YOKOGAWA RC400G User Manual
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YOKOGAWA RC400G User Manual

Residual chlorine analyzer
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User's
Manual
Model RC400G
Residual Chlorine Analyzer
[Style: S4]
IM 12F4A1-01E
IM 12F4A1-01E
14th Edition

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Summary of Contents for YOKOGAWA RC400G

  • Page 1 User’s Manual Model RC400G Residual Chlorine Analyzer [Style: S4] IM 12F4A1-01E IM 12F4A1-01E 14th Edition...
  • Page 2 CAUTION Carry the RC400G in the same attitude as it will be installed. the RC400G weight exceeds 60 kg. (For details, see subsection 2.1.1.) • For storing the RC400G, select a place where the ambient temperature is in the range of from -30 to 70 °C.
  • Page 3 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. n Trademark Acknowledgments •...
  • Page 4 • If we replace the product with a new one, we won’t provide you with a repair report. • Yokogawa warrants the product for the period stated in the pre-purchase quotation Yokogawa shall conduct defined warranty service based on its standard. When the customer site is located outside of the service area, a fee for dispatching the maintenance engineer will be charged to the customer.
  • Page 5 Blank Page...
  • Page 6 Toc-1 Model RC400G Residual Chlorine Analyzer [Style: S4] IM 12F4A1-01E 14th Edition CONTENTS Introduction ......................i Safety Precautions ....................ii After-sales Warranty ....................iii Outline ....................... 1-1 1.1 RC400G Residual Chlorine Analyzer Configuration ........1-2 1.2 Operating Principle of RC400G Residual Chlorine Analyzer ....... 1-3 Specifications ................... 2-1 2.1 RC400G Residual Chlorine Analyzer .............. 2-1 2.2 RC401G Reagent Tank..................2-10 Installation, Tubing and Wiring ............... 3-1 3.1 Installation ......................3-1 3.2...
  • Page 7 Toc-2 4.3.3 Supplying Cleaning Water ..............4-6 4.3.4 Turning on Power ................4-6 4.3.5 Confirming Sample Water Metering Pump Delivery Flow ....4-7 4.3.6 Confirming Reagent Metering Pump Delivery Flow ......4-7 4.3.7 Confirming Indicator Electrode Operation ......... 4-8 4.3.8 Confirming Cleaning Solenoid Valve Operation and Adjusting Ball Valve Opening....................
  • Page 8 Toc-3 7.2.3 Automatic Zero Calibration Using Chlorine-Free Water ....7-3 7.3 Span Calibration ....................7-5 Maintenance ....................8-1 8.1 Inspection/Maintenance Items and Intervals ..........8-1 8.2 Reagent Replenishment ................... 8-1 8.3 Indicator Electrode Polishing ................8-1 8.4 Glass Beads and Measuring Tank Cleaning ..........8-2 8.5 Calibration ......................8-3 8.6 Metering Pump Driving Section Oiling ............8-3 8.7 Replacement of “Bellofram” and Valve Sheet in Metering Pump ....
  • Page 9 Blank Page...
  • Page 10 The electrode configuration, reagent composition and applied voltage have been changed, otherwise, the measurement principle, equipment, specifications and performance remain unchanged from the previous model. In this chapter, the operating principle and structural outline of the RC400G Residual Chlorine Analyzer is described. Converter...
  • Page 11 <1. Outline> 1.1 RC400G Residual Chlorine Analyzer Configuration The RC400G Residual Chlorine Analyzer is mainly composed of a “measuring system”, a “sampling system” and an “air tubing system”. In addition, a “cleaning piping system” is added to raw water treated water analyzers. n Measuring System “Measuring System”...
  • Page 12 1.2 Operating Principle of RC400G Residual Chlorine Analyzer The measuring object of the RC400G residual Chlorine Analyzer is either free available chlorine or combined available chlorine. Free available chlorine exists in the forms of chlorine (Cl ), hypochlorous acid (HClO), or hypochlorite ion (ClO ) in water.
  • Page 13 Except for the liberation of bromine, the measurement of free available chlorine is the same as the measurement of total residual chlorine. Figure 1.4 illustrates the principle of the RC400G Residual Chlorine Analyzer. The current flowing between the indicator (ME) and the counter (RE) electrodes is measured when a specific voltage is applied across the electrodes.
  • Page 14 <2. Specifications> Specifications n this chapter, specifications are given for the RC400G Residual Chlorine Analyzer, the RC401G Reagent Tank and others. 2.1 RC400G Residual Chlorine Analyzer n Standard specifications Measurement object: Free chlorine or residual chlorine (total chlorine) in water Measurement method: Rotating electrode type polarographic system Measurement range: 0 to 10 mg/l (mg/l used as concentration units per JIS K0101 and...
  • Page 15 <2. Specifications> Sample conditions: Temperature: 0 to 50 °C 3 to 9 pH Flow: 1 to 4 l/min, for pure water or municipal water application. 5 to 10 l/min, for raw water or sea water application. 10 to 20 l/min, for secondary sewage treatment application. Pressure: 20 to 500 kPa Electrodes:...
  • Page 16 Indoors (A separate rainproof cover is required for outdoor installation. Avoid direct sunlight.) Utilities Power supply: 100/110/220 V AC ±10%, 50/60 Hz Power consumption: RC400G-1: Approx. 65 VA RC400G-2: Approx. 125 VA RC400G-3: Approx. 210 VA Cleaning water (required with sand filter system)
  • Page 17 <2. Specifications> Air purge (using instrument air) Supply pressure: 140 kPa Air consumption: Approx. 5 l/min Weight For pure water: Approx. 65 kg For raw water (1-cylinder): Approx. 70 kg For raw water (2-cylinder): Approx. 75 kg Optional specifications Pump for air purge (if instrument air cannot be used) Install to enable intake of clean air.
  • Page 18 Less affected by combined chlorine in free chlorine measurement. When ordering the RC400G, select /NR and get reagent sets for start-up from local reagent supplier. These reagent sets can not be exported from Japan due to both safety and transportation issues.
  • Page 19 In this case, combined chlorine type is recommended. Oxidizing or reducing agents other than chlorine may be present. If so, chlorine concentration measurement may not be possible. There are Residual chlorine analyzer for sewage secondary treatment or sea water. Please ask Yokogawa. Accessories...
  • Page 20 <2. Specifications> n Flow diagrams and outline drawings (1) RC400G-1 Residual chlorine analyzer for tap water unit : mm Air purge inlet Standard solution inlet Rc1/4(female) Rc1/4(female) Maintenance Maintenance space space Reagent inlet Approx. Approx. 4-ø15 holes Rc1/4 (female) for anchor bolt Stand Ball valve (V3) Maintenance Strainer (S1) Front space...
  • Page 21 <2. Specifications> (2) RC400G-2 Residual chlorine analyzer for raw water with one cylinder sand filter unit unit : mm Air purge inlet Standard solution inlet Rc1/4 (female) Rc1/4 (female) Maintenance Maintenance Reagent inlet 4-ø15 holes Rc1/4 (female) space space for anchor bolt Approx. Approx. Ball valve (V6) Stand Strainer (S1) Maintenance Front...
  • Page 22 <2. Specifications> (3) RC400G-3 Residual chlorine analyzer for treated water with two cylinder sand filter unit unit : mm Air purge inlet Standard solution inlet Rc1/4 (female) Rc1/4 (female) Maintenance Maintenance Reagent inlet space space 4-ø15 holes Rc1/4 (female) Approx. Approx. for anchor bolt Stand Ball valve (V8) Strainer (S1) Maintenance Front...
  • Page 23 2-10 <2. Specifications> 2.2 RC401G Reagent Tank It is a tank to hold reagent to be supplied to the residual chlorine analyzer. It is equipped with a stirrer (manual) and a level gauge. Either a tank only or a tank installed on a stand are available. NOTE When the tank with a stand (RC401G-B) is used, open a needle valve gradually and stop it at the position when reagent starts to flow.
  • Page 24 2-11 <2. Specifications> n Product model and suffix codes Model Suffix code Option code Description RC401G ----------------------- -------------------- Reagent tank Type -------------------- Reagent tank only -------------------- Reagent tank with stand -------------------- Reagent mixing tank with mobile stand -------------------- With manual mixer -------------------- Style A Accessories Reagent tank (RC401G-A, RC401G-B) Name Quantity Remark Couplings...
  • Page 25 Blank Page...
  • Page 26 When transferring the RC400G from storage or in unpacking it, observe the caution in the foreword in the early part of this user’s manual. 3.1 Installation n Location Install the RC400G analyzer in a location to satisfying the following conditions. • A building or a cabinet free rain water. • Slight vibration • Substantially free from corrosive gases. • Low humidity. • Slight temperature variation. Ambient temperature should be approximately maintainable near ordinary temperatures.
  • Page 27 <3. Installation, Tubing and Wiring> Tubing connections and flow charts for the RC400G-1, RC400G-2 and RC400G-3 are illustrated in Figure 3.1.1 to 3.1.3, Figure 3.2.1 to 3.2.3 and Figure 3.3.1 to 3.3.3, respectively. (1) RC400G-1 Residual Chlorine Analyzer for Tap Water Drain VP40 pipe Standard solution inlet...
  • Page 28 Calibration solution (VP16) Standard solution (Rc1/4) Strainer Reagent (Rc1/4) Air (Rc1/4) *Air pump Drain (VP40) F1_4_4E.ai Figure 3.1.3 Tubing Diagram RC400G-1/AZC (2) RC400G-2 Residual Chlorine Analyzer for Raw Water Drain VP40 pipe Standard solution inlet For air purge inlet Reagent inlet Measuring sample inlet Tap water inlet VR16 pipe VR16 pipe F3_2_1E.ai...
  • Page 29 Ball valve Standard solution (Rc1/4) Strainer Reagent (Rc1/4) Air (Rc1/4) *Air pump Drain (VP40) F1_4_2E.ai Figure 3.2.2 Tubing Diagram of RC400G-2 Tubing materials ø6 x ø4 Converter polyethylene tube Sand filter ø8 x ø6 polyethylene tube ø22 x ø15 braided wire reinforced soft PVC tube ø33 x ø25...

  • Page 30: Table Of Contents

    <3. Installation, Tubing and Wiring> (3) RC400G-3 Residual Chlorine Analyzer for Treated Water Drain VP40 pipe Standard solution inlet For air purge inlet Reagent inlet Measuring sample inlet Tap water inlet VP16 pipe VP16 pipe F3_3_1E.ai Figure 3.3.1 Piping of RC400G-3 Residual Chlorine Analyzer for Treated Water Tubing materials ø6 x ø4 Converter polyethylene tube Sand filter ø8 x ø6...

  • Page 31: Polyethylene Tube Ø8 X Ø6

    Note: Perform tubing so that sample water pressure at the connection falls within the range of 20 to 500 kPa. Sample water flow rates to the analyzer in operation are as follows: In RC400G-1: 1 to 4 l/min In RC400G-2:...

  • Page 32: Drain (Vp40)

    When the RC400G is provided with an air pump, extend the tubing to an area free from corrosive gases for intake of clean air. If an air pump is not available, employ instrument air, etc. and perform tubing so that air is supplied at a pressure of approx.

  • Page 33: Figure 3.4

    <3. Installation, Tubing and Wiring> 3.3 Wiring The type of wiring required by the residual chlorine analyzer are as shown below. All are connected to wiring terminals (M4 screw) in the converter. When the analyzer with arrestors, connect terminals of power and analog output to the terminal box. (1) Wiring for power supply and grounding.
  • Page 34 <3. Installation, Tubing and Wiring> RC400G-1 Residual Chlorine Analyzer for Tap Water Converter Detector Dedicated cable (CON) (CELL) K9332WA Fail contact output Maintenance contact output (Wired by customer) Terminal mounting Range switching output screw Remote range switching input Pump Power terminal box (*2) (PU) Dedicated cable...
  • Page 35 3-10 <3. Installation, Tubing and Wiring> RC400G-2 Residual Chlorine Analyzer for Raw Water Converter Detector Dedicated cable (CON) (CELL) K9332WA Fail contact output Maintenance contact output (Wired by customer) Terminal mounting Range switching output screw Remote range switching input Pump Power terminal box (*2) (PU) Dedicated cable...
  • Page 36 3-11 <3. Installation, Tubing and Wiring> RC400G-3 Residual Chlorine Analyzer for Raw Water Converter Detector Dedicated cable (CON) (CELL) K9332WA (Wired by customer) Fail contact output Maintenance contact output Terminal mounting Range switching output screw Remote range switching input Pump Power terminal box (*2) Analog Dedicated cable...
  • Page 37 3 ports are available for external wiring. NOTE In the RC400G-1 analyzer which has no air pump, 4 ports are available for external wiring. Use one cable for each wiring. The analog output wiring and contact input wiring are collected together in one cable as a rule, but they can be assigned separate cables if cable ports are available.
  • Page 38 3-13 <3. Installation, Tubing and Wiring> 3.3.1 Wiring for Power Supply and Grounding This is for supplying power of voltage and frequency meeting the specification of the analyzer and for grounding the converter case. Connect the terminals L1 and L2 of the converter to power supply with a two-conductor cable of 6 to 12 mm finished O.D..
  • Page 39 3-14 <3. Installation, Tubing and Wiring> 3.3.2 Wiring for Analog Output Signals This is for transmitting output signals of 1 to 5 V DC or 4 to 20 mA DC by the respective range to receives such as a recorder. Use a two-conductor shielded cable of 6 to 12 mm finished O.D.. When the analyzer is equipped with arrestors (when option code “/ARS”...
  • Page 40 3-15 <3. Installation, Tubing and Wiring> 3.3.4 Wiring for Contact Output The converter supplies contact signals of either <failure>, <maintenance> or <range>, for which contact output wiring is provided. For the wiring, use a cable or 6 to 12 mm finished O.D. (select a two-, three- or four-conductor cable depending on the number of contract outputs used.) Treat the cable end to be connected to the converter terminals in the same manner as the analog output signal cable (see subsection 3.3.2.)
  • Page 41 Blank Page...
  • Page 42 <4. Operation> Operation This chapter chiefly describes preparation procedures for stable analyzer operation. 4.1 Component Identification and Function <RC400G-1> Air pump (*3) Converter (AP) (CON) Detector (CELL) Power terminal Head tank box (*1) (HD) Metering Meas./Std. solution pump switching valve Drain VP40 pipe (PU) (V2) Pressure reducing Ball valve Activated valve (PR) (*2)
  • Page 43 <4. Operation> <RC400G-3> Air pump (*3) Converter (AP) (CON) Detector Sand filter Sand filter (CELL) (F1) (F2) Solenoid Solenoid valve (SV1) valve (SV3, 4) Ball valve Power terminal Ball valve Solenoid (V15) box (*1) (V2) valve (SV1, 2, 5) Metering Meas./Std.
  • Page 44 <4. Operation> n Detector and electrode mechanism block Electrode mechanism block cover 　prevents the corrosive gas from intruding into analyzer. Base Electrode mechanism block Fixing screws Measuring tank Ceramic beads 　Polish the indicator electrode to maintain the clean surface of the indicator electrode Driven shaft Drive shaft The driven shaft is connected to the indicator electrode by a belt, and...
  • Page 45 <4. Operation> 4.2 Preparation for Operation 4.2.1 Reagent Preparation Reagent used for measurement differs in free available chlorine measurement and residual chlorine (total chlorine) measurement. Also, in total chlorine measurement, the component amounts in the reagent must be changed depending on the chlorine concentration in the solution to be measured.
  • Page 46 <4. Operation> Table 4.3 Reagent Composition and Its Component Quantities Residual Chlorine Required quantity of containers for each Measurement More than 6 mg/l to measurement (approx. for 45 days) Object Up to 6 mg/l 10 mg/l (inclusive) and Max. More than 6 mg/l to Concentration Quantity in 100 l Up to 6 mg/l 10 mg/l (inclusive) 500 g 1000 g 500 g x 1 500 g x 2 COONa 150 g 500 g x 1 (3 times) COOH 1000 ml 500 ml x 2...
  • Page 47 4.3.3 Supplying Cleaning Water This step is necessary only for an analyzer for raw water (the RC400G-2) or treated water (the RC400G-3) measurement. Supply cleaning water at a pressure of 100 to 500 kPa to the analyzer. In so doing, leave the ball valve in the cleaning water line, (V4 for raw water), (V6 for treated water), at the rear of the analyzer, open.
  • Page 48 (2) Press [PUMP] key to once stop the metering pump operation. (3) Close the ball valve (*1) in the reagent flow line. Remove the tubing connected to the reagent metering pump suction tubing joint. *1: RC400G-1 For tap water: RC400G-2 For raw water: RC400G-3 For treated water: (4) Connect the prepared soft PVC tube to the burette and fill the tube and burette with water (alternative of reagent).
  • Page 49 <4. Operation> Consumption measuring range 10 cm 50ml burette 10 cm Detector Burette stand Metering pump Soft PVC tube, Reagent metering pump 6 mm O.D. x 4 mm I.D. suction tubing joint F4.5.ai Figure 4.5 Burette Setting (5) Measure the delivery flow rate using the method for measuring a time interval in which water in the burette is consumed by a definite volume (4.5 ml).
  • Page 50 <4. Operation> 4.3.8 Confirming Cleaning Solenoid Valve Operation and Adjusting Ball Valve Opening There are performed only for the residual chlorine analyzer RC400G-2 or RC400G-3 for raw water or treated water. Perform solenoid valve operation confirmation and ball valve opening adjustment in the following procedure: (1) Adjust the flow rate of cleaning water entering the sand filter.
  • Page 51 4-10 <4. Operation> 4.3.10 Polishing Indicator Electrode The gold alloy surface of the indicator electrode must be kept clean. Polish the gold alloy surface in the following procedure: (1) Confirm that the mode is <MAINT.> and then press [CELL] key on the control panel to stop revolution of the indicator electrode.
  • Page 52 (1) Make sure that solenoid valve SV2 is closed. Then, open the solenoid valve SV6. (The RC400G for tap water does not have the solenoid valve SV2.) (2) Check that no leakage has occurred and no air bubbles have formed.
  • Page 53 Determine maintenance items and periods referring to Chapter 8 “Maintenance”. The RC400G residual chlorine analyzers have the function for displaying various data items effective for understanding operating conditions, not limited to residual chlorine concentration (see subsection 5.3.2).
  • Page 54 <5. Converter Operation> Converter Operation The converter has functions for cleaning sequence, failure detection, and self-diagnosis by fully utilizing the incorporated microprocessor as well as the residual chlorine concentration measuring function. The converter is operated when executing various data value display, solenoid valve operation commanding, and operation parameters entry, etc.. This chapter describes key operations and display contents indicated in this displays. 5.1 Component Identification and Functions on the Control Panel Converter operations are all performed on the control panel. The control panel includes displays for data, mode, function code, and others, in which measured values and operating conditions are displayed.
  • Page 55 <5. Converter Operation> Table 5.1 Operation Key/Display Names and Functions Name Function Data display (indicated by red LEDs) Measured values, setting data, message, etc. are displayed. Function code display (indicated in red) A selected function code is displayed. Mode display (indicated in green; lamp A operation mode is displayed. A lamp relevant to the current lights) mode is lit.
  • Page 56 • If "execution" of cleaning function is selected, sequence operation is performed (for RC400G-2 or RC400G-3). • This is the mode in which maintenance is performed and calibration or taking plateau characteristics can be done (execution items are selected using [FUNC] MAINT.
  • Page 57 <5. Converter Operation> 5.2.2 Function Codes and Their Description in <MAINT.> Mode Table 5.4 shows the types of function code and their description in <MAINT.> mode. Table 5.4 Functions List in <MAINT.> Mode Display Initial Description Setting Range Remarks (example) Value 0.00 mg/l Display in ppm is Zero calibration (Display: -1.00 to 000.02 mg/l also available.
  • Page 58 <5. Converter Operation> Table 5.5 Functions List in <PROGRAM.1> Mode Display Initial Description Setting Range Remarks (example) Value 0.00 to 10.00 mg/l L00.00 Display in ppm is 1 Output range setting for "output range-1" L00.00 mg/l (Span 1.00 or more) H05.00 also available. L00.00 Display in ppm is 0.00 to 10.00 mg/l 2 Output range setting for "output range-2"...
  • Page 59 Functions List in <PROGRAM.2> Mode Display Initial Description Setting Range Remarks (example) Value Applied to RC400G-3 3 Setting measuring tank cleaning cycle 0.1 to 24.0 hours 0001.0 hours analyzer only 4 Setting measuring tank cleaning time 0.1 to 25.0 min 0001.0 min The value in ( ) is for 5 Setting relaxation time after cleaning 0.1 to 25.0 min...
  • Page 60 <5. Converter Operation> 5.3 Key Operation 5.3.1 Operation Key Types and Functions (1) Mode Key ([MODE]) By pressing [MODE] key, the operation mode changes. The current operation mode is known through a mode lamp which is lit. Mode is transferred in the order shown in Figure 5.2 every time the [MODE] key is pressed. However, when a function code other than “1”...
  • Page 61 Accordingly, none of these keys are used in the “the RC400G-1 residual chlorine analyzer for tap water” which does not incorporate cleaning functions for measuring tank and sand filter cylinder.
  • Page 62 <5. Converter Operation> Table 5.7 Operation Command Keys-2 and Relevant Solenoid Valves Operation RC400G-1 RC400G-2 RC400G-3 Command Relevant Solenoid Valve (no cleaning (number of (number of function) sand filters: 1) sand filters: 2) SV1: Solenoid valve in one sand filter cylinder cleaning water line SV2: Solenoid valve in measuring tank cleaning water line SV3: Solenoid valve in one sand filter...
  • Page 63 5-10 <5. Converter Operation> However, if the limit of “output range-1” and “output range-2”, whichever is greater, is set at 5.00 mg/l (ppm) or lower, the maximum displayed value is approx. 35 µA because the current input range is set to “Low” (approx. -5 to 35 µA). When the diffusion current exceeds a value corresponding to 5.00 mg/l, “O.L”...
  • Page 64 5-11 <5. Converter Operation> (2) Span calibration (Function code “2”) (3) Span calibration (reference sensitivity updating) (Function code “d”) (4) Manual start of measuring tank cleaning and sand filter cylinder cleaning (Function code “4”, “5”, and “6”) (5) Measurement of sample water and reagent metering pump flow (Function code “7” and “8”) (6) Taking plateau characteristics (Function code “9”) (7) Plateau characteristics display (Function code “A”)
  • Page 65 5-12 <5. Converter Operation> (2) Span Calibration (Function code “2”) Span calibration is performed using a standard calibration solution. For details, see section 7.3 “Span Calibration”. In this subsection, key operation for it is described. First set the residual chlorine concentration in the standard calibration solution and then start the calibration operation.
  • Page 66 If span calibration is executed with function code set to “d”, the reference sensitivity set in function code “4” in <PROGRAM.1> mode is automatically updated. Since the RC400G residual chlorine analyzer is calibrated for span using the amperometric titration in the factory, the reference sensitivity on shipment is also set to “2.62 µA/(mg/l) at 20 °C”...
  • Page 67 5-14 <5. Converter Operation> (a) Select function code “4”, "5", or "6" in <MAINT.> mode. The data display indicates as shown below. (Example) Function code "4" (measuring tank cleaning) "JEt" Function code "5" (sand filter cylinder-1 cleaning) "bLo_1" Function code "6" (sand filter cylinder-2 cleaning) "bLo_2"...
  • Page 68 5-15 <5. Converter Operation> If the time measurement does not reach 90 sec, "O.L" is displayed. If [ENT] key is not pressed even after 360 sec have elapsed, "Error" is displayed. These displays are reset by pressing [ENT] key and the message in operation step (b) appears. (e) After the flow rate is displayed and confirmed normal, restore tubing and the like.
  • Page 69 5-16 <5. Converter Operation> Plateau characteristic (example) (Setting example) Starting voltage : 0 V Stopping voltage : -0.8 V Diffusion current Number of steps (µA) Relevant to initial values -0.5 -1.0 Applied voltage (V) Step 0 Step 2 Step 4 Step 6 Step 8 Step 1...
  • Page 70 5-17 <5. Converter Operation> • Data taking proceeds in turn by displaying the step No. and time lapse. 00.001 Number of steps Time lapse (sec) F5.5.ai Figure 5.5 Display Content in Taking Plateau Characteristic • Data taking at a step is over, the next step display appears. Time lapse display is also reset and counts up from the beginning.
  • Page 71 5-18 <5. Converter Operation> When a series of taking operations is completed, "End" is displayed. → End During plateau data taking, any step can be skipped and data taking is transferred to the next step. This operation is performed using [ENT] key. When [ENT] key is pressed, the step display then displays the next step number and the time display is also reset to start the next step time counting.
  • Page 72 5-19 <5. Converter Operation> Ex. number of steps : 8 [>] key operation P_ _00 00.000 V 000.00 µA [>] key operation P_ _01 -0.100 V 001.50 µA [ENT] key operation P_ _02 [>] key operation P_ _08 -0.800 V 005.80 µA Step display Applied voltage display...
  • Page 73 5-20 <5. Converter Operation> Table 5.15 Types of <failure> for Which <FAIL> Lamp Lights Selection Mode in which Error Detecting Detectable <failure> <failure> Contents Detecting Code Conditions Mode Contact Signal Function is Output "stop" Out of -0.5 to Err11 Concentration range exceeded All modes <MEAS.> Unavailable 11.0 mg/l range Out of 0 to 50 Err12 Sample temperature failure All modes...
  • Page 74 Function codes "1." to "F." in <MAINT.> mode are provided as function codes in "service mode" used when YOKOGAWA performs servicing. These function codes can be selected by entering the password (77) in function code "F". However, request servicing by YOKOGAWA as a rule if operations are required in "service mode". 5.3.4 Key Operations in <PROGRAM.1> Mode...
  • Page 75 The RC400G residual chlorine analyzer detects an error (“Err22”) when the measured sensitivity is less than 50 % of the reference sensitivity and makes that span calibration invalid.
  • Page 76 5-23 <5. Converter Operation> If it is found that inconvenience such as calibration is not performed because of the error (“Err22”) occurrence is caused by the difference between the employed method and manual analytical methods, set a reference sensitivity conforming to the employed manual analytical method. NOTE If “Err22”...
  • Page 77 5-24 <5. Converter Operation> Concentration Concentration change : Response time limit ∆S ≤ ∆S : Detection time for detecting indication stabilization Stable ∆S : Concentration change within detecting time ∆S ∆S : Concentration for detecting indication stabilization Time 1 sec Detection Response failure (Err24) start...
  • Page 78 5-25 <5. Converter Operation> (6) Line-Segment Function Output Setting (Function code “A”) Analog signals can be output in the form of line-segment function. The setpoint value (%) of the function for a span (mg/l) in the output range is the break point corresponding to 50 % of the output signal (4 to 20 mA or 1 to 5 V) span.
  • Page 79 5-26 <5. Converter Operation> The setting key operation procedure is shown below. (a) Select function code "A". → 00050 % (b) Press [>] key. → 00050 % (Leftmost digit flashes.) (c) Select the digit using [>] key and set a numeric value using [Λ] and [v] keys.
  • Page 80 5-27 <5. Converter Operation> (9) Setting Averaging Coefficient (time constant) (Function code "d") The converter display and analog output are computed for average by the program. In this setting, the extent of averaging (signal time constant) can be changed. Table 5.19 shows an approximate correspondence between the averaging coefficient and a 90 % response time. Table 5.19 Averaging Coefficient and 90 % Response Time Averaging coefficient Standard for 90 % response time...
  • Page 81 5-28 <5. Converter Operation> Remote/Local Selecting Operation (a) Select function code "1.". → on (Remote) (Local) (b) Every time [>] key is pressed, on and oFF are alternately displayed. → on ↔ oFF (c) Select on (remote) or oFF(local). → oFF (d) Press [ENT] key to enter it. →...
  • Page 82 *2: The automatic zero calibration cycle is longer than one day. (Refer to subsection 7.2.2) (14) Selection of Cleaning Sequence to be used (Function code “8.”) One sand filter is used for the RC400G-2 residual chlorine analyzer for raw water, and two sand filters are used for the RC400G-3 residual chlorine analyzer for treated water.
  • Page 83 5-30 <5. Converter Operation> If it is necessary to stop the measuring tank cleaning function, operate keys in the following procedure: (a) Select function code "9.". → on (Cleaning execution) → oFF (Cleaning stop) (b) Every time [>] key is pressed, on and oFF are alternately displayed.
  • Page 84 5-31 <5. Converter Operation> (b) Every time [>] key is pressed, _ _ 1 and _ _ 2 are alternately displayed. → _ _ 1 ↔ _ _2 (c) Select _ _ 1 (mg/l) or _ _ 2 (ppm). → _ _ 2 (d) Press [ENT] key to enter it.
  • Page 85 5-32 <5. Converter Operation> NOTE If the value is below -1.00 mg/l, “O.L” is displayed, regardless of the setting. (21) S election of below-4-mA output hold in <MEAS.> mode (Function code “F.”) When the function is set to on (enabled), analog output does not fall below 4 mA but is held at 4 mA.
  • Page 86 5-33 <5. Converter Operation> (1) C leaning Sequence and Time Setting for Sand Filter “One Cylinder Type” (Function code “4”, “5”, “6”, and “7”) Figure 5.13 shows the cleaning sequence for sand filter “one cylinder type” applied to the RC400G-2 residual chlorine analyzers for raw water. T1 *4 T1 *4 SV2(WASH) *3 Measuring tank cleaning operation *1...
  • Page 87 (2) C leaning Sequence and Time Setting for Sand Filter “Two Cylinder Type” (Function code “3”, “4”, “5”, “6”, “7”, “8”, and “9”) Figure 5.14 shows the cleaning sequence for sand filter “two-cylinder type” applied to the RC400G-3 residual chlorine analyzers for treated water. IM 12F4A1-01E 14th Edition : Jul. 15, 2020...
  • Page 88 5-35 <5. Converter Operation> Switched to <MEAS> (LINE 2) Sand filter (LINE 1) cylinder 2 sec 5 sec 2 sec 5 sec cleaning operation (FILTER 1) 2 sec 5 sec 2 sec 5 sec (FILTER 2) T7 * 3 Measuring tank (WASH) cleaning...
  • Page 89 5-36 <5. Converter Operation> If it is necessary to change the value set on shipment, re-set it in the following procedure: (Example) (a) Select function code “8” ("3" to "7", "9"). → 0006.0 (min) (b) Press [>] key. → 0006.0 (min) (Leftmost digit flashes.) (c) Select a digit using [>] key and set a numeric value using [Λ] and [v] keys.
  • Page 90 <6. Converter Operating Functions> Converter Operating Functions Operating functions related to converter operation were partially described in 5. Converter Operation. This chapter describes details of the already described functions and the other operating functions. 6.1 <failure> Detecting Operation For types of <failure> detected, see subsection 5.3.3 (8) and others. This section describes detecting operations for major <failure>. The <failure> status is reset by turning the power off. If abnormal cause is not eliminated after turning the power on, <failure>...
  • Page 91 <6. Converter Operating Functions> Figure 6.1 shows the discriminating method between the state either sample is present or not in the measuring tank. When a measured value of residual chlorine concentration decrease below the predetermined value (set using function code “c” in <PROGRAM.1> mode), the applied voltage changes for a very short time as shown in Figure 6.1.
  • Page 92 <6. Converter Operating Functions> A few sec. Applied coltage Detecting voltage Setting voltage Time Reverse voltage F6.2.ai Figure 6.2 Detecting Voltage Waveform 6.1.4 Converter Failure (Err14, Err15, Err16, and Err17) Converter circuit failure and memory failure are detected in the following method: (1) AD Circuit Failure (Err14) By periodically sampling the reference resistance value and reference voltage value in the temperature input circuit, check whether these values are the predetermined ranges or not.
  • Page 93 Their selection is performed by changing PCB jumper pin connection in the converter. On shipment, either one that was required by the user has been set. If change is required, contact Yokogawa because service work is required to be conducted for removing the control panel.
  • Page 94 Table 6.4 shows default status of cell motor, metering pumps, and solenoid valves (SV1 to SV6) when mode change. Table 6.4 Default Status of Pumps, Solenoid Valves, etc. When Mode Change <MEAS.> Mode <MAINT.> Mode Equipment Name/ <PROGRAM.1> <PROGRAM.2> Symbol Mode Mode RC400G-1, 2 RC400G-3 RC400G-1, 2 RC400G-3 Cell motor Metering pump Air pump *1 ON/OFF ON/OFF ON/OFF ON/OFF SV1 (FILTER 1)
  • Page 95 Blank Page...
  • Page 96 Calibration should be performed after continuing this “running-in” operation for about 30 min. When new sand is used in the sand filters of the RC400G-2 or RC400G-3 residual chlorine analyzer, chlorine in the sample water may be absorbed by the sand, resulting in measurement errors.
  • Page 97 <7. Calibration> (4) Re-mount the electrode mechanism block to the measuring tank. Also, press [CELL] key to rotate the indicator electrode. 7.2.2 Zero Calibration Using Chlorine-Free Water Conduct zero calibration using the chlorine-free water in the following procedure: Mount the electrode mechanism block to the measuring tank and turn the indicator electrode in advance. (1) Prepare chlorine-free water of approx.
  • Page 98 <7. Calibration> 7.2.3 Automatic Zero Calibration Using Chlorine-Free Water Automatic zero calibration is performed using an activated charcoal filter. The parameters should be set in following the procedure. (1) Select “execution (on)” in function code “5.”, “Automatic zero calibration function” in <PROGRAM.1>. The default setting is “stop (oFF).” (2) Set the automatic zero calibration sequence parameters in “A,”...
  • Page 99 <7. Calibration> T3 * T2 T3 * SV6 (zero water/ measurement) Output hold T1: Automatic zero calibration cycle * Zero calibration time may vary depending on T2: Automatic zero calibration preparation time calibration condition. T3: Zero calibration time (Maximum time = limit value of response time) T4: Automatic zero calibration relaxation time F7.2.3.ai Figure 7.2...
  • Page 100 <7. Calibration> NOTE • Zero filter flushing will be aborted if the mode is changed to the one other than the <MEAS.> mode during the flushing. Upon abort, the held analog output is released, and <HOLD> lamp turns off. Also, the zero filter flushing cycle timer is reset. •...
  • Page 101 First, measure residual chlorine concentration of the calibrating standard solution by manual analysis. In principle, perform measurement using amperometric titration (AT method). Note: Yokogawa employs amperometric titration for calibration. On pressing [>] key, the most significant digit of the displayed value flashes indicating that input is possible.
  • Page 102 <8. Maintenance> Maintenance This chapter describes inspection and maintenance implemented for good operating conditions. For measures when failure occurs in operations and others, see Chapter 9. 8.1 Inspection/Maintenance Items and Intervals Main inspection and maintenance items and recommended intervals to keep the analyzer in good operating condition, are shown. Tables 8.1 and 8.2 show recommended intervals for inspection and maintenance of limited life components. Recommended intervals shown in Table 8.1 is set from the preventive point of view and there is no guarantee against failure.
  • Page 103 <8. Maintenance> 8.4 Glass Beads and Measuring Tank Cleaning If the glass beads are contaminated, polishing effect is reduced and the indicator electrode is likely to be contaminated. Periodically clean the glass beads. At the same time, clean the measuring tank. Conduct cleaning in the following procedure: (1) Press [CELL] key in <MAINT.>...
  • Page 104 <8. Maintenance> 8.5 Calibration It is recommended that calibration be conducted every month. When the indicator electrode has been polished or operation is restarted after being stopped for a long period of time, calibrate zero point and span in the procedure described in Chapter 7. 8.6 Metering Pump Driving Section Oiling Oil only the lever support block bearing parts shown in Figure 8.1.
  • Page 105 <8. Maintenance> Metering pump mounting screws (4 screws) Valve assembly Pump mounting plate Pump main body O-ring “Bellofram” Piston Transparent plate mounting screws Ring Retainer Transparent plate Retainer mounting screw F8.2.ai Figure 8.2 Metering Pump Construction 8.7.1 “Bellofram” Replacement Perform “Bellofram” replacement work using the following procedure: (1) Press [PUMP] key to stop metering pump operation.
  • Page 106 <8. Maintenance> 8.7.2 Valve Sheet Replacement Perform replacement work in the following procedure: (1) Remove the metering pump with the mounting plate. First, press [PUMP] key to stop metering pump operation. Next, disconnect the tubing connected to the sample water metering pump delivery joint and the tubing connected to the reagent metering pump suction and delivery joints.
  • Page 107 (4) When the flow rate in the predetermined range is obtained, confirm that the lock nut is fully tightened and then restart operation. 8.9 Inspection and Maintenance of Sand Filters The inspection and maintenance of sand filters are required when the RC400G-2 or RC400G-3 residual chlorine analyzer is used. Follow the procedures below. 8.9.1 Inspection of Sand Filter Surface Check the surface of sand filter for the formation of mud balls.
  • Page 108 Sand Replacement Procedure (see Figure 8.6) (1) Close the sample water valve(s) and cleaning water valve to stop supplying sample water and cleaning water. RC400G-2: Sample water valve V3, cleaning water valve V4 RC400G-3: Sample water valves V3 and V4, cleaning water valve V6 (2) Remove the top cover on the sand filter and remove the sand from the sand filter by hand or using a container.
  • Page 109 <8. Maintenance> Sample Water Inlet Filter Cylinder Overflow Outlet Filter Sand O-ring Set Screws (4) Filtrate Outlet Fixing Screws (4) Cleaning Water Inlet F8.6.ai Figure 8.6 Inspection and Maintenance of Sand Filter 8.10 Inspection of Electrode Mechanism Block and Replacement of Damaged Parts Parts used in the detector’s electrode mechanism block, such as a motor assembly and rotating shaft assembly, have a limited service life.
  • Page 110 <8. Maintenance> 8.10.1 Check/Maintenance/Replacement of Rotating contact CAUTION Never touch Rotating contact except when replacement is performed. When you hold Rotating contact, pinch it with two fingers and never touch the center contact part. Never drop it or gives a shock. Contact part CAUTION The storage limit for Rotating contact is 1 year after the purchase, considering degradation of the lubricant used inside.
  • Page 111 8-10 <8. Maintenance> (2) Remove the two pulleys of the drive shaft (cell motor shaft) and driven shaft (indicator electrode-mounting shaft). The driven shaft pulley can be removed by inserting a 2 mm nominal size Allen wrench (accessory) into the hole in the shaft, which is used as a lock, and unscrewing the end of the driven shaft.
  • Page 112 Steps (1) to (9) are a disassembly procedure and steps (10) and the following steps are an assembly procedure. (1) Shut off the power fed to the RC400G, then place the electrode mechanism block in the maintenance position then remove the cover (see Figure 4.7).
  • Page 113 8-12 <8. Maintenance> NOTE It is recommended that an O-ring (P/N Y9115XB) be replaced after 3 years even if no damage has occurred. Step (8) and the following steps are an assembly procedure. Keep the following in mind when assembling the driven shaft assembly. •...
  • Page 114 (15) Remount counter electrode, reconnect wiring in place, and fix clamp. This completes the replacement procedure. Feed power to RC400G. Check that the drive shaft/drive belt/driven shaft rotates smoothly and there is no abnormal noise like vibration or intermittent sound.
  • Page 115 8-14 <8. Maintenance> 8.10.5 Replacement of Activated Charcoal Filter Stop supplying sample water by closing the main valve. 1. Remove the filter case by turning it in the direction shown below. 2. Clean the inside of the case with a brush or appropriate tool. 3.
  • Page 116 <9. Troubleshooting> Troubleshooting Routine maintenance work for keeping good operating conduction was described in Section 8. Maintenance work for failures is described in this section. Failure conditions are divided into the following three patterns: (1) Only error messages are indicated in the operations of calibration, plateau characteristics collection or data setup. (2) On <failure> detection, <FAIL> lamp is lit and <failure> contact signal is sent. (3) <failure> is not detected, but normal measurement is hampered. 9.1 When <failure> is Indicated. 9.1.1 Indication of Error Message or Error Code During Operation Types of <failure> during operation and respective error messages/error codes are listed in Table 9.1. Except for “Err16” and “Err17”, these <failure>s are indicated only by error messages or error codes, without accompanying <FAIL>...
  • Page 117 <9. Troubleshooting> Start Confirmation Method Disposition Check <PUMP> Is pump ON? Turn on the pump by pressing [PUMP] key. lamp is lit. (<PUMP> lamp is lit.) Check with a tester that setup voltage is imposed between the Is terminal The relay in the converter may be defective. connecting terminals voltage normal? If defective, replace the relay.
  • Page 118 <9. Troubleshooting> (4) Error code “Err22” (sensitivity failure): Conduct inspection following the inspection flow chart shown in Figure 9.2. Start Confirmation Method Disposition Confirm that the calibration standard Is span setpoint solution concentration Set the span again, and recalibrate the correct? is in the allowable analyzer.
  • Page 119 <9. Troubleshooting> (5) Error code “Err23” (response failure): Reset the response failure detection limit at a larger value (referring to subsection 5.3.4 (4)), and recalibrate the analyzer. If error is still displayed after changing the limit value, confirm the applied voltage. Measure the voltage between the connecting terminals ME and RE with a voltmeter of input resistance 1 MΩ...
  • Page 120 <9. Troubleshooting> Start Confirmation Method Disposition Confirm sample temperature display with sample temperature function code “2” in Other failures should be considered (the display <MEAS.>. indicator electrode failure, etc.). normal? Disconnect the terminals T1 and T2 of the converter, and measure Is the resistance of the wiring.
  • Page 121 (b) Check the metering pump operation following the inspection flow of Figure 9.1. (c) For the RC400G-3 analyzers for treated water, check the operation of the solenoid valves (SV3 and SV4). Check if the solenoid valves function by operating [SV3] and [SV4] keys in <MEAS.>...
  • Page 122 As setting except for the setup of calibration factor must be made in “service mode”, contact Yokogawa when the <failure> described above has occurred. (a) Once turn the converter power OFF.
  • Page 123 <9. Troubleshooting> “Err25” <failure> therefore serves as a common “upper limit alarm”. However, <failure> output is not reset even when chlorine concentration reduces below the set value. Reset the display by the error resetting operation (see subsection 5.3.3 (9)). (7) Error code “Err16” or “Err17” (Converter failure) <failure>...
  • Page 124 <9. Troubleshooting> Table 9.3 Causes and Corrective Actions for Operation Failures in Measurement Symptoms Possible Causes Corrective Actions Measured 1. Reagent is not mixed with sample water. value is a. No reagent in the reagent tank. 1. a. Supply reagent to the reagent tank. abnormal. b. Reagent metering pump failure 1. b. Check delivery flow rate. If flow rate is not in specified range, adjust it.
  • Page 125 9.3.2 Cleaning is not Conducted Properly. This problem may appear when the RC400G-2 or RC400G-3 is used. When a symptom possibly caused by malfunctioning of the solenoid valve is observed, e.g. irregular cleaning of the “measuring tank/sand filter cylinder” or evidence of cleaning water mixing into sample water;...
  • Page 126 10-1 <10. Spare Parts and Consumables> 10. Spare Parts and Consumables Replacement intervals vary depending on the application. This information is for reference only. It does not guarantee any period of time stated in the table. Recommended Name Part No. Description Q'ty replacement interval JIS grade 1 acetic acid For reagent preparation (*1) COOH)
  • Page 127 10-2 <10. Spare Parts and Consumables> n Complementary Description l Reagent The reagent for free available chlorine measurement is prepared by acetic acid, sodium acetate and potassium bromide. For making 100 liter of this reagent, 1000 mL of acetic acid, 1 kg of sodium acetate and 4 kg of potassium bromide are required.
  • Page 128 10-3 <10. Spare Parts and Consumables> l “Bellofram” (L9819AA, L9819AB) “Bellofram” used in the piston sections of the metering pumps should be replaced after six- months use even if no defect has developed, as is the case with the valve sheet. “Bellofram” for the sample water metering pump and that for the reagent metering pump have different sizes.
  • Page 129 3-year operation. The replacement, in principle, should be conducted by Yokogawa. Note: It is recommended that the O-ring (P/N Y9115XB) in the electrode holder in the driven shaft assembly should also be replaced at the same time.
  • Page 130 (For 200 V AC power supply) K9087XH (For 220 V AC power supply) CMPL 12F04A01-04EN All Rights Reserved, Copyright © 2019, Yokogawa Electric Corporation. Subject to change without notice. 1st Edition : Apr. 2019 (YK) 3rd Edition : Feb. 2020 (YK)
  • Page 131 ● Model RC400G - 2 Item Part No. Description —— Converter ( see page 4 ) —— Detector ( see page 5 ) —— Metering Pump Assembly (see page 6 ) —— Sand Filter Assembly ( see page 7 ) ——...
  • Page 132 ● Model RC400G - 3 Item Part No. Description —— Converter ( see page 4 ) —— Detector ( see page 5 ) —— Metering Pump Assembly (see page 6 ) —— Sand Filter Assembly ( see page 7 ) ——...
  • Page 133 CONVERTER SV1 SV2 SV3 SV4 SV5 SV6 MEAS MABT PROGRAM 1 PROGRAM 2 DATASET > MODE MANUAL OPERATION Item Part No. Description —— Converter A1109EF Fuse ( 1 A ) A1113EF Fuse ( 3 A ) CMPL 12F04A01-04EN 3rd Edition : Feb. 2020 (YK)
  • Page 134 DETECTOR Capacitor Motor Assembly 10, 11 Capacitor 17, 18 14, 15 12, 13 Motor Item Part No. Description Item Part No. Description K9334JV Shaft Assembly L9804UK Drive Belt —— Gear Head Y9115XB O-Ring K9332JP (For 100/110 V AC power supply) L9831HC K9334VA (For 200/220 V AC power supply)
  • Page 135 METERING PUMP ASSEMBLY Item Part No. Description Item Part No. Description K9332HG Cam Assembly K9041JA Lever Assembly K9041BT Gear K9041JP Block Assembly K9041BK Bracket Assembly G9303AT O-Ring K9041DA Gear G9303AM O-Ring L9805GF Bearing K9041HC Valve Sheet K9041DF Gear Head Assembly L9819AA Bellofram (for Reagent Pump) K9041EN...
  • Page 136 (For 110 V AC power supply) K9332RY (For 200 V AC power supply) K9332RZ (For 220 V AC power supply) —— Solenoid Valve (SV1, SV2, SV5 for Model RC400G-3) K9332RS (For 100 V AC power supply) K9332RT (For 110 V AC power supply) K9332RU...
  • Page 137 ● Model RC400G/AZC with Auto Zero Calibration Option Item Part No. Description K9726EG Filter Assembly L9862AY Filter Element A1029MV Solenoid Valve CMPL 12F04A01-04EN 3rd Edition : Feb. 2020 (YK)
  • Page 138 Part No. Description K9041ZN K9725GQ Pipe K9725GY Plug G9303NV O-Ring K9725HA Needle Valve K9332XA Stand L9869FJ Pump * * : Consult with Yokogawa for the product before April, 1999. CMPL 12F04A01-11E All Rights Reserved, Copyright © 1991, Yokogawa Electric Corporation. Subject to change without notice. 5th Edition : Mar. 2013 (YK)
  • Page 140 Dec. 2019/12th Edition Revised CMPL 12F04A01-04EN to 2nd edition. Apr. 2019/11th Edition Style of RC400G changed to S4 (pages 2-5, 2-6, 4-3, 4-10, 8-1, 8-8, 8-9, 8-10, 8-12, 8-13, 9-9, 10-4) CMPL 12F04A01-04EN newly released. Aug. 2017/10th Edition Revised regarding reagents.(pages 2-2, 2-6, 4-4, 4-5, 10-1, 10-2) Corrected errors.(pages ii, 1-2, 2-1, 2-4, to 2-11, 3-1, 3-12, 3-13, 4-2, 10-1 to 10-5)
  • Page 141 Add notice for installation; P.8-12 Change the tension of cogged belt; Revise up CMPL CMPL 12F04A01-01E (8th Edition), CMPL 12F04A01-11E (4th Edition) May 2007/2nd Edition The overall review (Computerization) Dec. 1992/1st Edition Newly published n Yokogawa Electric Corporation http://www.yokogawa.com/an IM 12F4A1-01E 14th Edition : Jul. 15, 2020...

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