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Hach CODmax III User Manual
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Hach CODmax III User Manual

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DOC023.80.80637
CODmax III
02/2021, Edition 1
User Manual

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Summary of Contents for Hach CODmax III

  • Page 1 DOC023.80.80637 CODmax III 02/2021, Edition 1 User Manual...

  • Page 3: Table Of Contents

    Table of Contents Section 1 Specifications ..................3 Section 2 General information ................4 2.1 Use of hazard information ..................4 2.2 Safety information ....................4 2.2.1 Precautionary labels ................... 4 2.2.2 Icons used in illustrations ................6 2.2.3 Chemical and biological safety ..............6 2.3 Intended use ......................
  • Page 4 Table of Contents 6.8 Configure the relays, inputs and outputs ............28 6.9 Configure the Modbus communication settings ..........29 6.10 Start an analyzer task manually ................ 29 6.11 Calibrate the touch screen ................29 6.12 Go back to the factory settings ................. 30 6.13 Enable the Prognosys diagnostic system ............

  • Page 5: Section 1 Specifications

    Section 1 Specifications Specifications are subject to change without notice. Table 1 General specifications Specification Details Dimensions (W x H x D) 455 x 805 x 365 mm (17.9 × 31.7 × 14.4 in.) Enclosure IP54 with doors closed; indoor use only Weight 27 kg (59.5 lb) without reagents Pollution degree...

  • Page 6: Section 2 General Information

    Table 2 Measurement specifications (continued) Specification Details Accuracy 10.0 to 39.9 mg/L: ≤ ± 10% 40.0 to 100.0 mg/L: ≤ ± 6% 100.1 to 5000.0 mg/L: ≤ ± 3% Precision 10.0 to 39.9 mg/L: ≤ 5% 40.0 to 5000.0 mg/L: ≤ 3% Calibration Manual or automatic at selected interval Reagent consumption...
  • Page 7 This is the safety alert symbol. Obey all safety messages that follow this symbol to avoid potential injury. If on the instrument, refer to the instruction manual for operation or safety information. This symbol indicates the need for protective eye wear. This symbol identifies a risk of chemical harm and indicates that only individuals qualified and trained to work with chemicals should handle chemicals or perform maintenance on chemical delivery systems associated with the equipment.

  • Page 8: Icons Used In Illustrations

    2.3 Intended use The CODmax III is an online COD analyzer that is intended for use by industrial and municipal professionals to automatically monitor the chemical oxygen demand (COD) in domestic wastewater, industrial wastewater and surface water applications.

  • Page 9: Product Overview

    Explosion/Fire hazard. Use original reagents only. Operation even with potable or distilled water may cause overheating and explosion of the digestion unit. The CODmax III is an online analyzer that measures chemical oxygen demand in wastewater and surface water. Refer to...

  • Page 10: Product Components

    2.6 Product components Make sure that all components have been received. Refer to Figure 2. If any items are missing or damaged, contact the manufacturer or a sales representative immediately. Figure 2 Product components 1 Instrument 5 Plastic bottle cap (2x) 2 Brackets for wall mount (2x) 6 Glass bottle cap (2x) 3 Screws for wall and table mount (12x)

  • Page 11: Installation Guidelines

    3.1 Installation guidelines C A U T I O N Chemical exposure hazard. Obey laboratory safety procedures and wear all of the personal protective equipment appropriate to the chemicals that are handled. Refer to the current safety data sheets (MSDS/SDS) for safety protocols. C A U T I O N Chemical exposure hazard.
  • Page 12 Attach the instrument upright and level on a flat, vertical wall surface. Install the instrument in a location and position where the user can easily disconnect the instrument from the power source. Refer to the illustrated steps that follow. Mounting hardware is supplied by the user. 10 English...

  • Page 13: Install The Instrument On A Table

    3.2.2 Install the instrument on a table W A R N I N G Personal injury hazard. Instruments or components are heavy. Use assistance to install or move. Install the instrument on a stable, level surface. Install the instrument in a location and position where the user can easily disconnect the instrument from the power source.

  • Page 14: Open Or Remove The Doors

    3.2.3 Open or remove the doors Open the analyzer doors to get access to the instrument display, wiring and plumbing. Remove the doors for better access during installation and maintenance procedures. Refer to Figure 4. Make sure to install and close the doors before operation to maintain the enclosure rating and safety rating. Figure 4 Open or remove the doors 12 English...

  • Page 15: Remove The Transport Lock

    (MSDS/SDS) for safety protocols. W A R N I N G Reagents are toxic and corrosive. Only get prepared, controlled chemicals from HACH to prevent personal injury and environmental damages and get accurate measurement and calibration results.

  • Page 16: Prepare Reagent A

    3.3.1 Prepare reagent A W A R N I N G Chemical and inhalation hazard. Mercury sulfate is highly toxic. Exposure may result in severe injury or death. Do not breathe mercury sulfate fumes. Use a fume hood to prepare the solution. Prepare potassium dichromate and mercury sulfate reagent (reagent A).

  • Page 17: Prepare Standard 1

    4. Stir to mix. Add 0.1 g of sodium sulfate to the container. 5. When sodium sulfate is fully dissolved, dilute to 1000 mL with deionized water. 3.3.4 Prepare standard 1 Prepare 1500 mg/L standard solution (STD1). Items to collect: •...

  • Page 18: Plumbing

    3.4 Plumbing 3.4.1 Plumbing overview C A U T I O N Chemical exposure hazard. Dispose of chemicals and wastes in accordance with local, regional and national regulations. Open the display panel to see the components of the analysis section. Refer to Figure Figure 6 Analysis section components 1 Plumbing diagram...

  • Page 19: Install The Sample And Drain Lines

    3.4.2 Install the sample and drain lines N O T I C E Do not connect the drain lines to other lines because backpressure or damage to the analyzer can occur. The drain lines contain analysis waste and cleaning wastewater, which include chemical reagents. All waste solutions must be disposed in accordance with local and national law.

  • Page 20: Install The Bottles

    3.5 Install the bottles C A U T I O N Chemical exposure hazard. Obey laboratory safety procedures and wear all of the personal protective equipment appropriate to the chemicals that are handled. Refer to the current safety data sheets (MSDS/SDS) for safety protocols. Install the bottles of reagents and standard solutions in the analyzer.

  • Page 21: Electrical Installation

    3.6 Electrical installation 3.6.1 Electrical access ports Connect external cables to the communications, relays and/or input/output modules through the electrical access ports. Refer to Figure 9. Refer to Specifications on page 3 for wire gauge requirements. Keep the plugs in the electrical access ports that are not used to keep the enclosure rating.

  • Page 22: Electrical Overview

    3.6.2 Electrical overview Pull the handle on the analysis section to access the internal electrical connections. Refer to Figure Figure 10 Electrical overview 1 Electrical connections 3 Air circuit breaker switch 2 Air circuit breaker 3.6.3 Electrical safety The air circuit breaker automatically cuts off the main power supply from the AC power line if an overcurrent (e.g., short circuit) occurs.

  • Page 23: Section 4 Startup

    Table 3 Wiring information Device Connection Signal Relay 1 and 2 Normally open Common Normally closed Digital inputs Positve – Negative 4-20 mA outputs 1 and 2 Positve – Negative Modbus SC Common signal Signal A (–) Signal B (+) SC (reserved) G / BN Common signal...

  • Page 24: Initialization Guide

    Figure 11 Apply power to the analyzer 4.1 Initialization guide The initialization guide starts when the instrument is powered on for the first time. The initialization guide helps the user set the date and time, language and measurement range. 1. Open the top door to get access to the instrument display. 2.

  • Page 25: Section 5 User Interface And Navigation

    Section 5 User interface and navigation The instrument display is a touch screen. Only use a clean, dry finger tip to navigate the functions of the touch screen. Do not use writing tips of pens or pencils or other sharp objects to make selections on the screen or damage to the screen will occur.

  • Page 26: Menu Overview

    5.1 Menu overview Refer to Figure 13 Table 4 for an overview of the main menu. Figure 13 Menu overview Table 4 Main menu overview Icon Description Settings Configures the settings for measurements, calibrations, standard verification, cleaning, I/O Modbus and the system. Service •...

  • Page 27: Status Indicator Light

    5.2 Status indicator light When power is applied to the analyzer, the status indicator light comes on. Refer to Table 5 Product overview on page 7. Table 5 Status indicator definitions Light color Definition Green The analyzer is in operation with no warnings, errors or reminders. Yellow The analyzer is in operation with active warnings or reminders.

  • Page 28: Configure The Measurement Options

    7. Enter a new password for the Operator. 8. Enter the password again to confirm. 9. Push CHANGE, then OK. 6.3 Configure the measurement options Use the Measure menu to select the measurement range, interval and mode. 1. Push Menu > Settings > Measure. 2.

  • Page 29: Configure The Standard Verification Options

    Option Description Mode Sets the instrument to use the Standard or Customized calibration or flush the lines after calibration. Standard—The instrument uses the default calibration points: STD0 and STD1 standard solutions. Customize—The instrument uses user-defined calibration points. STD0 standard solution and one configurable point (100 to 1500 mg/L) Calibration standard—...

  • Page 30: Configure The Alarms

    6.7 Configure the alarms Set the low and high concentration values that trigger an alarm condition. 1. Push Menu > Diagnosis > Alarm settings. 2. Select the Concentration alarm screen. 3. Enter the high and low concentration values. Option Description Low limit Sets the low concentration value.

  • Page 31: Configure The Modbus Communication Settings

    6.9 Configure the Modbus communication settings For remote communications with the instrument, connect the network to the RS485 communications module, then configure the instrument for the Modbus communications protocol. 1. Push Menu > Settings > IO/Modbus. 2. Select the Modbus screen. 3.

  • Page 32: Go Back To The Factory Settings

    6.12 Go back to the factory settings If necessary, the approved user can replace the user settings with the factory settings. 1. Push Menu > Service > Advanced. 2. Select the Factory Reset screen. 3. Push RESET, then YES to confirm. 4.

  • Page 33: Send Data To A Usb Drive

    Figure 14 Graph of data 1 Sliders to change the time interval 4 Large or small data points button 2 Movement arrows and Reset button 5 Zoom in or out buttons 3 Hide or show button 7.2 Send data to a USB drive Send data from the analyzer to a USB flash drive (USB 2.0 or newer recommended) for storage or transfer to a computer.

  • Page 34: Maintenance Schedule

    8.1 Maintenance schedule Table 6 shows the recommended schedule of maintenance tasks. Facility requirements and operating conditions may increase the frequency of some tasks. Table 6 Maintenance schedule Task 4 weeks 6 months 1 year 2 years As necessary Schedule automatic cleanings on page 33 Manually clean the digestion cuvette on page 34...

  • Page 35: Examine For Leaks And Malfunctions

    Figure 15 Remove the safety panel Note: Make sure to install the safety panel before measurements are started. 8.3 Examine for leaks and malfunctions C A U T I O N Chemical exposure hazard. Obey laboratory safety procedures and wear all of the personal protective equipment appropriate to the chemicals that are handled.

  • Page 36: Manually Clean The Digestion Cuvette

    8.5 Manually clean the digestion cuvette W A R N I N G Chemical exposure hazard. Obey laboratory safety procedures and wear all of the personal protective equipment appropriate to the chemicals that are handled. Refer to the current safety data sheets (MSDS/SDS) for safety protocols. 1.
  • Page 37 English 35...
  • Page 38 36 English...

  • Page 39: Manually Clean The Dosing Cuvette

    8.6 Manually clean the dosing cuvette W A R N I N G Chemical exposure hazard. Obey laboratory safety procedures and wear all of the personal protective equipment appropriate to the chemicals that are handled. Refer to the current safety data sheets (MSDS/SDS) for safety protocols. 1.
  • Page 40 38 English...

  • Page 41: Clean The Instrument

    8.7 Clean the instrument Clean the exterior of the instrument with a moist cloth and a mild soap solution and then wipe the instrument dry as necessary. 8.8 Dry the leak detector W A R N I N G Chemical exposure hazard. Obey laboratory safety procedures and wear all of the personal protective equipment appropriate to the chemicals that are handled.

  • Page 42: Set The Bottle Fill Levels

    1. Push the circular START/STOP button to stop the analyzer operation. Select YES to confirm. The analyzer starts a sequence of procedures to prepare the system for maintenance. Wait for all of the procedures to stop. 2. Remove the solution bottles from the bottom compartment. 3.
  • Page 43 Figure 18 Dump waste liquid Figure 19 Piston pump waste liquid English 41...

  • Page 44: Replace The Pharmed Tubing

    8.11 Replace the pharmed tubing Replace the waste pharmed tubing after 4 weeks of operation. Replace the sample pharmed tubing after 6 months of operation. Replace the sample or waste pump tubing when a blockage or instrument problem occurs. 1. Push the circular START/STOP button to stop the analyzer operation. Select YES to confirm. The analyzer starts a sequence of procedures to prepare the system for maintenance.

  • Page 45: Replace The Digestion Cuvette O-Rings

    8.12 Replace the digestion cuvette o-rings Replace the digestion cuvette o-rings after 12 months of operation. Replace the digestion cuvette after 24 months of operation. 1. Push the circular START/STOP button to stop the analyzer operation. Select YES to confirm. The analyzer starts a sequence of procedures to prepare the system for maintenance.
  • Page 46 8. Push the circular START/STOP button to start the analyzer operation. Select YES to confirm. The analyzer starts a series of procedures to prepare the system for operation. 9. Start a calibration task to fill the tubing and update the calibration curve. Refer to Start an analyzer task manually on page 29.

  • Page 47: Replace The Dosing Cuvette O-Rings

    8.13 Replace the dosing cuvette o-rings Replace the dosing cuvette o-rings after 12 months of operation. Replace the dosing cuvette after 24 months of operation. 1. Push the circular START/STOP button to stop the analyzer operation. Select YES to confirm. The analyzer starts a sequence of procedures to prepare the system for maintenance.
  • Page 48 46 English...

  • Page 49: Replace The Piston Pump

    8.14 Replace the piston pump Replace the piston pump after 24 months of operation. 1. Push the circular START/STOP button to stop the analyzer operation. Select YES to confirm. The analyzer starts a sequence of procedures to prepare the system for maintenance. Wait for all of the procedures to stop.

  • Page 50: Section 9 Troubleshooting

    Section 9 Troubleshooting 9.1 Use the help system The user interface has help screens that give troubleshooting instructions to correct problems and to complete maintenance tasks. Look for the Help icons to open the help screens. The help screens have links to the applicable menus to complete a task. 1.

  • Page 51: View The Analyzer Signals

    9.3 View the analyzer signals The Signals menu shows the absorbance data and data for valve operation, pump operation, power, leakage and temperature. Use the data to troubleshoot a problem. 1. Push Menu > Service > Signals. 2. Select the Measure, Flow Actions or Others screen to see the recorded data. 9.4 View the recorded events The analyzer records all errors, warnings and reminders that occur during operation.
  • Page 52 Consumables Description Quantity Item no. Reagent Set, includes: 8987900 Reagent A 2.2 L Reagent B 2.2 L Standard solution 0 Standard solution 1 0.5 L Replacement parts Description Quantity Item no. Digestion cuvette 8994000 Dosing cuvette 8971000 Pistion pump 8840800 Pharmed, ID: 2.4 mm, OD: 5.6 mm 1.2 m YY0000141...
  • Page 54 Tel. +49 (0) 2 11 52 88-320 SWITZERLAND Fax (970) 669-2932 Fax +49 (0) 2 11 52 88-210 Tel. +41 22 594 6400 orders@hach.com info-de@hach.com Fax +41 22 594 6499 www.hach.com www.de.hach.com © Hach Company/Hach Lange GmbH, 2021. All rights reserved. Printed in China.