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ABB Aztec 600, User Manual

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ABB Aztec 600 User Manual Download Page 55

Aztec 600 aluminium, ammonia, color, iron, manganese, phosphate 

Single- and multi-stream colorimetric analyzers

10 Diagnostics

52

IM/AZT6CR–EN Rev. J

10 Diagnostics

10.1 Monitor Status

There are five tabs in the Monitor Status screen:

10.1.1 Status

Note.

The 'Diagnostics' menu can be accessed only from the 'Indicator View’ screen.

Fig. 10.1 User Diagnostic Screens

 see Section 10.1, page 52

see Section 10.2, page 54

see Section 10.3, page 54

 see Section 10.4, page 54

Fields

Description

Current State

Displays the current state of the analyzer (for example, Measuring, calibrating, off).

Current Step 

An indication of what the analyzer is doing in 'real time'.

Measurement Complete 

A 'real-time' indication of measurement cycle progress

Sample Concentration

The current estimated concentration, derived from the raw detector signal. This is displayed only after
the addition of all reagents.

Detector mV

The raw signal from the analyzer detector (0 to 4095 mV).

LED Current 

Displays the current of the LED.

Dilution Ratio(s) 

The current dilution ratio applied to each of the measurement streams.

Cell Temperature

The current recorded cell temperature.

Summary of Contents for Aztec 600

Page 1: ... Aztec 600 MANUAL JUNHO 2013 ...

Page 2: ...d analysis and environmental applications As a part of ABB a world leader in process automation technology we offer customers application expertise service and support worldwide We are committed to teamwork high quality manufacturing advanced technology and unrivalled service and support The quality accuracy and performance of the Company s products result from over 100 years experience combined w...

Page 3: ...ns see Section 6 7 Chart View Menu shown logging options from this top level menu cannot be accessed from Configuration Logging Current Outputs see Section 6 5 see section 6 page 24 see section 7 page 42 see section 8 page 49 see section 11 page 55 see section 12 2 page 61 see section 3 2 page 11 see section 9 page 51 see section 10 page 52 Chart View Menu see Section 2 1 Indicator View Menu see S...

Page 4: ...ontrols 22 5 2 Navigation and Editing 22 5 2 1 Text Editing 22 5 2 2 Numeric Editing 23 5 2 3 Other Methods of Editing 23 5 2 4 Menus 23 5 3 Software Screen Structure 23 5 3 1 Indicator View Menus 23 5 3 2 Chart View Menus 23 6 Configuration 24 6 1 Common 26 6 1 1 Setup 26 6 1 2 Screen 26 6 1 3 Time 27 6 1 4 Security 28 6 1 5 User 31 6 1 6 Operator Messages 31 6 2 Measurement 32 6 2 1 Setup 32 6 2...

Page 5: ...agents 77 A 1 Reagent Solutions 77 A 1 1 Reagent Storage 77 A 2 Reagent Consumption 77 A 3 Consumption of Sample Standards and Dilution Water 78 A 4 Cleaning Solutions 78 Appendix B Troubleshooting 79 B 1 Analyzer Malfunction 79 B 2 Cell Diagnostics 79 B 3 Effects of Loss of Power to the Analyzer 79 B 4 Simple Checks 80 B 4 1 Unstable or Erratic Readings 80 B 4 2 High Low Measured Values 82 B 4 3 ...

Page 6: ...uipment may be impaired Health and Safety To ensure that our products are safe and without risk to health the following points must be noted The relevant sections of these instructions must be read carefully before proceeding Warning labels on containers and packages must be observed Installation operation maintenance and servicing must only be carried out by suitably trained personnel and in acco...

Page 7: ... or remove the barrier This symbol indicates that the marked item can be hot and should not be touched without care This symbol indicates the presence of devices sensitive to electrostatic discharge and indicates that care must be taken to prevent damage to them This symbol identifies a risk of chemical harm and indicates that only individuals qualified and trained to work with chemicals should ha...

Page 8: ...uring that the risk of any environmental damage or pollution caused by any of its products is minimized as far as possible The European Waste Electrical and Electronic Equipment WEEE Directive 2002 96 EC that came into force on August 13 2005 aims to reduce the waste arising from electrical and electronic equipment and improve the environmental performance of all those involved in the life cycle o...

Page 9: ... you have any problems with installation starting or using the instrument please contact the company that sold it to you If this is not possible or if the results of this approach are not satisfactory please contact the manufacturer s Customer Service 1 12 Potential Safety Hazards The following potential safety hazards are associated with operating the analyzer Electrical line voltage Potentially ...

Page 10: ... is presented on the display Analyzer main components are shown in Fig 2 1 The hinged lower door provides environmental protection for the liquid handling section to ensure stabilized measurement conditions To maintain optimum measurement accuracy the analyzer performs a 2 point calibration automatically by introducing standard solutions of known concentrations The analyzer utilizes solenoid valve...

Page 11: ...us icons 3 Measurement unit l Indication of SD card capacity full empty as a associated with displayed status icon 4 Measured value m Current date and time 5 Diagnostic icon and message see Section 12 page 56 n Audit Log screen 6 Chart view multi stream shown Note Alarm Event and Operator Message annotations are not shown on the chart unless enabled see Section 6 6 1 page 37 o Audit Log icon event...

Page 12: ... an alarm becomes active a red alarm event icon surrounded by a channel colored box is displayed at the point at which the alarm occurred together with the alarm time and tag for example If more than one alarm occurs in the same sample period and the second alarm on a channel becomes active its icon is added behind the first and more than one operator message is active max 6 a second icon is added...

Page 13: ... and use the and keys to select Common Configuration to configure the analyzer Setup see Section 6 1 1 page 26 Screen see Section 6 1 2 page 26 Time see Section 6 1 3 page 27 Security see Section 6 1 4 page 28 User see Section 6 1 5 page 31 Operator Messages see Section 6 1 6 page 31 5 Press the key and use the and keys to select Measurement to set up the analyzer measurement parameters Setup see ...

Page 14: ...e Once stabilized calibration is performed automatically the analyzer then enters measuring mode 3 2 On line Help If any alarms or messages appear on the operator screen press the key to open the help at the relevant diagnostic help topic For example if the Calibration Failed message is active and the help is opened the help opens at the Calibration Failed diagnostic topic 1 Press the key and use ...

Page 15: ...crons in size Above these levels an external filter must be fitted to the sample lines Sample must be at atmospheric pressure It must be as close to the analyzer as possible and the sampling point must provide a thoroughly mixed representative sample 4 3 Location For general location requirements refer to Fig 4 1 Install in a clean dry well ventilated and vibration free location giving easy access...

Page 16: ...s to the wall 1 Mark the wall using the dimensions shown in Fig 4 3 Alternatively with the shelf supported carefully against the wall mark through the mounting holes 2 For each tray drill and plug mounting holes suitable for M8 or 5 16 in fixings All Dimensions in mm in Fig 4 2 Mounting the Analyzer Note Clearance the enclosure doors can open 180 If mounting in a confined area allow sufficient cle...

Page 17: ...phate Single and multi stream colorimetric analyzers 4 Installation 14 IM AZT6CR EN Rev J 4 5 Dimensions All Dimensions in mm in Fig 4 4 Dimensions 366 14 4 315 12 4 279 11 0 653 25 7 430 16 9 183 7 2 600 23 6 400 15 7 300 11 8 Maximum Distance 1100 43 3 ...

Page 18: ...ent of the internal battery type Varta CR2025 3V lithium cell must be carried out by an approved technician only The analyzer conforms to Installation Category II of IEC 61010 All connections to secondary circuits must have insulation to required local safety standards After installation there must be no access to live parts for example terminals If the analyzer is used in a manner not specified b...

Page 19: ... using a small flat bladed screwdriver make connections to each plug Ensure wires are connected to the correct terminals see Fig 4 7 page 18 8 Reconnect the terminal block plugs to the appropriate sockets on the application board 9 Tighten gland nut H for each connection made 10 If required connect the Ethernet cable see Section 4 6 2 page 17 11 When all the connections are made replace the transp...

Page 20: ...ing clip A off blanking plug B and remove the blanking plug b Fit cable gland C and secure using nut D c Remove gland cover E and route cable F through it d Fit the rubber split bush G and split washer H over the cable e Route the cable through cable gland C and into the enclosure case f Plug the RJ45 connector I into the Ethernet RJ45 connector socket on the application board see Fig 4 7 page 18 ...

Page 21: ...s Ethernet RJ45 Connector NO C NC NO C NC NO C NC NO C NC NO C NC Attention Relay Failure Relay Alarm 2 Relay Alarm 4 Relay Alarm 6 Relay NO C NC NO C NC NO C NC NO C NC NO C NC Stop Relay Calibration in Progress Relay Alarm 1 Relay Alarm 3 Relay Alarm 5 Relay Fuse 1 A Type T Fuse 12 5 A Type T L N E E OR Use fuse rating AC Supply 1 A max Type T 250 V DC Supply 12 5 A 125 V DC Type T Manufacturer ...

Page 22: ...orrect readings To minimize the effects of RFI arc suppression components are required these are resistor capacitor networks for AC applications or diodes for DC applications These components can be connected across the load Maximum relay ratings are 250 V 5 A AC 1250 VA non inductive 30 V 5 A DC 150 W For AC applications the value of the resistor capacitor network depends on the load current and ...

Page 23: ...ing a sample flow failure indication Single stream Units Using rigid nylon tubing 1 Connect stream 1 to sample inlet connection A 6 mm OD tubing 2 Connect stream 1 drain line to sample outlet connection B 10 mm OD tubing Multi stream Units Using rigid nylon tubing 1 Connect stream 1 to black sample inlet connection A 6 mm OD tubing 2 Connect stream 1 drain line to black sample outlet connection B ...

Page 24: ...se proximity to the bottom of the reagent container Adjustment can be made by loosening D moving the sensor to position retightening D and then A 5 Secure the reagent level sensor to the reagent container with cap C 4 7 3 Connecting the Analyzer Waste Analyzer waste is expelled through the dedicated waste port on the valve manifold assembly identified by a W symbol Route analyzer waste tubing to a...

Page 25: ...ll right e Enter Key Selects the highlighted menu item operation button or edit selection 5 2 Navigation and Editing Depending on the type of field to be edited the software provides a variety of methods for entering values 5 2 1 Text Editing If the field to be edited requires text a keyboard is displayed To enter text use the and keys to highlight the required character and press There are three ...

Page 26: ...required checkbox and press To finish highlight OK and press to exit and save changes or press to exit without making any changes Slider Bars To select a value use the and keys to move the slider To finish press to exit and save changes or press to exit without making any changes Tabs To select a tab use the and keys 5 2 4 Menus Press to open the menu and use the and keys to select a menu item Pre...

Page 27: ... Basic see on line help system Edit the current configuration Changes are not implemented until saved on exit from Configuration Open a configuration saved previously to internal or external storage up to 16 configurations can be stored in internal memory see Note 1 overleaf Cancel Toggle between internal external storage Accept selection Open a new configuration with the default settings see Note...

Page 28: ...ctive configuration is saved to internal storage Selecting Save as Current Configuration suspends recording for a short time while the new configuration is implemented When saving the current configuration to internal storage the file is saved automatically with a time date instrument tag cfg filename When saving the current configuration to external storage the file is saved automatically to inte...

Page 29: ...o 20 characters can be used The instrument tag is also displayed on the analyzer on configuration files and audit log files Main View Timer The time after no key presses the display reverts to the main operator screen excludes Configuration screens Fields Description Screen saver wait time The time delay for the screen saver The screen dims after the time set Screen Capture Toggles between Enabled...

Page 30: ...atically by 1 hour at 2 00 am on the second Sunday in March and decremented automatically by 1 hour at 2 00 am on the first Sunday in November Auto Europe The start and end of the daylight saving period in Central Europe is calculated automatically The clock is incremented automatically by 1 hour at 2 00 am on the last Sunday in March and decremented automatically by 1 hour at 2 00 am on the last ...

Page 31: ...d screwdriver remove the four cover plate retaining screws B and remove the cover plate 3 Set the security switch C to the required position Configuration security parameter setting see page 29 Internal Security Switch Setting see Fig 6 2 Password protected Factory Default Internal switch protected Alternative Disabled Factory Default Password Access No Access Enabled Free Access Free Access Fig 6...

Page 32: ...system toggles between Basic and Advanced Basic Allows access to the Configuration menu for up to four users User 1 to 4 a unique password of up to four digits can be set for each user A separate password can be set to access the Calibration Maintenance and Logging menus up to four users share this password Advanced Allows up to twelve users password protected access to any of the Configuration Ca...

Page 33: ...enus The following fields are displayed only if Security system is set to Advanced Reconfigure preset Passwords are set initially by User 1 System Administrator but any user can make subsequent changes to their own password When set to Yes each user must change their password after it is used for the first time following initial configuration Password expiry Select the number of days that the pass...

Page 34: ...passwords If selected additional fields appear User X Name Where X is the user number 2 to 12 up to 20 characters can be used User X Access Where X is the user number 2 to 12 A dialog box is displayed listing the access available for the user Logging Configuration No access Configuration Load Configuration Limited Configuration Full User X Password Where X is the user number 2 to 12 The password f...

Page 35: ...nsed with sample prior to measurement Configurable between 1 and 4 rinses Fields Description Stream 1 2 3 The Stream tag text is displayed in the operator views Up to 20 characters can be used The Stream tag is also displayed in the configuration files and audit log files Stream 1 2 3 Dilution Ratio Sets the Max Dilution Factor values for each stream Notes Changing the Dilution Ratio affects the a...

Page 36: ...h standard Gradient Coefficient The gradient coefficient is an indication of the variation between the actual calibration curve and the ideal calibration curve A limit to the gradient coefficient can be set ideal coefficient 1 Above this limit the analyzer fails a calibration Default fail criteria occurs when the coefficient exceeds 1 0 6 Calibration Fail Event If this is set to FAIL default after...

Page 37: ... On Alarm switches off automatically Concentration Hysteresis Alarm Off Trip Point Alarm On Alarm Latched Alarm Off Alarm acknowledged by operator Earliest point that the alarm can be acknowledged Earliest point that the alarm can be acknowledged Hysteresis Alarm On Alarm Latched Concentration Alarm acknowledged by operator High Latch Alarm Action Low Latch Alarm Action Concentration Alarm acknowl...

Page 38: ...if an out of sample condition occurs in the selected stream source Alarm Tag The Alarm identification tag up to 20 characters Trip The value at which the alarm is to activate Hysteresis When an alarm trip value is exceeded the alarm does not become active until the time hysteresis value has expired If the signal goes out of the alarm condition before the time hysteresis has expired the hysteresis ...

Page 39: ... between the zero and span is too small the output is very noisy Output Type The electrical high and low limits 0 to 22 mA For example if the output range is set to 0 to 2000 ppb and the Output Type to 4 00 to 20 00 mA at 0 ppb the output is 4 00 mA and at 2000 ppb the output is 20 00 mA Calibration Hold If set to Yes the output value remains at the level prior to calibration Out of Sample Ind Out...

Page 40: ...on and direction of the chart display Options are Horizontal Horizontal Vertical Chart annotation Enables chart annotations to be visible Options are None Alarms Alarms Operator Messages Chart divisions The major and minor chart divisions Trace pointers Toggles the trace pointers on off Screen interval The amount of data shown on the screen Trace width The width of each trace in pixels 1 to 3 Fiel...

Page 41: ... enables At least one of these options must be selected for data to be archived automatically to an SD Card A dialog box is displayed showing the log files that are to be recorded Text format file containing the stream data Binary format file containing stream data Alarm event log file enable e Audit log file enable a New file interval Available only if Wrap is set to Off and text format is select...

Page 42: ...of the IP address is for the network ID and which is for the host ID Set each section that is part of the network ID to 255 For example 255 255 255 0 indicates first 24 bits are for the network ID Default Gateway The IP address for the Default gateway for example router switch required to communicate with other networks The default setting is 0 0 0 0 FTP user 1 to FTP user 4 Enables up to four use...

Page 43: ...ail sent includes a link to the analyzer s embedded web server enabling the analyzer s data and status to be viewed remotely using an internet browser on a PC 6 7 3 Profibus Refer to separate Profibus manual IM AZT6PBS Fields Description SMTP Server IP Address The IP address of the SMTP server through which e mails are to be routed Recipient 1 to Recipient 3 The e mail address of recipient 1 to 3 ...

Page 44: ...reams is to be changed For further information on the function of the Internal Security Switch refer to Section 6 1 4 page 28 Fields Description Instrument type The parameter to be measured by the analyzer The options are Aluminium Monitor Ammonia Monitor Iron Monitor Manganese Monitor Manganese LR Monitor Phosphate Monitor Colour Monitor Streams Fitted The number of streams to be measured by the ...

Page 45: ...data Configuration files Screen capture images Fig 7 1 Recording and Archiving Invalid Password Valid Password No Password Required Password Required if set Resets Archiving see Section 7 2 page 44 Switches the removable media online offline Opens the file viewer see Section 7 3 page 44 On line help see Section 3 2 page 11 Note ABB s DataManager software can be used to store and view data archived...

Page 46: ...rovides a buffer for the most recent data so if data stored on an SD card is lost it can be re archived see Section 7 2 page 44 Data is copied to an SD card when required An SD card is inserted into the analyzer and a prompt is displayed asking the user to select the unarchived data to be copied see Section 12 page 56 7 1 1 SD Card Insertion Removal To access the SD Card 1 Ensure the analyzer is o...

Page 47: ...2 Reset Archiving If Reset Archiving is selected all data in the internal memory is re archived to external media To re archive data 1 Insert an SD card with sufficient free space into the analyzer 2 Select Off line in the menu 3 Select Reset archiving in the menu 4 Select On line in the menu 5 Select the data to be archived if 1 hour Text format or 1 day Binary format of data in internal memory a...

Page 48: ...n a comma separated value format and can be imported directly into a standard spreadsheet for example Microsoft Excel as shown in Figs 7 3 and 7 4 The files can also be saved in ASCII text format Alternatively the data can be analyzed graphically in detail on a PC using ABB s DataManager data analysis software Fig 7 3 Example of Text Format Channel Data File Fig 7 4 Example Text Format Audit Log F...

Page 49: ...sion of D01 7 5 2 Text Format Stream Data Example Filenames New file interval set to Hourly Filename tag set to Process Group 1 date is 10th October 2007 Channel data and alarm event log files only enabled 9 00 am new file created in which all channel data recorded between 9 00 and 9 59 59 is archived in the following file 09_00_10 Oct07_Process_Group_1 d00 09 12am Power interrupt occurs 09 13am P...

Page 50: ... data generated from 02 00 00 7 5 5 Text Format Data Verification and Integrity When text format data is saved to the archive media it is checked automatically to verify that the data stored on the media matches exactly what is stored in the internal memory 7 6 Binary Format Data Files Binary format archived data is stored in a secure binary encoded format A separate file is created for each recor...

Page 51: ...s created filename 02000026Oct08Ch1_1AnlgAW633 B00 The file 00150026Oct08Ch1_1AnlgAW633 DS D00 contains data generated from 00 15 00 to 02 59 59 before summertime ends The file 02000026Oct08Ch1_1AnlgAW633 contains data generated from 02 00 00 after summertime ends 7 6 3 Binary Format Log Files A new binary format log file is created under the following conditions When an existing valid binary file...

Page 52: ...4 pre defined messages see Section 6 1 6 page 31 Alternately the messages can be user defined Annotations can also be added remotely via the web see Appendix D page 90 The annotation is added to the chart at the time it is entered For example An entry is also included in the Alarm Event Log 8 3 Chart Annotation Toggles any operator messages and or alarms on off Note The Chart Functions menu can be...

Page 53: ... selected from this menu it is retained only as long as the Chart View screen is displayed To save a different screen interval as the default for future use select Configuration Logging Chart Screen Interval set the screen interval required and save the revised configuration on exit 8 5 Scales Selects the scale to be used Up to three color coded streams can be displayed simultaneously and each str...

Page 54: ...ss to initiate calibration When calibration is complete the measurement cycle begins automatically 9 4 Prime Lines and Calibrate When the reagents are changed or the analyzer is either operated for the first time or operated following an extended period of shut down prime the reagent and sample lines The Prime function draws in each reagent sample and standard in turn filling the lines and then pu...

Page 55: ...ds Description Current State Displays the current state of the analyzer for example Measuring calibrating off Current Step An indication of what the analyzer is doing in real time Measurement Complete A real time indication of measurement cycle progress Sample Concentration The current estimated concentration derived from the raw detector signal This is displayed only after the addition of all rea...

Page 56: ... gradient and an ideal calibration gradient stored within the analyzer Any slight differences due to temperature variations reagent ageing etc are expected and calibrated out If there is a large variation the analyzer fails calibration The ideal coefficient 1 default fail criteria occurs when the coefficient is outside the range 0 4 to 1 6 Time Last Cal The date and time of the previous calibratio...

Page 57: ...ammeter Use the and keys to increase decrease the milliamp value If the ammeter and analyzer do not agree it may be necessary to recalibrate the current outputs see Section 6 5 2 page 36 Note If this procedure is selected when the analyzer is in operation a warning is displayed Note Select Back and press to return to normal operation Select Continue and press to continue to cell diagnostics This s...

Page 58: ...11 Statistics IM AZT6CR EN Rev J 55 11 Statistics Displays the highest lowest and mean values of the sample s since the analyzer was either switched on or the values were reset Press the key to reset the values Note The Statistics menu can be accessed only from the Chart View screen Fig 11 1 Chart Functions ...

Page 59: ...nction Out of specification Maintenance required Icon Diagnostic message Stop Relay Attention Relay Calibration Relay Failure Relay Monitor in Service The analyzer is measuring correctly OFF OFF OFF OFF 20 Character User defined Alarm Tag User defined alarm message Monitor Stopped Analyzer operation has been stopped by the user ON OFF OFF OFF Monitor Off Analyzer operation has not been started or ...

Page 60: ...il Event has been set to Attention from the default Fail the analyzer continues to measure after a failed calibration using the last valid calibration OFF ON OFF OFF Calibration Standard Empty The calibration standard bottle is empty Replace the calibration solution OFF OFF OFF ON Cleaning A clean routine is being run ON OFF OFF OFF Critical Temperature Reached This alarm is initiated if the analy...

Page 61: ...ay measurement values The routine can be used without a prior calibration and is useful when a analyzer is swapped from one parameter to another The analyzer remains in flushing mode until it is stopped ON OFF OFF OFF Head Comms Failure Communication failure with Head Control Module 1 Check that the head chip is inserted correctly 2 Contact the local ABB representative OFF OFF OFF ON Heating Failu...

Page 62: ...fter moving up and down twice the measurement cell is continuously dark and no LED or motor fault is detected 1 Check that the LED and detector are connected correctly and working 2 Check the measurement cell and piston OFF OFF OFF ON No Valid Calibration There is no valid calibration stored within the analyzer memory Calibrate the analyzer ON OFF OFF OFF Non Volatile Memory Error This message app...

Page 63: ...hat the LED and detector are connected correctly and working 2 Check the measurement cell and piston OFF OFF OFF ON Priming The analyzer is priming the tubing The priming routine draws in each reagent sample and standard in turn filling the tubing and then pumping to waste An automatic calibration starts when the priming routine is completed ON OFF OFF OFF Reagent n Empty The indicated reagent bot...

Page 64: ...overwritten by the newest data Entries are renumbered so that the number of the oldest entry is always 00 Both logs are accessible from the chart view and bar view see Section 2 1 page 8 for details of how to navigate to these logs 12 3 1 Audit Log Icons Note Active unacknowledged alarms are identified by a flashing red alarm event icon Active acknowledged alarms are identified by a continuous red...

Page 65: ...nciate alarm active inactive Low annunciate alarm active inactive Clean in progress alarm active inactive In sample alarm Out of sample alarm Daylight saving start end changed Alarm acknowledged Operator message Note Status icons are displayed in the Status Bar see Fig 2 1 page 8 Icon Event Historical review active External archive media on line with used indication External archive media off line...

Page 66: ...s are correctly in place hand tighten the bottle caps This protects against the ingress of dust water etc 6 Select Prime lines and Calibrate and press the key Take care when storing the bottles Ensure they are date stamped used in strict rotation and not used after the expiry date Warning Ensure personal protective equipment PPE such as gloves and eye protection are worn during any maintenance and...

Page 67: ...flat bladed screwdriver No 2 Pozidrive screwdriver 3 mm Allen key 4 mm Allen key 13 3 4 Replacing the Valve Diaphragms 1 Referring to Fig 13 1 a Check that anti rotation device A is positioned at the bottom of the slot in the measurement cell top cover indicating that the measurement cell piston is at the bottom of its stroke b Press and select Diagnostics followed by Cell Diagnostics from the Ope...

Page 68: ... IM AZT6CR EN Rev J 65 c Remove the 3 M4 screws C securing the valve manifold to the analyzer remove the valve manifold and place on a clean work surface Fig 13 1 Removing the Manifold Note During step 5 remove and refit the valves one at a time in the order given to ensure they are refitted in the correct position B C A ...

Page 69: ...ainer K insert the diaphragm retainer complete with washer L and diaphragm M into the valve ensuring the spring remains in position h Press the diaphragm seat I into the valve body until the retaining clips H lock into place i Fit the new Kalrez valve face gasket G into the recess in the diaphragm seat j Refit the valve D to the valve manifold and secure using the two M3 screws F k Working in a cl...

Page 70: ...e with the three M4 screws N 13 3 5 Replacing the Tubing 1 Referring to Fig 13 4 a Note the routing of sample tube S1 recorded in Section 13 3 4 step 4a b Disconnect the tube from the base of the side sample pot A and discard c Connect one end of the new sample tube to the side sample pot d Route the tube as noted in step a and connect the other end to the S1 valve connector B on the valve manifol...

Page 71: ...e valve connector D on the valve manifold 3 Referring to Fig 13 6 a Disconnect the interconnecting tube recorded in Section 13 3 4 step 4a from the connector E at the base of the measurement cell assembly and discard b Fit the new interconnecting tube to the valve manifold center connection F Do not connect the tube to connector E at this stage Caution Ensure the correct tube is fitted AW630 371 T...

Page 72: ...nnect the tube from the level sensor I and withdraw the tube from the rubber boot J d Insert the new tubing through the rubber boot J and route the tubing into the analyzer as noted in step a Connect the tubing to the R1 connector on the valve manifold K e Refit the spiral wrapping G f Cut the tubing to the required length and connect it to the level sensor I g Adjust the position of the spiral wr...

Page 73: ...alytical section forward and allow it to rest against its stops 2 Referring to Fig 13 9 a Disconnect the measurement cell ribbon cable B from the connector on the back of the measurement cell b Remove the four M4 screws C and remove the measurement cell assembly 3 Referring to Fig 13 10 depress catch D and remove cover E Fig 13 8 Opening the Analytical Section A Fig 13 9 Removing the Measurement C...

Page 74: ...e J 5 Referring to Fig 13 12 remove the two screws K and remove the measurement cell top cover L 6 Referring to Fig 13 13 disconnect the motor wiring plug M Continued Caution During step 4 do not allow any fluid from the measurement cell sample tube to come into contact with either the skin or any metallic electronic parts of the analyzer The fluid is contaminated with acid from the reagents used ...

Page 75: ... the new piston top W and secure loosely with the new piston cone adjusting screw X and spring washer Y Do not tighten the piston cone adjusting screw at this stage f Insert the new piston assembly Q into the top of the new sample tube P and holding the piston firmly tighten the piston cone adjusting screw X until a continuous seal is achieved between the piston seal U and the sample tube P g Remo...

Page 76: ...groove in the end cap b Invert the measurement cell assembly and position end cap H over the end of the sample tube J c Refit base plate G ensuring that the end cap is centered in the hole in the base plate Secure the base plate with the four screws F 13 Referring to Fig 13 10 refit cover E 14 Referring to Fig 13 9 a Locate the measurement cell assembly onto the analytical section back plate and s...

Page 77: ...se low range Range 0 000 to 0 100 ppm Mn Phosphate Auto ranging 0 05 to 50 ppm PO4 Undiluted range 0 05 to 10 ppm PO4 Diluted range 10 to 50 ppm PO4 Chemical Method Aluminium Pyrocatechol Violet PCV Ammonia Indophenol blue Color Measurement of water color by absorbance at 400nm expressed in Alpha Hazen scale or Platinum Cobalt scale Iron Tripyridyl triazine TPTZ Manganese Formaldoxime Manganese lo...

Page 78: ... Frequency Color analyzer only User selectable 1 to 12 hour frequency 1 Maximum measured error across full measurement range 2 Tested in accordance with IEC 61298 Parts 1 4 Edition 2 0 2008 10 3 Tested in accordance with BS ISO 15839 2003 Environmental Data Ambient Operating Temperature Aluminium ammonia iron manganese phosphate 5 to 45 ºC 41 to 113 ºF Manganese low range 5 to 35 ºC 41 to 93 ºF Co...

Page 79: ...cure Digital SD card Trend analysis Local and remote Data transfer SD card or FTP Approvals Certification and Safety Safety Approval cULus CE Mark Covers EMC LV Directives including latest version EN 61010 General Safety EN 61010 1 Overvoltage Class 11 on inputs and outputs Pollution category 2 EMC Emissions immunity Meets requirements of IEC61326 for an Industrial Environment DS AZT6AL EN Rev F D...

Page 80: ...an hour are measured Typically 0 75 ml of each reagent is used per determination Warning Ensure personal protective equipment PPE such as gloves and eye protection are worn during any maintenance and that any spillages are cleaned up Observe all health and safety procedures for handling chemicals Aztec 600 Analyzer Reagent 1 5 l Reagent 2 5 l Reagent 3 5 l Standard 2 5 l Aluminium Acid Buffer Colo...

Page 81: ...ml Sample 13 25 ml DI Water 18 ml Sample 18 ml DI Water 1 2 2 5 ml Sample 5 0 ml DI Water 5 7 ml Sample 11 3 ml DI Water 8 85 ml Sample 17 65 ml DI Water 12 ml Sample 24 ml DI Water 1 3 1 90 ml Sample 5 60 ml DI Water 4 25 ml Sample 12 75 ml DI Water 6 6 ml Sample 19 9 ml DI Water 9 ml Sample 27 ml DI Water 1 4 1 5 ml Sample 6 0 ml DI Water 3 4 ml Sample 13 6 ml DI Water 5 3 ml Sample 21 2 ml DI W...

Page 82: ...ntrolled manually This mode is used to check the basic performance of the analyzer such as the operation of the piston assembly the activation of valves and the general fluid handling It also displays the detector output in real time allowing the checking of the LED light source and the response of the detector B 3 Effects of Loss of Power to the Analyzer The automatic action taken by the analyzer...

Page 83: ...t the valve face gasket is located correctly see Section 13 3 4 page 64 2 From the reagent line s a Check the reagent barbed connector on the valve manifold tighten if necessary b Check the reagent barbed connector on the top of the level sensor tighten if necessary c Ensure that reagent tubing is fitted correctly to the barbed connectors d Check the reagent solenoid valve s and ensure that the va...

Page 84: ...ows freely d Replace the valve ensuring that the face gasket is located correctly e Repeat for each of the remaining valves 5 Prior to refitting the valve block to the analyzer test for an air tight seal by attaching the syringe to the centre barbed connector drawing back the plunger and releasing it Check the syringe plunger returns to the start position 6 Replace the valve block connect the tubi...

Page 85: ...nalysis techniques it is important to ensure that the samples analyzed are the same and that the analysis methods are comparable 1 Check that the sample taken for external analysis is the same sample the analyzer is measuring by collecting the sample from the overflow from the side sample pot 2 Check that samples taken are analyzed in a timely manner 3 Check that the collected sample does not unde...

Page 86: ...every 24 hours This can be reduced to save reagent and standard usage 1 Press the key and enter the configuration menu to configure the analyzer 2 Set the Measurement Frequency see Section 6 2 1 page 32 3 Set the Calibration Time and Frequency see Section 6 3 1 page 33 Excessive usage of one reagent Excessive usage of one reagent could indicate a blocked or partially restricted flow through the an...

Page 87: ...k the OD Low value and the OD High value against the acceptable values see Table C 3 page 89 for acceptable values OD Low Value too High If the OD Low value is too high too much color is being formed when measuring the blank This could be due to the de ionised water becoming contaminated a restriction in the tubing or a faulty valve 1 Replace the DI water with fresh solution and prime and calibrat...

Page 88: ...ample and reagents are introduced and expelled resulting in an automatic cleaning process This cleaning process reduces maintenance and increases the accuracy and repeatability of the analyzer The piston pump design enables the analyzer to make use of a unique patented air mixing system The final upward movement of the piston coincides with the opening of the air valve drawing air vigorously throu...

Page 89: ...hen a known standard The two values obtained are used to produce a calibration graph The analyzer compares the calibration graph with the ideal working curve stored within its memory If the variation between the ideal working curve and the 2 point calibration is acceptable the analyzer returns to the measurement cycle if it is not the analyzer fails calibration C 5 LED Calibration Before each cali...

Page 90: ...chloramine product then reacts with a phenolic compound giving the indophenol blue compound which is measured spectrophotometrically in the analyzer 1 Rinse cell with sample 2 Bring in color reagent 3 Bring in sample 4 Wait 30 seconds 5 Measure background absorbance 6 Bring in catalyst 7 Bring in alkaline buffer 8 Mix with air 9 Wait 10 minutes for color to develop 10 Measure final absorbance Azte...

Page 91: ...manganese and leucomalachite green 1 Rinse cell with sample 2 Bring in preconditioner to remove chlorine interference 3 Bring in sample 4 Wait for 30 seconds 5 Measure background absorbance 6 Bring in bring in buffer oxidant 7 Wait 5 minutes 8 Bring in color forming reagent 9 Mix with air 10 Wait 3 minutes for color to develop 11 Measure final absorbance Aztec 600 Phosphate Phosphomoly bdenum Blue...

Page 92: ...Calibration Gradient Aluminium 0 035 to 0 085 0 400 to 0 600 2 000 to 2 700 Ammonia 0 010 to 0 070 0 245 to 0 420 0 630 to 1 000 Color 0 000 0 056 to 0 084 595 to 893 Iron 0 000 to 0 010 0 100 to 0 120 0 450 to 0 600 Manganese 0 020 to 0 000 0 120 to 0 140 0 240 to 0 300 Manganese Low Range 0 000 to 0 100 0 580 to 0 750 5 500 to 7 500 Phosphate 0 005 to 0 015 0 210 to 0 240 0 064 to 0 080 Table C ...

Page 93: ... 7 1 page 39 b Analyzer View displays the current screen of the analyzer If the analyzer has a screen saver set it does not affect this view c Access Buttons provides access to the analyzer s data if the user has the appropriate access permission Stream Values see Appendix D 1 page 90 Operate see Appendix D 2 page 91 Monitor Status see Appendix D 3 page 91 Statistics see Appendix D 4 page 91 Loggi...

Page 94: ...alyzer as a warning for example Operator instructions can be removed only by pressing the key To send an operator message or instruction to the analyzer 1 Type the User name and Password Up to 160 characters can be used These are the FTP username and password that are set in the configuration see Appendix D page 90 2 Type either the message or an instruction only one field can be populated at any ...

Page 95: ...lick OK 4 Select the Advanced tab of the Internet Options dialog box ensure that the Enable folder view for FTP sites option under the Browsing heading is selected and click OK To access data stored on the analyzer via Internet Explorer 1 Start Internet Explorer 2 In the Address bar enter ftp followed by the IP address of the analyzer from which the files are to be copied A log in dialog box is di...

Page 96: ... FTSP is available that enables archive and configuration files to be transferred automatically to a PC using FTP The transferred files can be stored either on the local drive of the PC or on a network drive for easy access and secure back up To download the FTSP program FTS exe enter the following without spaces in your web browser s Address bar http search abb com library ABBLibrary asp Document...

Page 97: ...rt the SD card close the door and switch on the analyzer A start up message appears for a short duration approximately 5 seconds followed by a File Load Progress bar then the ABB splash screen 9 A Warning screen appears next This provides the option to upgrade the existing system software or exit without upgrading 10 To proceed press the key 11 The Commissioning V2 0 screen appears with the Upgrad...

Page 98: ... 1 5 l Aztec Aluminium Reagent 2 5 l Aztec Aluminium Reagent 3 5 l Aztec Aluminium Standard 2 5 l AWRK632 0360 Set of Aztec Ammonia Reagents consisting of Aztec Ammonia Reagent 1 5 l Aztec Ammonia Reagent 2 5 l Aztec Ammonia Reagent 3 5 l Aztec Ammonia Standard 2 5 l AWRS630 0105 Aztec Color Standard 50 Hazen 50 mg l Pt Co 5 l AWRK633 0619 Set of Aztec Iron Reagents consisting of Aztec Iron Reagen...

Page 99: ...5 l empty reagent bottles transparent for use with AW631 Aluminium AW637 Color AW633 Iron AW635 Manganese for AW634 Manganese low range version use AW630 031 AW636 Phosphate AW630 031 Set of 4 x 5 l empty reagent bottles opaque for use with AW632 Ammonia AW634 Manganese low range AW630 032 1 x 10 l empty bottle transparent for use with de ionised water Part No Description ...

Page 100: ...ment valve manifold assembly single stream AW630 075 Replacement valve manifold assembly multi stream AW630 090 Replacement valve EPDM diaphragm AW630 091 Replacement waste valve AW630 088 Pack of 5 valve diaphragms and valve face gaskets EPDM AW630 089 Pack of 1 valve diaphragm and valve face gasket for waste valve AW630 092 Pack of 5 valve face gaskets EPDM AW630 093 Valve face gasket for waste ...

Page 101: ... stream AW630 080 Complete side sample pot assembly multi stream AW630 062 Side sample pot elbow fitting 3 8 in BSPP x 10 mm AW630 065 Side sample pot elbow fitting 1 4 in BSPP x 6mm AW630 063 Replacement sample float assembly AW630 084 Sample pot top cap complete with O ring AW630 085 Sample pot bottom cap complete with O ring and barbed fitting AW630 096 Side sample pot reed switch AW630 067 Rep...

Page 102: ... Associated Parts Part No Description AW630 078 Measuring head assembly without LED AW630 086 Measuring head linear drive stepper motor and leadscrew assembly AW630 097 Glass piston tube AW630 098 Piston seal kit AW630 061 Detector assembly PCB AW630 051 LED assembly PCB Color blue AW630 052 LED assembly PCB Phosphate infrared AW630 053 LED assembly PCB Manganese blue Part No Description ...

Page 103: ...d multi stream colorimetric analyzers Appendix F Spare Parts 100 IM AZT6CR EN Rev J AW630 054 LED assembly PCB Manganese Low Range Ammonia red AW630 055 LED assembly PCB Aluminium Iron amber AW630 060 Measurement head PCB AW630 099 LED detector cover Part No Description ...

Page 104: ...Description AW630 064 Pack of 5 replacement barbed fittings M6 AW630 094 Pack of 5 replacement barbed fittings M5 AW630 059 Analyzer tubing Tygon R3603 1 16 in ID x 1 32 in wall thickness 15 24 m 50 ft AW630 058 Analyzer tubing Tygon 2075 Used on Manganese Low Range analyzer 15 24 m 50 ft AW630 057 Level sensor assembly 2 5 l 5 l AW630 056 Level sensor assembly 10 l Part No Description ...

Page 105: ...v J F 4 5 Electronic Boards Part No Description AW630 087 Interconnection PCB assembly AW630 073 Applications PCB assembly AW600 051 Aztec Navigator PSU kit AC AW600 056 Aztec Navigator PSU kit DC AW630 066 Front door assembly with membrane keypad excluding display AW630 068 Front door assembly with membrane keypad plus display Part No Description ...

Page 106: ...orimetric analyzers Appendix F Spare Parts IM AZT6CR EN Rev J 103 F 5 Accessories Part No Description 03 0051 A Reagent support tray stainless steel 01 0107 A Sample header pot 23 0022 A EasyClean manual system 25 micron 90 0098 C EasyClean automatic system 25 micron Part No Description ...

Page 107: ...ry 41 Commissioning 41 Communications 39 Configuration Exiting configuration mode 25 Internal switch protection 28 Password protection 28 Security Internal switch 28 41 Type 28 Connections Cable connections 16 Electrical connections 15 Controls 22 Current output test 54 Current outputs 36 D Date and time 27 Daylight saving 27 47 48 49 Diagnostic information 56 Dilution point 41 Dimensions 14 Displ...

Page 108: ...it 30 Passwords 28 31 R Ranges 37 Reagents 77 Consumption of sample standards and dilution water 78 Reconfigure preset 30 Relay test 54 Relays 34 Contact protection and interference suppression 19 S Sampling requirements 12 Screen capture 26 Screen interval 50 Screen saver wait time 26 SD card 43 Secure digital media 43 Security 28 Security type 29 Serial number 41 Software Updating the software 9...

Page 109: ...351 21 843 64 00 Note ABB the owner of this document reserves the right to make technical changes or modify the contents of this document without prior notice With regard to purchase orders the agreed particulars shall prevail ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document Copyright 2011 ABB All rights reserved ...

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