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Overview 

10 

Waltron User Manual 
3051 Hardness Analyzer 

1.1.3 

SIGNAL OUTPUTS 

Analog Outputs:  

4-20mA (galvanic isolator module available as option) or 0-5V 

Serial I/O for Signals:  

Serial data output RS232 standard, RS485 available as option 

1.1.4 

OPERATIONAL CALIBRATION 

Frequency/Intervals:  

Recommended: 7 days 

Single/Multi-Point: 

Multi-Point: zero and mid-range 

Matrix Corrections: 

Yes, sample blank correction 

Manual/Automatic: 

Both 

 
 

1.2 

SAFETY PRECAUTIONS, INSTRUCTIONS, AND HAZARDS 

1.2.1 

GENERAL INFORMATION 

This manual contains important information which is required for installation, start up and 
operation of the Waltron 3051 Hardness Analyzer. Please read this manual carefully before 
installing and placing the analyzer into service! 
 
Pay attention to all caution and danger labels present on the analyzer and all caution and danger 
statements written on this manual. 
 

 

Waltron shall not be liable for errors contained herein and/or for an incorrect use of the 
analyzer. The department head and analyzer’s users must be sure to read and observe the 
following instructions and to apply all the national and local regulations and laws 
regarding workers health and safety.  

 

Use, maintenance, and service of this analyzer is allowed only by qualified personnel 
who are fully trained on the analyzer’s operations. This personnel is intended to be 
physically and mentally fit and not under effect of alcohol or/and drugs. 

 

When the analyzer is not used it should be protected from intentional or unintentional 
powering on, using a proper circuit breaker. 

 

Failure to do so and non-observance of hazards or dangers warnings could result in death 
or serious injury to the operators or damage to the analyzer. 

 

Before using the analyzer, it is necessary to visually check for damages to safety devices 
and report to your department head even if they don’t cause the analyzer to stop or 
malfunction. 

 

All the analyzer’s components are installed inside a metallic enclosure with a door 
equipped with a special key opening, only endowed to qualified maintenance personnel.  

 

1.2.2 

LIST OF WARNINGS AND POTENTIAL DANGERS 

The table below is a list of hazards and dangers warning labels that may be found on the analyzer 
and/or in this manual. In case of these labels becoming outdated, they should be replaced with 
new ones by the analyzer owner. 
 

Summary of Contents for AQUALERT Aqualyzer 3051

Page 1: ...Version 3 01 Waltron AQUALERT Division Water Chemistry Measurement Control Aqualyzer 3051 Hardness Analyzer Instruction Manual ...

Page 2: ...e following information Date analyzer was purchased Analyzer model and serial number Recent maintenance history Calibration slope values and detailed description of problem Waltron s technical expertise and extensive experience provides personalized solutions to the water quality industry It is Waltron s commitment to provide the customer with timely and accurate technical service and support Walt...

Page 3: ...rs packages and chemicals Only qualified personnel should be involved in the installation operation and servicing of the analyzer Follow safety precautions when operating analyzer in conditions of high pressure and or temperature Keep analyzer chemicals away from heat and extreme temperatures Reagent powders must be kept dry Follow all regulations and warning labels when disposing of chemicals Do ...

Page 4: ...dress and department Name and telephone number of the individual responsible for returning items for repair Brief problem description Ship to Waltron service center Via Mail Waltron LLC 50 Tannery Road P O Box 70 Whitehouse NJ 08888 Via UPS FED EX Motor Carrier Waltron LLC 50 Tannery Road Somerville NJ 08876 The Waltron Warranty Agreement Covers expendable sensors for one month after shipment and ...

Page 5: ...d shipping needs Check all items received against those on the packing list Chemicals are usually shipped in a separate package and will be itemized accordingly Verify that the number of packages received agrees with the packing list and shipping papers Notify both Waltron and the carrier if any problems occur Important Notice All analyzers are inspected and tested prior to shipment In normal use ...

Page 6: ...1 General Information 10 1 2 2 List of Warnings and Potential Dangers 10 1 2 3 Reagents 12 1 2 4 Sample 12 1 2 5 Waste Disposal 12 1 2 6 Analyzer General Hazards 12 2 Introduction 15 2 1 Analyzer Description 15 2 2 Applications 16 2 3 Working Principle 16 2 4 Analysis Cycle 18 2 4 1 Programming Commands 18 2 4 2 Flow Diagram 19 2 4 3 Analyzer Operations 19 2 5 Fast Loop Reservoir 20 2 6 Wet Sectio...

Page 7: ...ues 34 5 6 2 Chart 34 5 6 3 Manual Step 34 5 6 4 Data Logger 35 5 7 Program Menu 36 5 7 1 Settings Menu 36 5 7 2 Calibration Menu 37 5 8 Service Menu 38 5 9 Help Menu 39 6 Operation 40 6 1 Reagents Prime 40 6 2 Blank Calibration 40 6 3 Slope Factor Calibration 41 6 4 Single Analysis Cycle 41 6 5 Online Measurement 42 6 6 Grab Sample 42 6 7 Emergency Stop 43 7 Maintenance 44 7 1 Scheduled Maintenan...

Page 8: ...ace after pressing the RUN Menu 33 Figure 5 4 User interface in the DISPLAY Menu 34 Figure 5 5 Manual step functions shown in the bottom left corner 35 Figure 5 6 Data logger screen of the user interface 35 Figure 5 7 User interface after pressing the PROGRAM Menu 36 Figure 5 8 The SETTINGS Menu and options are displayed 36 Figure 5 9 User interface at the CALIBRATION Menu 37 Figure 5 10 User inte...

Page 9: ...ble 5 1 User password 30 Table 5 2 Menu access level with password 30 Table 5 3 Analyzer operating statuses 31 Table 5 4 Main menu button descriptions 31 Table 7 1 Scheduled manintenance reference chart 45 Table 9 1 Alarm descriptions 48 Table 10 1 Routine Maintenance Parts Listing 49 Table 10 2 Standards and Reagents Parts Listing 49 Table 10 3 Spare Parts Listing 49 Table C 1 Multistream sequenc...

Page 10: ...e alarm relays Reproducibility 1 ppb or 2 of reading whichever is greater Degree of Protection IP55 NEMA 4 Wet section IP65 NEMA 4x Electronics Required Maintenance Once a month replenish reagents once a year replace tubing Reagent Consumption approx 2 reagents 2L each per month Materials in Contact with Sample Glass Silicone Plexiglass Stainless Steel AISI 316 CE Certification on request Meets lo...

Page 11: ...structions and to apply all the national and local regulations and laws regarding workers health and safety Use maintenance and service of this analyzer is allowed only by qualified personnel who are fully trained on the analyzer s operations This personnel is intended to be physically and mentally fit and not under effect of alcohol or and drugs When the analyzer is not used it should be protecte...

Page 12: ...s chemicals manipulation All handling and operations maintenance on chemicals labeled with this symbol should be made by qualified personnel in accordance with national or local regulations Qualified Personnel means personnel who have been fully trained and have professional experience in avoiding chemical hazards and dangers Before proceeding with the handling of chemicals and service operations ...

Page 13: ...ibility of the user to collect all the information and potential hazards regarding the chemical and physical compatibility of sample stream with analyzer materials Table 1 2 List of materials used in Waltron 3051 Analyzer Pump tubings Silicon or Norprene Fittings PP Connection tubings Norprene Silicon Colorimetric cell Glass Mixing membrane pump PP EPDM Pinch valve Vyton silicon tubing 1 2 5 WASTE...

Page 14: ...void risks the analyzer s moving parts have been designed built and located in closed enclosure with a special opening key Inside the enclosure these parts have protective covers to avoid any contact and physical injuries to users HAZARD Hazard of burns and poisoning caused by contact with dangerous chemicals Preventive Actions To avoid risks the analyzer s parts that can cause contact with chemic...

Page 15: ...losed enclosure with a special opening key Inside the enclosure these parts have protective covers and warning labels to avoid any contact and serious injuries or death to users NOTE Electrical equipment with input power and grounding must comply with the national or local regulations and laws Preventive Actions Check that the source voltage to be used corresponds with that requested by the analyz...

Page 16: ...ise analysis sequence of sampling analysis and result processing using colorimetric method The analyzer is assembled in an enclosure with lockable door The LIQUIDS enclosure includes all the components involved in sample and reagents flows as well as their mixing and reaction stages sampling pump colorimetric reaction cell reagents micropumps The ELECTRICAL enclosure includes the main power supply...

Page 17: ...ution is measured at a specific wavelength The absorbance is related to sample concentration according to Beer s law Lambert Beer law is an empirical relationship that relates the absorption of light to the properties of the material through which the light is travelling The law states that there is a logarithmic dependence between the transmission or transmissivity T of light through a substance ...

Page 18: ... 0 to 1 but it can go higher than that An absorbance of 0 at some wavelength means that no light of that particular wavelength has been absorbed The intensities of the sample and reference beam are both the same so the ratio I0 I1 is 1 Log10 of 1 is zero An absorbance of 1 happens when 90 of the light at that wavelength has been absorbed which means that the intensity is 10 of what it would otherw...

Page 19: ...od one or more reagents may be added before reference Mixing and wait Mix and wait functions The mixing pump is activated and the liquid is pumped from the lower part to the upper part of the colorimetric cell The waiting time is programmed in order to eliminate bubbles suspensions First measurement Reference function Regulation of the light intensity to a programmed value in order to start from a...

Page 20: ...2 4 2 FLOW DIAGRAM Figure 2 4 Flow diagram 2 4 3 ANALYZER OPERATIONS The Waltron 3051 Hardness Analyzer performs several operations throughout a cycle A list of common operations is shown below Rinse 1 Rinse 2 Drain Sample 1 Sample 2 Add Reagent 1 Add Reagent 2 ...

Page 21: ...oper sample circulation to avoid suspended solids accumulation The sample flow should be adjusted to have the complete sample overflow through the U shaped stainless steel tube A small hole at the stainless steel tubing allows the fast loop reservoir to empty for cleaning purposes just with finger pressure Inside the reservoir a level sensor checks for water presence The loss of sample switch puts...

Page 22: ...Introduction 21 Waltron User Manual 3051 Hardness Analyzer Figure 2 6 Mounting dimensions for the fast loop reservoir 10 36 259 mm 5 84 146 mm 5 24 131 mm 5 20 130 mm Ø 0 26 6 5 mm ...

Page 23: ...et for analysis Sample Inlet The tubing for the sample inlet s and calibration standard inlet pass through the housing enclosure on the right hand side of the unit and are connected to the 3 way valve Colorimetric Reaction Cell The colorimetric reaction cell is made of glass the diameter is 16 or 25 mm depending on the parameter The cell is positioned inside a thermostated block fixed with 2 screw...

Page 24: ...s Λ and V Sample Drain The tubing for the sample drain maintains a constant level of few cm of liquid on the colorimetric cell 2 7 ELECTRONICS The microprocessor and its PCB assembly are located in the electronic section It provides to control the entire analyzing system It handles the analyzer operations it collects all the information and data coming from the different analyzer devices and it co...

Page 25: ... max 80 relative humidity If the temperature is below 5 C the analyzer should be installed in a heated cabinet Because of chemicals and waste gases it is absolutely necessary to have a well ventilated location for the analyzer The analyzer is supplied with four mounting brackets for wall or stainless steel support rack installation Use 4 screws M6 or M8 to mount the analyzer Reagent bottles are su...

Page 26: ...20 cm on either side and about 40 100 cm in the front Sufficient space for the reagent containers should be provided on the side or beneath the analyzer The reagent containers should be positioned in the reagent bracket or a suitable basin in case of spills NOTE Respect the maximum height of 16 40 cm between the reagent s bottle s and the reagent s pump s 3 5 MOUTING SCHEMATICS Figure 3 1 The dime...

Page 27: ...l be user s task to periodically check and guarantee the efficiency of analyzer s grounding Users and qualified maintenance personnel must proceed as follows Be careful of electrical shock and or electrocutions labels placed on the analyzer Always isolate power before servicing the analyzer In case of loss of power the analyzer stops and automatically restarts into standby mode as soon as power is...

Page 28: ...abels starting with pin 1 on the left Figure 3 2 Electrical connections for user connections and power connections Table 3 1 Terminal block pin locations Pin Number Terminal Label Description 1 Input NO contact from an External Device to tell the analyzer to take a measurement 2 Input 3 Signal 2 4 20mA output for Sample 2 Measurement 4 Signal 2 5 Signal 1 4 20mA output for Sample 1 Measurement 6 S...

Page 29: ...halein Reagent Reagent 2 Ethanolamine Reagent 3 8 REAGENTS HOLDING BRACKET Use the drawing below to mount the reagents bracket below the analyzer NOTE Respect the maximum height of about 16 40 cm between the reagent s bottle s and the reagent s pump s Figure 3 3 Mounting schematics for the reagent holding bracket 19 50 496 mm Ø 0 48 12 mm 1 0 25 mm 7 00 178 mm 4 00 102 mm 11 50 292 mm ...

Page 30: ...o the waste line 3 Put the reagent inlet tubings into the appropriate reagent containers a Reagent 1 Cresolphthalein Reagent b Reagent 2 Ethanolamine Reagent 4 Put the calibration solution inlet tubing into the calibration solution positioned beneath the analyzer 5 Connect the analyzer drain tubing to waste drain line WARNING The drain of the analyzer must be at ambient pressure with no restrictio...

Page 31: ...ng the touchscreen buttons Figure 5 1 User interface main display screen 5 2 USER PASSWORD Table 5 1 User password First Level Password service 1111 Second Level Password admin Contact Waltron Table 5 2 shows the menus and sub menus that are available based on which level of password is input Table 5 2 Menu access level with password No Password Service Password Admin Password Main Menu Display Me...

Page 32: ...s based on the steps set in the PROGRAM menu Analysis Cycle and started when the START ON LINE button has been pressed As soon as the analyzer completes an analysis cycle it will restart with a new analysis This condition is identified as the online condition MANUAL STOP The analyzer has been forced to stop A message in the main menu shows the manual stop and the fault alarm is initialized Table 5...

Page 33: ...l falls below a value of 4 the analyzer goes into FAULT status and stops automatically The alarm message will be displayed in the main menu and the FAULT contact will be activated Every time the reagents are refilled it is necessary to reset the value to 100 1 Press on the value of each displayed reagent 2 Bottle Reag 1 2 Filled YES Figure 5 2 User interface screen for Reagents Refill ...

Page 34: ...nd wait for the user s next command CH 2 available on dual stream units only This command will perform a single analysis cycle on stream 2 At the end of the cycle the analyzer will go into stand by mode and wait for the user s next command EXTRA This command will perform a cycle based on the programming of the extra cycle The default programming for the extra cycle is set to a CALIBRATION cycle EM...

Page 35: ...he most recent blank value Led shows the led supplied Valid it shows the validation value in compared to the calibration value Current operation this window displays the current analysis step and the time in progress countdown for every step programmed 5 6 2 CHART It displays in a graphic the sensor s signal trend during the current analysis cycle 5 6 3 MANUAL STEP This button allows to access to ...

Page 36: ...er Figure 5 5 Manual step functions shown in the bottom left corner 5 6 4 DATA LOGGER From the DISPLAY menu pressing the Data Logger button in the upper right hand corner will display the previous 500 results Figure 5 6 Data logger screen of the user interface ...

Page 37: ...set the ratio of the analysis cycles versus the extra cycles the alarm value low or high and to enable or disable the loss of sample alarm and the 4 20 mA output CALIBRATION MENU This function is protected with the 1st level of password Allows the user to set the value of the standard used for calibration and to perform blank and calibration cycles 5 7 1 SETTINGS MENU Figure 5 8 The SETTINGS Menu ...

Page 38: ...alysis cycles when the analyzer is in on line mode Result alarm Programs the low high value alarm The alarm is expressed in of the full scale Output Signal Enables disables the 4 20 mA output Datalog Enables disables the internal data logger Sample Alarm Enables disables the loss of sample alarm 5 7 2 CALIBRATION MENU Allows the user to display and set the value of the standard used for calibratio...

Page 39: ...n the service screen to configure Relay 1 Relay 2 Relay 3 and Relay 4 Touch one of these cells and select the parameter to activate the relay Result Alarm The measurement is greater than the specified on the Settings screen For example If the Result Alarm on the Settings screen is set to greater than 50 the relay will close when the measurement goes above 50 of the analyzer range Loss of Sample 1 ...

Page 40: ...ENU The internal HELP Menu can be accessed by pressing the on the main display screen The help menu has the following sub menus that can be viewed directly from the analyzer and can also be found in Appendix B Figure 5 10 User interface showing the topics in the HELP Menu ...

Page 41: ...t SAMPLE function for 20 seconds 4 Select ADD REAG 1 2 functions for 40 seconds each in order to prime the three reagent lines Visually confirm that reagent is being drawn into the lines and into the flowcell If no reagent is seen it may be necessary to repeat the ADD REAG function 5 Select DRAIN function for 5 seconds 6 Select SAMPLE function for 20 seconds 7 Repeat steps 5 and 6 to rinse the flo...

Page 42: ...form an EXTRA Cycle two to three times with the calibration standard to ensure a repeatable calibration factor 6 To check the value of the calibration factor from the PROGRAM Menu select CALIBRATION to open the calibration menu window 6 4 SINGLE ANALYSIS CYCLE The analyzer can be set to run either in continuous analysis mode or single analysis mode Follow the steps below to perform a single analys...

Page 43: ...measurement results 5 The analyzer will wait the user defined amount of time see Section 5 7 1 and then proceed to run additional analysis cycles 6 To bring the analyzer out of online operation press the RUN Menu The top box where START ONLINE was previously will now be blank and dark gray Pressing this box will tell the analyzer to complete the current analysis cycle and go into stand by mode at ...

Page 44: ...6 7 EMERGENCY STOP The analyzer has an emergency stop function that will stop the analyzer immediately during any analysis cycle that it is performing 1 Press the RUN Menu 2 Select EMERGENCY STOP The analyzer will stop its current function and return to the main display screen The emergency stop fault alarm will be activated 3 To put the analyzer into standby mode after an emergency stop press the...

Page 45: ... Prior to the maintenance work all necessary precautions regarding personal safety protective clothing safety glasses etc are to be taken into consideration Always be sure to label and rinse all connected tubing with water prior to removal Waltron Colorimeter is based on colorimetric analysis methods using chemical solutions Make sure that proper safety precautions are taken e g using safety glove...

Page 46: ... OPERATION FREQUENCY Daily Monthly 2 Mos 4 Mos 6 Mos Annually Visual check of FAULT alarm indicator X Visual check of liquids enclosures for leakages detection X Visual check of reagents level X Sample fast loop reservoir cleaning X Colorimetric cell cleaning X Reagents replacement reset reagent counters X Pinch valve tubing replacement X Pump tubing replacement X 3 way valve and fittings cleaning...

Page 47: ...ce the pump half containing the rotor in one hand and place the rollers in the 2 6 and 10 o clock positions Place tubing in the outer port and against the two rollers as shown keeping your thumb on the tubing to hold it in place insert tubing key on the back of the rotor shaft and push in as far as possible Tubing is now positioned in deep into the pump head body With the key firmly pressed agains...

Page 48: ...od please proceed as follows 1 Replace the reagents in the container with distilled water and perform a priming of all the pumps with DI water a Login with the 1st level service password 1111 b Press DISPLAY MANUAL STEP ADD REAG 1 2 for 40 seconds 2 Disconnect the sample line and fill the fast loop reservoir if present with DI water 3 Run the analyzer for at least 2 cycles with all of the reagent ...

Page 49: ... Loss of Sample 1 The sample to stream 1 is lost Check the flow of Sample 1 Loss of Sample 2 The sample to stream 2 is lost Check the flow of Sample 2 Dual stream analyzers only Emergency Stop Someone felt it was necessary to press the Emergency Stop button Determine why Emergency Stop was pressed correct problem and then press the RESET button on the RUN window Cal Error The Calibration Factor is...

Page 50: ... Description Part Number Pump Head 7016 sampling pump W9040 007 Sample level sensor W3040 002 External reservoir Fast loop with level switch W3040 003 Peristaltic pump for reagents W3040 057 Reaction quartz cell 16 mm W3040 005 Heated block for 16 mm quartz cell W3040 007 Heater W3040 009 Support for 3 way valve W3040 011 Mixing pump PP EPDM W3040 012 Mixing pump PP TEFLON W3040 013 Pinch valve W3...

Page 51: ...Appendix A Panel Mount Schematics 50 Waltron User Manual 3051 Hardness Analyzer APPENDIX A PANEL MOUNT SCHEMATICS ...

Page 52: ...Appendix A Panel Mount Schematics 51 Waltron User Manual 3051 Hardness Analyzer ...

Page 53: ...Appendix B Help Menu 52 Waltron User Manual 3051 Hardness Analyzer APPENDIX B HELP MENU ...

Page 54: ...Appendix B Help Menu 53 Waltron User Manual 3051 Hardness Analyzer ...

Page 55: ...Appendix B Help Menu 54 Waltron User Manual 3051 Hardness Analyzer ...

Page 56: ...Appendix B Help Menu 55 Waltron User Manual 3051 Hardness Analyzer ...

Page 57: ...Appendix B Help Menu 56 Waltron User Manual 3051 Hardness Analyzer ...

Page 58: ...Appendix B Help Menu 57 Waltron User Manual 3051 Hardness Analyzer ...

Page 59: ...Appendix B Help Menu 58 Waltron User Manual 3051 Hardness Analyzer ...

Page 60: ...Appendix B Help Menu 59 Waltron User Manual 3051 Hardness Analyzer ...

Page 61: ...Appendix B Help Menu 60 Waltron User Manual 3051 Hardness Analyzer ...

Page 62: ...Appendix B Help Menu 61 Waltron User Manual 3051 Hardness Analyzer ...

Page 63: ... s datalogger A sampling valves manifold is mounted on the sequencer plate and ensures sample is available for switching between streams The fast loop reservoir with level switch is mounted on the sequencer to provide the flow alarm in case of loss of sample in any of the streams The sequencer is factory tested and ready for installation and operation Specifications Power supply Tthe sequencer is ...

Page 64: ...Appendix C Multiple Stream Sequencer 63 Waltron User Manual 3051 Hardness Analyzer Figure C 1 Dimensons of the Multistream Sequencer 15 75 400 mm 7 87 200 mm 7 91 201 mm 3 66 93 mm ...

Page 65: ...ably smooth surface to mount the sequencer for wall mounting b Mark 4 holes on the wall for the position of the sequencer c Drill 4 holes for M8 screws d Mount the sequencer on the right side of the analyzer e Ensure that the sequencer is mounted securely in place Figure C 2 Suggested installation layout of the multistream sequencer ...

Page 66: ...Appendix C Multiple Stream Sequencer 65 Waltron User Manual 3051 Hardness Analyzer Figure C 3 Mounting Dimensions for multistream sequencer Ø 5 16 N 4 M8 5 08 129 mm 14 65 372 mm ...

Page 67: ...ector of the sequencer on the top of the electronic box Figure C 4 Accessing the electronic box of the multistream sequencer Connect the 4 20 mA outputs 1 Open the electronic box of the sequencer 2 Connect the outputs ensuring you get the right polarity 3 Close the electronic box of the sequencer Figure C 5 4 20mA output of the multistream sequencer ...

Page 68: ...w the drain of analyzed sample for gravity and the overflow coming from external fast loop reservoir WARNING The drain of the analyzer must be at ambient pressure with no restriction Please verify that this condition has been strictly respected during installation Sample Connections 1 Connect the sample line inlet tubing to the sampling valves manifold according to the labels 2 Connect the drain o...

Page 69: ... main page to gain access to the sequencer main page Figure C 6 Multistream sequencer main page of the user interface The CH button will be enabled after login with the service password This button allows the user to manually open each valve of the sequencer manifold This function should be used with the analyzer in stand by mode The CH1 CH2 CH3 and CH4 buttons will be enabled after login with the...

Page 70: ...is command allows the user to perform an analysis cycle on the active channel At the end of the cycle the analyzer will go into stand by mode and wait for the user s next command EXTRA This command will perform a cycle based on the programming of the extra cycle The default programming for the extra cycle is set to a CALIBRATION cycle EMERGENCY STOP This command will immediately stop the analyzer ...

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