 5. Reagents Close to completion 6. No Reagents 7. External Disconnected Communication Connection 8. RS485 Communication Terminal Block 17. RS 232 Communication Terminal Block Communication Connection 9. Free Cl 4mA = 0 20mA = 9.99 10.
  • Page 37 Electrical Installation The 4 to 20 mA module is powered through the ribbon cable and does not require a separate electrical supply as the external module. Software Set-up 1) Go to “4-20mA Output Settings” menu and press OK 2) Enter the technician password and press OK 3) Select the channel (1 to 4) and press 4) Press OK and Select the parameter for that channel (Free Cl, Total Cl, pH, etc.) 5) Press Menu and then OK to set the minimum range (4mA value)

  • Page 38: Appendix A: Relays And Closed-Loop Control

    Connecting to External Monitoring System 1) Connect two wires from the active output to the appropriate connection on the external system 2) Repeat for each active output 3) If an active output (output with a chipset installed) is not to be used, place a jumper wire between the contacts.

  • Page 39: Proportional Control Overview

    6.1.2 Proportional Control Overview Proportional Control Overview WaterGuard controls dosing proportionally. This met WaterGuard controls dosing proportionally. This method sets dosing rates in relation to how far curren hod sets dosing rates in relation to how far current chemical levels are from the set point. The dosing chemical levels are from the set point.

  • Page 40: Setting Proportional Factor

    6.1.3 Setting Proportional Factor Proportional control of chemical dosing requires configuration according to various factors. The primary factors are the ratio between the system size and the rate the chemical dosing systems can feed chemicals, and the delay time between when the chemical level changes and when it is sensed by the controller.

  • Page 41: Appendix B: Technical Specifications

    7 Appendix B: Technical Speci cations...
  • Page 42 APPENDIX 1...

  • Page 43: Conductivity Calibration

    Background: Based on feedback from the field, several changes have been made to the software for the WG 602/702. This document explains only these new features. Changes: Two standard on-board 4-20mA outputs: The control panel (electronics card with the LCD display) will now come standard with two 4-20mA outputs. Up to 4 additional internal outputs may be added using the 4-20mA outputs card.
  • Page 44 APPENDIX 2...
  • Page 45 Maintenance Check the measurement at regular intervals; depending on the respective conditions at least once a month. Perform the following tasks: • If the membrane is visibly soiled, clean the sensor (see section "Cleaning the sensor"). • Re ll the sensor with electrolyte once per season or every 12 months. Depending on the chlorine content on site, this period can be reduced or extended (see section "Re lling the electrolyte").
  • Page 46 Re lling the electrolyte Warning ! Do not swallow the electrolyte! Avoid contact of the electrolyte with skin or eyes. Otherwise wash with a lot of cold water! In case of eye in ammation, contact a doctor! Wear gloves when re lling the electrolyte. Caution ! •...
  • Page 47 – Rinse the sensor with demineralized water (or electrolyte). 5. Top up the electrolyte if required (see chapter "Re lling the electrolyte") and screw the measuring chamber back into place. 6. Fill the beaker with chlorine bleach liquor to about 10 mm (0.39") and position it safely.
  • Page 48 A c ro me t (A us t) P ty L td 14 Winterton Road, Clayton, Victoria 3168 (P O Box 1105, Clayton South, Victoria 3169) Ph: (03) 9544 7333 Fax: (03) 9543 6706 Email: chemex@acromet.com.au www.acromet.com.au...

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