TOA-DKK ALF-1600 Instruction Manual
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TOA-DKK ALF-1600 Instruction Manual

Alkalinity analyzer
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No. ALF-IB50604E
ALKALINITY ANALYZER
Please keep this instruction manual close at hand of the persons who are in charge of
the operation of this product.
Before operating this product, please read this instruction manual carefully for its
correct handling.
MODEL ALF-1600

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Summary of Contents for TOA-DKK ALF-1600

  • Page 1 ALKALINITY ANALYZER MODEL ALF-1600 Please keep this instruction manual close at hand of the persons who are in charge of the operation of this product. Before operating this product, please read this instruction manual carefully for its correct handling. No. ALF-IB50604E...
  • Page 2 Introduction Introduction (a) Thank you for your purchase of the Model ALF-1600 Alkalinity Analyzer (hereinafter called the analyzer or product). The analyzer measures the alkalinity of raw water for water supply and purified water. It has two measurement systems; continuous and intermittent (batch measurement at a minimum 1 hour interval).

  • Page 3: Safety Information

    Model: ALF-1600 Safety Information Safety Information (1) Meaning of markings Meaning of signal terms and symbols used in notations of warning in the instruction manual is described below. In addition, the alert symbol ( : General caution symbol) used on a product label, etc.

  • Page 4: Notes On Use Of The Instruction Manual

    Model: ALF-1600 Safety Information Hazardous substances Wear protective gear when handling the chemicals or the solutions which are prepared based on it. Also always check the Material Safety Data Sheet (MSDS). Disassembly and Modification Do not disassemble or modify the sections of the product that are not described in the instruction manual.

  • Page 5: Warranty

    Model: ALF-1600 Warranty Warranty (1) Warranty Coverage DKK-TOA Corporation (DKK-TOA) warrants its products against defective material or workmanship for the warranty period. (a) The warranty period is one year from the date of delivery to the original user. If the date of delivery cannot be specified, the warranty period is 24 months from the month following the date of manufacture shown on the product nameplate.

  • Page 6: Reading Guide

    Model: ALF-1600 Reading Guide Reading Guide Refer to the necessary sections of this instruction manual depending on your purposes such as understanding the outline of this product or starting the product as shown below. The numbers in circles indicate sections to be referred to in sequential order.

  • Page 7: Table Of Contents

    Model: ALF-1600 Table of Contents Table of Contents ●Introduction ················································································································· 1 ●Safety Information ································································································ 2 (1) Meaning of markings ⋅⋅⋅⋅ 2 (2) Safety compliance items ⋅⋅⋅⋅ 2 (3) Notes on use of the instruction manual ⋅⋅⋅⋅ 3 ●Warranty ························································································································ 4 ●Reading Guide...
  • Page 8 Model: ALF-1600 Table of Contents (2) Span calibration 2 ⋅⋅⋅⋅ 31 4.4 Automatic Span Calibration ···················································································· 34 4.5 Calibration Solution Measurement ········································································· 36 4.6 Flow Control············································································································· 39 Modes of Operations ··················································································· 41 5.1 Modes and Operation Map ····················································································· 41 (1) Mode switching ⋅⋅⋅⋅ 41 (2) LCD high contrast ⋅⋅⋅⋅...
  • Page 9 Model: ALF-1600 Table of Contents Maintenance ········································································································ 79 6.1 Maintenance List ····································································································· 79 6.2 Accessories and Spare Parts ················································································· 81 6.3 Removing the Electrodes ························································································ 85 6.4 Cleaning the Glass Electrode ················································································· 87 6.5 Filling with the Reference Electrode Internal Solution ·········································· 88 6.6 Replacing the Reference Electrode Ceramic ························································...
  • Page 10 Model: ALF-1600 Table of Contents (2) Outdoor installation and an installation in cold climates ⋅⋅⋅⋅ 124 (3) Installation particulars ⋅⋅⋅⋅ 124 9.2 Piping ······················································································································ 127 (1) Sample water piping ⋅⋅⋅⋅ 127 (2) Drain piping ⋅⋅⋅⋅ 127 (3) Wash water piping ⋅⋅⋅⋅ 127 9.3 Wiring ······················································································································...

  • Page 11: Composition

    Model: ALF-1600 1. Composition Composition (1) Names Calibration solution tank Transmitter Detection section cover Regulating tank Flow cell Standard Specifications - 10 -...
  • Page 12 Model: ALF-1600 1. Composition Operation panel Display panel Escape key Standby key Calibration key Up key Down key Data key Read key Enter/Lock key Transmitter - 11 -...

  • Page 13: Operation Keys And Screen Display

    Model: ALF-1600 1. Composition (2) Operation keys and screen display Operation Key Functions Operation key (Notation in the text) Function Measure/Standby key Switches to the maintenance mode when this key is pressed for 4 seconds or more in the measurement mode.
  • Page 14 Model: ALF-1600 1. Composition 〔NOTE〕 ＞＞ 5.1(1) “Mode switching” About modes and screen groups ＞＞ 5.1(4) “Operation map” About screen composition and switching Key Lock display LCD high contrast display Flow control display Time display Error display Measurement item display...

  • Page 15: Preparation For Operation

    Model: ALF-1600 2.1 Preparing the Reagent Solution 2. Preparation for Operation 2.1 Preparing the Reagent Solution Hazardous substances Wear protective gear when handling the Extra pure grade anhydrous sodium sulfate used for preparing the reagent. Also always check the Material Safety Data Sheet (MSDS).

  • Page 16: Amount Of Reagent 30L

    Model: ALF-1600 2.1 Preparing the Reagent Solution 【IMPORTANT】 A float switch and suction tube are attached to the cover. Do not get them dirty. ④ Wash the tank A. Discard the reagent remaining in tank A and wash tank A with ion exchange water.
  • Page 17 Model: ALF-1600 2.1 Preparing the Reagent Solution 【IMPORTANT】 When reagent was prepared, always perform zero and span calibration. ＞＞ 4. “Calibration”. When changing the reagent solution, turn off the analyzer power or place the analyzer into the maintenance mode. We recommend that a spare tank A be provided. The replacement time can be shortened by preparing the reagent in the spare tank A and replacing the cover of empty tank A.

  • Page 18: Removing The Electrode Caps

    Model: ALF-1600 2.2 Removing the Electrode Caps 2.2 Removing the Electrode Caps To prevent damage during transportation, a rubber cap is attached to the glass electrode and reference electrode. Remove these caps by the following procedure: Stir motor Fixing plate...

  • Page 19: Preparing The Calibration Solution Tank

    Model: ALF-1600 2.3 Preparing the Calibration Solution Tank 2.3 Preparing the Calibration Solution Tank Before starting operation, connect the empty calibration solution tank (hereinafter referred to as tank B) to the analyzer. Before performing manual calibration, fill tank B with zero or span calibration solution.

  • Page 20: Operation

    Model: ALF-1600 3.1 Starting Operation 3. Operation 3.1 Starting Operation ① Check the installation work. Make sure that the installation work (installation, piping, wiring and power) is completed. ＞＞ 8.1 “Specifications”, 9. “Installation”, “Specification for delivery” ② Make the operation preparations.
  • Page 21 Model: ALF-1600 3.1 Starting Operation Electric Shock Do not touch the terminals inside the product while power is applied. Touching the terminals may cause electric shock. Power switch (Top: For transmitter) Power switch (Bottom: For detection section) Position of Power Switches Measurement Mode Screen ⑤...

  • Page 22: Checking The Wash Operation

    Model: ALF-1600 3.2 Checking the Wash Operation 3.2 Checking the Wash Operation (when automatic wash function is provided) Check the wash operation at the start of operation by the following procedure: ＞＞ 8.2(3) “Measurement system with wash” ① Check valve BV4.
  • Page 23 Model: ALF-1600 3.2 Checking the Wash Operation LOCK Blinks ⑤ Open valve BV4 little by little. 【IMPORTANT】 When passing the wash water for the first time, always open valve BV4 little by little. If valve BV4 is opened fully at one stroke, washing water may spurt from the open-to-air port (overflow) of the regulating tank.

  • Page 24: Stopping And Restarting Operation

    Model: ALF-1600 3.3 Stopping and Restarting Operation 3.3 Stopping and Restarting Operation (1) Stopping operation ① Start washing. To wash the sample water piping, start the wash function (when the wash function is provided). ＞＞ 3.2 “Checking the Wash Operation (when automatic wash function is provided)”...

  • Page 25: Calibration

    Model: ALF-1600 4.1 Preparing the Calibration Solution 4. Calibration At the start of operation and after the electrodes have been washed, perform warm-up operation for 1 hour or more for the sensing electrode to stabilize. Furthermore, perform zero and span calibration after the indication stabilizes.

  • Page 26: Zero Calibration

    Model: ALF-1600 4.2 Zero Calibration 4.2 Zero Calibration (a) Perform zero calibration using the zero calibration solution. (b) Fill tank B with ion exchange water. ＞＞ 4.1(1) “Zero calibration solution” ① Install tank B. Install tank B prepared at (b) to the frame. Check the tube connection and open valve BV3 (for calibration solution).
  • Page 27 Model: ALF-1600 4.2 Zero Calibration ④ Start the calibration. Press After operation, the following are displayed on the bottom display: Bottom display： “ZERO CAL START” → “STABLE ON” LOCK ⑤ Check stability check. Press After operation, the cursor blinks at “ON”.
  • Page 28 Model: ALF-1600 4.2 Zero Calibration LOCK <When "STABLE ON"> LOCK <When "STABLE OFF"> ⑦ Check the indication. Check the stability of the indication and press 〔NOTE〕 was pressed is calculated and the screen of step ⑧ • The calibration value when appears.

  • Page 29: Span Calibration

    Model: ALF-1600 4.3 Span Calibration 4.3 Span Calibration (a) There are 2 methods of span calibration. Select the method according to the conditions. Span calibration 1 (by sample water) • • Span calibration 2 (by calibration solution) (b) Always perform span calibration after zero calibration.
  • Page 30 Model: ALF-1600 4.3 Span Calibration DATA Cursor blinks ⑤ Enter the concentration. Enter the sample water concentration using the following operation and press Numeric change Digit change After operation, the following are displayed on the bottom display: Bottom display: “CAL SAMPLE ***.* mg/L” → “STABLE ON”...
  • Page 31 Model: ALF-1600 4.3 Span Calibration “STABLE ON” → “WAITING FOR START” → Bottom display: “ON” ” → Go to step ⑨. “MANUAL SPAN CAL ”STABLE OFF” → “WAITING FOR START” → “OFF” “CAL OK?” → Go to step ⑧. LOCK <When "STABLE ON">...

  • Page 32: Span Calibration 2

    Model: ALF-1600 4.3 Span Calibration (2) Span calibration 2 (SPAN CAL) (a) Span calibration 2 sets the analyzer indication to the concentration of the calibration solution. (b) Pour the span calibration solution into tank B. ＞＞ 4.1(2) “Preparing the span calibration solution”...
  • Page 33 Model: ALF-1600 4.3 Span Calibration Bottom display: “SPAN CAL **.* mg/L” → “STABLE ON” LOCK ⑥ Select stability check. Press After operation, the cursor blinks at “ON”. DATA Cursor blinks ⑦ Confirm stability check. Select stability check on/off and press On/off change “ON”...
  • Page 34 Model: ALF-1600 4.3 Span Calibration LOCK <When "STABLE ON"> LOCK <When "STABLE OFF"> ⑧ Check the indication. Check that the indication is stable and press The calibration value when this key was pressed is calculated and the calibration operation ends.

  • Page 35: Automatic Span Calibration

    Model: ALF-1600 4.4 Automatic Span Calibration 4.4 Automatic Span Calibration (a) “Automatic span calibration” is the span calibration performed by switching the flow path at a period set beforehand and automatically flowing the span calibration solution. (b) Here automatic span calibration can perform only 1 process.
  • Page 36 Model: ALF-1600 4.4 Automatic Span Calibration After operation, the following are displayed on the bottom display: Bottom display: “AUTO SPAN CAL START” → “AUTO SPAN CAL...” (blinking) → step ⑥ LOCK ⑥ Check that calibration is finished. Check that the display changed to the following screen.

  • Page 37: Calibration Solution Measurement

    Model: ALF-1600 4.5 Calibration Solution Measurement 4.5 Calibration Solution Measurement After zero and span calibration, flow the calibration solution and check the analyzer indication. ① Install the calibration solution tank. After installing the prepared calibration solution tank to the frame and checking the tube connection, open valve BV3 (for calibration solution).
  • Page 38 Model: ALF-1600 4.5 Calibration Solution Measurement Calibration solution indicator (blinks) LOCK ⑥ Check the indication. Check the indication value of analyzer. If the calibration mode is set to the maintenance mode by pressing on this screen, the parameters (electrode voltage value, etc.) can be checked.
  • Page 39 Model: ALF-1600 4.5 Calibration Solution Measurement At this time the solenoid valve will make a switching sound. LOCK ⑩ Select the maintenance mode. Press ⑪ Return to the measurement mode. Press for 4 seconds or more. - 38 -...

  • Page 40: Flow Control

    Model: ALF-1600 4.6 Flow Control 4.6 Flow Control In the measurement mode flow control is performed every 4 hours. Manual flow control operation can be checked here. ① Select the calibration mode. ＞＞ Step ② of 4.2 “Zero Calibration” ② Select the bottom display to “FLOW CONTROL START”.
  • Page 41 Model: ALF-1600 4.6 Flow Control ⑤ Confirm that the flow control is finished. Check that the display changed to the following screen. When wash is provided, the bottom display changes into “WASH START”. ⑥Select the maintenance mode. Press ⑦ Return to the measurement mode.

  • Page 42: Modes Of Operations

    Model: ALF-1600 5.1 Modes and Operation Map 5. Modes of Operations 5.1 Modes and Operation Map (1) Mode switching (a) The mode can be switched from the “measurement mode” to the “maintenance mode”, “setting mode”, or “calibration mode” by the key operations shown in the figure below.

  • Page 43: Lcd High Contrast

    Model: ALF-1600 5.1 Modes and Operation Map (c) In the “maintenance mode”, “setting mode”, and “calibration mode”, the measured value output is in the form (fixed value hold) automatically set by output type. ＞＞ 5.3(18) “Output type” (d) In the “maintenance mode”, “setting mode”, and “calibration mode”, alarm output is released.

  • Page 44: Key Lock

    Model: ALF-1600 5.1 Modes and Operation Map (3) Key lock When is pressed for 4 seconds or more in the “measurement mode” or “maintenance mode”, the operation keys are locked. Operation Procedure Procedure Operation Remarks ① Check if the analyzer is in the Check the mode.

  • Page 45: Operation Map

    Model: ALF-1600 5.1 Modes and Operation Map (4) Operation map [Measurement mode] and ＞＞｢5.2｣ <Screen after power [Measurement mode (MEAS)] [Maintenance mode] common items is turned on *3> ●Check the set values and other settings ・Range (M RANGE [N] 0-X) * ・Range 1 (RANGE [1])

  • Page 46: Measurement Mode Operation

    Model: ALF-1600 5.2 Measurement Mode Operation 5.2 Measurement Mode Operation (MEAS) In the “measurement mode”, the alkalinity concentration measured value (hereinafter called “alkalinity concentration”) and each set value can be checked. 〔NOTE〕 This operation can also be performed similarly in the maintenance mode.
  • Page 47 Model: ALF-1600 5.2 Measurement Mode Operation (Continued from previous page) Procedure Operation Remarks ⑦ Intermittent measurement Bottom display: “ITMC interval INTERVAL” When intermittent measurement mode was selected ⑧ Intermittent measurement start Bottom display: “ITMC TIME” time When intermittent measurement mode is selected ⑨...
  • Page 48 Model: ALF-1600 5.2 Measurement Mode Operation (Continued from previous page) Procedure Operation Remarks ⑭ Electrode potential Bottom display: “EL” ⑮ Sample water flow measured Bottom display: “FLOW” value ⑯ Error check Bottom display: “ERROR” ＞＞ 7. “Troubleshooting” ⑰ Error history Bottom display: “RELEASED...

  • Page 49: Setting Mode Operation

    Model: ALF-1600 5.3 Setting Mode Operation 5.3 Setting Mode Operation In the setting mode, the various set values related to measurement can be checked and changed. (1) Measurement type (INTERMITTENCE) (a) The measurement type can be set continuous measurement or intermittent measurement.

  • Page 50: Measurement Mode Remote Switching

    Model: ALF-1600 5.3 Setting Mode Operation (2) Measurement mode remote switching (REMOTE I) (a) When intermittent measurement is selected at (1), this item is displayed. (b) Intermittent measurement/continuous measurement switching can be set to remote system here. (c) In the remote system, the analyzer enters the intermittent measurement state when the specified terminals are open and the continuous measurement state when specified terminals are closed.

  • Page 51: Intermittent Measurement Interval

    Model: ALF-1600 5.3 Setting Mode Operation (3) Intermittent measurement interval (ITMC INTERVAL) (a) The intermittent measurement interval can be set. However, when set to 1h, the automatic calibration function is disabled. (b) Intermittent measurement is performed at the interval set here based on the time set at “intermittent measurement start time”...

  • Page 52: Intermittent Measurement Start Time

    Model: ALF-1600 5.3 Setting Mode Operation (4) Intermittent measurement start time (ITMC START TIME) The intermittent measurement start time can be set. Intermittent measurement is repeated at the interval set in the previous section beginning from this start time. Operation Procedure...

  • Page 53: Range Switching Type

    Model: ALF-1600 5.3 Setting Mode Operation (5) Range switching type (REMOTE R) (a) The measuring range switching type can be changed to either of the following: • Manual type ＞＞ 5.3(6) “Range” • Remote type (b) For the remote type, when between the specified terminals is “open”, range 1 (low side) is selected and when between the specified terminals is “closed”, range 2 (high side) is selected.

  • Page 54: Range

    Model: ALF-1600 5.3 Setting Mode Operation (6) Range (RANGE) (a) The range can be set to either 0 to 50mg/L or 0 to 100mg/L. (b) The range is not displayed when the range switching system is the remote system. ＞＞ 5.3(5) “Range switching type”...

  • Page 55: Alarm Point

    Model: ALF-1600 5.3 Setting Mode Operation (7) Alarm point (L SP，H SP) The low limit alarm and high limit alarm points can be set. Operation Procedure Procedure Operation Remarks ＞＞ 5.1(1) “Mode switching” ① Select the setting mode “PARAM” screen.

  • Page 56: Alarm Band

    Model: ALF-1600 5.3 Setting Mode Operation (8) Alarm band (BAND) This is used when an alarm changed at par. 5.3(7) “Alarm point” is repeatedly turned on and off. Adjust the repetition frequency by gradually increasing the alarm dead band. Operation Procedure...

  • Page 57: Wash Interval

    Model: ALF-1600 5.3 Setting Mode Operation (9) Wash interval (WASH INTERVAL, when automatic wash or automatic span calibration is provided) (a) The wash interval can be set. (b) The wash operation is performed at the interval set here based on the time set at “wash start time”...
  • Page 58 Model: ALF-1600 5.3 Setting Mode Operation Intermittent Intermittent measurement measurement standby Wash standby Wash (0 to 24 hours) Interval (8 mins fixed) Ozone wash (*1) (2 mins fixed) Water wash Wait time (*2) (0 to 30 mins, normally 20 mins)
  • Page 59 Model: ALF-1600 5.3 Setting Mode Operation Operation Procedure Procedure Operation Remarks ＞＞ 5.1(1) “Mode switching” ① Select the setting mode “PARAM” screen. (4 seconds or more) ↓ ② The cursor blinks at the item to be Select “WASH INTERVAL **hr”.

  • Page 60: Wash Start Time

    Model: ALF-1600 5.3 Setting Mode Operation (10) Wash start time (WASH START TIME，when automatic wash or automatic span calibration is provided) The wash start time can be set. 〔NOTE〕 • This item (next wash time) displays the next scheduled wash operation time. (For example, when the next wash time is set to 12:00 and the wash interval is set to 6H, after the 12:00, wash operation 18:00 is displayed.)

  • Page 61: Wait Time

    Model: ALF-1600 5.3 Setting Mode Operation (11) Wait time (WAIT TIME，when automatic wash or automatic span calibration is provided) (a) The wait time after the end of automatic wash and automatic span calibration can be set. (b) The wait time sets the time until the analyzer returns to the actual sample water measurement state and the indication returns to its state before each operation after the end of automatic wash and automatic span calibration.

  • Page 62: Calibration Interval

    Model: ALF-1600 5.3 Setting Mode Operation (12) Calibration interval (CAL INTERVAL，when automatic span calibration is provided) Automatic span calibration interval can be set. 〔NOTE〕 • The calibration conditions set at this section (calibration interval) and the next section (calibration date) are effective in the measurement mode only. They are not applicable to the maintenance mode, setting mode, and calibration mode.
  • Page 63 Model: ALF-1600 5.3 Setting Mode Operation Intermittent Intermittent measurement measurement waiting waiting Calibration Calibration (1 to 31days) Calibration interval Calibration time (12 to 45mins) (8 mins fixed) Ozone wash (*1) (2 mins fixed) Water wash (3 mins fixed) (*2) Span calibration...
  • Page 64 Model: ALF-1600 5.3 Setting Mode Operation Operation Procedure Procedure Operation Remarks ＞＞ 5.1(1) “Mode switching” ① Select the setting mode “PARAM” screen. (4 seconds or more) ↓ ② The cursor blinks at the item to be Select “CAL INTERVAL 10day”.

  • Page 65: Calibration Date

    Model: ALF-1600 5.3 Setting Mode Operation (13) Calibration date (CAL DATE，when automatic span calibration is provided) (a) The automatic span calibration execution date can be set. (b) The first automatic span calibration is performed on the date set here. (c) Thereafter automatic span calibration is performed at the calibration interval (CAL INTERVAL) set at the previous section.

  • Page 66: Calibration Start Time

    Model: ALF-1600 5.3 Setting Mode Operation (14) Calibration start time (CAL START TIME，when automatic span calibration is provided) The automatic span calibration start time can be set. Operation Procedure Procedure Operation Remarks ＞＞ 5.1(1) “Mode switching” ① Select the setting mode “PARAM”...

  • Page 67: Automatic Calibrated Value

    Model: ALF-1600 5.3 Setting Mode Operation (15) Automatic calibrated value (AUTO S VAL，when automatic span calibration is provided) The prepared standard solution concentration when automatic scan calibration is performed is set here. Operation Procedure Procedure Operation Remarks ＞＞ 5.1(1) “Mode switching”...

  • Page 68: Stability Check At Automatic Span Calibration

    Model: ALF-1600 5.3 Setting Mode Operation (16) Stability check at automatic span calibration (STBL AUTO SPAN，when automatic span calibration is provided) Stability check at automatic span calibration can be selected. Operation Procedure Procedure Operation Remarks ＞＞ 5.1(1) “Mode switching” ①...

  • Page 69: Response Speed

    Model: ALF-1600 5.3 Setting Mode Operation (17) Response speed (RESPONSE) (a) The measured value response speed can be changed to any of the following: FAST (Fast response) NORMAL (Standard) SLOW (Slow response) (b) Indication fluctuations during measurement are noticeable “SLOW”...

  • Page 70: Output Type

    Model: ALF-1600 5.3 Setting Mode Operation (18) Output type (OUT TYPE，DUMMY OUT) (a) The output type can be changed to any of the following: Hold ····························· Output is fixed to the immediately preceding measured value. Dummy ························· Output is fixed to an arbitrarily set value.
  • Page 71 Model: ALF-1600 5.3 Setting Mode Operation (Continued from previous page) Procedure Operation Remarks ⑤ Setting range: 000.0 to 100.0％FS Change the dummy value. (Factory setting: 50.0) After entry, the cursor disappears. (digit shift) : Returns to original state ↓ without making the change.

  • Page 72: Correction Coefficient

    Model: ALF-1600 5.3 Setting Mode Operation (19) Correction coefficient (SPAN KA) (a) The measured value can be corrected by correction coefficient (SPAN KA). (b) Perform this operation only when matching to manual analysis or other standard value is necessary. The measured value is changed by multiplying the calibration curve created by calibration by the correction coefficient.

  • Page 73: Flow Target Value

    Model: ALF-1600 5.3 Setting Mode Operation (20) Flow target value (FLOW) (a) The sample water flow target value can be set. (b) This analyzer periodically measures the sample water flow automatically and controls it to 3.7mL/min (factory setting). (c) Here only check the flow target value, do not change it. If the target value is changed, correct measurement will become impossible.

  • Page 74: Pump Control

    Model: ALF-1600 5.3 Setting Mode Operation (21) Pump control (PUMP) (a) The pump flow can be temporarily increased. Combined with “sampling pump ON/OFF” of the next section, only the reagent can be filled and replaced by fast feeding only the reagent pump.

  • Page 75: Sampling Pump On/Off

    Model: ALF-1600 5.3 Setting Mode Operation (22) Sampling pump ON/OFF (SAMPLING PUMP) (a) The sampling pump can be temporarily stopped when you want to fill the reagent, etc. by operating only the reagent pump at the start of operation, etc.

  • Page 76: Input Signal

    Model: ALF-1600 5.3 Setting Mode Operation (23) Input signal (DI-□□□□) Terminal assignment of each of the following signal inputs can be set. Wash start Calibration start Measurement switching Range switching 【IMPORTANT】 If a terminal is not allocated, remote operation is impossible.

  • Page 77: Output Signal

    Model: ALF-1600 5.3 Setting Mode Operation (24) Output signal (DO-□□□□) Allocation of the terminals which output the following signals can be changed: Maintenance in progress Wash in progress Calibration in progress Analyzer error Low limit alarm High limit alarm Range 1...

  • Page 78: Lcd High Contrast

    Model: ALF-1600 5.3 Setting Mode Operation (25) LCD high contrast (LCD MAX CTL, LCD MAX TIME) (a) The contrast of LCD screen can be temporally maximized by this function. (b)Use this function in the measurement mode or maintenance mode when the LCD is difficult to see For the method of using ＞＞...

  • Page 79: Clock Adjustment

    Model: ALF-1600 5.4 Clock Adjustment 5.4 Clock Adjustment (a) The time displayed at the top right-hand side of the screen can be adjusted. (b) Automatic wash or automatic zero calibration is started in accordance with this clock. 【IMPORTANT】 In clock adjustment, items important from the standpoint of operation are operable.

  • Page 80: Maintenance

    Model: ALF-1600 6.1 Maintenance List 6. Maintenance 6.1 Maintenance List (a) To operate the product correctly at all times and maintain its specified performance, it is necessary for you to thoroughly understand its function and perform maintenance periodically. 【IMPORTANT】 Operating the product without performing maintenance periodically can result in a failure.
  • Page 81 Model: ALF-1600 6.1 Maintenance List (Continued from previous page) Maintenance Cycle Subject Contents Execution method, etc ○ ＞＞ 4.1 “Preparing the Without Zero, span calibration automatic Calibration Solution” calibration ○ With automatic calibration ○ ＞＞ 6.12 “Replacing the Solenoid valve...

  • Page 82: Accessories And Spare Parts

    Model: ALF-1600 6.2 Accessories and Spare Parts 6.2 Accessories and Spare Parts General accessories and spare parts are shown in the table below. These items differ depending on the specification and they are subject to change without notice. In addition, the instruction manual may be delivered separately from the product depending on the specification when ordered.
  • Page 83 Model: ALF-1600 6.2 Accessories and Spare Parts (Continued from previous page) Q’ty Sketch Order Code No. Part name Note view EL2066CF Electrolysis Flow cell part 1 year electrode 2066 type 104A292 Time lag fuse Transmitter and 1 year detection section...
  • Page 84 Model: ALF-1600 6.2 Accessories and Spare Parts (Continued from previous page) Q’ty Sketch Order Code No. Part name Note view 466671K Filter assembly Filter for 1 year electrolysis solution of flow cell 47107200 Electrolysis For electrolysis 1 year electrode packing...
  • Page 85 Model: ALF-1600 6.2 Accessories and Spare Parts (Continued from previous page) Q’ty Sketch Order Code No. Part name Note view 7157100K Solenoid valve assembly years (3-way valve) 125B182 Pump head For Reagent solution pump years 125B800 Pump head For sample water...

  • Page 86: Removing The Electrodes

    Model: ALF-1600 6.3 Removing the Electrodes 6.3 Removing the Electrodes ① Turn off the power. Turn off the transmitter power switches in the following order: Top switch → Bottom switch • Power switch (Top: for transmitter) Power switch (Bottom: for detection section) Power Switch Position ②...
  • Page 87 Model: ALF-1600 6.3 Removing the Electrodes Disconnect Disconnecting the Electrode Lead Wires ④ Pull out lead wires. Loosen the hexagon cap nut and slowly pull out each lead wire from the cable gland. ⑤ Disconnect each electrode. Disconnect each electrode as follows.

  • Page 88: Cleaning The Glass Electrode

    Model: ALF-1600 6.4 Cleaning the Glass Electrode 6.4 Cleaning the Glass Electrode When the film surface of the glass electrode is dirty, the electromotive force of the glass electrode will change and its response will be slow. Therefore, periodically remove and clean the electrode.

  • Page 89: Filling With The Reference Electrode Internal Solution

    Model: ALF-1600 6.5 Filling with the Reference Electrode Internal Solution 6.5 Filling with the Reference Electrode Internal Solution The reference electrode internal solution slowly flows out from the ceramic part of the electrode end and the liquid surface drops. Prepare the internal solution as described below and periodically fill with the solution.
  • Page 90 Model: ALF-1600 6.5 Filling with the Reference Electrode Internal Solution ⑥ Fill with internal solution. Transfer the internal solution to a washing bottle or dropper and pour it into the filling port of the reference electrode. 〔NOTE〕 When the reference electrode is nearly empty, refill it with approximately 40mL of internal solution.

  • Page 91: Replacing The Reference Electrode Ceramic

    Model: ALF-1600 6.6 Replacing the Reference Electrode Ceramic 6.6 Replacing the Reference Electrode Ceramic The ceramic at the end of the reference electrode may become clogged by the reaction of the silver chloride of the internal solution with the sample water. If the white ceramic changes color to black, replace it.

  • Page 92: Cleaning The Electrolysis Electrodes

    Model: ALF-1600 6.7 Cleaning the Electrolysis Electrodes 6.7 Cleaning the Electrolysis Electrodes ① Stop the sample water and wash water. Close valves BV1 (for sample water) and BV4 (for wash water (when wash function provided)). ② Disconnect the electrolysis electrodes lead wires.
  • Page 93 Model: ALF-1600 6.7 Cleaning the Electrolysis Electrodes 【IMPORTANT】 When disconnecting the piping, the sample water and reagent remaining in the pipe may leak out or flow in the opposite direction. When disconnecting the piping, always receive this residue in a polyethylene beaker, etc.

  • Page 94: Replacing The Electrolysis Filter

    Model: ALF-1600 6.8 Replacing the Electrolysis Filter 6.8 Replacing the Electrolysis Filter (a) The electrolysis filter is a film that separates the plus side electrolysis electrode that generates acid at the reagent side and the minus side electrolysis electrode that generates alkali at the drain solution side.
  • Page 95 Model: ALF-1600 6.8 Replacing the Electrolysis Filter 〔NOTE〕 • When O-ring B (P14) and the lock bolt have deteriorated, replace the entire filter assembly. ⑥ Return to original state. Return to their original state by the opposite procedure of steps ①...

  • Page 96: Cleaning The Flow Cell

    Model: ALF-1600 6.9 Cleaning the Flow Cell 6.9 Cleaning the Flow Cell When the flow cell is noticeably dirty, spray it with wash water from a washing bottle, etc. If this does not remove the dirt, wash it with acid by the following procedure.

  • Page 97: Replacing The Pump Tube

    Model: ALF-1600 6.10 Replacing the Pump Tube 6.10 Replacing the Pump Tube ① Turn off the power switch. Turn off the transmitter power switch in the following order. ・Top switch → Bottom switch ② Remove the piping tube. Remove the piping tube by the following procedure: ＞＞...
  • Page 98 Model: ALF-1600 6.10 Replacing the Pump Tube Rotor shaft Resin washer (slot ) Pump head case Roller Pump tube Grooves for tube Pump head case inlet and outlet Disassembling the Pump Head into 2 Parts ⑤ Install the tube. Install the new pump tube to the pump head.
  • Page 99 Model: ALF-1600 6.10 Replacing the Pump Tube slowly pull out the tubing key. Cover the pump head. Cover one side of the pump head previously removed. 【IMPORTANT】 At this time set so as not to generate gap so that the tube is not pinched between the top and bottom of the pump head.
  • Page 100 Model: ALF-1600 6.10 Replacing the Pump Tube ⑨ Turn on the power switch. Turn on the power switch. Operate the solution feed pump. ⑩ Fill with reagent. Fill by the following procedure: ＞＞ 5.3(22) “Sampling pump ON/OFF” Stop the sample water pump.

  • Page 101: Regulating Tank Maintenance

    Model: ALF-1600 6.11 Regulating Tank Maintenance 6.11 Regulating Tank Maintenance ① Stop the supply of sample water and wash water. Close valve BV1 (for sampling water) and valve BV4 (for wash water). Operate the analyzer in this state and feed the all sample water in the regulating tank to the flow cell side (about 10 to 15 minutes).
  • Page 102 Model: ALF-1600 6.11 Regulating Tank Maintenance Pipe H (White, PTFE) Push Push One-touch connector One-touch connector <Remove the tube> O-ring E (S34, 115A444) Screw F O-ring F Pull out turning (4 places) Fixing ring little by little (P10, 115A021) Hexagon cap nut...
  • Page 103 Model: ALF-1600 6.11 Regulating Tank Maintenance 〔NOTE〕 • When the ring and tube are difficult to remove after loosening and removing the white hexagon cap nut of pipe G, remove them while shifting them with radio pliers, etc. • Pipe H is connected to a one-touch connector. While pushing the ring of the tube insertion section, pull the tube (white, PTFE tube).
  • Page 104 Model: ALF-1600 6.11 Regulating Tank Maintenance ⑪ Replace O-ring. Replace O-rings H and I with new rings. ⑫ Return to original state. Return to their original state by the opposite procedure of steps ① to ⑪ with careful attention to the followings.

  • Page 105: Replacing The Solenoid Valves

    Model: ALF-1600 6.12 Replacing the Solenoid Valves 6.12 Replacing the Solenoid Valves ① Clean the regulating tank. ＞＞ Steps ① to ⑦ of 6.11 “Regulating Tank Maintenance” ② Disconnect the solenoid valve connector. Disconnect the solenoid valve connector by the following procedure: Press the claw section of the connector with a small flat blade screwdriver, etc.
  • Page 106 Model: ALF-1600 6.12 Replacing the Solenoid Valves ⑤ Replace the solenoid valve. Loosen the fixing screws (4 places) of each solenoid valve and replace the solenoid valve with a new valve. 【IMPORTANT】 When installing the solenoid valve and packing, check the direction.

  • Page 107: Replacing The Varistor Unit

    Model: ALF-1600 6.13 Replacing the Varistor Unit 6.13 Replacing the Varistor Unit Replace the varistor unit approximately 1 year in the procedure below: ① Turn off the power. Turn off the transmitter power switches in the following order: Top switch → Bottom switch Power Switch Position ②...
  • Page 108 Model: ALF-1600 6.13 Replacing the Varistor Unit ④ Replace the varistor unit (transmitter and detection section) Remove the old varistor unit from the base and replace it with a new varistor unit. Power switch (Detection section) 電源スイッチ ( 上側：変換器用) Varistor unit...

  • Page 109: Troubleshooting

    Model: ALF-1600 7.1 Errors and Corrective Actions Troubleshooting 7.1 Errors and Corrective Actions (a) If an error occurs during measurement mode (measurement in progress), an error indication shown in the following table blinks on the above of the screen. (b) If an error occurs in the measurement mode, contact is closed at the already set output terminal.
  • Page 110 Model: ALF-1600 7.1 Errors and Corrective Actions (Continued from previous page) Error removing method Error indication Error name Mode Operation key E-3: Span calibration Maintenance, Press for 1 second or more. CAL-SPAN FAILURE failure Calibration Measurement Press for 4 seconds or more.
  • Page 111 Model: ALF-1600 7.1 Errors and Corrective Actions Inspection of detector ＞＞ 7.3 “Detector Troubleshooting” Contact DKK-TOA if the failure is not resolved. (c) “E-3” − Span calibration failure [Indication conditions] Indicated when span coefficient value was outside the 0.5 to 2.0mA range during span calibration.
  • Page 112 Model: ALF-1600 7.1 Errors and Corrective Actions Continues the measurement and outputs the measured value (transmission output value) in the set output type. ＞＞ 5.3(18) “Output type” [Main cause of failure] Reagent solution is lacking. Level sensor of reagent tank abnormal [Corrective action] Check the reagent solution amount and replace it.
  • Page 113 Model: ALF-1600 7.1 Errors and Corrective Actions [Analyzer status] Stops the operation and output of analyzer. [Main cause of failure] Set values are outside the given range. [Corrective action] Turn on the power again. If the hardware becomes normal, the indication disappears.

  • Page 114: Transmitter Troubleshooting

    Model: ALF-1600 7.2 Transmitter Troubleshooting 7.2 Transmitter Troubleshooting If an error is found in the measured value, check the transmitter in the following procedure. (1) Measured value error “0” is indicated or no (a) Power off (fuse blown) Check the voltage at power supply terminals “90, 91”.

  • Page 115: Measured Value Output Error

    Model: ALF-1600 7.2 Transmitter Troubleshooting (2) Measured value output error Measured value is within the measuring (a) Change the measuring range. range. (b) Check if any problem exists in the sample water. Load resistance Make the load resistance within 600 Ω .

  • Page 116: Detector Troubleshooting

    Model: ALF-1600 7.3 Detector Troubleshooting 7.3 Detector Troubleshooting If an error is found in the measured value, check the detector in the following procedure. “0”is indicated. (a) Sample water shut off Check the sample water pressure or flow rate. Clean the regulating tank and internal filter.

  • Page 117: Replacing The Fuse

    Model: ALF-1600 7.4 Replacing the Fuse 7.4 Replacing the Fuse If the fuse is blown, replace it as follows. ① Remove the top cover. ＞＞ Step ① to ③ of 6.13 “Replacing the Varistor Unit” ② Remove the fuse. Turn the cap counterclockwise to remove it with the blown fuse.

  • Page 118: Specifications And Operational Explanation

    Model: ALF-1600 8.1 Specifications 8. Specifications and Operational Explanation 8.1 Specifications (1) Standard specifications Product name : Alkalinity analyzer Model : ALF-1600 Measuring object : Alkalinity (CaCO conversion) of city water and wash water Measurement method : Coulometric titration method (neutralization titration) Display : LCD digital display (Minimum display 0.1)
  • Page 119 Model: ALF-1600 8.1 Specifications setting error, sample water shut-off, reagent shut-off, zero calibration (*2) failure, span calibration failure (*2) stability check failure *2 ····· When automatic span calibration function provided *3 ····· Power off is fixed to contact output 1.

  • Page 120: Automatic Wash

    Model: ALF-1600 8.1 Specifications with option) Structure : Indoor wall mounted system Transmitter ··················· IP65 (When outdoors, must be housed in a cubicle) Main materials and finish : Indicated transmitter ····· Aluminum die cast, metallic silver finish Detector cover ··············· Aluminum plate, metallic silver finish...

  • Page 121: Automatic Calibration

    Model: ALF-1600 8.1 Specifications (3) Automatic calibration (options set with automatic wash) Calibration method : Zero calibration ············· None Span calibration ············ Span standard solution is periodically introduced to the flow cell from the calibration solution tank and calibrated. Calibration start mode : Automatic ·····················...

  • Page 122: Operational Explanation

    Model: ALF-1600 8.2 Operational Explanation 8.2 Operational Explanation (1) Principle of measurement This analyzer automatically performs the neutralization titration by coulometric titration, and features acquisition of the titrant used in titration by electrolysis. The current needed by electrolysis corresponds to the concentration of the measurement target substance. Normal neutralization titration is performed with a titrant of a known concentration.

  • Page 123: Measurement System With Wash

    Model: ALF-1600 8.2 Operational Explanation (Option) (3) Measurement system with wash When the water wash system is provided, solenoid valves and other wash water piping are added to the standard specifications. When the ozone + water wash system is provided, an ozone supply unit and air piping are added in addition to the wash water piping.

  • Page 124: Intermittent Measurement

    Model: ALF-1600 8.2 Operational Explanation (4) Intermittent measurement This analyzer can perform intermittent measurement in addition to normal continuous measurement. Continuous measurement keeps the sample water and reagent flow constant at all times and measures continuously. On the other hand, intermittent measurement is a standby state in which the reagent consumption is reduced by cutting the sample water and reagent flow by approximately 1/2 and starts operation and measures at a preset interval (batch measurement).

  • Page 125: Installation

    Model: ALF-1600 9.1 Installation 9. Installation 9.1 Installation (1) Installation site Install the analyzer in a location which conforms to the specifications and satisfies the following conditions. (a) A location where installation and maintenance work can be performed. (b) A location where the ambient temperature and humidity are within the specifications, and where direct sunshine does not strike and a sudden change of temperature does not occur, and temperature does not change locally.
  • Page 126 Model: ALF-1600 9.1 Installation Reagent tank Reagent tank tray 4-φ7 Power line Wiring material: CVV 1.25mm to 2mm Calibration (Installation No. of cores: 3 solution tank dimension) Finished outside diameter: φ6 to φ12 Signal line <Transmission> Wiring material: CVV-S 0.5mm to 2mm No.
  • Page 127 Model: ALF-1600 9.1 Installation Power line Signal line Wiring material: CVV 1.25mm to 2mm <Transmission> No. of cores: 3 Wiring material: CVV-S 0.5mm to 2mm Finished outside diameter: φ6 to φ12 No. of cores: 2 Finished outside diameter: φ6 to φ12 <Contacts>...

  • Page 128: Piping

    Model: ALF-1600 9.2 Piping 9.2 Piping Use 13 to 25A rigid PVC pipe, and pipe it to the connection port on the back of the analyzer. (1) Sample water piping (a) Use VP13 to 16 rigid PVC pipe. (b) Insert a union so that the inside of the piping from the sampling point to near the analyzer can be blow cleaned and provide a means of removal.

  • Page 129: Wiring

    Model: ALF-1600 9.3 Wiring 9.3 Wiring Electric Shock Do not touch the terminals inside the product while power is applied. Touching the terminals may cause electric shock. (1) Cables used Observe the following items when installing cables. (a) Use the cables specified in the following table or equivalent.

  • Page 130: Wiring Port

    Model: ALF-1600 9.3 Wiring Electric Shock The ground terminal must always be grounded. If the terminal is not grounded and a problem occurs in the power supply system, electric shock may result. (d) Output signal lines must be separated from power lines and other noise source.

  • Page 131: Terminals

    Model: ALF-1600 9.3 Wiring (3) Terminals RS485/1 RS485/2 External digital I/O For other devices － － － 4-20mA 4-20mA 4-20mA Input Output 1 Output 2 Spare Measured value Spare Maintenance in progress Measuring range switching Calibration in progress (measuring range 2...
  • Page 132 Model: ALF-1600 9.3 Wiring Rating: 4 to 20 mADC, load resistance 600 Ω or less, isolated output (not isolated between channels) Measured value, etc. can be allocated to 2 channel transmitter output terminals by setting. (d) “1, 2” Analog input signal terminals Action: 4-20 mA signal can be input.
  • Page 133 Revision History Instruction Manual No. 12/02/2011 (JJ) New Version in English ALF-IB50603E (RW1 Kitahama, DEC Kuribayashi) ALF-IB50604E (RW1 Takahashi, DEC Kuribayashi) 13/09/2013 (JJ) - 132 -...
  • Page 134 Head Office Address: 29-10, 1-Chome, Takadanobaba, Shinjuku-Ku, Tokyo, 169-8648 Japan Telephone: +81-3-3202-0225 Facsimile: +81-3-3202-5685 URL http://www.toadkk.co.jp/...

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