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ECD CA900 Instruction Manual

Alkalinity analyzer
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E
-C
D
LECTRO
HEMICAL
EVICES
Instruction Manual
Model CA900 Analyzer
Alkalinity
The information and technical data disclosed in this document may be used and disseminated only for the purposes and
to the extent specifically authorized in writing by Electro-Chemical Devices. Electro-Chemical Devices reserves the right to
change published specifications and designs without prior notice.
Part No. IM
CA900
Rev: D – 12/19

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Summary of Contents for ECD CA900

  • Page 1 HEMICAL EVICES Instruction Manual Model CA900 Analyzer Alkalinity The information and technical data disclosed in this document may be used and disseminated only for the purposes and to the extent specifically authorized in writing by Electro-Chemical Devices. Electro-Chemical Devices reserves the right to change published specifications and designs without prior notice.

  • Page 2: Preface

    PREFACE Purchasing products from Electro-Chemical Devices, Inc. provides you with the finest liquid analytical instrumentation available. If this is your first purchase from ECD, please read this manual before installing and commissioning your new equipment. If there are any questions concerning this equipment, please contact your local ECD representative, or the factory directly at: Electro-Chemical Devices, Inc.

  • Page 3: Table Of Contents

    Important Service Information ........................xi Unpacking the Instrument ........................... xi 1.0 Overview ..............................1 1.0.1 CA900 Technical Specifications ....................2 1.1 Safety Precautions, Instructions and Hazards ..................3 1.1.1 General information ........................3 1.1.2 List of warnings and potential dangers ..................3 1.1.3 Reagents ............................
  • Page 4 6.3.9 Bottle Maintenance ........................32 6.3.10 Store Sensor ..........................33 6.3.11 Acid Dissociation Chart ......................34 6.3.12 All Data Screen ......................... 35 6.3.13 Range ............................36 6.3.14 Range ............................37 6.3.15 Sensor Configuration ....................... 37 6.3.16 Relay Configuration ........................38 CA900 Analyzers Page iv...
  • Page 5 Information – Alarm Logs ...................... 70 6.8.4 Information – System ......................71 6.8.5 Information – Sensor ......................72 7.0 Maintenance ............................72 7.1 Visual check ............................73 7.2 Monthly ............................. 73 7.3 Every 4-6 months (depending on applications) ................74 CA900 Analyzers Page v...
  • Page 6 7.4 Annual ............................... 74 7.5 Parts and accessories ........................74 8.0 Analyzer Shut Down ..........................76 CA900 Analyzers Page vi...

  • Page 7: Terms And Conditions Of Sale

    Disclaimer of Damage. In no event shall Seller be liable for special, indirect, consequential or incidental damages whether arising under contract, warranty, tort, strict liability or any other theory CA900 Analyzers Page vii...
  • Page 8 Buyer will be invoiced at the freight charge prevailing at the date of shipment. Prices are firm for orders meeting Seller's normal shipping schedules. If shipments are held or postponed for any reason other than Seller's fault, and a price increase becomes effective during the period of such hold or CA900 Analyzers Page viii...
  • Page 9 15. APPLICABLE LAW. All questions arising hereunder or in connection with the quotations or any order submitted in connection therewith and/or the performance of the parties hereunder shall be CA900 Analyzers Page ix...

  • Page 10: Returned Goods Policy

    If all of the above conditions are met, and the item has been approved to return to our stock, a restocking charge of 25% of the purchase price is deducted from the applicable credit. CA900 Analyzers Page x...

  • Page 11: Important Service Information

    A Return Material Authorization (RMA) number must be obtained from the service department before returning any material to ECD. All material returned to ECD shall be shipped prepaid to the factory. UNPACKING THE INSTRUMENT Your Electro-Chemical Devices instrument has been carefully packaged to protect it from damage during shipment and dry storage.

  • Page 12: Overview

    1.0 OVERVIEW Thank you for purchasing our Model CA900 Analyzer. The CA900-Analyzer was designed and manufactured to be an easy-to-use, high-sensitivity and low-cost measuring instrument. This Analyzer should give you many years of reliable and hassle-free operation with regular care and maintenance.

  • Page 13: Ca900 Technical Specifications

    1.0.1 CA900 Technical Specifications Analysis: Alkalinity Method: Titration using pH Sensor Measuring range: Measurement Specific (See Chapter 11 for Analyzer performance) Response time: 10 minute cycle plus any user entered wait time Repeatability: +/- 2% or +/- 2 ppm, whichever is greater, on the measurement...

  • Page 14: Safety Precautions, Instructions And Hazards

    Electro-Chemical Devices shall not be liable for errors contained herein and/or for the incorrect use of the analyzer. The analyzer’s users must read the User’s Manual before placing the CA900 analyzer into service. Observe the instructions and follow all national and local regulations and laws regarding workers health and safety.
  • Page 15 Hazard of electrical shock Involved parts:  main power supply This symbol is used to represent a hazard of severe electric shock or electrocution. All adjustments and  peristaltic pump maintenance on electrical devices labeled with this motor symbol should be made by qualified personnel in accordance with national or local regulations.

  • Page 16: Reagents

    1.1.3 Reagents The Model CA900 Analyzer is based on titration analysis methods, using acids. For the dangers and hazards regarding the chemicals used for the analysis, refer to Chapter 5 for reagent preparation. Make sure that proper safety precautions are taken (e.g. using safety gloves and glasses) during handling the chemical solutions and the reagents containers / bottles.
  • Page 17 Before servicing the analyzer or any parts that are electrically powered, turn off the power to avoid the risk of electrocution. Inside the analyzer’s lower level, the electrical protection is IP2X. Analyzer’s enclosure is IP54. Protection against electrical shock is guaranteed by the grounding of all isolated metal surfaces. Grounding terminal/screw is located inside the electrical enclosure, in Upper Left position.
  • Page 18 The analyzer has been designed, built and equipped to avoid risks caused by physical and chemical factors such as noise, vibrations, radiations, dust, waste gas etc. Page 7...

  • Page 19: Introduction - Analyzer Description

    ECD’s advanced CA900 Titration Analyzer for alkalinity measurement is so easy to install and start up that a technician can do it in less than 15 minutes. All that is necessary is to perform simple connections of the sample, waste and reagent lines and then power up the factory pre-calibrated analyzer.

  • Page 20: Working Principle: Titration Using Ph Electrode

    To determine and maintain water quality, accurately measuring the alkalinity of the water is critical to assess its relationship and impact on pH levels. Titration analysis with the CA900 Analyzer calculates alkalinity by dispensing known doses of a titrant fluid into a reaction cell while monitoring the pH level to two end points.

  • Page 21: Analysis Cycle

    2.3 Analysis Cycle The CA900 Titration Analyzer typically performs a single alkalinity measurement per analysis cycle. Its standard program sequence consists of a cleaning cycle, sample acquisition, monitoring of pH, the addition of the titrant fluid, mixing the fluid, calculation of results and data storage. The desired frequency of analysis between cycles can be easily modified to the requirements of the user’s process.

  • Page 22: Components

    3.0 COMPONENTS The CA900 Analyzer has two distinct sections: 1. The Liquids Section which includes all of the liquid handling equipment. This is located in the Lower Compartment, highlighted below. 2. The Electrical Section including power supply, PLC controller, I/O and touch screen interface are located in the Upper Compartment, highlighted below.

  • Page 23: Liquids Section

    Model CA900 uses a Watson Marlow peristaltic pump for sampling Proper diameter and material of the tubing must be used for proper functioning of the CA900 Analyzer, use only ECD replacement tubing and parts. The pump is located in the liquid enclosure.

  • Page 24: Reaction Cell

    3.1.3 Reaction Cell The reaction cell is the vessel where the sample and titrant are added and mixed. The pH sensor is inserted through an opening on the top of the reaction cell where the sensor electrode is submerged in the sample/titrant mixture and reads the solution pH.

  • Page 25: Electronic Components

    3.2 Electronic Components The PLC based controller and its PCB assembly are located in the electronic section. The controller handles all analyzer operations. It collects all the information and data coming from the different analyzer devices and controls all I/O dialogue with the user touch screen interface and data transfer equipment.

  • Page 26: Relays

    3.2.2 Relays The CA900 is equipped with 4 relays. Each relay is SPDT 15A 250VAC 3.2.3 4-20 mA Output There are four 4-20 mA outputs. Page 15...

  • Page 27: Installation

    Use extreme care when lifting or moving the analyzer. If the analyzer has been in service, empty all liquids from the hydraulic parts before moving the analyzer. 4.3 Location and Mounting Instructions Install the CA900 Analyzer in a clean, dry and dust free environment or in an enclosure with good ventilation. Environmental Operating conditions are: ...

  • Page 28: Electrical Connections

    Turn off the power before beginning any service on the CA900 Analyzer. The CA900 must be properly grounded to prevent the possibility of electrical shock. All metal surfaces are connected to the Ground terminal. The Grounding Terminal/Screw is located inside the electrical enclosure in the upper left position.

  • Page 29: Ac Power Connections

    The analyzer is equipped with a Breaker (main power switch). It is recommended that the CA900 analyzer is connected to power via a circuit breaker or an ON/OFF switch installed near the unit.

  • Page 30: Reagents And Buffers

    Mind all Hazard and Poison labels. Pre-made reagents and solutions are available from ECD. The part #s for the reagents can be found in 9.3 Accessories and Spare Parts the recipe next to the reagent name and in section .

  • Page 31: User Interface

    6.0 USER INTERFACE 6.1 Touch Screen Display The user interface consists of the Touch Screen Display located on the front panel of the analyzer enclosure. All input/output data, information, alarms and fault conditions are shown on the display while all commands and settings may be transferred to the analyzer simply pressing the touch screen. Page 20...

  • Page 32: Base Screens

    6.2 Base Screens 5 inch, 640 x 480 pixel screen Main Recipe Base Screen letter designations are located at the left bottom of the screen Acid Dissociation Chart Data Alkalinity Concentration Chart Page 21...

  • Page 33: Main Screen

    6.3 Main Screen Blinking green indicator Blinking green indicator when in System Hold Solid green indicates the when in Any Timed Relay is recipe run will be in Hold remotely activated Relay indicators, green when active Past process measurement All menu popups will close after exceeding a timeout set by the user Runs 1 recipe cycle...

  • Page 34: Run Command

    6.3.1 Run command Remote Activation allows the operator to use Input 1 for activating a recipe run from another location or a button outside the housing. Input 1 can still be employed with a relay for local indication, for example All pull-down menus will close in 2 seconds without any selection...
  • Page 35 Past process measurement Run Type Runtime of the Recipe run Recipe Steps Current Recipe Operation De-activated buttons The STOP button appears The MENU and RUN buttons are are grayed out during a recipe run de-activated during a recipe run Stops the process and sets up the next Page 24...

  • Page 36: System Hold Indications

    6.3.2 System Hold Indications Pressing the red square activates SYSTEM HOLD Page 25...

  • Page 37: Timed Relay Hold Indications

    6.3.3 Timed Relay Hold Indications Selecting a Hold Time de-activates the outputs and the sensor. However; PV indicators are unaffected Page 26...

  • Page 38: Time Of Day

    6.3.4 Time of Day Time Of Day (TOD) is changed by pressing the TOD display entering values in the Change Time / Date popup. Note: time is in 24-hour format. TOD can only be changed where the TOD is displayed. Page 27...

  • Page 39: Screen Saver

    6.3.5 Screen Saver Pressing the red square (without the check mark) turns on the screen saver Pressing the green square (with the check mark) turns off the screen saver Page 28...

  • Page 40: Range

    6.3.6 Range The Titrant and Sample Volume can be changed by pressing the range display on either the Main or All Data Screens Page 29...

  • Page 41: Run Recipe

    6.3.7 Run Recipe During a recipe run, each device turns green indicating activation. Outside of a run, each device can be pressed Run Type for manual activation of that device Recipe Steps Runtime of the Recipe run Current Recipe Operation Page 30...

  • Page 42: Prime Reagent/Titrant

    6.3.8 Prime Reagent/Titrant Page 31...

  • Page 43: Bottle Maintenance

    6.3.9 Bottle Maintenance Page 32...

  • Page 44: Store Sensor

    6.3.10 Store Sensor When the Analyzer is not running an analysis, it is recommended that the sensor be stored in pH 4 Buffer. The reaction cell will automatically fill up with the correct buffer. Follow the sequence below to store sensor. Page 33...

  • Page 45: Acid Dissociation Chart

    6.3.11 Acid Dissociation Chart Sensor’s current response Running chart of past pH readings and inflections This chart allows you to visualize the pH concentration as the acid is titrated into the sample. Page 34...

  • Page 46: All Data Screen

    6.3.12 All Data Screen Press the button to go to the configuration for the Past process relay number on the measurement button. The button also displays the configuration type of the relay and the activation state (grey off, green on) Press the sensor name to Press the button to go to manually activate the sensor...

  • Page 47: Range

    6.3.13 Range The Range setup is the same as shown for the Main screen Page 36...

  • Page 48: Range

    6.3.14 Range Isopotential and/or Temperature Compensation are only shown for sensor elements with those properties 6.3.15 Sensor Configuration Page 37...

  • Page 49: Relay Configuration

    6.3.16 Relay Configuration Relay simulation (each relay) Press the Relay Type button to switch between the 4 types Page 38...

  • Page 50: Relay Configuration- Alarm- Sensor Value

    6.3.17 Relay Configuration- Alarm- Sensor Value Page 39...
  • Page 51 Page 40...

  • Page 52: Relay Configuration- Alarm- Sensor Temperature

    6.3.18 Relay Configuration- Alarm- Sensor Temperature The setup for the rest of the parameters are the same as shown previously Page 41...

  • Page 53: Relay Configuration- Alarm- Process

    6.3.19 Relay Configuration- Alarm- Process The setup for the rest of the parameters are the same as shown previously Page 42...

  • Page 54: Relay Configuration- Alarm- Inputs

    6.3.20 Relay Configuration- Alarm- Inputs The setup for Delay On, Delay Off and State are the same as shown previously The On Setpoint and Off Setpoint are always opposite of each other Run recipe configured as Remote Activation uses Input 1 for activating a recipe run from another location or a button outside the housing.

  • Page 55: Relay Configuration- Alarm- Timed

    6.3.21 Relay Configuration- Alarm- Timed Page 44...
  • Page 56 A Fault is generated if the duration >= period or the duration + hold time >= period. The Fault condition will persist until corrected. Page 45...

  • Page 57: Ma Configuration

    6.4 4-20 mA The CA900 has Four 4-20 mA outputs 6.4.1 4-20 mA Configuration Page 46...

  • Page 58: Ma Configuration - Sensor Value

    6.4.2 4-20 mA Configuration – Sensor Value Page 47...

  • Page 59: Ma Configuration - Sensor Temp

    6.4.3 4-20 mA Configuration – Sensor Temp Page 48...

  • Page 60: Ma Configuration - Process Variable

    6.4.4 4-20 mA Configuration – Process Variable Page 49...

  • Page 61: Ma Configuration - Simulate

    6.4.5 4-20 mA Configuration – Simulate 4-20 simulation (each channel) 6.5 Alkalinity Concentration Chart Past process measurement Running chart of past process measurements Page 50...

  • Page 62: Menu Home Screen

    6.6 Menu Home Screen System Hold and Time setting Base Screen Jump Buttons Menu Buttons Page 51...

  • Page 63: Menu Home - System Hold

    6.6.1 Menu Home – System Hold Page 52...

  • Page 64: Menu Buttons

    6.6.2 Menu Buttons Exit totally out of Menuing The Bar Graph depicts the amount of time left before a menu timeout and the menus close (exit) BACK one menu level Page 53...

  • Page 65: Calibration

    6.7 Calibration When Calibrating the analyzer you are given two tabs: System and Sensor. Alkalinity should be Calibrated using the System Tab, and the pH sensor should be calibrated using the Sensor Tab. Page 54...

  • Page 66: Calibrate System

    6.7.1 Calibrate System Calibrate System is the Primary Calibration for Alkalinity. When you press the Systems key on the Calibrate Screen, the Calibrate Systems screen will appear. A standard or known sample should be used. When calibrating, the Sample line should be connected to the appropriate standard solution or known process sample.

  • Page 67: Calibrate Sensor

    6.7.2 Calibrate Sensor To calibrate the pH Sensor you must press the Sensor Key on the Calibrate Screen. Calibration of the pH sensor is very important as it contributes to the calculation of Alkalinity. There are 4 tabs that can be used to Calibrate: AUTO, STAND, Manual, and Temp.

  • Page 68: Calibrate Sensor - Auto Calibration

    6.7.3 Calibrate Sensor – Auto Calibration Auto calibration is the primary calibration method for pH. AUTO calibration automatically recognizes the calibration solution the sensor is in and proposes the actual temperature compensated value for acceptance. AUTO calibration can be a single point or two point calibration. A single point calibration sets the zero point or offset value of the sensor.

  • Page 69: Calibrate Sensor - Standardize Calibration

    6.7.4 Calibrate Sensor – Standardize Calibration A Standardize Calibration is a single point calibration where the transmitter’s reading is adjusted to agree with a solution of known value, either a calibration standard, a grab sample or laboratory determined value. In many cases the constituents and the pressure and temperature of the process solution are very different from the calibration solution.

  • Page 70: Calibrate Sensor - Manual Calibration

    6.7.5 Calibrate Sensor – Manual Calibration Manual calibration allows the user to enter calibration data for an electrode into the transmitter without performing a calibration. A MANUAL Calibration requires the entry of three pieces of data: (1) A concentration with the (2) corresponding mV value and (3) a slope for the electrode. This allows laboratory generated calibration data for an electrode to be entered in a remote analyzer where calibration is difficult or impractical.

  • Page 71: Calibrate Sensor - Temperature Calibration

    6.7.6 Calibrate Sensor – Temperature Calibration TEMP Key allows the displayed temperature to be trimmed to agree with actual process temperature. Place the Sensor in a known temperature liquid solution. Press TEMP to initiate Temp Calibration Enter the Correct Temperature Value. Press the Arrow Key Press OK to Accept to enter...

  • Page 72: Configure

    6.8 Configure Two options are available under the CONFIG key: System and Sensor. By pressing the SYSTEM key, you are able to Configure: 1. Bottle Maintenance 2. System Settings 3. Display 4. Reset User choices 5. Outputs 6. Ethernet Settings 7.

  • Page 73: Configure - System Screens

    6.8.1 Configure – System Screens Page 62...
  • Page 74 6.8.1.1 Configure – System – Bottle Maintenance Bottle Maintenance Key lets you Name the Bottles, input the bottle volume, and provide a low volume alert level. Press on the highlighted blue to edit bottle name Press on the highlighted blue to edit bottle volume Press SAVE to Finalize...
  • Page 75 6.8.1.2 Configure – System – System Settings System Settings Key lets the user input the titrant pump shot volumes, reaction cells fill and drain rates, and Shot max. These Settings are configured at the ECD factory. These settings should only be done by qualified personnel.
  • Page 76 6.8.1.3 Configure – System – Display Pressing the red square (without checkmark) will turn the Screen Saver On (green square with checkmark), pressing again will turn it Off The screen saver turns off the display backlight (dark screen) but the HMI’s power LED is still on.
  • Page 77 6.8.1.4 Configure – System – Reset User Choices The reset user choices screen allows the user to set or reset previous choices made about viewing the warning screens again. The red square without check mark means the warning will be displayed, whereas, the green square with check mark means the warning will not be displayed.
  • Page 78 6.8.1.5 Configure – System – Ethernet settings Pressing the Ethernet settings allows changes to the external web page Ethernet web page addressing. 6.8.1.6 Configure – System – Data log Allows the USB memory stick to be Forces the Datalog to be written eject from the system without to the SD now instead of waiting the real-time timeout...
  • Page 79 6.8.1.7 6.8.1.7 Configure – System – Password Pressing the red square (without checkmark) will turn on both the Calibration (green square with checkmark) and Configuration passwords. The gray square with check mark denotes the Configuration password cannot be turned off Both passwords are the same by default but are user modifiable.

  • Page 80: Information

    6.8.2 Information Page 69...

  • Page 81: Information - Alarm Logs

    6.8.3 Information – Alarm Logs Displays the occurrence and messages associated with the occurrence Moves the cursor up/down the occurrences Deletes all confirmed occurrences Selects an occurrence Confirms the Confirms all Deletes the selected, recovered selected, recovered occurrences confirmed occurrence occurrence.

  • Page 82: Information - System

    6.8.4 Information – System The information Systems Key will display key systems information: Revisions, Ethernet information, Calibration factor logs, Relays and output information. Page 71...

  • Page 83: Information - Sensor

    6.8.5 Information – Sensor The Information Sensors key will provide important information regarding the pH sensor: Revisions, Cal Logs 1, 2, and 3. Page 72...

  • Page 84: Maintenance

    7.0 MAINTENANCE Basic maintenance on the CA900 Analyzer requires refilling or replacing reagent containers and cleaning the Reaction cell on a regular basis. In addition we advise that you perform an overall visual check of the wetted parts for any leakage. If any leaks are detected, take immediate corrective action.

  • Page 85: Every 4-6 Months (Depending On Applications)

    Hydraulics tubing replacement Clean / Replace Fittings 7.4 Annual Analyzer general inspection (for qualified personnel only) 7.5 Parts and accessories Model CA900 Analyzer: Spare Parts Part# Description 2010125-1 KIT, 4pH & 7pH BUFFERS (1L EA), CLEANER (2L), REAGENT(S) 500ML *RECOMMENDED SPARE PART 2010100‐1L...
  • Page 86 *MUST PROGRAM DOSAGE VALVE 2005111.VIT ELECTRODE *RECOMMENDED SPARE PART DS80‐ SENSOR W/ ELECTRODE 000C67‐ 4B00‐013 2000155‐7 PINCH VALVE ASSY 9580006 KEY ENCLOSURE 9600072 MAGNETIC STIRRER 2000151‐1 SAMPLE PUMP Page 75...

  • Page 87: Analyzer Shut Down

    8.0 ANALYZER SHUT DOWN If the CA900 Analyzer will be out of service for a period of two weeks or greater, proceed as follows: Empty all reagent containers. Rinse and refill all reagent containers with distilled water. Prime all of the pumps with DI water.
  • Page 88 1500 North Kellogg Drive ● Anaheim, CA 92807 ● +1-714-695-0051 ● FAX +1-714-695-0057 ● ecdi.com...