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.

5
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.

6
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

7
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

11
400mg/L for Free Chlorine analysis (PCA
300) or 700mg/L for Total Chlorine
analysis (PCA 301)
Operating 5 to 40°C (41 to 104°F)
temperature range
Recorder output Selectable 0-10mV, 0-100mV, 0-1V or
4-20 mA. Output span is settable
anywhere in the 0-5 mg/L range
Dosage Proportional on one point with a delta
adjustable at 0.1, 0.2, 0.3, 0.4, 0.5,
0.6, 0.7, 0.8, 0.9, 1.0, 1.5, 2.0 mg/L,
equipped with a SPDT relay with
contacts rated for resistive load: 5 A at
250VAC or 5 A at 30VDC; inductive
load: 2 A at 250VAC or 3 A at 30VDC.
Alarms One sample concentration alarm
adjustable as minimum or maximum
acceptable value, equipped with a
SPDT relay with contacts rated for
resistive load: 5 A at 250VAC or 5 A at
30VDC; inductive load: 2 A at 250VAC
or 3 A at 30VDC.
One system error alarm
Power 20VA at 115VAC/230VAC;
requirements 50/60 Hz
Sample inlet 12 mm (1/2”) male NPT fitting
connection
Drain connection 10 mm (3/8”) barb fitting
Case NEMA-4X molded fiberglass polyester
instrument enclosure with transparent
GE Lexan window (not PCA 300AC and
PCA 301AC)
Dimensions 318 x 267 x 159 mm
(12.5 x 10.5 x 6.25")
Weight 5 Kg (11 lb.)

12
OPERATING DESCRIPTION
Referring to the drawing on page 7 and the Fluidic Dia-
gram on page 13, the Sample Line is connected to the
instrument at the Sample Port (#16); an internal Regulator
(#17) reduces the inlet pressure from a maximum of 4 bar
(57.2 psig) down to 1 bar (14.3 psig); from the Regulator
a nylon tube is connected to the input of the Electrovalve
(#18). The output of the valve goes to the Drain Port (#11
in PCA 300 and PCA 301 only) and then to the Measur-
ing Cell (#8). An optional Filter can be installed to the sample
port if the stream is excessively turbid.
The sample coming from the line normally flows through the
Measuring Cell. It goes out from the Measuring Cell through
the Drain Tube (#10) and the Output Port (#9).
The Measuring Cell is accessible from the port placed on the
top (#7) for speedy cleaning and maintenance.
During the time between two successive sampling, the ana-
lyzer solenoid input valve is open to allow sample flow to
flush the colorimeter cell. Every 3 to 102 minutes (user se-
lectable), the valve closes stopping the sample flow and
leaving the sample cell full of fresh sample. Cell volume is
controlled by an overflow gateway.
As the sample inlet valve closes, a series of measurements
(with LED on and off) of the unreacted sample is taken to
determine an average Blank level prior to reagent addi-
tion. The measurement of sample blank signal permits
compensation for any turbidity or natural color, and pro-
vides the zero reference point for the measurement.
The two channel Peristaltic Pump (#6) starts rotating caus-
ing a precise quantity of buffer and indicator (#14 and
#15) to enter the colorimeter sample cell where a mag-
netically coupled stirrer mixes the reagents with the sample.
After a delay for the development of color, a series of mea-
surements (with LED on and off) are taken (Sample level)
to determine an average Chlorine concentration measure-
ment. The reacted sample signal is then measured and
displayed.
This sequence is repeated every 3 to 102 minutes (user-se-
lectable).

13
METHOD OF ANALYSIS
Free available Chlorine (monitored by the PCA300 series)
oxidizes the DPD indicator reagent at a pH between 5.5 and
6.0 to form a magenta-colored compound. The intensity of
the resulting color is proportional to the concentration of Chlo-
rine in the sample. The purpose of the buffer solution is to
maintain the proper pH.
To measure Total Residual Chlorine (Free available Chlorine
plus combined Chloramines) the PCA301 series adds Po-
tassium Iodide. The Chloramines in the sample cause
iodide ions to become iodine which then act with free Chlo-
rine to oxidize the DPD indicator. After the chemical reaction
is complete, the optical signal at 555 nm is compared to
the signal measured through the sample (before the re-
agents were added). From these measurements Chlorine
concentration is calculated.
Fluid Diagram of the Analyzers

14
INITIAL PREPARATION AND INSTALLATION
INSTALLATION PERSONNEL
Installation of the PCA 300 and PCA 301 family of Chlo-
rine Analyzers should be undertaken by persons with technical
knowledge of the dangers associated with chemical exposure
and electrical shock.
Hanna Instruments assumes persons performing the instal-
lation tasks are aware of the appropriate safety procedures.
Review the Material Safety Data Sheets (MSDS) before han-
dling the supplied chemical reagents.
LOCATION OF THE INSTRUMENT
Analyzer Location
Locate the analyzer as close as is reasonably possible to
the point where the sample is withdrawn from the product
stream (referred to as the “sampling point”). This practice
will minimize the amount of time it takes for the sample to
flow to the analyzer from the sampling point. The result is
improved response time of the analyzer to changes in Chlo-
rine contents.
The instrument should be mounted indoors, out of direct
sunlight. Instrument operating temperature is 5 to 40°C
(41 to 104°F).
Sampling Point Location
Locate the sampling point to obtain a truly representative
sample from the product stream. For example, be sure the
sampling point is well downstream from a Chlorine feed.
This assures that adequate mixing and reaction of the
Chlorine before a sample is extracted.
HYDRAULIC CONNECTIONS
Note Hydraulic connections should be installed only by qualified
personnel to assure conformity to applicable plumbing codes.
Sample Line Installation
Sample lines of 3 mm (1/8") ID tubing are recommended to
keep the sample volume in the tubing to a minimum. This
reduces lag time for the sample flow from the sampling point
to the instrument. In any case note that sample should reach
the measuring cell in less then 100 seconds.

15
Direct routing of sample lines is also recommended.
If the large process pipes are horizontal, taps should be in-
serted vertically in the middle of the pipe to avoid pulling
sediment from the bottom or air bubbles from the top of
the pipe into the sample line.
A 1/2” BSP sample input fitting allows direct connection to
the optional input filter.
Sample line pressure should be between 0.07 and 4 bar (1
and 57.2 psig) with an ideal pressure of 0.7 bar (10 psig).
Drain Line Installation
The drain hose fitting is a 20 mm (3/4”) hose barb on the
bottom of the instrument enclosure. An air gap between the
end of the drain hose and the drain is recommended to prevent
any back flow into the instrument in the event of drain block-
age.

16
Return Line Installation
The return hose fitting is a 12 mm (1/2”) hose barb on the
bottom of the regulator output port and should always be
connected even when pressure is below 1 bar.
INSTALLING THE INPUT FILTER
In order to ensure maximum accuracy of measurements, it is
recommended to have always clear sample, with suspended
particles smaller than 0.5 µm. This can be achieved by in-
stalling two filters before the sample input.
The type of filters depends on the quality of the water: the first
filter should have 50-100 µm pore size, whereas in any case
the second filter, the one closer to the analyzer, has to be
0.5 µm.
For correct installing procedure and maintenance, see the
instructions of filters.
INSTALLING THE PUMP TUBES
Locate the analyzer reagent tubes in the accessory kit. Each
tube is composed of three sections. The sections are joined
together by plastic connectors with plastic collars at the ends
of the center section.
Locate the peristaltic pump.
Feed one tube from the shorter end section behind the pump
rollers from the right side of the pump. Seat the plastic collar
at the right end of the center sec-
tion of tubing into the lower right
indentation hole of the pump face.

17
Grasp the other plastic collar and pull, stretching the center
section, and place the grommet in the lower left indentation
hole.
Repeat this process with the second pump tube, placing it in
the upper indentation holes.
Separate reagent caps are provided in the accessory kit. Put
the supplied caps onto each reagent bottle prior to installing
them. Place the indicator bottle (HI 70450 for PCA 300
and HI 70460 for PCA 301) on the right and the buffer
bottle (HI 70451 for PCA 300 and HI 70461 for PCA
301) on the left.
Note Add the content of 5 HI 70452 sachets, DPD Compound,
to the Indicator Solution prior to installing it.
Connect the longer tube
ends on the left side of
the pump to the reagent
bottle cap insert fitting.
Connect the short ends
on the right side of the
pump to the measuring
cell reagent input port
through the "Y" connec-
tor.

18
ELECTRICAL CONNECTIONS
A power cable (3 mt.) is provided with your analyzer. How-
ever, if access to the terminal block is required, see below.
Warning Electrical connections should be installed only by qualified
personnel to assure conformity to applicable electrical codes.
Unplug the meter before any electrical connection.
Power
Power connections are made at a terminal block located in
the center of the electrical compartment to the right of the
fuses.
Hard wiring with 13 mm (½") conduit is recommended and
usually required by most municipal electrical codes.
Warning Before connecting the instrument to the line:
1) Check the sticker near the fuses for proper voltage.
2) Be sure the power cord is not connected to the line.
3) Open front panel.
4) Remove the cover screws (Allen head).
5) Do not remove peristaltic pump or motor.
6) Unplug all alarms and recorder jacks.
Feed the power cord through the watertight grommet and
tighten the grommet nut. See the picture below for proper
wire connections.

19
Recorder Output and Relay Access
Hard wiring for alarms and relays can be accomplished
through four watertight connectors on the left of the enclo-
sure, by passing wires through the rubber grommet and
tightening the nut as described earlier.
Refer to the drawing on the right for proper wire connections.
Alarm System
A system alarm feature provides relay acti-
vation to signal need for operator
intervention through an external device, such
as a buzzer, a light or any other electrical
equipment.
Refer to the drawing on the right for proper
wire connections.
The SYS.ERROR LED goes on when a sys-
tem error has occurred. If the situation persists
for more than a few samples, the operator
should notify maintenance personnel for in-
vestigation of the problem. When the meter
is in system error mode, the user can di-
rectly access the diagnostic code that
indicates the source of error (see Error Codes
section at page 49). The analyzer continues
to perform the sampling operations during
an alarm condition.

20
Recorder Output
Recorder output connections are made as indicated on the
picture aside. The control panel must be opened.
A wiring access hole is located on the left side of the instru-
ment case. Use two wire shielded cable with the shield
connected at the analyzer end only. This wire access hole
should be used only for recorder or serial I/O cables (low
voltage).
The recommended recorder hookup uses a
shielded, twisted-pair cable. The shield
should be connected to Earth terminal at
the instrument end and left open at the re-
corder end. Refer to the drawing here for
proper wire connections.
To operate with this hookup, the following conditions are re-
quired at the recorder end:
• The input to the recorder must be isolated from the chassis
ground (earth) of the recorder;
• If the recorder has more than one input, they must be dif-
ferential inputs.
A choice of outputs, 0-10mV, 0-100mV, 0-1V or 4-20 mA
may be made by selecting the appropriate DIP switch con-
figuration. The DIP switch is located in the upper right corner
of the main board on the back of the control panel.
Earth
Ground
Out
Recorder
Output