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Summary of Contents for Waltron 3046
- Page 1 EXPERTS IN WATER CHEMISTRY SINCE 1903 3046 Ammonia Analyzer User Manual Revision 3.04...
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Page 2: Waltron Customer Commitment
It is Waltron’s commitment to provide the customer with timely and accurate technical service and support. Waltron fully expects the customer to be satisfied with the quality, performance, and cost of this product. If there are any questions or concerns regarding this product, please feel free to contact Waltron at (908)-534-5100. -
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... -
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 8 Analyzer Shut-Down ................. 47 9 Troubleshooting ................48 10 Spare Parts ..................49 Appendix A – Panel Mount Schematics ..........50 Appendix B – Help Menu ................ 52 Appendix C – Multiple Stream Sequencer ..........62 Waltron User Manual 3046 Ammonia Analyzer...
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Page 8: List Of Figures
List of Figures LIST OF FIGURES Figure 2.1: Waltron 3046 Analyzer front view............15 Figure 2.2: Waltron 3046 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. -
Page 9: List Of Tables
LIST OF TABLES Table 1.1: List of hazards and dangers..............11 Table 1.2: List of materials used in Waltron 3046 Analyzer........12 Table 2.1: The run sequence of colorimetric determination........18 Table 3.1: Terminal block pin locations..............27 Table 5.1: User password. -
Page 10: Overview
5-55º C (41-131º F) 100–500 ml/min, atmospheric, flexible tubing O.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 3046 Ammonia Analyzer... -
Page 11: Signal Outputs
Waltron shall not be liable for errors contained herein and/or for an incorrect use of the analyzer. The department head and analyzer’s users must be sure to read and observe the following instructions and to apply all the national and local regulations and laws regarding workers health and safety. -
Page 12: Table 1.1: List Of Hazards And Dangers
Only qualified personnel fully trained on analyzer use and maintenance is allowed to proceed with service operations on the unit. Waltron User Manual 3046 Ammonia Analyzer... -
Page 13: Reagents
Overview REAGENTS 1.2.3 The Waltron 3046 Ammonia Analyzer is based on colorimetric analysis methods, using chemical solutions. For the dangers and hazards regarding the chemicals used for the analysis, refer to the appendix of the specific analytic parameter and colorimetric reaction. - Page 14 Hazard of poisoning caused by waste gas coming out from HAZARD leakages of the hydraulic parts. Preventive Actions: Install the analyzer in a location of adequate dimensions and ventilation. Hazard of electric shock and/or electrocution in the electrical HAZARD enclosure. Waltron User Manual 3046 Ammonia Analyzer...
- Page 15 Preventive Actions: Check that the source voltage to be used corresponds with that requested by the analyzer. Check periodically the power cord grounding in addition to the analyzer grounding. Waltron User Manual 3046 Ammonia Analyzer...
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Page 16: Introduction
This manual provides general information regarding the principle of operation, proper installation and operation of the Waltron 3046 Ammonia Analyzer. The Waltron 3046 is an on-line analyzer for batch-wise analysis (sequence of sampling, analysis and result processing), using colorimetric method. The analyzer is assembled in an enclosure with lockable door. -
Page 17: Applications
Introduction Electrical Box Liquids Box Figure 2.2: Waltron 3046 inside view with electrical box and liquids box shown. APPLICATIONS The application for the Waltron 3046 Analyzer is for the measurement of ammonia concentrations in high purity water. WORKING PRINCIPLE Lambert-Beer Law A colorimetric determination is based on the color-formation after addition of reagents. -
Page 18: Figure 2.3: Color Development
Light with a specific wavelength is send through the reaction mixture. The absorbance of this light by the formed 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 3046 Ammonia Analyzer... -
Page 19: Analysis Cycle
PROGRAMMING COMMANDS 2.4.1 An analysis time program in the Waltron 3046 Ammonia Analyzer has the following structure: 1. After rinsing the reaction colorimetric cell and taking a sample, one or more miscellaneous reagents, like buffer or masking agent, may be added after which a first measurement takes place (reference);... -
Page 20: Flow Diagram
Introduction FLOW DIAGRAM 2.4.2 Figure 2.4: Flow diagram ANALYZER OPERATIONS 2.4.3 The Waltron 3046 Ammonia 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 3046 Ammonia 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 3046 Ammonia Analyzer... -
Page 23: Wet-Section Box
The cell is positioned inside a thermostated block fixed with 2 screws. The block can be easily removed to allow the cleaning of the glass cell. Reagent Pumps The reagents are dosed with peristaltic pumps. The 3046 has four reagent pumps. Waltron User Manual 3046 Ammonia Analyzer... -
Page 24: Electronics
Normally-closed pinch valve to pinch or open a silicon / viton tubing O.D. ⅜ in order to close or open the 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. -
Page 25: Installation
Installation 3 INSTALLATION RECEIVING The Waltron 3046 Ammonia 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) 14.96” (380 mm) 9.76” (248 mm) Figure 3.1: The dimensions for mounting the analyzer. Waltron User Manual 3046 Ammonia Analyzer... -
Page 27: Electrical Connections
AC POWER CONNECTION 3.6.1 The Waltron 3046 Ammonia Analyzer is designed for operation with 110-220Vac, 50 Hz power. All the connections must be made in accordance with national or local regulations. The analyzer is equipped with a thermal switch (main power switch). It is always recommended that the analyzer is connected to the mains via a circuit breaker or an isolating switch installed near the unit. -
Page 28: User Signal Connections
Alarm Relay 1 NO Contacts OUT Relay 2 Alarm Relay 2 NO Contacts OUT Relay 3 Alarm Relay 3 NO Contacts OUT Relay 4 Alarm Relay 4 NO Contacts COM 3/4 Common for Relay 3 and 4 Waltron User Manual 3046 Ammonia Analyzer... -
Page 29: Reagent Information
Installation REAGENT INFORMATION The Waltron 3046 Ammonia Analyzer uses 3 reagents for the colorimetric measurement. Reagent 1: Buffer Reagent Reagent 2: Salicylate Reagent Reagent 3: Dichloroisocyanuric Acid Reagent Reagent 4: Sulphuric Acid Cleaning Reagent REAGENTS HOLDING BRACKET Use the drawing below to mount the reagents bracket below the analyzer. -
Page 30: 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 3046 Ammonia Analyzer... -
Page 31: 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 Help Menu Waltron User Manual 3046 Ammonia Analyzer... -
Page 32: Main Screen
SERVICE Second level admin password required. This menu allows access to the analysis parameter, time, blank value, and regulation of the 4-20 mA output, led, and reference. This menu shows the help user guide. Waltron User Manual 3046 Ammonia Analyzer... -
Page 33: Reagents 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 3046 Ammonia Analyzer... -
Page 34: 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 3046 Ammonia Analyzer... -
Page 35: Display Menu
Section 2.3.1) separately. The operator could decide the single operation to run (select function) and the time of the operation. This function is protected with the 1st level of password and is available only when the analyzer is in stand-by mode. Waltron User Manual 3046 Ammonia Analyzer... -
Page 36: Data Logger
Figure 5.5: Manual step functions shown in the bottom left corner. DATA LOGGER 5.6.4 From the DISPLAY menu, pressing the Data Logger button in the upper right hand corner will display the previous 500 results. Figure 5.6: Data logger screen of the user interface. Waltron User Manual 3046 Ammonia Analyzer... -
Page 37: 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 5.7.1 Figure 5.8: The SETTINGS Menu and options are displayed. Waltron User Manual 3046 Ammonia Analyzer... -
Page 38: 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 3046 Ammonia Analyzer... -
Page 39: 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 3046 Ammonia Analyzer... -
Page 40: Help Menu
The internal HELP Menu can be accessed by pressing the ? on the main display screen. The help menu has the following sub-menus that can be viewed directly from the analyzer and can also be found in Appendix B. Figure 5.10: User interface showing the topics in the HELP Menu. Waltron User Manual 3046 Ammonia Analyzer... -
Page 41: Operation
DI water to flush the system. The absorbance detected by the analyzer is assumed to be absorbance produced by reagent(s) and DI water. 4. To store this value as the blank, from the PROGRAM menu, select the CALIBRATION Waltron User Manual 3046 Ammonia Analyzer... -
Page 42: Slope (Factor) Calibration
4. When the analyzer has finished the analysis cycle, the concentration reading will be displayed on the main screen. The result can also be found in the data logger. 5. The analysis returns to standby mode and waits for another user command. Waltron User Manual 3046 Ammonia Analyzer... -
Page 43: Online Measurement
3. Disconnect the sample tubing from the fast-loop reservoir and connect it to the grab sample source. The grab sample source should have at least 200 ml of sample present. 4. Perform an analysis cycle by pressing the RUN Menu and selecting CH 1. Waltron User Manual 3046 Ammonia Analyzer... -
Page 44: Emergency Stop
5. Select RESET to deactivate the alarms and return the analyzer to the main display screen in standby mode. 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 3046 Ammonia Analyzer... -
Page 45: Maintenance
7 MAINTENANCE SCHEDULED MAINTENANCE Basic maintenance of the Waltron 3046 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
Reagents replacement (reset reagent counters) Pinch valve tubing replacement Pump tubing replacement 3 way valve and fittings cleaning Colorimetric cell O-ring replacement Hydraulics and sample tubing replacement Analyzer general inspection (for qualified personnel only) Waltron User Manual 3046 Ammonia Analyzer... -
Page 47: 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 3046 Ammonia Analyzer... -
Page 48: Analyzer Shut-Down
It is important to know that the analyzer should run continuously, if possible. For a short downtime of the 3046 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 49: Troubleshooting
3. Check reagent pump dosage 4. Check Cal Sample level 5. Verify analyzer is draining properly Measurement is greater The sample is out of range. Corrective action required. Result Alarm than the % on the Settings screen Waltron User Manual 3046 Ammonia Analyzer... -
Page 50: 10 Spare Parts
Sample Selection Block with 2 Valves (Dual Stream Unit) W3040-065 Power supply – 24 Vdc W3040-021 Touchscreen W3040-022 Preamplifier photometer board W3040-026 Electronics, Complete W3040-097 Display Cable W3040-093 Output Cable for User Connections W3040-094 Led 660 nm with connector W3040-030 Waltron User Manual 3046 Ammonia Analyzer... -
Page 51: Appendix A - Panel Mount Schematics
Appendix A – Panel Mount Schematics APPENDIX A – PANEL MOUNT SCHEMATICS Waltron User Manual 3046 Ammonia Analyzer... - Page 52 Appendix A – Panel Mount Schematics Waltron User Manual 3046 Ammonia Analyzer...
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Page 53: Appendix B - Help Menu
Appendix B – Help Menu APPENDIX B – HELP MENU Waltron User Manual 3046 Ammonia Analyzer... - Page 54 Appendix B – Help Menu Waltron User Manual 3046 Ammonia Analyzer...
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Page 63: Appendix C - Multiple Stream Sequencer
Table C.2: Multistream sequencer technical specifications. Electronics Case: Aluminum Protection Degree: IP54 or IP65 upon request Electrical Connections: Screw clamps 15.75” x 7.87” x 7.91” (400mm x 200mm x 201mm) Panel Dimensions: Weight: 8.8 lbs (4 kg) Waltron User Manual 3046 Ammonia Analyzer... -
Page 64: Figure C.1: Dimensons Of The Multistream Sequencer
Appendix C – Multiple Stream Sequencer 7.91” 7.87” (201 mm) (200 mm) 3.66” (93 mm) Figure C.1: Dimensons of the Multistream Sequencer. Waltron User Manual 3046 Ammonia Analyzer... -
Page 65: Figure C.2: Suggested Installation Layout Of The Multistream Sequencer
Drill 4 holes for M8 screws. d. Mount the sequencer on the right side of the analyzer. e. Ensure that the sequencer is mounted securely in place. Figure C.2: Suggested installation layout of the multistream sequencer. Waltron User Manual 3046 Ammonia Analyzer... -
Page 66: Figure C.3: Mounting Dimensions For Multistream Sequencer
Appendix C – Multiple Stream Sequencer Ø 5/16” N° 4 M8 5.08” (129 mm) Figure C.3: Mounting Dimensions for multistream sequencer. Waltron User Manual 3046 Ammonia Analyzer... -
Page 67: Figure C.4: Accessing The Electronic Box Of The Multistream Sequencer
1. Open the electronic box of the sequencer. 2. Connect the outputs, ensuring you get the right polarity. 3. Close the electronic box of the sequencer. Figure C.5: 4-20mA output of the multistream sequencer. Waltron User Manual 3046 Ammonia Analyzer... -
Page 68: Figure C.5: Multistream Sequencer Hydraulic Connections
1. Connect the sample line inlet tubing to the sampling valves manifold according to the labels. 2. Connect the drain of the fast-loop reservoir to the waste line. Figure C.5: Multistream sequencer hydraulic connections. Waltron User Manual 3046 Ammonia Analyzer... -
Page 69: Figure C.6: Multistream Sequencer Main Page Of The User Interface
This function should be used with the analyzer in stand-by mode. The CH1, CH2, CH3, and CH4 buttons will be enabled after login with the admin password. These buttons allow the user to enable or disable each channel. Waltron User Manual 3046 Ammonia Analyzer... -
Page 70: Figure C.7: Multistream Sequencer Run Menu Of The User Interface
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 3046 Ammonia Analyzer...