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50

Maintenance and Troubleshooting

8.6.4 Troubleshooting table

Table 6  Troubleshooting table

Symptom

Cause

Possible Solution

Unstable
measurement

Degassing

Adjust sample flow rate

Flow chamber and/or membrane not clean

Clean system

Sensor’s membrane not tight smooth and 
wrinkle free

Replace membrane and 
recalibrate

Leaking solenoid valve

No gas bubbles should escape from 
the purge gas outlet during 
measurement. If the solenoid leaks 
(more than 1 bubble in 15 seconds) 
contact your Hach Lange 
representative.

An external power supply is used but the 
power supply is not clean

Switch to battery power

Low readings

Sample flow rate too low

Check flow rate

Degassing

Adjust forcing gas and/or sample flow 
rate

Membrane is not at sample temperature

Allow sample to flow past the 
membrane to make sure the 
membrane is at sample temperature 
before making measurements

Membrane not clean

Clean system

Incorrect solubility curve

Change solubility

Incorrect calibration

Recalibrate

High readings

Membrane is not at sample temperature

Allow sample to flow past the 
membrane to make sure the 
membrane is at sample temperature 
before making measurements

Incorrect solubility curve

Change solubility

Incorrect calibration

Recalibrate

Summary of Contents for ORBISPHERE 3654

Page 1: ...ORBISPHERE Model 3654 Portable Analyzer USER MANUAL June 2009 Revision I ...

Page 2: ......

Page 3: ...k setting 15 3 8 4 Barometric pressure setting 15 3 8 5 Sensor membrane 15 3 8 6 Flow chamber 15 Section 4 Operating Instructions 17 4 1 Operating controls 17 4 2 Taking measurements 18 4 2 1 Select gas measurement phase 19 4 2 2 Measurement mode 19 4 3 Storing measurements in the instrument 19 4 3 1 Automatic data acquisition 20 4 3 2 Manual data acquisition 21 4 3 3 Viewing stored measurements 2...

Page 4: ... Sensor maintenance 41 8 2 1 Maintenance schedule 41 8 2 2 Mounting dual membranes 41 8 2 3 Testing the sensor condition 42 8 3 Membrane replacement 42 8 3 1 Removing the membrane 42 8 3 2 Installing the membrane 43 8 4 Purge gas cylinder refill 45 8 4 1 N2 Purge gas 46 8 4 2 CO2 Purge gas 46 8 4 3 Filling the purge gas cylinder 46 8 5 Troubleshooting instrument 47 8 5 1 Serial test 47 8 5 2 Keybo...

Page 5: ...h is specified in this manual 1 2 1 Use of hazard information WARNING A warning is used to indicate a condition which if not met could cause serious personal injury and or death Do not move beyond a warning until all conditions have been met CAUTION A caution is used to indicate a condition which if not met could cause minor or moderate personal injury and or damage to the equipment Do not move be...

Page 6: ...en noted on the product 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 This symbol if noted on the product indicates the need for protective eye wear This symbol when noted on the product identifies the location of the connec...

Page 7: ...réglementation européenne directive UE 2002 96 EC les utilisateurs de matériel électrique en Europe doivent désormais retourner le matériel usé ou périmé au fabricant pour élimination sans frais pour l utilisateur Remarque Veuillez vous adresser au fabricant ou au fournisseur du matériel pour les instructions de retour du matériel usé ou périmé aux fins d élimination conforme ITALIANO Le apparecch...

Page 8: ...tlijn 2002 96 EC dienen gebruikers van elektrische apparaten voortaan hun oude of afgedankte apparatuur kosteloos voor recycling of vernietiging naar de producent terug te brengen Nota Als u apparatuur voor recycling terugbrengt moet u contact opnemen met de producent of leverancier voor instructies voor het terugbrengen van de afgedankte apparatuur voor een juiste verwerking POLSKI Sprzęt elektry...

Page 9: ... above symbol may not be disposed of in European public disposal systems after 12 August 2005 Hach Lange will offer to take back free of charge to the customer any old unserviceable or redundant analyzers and systems which carry the above symbol and which were originally supplied by Hach Lange Hach Lange will then be responsible for the disposal of this equipment In addition Hach Lange will offer ...

Page 10: ...8 General Information ...

Page 11: ...purge gas cylinder and sensor 4 6 kg Purge Gas Nitrogen H2 sensors Carbon Dioxide N2 and H2 sensors Purge Gas Cylinder Pressure Limit see also Note below 200 bar maximum for N2 purge gas 60 bar maximum for CO2 purge gas Purge Gas Autonomy 40 hours when cylinder filled to 200 bar of N2 20 hours when cylinder filled to 100 bar of N2 120 hours when cylinder filled with 75 of CO2 liquid Capacity of Pu...

Page 12: ...Table 2 Sensor Specifications Sensor Type 31 272 H2 31 570 N2 Membranes 29561A 2952A 2935A 29561A Thickness 25 µm 25 µm 25 µm 25 µm Membrane material PFA ETFE ECTFE Halar PFA Recommended applications Waste gas and offgas Waste gas offgas reactor coolant Reactor coolant and High H2 level Beverage Radiation limits 105 rad 108 rad 108 rad 105 rad Measurement range at 25 C 0 0 075 ppm or 0 8 cc kg or ...

Page 13: ...type batteries a recharge kit in a plastic case containing materials to maintain your sensor and a model 32824A refilling hose to refill the purge gas cylinder Locate the instrument close to the sample being analyzed and to the Personal Computer PC if one is being used A LEMO 6 connector for RS 232 serial output to a PC is on the right side of the instrument see Figure 1 above Make sure you instal...

Page 14: ...inder located at the bottom of the instrument supplies the purge gas This cylinder is refillable see Purge gas cylinder refill on page 45 The TC sensor is purged cyclically In measurement mode a cycle consists of a 4 second purge followed by 16 seconds of measurement When the instrument is in standby the purge time is the same followed by a 17 minute delay During the purge time the flow rate varie...

Page 15: ...rument with a 6 pin LEMO plug on one end and a 9 pin D Type plug on the other Note If you use an adapter for the connection to the PC make sure it is designed for this purpose and thus has all nine pins accessible Some 25 to 9 pin adapters are supplied for specific use such as a mouse and these may have only certain pins available It is not necessary to keep the PC connected to the instrument duri...

Page 16: ...1 5 mm CAUTION At the top of the TC sensor is a thermistor to measure the sample temperature Do not bend or damage this component The flow chamber s inlet and outlet use inch diameter transparent plastic tubing Connect by compression fittings to the sample source and to the drain respectively You may also have received a model 32051 sample tube adapter to attach the flow chamber inlet tubing to th...

Page 17: ...nal external DC power constantly if the instrument is in standby and the sensor is exposed to a sample The batteries will provide about three weeks of power for purging while the instrument is off 3 8 3 Instrument clock setting If you use the instrument to store measurements for downloading to a PC you should verify the date and time settings of the instrument s internal clock as described in Cloc...

Page 18: ...16 Installation ...

Page 19: ...ssure relief valve on top of the instrument as indicated in Figure 1 on page 11 This button need only be pressed as part of the installation procedures and or if pressure builds up inside the instrument due to large temperature changes The panel keyboard has the following push button controls Figure 5 Instrument front panel Power switch Turns instrument power on or places in standby When switched ...

Page 20: ...te The start up tests will be repeated until successful or for a maximum of 15 minutes If the tests are still unsuccessful after 15 minutes a Err message will be displayed and the instrument locked Turn the instrument off and retry the start up procedures but if the problem persists please contact your local Hach Lange service representative for assistance Measurement updates are displayed every 2...

Page 21: ...s making measurements in bottles and cans To search for a maximum measurement value press the MEAS button The LCD first shows the message run for a few seconds before displaying measurement values After a 60 second measurement cycle the instrument searches for two consecutive gas measurements with less than 2 difference When this condition occurs the displayed value freezes on the LCD indicated by...

Page 22: ...ote If you accidentally interrupt the automatic data storage by switching off the instrument while it is in the process of storing a value and you then attempt to download the stored values by the WIN3654 program you will get a Windows Checksum Error message and you will not be able to view the measurement data If this happens go back to the instrument and manually log one more value described in ...

Page 23: ...nce to display a sample number The default sample number is 000 for first time access or the last used memory position where data was stored incremented by a value of 1 2 You can increase or decrease this number by pressing the Up Down Arrow buttons within three seconds 3 Should you decide at this point not to store this particular measurement just wait five seconds and the display returns to meas...

Page 24: ...easurements from the instrument The window displays five columns of data Sample sequence number of the sample Conc concentration of the measured gas Date date of the measurement Time time of the measurement Sample Description The descriptions can be modified for your applications using the procedures described below 1 Put the instrument into standby by pressing the POWER key 2 Hold down the Up Arr...

Page 25: ...n be pasted into a spreadsheet word processor or other Windows program that accepts tabular text information choose the Clipboard command from the Export menu 4 4 4 Saving values To save this list of measurements as a text txt file capable of being recalled by the WIN3654 program or imported as a file into other Windows programs choose the Save As command from the File menu A dialog box appears wi...

Page 26: ...allowing the analyzer to overwrite a set of stored values with new ones 4 5 Monitoring measurements in real time You may wish to analyze a particular sampling point via the WIN3654 program s Monitoring menu To use this Monitoring chart the analyzer must be connected to your PC Choose Monitoring from the WIN3654 menu to bring up a chart display like the one illustrated in Figure 8 The Monitoring ch...

Page 27: ...ion to the Windows Clipboard This information can be pasted from the clipboard into any Windows application such as a spreadsheet or word processor See Table 3 above for the maximum number of samples that can be copied for each chart time scale Finally choose Close to close the Monitoring window 4 6 After use and storage You can power off the instrument without losing setup or calibration paramete...

Page 28: ...26 Operating Instructions ...

Page 29: ...tcut keys such as Ctrl P to print a list of stored values As you become familiar with the program you may choose these keystroke commands for faster operation File shown below serves typical Windows file management needs WIN3654 data files can be opened saved under a different name closed or printed You can also exit the program The Logger menu appears as follows Here you can download measurement ...

Page 30: ... use this menu to change the configuration parameters should your application needs change The Troubleshooting menu includes a series of tests allows you to set the clock and enables a barometric pressure calibration routine Finally the Help menu gives access to the Help file and displays the identification of the WIN3654 program version number and copyright date Note If the PC operating system is...

Page 31: ...e any configuration parameters 5 4 1 Gas measurement phase Usually COM1 is used to connect to a mouse so try COM2 first You may find that a separate program supplied with your PC may be necessary to activate this port Click on OK to activate the selected port If the port you have selected here is available the WIN3654 program will return to the main menu Otherwise you will see an RS232 ERRORS mess...

Page 32: ...e instrument power OFF 2 Switch the instrument on by holding down the CAL button and then pressing the POWER button while still pressing the CAL button 3 The instrument display will first show PHA before switching to either dIS for dissolved or gAS for gaseous measurements 4 Use the Up Down Arrow buttons to change the gas phase to your choice 5 Press the MEAS button to save the selected gas measur...

Page 33: ...asurements in real time on page 24 The sampling rate menu applies only to automatic data acquisition while the chart updating rate is used only for displaying real time results via the monitoring chart 5 4 5 Calibration medium You can use the Configuration Calibration medium command to select how the sensor is to be calibrated Note You can create a solution having a known H2 or N2 concentration by...

Page 34: ...lock out the keyboard CAL button To unlock this capability choose Enabled Choose OK when the desired mode is selected Choose Rolling Average Status from the Configuration menu to enable or disable the averaging of gas concentration measurements To enable averaging on three successive gas measurements choose Enable Choose Disable to disable rolling average Choose Automatic Shutdown Status from the ...

Page 35: ... gas at atmospheric or elevated pressure The following table gives information regarding the different methods Before calibrating check that the sensor membrane surface is tight smooth and wrinkle free Select the gas measurement phase for calibration for full details see Gas measurement phase on page 29 Next select the calibration medium using the WIN3654 program see Calibration medium on page 31 ...

Page 36: ...ow chamber for 3 minutes before calibrating 6 2 1 Calibration setup Ensure that the purge gas is flowing at the recommended rate through the sensor by placing the purge gas exit tubing into water This rate should be more than four bubbles during the purge which lasts for 4 seconds This purge cycle is repeated every 20 seconds The calibration procedure requires a source of pure gas regulated by a p...

Page 37: ...gas at atmospheric pressure as detailed in Calibration medium on page 31 2 Connect a source of pure H2 or N2 gas to the inlet of the flow chamber as illustrated in Figure 10 on page 34 and adjust the gas flow to one bubble per second when the exit tube is immersed in water 3 Press the CAL button Remember this button may have been locked out to prevent an accidental reset see Locking out the instru...

Page 38: ...f 1 to 5 bar it is best to use a pressure close to the application conditions 3 Press the CAL button Remember this button may have been locked out to prevent an accidental reset see Locking out the instrument s CAL button on page 32 for details 4 A brief clearing message appears 5 Press CAL again within a 3 second period The instrument then displays the absolute pressure of calibration gas i e gau...

Page 39: ...pleted If the calibration does not complete the LCD displays the message Err The reason for this calibration error is either that the measured gas partial pressure is under 5 mbar or that a wrong instrument key was pressed during the calibration steps 1 Set the gas measurement phase to Dissolved and set the calibration medium to In a liquid or a gaseous sample at known concentration as detailed in...

Page 40: ...38 Calibrations ...

Page 41: ... used for the calibration The recommended flow rate should be set at 50 though a minimum flow rate for small volume packages of 30 can be used To set the flow rate adjust the knob at the top of the flow meter until the center point of the bead indicates the desired flow rate 7 2 Model 32939 external power supply Provided you have a clean external power supply you can connect the power directly to ...

Page 42: ...40 Accessories and Attachments ...

Page 43: ...des membrane replacement and external cleaning to restore the original sensor sensitivity This means low running costs and down time reduced to a minimum The membrane needs to be replaced once or twice a year depending on application conditions This can be tailored accordingly Note If you are not familiar with ORBISPHERE sensor servicing your Hach Lange representative will be glad to assist you 8 ...

Page 44: ...or 30 minutes in measurement phase to allow measurements to stabilize before performing the sensor calibration 8 3 1 Removing the membrane It is recommended to leave the sensor in place in the instrument when changing the membrane It is not necessary to remove it To remove the membrane follow the steps below First remove the flow chamber from the sensor by turning the flow chamber locking pin see ...

Page 45: ... out of the storage box Using tweezers included in the kit pick up one membrane from the stack and gently place it on the sensor tip Make sure it is centered To mount dual membranes Remove one 29562A secondary membrane along with one piece of the separation paper from its box Place the membrane and paper paper side down on a clean flat surface Remove a primary membrane along with its separation pa...

Page 46: ... tool tip CAUTION To avoid damaging the membrane make sure that the tool tip is totally clean and its surface is even Insert the installation tool inside the guiding sleeve Push the installation tool firmly downwards This clasps the mounting ring onto the sensor head folding the membrane over the sensor tip Remove the installation tool and guiding sleeve Visually check for correct ring placement t...

Page 47: ...lations issued by local health and safety authorities Finally replace the flow chamber Gently lower the flow chamber onto the sensor guiding the thermistor on the sensor into the hole in the flow chamber base Turn the flow chamber locking pin see Figure 1 on page 11 clockwise to secure it in place CAUTION The thermistor is used to measure the sample temperature Do not bend or damage this component...

Page 48: ... different purge gases refer to the two sections above Refill the purge gas cylinder in a clean and dry area as follows referring to the illustration in Figure 12 on page 45 for more information 1 Connect the refilling hose model 32824A to the master storage cylinder 2 Close the bleed valve on the refilling hose 3 Carefully open the main valve on the master storage cylinder 4 Close the main valve ...

Page 49: ...instrument 8 5 2 Keyboard test 8 5 3 Display test Choosing Troubleshooting Display Test lets you perform a one way communication between computer and instrument Enter text characters in the Text to be sent box then click Send If the serial link is operating correctly the exact same text will be displayed back from the instrument in the Echo box Any difference in text indicates a possible problem w...

Page 50: ...look at voltages used by the system to transmit information about gas temperature and pressure This is useful when trying to identify an instrument problem with a Hach Lange service representative either on site or over the phone The voltage limits for normal operation are Gas channel between 0 1 V and 4 V depending on the gas being measured Temperature channel 10 mV to 4 V Pressure channel 100 mV...

Page 51: ... the purge gas voltage At 20 25 C this voltage should be about 3 00V 200 mVolt for H2 N2 measurements To exit from continuous purge mode put the instrument in standby then switch back on again without holding any keys The Troubleshooting Measurements View confirms on your PC monitor what your analyzer should be displaying on the LCD for gas concentration and sample temperature Choose Cancel to exi...

Page 52: ...n external power supply is used but the power supply is not clean Switch to battery power Low readings Sample flow rate too low Check flow rate Degassing Adjust forcing gas and or sample flow rate Membrane is not at sample temperature Allow sample to flow past the membrane to make sure the membrane is at sample temperature before making measurements Membrane not clean Clean system Incorrect solubi...

Page 53: ... 211 Portable battery powered RS232 serial output For use with sensor 31272 Special sensor purge Carbon dioxide 3654 510 Portable battery powered RS232 serial output For use with sensor 31570 Membrane 29561A Table 8 Sensor and parts on configured system Configured System Gas Sensor Membrane Holding Ring Protection Cap Maint Kit 3654 Portable Analyzer N2 31 570 1 x 29561A 29228 29142 32746 H2 0 to ...

Page 54: ...14 rubber sealing gasket 32311 Flow meter equipped with metal exit tube Graduation from 10 to 100 32537 03 3 meter RS232 cable for use with portable instruments Supplied with LEMO 6 connector instrument end and 9D connector computer end 32688 WIN3654 Windows software and communications cable 32751 Battery recharger with pack of two rechargeable NiCd batteries Europe only 32824A Fill adapter kit fo...

Page 55: ...llion by weight v v volume per volume ratio Table 12 Terms and definitions Terms Meaning Absolute pressure Absolute pressure is relative pressure plus atmospheric pressure Concentration The relative content of a component in a gaseous or liquid media Conductivity The reciprocal of electrical resistivity Headspace The empty volume above a liquid or solid in a closed container Relative pressure Rela...

Page 56: ...54 Glossary of Terms ...

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