IOTRONIC AQUACON PH-CL User manual

May 2011
Fillerkampsweg 1 – 5 •31832 Springe OT Eldagsen •Tel.: [phone] (Fax: -99)
E-Mail: [email protected] Internet: http://www.iotronic.de
Operating Manual
Process photometer
for free chlorine and pH value
AQUACON PH-CL
(PC- Cabinet)

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1 GENERAL GUIDELINES FOR SAFETY 3
2 PRINCIPLE OF OPERATION 4
3 DESCRIPTION OF THE PROCESS PHOTOMETER 4
3.1 Analytical Part 7
3.2 Measurement and Control 7
3.3 Operation and Measurement Security 8
3.4 Automatic Operation 9
3.5 Manual Operation 10
3.6 Display/Set Parameters 11
3.6.1 Limit Value 1 pH 12
3.6.2 Limit Value 2 pH 12
3.6.3 Limit Function pH 13
3.6.4 Limit Value 1 Cl2 13
3.6.5 Limit Value 2 Cl2 13
3.6.6 Limit Function Cl2 13
3.6.7 Sampling Intervall 13
3.6.8 Titer/Calibration factor 14
3.6.9 Rinsing time 14
3.6.10 Reagent Volume 14
3.6.11 Analog Output setting (mode) 14
4 SWITCHING FUNCTIONS OF THE AQUACON PH-CL 15
4.1 External Switching 15
4.2 Display in the standby mode 15
4.3 Analysis state relay 15
4.4 Limit Value Relay K2 and K3 16
4.5 Alarm Limit Relay 16

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4.6 Current Output 16
5 START-UP AND MAINTENANCE INSTRUCTIONS 17
5.1 Connection of sample water 17
5.2 Connection of reagent, bleeding of pumps and tubes 17
5.3 Replenishment of Reagent 17
5.4 Changing of Tube box 18
5.5 Recalibration of the Process analyzer 18
5.6 Maintenance interval 18
5.7 Shut down procedure 18
6 ALARM MESSAGES 19
7 TECHNICAL DATA 19
8 SPECIFICATIONS 20
9 CONNECTION DIAGRAM 20
9.1 Set 0/4 - 20 mA-Output 20
9.2 Connections 21
9.3 Installation 22
10 APPENDIX 23
10.1 Analysis cycle AQUACON PH-CL 23
10.2 Spare part and consumable item list 24
11 TROUBLESHOOTING GUIDE 25

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1 General Guidelines for Safety
WARNING (Non-observance or misapplication of the contents
of the “Warning” section could lead to serious
accident, including death or injury)
Turn off the power supply.
Working without disconnecting the power supply may cause an electrical
shock. Before engaging upon any working procedures make sure to
disconnect the power supply.
No remodelling !
Never remodel an analyzer. Otherwise, a serious accident may result.
IOTRONIC will not be responsible for any accident or damage of any kind
which is caused by the user remodelling the analyzer.
Operating site must be free of water and humidity
The analytical instrument is not designed to be water-proof or dust-proof.
The use of the analyzer in places where water splashes or humidity is high
may result in an electrical shock or short-circuit.
CAUTION !
(Non-observance or misapplication of the
contents of the “Caution” section could lead to
serious physical injury to the user or serious
damage to the product.)
Specified power only
Do not operate the analyzer on voltage which is not specified on the label
on the right side of the transmitter housing. Failure to do so can result in
damage or fire. Only the specified power level is to be applied.
Do not damage or change power cable !
Do not scratch, damage, process, or pull the power cable forcibly. Non-
observance could cause a fire or an electrical shock.
Notes on operation
zDropping the device or subjecting it to strong impacts may result in
faulty performance. Handle the analyzer with care.
zSelect an installation site convenient for future maintenance and
inspection, and fix the device carefully so that it is free of vibrations.

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2 Principle of Operation
The process photometer AQUACON PH-CL performs a discontinuous photometric determination of
the concentration of free chlorine and of the pH value. The measurements are performed one after the
other. The entire operation, which includes filling and rinsing of the measuring cuvette, is controlled
by a microprocessor.
PH value:
A special indicator reagent is added via a peristaltic pump and mixed with the water sample in the
measuring chamber. The color formed as a result of the reaction is detected by the monochromatic
photometric detection system built into the measuring chamber. The measured absorbance is a
function of the pH value.
Free chlorine:
A special developed reagent based on N-N-Diethyl-p-phenylendiaminsulfat (DPD) and a buffering
solution are added via a peristaltic pump and mixed with the water sample in the measuring chamber.
The color formed as a result of the reaction is detected by the monochromatic photometric detection
system built into the measuring chamber. The measured absorbance is a function of the free chlorine
concentration. With this method, the concentration of free chlorine (Cl2), hypochlorous (HOCl),
hypochlorite (OCl-) is measured.
The measurement results for pH value and free chlorine concentration are displayed on the
touchscreen.
3 Description of the Process Photometer
The process photometer is delivered completely mounted in a polycarbonate wall cabinet, ready for
installation. This includes all the components for sample and drain connection, measurement chamber,
reagent pumps, display and connections for remote display and control. All functions of the process
photometer can be operated via touchscreen.

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Sample
inlet
Sample
outlet
700
300
1
2
3
4
8
9
5
6
7
Automatic Operation
Manual Operation
Mode is selected for the following
drives by pressing the appropiate
key i n t he to p r ow
Rea gent pum p 1+ 2 o n/ off
Reagent pump 3 on/off
Sample Inlet valve open/close
Stirrer on/off
Mode isselected
and contents of parameter 3 to -
are viewed sequentially by
repeated pre ssing of this key
Alters contents of displayed
parameter
1+2 3
Return to AUTOMATIC mode
View/Change Parameters
Standby
Analy zing
Manual
0
1
2
Limit value
Alarm v alue
AQUACON FE10
Calibration factor
Reagent volume (ml)
Rinse t ime (sec)
Sam pli ng int er va l ( mi n)
Start va lue for 2 0 mA Output
End value for 20 mA Output
Photometer error /Loss
of sample
Overrange
Reagent depleted
Remote operation activated
Reagent volume < 50 ml
E - 1
E - 2
E - 3
E - 4
H - E
Error Messages
3
4
5
6
7
8
9
-
Display / Set Parameters:
Operating Mode /
Parameter
OPERATING MODE /
PARAMETER DISPLAY
Operating Mode:
ppb
View of the process photometer AQUACON PH-CL
1 Transmitter
2 Measuring chamber
3 Sample inlet valve
4,5,6 Reagent tube pump
7Reagent 1 vessel (500 ml)
8Reagent 2 vessel (250 ml)
9Reagent 3 vessel (250 ml)
600

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AQUACON PH-CL Display and Keyboard
Explanation of Symbols
Symbol Function
Select Automatic Mode, start an analysis
Reagent pump 1 on/off
Reagent pump 2 on/off
Reagent pump 3 on/off
Sample inlet valve open/close
Stirrer on/off
View / Change parameters

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3.1 Analytical Part
The transmitter of the process photometer AQUACON PH-CL is contained in a compact housing and
includes the microprocessor which recognizes the absorbance (extinction), displays the final
calculated result on a touch screen and controls the operation of the process photometer with respect
to sampling, rinsing of the measurement chamber, dosing of the reagent and surveillance of the
photodetection system.
3.2 Measurement and Control
Inside the control unit of the analyzer, there is one limit value relay (K2) for the pH value and one
limit value relay (K3) for the free chlorine. Both relays can be operated in min function mode or in
max function mode. For both relay, 2 limit values (limit value 1 and limit value 2) can be
parametrized.
Min function:
If the limit function of the relay K2 or K3 is set as min function, the appropriate relay will be activated
if the measured value is lower than the set limit value 1 for this relay. The relay will be deactivated if
the measured value is higher than the set limit value 2 for this relay.
Max function:
If the limit function of the relay K2 or K3 is set as max function, the appropriate relay will be
activated if the measured value is higher than the set limit value 2 for this relay. The relay will be
deactivated if the measured value is lower than the set limit value 1 for this relay.
In addition, two 0/4 - 20 mA current outputs deliver a signal which is proportional to the measured
values for pH and free chlorine (see chapter 9.1). The start value and the end value of the output range
are fixed for both parameters .
All user-defined settings are maintained during power failure to the instrument.

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3.3 Operation and Measurement Security
When the end-user defined maximum alarm value is exceeded or when an error occurs (ERROR E-1
to ERROR E-4) the alarm relay will activate.
The actual reagent volume of reagent 1 is calculated by the microprocessor and is corrected for usage
after each analysis. Once the calculated remaining reagent volume falls below the factory-
predetermined value of 50 ml, an alarm message (ERROR E-3) is displayed on the touchscreen and
the alarm relay (found on the transmitter terminal connector) is activated. The remaining 50 ml
reagent is sufficient for appr. 92 analysis. Should this alarm be ignored and the reagent is depleted, a
second alarm message (ERROR E-4) is displayed on the touchscreen, subsequent relay activation is
initiated by the process photometer AQUACON PH-CL and the analyzer stops.
The optical transparency of the measurement cuvette is measured at the start of each analysis. An
automatic zero adjustment takes place before each measurement to compensate colored or turbid
samples or discoloration/contamination of the cuvette windows.
Once the factory-predetermined limit to the zero adjustment is exceeded, another alarm message
(ERROR E-1) is displayed on the touchscreen, the alarm relay is activated and the analysis cycle is
interrupted. In the event of sample failure, the photometer will detect this and display the alarm
message ERROR E-1 on the touchscreen, activate the alarm relay and interrupt the measurement.
When the sample interval defined by the end-user has elapsed, the process photometer will
automatically resume measurement as normal and repeat the procedure until sample flow is re-
established.
The analysis cycle may be interrupted at any stage by touching the button ”Hand” or the button
”Param” on the touchscreen. The process photometer remains in manual operation mode until the
automatic mode is selected by pressing the appropriate symbol or touch button.

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3.4 Automatic Operation
The process photometer will automatically carry out an analysis once the ”Start” button is pressed.
On the return of power, following a power failure, the process photometer will automatically enter the
automatic mode and starts a measurement. This is displayed as state ”MEASURING”.
On the touchscreen, the last actual measured values for the pH value and for free chlorine are
displayed. Below the last measured value, the set parameters for the first limit values (LV 1 pH, LV 1
CL2) and for the second limit values (LV 2 pH, LV 2 CL2) are displayed. This values can be
parametrized by the end-user (see chapter 3.6).
The automatic analysis cycle can be interrupted at any stage by touching the button ”Hand” or the
button ”Param” on the touchscreen (see 3.5). After the finish of the analysis, the new measured value
will be displayed on the touchscreen and the analyzer state is changed to ”STANDBY”.
When the upper measurement range is exceeded, the alarm message “ERROR E-2” is displayed
as state on the touchscreen and the alarm relay is activated.
AQUACON PH-CL
LV 1 pH: 7.20 LV 2 pH: 7.60
LV 2 Cl2: 0.60
LV 1 Cl2: 0.60
State: MEASURING
Start
Hand
Param
pH: 7,40
Cl2: 0,10 ppm

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3.5 Manual Operation
Manual operation of the process photometer is useful for maintenance, commissioning of the analyzer
and when correction of alarm conditions during normal operation occur.
Manual operation of the process photometer is effected by pressing the button ”Hand” on the
touchscreen. During the internal zero adjustment of the photometer short delays can occur. Automatic
operation is interrupted and the screen displays the manual mode (state: MANUAL). Simultaneously,
the actual absorbance (extinction) value is displayed in the upper display.
During manual operation, the pumps, the sample inlet valve and the stirrer can be
activated/deactivated by touching the appropriate symbols. The active part will be displayed with
inverse letters.
During manual operation, the mode can be switched to automatic mode and an analysis can be
started by touching the symbol .
During manual operation, the mode can be switched to parameter mode by touching the
symbol
12
AQUACON PH-CL
State: MANUAL 0,050
Valve
Pump 1
Pump 2
Pump 3
Stirrer
3

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3.6 Display/Set Parameters
The parameter mode can be activated from automatic mode by touching the button ”Param” or from
manual mode by touching the symbol
In parameter mode, a new screen will be displayed which shows the parameters Limit value 1 pH,
Limit value 2 pH, Limit function pH, Limit value 1 Cl2, Limit value 2 Cl2 and Limit function Cl2.
By touching the button ” >>” , a second screen will be displayed with the parameters Sampling
interval, Calibration factor, Rinse time, Reagent volume and Output mode.
By touching the button ” << ” , the first parameter screen will be displayed again.
All parameters are set to a certain value (factory settings), but can also be parametrized by the end-
user (see the following chapters 3.6.1 – 3.6.11).
AQUACON PH-CL
7.20
7.60
Limit value 2 pH:
Limit value 2 Cl2:
Limit function pH:
Limit function Cl2:
Limit value 1 pH:
Limit value 1 Cl2: 0.30
0.60
Start
Hand
AQUACON PH-CL
Calib. factor: 1.00
Rinse time: 15
Reagent volume: 250
Output mode: 4-20 mA
Sampling interval: 10
Start
Hand

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To change the parameters, the corresponding values must be touched. Then, a parameter specific
screen opens where the new parameter values can be typed by touching the figures (except
parameters Output mode, Limit function pH, Limit function Cl2).
To leave the screen and confirm/safe the new parameter value, the button ”Save” must be touched.
To leave the screen without saving, the button ”Clear” must be touched.
3.6.1 Limit Value 1 pH
Min function:
If the limit function pH is set as min function, the appropriate relay K2 will be activated if the
measured value is lower than the set limit value 1 (LV 1 pH) for this relay. The relay will be
deactivated if the measured value is higher than the set limit value 2 (LV 2 pH) for this relay.
Max function:
If the limit function pH is set as max function, the appropriate relay K2 will be activated if the
measured value is higher than the set limit value 2 (LV 2 pH) for this relay. The relay will be
deactivated if the measured value is lower than the set limit value 1 (LV 1 pH) for this relay.
The limit value 1 pH is set factory-predetermined to 7.20 pH A value between 6.80 and 8.80 may be
chosen, but only values within the measurement range of the analyzer are useful.
3.6.2 Limit Value 2 pH
The limit value 2 pH is set factory-predetermined to 7.60 ppm. A value between 6.80 and 8.80 may be
chosen, but only values within the measurement range of the analyzer are useful.
The set limit value 2 pH must be higher than the set limit value 1 pH.
AQUACON PH-CL
Calib. factor 1.00
Save
Clear
123
456
78 9
0

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3.6.3 Limit Function pH
The parameter limit function pH defines the function of the limit value relay K2 for the pH analysis. It
can be set to min function or to max function.
This parameter is set factory-predetermined to min. It can be changed by touching the appropriate
field on the touchscreen. No further confirmation is required.
3.6.4 Limit Value 1 Cl2
Min function:
If the limit function Cl2 is set as min function, the appropriate relay K3 will be activated if the
measured value is lower than the set limit value 1 (LV 1 Cl2) for this relay. The relay will be
deactivated if the measured value is higher than the set limit value 2 (LV 2 Cl2) for this relay.
Max function:
If the limit function Cl2 is set as max function, the appropriate relay K3 will be activated if the
measured value is higher than the set limit value 2 (LV 2 Cl2) for this relay. The relay will be
deactivated if the measured value is lower than the set limit value 1 (LV 1 Cl2) for this relay.
The limit value 1 Cl2 is set factory-predetermined to 0.30 ppm. A value between 0.00 and 9.99 may
be chosen, but only values within the measurement range of the analyzer are useful.
3.6.5 Limit Value 2 Cl2
The limit value 2 Cl2 is set factory-predetermined to 0.60 ppm. A value between 0.00 and 9.99 may
be chosen, but only values within the measurement range of the analyzer are useful.
The set limit value 2 Cl2 must be higher than the set limit value 1 Cl2.
3.6.6 Limit Function Cl2
The parameter limit function Cl2 defines the function of the limit value relay K3 for the chlorine
analysis. It can be set to min function or to max function.
This parameter is set factory-predetermined to min. It can be changed by touching the appropriate
field on the touchscreen. No further confirmation is required.
3.6.7 Sampling Intervall
The sampling interval between two automatically initiated samples may be programmed. The factory-
predetermined sample interval is set to 10 min. A values between 1 and 99 min. may be chosen.

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3.6.8 Titer/Calibration factor
The process photometer AQUACON PH-CL may be re-calibrated by entering a titer/calibration
factor (see chapter 5.5). A value between 0.00 and 9.99 may be chosen.
3.6.9 Rinsing time
The measuring chamber is rinsed for 15 seconds before an analysis takes place. The preset rinsing
time may be altered by the end-user. A value between 15 and 99 seconds may be chosen.
Important:
Depending on the length of the sample inlet tube and the water flow rate, the rinsing time should be
long enough to flush the sample lines and fill the measuring cuvette with fresh sample. A tube
length of max. 5 m is recommended between sample valve and the analyzer.
3.6.10 Reagent Volume
The remaining reagent volume of the reagent 1 is calculated and stored in memory by the
microprocessor. A value between 0 and 999 ml may be chosen.
3.6.11 Analog Output setting (mode)
Two analog current signal (0/4 - 20 mA), proportional to the measured values for pH and for free
chlorine, may be directed from the process photometer AQUACON PH-CL to remote
recording/controlling devices. The mode of both analog outputs can be parametrized by the end-
user. The mode of the analog output can switched from 0-20 mA to 4-20 mA by touching of the
corresponding value on the touchscreen. No further confirmation is required. The start and end
values are fixed and cannot be parametrized. They are set to 0.00 and 8.80 for the pH analysis and
to 0.00 and 2.00 for the chlorine analysis.
The automatic operation mode starts again when the button ”Start” is touched.

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4 Switching Functions of the AQUACON PH-CL
CAUTION:
Before opening the cover below the process photometer display, the AQUACON PH-CL must
be disconnected from the mains supply.
4.1 External Switching
The process photometer PH-CL has a potential-free input contact which may be used to control the
instrument from a remote position/device. When the input contact is closed the process photometer
will automatically carry out an analysis, when the input contact is open the process photometer
completes the actual analysis and stops. When the limit relay is activated and the process photometer
is stopped by a remote position/device the limit relay will be inactivated after 15 minutes.
The process analyzer is delivered with bridged external switching contact into female. For using
external switching contact remove this bridge! During the interval between two analyses the process
photometer may be activated by a short off/on impulse of the external contact.
4.2 Display in the standby mode
In the standby mode the display will show “H-E” and the last measured value (the value that was
determined in that analysis before that one that was terminated by opening the external contact)
when the external contact is open.
When an error message occurs this will be displayed additional to “H-E”.
4.3 Analysis state relay
The analysis state relay K 1 is activated during the time when the analyzer operates an analysis.
AQUACON PH-CL
LV 1 pH: 7.20 LV 2 pH: 7.60
LV 2 Cl2: 0.60
LV 1 Cl2: 0.60
State: STANDBY
H - E
Start
Hand
Param
pH: 7,40
Cl2: 0,10 ppm

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4.4 Limit Value Relay K2 and K3
Inside the control unit of the analyzer, there is one limit value relay (K2) for the pH value and one
limit value relay (K3) for the free chlorine. Both relays can be operated in min function mode or in
max function mode. For both relay, 2 limit values (limit value 1 and limit value 2) can be
parametrized.
Min function: If the limit function of the relay K2 or K3 is set as min function, the appropriate relay
will be activated if the measured value is lower than the set limit value 1 for this relay. The relay will
be deactivated if the measured value is higher than the set limit value 2 for this relay.
Max function: If the limit function of the relay K2 or K3 is set as max function, the appropriate relay
will be activated if the measured value is higher than the set limit value 2 for this relay. The relay will
be deactivated if the measured value is lower than the set limit value 1 for this relay.
4.5 Alarm Limit Relay
The potential-free alarm relay is activated when an alarm is exceeded within the process photometer.
The alarm is caused by an error in the optical system, when the measurement range is exceeded or
when the reagent volume falls below than 50 ml. The appropriate alarm message will be displayed as
”ERROR E-1, ERROR E-2, ERROR E-3” or ”ERROR E-4” (see also chapter 6).
4.6 Current Output
The process photometer AQUACON PH-CL delivers a current output, 0 or 4 to 20 mA, which is
proportional to the measurement range selected by the end-user (see chapter 9.1). This current output
may be used as input to remote recording devices, for data processing, controlling functions etc. The
current output is independent of resistance load up to a value of 500 ohm. The start and end value of
the current output signal can be set by the user within the measurement range.
Don’t connect any external voltage to the connections of the current
output. Failure to observe this information could result in damage to the
equipment.
See above, " 3.6.3 Setting the Analog Output". To avoid resolution losses of the current output signal
the user defined measuring range should be > 6 % of the total measurement range. The start value
should be lower than the end value. Setting the start value higher than end value results in a constant
output of 20 mA. Similarly, setting the end value lower than that of the start value results in a constant
0 or 4 mA output.

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5 Start-up and Maintenance Instructions
CAUTION:
As soon as the analyzer is connected to the main supply, automatic operation commences. This is
required for automatic restart of the analyzer in the event of a power failure. At start-up, it is
necessary to access the Manual Operating mode by touching the ”Hand” button as soon as the
analyzer is connected to main supply and is operational.
5.1 Connection of sample water
1. Connect inlet and outlet connectors (6/4; 8/6) max. length 5 m
2. Connect power supply to device
Caution: see label on the housing for specified voltage
3. Select the sample inlet valve to “open” (press button on the touchscreen)
4. Carefully open the manually-operated valve beneath the solenoid operated valve to set the
sample flow (20-30 l/h)
Caution: Maximum sample pressure 10 bar!
5.2 Connection of reagent, bleeding of pumps and tubes
1. Open the reagent vessel top.Ensure that the pump tube is installed and the pump head is screwed
down.
2. Switch on the stirrer (button ) and the first pump (button ) in order to fill the suction-
lances and pressure-tubes (Sign:the extinction in the display is rising).
3. After filling the tubes switch off the pump and stirrer.
4. If there is a second or third reagent avaible, repeat step 1-3 with this reagents.
5. Rinse the measuring chamber by activating the sample inlet valve (button ) and stirrer
(button ) in order to wash out the reagent entered while filling the tubes
6. Select automatic operation (button ). The device now operates in automatic mode and start
the measurement.
Perform 2 to 3 analyses. Regard correct filling by observing the measurement outlet tube with
the selected sample flow conditions. When satisfied that the system is performing correctly,
the parameter settings may be carried out prior to automatic operation
5.3 Replenishment of Reagent
The reagent bottle may be replaced, after setting the analyzer to manual mode. Now the volume of
reagent must be entered in “Param” mode step to 250 (if the volume of reagent 1 is 250 ml) or to
500 (if the volume of reagent 1 is 500 ml). See also chapter 3.6.7.
Important:
The handling with chemical standards and reagents can be dangerous. Before the reagent bottles are
connected or replaced, it is necessary to read their specific MSDS (material safety data sheets).

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5.4 Changing of Tube box
Replacement of the complete tube-box by pressing the brackets at the sides,take off the old box and
give up a new box.
Important:
All tube boxes must be replaced after consumption of 5 bottles reagent or latest after 6
months.
5.5 Recalibration of the Process analyzer
Under normal conditions, a re-calibration of the process analyzer is not required since the reagent to
sample ratio have been correctly determined at the time of manufacture. However should the need
arise to verify the process analyzer, a standard solution may be introduced. In the unlikely event of a
deviation from the introduced standard (incorrect reagent strength, pump tube aging, incorrect pump
tube, contaminated measuring cell), a titer/calibration factor may be calculated as follows:
titer/calibration factor = Standard solution value : Measured value
Should the titer/calibration factor deviate by more than 20 % from 1, then a change of the tube box
or a cleaning of the measurement chamber is maybe necessary.
5.6 Maintenance interval
A maintenance of the analyzer should be made after 5 consumed reagent bottles or latest after 6
month. A maintenance should include at least an optical control of the analyser, a function control
and a change of the tube boxes. If necessary, the maintenance should also include a cleaning of the
measurement chamber and of the injectors for the tube connection at the measurement chamber.
5.7 Shut down procedure
If the analyzer is shut down for an extended period of time, all reagents and samples should be
removed out of tubings and the measurement chamber, and all tubings and the measurement
chamber should be cleaned and flushed with deionized water.