Swan Analytical Instruments AMI Codes-II O3 User manual

Operator’s Manual
Firmware V6.21 and higher
AMI Codes-II O3
A-96.250.881 / 070622

© 2020, Swan Analytische Instrumente AG, Switzerland, all rights reserved.
The information contained in this document is subject to change without notice.
Customer Support
Swan and its representatives maintain a fully trained staff of technical specialists around
the world. For any technical question, contact your nearest Swan representative, or the
manufacturer:
Swan Analytische Instrumente AG
Studbachstrasse 13
8340 Hinwil
Switzerland
Internet: www.swan.ch
E-mail: [email protected]
Document status
Title: Operator’s Manual for AMI Codes-II O3
ID: A-96.250.881
Revision Issue
00 Jan. 2018 First edition
01 June 2020 Mainboard V2.6

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AMI Codes-II O3
3
Table of Contents
1. Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1. Warning Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2. General Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3. Restrictions for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2. Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1. Instrument Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2. Instrument Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1. Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2. Mounting of Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3. Connecting Sample and Waste. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3.1 FEP Tube at Sample Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3.2 FEP Tube at Sample Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.4. Installation of Flow Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.5. Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.5.1 Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5.2 Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.5.3 Opening the peristaltic pump housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.6. Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.7. Relay Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.7.1 Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.7.2 Relay 1 and 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.8. Signal Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.8.1 Signal Output 1 and 2 (current outputs). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.9 Interface Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.9.1 Signal Output 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.9.2 Profibus, Modbus Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.9.3 HART Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.9.4 USB Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4. Instrument Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.1. Prepare Reagents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.2. Peristaltic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.3. Establish Sample Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.4. Fill or Flush Reagent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.5. Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.6. Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.7. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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AMI Codes-II O3
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5. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1. Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2. Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3. Software Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.4. Changing Parameters and values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.1. Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.2. Stop of Operation for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.3. Refill or replace Reagents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.3.1 Reagents for measuring Ozone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.4. Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.5. Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.6. Cleaning the Photometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.7. Cleaning the Flow Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.7.1 Disassemble the Flow Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.7.2 Assemble the Flow Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.8. Tube Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.8.1 Replace the Pump Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.9. Longer Stop of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7. Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.1. General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.2. Calibration Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.2.1 Process Calibration DIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.3. Verification Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.4. Error List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.5. Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8. Program Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.1. Messages (Main Menu 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.2. Diagnostics (Main Menu 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.3. Maintenance (Main Menu 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.4. Operation (Main Menu 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.5. Installation (Main Menu 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9. Program List and Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1 Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

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10. Material Safety Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
10.1. Reagents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
11. Default Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
12. Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
13. Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

A-96.250.881 / 070622
AMI Codes-II O3
Safety Instructions
6
Operator’s Manual
This document describes the main steps for instrument setup, opera-
tion and maintenance.
1. Safety Instructions
General The instructions included in this section explain the potential risks
associated with instrument operation and provide important safety
practices designed to minimize these risks.
If you carefully follow the information contained in this section, you
can protect yourself from hazards and create a safer work environ-
ment.
More safety instructions are given throughout this manual, at the re-
spective locations where observation is most important. Strictly fol-
low all safety instructions in this publication.
Target
audience
Operator: Qualified person who uses the equipment for its intended
purpose.
Instrument operation requires thorough knowledge of applications,
instrument functions and software program as well as all applicable
safety rules and regulations.
OM Location Keep the AMI Operator’s Manual in proximity of the instrument.
Qualification,
Training
To be qualified for instrument installation and operation, you must:
read and understand the instructions in this manual as well as
the Material Safety Data Sheets.
know the relevant safety rules and regulations.

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AMI Codes-II O3
Safety Instructions
7
1.1. Warning Notices
The symbols used for safety-related notices have the following
meaning:
DANGER
Your life or physical wellbeing are in serious danger if such warn-
ings are ignored.
Follow the prevention instructions carefully.
WARNING
Severe injuries or damage to the equipment can occur if such
warnings are ignored.
Follow the prevention instructions carefully.
CAUTION
Damage to the equipment, minor injury, malfunctions or incorrect
process values can be the consequence if such warnings are ig-
nored.
Follow the prevention instructions carefully.
Mandatory
Signs
The mandatory signs in this manual have the following meaning:
Safety goggles
Safety gloves

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AMI Codes-II O3
Safety Instructions
8
Warning Signs The warning signs in this manual have the following meaning:
Electrical shock hazard
Corrosive
Harmful to health
Flammable
Warning general
Attention general

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Safety Instructions
9
1.2. General Safety Regulations
Legal
Requirements
The user is responsible for proper system operation. All precautions
must be followed to ensure safe operation of the instrument.
Spare Parts
and
Disposables
Use only official SWAN spare parts and disposables. If other parts
are used during the normal warranty period, the manufacturer’s war-
ranty is voided.
Modifications Modifications and instrument upgrades shall only be carried out by
an authorized Service Technician. SWAN will not accept responsibili-
ty for any claim resulting from unauthorized modification or alter-
ation.
WARNING
Electrical Shock Hazard
If proper operation is no longer possible, the instrument must be
disconnected from all power lines, and measures must be taken
to prevent inadvertent operation.
To prevent from electrical shock, always make sure that the
ground wire is connected.
Service shall be performed by authorized personnel only.
Whenever electronic service is required, disconnect instrument
power and power of devices connected to.
– relay 1,
– relay 2,
– alarm relay
WARNING
For safe instrument installation and operation you must read and
understand the instructions in this manual.
WARNING
Only SWAN trained and authorized personnel shall perform the
tasks described in this document.

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AMI Codes-II O3
Safety Instructions
10
1.3. Restrictions for use
The sample must not contain any particles, which may block the flow
cell. Sufficient sample flow is coercive for the correct function of the
instrument.
WARNING
Health hazard
Some reagents are etching and can cause severe burns or eye
damage.
For safe handling of the reagents you must read and under-
stand the instructions in this manual, as well as the Material
Safety Data Sheets (MSDS)
Download
MSDS
The current Material Safety Data Sheets (MSDS) for the below listed
Reagents are available for downloading at www.swan.ch.
OXYCON ON-LINE DPD
OXYCON ON-LINE Ozone

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AMI Codes-II O3
Product Description
11
2. Product Description
Application
Range
The AMI Codes-II O3 analyzer is a complete monitoring system for
the automatic, continuous measurement and dosing control of ozone
based on the DPD colorimetric method according to DIN 38408-
3:2011-4.
It can be used for measuring ozone in pharma water and industrial
high purity water applications.
Signal
Outputs
Two signal outputs programmable for measured values (freely scale-
able, linear or bilinear) or as continuous control output (control pa-
rameters programmable).
Current loop: 0/4–20 mA
Maximal burden: 510 Ω
Third signal output available as an option. The third signal output can
be operated as a current source or as a current sink (selectable via
switch).
Relays Two potential-free contacts programmable as limit switches for mea-
suring values, controllers or timer for system cleaning with automatic
hold function. Both contacts can be set as normally open or normally
closed with a jumper.
Maximum load: 1 A/250 VAC
Alarm Relay One potential free contact.
Alternatively:
Open during normal operation, closed on error and loss of
power.
Closed during normal operation, open on error and loss of
power.
Summary alarm indication for programmable alarm values and in-
strument faults.
Input For potential-free contact to freeze the measuring value or to inter-
rupt control in automated installations (hold function or remote-off).
Safety
Features
No data loss after power failure. All data is saved in non-volatile
memory. Overvoltage protection of inputs and outputs. Galvanic sep-
aration of measuring inputs from signal outputs.

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AMI Codes-II O3
Product Description
12
Communica-
tion Interface
(optional)
USB Interface for logger download
Third signal output (can be used in parallel to the USB interface)
RS485 with Fieldbus protocol Modbus or Profibus DP
HART interface
Special
features
Specific features for pharmaceutical industry: Audit Trail, perfor-
mance verification and an optional validation package (IQ, OQ, PQ).
Fluidics The sample flows through the sample inlet [F] into the constant head
[A]. Adjust the flow regulating valve [D] so that always a small part of
the sample flows through the overflow tube [B] into the drain [H]. A
part of the sample flows through the photometer inlet [C] into the mix-
ing chamber [E], where reagent [K] is added and mixed with the
sample. The mixed sample then flows through the coiled tube to the
photometer [N]. Shortly before entering the photometer, reagent [J] is
added to the mixture through a T-piece.
In the photometer [N], the ozone concentration is measured. After
the measurement, the sample flows through the outlet of the pho-
tometer where it is aerated through air inlet [P] to generate bubbles.
Then the sample flows through the bubble detector [M] into the pho-
tometer drain [I].

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AMI Codes-II O3
Product Description
13
A
B
C
D
E
F
G
H
Constant head
Overflow tube
Photometer inlet
Flow regulating valve
Mixing chamber
Sample inlet
Filter vessel (no filter)
Constant head drain
I
J
K
L
M
N
O
P
Photometer drain
Oxycon on-line DPD reagent
Oxycon on-line Ozone reagent
Reagent level detector
Air bubble detector
Photometer
Peristaltic pump
Photometer air inlet
Level
D
B
A
C
F
H
I
J
K
L
M
N
O
P
E
G

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AMI Codes-II O3
Product Description
14
Time
interval of a
measurement
The measuring interval can be set between 5 and 10 minutes. The
time sequence of a measurement with a measuring interval of 5 min
is shown in the diagram below.
The blue bar represents the sample which flows continuously
through the photometer. A short time before the measurement starts,
a zero point measurement is performed. Then the peristaltic pump
starts and a small portion of the reagents [J] and [K] is added. Shortly
after, when the mixture is in the photometer, the sample is measured.
J
K
OXYCON ON-LINE DPD reagent
OXYCON ON-LINE Ozone reagent
Zero point measurement
Sample measurement
10 2345678910111213141516171819 20
min
J
K

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AMI Codes-II O3
Product Description
15
2.1. Instrument Specification
Power Supply AC variant:
DC variant
Power consumption:
100–240 VAC (± 10%)
50/60 Hz (± 5%)
10–36 VDC
max. 35 VA
Transmitter
specifications
Housing:
Ambient temperature:
Storage and transport:
Humidity:
Display:
aluminum, with a protection degree of
IP 66 / NEMA 4X
−10 to +50 °C
−30 to +85 °C
10–90% rel., non condensing
backlit LCD, 75 x 45 mm
Sample
requirements
Flow rate:
Temperature:
Inlet pressure:
Outlet pressure:
min. 10 l/h
5–50 °C
0.15–2 bar
pressure free
Note: No oil, no grease, no sand.
On-site The analyzer site must permit connections to:
requirements Sample inlet:
Sample outlet:
Serto PVDF 6 mm (1/4” thread)
Tube 6x4 mm
1/2” hose nozzle for flexible tube
diam. 20x15 mm
Ozone
measurement
Measuring range:
0–500 ppb
Accuracy:
±1 ppb or 5%, whichever is greater
Limit of detection: 1 ppb
Cycle time: 5–10 min

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AMI Codes-II O3
Product Description
16
Dimensions Panel:
Dimensions:
Screws:
Weight:
stainless steel
400x850x200 mm
8 mm diameter
14.0 kg
13 mm / 0.51"4 x dia. 10 mm / 0.39"
850 mm / 33.46" 824 mm / 32.44"
374 mm / 14.72"
400 mm / 15.75"
Exit Enter
AMI Codes-II O3

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AMI Codes-II O3
Product Description
17
2.2. Instrument Overview
A
B
C
D
E
F
G
Panel
Transmitter
Peristaltic pump
Oxycon on-line DPD reagent
Oxycon on-line Ozone reagent
Constant head
Flow regulating valve
H
I
J
K
L
M
Sample inlet
Filter vessel (no filter)
Photometer
Air bubble detector
Constant head drain
Photometer drain
F
G
H
I
J
K
L
M
A
B
C
D
E

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Installation
18
3. Installation
3.1. Installation Checklist
On-site require-
ments
AC variant: 100–240 VAC ( 10%), 50/60 Hz ( 5%)
DC variant: 10–36 VDC
Power consumption: 35 VA maximum.
Protective earth connection required.
Sample line with sufficient sample flow and pressure (see Instru-
ment Specification, p. 15).
Installation Mount the instrument in vertical position.
Display should be at eye-level.
Mount the constant head.
Connect the sample and waste line. See Connecting Sample and
Waste, p. 19
Electrical Wiring Do not switch on the Instrument until all electrical connections have
been completed.
Connect all external devices like limit switches, current loops and
pumps.
Connect power cord. Do not switch on power yet.
See Electrical Connections, p. 22.
Reagents Prepare reagents. See Refill or replace Reagents, p. 43.
Insert the suction lances.
Power-up Lock pump tubes.
Turn on the sample flow and wait until the flow cell is completely
filled.
Switch on power.
Adjust sample flow.
Start <Fill system>. See Fill or Flush Reagent System, p. 35.
Instrument
Setup
Program all parameters for external devices (interface, recorders,
etc.). Program all parameters for instrument operation (limits,
alarms, measuring interval).

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3.2. Mounting of Instrument Panel
The first part of this chapter describes the preparing and placing of
the system for use.
The instrument must only be installed by trained personnel.
Mount the instrument in vertical position.
For ease of operation mount it so that the display is at eye
level.
For the installation a kit containing the following installation ma-
terial is available:
– 4 Screws 8x60 mm
– 4 Dowels
– 4 Washers 8.4/24 mm
Mounting
requirements
The instrument is only intended for indoor installation.
For dimensions see 16.
3.3. Connecting Sample and Waste
3.3.1 FEP Tube at Sample Inlet
Use plastic tube (FEP, PA, or PE 6 x 4 mm) to connect the sample
line.
Mounting of
SERTO fitting A
B
C
D
Screw connection
Compression ferrule
Knurled nut
Flexible tube
B
C
D
A

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3.3.2 FEP Tube at Sample Outlet
WARNING
Risk of water pollution
The drain of the photometer outlet contains DPD.
At no means recirculate it into the water system.
Connect the 1/2” tubes [F] to the hose nozzles [E] and place them
into a pressure free drain with sufficient capacity.
A
B
C
D
E
F
Tube from photometer
Drain Photometer
Tube from constant head
Drain constant head
Hose nozzles
1/2” tubes
BD
E
F
A
C