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Summary of Contents for Waltron 3041
- Page 1 EXPERTS IN WATER CHEMISTRY SINCE 1903 3041 Silica Analyzer User Manual 101-016-B.3...
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Page 2: Waltron Customer Commitment
Waltron fully expects the customer to be satisfied with the quality and performance of this product. If there are any questions or concerns regarding this product, please feel free to contact Waltron at (908)-534-5100. Thank you for choosing Waltron! Please note the Waltron mailing and shipping address: Waltron Bull &... -
Page 3: Safety
Follow all regulations and warning labels when disposing of chemicals. Do not mix chemicals. To obtain analyzer safety information or Safety Data Sheets (SDS), please contact Waltron or visit the website at www.waltron.net Waltron User Manual 101-016-B.3... -
Page 4: Warranty Agreement
If, within one year from the date of shipment, the customer experiences any equipment defects or is not satisfied with the analyzer manufacturing, Waltron will repair, or at its option, replace any defective part(s) free of charge. This warranty requires that the defective part(s) be returned to Waltron with shipping charges prepaid. -
Page 5: Checklist Of Materials
Checklist of Materials CHECKLIST OF MATERIALS In order to ensure customer satisfaction, Waltron does its best to provide adequate and timely packaging and shipping services. Please perform the following after receiving a shipment: Inspect all shipping containers upon receipt and record any visible damage. If there are any outward signs of damage, please retain all containers and packages for inspection by carrier. -
Page 6: Table Of Contents
Table of Contents TABLE OF CONTENTS Waltron Customer Commitment .............. 1 Safety ......................2 Warranty Agreement ................. 3 Checklist of Materials ................4 Table of Contents ..................5 List of Figures ................... 7 List of Tables ..................... 8 1 Overview ....................9 Specifications ....................... - Page 7 Drain Pinch Valve Tubing Replacement ..............47 Reagent Pump Tubing Replacement ................47 8 Analyzer Shut-Down ................. 49 9 Troubleshooting ................50 10 Spare Parts ..................51 Appendix A – Panel Mount Schematics ..........53 Waltron User Manual 101-016-B.3 3041 Silica Analyzer...
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Page 8: List Of Figures
List of Figures LIST OF FIGURES Figure 2.1: Waltron 3041 Analyzer front view...............15 Figure 2.2: Waltron 3041 inside view with electrical box and liquids box shown.....16 Figure 2.3: Color development....................17 Figure 2.4: Flow diagram ......................19 Figure 2.5: Depiction of the fast-loop reservoir..............20 Figure 2.6: Mounting dimensions for the fast loop reservoir. -
Page 9: List Of Tables
List of Tables LIST OF TABLES Table 1.1: List of hazards and dangers.................11 Table 1.2: List of materials used in Waltron 3041 Analyzer..........12 Table 2.1: The run sequence of colorimetric determination..........18 Table 3.1: Terminal block pin locations.................28 Table 5.1: User password. -
Page 10: Overview
100–500 ml/min, atmospheric, flexible tubing I.D. ¼” (6 mm) Inlet Sample: Atmospheric, waste tubing O.D. 3/8” (9 mm) Outlet Sample: Turbidity: Not applicable, sample blank correction Color: Not applicable, sample blank correction 3-12 Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 11: Signal Outputs
1.2.1 This manual contains important information which is required for installation, start up and operation of the Waltron 3041 Silica Analyzer. Please read this manual carefully before installing and placing the analyzer into service! Pay attention to all caution and danger labels present on the analyzer and all caution and danger statements written on this manual. -
Page 12: List Of Warnings And Potential Dangers
Specific indication depending on the parameter analyzed and · fluidics section the chemical colorimetric method used. · reagent container Warning of general hazard Indication of general hazards or warnings to follow during installation, operation, or maintenance. Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 13: Reagents
Overview REAGENTS 1.2.3 The Waltron 3041 Silica Analyzer operates based on standard colorimetric analysis methods, using chemical solutions. For the dangers and hazards regarding the chemicals used for the analysis, refer to the appendix or the supplied SDS sheets. - Page 14 Wear eye protection, gloves, mask and clothing if necessary. Hazardous fumes may be generated in the event of leaks in HAZARD the reagent tubing. Preventive Actions: Install the analyzer in anadequately ventilated area. Waltron User Manual 101-016-B.3 3041 Silica Analyzer...
- Page 15 Preventive Actions: Check that the source voltage to be used corresponds with that requested by the analyzer. Periodically check the power cord grounding in addition to the analyzer grounding. Waltron User Manual 101-016-B.3 3041 Silica Analyzer...
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Page 16: Introduction
2 INTRODUCTION ANALYZER DESCRIPTION The Waltron 3041 is an on-line analyzer for batch analysis (sequence of sampling, analysis and result processing), using a colorimetric method. The analyzer is assembled in an enclosure with a lockable door. The LIQUIDS enclosure includes all the components involved in sample and reagent flows as well as mixing and reaction stages (sampling pump, colorimetric reaction cell, reagent micropumps). -
Page 17: Applications
Electrical Box Liquids Box Figure 2.2: Waltron 3041 inside view with electrical box and liquids box shown. APPLICATIONS The Waltron 3041 Analyzer is designed for measurement of silica concentrations in high purity water. WORKING PRINCIPLE Lambert-Beer Law A colorimetric determination is based on the color-formation after addition of reagents. The absorbance of the solution is measured at a specific wavelength. -
Page 18: Figure 2.3: Color Development
Light with a specific wavelength is passed through the sample and reagent solution. . The absorbance of this light by the reaction complex, measured by a photometer, is related to the concentration of the analyte. reference Absorbance log sensor reading Figure 2.3: Color development. Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 19: Analysis Cycle
PROGRAMMING COMMANDS 2.4.1 An analysis time program in the Waltron 3041 Silica Analyzer has the following structure: 1. After rinsing the reaction colorimetric cell and taking a sample, two of the reagents (R1 and R2) are added and mixed after which a reference measurement is taken. in this way interfering factors are eliminated such as sample color or turbidity, reagent color, or refractive index variations. -
Page 20: Flow Diagram
Introduction FLOW DIAGRAM 2.4.2 Figure 2.4: Flow diagram ANALYZER OPERATIONS 2.4.3 The Waltron 3041 Silica Analyzer performs several operations throughout a cycle. A list of common operations is shown below. Rinse #1 Rinse #2 Drain Sample #1 ... -
Page 21: Fast Loop Reservoir
Sample to Air to Analyzer Overflow Stream Inlet Drain Level Switch Process Sample Inlet (behind overflow tubing) Process Sample Overflow Drain Figure 2.5: Depiction of the fast-loop reservoir. Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 22: Figure 2.6: Mounting Dimensions For The Fast Loop Reservoir
Introduction Ø 0.26” (6.5 mm) 5.24” (131 mm) 5.84” (146 mm) Figure 2.6: Mounting dimensions for the fast loop reservoir. Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 23: Wet-Section Box
Reagent Pumps The reagents are dosed with peristaltic pumps. The 3041 has three reagent pumps. Pinch Valve Normally-closed pinch valve to pinch or open the drain tubing in order to close or open the Waltron User Manual 101-016-B.3... -
Page 24: Electronics
Introduction drain of the colorimetric cell. The size and the material of the tubing is very important; use only Waltron spare parts. Mixing Pump The sample is mixed with reagents with a membrane mixing pump. The liquid is pumped from the lower part to the upper part of the colorimetric cell. -
Page 25: Installation
Installation 3 INSTALLATION RECEIVING The Waltron 3041 Silica Analyzer is assembled and fully tested for proper performance. Before proceeding with analyzer installation, it is recommended to: Check that the box and analyzer have not been damaged during transportation. ... -
Page 26: Mouting Schematics
Respect the maximum height of 16” (40 cm) between the NOTE: reagent's bottle(s) and the reagent's pump(s). MOUTING SCHEMATICS 16.22” (412 mm) 10.16” (258 mm) 9.76” (248 mm) 14.96” (380 mm) Figure 3.1: The dimensions for mounting the analyzer. Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 27: Figure 3.2: Reccomended Complete System Installation
Installation Figure 3.2: Reccomended complete system installation. Note: Single channel analyzers will only have one Fast Loop Reservoir. Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 28: Electrical Connections
AC POWER CONNECTION 3.6.1 The Waltron 3041 Silica Analyzer is designed for operation with 110-220Vac, 50/60 Hz power. All the connections must be made in accordance with national or local regulations. The analyzer is equipped with a main power switch. It is always recommended that the analyzer is connected to the main via a circuit breaker or an isolating switch installed near the unit. -
Page 29: User Signal Connections
Alarm Relay 1 N/O Contacts OUT Relay 2 Alarm Relay 2 N/O Contacts OUT Relay 3 Alarm Relay 3 N/O Contacts OUT Relay 4 Alarm Relay 4 N/O Contacts COM 3/4 Common for Relay 3 and 4 Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 30: Reagent Information
Installation REAGENT INFORMATION The Waltron 3041 Silica Analyzer uses 3 reagents for the colorimetric measurement. Reagent 1: Molybdate Reagent Reagent 2: Oxalic Reagent Reagent 3: Reducing Reagent REAGENT HOLDING BRACKET Use the drawing below to mount the reagent bracket below the analyzer. -
Page 31: Analyzer Initial Start-Up
7. Turn the analyzer on using the switch in the electronics compartment 8. Perform reagents prime (see Section 6.1) 9. Perform calibration (see Section 6.2 & 6.3) 10. Set the analyzer to online mode (see Section 6.5) Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 32: User Interface
Program Menu – Analysis Display Menu – Manual Step Main Menu Cycle Display Menu – Display Program Menu – Calibration Program Menu – Extra process values Menu Cycle Program Menu – Settings Service Menu Data Log Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 33: Main Screen
Second level admin password required. This menu allows access to the analysis parameter, time, blank value, and configuration of the 4-20 mA output, led light source, and reference value. DATA LOG This menu shows the data log. Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 34: Reagent Refill
Every time the reagents are refilled, it is necessary to reset the value to 100%. 1. Press on the value % of each displayed reagent. 2. Bottle Reag. 1,2,3 Filled? YES. Figure 5.2: User interface screen for Reagents Refill. Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 35: Run Menu
“manual stop” red coloured and the FAULT alarm contact will be activated. To restart the analyzer after an emergency stop, it is necessary to reset the fault by pressing the yellow colored RESET EM. STOP. This will force the analyzer to stand-by conditions. Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 36: Display Menu
Section 2.4.1) individually. The operator can determine which single operation to run (select function) and the elapsed time for the operation in seconds. This function is available only when the analyzer is in stand-by mode. Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 37: Data Logger
5. A status circle should appear. After the button has been held down for a few seconds, the status circle will dissapear, indicating that the results have been downloaded. 6. Remove the USB memory stick from the touchscreen. Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 38: Program Menu
This function is protected with the 1st level of password. Allows the user to set the value of the standard used for calibration and to perform blank and calibration cycles. SETTINGS MENU 5.8.1 Figure 5.8: The SETTINGS Menu and options are displayed. Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 39: Calibration Menu
Allows the user to display and set the value of the standard used for calibration and perform manual blank and calibration cycles (refer to Section 6). Figure 5.9: User interface at the CALIBRATION Menu. Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 40: Service Menu
GO to the Display screen and press the Manual button. Scroll through the options and select Relay #1. Set the activation duration and press ON. The Relay #1 contacts will close for the designated duration. Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 41: Operation
3. Perform an analysis cycle by pressing the RUN Menu and selecting CH 1. It is recommended to proceed with a blank refreshment after performing three analysis cycles with DI water to flush the system. Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 42: Slope (Factor) Calibration
1. Connect the sample tubing to the fast-loop reservoir and turn on sample flow to the fast Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 43: Online Measurement
The grab sample feature allows the user to measure the concentration of an external sample. When starting the analyzer for the first time or restarting it NOTE: from any period of shutdown, do not proceed to run a grab sample analysis until a calibration has been performed. Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 44: Emergency Stop
After initiating an emergency stop, there may be sample and NOTE: reagents remaining in the analyzer. It will be necessary to flush the system before performing a new analysis cycle. Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 45: Maintenance
7 MAINTENANCE SCHEDULED MAINTENANCE Basic maintenance of the Waltron 3041 Analyzer requires that the reagent containers are refilled or replaced and that the colorimetric cell is cleaned on a regular basis. In addition, the user should perform a regular 'visual overall-check' of the wet part for immediate corrective measures, e.g. -
Page 46: Table 7.1: Scheduled Manintenance Reference Chart
Reagent straw and sample tubing replacement Analyzer general inspection (for qualified personnel only) Waltron provides all of the tubing and fittings required for scheduled maintenance as part of the yearly consumables kit, part number W3040-101. Table 7.1: Scheduled manintenance reference chart. -
Page 47: Sample Pump Tubing Replacement
11. Secure the four wing nuts by finger tightening until they have a firm mounting of the pump head 12. Restart the analyzer Figure 7.1: Pump tubing replacement. Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 48: Drain Pinch Valve Tubing Replacement
4. Disconnect the reagent pump tubing from the reagent straw tubing and the flowcell cap tubing and discard. 5. Check pump rollers for signs of excessive wear and replace if neccessary. The rollers Waltron User Manual 101-016-B.3 3041 Silica Analyzer... - Page 49 60 second command. 13. Repeat steps 2-12 for each remaining reagent pump. Waltron User Manual 101-016-B.3 3041 Silica Analyzer...
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Page 50: Analyzer Shut-Down
It is important to know that the analyzer should run continuously, if possible. For a short downtime of the 3041 analyzer (from 1 to 3 days), it is recommended to put all the inlet tubing (reagents and sample source) in a DI water source and leave the unit running in these conditions. -
Page 51: Troubleshooting
3. Check reagent pump dosage 4. Check Cal Sample level 5. Verify analyzer is draining properly The sample is out of range. Corrective Measurement is greater action required. Result Alarm than the % on the Settings screen Waltron User Manual 101-016-B.3 3041 Silica Analyzer... -
Page 52: 10 Spare Parts
Sample Selection Block with 1 Valve (Single Stream Unit) W3040-064 Sample Selection Block with 2 Valves (Dual Stream Unit) W3040-065 Power supply – 24 Vdc W3040-021 Touchscreen W3040-022A Preamplifier photometer board W3040-026 Led 850 nm W3040-331 Electronics, Complete W3040-097 Waltron User Manual 101-016-B.3 3041 Silica Analyzer... - Page 53 Spare Parts Display Cable W3040-093 Output Cable for User Connections W3040-094 Waltron User Manual 101-016-B.3 3041 Silica Analyzer...
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Page 54: Appendix A - Panel Mount Schematics
Appendix A – Panel Mount Schematics APPENDIX A – PANEL MOUNT SCHEMATICS Waltron User Manual 101-016-B.3 3041 Silica Analyzer... - Page 55 Appendix A – Panel Mount Schematics Waltron User Manual 101-016-B.3 3041 Silica Analyzer...