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<8. Maintenance Schedule>

8-7

IM 12Y18A04-01EN

1st Edition : Oct. 04, 2019-00

STEP3:

Connect Sample Chamber Tubing (SAM1) to sample Chamber.

STEP 4:

Connect all tubing from the tubing channel to the pumps and valve, following the labels on

the tubing. Connect the two remaining tubes into the reaction cell cap.

STEP 5:

Connect the reaction cell vent tube to the front top fitting on the cell cap to the top of reaction

cell.

8.6

Stand-By Mode and Extended Shutdown

To put the system in Stand-by mode, make sure to press the STOP key and check the DISPLAY

field next to F4 to show MANUAL RESTART. If AUTO RESTART is selected, you need to set the

mode to Manual:

MENU → SETUP → + ANALYSIS PARAMETERS → MODE

The system will switch to Stand-By after 60 minutes of no keypad activity. In Stand-By, the

analyzer will rotate the pumps periodically to avoid pinched tubing from sealing.

Extended Shutdown

To avoid clogging, flush the entire system with distilled water before shutdown. Disconnect and

empty out the reagents bottles and flush the lines using FLUIDICS PRIME menu. Release the

pressure on the peristaltic pump tubing.
Use the Table 3 to diagnose and correct analyzer problems.

Summary of Contents for WE440

Page 1: ...User s Manual Model WE440 Phosphate Analyzer IM 12Y18A04 01EN IM 12Y18A04 01EN 1st Edition ...

Page 2: ...ents Document number Note WE410 WE420 WE430 WE440 WET CHEMISTRYANALYZER Safety Precautions and Protection of Environment IM 12Y18A00 01EN Attached to the product printed manual Model WE440 Phosphate Analyzer IM 12Y18A04 01EN Online manual This manual EN in the document number is the language code An exclusive User s Manual might be attached to the products whose suffix codes or option codes contai...

Page 3: ...nuals and product at any time without notice or obligation If you have any questions or you find mistakes or omissions in the user s manuals please contact our sales representative or your local distributor n Drawing Conventions Some drawings may be partially emphasized simplified or omitted for the convenience of description Some screen images depicted in the user s manual may have different disp...

Page 4: ...he following safety symbols are used on the product as well as in this manual WARNING This symbol indicates that an operator must follow the instructions laid out in this manual in order to avoid the risks for the human body of injury electric shock or fatalities The manual describes what special care the operator must take to avoid such risks CAUTION This symbol indicates that the operator must r...

Page 5: ...designed to be used by a person with specialized knowledge n How to dispose the batteries This is an explanation about the EU Battery Directive This directive is only valid in the EU Batteries are included in this product Batteries incorporated into this product cannot be removed by yourself Dispose them together with this product When you dispose this product in the EU contact your local Yokogawa...

Page 6: ...nsumption 1 6 2 Installation 2 1 2 1 Mounting the Instrument 2 1 2 2 Plumbing Connections 2 2 2 2 1 Installing Peristaltic Pump Head Tubing 2 3 2 2 2 Installing the Reagents 2 4 2 3 Connecting Power to the Analyzer 2 4 2 3 1 Analog Outputs Connections 2 6 2 3 2 Alarm Connections 2 6 2 3 3 Inputs Signal Connections 2 9 2 3 4 Communication Signal Connections 2 9 3 Startup and Operation 3 1 3 1 Execu...

Page 7: ...5 2 5 6 Theory of Measurement 5 3 5 7 Mode of Measurement 5 3 5 8 Auto Restart Mode 5 4 5 9 Manual Restart Mode 5 4 5 10 Measurement Cycle 5 4 5 10 1 Cell Wash 5 5 5 10 2 Sample Capture 5 5 5 10 3 Optics Testing 5 5 5 10 4 Checking Reaction Temperature 5 5 5 10 5 Blank Measurement 5 6 5 10 6 Add Reagents 5 6 5 10 7 Collect Data 5 7 5 10 8 Post Wash 5 7 5 10 9 Measurement Data 5 7 5 10 10 Printing ...

Page 8: ... 8 1 8 1 Changing Reagents 8 1 8 2 Installing Tubing Maintenance Kit 8 2 8 3 Cleaning the Reaction Cell 8 4 8 4 Cleaning the Sample Flow Chamber 8 5 8 5 Installing Tubing Kit 8 6 8 6 Stand By Mode and Extended Shutdown 8 7 9 Standby and On Demand Modes 9 1 Revision Record i ...

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Page 10: ...ay be shipped with a translucent protective cover on the LCD Carefully peel off this translucent layer and discard it WARNING DO NOTAPPLY ELECTRICAL POWER TO VISIBLY DAMAGED COMPONENTS AS INJURY OR FURTHER EQUIPMENT DAMAGE MAY OCCUR 1 1 Startup Procedure This section describes the necessary steps to begin using the WE440 Phosphate Analyzer Refer to Chapter 2 for instructions on mounting the analyz...

Page 11: ...d Calibration 5 Calibration of the Instrument for Measurement Analysis 6 Menu Overview 7 Terms Definition 8 Maintenance Schedule SAMPLE CHAMBER SAMPLE CHAMBER WITH FLOAT SENSOR DRAIN SAMPLE INLET SAMPLE RETURN RGT STD REAGENT STANDARD SMP SAMPLE Figure 1 1 Reagent bottle numbers in proper order 1 2 General Product Description This user manual provides the information necessary to obtain the maximu...

Page 12: ...nt water analysis only suspended solids must be less than 60 microns 1 2 1 User Interface n General Description The user interface consists of a keypad and a graphical LCD display The keypad is located to the right of the display The F1 F4 function keys soft keys take on different meanings depending on the menu selection The column on the left of the soft keys labels the keys with their appropriat...

Page 13: ...ols used Escape Cancel Back Cursor Logged out Locked Logged in Scroll Up Scroll Down Print Delete Scroll Left Scroll right Accept Reject 1 2 2 Menus Display A before a menu item denotes that the item has multiple options Keys UP DOWN arrow scrolls up or down through options ENTER shows details of the options MENU shifts to Main Menu Parameters can be configured from the Main Menu NOTE The analyzer...

Page 14: ...SMP SAMPLE Figure 1 3 WE440 Phosphate Analyzer PO4 layout WARNING Handling chemical samples standards and reagents can be dangerous Review the necessary Material Safety Data Sheets and become familiar with all safety procedures before handling any chemicals CAUTION REAGENT BOTTLES MUST BE KEPT TIGHTLY CLOSED Observe all health and safety procedures for handling chemicals Wash any spillage with Dis...

Page 15: ... Ensure that the reagents are correctly installed the analyzer tubing is correctly routed in the pumps and that the analyzer drain tube is connected to an atmospheric drain All of the reagents and standard vent tubes need to exhaust to the outside of the enclosure to minimize the trapping of any vapors inside the enclosure 1 Connect sample to the analyzer and ensure that it is flowing through the ...

Page 16: ...for wall or panel mounting Use four 10 screws or equivalent for proper support Refer to Figure 2 1 and Figure 2 2 for dimensions in mm and inches Make sure that the wall that you choose can support the weight of the instrument approximately 20 kg or 44 lbs See Figure 2 1 Locate the instrument as close to the sampling point as practical to ensure complete purging of the sample line during each cycl...

Page 17: ...g or service to the sample chamber 2 Air purging of upper and lower enclosures is recommended 3 Each analyzer MUST have its own drain tube vented to atmosphere 4 The installation of a power circuit breaker is highly recommended 2 2 Plumbing Connections Sample inlet sample return and drain connections are made on the bottom side of the instrument The sample inlet and sample return fittings on the b...

Page 18: ...ngage the U shape pressure plate of the pump head assembly by pressing with two fingers and gently move upside as shown in Figure 2 4 Slide the tube fitting retainers at each side Replace the old tube by sliding off the barbed fitting If necessary clean the pump rollers Lubricate the tubing with pea sized quantity of silicone oil which should be purchased separately Fit the new tube and replace in...

Page 19: ...er handling is required to avoid ESD Electrostatic Discharge as the internal electronic components on the circuit boards can be damaged by static electricity It is recommended that before touching any electronic components such as printed circuit cards and the components on them you should discharge static electricity from your body This can be accomplished by touching an earth grounded metal surf...

Page 20: ...he wires are not powered before connecting to the instrument Disconnect any power previously connected to the relays Connect the Phase Hot or L line Earth and Neutral to the terminal block Note the location of the fuse Insert the wire into the terminal connector and make sure to tighten the screw Route signal connections to the back hub and power connections separately to the front hub All connect...

Page 21: ...s The analog outputs can be programmed to be any one of the following 0 20 mA or 4 20 mA or reverse acting i e 20 0 mA or 20 4 mA The range is also programmable and can be scaled according to application needs The outputs have a common isolation from the main system and can drive up to a 900 Ohms load Please refer to Figure 2 7 and Table 2 1 for signal terminal connection detail 2 3 2 Alarm Connec...

Page 22: ... below the terminal screw and make sure that the stripped wire ends are in the terminal tighten the connector screws Figure 2 7 Terminal strips for analog and relay outputs RELAY contacts are rated at 250 V 2 AAC 500 W non inductive load All inputs except IN 6 7 must be connected to POTENTIAL FREE contacts Ethertnet RS 232 Figure 2 8 Communication ports ...

Page 23: ...External 1 control 12 rTn Digital input 6 return External 1 control return 13 in7 Digital input 7 live External 2 control 14 rTn Digital input 7 return External 2 control return 15 24V 24V DC live limited to 20 mA source 16 GnD 24V DC ground 17 Earth Ground System earth ground 18 GnD Analog output 1 ground 19 OUT1 Analog output 1 900 Ohms Max 20 Earth Ground System earth ground 21 GnD Analog outpu...

Page 24: ...tal input 7 return 15 24V DC live 16 24V DC ground USING INTERNAL 24VDC USING EXTERNAL SUPPLY 5 24VDC GND GND INP7 24VDC RETURN 13 14 15 16 INP7 13 14 15 16 Figure 2 9 Input 6 is assigned by default to RUN STOP function with Close Open of a dry contact Input 7 is left unassigned by default Dry contact voltage free contact The functionality along with the state of the enabling signal is programmabl...

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Page 26: ...es are primed and there are no trapped air bubbles in any of the lines To prime the lines MENU SERVICES PRIME FLUIDICS AUTO PRIME ALL Repeat auto prime as necessary to purge all the air from the lines When done proceed to calibrate MENU MEASUREMENT CALIBRATE CALIBRATE STANDARD ENTER NOTE It is highly recommended to allow the WE440 Phosphate Analyzer to complete its measurement cycle rather than us...

Page 27: ...cle and reporting the result in concentration This reported result can then be compared to the expected value which is the known concentration of the validation solution to determine the accuracy of system calibration The advantage of using this function over the Run Analysis function is that prior knowledge of the concentration allows for validating the accuracy of the analyzer without affecting ...

Page 28: ...asurement cycle except that the result is not reported on the analog loops and not stored in the sample analysis results data storage The result of the validation analysis is displayed and printed on the RS 232 port The validation cycle can be executed on any available solution standard or sample selected by the user in the validation setup parameters menu 3 8 Calibration The user may execute manu...

Page 29: ...lt before modifying any of the parameters 3 11 Priming Priming of the instrument lines may be done as auto all the solutions or manually by selecting the specific reagent or standard Priming fills the tubing purges the lines of air and prepares the analyzer for measurement mode The PRIME VOLUME in mL applies to all the listed solutions in the priming menu The Prime Volume may be specified as a num...

Page 30: ...e second stage of calibration consists of adjusting the intensity of the LED and the gain of the photo detector amplifier to get an optimum level of output close to a fixed reference level This is optimized for the specific LED and the results of the calibration are stored The reaction cell sample chamber must be clean and filled with de ionized water for proper optics calibration cycle 4 2 Optics...

Page 31: ...e sequence MENU SERVICE HARDWARE SETUP EDIT CALIBRATED VALUES 4 4 Pumps Calibration The WE440 Phosphate Analyzer uses peristaltic pumps to move fluids through the reaction cell The pump tubing will require replacement periodically Please refer to Chapter 8 for details The maximum rate of flow of the fluid is dependent on both the inner diameter of the tubing conveying the fluid and the rpm of the ...

Page 32: ... under test The user may select one output at a time for calibration The calibration starts by adjusting the full scale to 20 mA The buttons are used to adjust the output to 20 mA The instrument waits for the user to confirm the calibration by pressing ENTER If there is no user response within 90 seconds the analog output procedure calibration is aborted Upon successful calibration of one of the a...

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Page 34: ...e Concentration of Low Standard Intercept Concentration of High Standard Figure 5 1 The Measured Absorbance is the result absorbance after subtracting the Blank Absorbance 5 2 Methods of Calibration Two methods of calibration are provided in the WE440 Phosphate Analyzer SINGLE POINT calibration uses high concentration standard alone and BASE LINE calibration uses either very low or zero standards ...

Page 35: ...ified range of the product For improved accuracy the user may calibrate the dilution factor using a high concentration standard like a 100 ppm This calibration is only allowed in manual mode with user prompts and confirmation required at the end of the cycle Extended range calibration MENU SETUP CALIBRATION PARAMETERS Set the STANDARD CONC 100 ppm and calibration MAIN MENU MEASUREMENT CALIBRATE CA...

Page 36: ...e Figure 5 2 5 7 Mode of Measurement The WE440 Phosphate Analyzer is designed to provide on line process measurements and has two modes of operation The mode is always displayed at the bottom right i e below the Info field and above the status field of the display The two modes of the instrument are AUTO restart mode the instrument resumes auto analysis mode after 0 5 Hr of inactivity and MANUAL r...

Page 37: ...strument in RUN MODE and pressing STOP key during measurement gets back to the MANUAL RESTART mode In this mode if the instrument is untouched for a period of the standby mode idle time 60 minutes default it switches to standby mode During standby operation all fluidics devices are shut down and the analyzer goes into a standby housekeeping mode in which the pumps are activated on an hourly basis ...

Page 38: ...s test failed due to the non functionality of the LED source or detector measurement is aborted and the info field will flash the error message TESTING OPTICS PLEASE CHECK FOR STRAY LIGHT Stray light reading outside the allowed limits will flash with a warning message TESTING OPTICS LOW SIGNAL LEVEL CELL MAY BE COATED AND MAY REQUIRE CLEANING If the test determines that the light energy reading is...

Page 39: ...he measurement cycle is done before adding the third color developing reagent NOTE When unstable and not meeting the stability criteria the info field will flash with the warning message TAKING BLANK MEASUREMENT UNSTABLE SIGNAL 5 10 6 Add Reagents In add reagent the reagent is pumped into the reaction cell You are allowed to edit the volume of the reagent to be pumped by the parameter called REAGE...

Page 40: ...ters from the MAIN MENU follow the sequence MAIN MENU SETUP ANALYSIS PARAMETERS POST WASH EVENT POST WASH CYCLES 5 10 9 Measurement Data The WE440 Phosphate Analyzer product stores measurement and calibration results for up to 31 days The data for each sample analysis cycle or calibration may be retrieved under REVIEW RESULTS menu screen with the corresponding time stamp and other related operatin...

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Page 42: ...onfiguration of five internal inputs for fluidics sensors and two external inputs for instrument control Display Parameters Menu Allows configuration of display related parameters Calibration Parameters Menu Allows configuration of parameters for calibration The menu shows two columns tagged as REFERENCE and CURRENT The parameters listed under the REFERENCE column are set for validating auto calib...

Page 43: ...the ANALYSIS MENU When performing a manual analysis the user is restricted from navigating through other menus Calibrate Allows manual calibration to be performed using standard solutions The slope and intercept values obtained here may be edited in the CALIBRATION PARAMETERS menu When performing a manual calibration the user is restricted from navigating through other menus Validate Allows manual...

Page 44: ...d password Menus also allow technician to change factory settings factory password required printing options instrument label and to view instrument setup details Hardware Setup Menu Allows technician to calibrate several hardware components of the analyzer Calibration results are editable by the technician Prime Fluidics Menu Allows user to prime the fluidics lines of the analyzer Diagnostics Men...

Page 45: ...hermometer Calibrate Pumps Allows technician to calibrate the flow rate of the pumps Calibrate Optics Allows technician to calibrate the optics Calibrate Analog Outputs Allows technician to calibrate the two analog outputs Edit Calibrated Values Allows technician to edit the calibrated results for fine tuning 6 7 Prime Fluidics Menu and New Reagents Blank Auto Prime All This menu runs an automatic...

Page 46: ...d on the screen and the serial outputs Relays Allows technician to selectively check the functionality of the four relays The relay status is shown next to the selected relay Pressing the ENTER key toggles the state of the relay The relay initial status will be updated upon leaving this diagnostics menu Analog Output Allows technician to selectively check the two analog outputs Previous analog out...

Page 47: ...ministration Alarms Calibrate Review Calibration Results Hardware Setup Relays Mapping Validate Review Analysis Results Prime Fluidics Analog Outputs Clean Delete All Calibration Results Diagnostics Inputs Delete All Analysis Results Display Parameters Temperature Units Page 2 Press sign to go to next page Analysis Parameters Validation Parameters Cleaner Parameters Calibration Parameters Method P...

Page 48: ... Serial Number Clean Review Analysis Results Unit Label Change Press Enter Display Printing Options Print System Configuration View Graph Print Analysis Parameters Print Print Method Parameters Data Range Selection Print Cleaner Parameters Delete All Calibration Results Online Print Enable Disable Delete All Analysis Results Hardware Setup Calibrate Thermistor Calibrate Pumps Pump 1 Pump 2 Calibra...

Page 49: ...ddress Level Sensors Sensor 1 5 Stability Criteria Dilution Parameters Server IP External Inputs Input 1 2 Validation Parameters RS232 Parameters Display Parameters Validation Source Baud Rate Contrast No of Repeats Language Back Light On time Cleaner Parameters Display Help Cleaner Source Display Info Volume to Add Result Decimal Point Clean Flow Rate Large Font Screen Stir Time Temperature Units...

Page 50: ...igate between the menus Enabled Disabled Display Info Message showing the status of the current cycle performing Enabled Disabled Results Decimal Point Selectable precision to show the analysis result XXXX X XXX XX XX XXX X XXX XXXXX Auto Large Fonts Screen To display the result with large fonts Enabled Disabled CALIBRATION PARAMETERS Standard The concentration of the standard used for calibration...

Page 51: ...eaction cell Sample Reagent Cleaner Standard Post Wash Cycle Volume The amount of fluid pumped for post washing 99 9 to 99 9 mL Post Wash Cycle Stir Time The amount of time the fluid is stirred for post washing the cell 0 to 999 seconds CLEANER PARAMETERS Cleaner Source Fluid for cleaning the cell Sample Reagent Cleaner Standard Not Assigned Volume to add The amount pumped for cleaning 0 to 255 mL...

Page 52: ...ibration results on to the PC for the selected data range None Data Range The time interval in which the calibration results are to be retrieved Last 12 hr 1 Day 2 Days 3 Days 1 Week 2 Weeks 3 weeks and All REVIEW ANALYSIS RESULTS Display Displays the analysis results for the selected data range None View Graphs Displays the Linear graph for the selected data range of Analysis records None Print P...

Page 53: ...all the system parameters None Print Analysis Parameters Prints only the analysis parameters None Print Method Parameters Prints only the method parameters None Print Clean Parameters Prints only the clean parameters None Online Print Prints the date time and concentration after each analysis cycle Enabled Disabled EDIT CALIBRATED VALUES Pump1 Pump2 To change the flow rate of the pumps after their...

Page 54: ...de 01X358701 8 1 Changing Reagents CAUTION Wear gloves or protective equipment your site may require when changing reagents Press the STOP key Press the MENU key Remove the cap from each bottle and change them over one by one Do NOT re use or re fill old or existing bottles Dispose of the used bottles and contents safely and according to local regulations Tighten bottle caps and route the tubing p...

Page 55: ...y out the contents of the tubing using the PRIME back method as described here Press MENU and scroll down to SERVICES and then select PRIME FLUIDICS and then set the PRIMING VOLUME to 5 mL This step allows the user to pump back the reagents contents of the connecting tubing including the peristaltic pump tubing Scroll up to each of the reagents and press ENTER to pump back the selected reagent flu...

Page 56: ... platen before replacing on pump n Plumbing Connections STEP 1 Remove pump convers as shown by squeezing the sides and lifting up for the Sample Pump and Reagent 1 STEP 2 Remove old tubing by sliding out the retainers STEP 3 Apply two or more drops of silicone oil on the tubing STEP 4 Lay the tubing over the pump ...

Page 57: ...5 0 ml and PRIME SAMPLE note negative sign this will empty out the cell Remove reaction cell cap and deposit cleaning solution into the reaction cell you can use a 10 ml syringe to fill the cell with cleaning solution and let it soak for about hour For a more thorough cleaning swing the reaction cell down as shown in photos below and use a non fiber swab with a bent tip reach inside the reaction c...

Page 58: ... down 8 4 Cleaning the Sample Flow Chamber It is recommended that you inspect the sample flow chamber at least once a year to check for any flow blockage and to inspect the operation of the float level sensor The sample chamber is located on the right lower corner of the fluidics enclosure The chamber can be removed for service and clean up Figure 8 2 Sample chamber detail ...

Page 59: ...mbly K9705CL The two sections of tubing are connected via luer fittings The complete tubing layout is shown in below STEP 1 lnstall the tubing channel using the pictures below Note the the white labels will need to be on the left side of the analyzer The tubing channel will connect into the upper receiving channel STEP 2 Insert vent tube 1 and 2 through vent holes in the bottom left of the enclosu...

Page 60: ...nd by mode make sure to press the STOP key and check the DISPLAY field next to F4 to show MANUAL RESTART If AUTO RESTART is selected you need to set the mode to Manual MENU SETUP ANALYSIS PARAMETERS MODE The system will switch to Stand By after 60 minutes of no keypad activity In Stand By the analyzer will rotate the pumps periodically to avoid pinched tubing from sealing l Extended Shutdown To av...

Page 61: ...ess F1 and re enter valid date Error in hours press F1 to continue Hours entered is invalid Press F1 and re enter valid hours More than 6 users are not allowed delete a user to add further Technician trying to add more than 6 users More than 6 users are not permitted at any time To add a new user after 6 delete an existing user No records to delete User is trying to delete Calibration Analysis rec...

Page 62: ...erature above set point If the temperature is not able to reach the set point and is above the set point Re calibrate the Thermistor Try a different set point temperature Call a service agent Taking blank measurement unstable signal Unstable temperature Cell may be coated or may be due to Optics failure Perform Clean Cycle and Calibrate Optics and thermistor Collecting data unstable signal Unstabl...

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Page 64: ...n stand by the system will execute periodic house keeping routines Every one hour the fluids in reagent standard and sample lines are moved back and forth Every 6 hours the system primes all the reagents lines with 1 mL each and then flushes the reaction cell with either 2 5 mL of standard or if sample is present the system executes a clean cycle Fluids consumption while unit is left in Stand by 4...

Page 65: ...er one hour of inactivity after receiving the STOP command MENU SETUP pg 2 ANALYSIS PARAMETERS MODE Select MANUAL mode 2 Program external control input 6 MENU SETUP INPUTS EXTERNAL INPUTS INPUT 6 Press the down key to select ACTION RUN STOP Refer to Manual Inputs Signal Connections section for additional wiring details USING INTERNAL 24VDC USING EXTERNAL SUPPLY 5 24VDC RETURN RETURN INP6 24VDC GND...

Page 66: ...04 2019 00 Revision Record Manual Title Model WE440 Phosphate Analyzer Manual No IM 12Y18A04 01EN Oct 2019 1st Edition Newly published Yokogawa Electric Corporation 2 9 32 Nakacho Musashino shi Tokyo 180 8750 JAPAN http www yokogawa com ...

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