Hach 5410001 User manual

DOC023.53.80422
SP-510
03/2022, Edition 13
User Manual

Table of Contents
Section 1 Specifications........................................................................................ 3
Section 2 General information............................................................................ 4
2.1 Safety information................................................................................................. 4
2.1.1 Use of hazard information.......................................................................... 5
2.1.2 Precautionary labels................................................................................... 5
2.1.3 Compliance and certification...................................................................... 5
2.2 Product overview.................................................................................................. 6
2.3 Product components............................................................................................. 7
Section 3 Installation..............................................................................................8
3.1 Install the instrument............................................................................................. 8
3.2 Plumb the instrument.......................................................................................... 10
3.2.1 Connect the air purge (optional)............................................................... 10
3.2.2 Sample line guidelines.............................................................................. 10
3.2.3 Connect the sample stream...................................................................... 10
3.2.4 Install the pump valve pressure plate....................................................... 11
3.2.5 Install the sample conditioning kit............................................................. 11
3.3 Electrical installation........................................................................................... 12
3.3.1 Remove the access cover........................................................................ 12
3.3.2 Electrical connections for conduit............................................................. 13
3.3.3 Wiring for power....................................................................................... 14
3.3.4 Select the voltage..................................................................................... 14
3.3.5 Connect the alarm relays.......................................................................... 14
3.4 Install the buffer solution..................................................................................... 15
3.5 Install the indicator solution................................................................................ 15
3.6 Install the stir bar................................................................................................ 16
Section 4 User interface and navigation...................................................... 16
4.1 Keypad description............................................................................................. 16
Section 5 Startup..................................................................................................... 17
5.1 Start the instrument............................................................................................ 17
5.2 Prime the reagents (optional)............................................................................. 17
Section 6 Calibration............................................................................................. 18
6.1 Complete a 2-point calibration............................................................................ 18
Section 7 Operation............................................................................................... 18
Section 8 Maintenance......................................................................................... 18
8.1 Maintenance schedule........................................................................................ 19
8.2 Clean the instrument........................................................................................... 19
8.3 Clean the instrument interior............................................................................... 19
8.4 Clean spills......................................................................................................... 19
8.5 Replace the reagent........................................................................................... 19
8.6 Change the alarm trip point................................................................................ 20
8.7 Replace the pump tubes..................................................................................... 20
8.8 Replace the tubing.............................................................................................. 20
8.9 Clean the colorimeter.......................................................................................... 20
8.10 Replace the sample conditioning filter.............................................................. 20
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8.11 Replace the fuse............................................................................................... 21
Section 9 Troubleshooting................................................................................. 21
9.1 Troubleshooting for a hard reading..................................................................... 22
Section 10 Replacement parts and consumables.................................... 23
Index...............................................................................................................................25
Table of Contents
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Section 1 Specifications
Specifications are subject to change without notice.
General specifications
Specification Details
Dimensions (W x D x H) 42 x 31.5 x 18 cm (16.5 x 12.5 x 7 in.)
Enclosure rating IP62
Weight 11.3 kg (25 lbs)
Installation environment Indoor
Mount Wall
Pollution degree/installation
category
2/II
Protection class I
Altitude Maximum 2000 m (6562 ft)
Light source Class 1 LED (light emitting diode) with peak wavelength of
610 nm. Estimated 50,000 hours minimum life; hard water
and soft water indicator.
Detector Silicon photo detector
Optical path length 8.89 mm (0.35 in.)
Time delay One reading above the trip point is necessary to trigger a
soft-to-hard water alarm transition. One reading below the
trip point is necessary to trigger a hard-to-soft water alarm
transition.
Trip point 0.3, 1, 2, 5, 10, 20, 50 and 100 mg/L. Refer to Trip point
specifications on page 4.
Reagents Buffer and indicator solution. 500 mL of each reagent every
2 months.
Reagent shelf life 1 year
Power requirements 115/230 VAC, 70 VA, 50/60 Hz, 1.25 A Fuse
Electrical connections Two 3-wire barrier terminal blocks. Wire range: 18–12 AWG
(0.75–1.0 mm2)
Hard water alarm relay SPDT relay, set to on when the hard water indicator is on.
The alarm can be disabled.
Contact rating 5 A resistive at 100–240 VAC
Operating temperature 5 to 40 °C (32 to 104 °F)
Storage temperature -40 to 60 °C (-40 to 140 °F)
Operating humidity Relative humidity: 5–95% at different temperatures, non-
condensing
Sampling rate New sample: every 1.9 minutes ±5% at 60 Hz; 2.3 minutes
±5% at 50 Hz
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Specification Details
Sample flow rate to sample
conditioning
50 to 500 mL/minute flow rate necessary (250 mL/minute
recommended)
Inlet pressure to instrument 1 to 5 psig (0.07 to 0.34 bar), 1.5 psig (0.1 bar) is optimum, >
5 psig (0.34 bar) can cause sample tubing failure
Inlet pressure to sample
conditioning
1.5 psig to 75 psig (0.1 to 5.2 bar)
Inlet fitting At instrument, 6.35 mm (0.25 in.) OD polyethylene tubing
with quick-disconnect fitting
Drain fitting Hose barb for 12.7 mm (0.5 in.) ID flexible tubing
Sample temperature range 5 to 40 °C (41 to 104 °F)
Certifications CE, cETLus
Warranty 1 year (EU: 2 years)
Trip point specifications
Alarm trip point Minimum trip
value
Maximum trip value Temperature influence on trip
point
0.3 mg/L 0.22 mg/L 0.38 mg/L –0.03 mg/L per °C
1 mg/L 0.75 mg/L 1.25 mg/L –0.03 mg/L per °C
2 mg/L 1.5 mg/L 2.5 mg/L –0.03 mg/L per °C
5 mg/L 3.75 mg/L 6.25 mg/L –0.06 mg/L per °C
10 mg/L 7.5 mg/L 12.5 mg/L –0.08 mg/L per °C
20 mg/L 15.0 mg/L 25.0 mg/L –0.09 mg/L per °C
50 mg/L 37.5 mg/L 62.5 mg/L –0.29 mg/L per °C
100 mg/L 75.0 mg/L 125.0 mg/L –0.60 mg/L per °C
Section 2 General information
In no event will the manufacturer be liable for direct, indirect, special, incidental or consequential
damages resulting from any defect or omission in this manual. The manufacturer reserves the right to
make changes in this manual and the products it describes at any time, without notice or obligation.
Revised editions are found on the manufacturer’s website.
2.1 Safety information
The manufacturer is not responsible for any damages due to misapplication or misuse of this product
including, without limitation, direct, incidental and consequential damages, and disclaims such
damages to the full extent permitted under applicable law. The user is soley responsible to identify
critical application risks and install appropriate mechanisms to protect processes during a possible
equipment malfunction.
Please read this entire manual before unpacking, setting up or operating this equipment. Pay
attention to all danger and caution statements. Failure to do so could result in serious injury to the
operator or damage to the equipment.
Make sure that the protection provided by this equipment is not impaired. Do not use or install this
equipment in any manner other than that specified in this manual.
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2.1.1 Use of hazard information
D A N G E R
Indicates a potentially or imminently hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING
Indicates a potentially or imminently hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a potentially hazardous situation that may result in minor or moderate injury.
N O T I C E
Indicates a situation which, if not avoided, may cause damage to the instrument. Information that
requires special emphasis.
2.1.2 Precautionary labels
Read all labels and tags attached to the instrument. Personal injury or damage to the instrument
could occur if not observed. A symbol, if noted on the instrument, will be included with a danger or
caution statement in the manual.
This is the safety alert symbol. Obey all safety messages that follow this symbol to avoid
potential injury. If on the instrument, refer to the instruction manual for operation or safety
information.
Electrical equipment marked with this symbol may not be disposed of in European
domestic or public disposal systems. Return old or end-of-life equipment to the
manufacturer for disposal at no charge to the user.
This symbol indicates the need for protective eye wear.
This symbol 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 indicates that a risk of electrical shock and/or electrocution exists.
This symbol indicates that a risk of fire is present.
This symbol, when noted on the product, identifies the location of a fuse or current
limiting device.
2.1.3 Compliance and certification
CAUTION
This equipment is not intended for use in residential environments and may not provide adequate
protection to radio reception in such environments.
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Canadian Radio Interference-Causing Equipment Regulation, ICES-003, Class A:
Supporting test records reside with the manufacturer.
This Class A digital apparatus meets all requirements of the Canadian Interference-Causing
Equipment Regulations.
Cet appareil numérique de classe A répond à toutes les exigences de la réglementation canadienne
sur les équipements provoquant des interférences.
FCC Part 15, Class "A" Limits
Supporting test records reside with the manufacturer. The device complies with Part 15 of the FCC
Rules. Operation is subject to the following conditions:
1. The equipment may not cause harmful interference.
2. The equipment must accept any interference received, including interference that may cause
undesired operation.
Changes or modifications to this equipment not expressly approved by the party responsible for
compliance could void the user's authority to operate the equipment. This equipment has been tested
and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules.
These limits are designed to provide reasonable protection against harmful interference when the
equipment is operated in a commercial environment. This equipment generates, uses and can
radiate radio frequency energy and, if not installed and used in accordance with the instruction
manual, may cause harmful interference to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference, in which case the user will be required to
correct the interference at their expense. The following techniques can be used to reduce
interference problems:
1. Disconnect the equipment from its power source to verify that it is or is not the source of the
interference.
2. If the equipment is connected to the same outlet as the device experiencing interference, connect
the equipment to a different outlet.
3. Move the equipment away from the device receiving the interference.
4. Reposition the receiving antenna for the device receiving the interference.
5. Try combinations of the above.
2.2 Product overview
D A N G E R
Chemical or biological hazards. If this instrument is used to monitor a treatment process
and/or chemical feed system for which there are regulatory limits and monitoring
requirements related to public health, public safety, food or beverage manufacture or
processing, it is the responsibility of the user of this instrument to know and abide by any
applicable regulation and to have sufficient and appropriate mechanisms in place for
compliance with applicable regulations in the event of malfunction of the instrument.
The SP-510™ Hardness Monitor continuously measures water softener levels to find hardness
breakthroughs based on softener exhaustion. The monitor is used in commercial and industrial water
applications. The monitor has an automatic control system that starts regeneration sequences with
the alarm circuit.
Hardness is measured at different levels as CaCO3 with the applicable indicator and reagent
solutions. A relay closes when the instrument measures a hardness value that is more than the trip
point. Refer to Figure 1 for the product overview.
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Figure 1 Product overview
1 Power switch 7 Keypad
2 Power access port 8 Pump/valve module
3 Relay and alarm contact access port 9 Indicator and reagent bottles
4 Air purge (optional) 10 Sample inlet
5 Access cover 11 Enclosure drain
6 Colorimeter 12 Sample drain
2.3 Product components
Make sure that all components have been received. Refer to Figure 2. If any items are missing or
damaged, contact the manufacturer or a sales representative immediately.
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Figure 2 Product components
1 SP-510 Hardness Monitor 5 Indicator solution
2 Installation kit16 Magnesium sulfate solution
3 Maintenance kit27 TitraVer® (EDTA) hardness titrant
4 Buffer solution
Section 3 Installation
D A N G E R
Electrocution hazard. Always remove power to the instrument before making electrical
connections.
D A N G E R
Multiple hazards. Only qualified personnel must conduct the tasks described in this
section of the document.
3.1 Install the instrument
Install this instrument on an indoor wall, away from direct sunlight.
• For a complete purge of the sample line during each cycle, install the instrument as close to the
sample point as possible.
• Leave sufficient clearance at the bottom and sides for tubing and cable connections.
Refer to Figure 3 and Figure 4.
1Refer to the installation kit documentation for more information.
2Refer to the maintenance kit documentation for more information.
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Figure 3 Dimensions for wall installation
Figure 4 Door clearance
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3.2 Plumb the instrument
CAUTION
Fire hazard. This product is not designed for use with flammable liquids.
CAUTION
Chemical hazard. If there is a leak in the fluid system, hazardous substances may leak
out of the lower enclosure. Put the supplied reagent bottle tray or a bucket under the
drain to catch any spills.
CAUTION
Chemical exposure hazard. Dispose of chemicals and wastes in accordance with local,
regional and national regulations.
Use quick-connect type connectors for ¼-inch OD tubes to install the sample inlet and drain
connections.
1. Install 3 feet of tubing in the ½-inch enclosure drain to keep dust out of the analyzer. Refer to
Figure 1 on page 7, item 11.
Note: Make sure that the enclosure drain is open. The drain must be open to remove sample water if leaks
occur.
2. Push the ¼-in OD poly tube on the sample line connector. The tube will "stop" two times as it is
pushed on the connector. For more information, refer to the installation kit documentation.
3. Make sure that the tubes are pushed completely on the connector. Incorrect installation can
cause the tube to come off of the connector when water pressure is applied.
Note: The sample drain connector will install on ½-inch ID flexible tubes (customer-supplied).
3.2.1 Connect the air purge (optional)
An air purge is necessary in an environment with high humidity or caustic vapors.
Note: Use only dry, oil-free instrument air at 0.42 m3 (15 standard cubic feet) per hour (scfh).
1. Find the air purge connection on the left side of the instrument enclosure. Refer to Figure 1
on page 7.
2. Remove the plug in the quick-connect fitting.
3. Push the ¼-inch poly tubing into the fitting. Make sure to have two different "stops" so that the
tubing cannot disconnect when air pressure is applied.
3.2.2 Sample line guidelines
Select a good, representative sampling point for the best instrument performance. The sample must
be representative of the entire system.
To prevent erratic readings:
• Collect samples from locations that are sufficiently distant from points of chemical additions to the
process stream.
• Make sure that the samples are sufficiently mixed.
• Make sure that all chemical reactions are complete.
3.2.3 Connect the sample stream
Install the sample line into the center of a larger process pipe to minimize interference from air
bubbles or bottom sediment. Figure 5 shows examples of good and bad installation.
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Keep the sample lines as short as possible to prevent the accumulation of bottom sediment. The
sediment can absorb some of the analyte from the sample and cause low readings. The sediment
can later release the analyte and cause high readings. This exchange with the sediment also causes
a delayed response when the analyte concentration in the sample increases or decreases.
Figure 5 Sampling methods
1 Air 2 Sample flow
3.2.4 Install the pump valve pressure plate
The pressure plate and screws are supplied with the installation kit. Remove the tape from the pump
tubes before installation.
Make sure to turn the screws in small increments and move from one screw to the other so that the
plate is pulled down equally. Do not overtighten. To install the pressure plate, refer to Figure 6.
Figure 6 Install the pressure plate
3.2.5 Install the sample conditioning kit
The sample conditioning kit is supplied with the instrument. The kit removes large particles from the
sample stream with a 40-mesh strainer. The ball valve on the raw sample inlet controls the flow to
the filter. The ball valve on the instrument supply line controls the flow rate of filtered sample to the
instrument. For complete sample conditioning installation instructions, refer to the installation kit
documentation. Refer to Figure 7.
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Figure 7 Sample flow through the conditioning kit
1 Sample flow 4 Bypass tee, unfiltered
sample
7 Unfiltered-sample ball valve
(shown open)
2 Bypass flow 5 Flow observation point 8 Low-flow valve option
3 Drainage flow 6 Filtered-sample bypass ball
valve (shown open)
9 High-flow valve option
3.3 Electrical installation
D A N G E R
Electrocution hazard. Always remove power to the instrument before making electrical
connections.
3.3.1 Remove the access cover
Remove the access cover to connect to the wiring terminals. Refer to Figure 8.
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Figure 8 Access cover removal
3.3.2 Electrical connections for conduit
D A N G E R
Electrocution hazard. Use only fittings that have the specified environmental enclosure
rating. Obey the requirements in the Specifications section.
D A N G E R
Electrocution hazard. If this equipment is used outdoors or in potentially wet locations, a
Ground Fault Circuit Interrupt (GFCI/GFI) device must be used for connecting the
equipment to its main power source.
WARNING
Electrocution hazard. Install a 10 A circuit breaker for mains power. Identify the circuit
breaker with a label, as a local disconnect for this equipment.
The instrument has plugs in all of the conduit holes. To keep the IP62 environmental rating, use
liquid-tight sealing-type conduit fittings and cord strain reliefs. Connect the equipment in accordance
with local, state or national electrical codes. If connections are not made through a conduit opening,
install a liquid-tight seal in place of the plugs. Refer to Figure 9.
Figure 9 Power connections
1 Conduit (preferred) 2 Power cord (optional)
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3.3.3 Wiring for power
To connect the instrument to power, refer to Figure 10 and Table 1.
Figure 10 Power connection
1 Voltage switch (in 115 V position) 3 AC power connector
2 Voltage switch (in 230 V position) 4 Fuses (F1 and F2)
Table 1 Terminal wiring
Wire color code Protective earth
ground
Hot or Ø1 Neutral or Ø2
North America Green Black White
International
electrotechnical
commission (IEC)
Green with yellow line Brown Blue
3.3.4 Select the voltage
N O T I C E
To prevent serious damage to the instrument, make sure that the line voltage is set correctly. Refer
to Figure 10 on page 14.
The instrument is set to 115-volt operation at the factory. To change the line voltage to 230-volt
operation, slide the voltage switch to the 230 V position. Refer to Figure 10 on page 14.
Note: The fuses are approved for North American and European use and do not need to be changed with the
voltage.
3.3.5 Connect the alarm relays
CAUTION
Fire hazard. Relay loads must be resistive. Always limit current to the relays with an
external fuse or breaker. Obey the relay ratings in the Specifications section.
The current to the relay contacts must be 5 A or less. Make sure to have a second switch available to
remove power from the relays locally in case of an emergency or for maintenance. Power can be
removed with an external switch and a 5 A fuse or with a switched 5 A circuit breaker.
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Figure 11 shows the alarm relay contacts connected to the terminal strip with normally open and
normally closed terminations. Terminals are unpowered and rated for 5 A at 100–240 VAC resistive
load.
The relay connector accepts 18–12 AWG (0.75–1.0 mm2) wire. Select the necessary wire gage that
operates with the application. A wire gauge less than 18 AWG (0.75 mm2) is not recommended.
Figure 11 Alarm connections
Table 2 Relay wiring
Terminal block Terminal 1 Terminal 2 Terminal 3
J7 COM Normally open (NO) Normally closed (NC)
3.4 Install the buffer solution
Buffer solutions are formulated at the factory and are ready to install without preparation. Put the
bottle in the instrument as shown in Figure 12 on page 16. Refer to Buffer and indicator solution for
the applicable trip point on page 24.
3.5 Install the indicator solution
Indicator solutions are formulated at the factory and are ready to install without preparation. Put the
bottle in the instrument as shown in Figure 12. Refer to Buffer and indicator solution for the
applicable trip point on page 24.
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Figure 12 Install the buffer and indicator reagents
1 Indicator reagent tube label and bottle 2 Buffer tube label and bottle
3.6 Install the stir bar
A stir bar is included in the installation kit. Install the stir bar in the colorimeter sample cell for correct
operation. Refer to Figure 13.
Figure 13 Install the stir bar
Section 4 User interface and navigation
4.1 Keypad description
Refer to Figure 14 and to Table 3 for the keypad description and navigation information.
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Figure 14 SP-510 keypad
Table 3 Keypad description
Key Function Description
1 HARD LED The monitor found hardness in the water. The status indicator light is red.
2 SOFT LED The monitor is in operation and no hardness shows. The status indicator light
is green.
3 ALARM OFF Sets the alarm to off. When more cycles are necessary to examine the water,
set the alarm to off. The status indicator light is yellow.
4 HARD CAL Completes a hard calibration. Refer to Calibration on page 18. The status
indicator light is yellow.
5 ZERO CAL Completes a zero-point calibration. Refer to Calibration on page 18. The
status indicator light is yellow.
Section 5 Startup
5.1 Start the instrument
Note: Install the pressure plate correctly to prevent sample flow directly into the reagents. Refer to Install the pump
valve pressure plate on page 11.
1. Open the supply valve to the instrument.
2. Let the pressure in the tubes stabilize.
Note: If leaks occur under pressure, examine all connections. Secure connections until all leaks have stopped.
3. Set the power to on.
4. Operate the instrument for approximately 2 hours with the sample and reagents.
Note: The sample cell will have bubbles on the surface until it is fully wetted. The bubbles can cause irregular
readings until the sample flow stabilizes.
5.2 Prime the reagents (optional)
Prime the reagents to decrease the start up time to 15 minutes.
1. Set the sample flow to the instrument to off.
2. Disconnect the reagent feed line after the “Y” fitting at the colorimeter.
3. Connect a syringe to the tubing that comes from the “Y” fitting.
4. Loosen the two screws on the pump pinch plate so that the reagents can be pulled through the
reagent lines.
5. Use the syringe to remove the air and fill the lines with reagent.
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6. Tighten the screws on the pump pinch plate. Do not overtighten.
7. Remove the syringe from the tubing and connect the fitting on the colorimeter.
Section 6 Calibration
CAUTION
Chemical exposure hazard. Obey laboratory safety procedures and wear all of the
personal protective equipment appropriate to the chemicals that are handled. Refer to
the current safety data sheets (MSDS/SDS) for safety protocols.
6.1 Complete a 2-point calibration
Complete a calibration after reagent installation or when an optical system component is replaced.
The standardization procedure makes the sample first hard, then soft.
1. Remove the plug from the top port of the colorimeter. Refer to Figure 13 on page 16.
2. Push HARD CAL. The hard cal LED is on continuously.
3. When the hard cal LED flashes, add two drops of Magnesium Standard Solution into the
colorimeter.
4. When the LED stops flashing and is on continuously, wait for the cycle to complete.
At the end of the cycle, the LED sets to off to show a successful calibration.
5. HARD CAL failure: When the LED starts to flash, push HARD CAL to confirm a hard cal failure.
Do steps 2–4 again.
6. Push ZERO CAL. The zero cal LED is on continuously.
7. When the zero cal LED flashes, add two drops of EDTA Solution, 10 g/L, into the colorimeter.
8. When the LED stops flashing and is on continuously, wait for the cycle to complete.
At the end of the cycle, the LED is set to off to show a successful calibration.
9. ZERO CAL failure: When the LED starts to flash, push ZERO CAL to confirm a zero cal failure.
Do steps 1–7 again.
10. Replace the plug in the top port of the colorimeter.
Section 7 Operation
After the instrument power is set to on, the SOFT LED flashes until the first reading cycle is
completed. The cycle takes 2 minutes. Then, the SOFT LED shows a stable green light.
The HARD LED comes on with a red light when the sample reagent mixture measurement is higher
than the trip point for one measurement. Push ALARM OFF to set the alarm relay to off. The ALARM
OFF light will show a yellow light.
The instrument operates maintenance-free for a minimum of 2 months. Periodically, do a visual
check to see if bubbles are in the tubing. If there are bubbles, look for an air leak. Refer to
Maintenance schedule on page 19 for maintenance tasks.
Section 8 Maintenance
D A N G E R
Multiple hazards. Only qualified personnel must conduct the tasks described in this
section of the document.
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