YOKOGAWA WE440 User Manual
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YOKOGAWA WE440 User Manual

YOKOGAWA WE440 User Manual

Phosphate analyzer
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User's
Manual
Model WE440
Phosphate Analyzer
IM 12Y18A04-01EN
IM 12Y18A04-01EN
1st Edition

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Summary of Contents for YOKOGAWA WE440

  • Page 1 User’s Manual Model WE440 Phosphate Analyzer IM 12Y18A04-01EN IM 12Y18A04-01EN 1st Edition...

  • Page 2: Introduction

    Introduction Thank you for purchasing the WE440 Phosphate Analyzer. This Instructor’s Manual contains all essential information for the user to make full use of WE440. Please read the following respective documents before installing and using the WE440. The related documents are listed as follows.
  • Page 3 • No part of the user’s manuals may be transferred or reproduced without prior written consent from YOKOGAWA. • YOKOGAWA reserves the right to make improvements in the user’s manuals and product at any time, without notice or obligation. • If you have any questions, or you find mistakes or omissions in the user’s manuals, please contact our sales representative or your local distributor.

  • Page 4: Safety Precautions

    The product is provided on an “as is” basis. YOKOGAWA shall have neither liability nor responsibility to any person or entity with respect to any direct or indirect loss or damage arising from using the product or any defect of the product that YOKOGAWA can not predict in advance. IM 12Y18A04-01EN...

  • Page 5: Ce Marking Products

    CE marking products Authorized Representative in EEA The Authorized Representative for this product in EEA is Yokogawa Europe B.V. (Euroweg 2, 3825 HD Amersfoort, The Netherlands). Identification Tag This manual and the identification tag attached on packing box are essential parts of the product.

  • Page 6: Table Of Contents

    Toc-1 Model WE440 Phosphate Analyzer IM 12Y18A04-01EN 1st Edition CONTENTS Introduction ....................i Safety Precautions ..................iii CE marking products ..................iv General Information ................. 1-1 Startup Procedure ..................... 1-1 General Product Description ................1-2 1.2.1 User Interface..................1-3 1.2.2 Menus Display ................... 1-4 1.2.3...
  • Page 7 Toc-2 3.10 Post Wash ......................3-4 3.11 Priming ....................... 3-4 Analyzer Hardware Configuration and Calibration ......4-1 Optics Calibration ..................... 4-1 Optics Calibration Steps .................. 4-1 Reaction Cell Temperature Calibration ............4-2 Pumps Calibration .................... 4-2 Pumps Calibration Method ................4-2 Analog Outputs Calibration ................
  • Page 8 Toc-3 Maintenance Schedule ................8-1 Changing Reagents ..................8-1 Installing Tubing Maintenance Kit ..............8-2 Cleaning the Reaction Cell ................8-4 Cleaning the Sample Flow Chamber .............. 8-5 Installing Tubing Kit ..................8-6 Stand-By Mode and Extended Shutdown ............8-7 Standby and On-Demand Modes ............
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  • Page 10: General Information

    OR FURTHER EQUIPMENT DAMAGE MAY OCCUR. Startup Procedure This section describes the necessary steps to begin using the WE440 Phosphate Analyzer. Refer to Chapter 2 for instructions on mounting the analyzer, making the plumbing connections, and connecting electrical power. More details can be found in subsequent chapters.

  • Page 11: General Product Description

    (4. a, b, c, d) press Run. Allow the unit to operate overnight or for at least 12 hours, to become stabilized in the local environment. For additional information on WE440 Phosphate Process Analyzer Operation, refer to Chapter 3.

  • Page 12: User Interface

    <1. General Information> Important standard analyzer capabilities include: • Sampling the process stream automatically. • Calculating concentration of your sample and reporting it in units of concentration. • Recalibrating automatically at preprogrammed intervals to compensate for any changes in captured sample volume, pump flow rates and reagent composition. •...

  • Page 13: Menus Display

    <1. General Information> Display Fields DATE FIELD shows the current date. CURSOR indicates current selection. APPLICATION NAME FIELD shows instrument name tag. TIME FIELD shows present time. DISPLAY FIELD shows menus / measurements. INFO field shows information / instructions to navigate. USER field shows current user name.
  • Page 14 WITH FLOAT SENSOR DRAIN SAMPLE (INLET) SAMPLE (RETURN) Figure 1.3 WE440 Phosphate Analyzer PO4 layout WARNING • Handling chemical samples, standards, and reagents can be dangerous. • Review the necessary Material Safety Data Sheets and become familiar with all safety procedures before handling any chemicals.

  • Page 15: Analysis Reaction Principle

    <1. General Information> 1.2.4 Analysis Reaction Principle The colorimetric method is based on the reaction of reagents with the sample to produce a color. This color is measured and compared to a standard color, which proportionally defines its concentration. The color compound, which is the reacted mixture of the sample with the reagents, absorbs energy at a specific wavelength in accordance to Beer-Lambert Law.

  • Page 16: Installation

    NEMA 12 and the Fluidics enclosure is a NEMA 4X fiberglass with a clear door window. The WE440 Phosphate Analyzer should be installed in a well-ventilated location, with ambient temperature between 5°C and 45°C (41°F to 113°F); and relative humidity not to exceed 90% at 40°C.

  • Page 17: Plumbing Connections

    <2. Installation> AC MAINS INSTALL HEIGHT TO OPERATOR EYE LEVEL FLOW DIRECTION AC POWER POWER CIRCUIT BREAKER FILTERED AND OIL FREE MUST BE CLEARLY IDENTIFIED AIR PURGE SUPPLY LINE FLOW DIRECTION SAMPLE (BACK) N.C. STANDARD (FRONT) N.O. REAGENT STANDARD SAMPLE CHAMBER SHUT-OFF DRAIN SAMPLE (INLET)

  • Page 18: Installing Peristaltic Pump Head Tubing

    <2. Installation> NOTE The enclosure drain produces no waste under normal use. However, in the event of spills or leaks, some waste may be produced. The analyzer is shipped with all of the internal tubing attached. Before starting up the instrument, verify that the tubing lines are secured.

  • Page 19: Installing The Reagents

    <2. Installation> Figure 2.4 Installing peristaltic pump head tubing - (Single channel) 2.2.2 Installing the Reagents The analyzer reagent startup kit contains all the necessary reagent for the specific application. The reagent and calibration standard are supplied in ready-to-use bottles that can be replaced directly onto the cap assemblies.
  • Page 20 <2. Installation> The analyzer has been designed to be hard-wired with provisions for the AC power lines to be routed in conduit pipes connecting to the ¾” FNPT hubs located on the left side of the electronics enclosure. See Figure 2.5. When using line cords, use only certified power cords of 3 core, min 0.75 mm / 18 AWG, min.

  • Page 21: Analog Outputs Connections

    <2. Installation> AC POWER CONNECTIONS Figure 2.6 AC power connections NOTE When using a UL/CSA approved power cord, loop cord through clip retainer as shown in Figure 2.6 for proper strain relief. CAUTION The analyzer is intended for use only with single-phase power. The analyzer is not equipped with a power switch, therefore a circuit breaking device such as a circuit breaker should conform to local safety standards and must be fitted before the final installation.
  • Page 22 <2. Installation> • Strip the insulation on each wire back ¼”. • Insert the wire ends through the uppermost opening below the terminal screw and make sure that the stripped wire ends are in the terminal, tighten the connector screws. Figure 2.7 Terminal strips for analog and relay outputs •...
  • Page 23 <2. Installation> Table 2.2 Main terminal strip pin assignments Terminal Number Designation Function Digital input 1 Live (Level sensor 1 live) Digital input 1 ground (Level sensor 1 ground) Digital input 2 live (Level sensor 2 live) Digital input 2 ground (Level sensor 2 ground) Digital input 3 live (Level sensor 3 live) Digital input 3 ground (Level sensor 3 ground) Digital input 4 live (Level sensor 4 live)

  • Page 24: Inputs Signal Connections

    <2. Installation> 2.3.3 Inputs Signal Connections The two inputs are assigned for external control commands. Inputs 6 and 7 require a DC voltage between 5 and 24 Volts to activate. A 24 V supply is available from the main terminal strip pins 15 and 16 that can be used for activating the external control inputs.
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  • Page 26: Startup And Operation

    <3. Startup and Operation> Startup and Operation Each WE440 Phosphate Analyzer gets thoroughly wet-tested and calibrated at the factory, so the system is ready to begin analyzing sample streams. The results of this activity are recorded in a Test Certificate shipped to you with the analyzer.

  • Page 27: In Auto-Calibration Mode

    It is highly recommended to allow the WE440 Phosphate Analyzer to complete its measurement cycle rather than using the STOP key. If the STOP key is pressed before a measurement cycle is complete, it is highly recommended to perform both the AUTO PRIME ALL and CLEAN sequences described in Chapter 3.

  • Page 28: Instrument Operation Modes

    <3. Startup and Operation> Instrument Operation Modes SAMPLE ANALYSIS CALIBRATION The instrument also operates cleaning and post wash cycles, along with a priming function useful for startup and priming feed tubing lines to the reaction-measuring cell. Sample Analysis and Validation The SAMPLE ANALYSIS mode is similar to the calibration mode, with the exception that during calibration the instrument calculates the relevant parameters correlating to the standard concentrations used for calibration.

  • Page 29: Post Wash

    <3. Startup and Operation> 3.10 Post Wash Automatic post wash cycles are typically part of every measurement cycle. At the end of the analysis, the post wash cycle evacuates the reacted sample from the cell and cleans it to minimize coating and residue deposits in the cell. The post wash cycle settings can be accessed from the ANALYSIS PARAMETERS menu: MENU →...

  • Page 30: Analyzer Hardware Configuration And Calibration

    Pumps and Analog Outputs. Optics Calibration WE440 Phosphate Analyzer optics consists of a LED light path and a photo-detector. The analyzer is capable of driving three LEDs and the intensity of each of the LED can be individually varied. The light path is preset in the reaction cell sample chamber. The photo detector receiving the light energy is connected to an amplifier with programmable gain.

  • Page 31: Reaction Cell Temperature Calibration

    In order to get consistent and repeatable measurements, the method is setup such that the reaction cell in the WE440 Phosphate Analyzer is heated to a specific set point (25°C). A heater element located on the back plate of the reaction cell controls the temperature. The temperature of the reaction cell is measured by a thermistor embedded in the reaction cell body.

  • Page 32: Analog Outputs Calibration

    <4. Analyzer Hardware Configuration and Calibration> Analog Outputs Calibration The analyzer has two isolated analog outputs. The outputs are rated 0/4-20mA with a maximum load of 900 ohms. They can be independently calibrated. From the MAIN MENU, follow the sequence: MENU → SERVICES → HARDWARE SETUP → CALIBRATE ANALOG OUTPUTS The user is asked to connect a 900 ohms resistor to each two analog outputs.
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  • Page 34: Calibration Of The Instrument For Measurement Analysis

    <5. Calibration of the Instrument for Measurement Analysis> Calibration of the Instrument for Measurement Analysis In the analysis mode, the WE440 Phosphate Analyzer measures the absorbance of light through the sample, and compares the result with the absorbance of light through a standard solution of known concentration.

  • Page 35: Base Line Calibration

    <5. Calibration of the Instrument for Measurement Analysis> The analyzer uses a 10 ppm concentration standard solution for calibration. The absorbance of the standard solution is measured and the slope is calculated and stored upon user’s confirmation. Base Line Calibration After calibrating using the single point, improved accuracy around the base or zero point may be further tuned by executing a base line calibration.

  • Page 36: Theory Of Measurement

    <5. Calibration of the Instrument for Measurement Analysis> Theory of Measurement Measurement in the WE440 Phosphate Analyzer is done by measuring the absorbance of a single wavelength of light through the sample, and comparing the result with the absorbance of the same wavelength of light through a standard solution of known concentration. If the two absorbencies match, then the sample concentration is equal to the standard solution.

  • Page 37: Auto Restart Mode

    RESTART mode of the instrument from MAIN MENU follow the sequence: MENU → SETUP → (+) ANALYSIS PARAMETERS → MODE 5.10 Measurement Cycle The WE440 Phosphate Analyzer follows a sequence of steps or events for performing the analysis cycle. They are: Cell Wash Sample Capture...

  • Page 38: Cell Wash

    <5. Calibration of the Instrument for Measurement Analysis> 5.10.1 Cell Wash In cell wash, the sample is pumped into the reaction cell. The user is allowed to edit the volume of the sample to be pumped by the parameter called CELL WASH VOLUME. To edit the cell wash volume, from the MAIN MENU follow the sequence: MENU →...

  • Page 39: Blank Measurement

    <5. Calibration of the Instrument for Measurement Analysis> NOTE No variation in temperature for a period of 80 seconds aborts the measurement, and the info field will flash with the error message: “PLEASE CHECK FOR HEATER FAILURE”. If the temperature is not stabilized within 200 seconds and below the set point, then the info field will flash with the warning message: “CHECKING THE REACTION TEMPERATURE.

  • Page 40: Collect Data

    5.10.9 Measurement Data The WE440 Phosphate Analyzer product stores measurement and calibration results for up to 31 days. The data for each sample analysis cycle or calibration may be retrieved under REVIEW RESULTS menu screen with the corresponding time stamp and other related operating parameters.
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  • Page 42: Menu Overview

    <6. Menu Overview> Menu Overview Explanations of the four major menu sections are described as follows: Setup - For configuring the instrument’s functionality and operational parameters, such as measurement range, measurement frequency, display contrast, date, time, and more. Measurement - For performing the manual analysis, calibration, validation and cleaning cycles. View Data and Alarms - For reviewing the collected data of up to the last 31 days in text and graphics mode, and for reviewing and resetting the various Alarms and Faults triggered during the latest cycle performed.

  • Page 43: Measurement Menu

    <6. Menu Overview> Temperature Units Menu Allows selection of units for displaying the temperature readings. Choice of Fahrenheit (°F) or Celsius (°C). Method Parameters Menu Allows configuration of the parameters for method and order of the events for analysis and calibration.

  • Page 44: Service Menu

    <6. Menu Overview> The view graph has the following operational keys: - Escape - Un-Zoom - Scroll Left - Scroll Right ENTER - Zoom - / + - Cursor Movement MENU - No Action Zoom works as (X hrs displayed)/4, around the cursor position. Un-zoom is the exact opposite of zoom.

  • Page 45: Hardware Setup Menu

    <6. Menu Overview> Factory Settings Menu Allows technician to restore factory defaults, update factory defaults and edit factory settings. Instrument Details Menu Allows viewing of instrument details: • Software version • Serial number • Model number Analysis Label Change Menu Allows technician to edit the analysis label.

  • Page 46: Diagnostics Menu

    <6. Menu Overview> Diagnostics Menu Pumps and Stirrer Allows technician to selectively check the functionality of the pumps and stirrer. Inputs Status Allows technician to check the status of the external inputs. Once a function has been assigned to a digital input, it disappears from the next menu of available functions for the next input.

  • Page 47: User Interface Tree

    <6. Menu Overview> PHOSPHATE 06/06/19 02:20 PM MAIN MENU +SETUP +MEASUREMENT +VIEW DATA AND ALARMS +SERVICES INFO: Figure 6.1 UNLOCK keypad 6.10 User Interface Tree Menu Setup Measurement View Data & Alarms Services (+) Page 1 Analyze Once Review / Reset Alarms System Administration Alarms Calibrate...
  • Page 48 <6. Menu Overview> Menu Measurement View Data & Alarms Services Analyze Once Review / Reset Alarms System Administration Press Enter Reset All Alarms Edit User User name and Password Reset All Faults Calibrate Review Calibration Delete User User Name X Results Calibrate Standards Display...
  • Page 49 <6. Menu Overview> Menu Setup (+) Page 1 (+) Page 2 (+) Page 3 Alarms Analysis Parameters Date & Time Display All + Page 1 (+) Page 2 Daylight Saving Alarm 1 thru 7 Type, value, Restart Mode Post Wash Event Recovery after Hysterisis Power Failure...

  • Page 50: Terms Definition

    <7. Terms Definition> Terms Definition Terms Description Possible Values, Options ALARM Type Assigning a fault type to the alarm. Low Limit, High Limit, Fluidics Fault, General Fault, not Assigned Value Boundary value for triggering an alarm, 0 to XXXXX (XXXXX Value depends on only for low limit and high limit type.
  • Page 51 <7. Terms Definition> Terms Description Possible Values, Options ANALYSIS PARAMETERS Mode Instrument RESTART mode. Auto Restart, Manual Restart Measuring Frequency In the RUN mode, the frequency is the 15, 30, 45 minutes, 1 hr, 0.20 hr are time duration between two analysis selectable and editable minutes range cycles.
  • Page 52 <7. Terms Definition> Terms Description Possible Values, Options DATE Format Selectable date format. MM/DD/YY, YY/MM/DD, DD/MM/YY Current Date Present date, validated depending on the Legible date format. TIME Current Time Present time. Legible time depending on time format Format Selectable time format. 12 hr, 24 hr RECOVERY AFTER POWER FAILURE Power Fail Duration...
  • Page 53 <7. Terms Definition> Terms Description Possible Values, Options ADD USER User Name Add a new user to the users list. User name is 6 characters long and only 6 users are allowed Password Password of the new user entered. 6 characters long A–Z, 0–9 * and space are allowed Measure Permission Measurement permission for the new...

  • Page 54: Maintenance Schedule

    <8. Maintenance Schedule> Maintenance Schedule Maintenance Conduct regular maintenance Schedule Frequency to ensure the analyzer performs properly. Every week Inspect in / out tubes, reagent bottle, and all tubes for fouling. Every month Inspect tubing and ensure that it is not blocked. Every 1.5 months Replace reagent if necessary every 45 days.

  • Page 55: Installing Tubing Maintenance Kit

    <8. Maintenance Schedule> Thermo Fisher Scientific Description Model code 229510 10ppm calibration standard, Phosphate, 1 L 229530 30ppm calibration standard, Phosphate, 1 L 229550 50ppm calibration standard, Phosphate, 1 L 2295REC Reagents 1, Phosphate, 1 liter, 45 day supply Please order necessary reagents with the main unit at same time. Installing Tubing Maintenance Kit Changing the Instrument Tubing It is recommended that the pump head tubing be replaced twice a year at a minimum, or as...
  • Page 56 <8. Maintenance Schedule> Always use 2 drops of Silicone Oil on the platen before replacing on pump. Plumbing Connections STEP 1: Remove pump convers as shown by squeezing the sides and lifting up for the Sample Pump and Reagent 1. STEP 2: Remove old tubing by sliding out the retainers.

  • Page 57: Cleaning The Reaction Cell

    <8. Maintenance Schedule> STEP 5: Insert the retainers into slots in pump housing and ensure it secure properly. STEP 6: Apply two or more drops to the tubing of silicone oil on the pump cover and install on the pump head. STEP 7: Repeat the process to all other pumps.

  • Page 58: Cleaning The Sample Flow Chamber

    <8. Maintenance Schedule> NOTE The reaction cell assembly can swing down to allow better access. Undo both thumb screws and swing down. Cleaning the Sample Flow Chamber It is recommended that you inspect the sample flow chamber at least once a year to check for any flow blockage, and to inspect the operation of the float level sensor.

  • Page 59: Installing Tubing Kit

    <8. Maintenance Schedule> Installing Tubing Kit The tubing in the WE440 Phosphate Analyzer consists of two parts, the Main Tubing Assembly (K9705CK) and the Pump Head Tubing Assembly (K9705CL). The two sections of tubing are connected via luer fittings. The complete tubing layout is shown in below.

  • Page 60: Stand-By Mode And Extended Shutdown

    <8. Maintenance Schedule> STEP3: Connect Sample Chamber Tubing (SAM1) to sample Chamber. STEP 4: Connect all tubing from the tubing channel to the pumps and valve, following the labels on the tubing. Connect the two remaining tubes into the reaction cell cap. STEP 5: Connect the reaction cell vent tube to the front top fitting on the cell cap to the top of reaction cell.
  • Page 61 <8. Maintenance Schedule> Table 8.1 Error messages Messages Cause Solution Login as Technician or Operator User has not logged in, and trying User has to login either as a to access restricted operations. Technician or Operator to access the restricted operations. User is logged in, but does not User is not authorized to access have adequate privileges to access...
  • Page 62 <8. Maintenance Schedule> Measurement/Calibration/Validation Messages Messages Cause Solution Sample empty Performing analysis with single Check for Sample flow. Check for sample and sample chamber is pipe blockages to sample chamber. empty. Testing optics, please check for No light output from optics. Run a Clean Cycle and try again.
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  • Page 64: Standby And On-Demand Modes

    This shift has caused a need for analyzers to work from a continuous mode to an on-demand mode. YOKOGAWA identified this requirement as an enhancement feature and has introduced this into the new WE440 Phosphate Analyzer.
  • Page 65 <9. Standby and On-Demand Modes> Factory Setup Recommendations When Operating In “ON-DEMAND” Mode If the system is to be used “ON-DEMAND”, it is highly recommended to keep it powered and to keep sample flowing to eliminate algae growth in the lines over extended time. It is best to control the analyzer operation either directly via the keypad (RUN / STOP) keys or using a remote ON/ OFF external control switch for controlling the analyzer.

  • Page 66: Revision Record

    Revision Record Manual Title : Model WE440 Phosphate Analyzer Manual No. : IM 12Y18A04-01EN Oct. 2019/1st Edition Newly published Yokogawa Electric Corporation 2-9-32 Nakacho, Musashino-shi, Tokyo 180-8750, JAPAN http://www.yokogawa.com/ IM 12Y18A04-01EN 1st Edition : Oct. 04, 2019-00...
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