Hanna Instruments PCA 300 Series User manual

PCA 300/PCA 301
Series
Panel-mounted,
Microprocessor-based
Chlorine Analyzers
Instruction Manual

2
TABLE OF CONTENTS
PRELIMINARY EXAMINATION . . . . . . . . . . . . 4
GENERAL DESCRIPTION. . . . . . . . . . . . . . . . 5
MECHANICAL DIMENSIONS . . . . . . . . . . . . 6
FUNCTIONAL DESCRIPTION . . . . . . . . . . . . 7
LED DISPLAY, INDICATORS AND KEYBOARD . 8
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 10
OPERATING DESCRIPTION. . . . . . . . . . . . . 12
Method of analysis . . . . . . . . . . . . . . . . 13
INITIAL PREPARATION AND INSTALLATION . 14
Installation Personnel . . . . . . . . . . . . . . 14
Location of the Instrument . . . . . . . . . . . 14
Hydraulic Connections . . . . . . . . . . . . . 14
Installing the Input Filter . . . . . . . . . . . . 16
Installing the Pump Tubes . . . . . . . . . . . 16
Electrical Connections . . . . . . . . . . . . . 18
Dear Customer,
Thank you for choosing a Hanna Product.
This instruction manual has been written for the following products:
PCA 300 Free Chlorine Analyzer with features such as alarm functions, user-se-
lectable sampling periods, LED warning indications, recorder outputs,
RS232 port and a Nema 4X, 12 and 13 enclosure.
PCA 301 Total Chlorine Analyzer with features such as alarm functions, user-
selectable sampling periods, LED warning indications, recorder outputs,
RS232 port and a Nema 4X, 12 and 13 enclosure.
PCA 300A Same as PCA 300 except for the RS232 port which is not supplied.
PCA 301A Same as PCA 301 except for the RS232 port which is not supplied.
PCA 300AC This OEM version is exactly the same as PCA 300 except for the
RS232 port and the enclosure.
PCA 301AC This OEM version is exactly the same as PCA 301 except for the
RS232 port and the enclosure.
Please read this instruction manual carefully before using the instrument. It will pro-
vide you with the necessary information for the correct use of the instrument, as well as a
more precise idea of its versatility.
These instruments are in compliance with directives. The PCA 300 and PCA 301 are
also registered by Underwriters Laboratories Inc. (UL approved).

3
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Instrument Power On . . . . . . . . . . . . . . . . 22
Display Brightness . . . . . . . . . . . . . . . . . . 22
Minimum and Maximum Concentration . . . 23
Sampling Rate . . . . . . . . . . . . . . . . . . . . 24
Priming the Reagent System . . . . . . . . . . . 24
ANALYZER PROGRAMMING . . . . . . . . . . . . . 26
Proportional Dosing . . . . . . . . . . . . . . . . 26
Concentration Setpoint Alarm Setting . . . . . 28
Recorder Output Span Setting . . . . . . . . . . 30
Standby Mode . . . . . . . . . . . . . . . . . . . . 32
Recorder Output Calibration. . . . . . . . . . . 33
Recorder Output Limits Check . . . . . . . . . . 40
Adjusting the Light Source . . . . . . . . . . . . 42
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . 44
Calibration Requirement. . . . . . . . . . . . . . 44
Hydraulic System . . . . . . . . . . . . . . . . . . . 44
Reagents Supply . . . . . . . . . . . . . . . . . . . 44
Changing Peristaltic Pump Tubing . . . . . . . 46
Tubing Replacement . . . . . . . . . . . . . . . . 47
“Y” Strainer Cleaning . . . . . . . . . . . . . . . 47
Cleaning Measurement Cell . . . . . . . . . . . 47
Relay Test . . . . . . . . . . . . . . . . . . . . . . . . 48
Calibration Procedure . . . . . . . . . . . . . . . 48
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . 50
OPERATIONAL & DIAGNOSTIC CODES . . . . . 53
INTERFACE WITH PC . . . . . . . . . . . . . . . . . . . 55
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . 56
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . 57
CE DECLARATION OF CONFORMITY . . . . . . . 59
© 1997 Hanna Instruments
All rights are reserved. Reproduction in whole or in part is prohibited without the
written consent of the copyright owner, Hanna Instruments Inc., 584 Park East Drive,
Woonsocket, Rhode Island, 02895 , USA.

4
PRELIMINARY EXAMINATION
Remove the analyzer from the packing material and examine
it carefully to make sure that no damage has occurred dur-
ing shipping. If there is any noticeable damage, notify your
Dealer immediately.
Each analyzer is supplied complete with:
• 2 reagent bottles (1 indicator and 1 buffer solution)
(PCA 300 and PCA 301 only)
• 2 reagent bottle caps (PCA 300 and PCA 301 only)
• 1 DPD compound powder (PCA 300 and PCA 301
only)
• tubing
• mounting brackets
Note Save all packing materials until you are sure that the instru-
ment functions correctly. Any damaged or defective items must
be returned in their original packing materials together with
the supplied accessories.
WARNING The PCA300 and PCA 301 series of Chlorine Analyzers are
not designed for use with samples that are inflammable or
explosive in nature. If any sample solution other than water is
used with these products, test the sample/product compat-
ibility to assure user safety and proper product performance.
Safety Precautions Please take the time to read the safety precautions carefully
wherever they appear in this manual. They are provided to
prevent personal injury and damage to the instrument. This
safety information applies to the operators and service per-
sonnel and the following two captions are used:
CAUTION: identifies conditions or practices that could re-
sult in damage to the instrument or persons;
WARNING: identifies conditions or practices that could
result in personal injury or loss of life.
Note Because of the inherent dangers in handling chemical
samples, standards and reagents, HANNA Instruments
strongly recommends the users of this product review the
Material Safety Data Sheets and become familiar with safe
handling procedures and proper usage prior to handling
any chemicals.

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GENERAL DESCRIPTION
The Hanna PCA 300 and PCA 301 series of Chlorine Ana-
lyzers are microprocessor-controlled, process analyzers which
continuously monitor a sample stream for Chlorine content.
The PCA 300 series monitor Free Chlorine and the PCA 301
series Total Chlorine in the 0 to 5 mg/L (ppm) range.
In the DPD Colorimetric method, N, N-Diethyl-p-phenylene-
diamine indicator and a buffer are mixed with the sample.
The resulting chemical reaction causes a magenta color to
form. The color intensity is proportional to the concentration
of Chlorine. The color intensity is measured photometrically
(with a light beam and a photodetector) and converted to
Chlorine concentration, in mg/L, which is displayed on the
front panel, four-digit, LED display.
Indicator and buffer reagent bottles are placed directly into
the instrument case. With a sampling period of 5 minutes,
reagents need to be replenished about once a month. The
reagent bottles are easily visible through the transparent win-
dow to allow the operator to check the reagent levels.
The cases of PCA 300 and PCA 301 meet NEMA 4X, 12
and 13 standards. Molded fiberglass polyester has outstand-
ing chemical and temperature resistance.
External mounting feet provide wall mounting capability and
a seamless gasket assures a watertight and dust-tight seal.
The electrical and hydraulic connections (except for
PCA 300AC and PCA 301AC OEM models) are made
through the side of the enclosure.
The front cover is secured with two lockable
latches.

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Two selectable chlorine level setpoints can be set by the op-
erator: a proportional dosing setpoint and an alarm setpoint.
Both setpoints control a SPDT relay.
The proportional dosing setpoint analyzers is user-selectable
with a delta from 0.1 to 2.0 mg/L (ppm).
The alarm level can be set by the user to be an “activate-
if-lower-than” setpoint or an “activate-if-greater-than” setpoint.
A system alarm feature provides relay activation to signal
need for operator intervention.
The PCA 300 and PCA 301 analyzers can supply data to
an external computer through an RS232C output connec-
tion.
Voltage output levels of 0-10mV, 0-100mV, 0-1V or a cur-
rent output of 4-20 mA are selectable to drive an external
device such as a chart recorder or an external regulator.
Recorder span minimum and maximum values in mg/L
are programmable by the operator through the keyboard.
MECHANICAL DIMENSIONS *
Note The enclosure is not supplied with PCA 300AC or
PCA 301AC
* Wall Mount Dimensions in mm & inches

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FUNCTIONAL DESCRIPTION
1. Alarms Indicators
2. LED Display
3. Keyboard
4. Alarms Output
5. Recorder Output
6. Peristaltic Pump
7. Access Point to Cell
8. Measuring Cell
9. Output Port
10. Drain Tube
11. Drain Port of Measuring Cell
12. Drain Port Valve
13. Sample Tubing
14. Buffer Bottle
15. Indicator Bottle
16. Sample Port
17. Incoming Pressure Regulator
18. Electrovalve
19. Reagent Tubing
20. Line Input
21. Pressure Regulator Output Port
Unplug the meter before any electrical connection.

8
LED DISPLAY, INDICATORS AND KEYBOARD
DIGITAL DISPLAY
The digital readout will indicate the Chlorine concentration of
the last sample measured in milligrams per liter (mg/L) dur-
ing normal operation.
Only when a key is pressed to execute some other function,
will the concentration reading be interrupted. In this case, the
Chlorine mg/L indicator is turned off.
If the Chlorine concentration is above 5 mg/L, the display will
blink.
mg/L CHLORINE INDICATOR
During normal operation, this green indica-
tor will be on continuously, indicating that the
LED is displaying Chlorine concentration. Dur-
ing the diagnostic or other modes this indicator
will be off.
DOSE INDICATOR
When proportional dosing is active, the dose
LED will be on and the corresponding relay
closes. This LED turns off automatically when
the proportional dosing stops.
ALARM INDICATOR
This LED will be on when the programmed
alarm setpoints are exceeded. The alarm
LED turns off automatically when the alarm
condition disappears.

9
SYSTEM ERROR INDICATOR
This LED is lit when a system error has oc-
curred. If the situation persists for more than
a few samples, the operator should notify
maintenance personnel for investigation of the
problem. When the meter is in system error
mode, the user can directly access the diag-
nostic code that indicates the source of error. The analyzer
continues to perform the sampling operations during an alarm
condition.
KEYBOARD DESCRIPTION
The Reset key clears system alarm and restarts the analyzer.
The Max/Min key alternately displays maximum and mini-
mum Chlorine concentration levels since last reset.
The RIGHT arrow key is used to shift digit position within a
displayed number.
The UP arrow key is used to scroll up a displayed digit: 0, 1,
2 ..... 9, 0, 1, 2, etc.
The DIAG key is used to select programming and self-diag-
nostic modes.
The Rec.Max key is used to enter and recall maximum value
of the recorder output in mg/L.
The Rec.Min key is used to enter and recall minimum value
of recorder output in mg/L.
The Set Point key is used to enter and recall concentration
setpoint.
The Set Alarm key is used to enter and recall concentration
alarm setpoint.
The Set Time key is used to enter and recall time intervals
between two consecutive samples.
RESET
MAX
MIN
DIAG
REC.
MAX
REC.
MIN
SET
TIME

10
SPECIFICATIONS
PCA 300 PCA 301
Range 0.00 to 5.00 mg/L 0.00 to 5.00 mg/L
Free Cl2Total Residual Cl2
Resolution 0.01 mg/L
Accuracy ±8% of reading or ±0.05 mg/L
whichever is greater
Typical EMC ±0.05 mg/L
Deviation
Minimum 0.05 mg/L
detectable level
Repeatability ±0.05 mg/L
Response time Related to the sampling time selected.
Typical for a full scale step change and
5 minutes between two consecutive
samples: one sampling cycle for 90%
response and two sampling cycles for
100% response
Sampling rate Adjustable from 3 to 102 minutes
Sample inlet 0.07 bar (1psig) min., 4 bar (57.2 psig)
pressure max. An internal regulator reduces
pressure from 4 bar (57.2 psig) to
1 bar (14.3 psig)
Sample flow Flow rate of 300 mL/min is recom-
range mended. Minimum and maximum
allowed are 100 mL/min and
500 mL/min, respectively
Sample 5 to 40°C (41 to 104°F)
temperature range
Interferences Oxidizing agents such as: Iodine,
Bromine, Ozone, Chlorine Dioxide,
Permanganate, Hexavalent Chromium.
Hardness must not exceed 1000 mg/L
as CaCO3. Alkalinity must not exceed