Waltron 2410 User manual

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EXPERTS IN WATER CHEMISTRY SINCE 1903
2410 Oil and Water Analyzer
Instruction Manual
Revision 2.51

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OUR COMMITMENT TO OUR CUSTOMERS
This instruction manual is a technical guide to aid the customer in the set-up, operation,
and maintenance of their new Waltron measuring system. Waltron provides continuous
product improvement and reserves the right to make any modifications to the information
contained herein without notice.
Copyright © Waltron Bull & Roberts, LLC, 2016
All Rights Reserved
Technical questions concerning this product should be addressed to:
Waltron Technical Service Department
Flemington, New Jersey
Phone: [phone]
Fax: [phone]
www.waltron.net
Please be ready to provide the following information:
Date analyzer was purchased
Analyzer model and serial number
Recent maintenance history
Calibration slope values and detailed description of problem
Waltron’s technical expertise and extensive experience provides personalized solutions to
the water quality industry. It is Waltron’s commitment to provide the customer with
timely and accurate technical service and support.
Waltron fully expects the customer to be satisfied with the quality, performance, and cost
of this product.
If there are any questions or concerns regarding this product, please feel free to contact
Waltron at (908)-534-5100.
Thank you for choosing Waltron!
Please note the Waltron mailing and shipping address:
Waltron Bull & Roberts, LLC
25 Minneakoning Road, Suite 101
Flemington, NJ 08822

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Observing Safety

AI-2410
Please observe proper safety and handling precautions when installing, operating,
maintaining, and servicing this product. The following should be noted and adhered to:
√ This instruction manual should be carefully read before proceeding.
√ Warning labels on enclosures, containers, packages and chemicals must be
abided by.
√ Only qualified personnel that have been trained in accordance to the
information provided should be involved in the installation, operation, and
servicing of the analyzer.
√ To avoid accidents from occurring, normal safety precautions must be
followed when operating the analyzers in conditions of high pressure and/
or temperature.
√ The chemicals that are used to operate this machine must be stored away
from heat, protected from temperature extremes and powders kept dry.
√ Follow all regulations and warning labels when disposing of chemicals. Do
not mix the chemicals together.
To obtain analyzer safety information or Safety Data Sheets (SDS), please contact
Waltron or visit the website at www.waltron.net .

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Warranty Agreement

AI-2410
If, within one year from the date of shipment, the customer experiences any
equipment defects or is not satisfied with the analyzer manufacturing, Waltron
will repair, or at its option, replace any defective part(s) free of charge. This
warranty requires that the defective part(s) be returned to Waltron with shipping
charges prepaid.
At Waltron discretion, a Technical Service Specialist may be sent out to repair or
replace the defective part(s) on location. Traveling time and expenses of the
Technical Service Specialist is at the customer’s expense.
Equipment sent to Waltron must be appropriately packaged and the following
information must be provided prior to returning to Waltron:
The Return Authorization (RA) number assigned to the customer by the
Waltron Technical Service Department
Customer name, address and department
Name and telephone number of the individual responsible for returning items
for repair
Brief problem description
Ship to Waltron service center:
Waltron Bull & Roberts, LLC
25 Minneakoning Road, Suite 101
Flemington, NJ 08822

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Warranty Agreement

AI-2410
The Waltron Warranty Agreement:
Covers expendable sensors for one month after shipment and reusable
electrodes for six months after shipment.
Does not apply to damages occurred during shipping.
Warranty will be nullified if goods have been used for purposes other than
those for which they are intended or if any seal has been removed, broken
or tampered with or if the Waltron trademark or serial number has be
removed, defaced, or altered.
Does not cover expendable supply items such as reagents, tubing and
electrolytes.
Does not cover misuse or mistreatment by the user.
Does not cover previous repair or alteration by unauthorized individuals.
Waltron does not assume responsibility for contingent liability through alleged
failure or failures of products or product accessories.

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Check List of Materials

AI-2410
Waltrons’ concern does not stop when your instrument leaves our loading dock. We
want to thank you for your confidence in Waltron., our product, and the service that we
provide. We want to make sure that your experience with us will be one of total
satisfaction starting with the condition in which you have received your product.
√ Inspect all shipping containers upon receipt and record any visible damage.
Count the number of packages, making sure that the number is in agreement
with the shipping paperwork. If there are any outward signs of damage,
please retain all containers and packages for inspection by carrier. It is
generally good practice to retain the packing material and boxes as they
make an excellent way to protect the instrument if you move it our ever need
to ship the instrument.
√ Make sure that all items received match the packing list. If you ordered
chemicals, they are usually shipped in a separate package and will be itemized
accordingly.
√ Verify that the number of packages received agrees with the package list
and shipping papers.
√ Notify both Waltron and the carrier, if any problems occur.
Important Notice
√ All Monitors in our range are inspected and tested prior to shipment
√ In normal use the units should operate correctly and without fault over a
long period of time requiring only minor maintenance, which should only
be carried out as outlined in this manual.
√ If electronic components are replaced, please note that due to varying
component characteristics it may be necessary to re-adjust or
calibrate the monitor.
√ Failure to carry out correct maintenance procedures could result in the monitor
over or under reading, which in turn could lead to oil pollution and
the consequences that follow.

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Table of Contents

AI-2410
Section
Contents
Page
1
Introduction
8-9
1.1
General Description/ Principle of Operation
8
1.2
Mechanical Characteristics
9
2
Installation and Mounting
10-13
2.1
Mounting and Layout
10
2.2
Wiring
11-12
2.3
External Piping Connections
13
3
Start-up
14-17
3.1
Commissioning—User Interface Guideline
14
3.11
Pre-Commissioning
15
3.2
Setting Alarm Points
16
3.3
Setting Alarm Delays
16
3.4
Calibrating for Clean Water
17
3.5
Output Range Selection
17
4
Operating Instructions
18
4.1
Operating Instructions
18
5
Routine Maintenance
19
5.1
Operator Maintenance
19
6
Troubleshooting
20
6.1
Troubleshooting Guideline
20
7
Specifications
21
7.1
Technical Specifications
21
8
Auto Clean System (where Fitted)
22
8.1
Auto Clean System
22 -23
8.2
Auto Clean Terminal Enclosure
24
8.3
Auto Clean Cycle Frequency
25
9
Spare Parts Listing
26
9.1
Recommended Spare Parts/ Other Spare Parts
26
10
Operator’s Notes
27-30

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Section 1. Introduction- Oil in Water Monitor

AI-2410
1.1 General Description—Principle of operation
The µAI-2410 Oil in Water Analyzer is a continuous online monitor for
direct measurement of oil or other hydrocarbons in sample streams in
concentrations between 0-99ppm. A set of optical sensors measures a
combination of light scattered and absorbed by oil droplets in the sample
stream and converts the mV signals to concentration values using a
microprocessor. The microprocessor drives voltage outputs, current outputs,
two seven segment displays, six light emitting diodes, two oil alarm relays,
and one fault relay.
In addition, the microprocessor checks the condition of the sensor
components and calibration verification to ensure accuracy is maintained
over time and in various environmental conditions.
Self-Diagnostic information is visually displayed as both the alarm status
indicators and fault indicators are set to Red. Furthermore this information
can be relayed through both the fault relay and alarm relay contacts. An
error code will be displayed on the display relating the fault identity.

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Section 1. Introduction-Oil in Water Monitor

AI-2410
1.2 Mechanical Characteristics
The system is composed of two components; a sample chamber assembly and an
electronic control unit (transmitter). (See figure below). The sample chamber
assembly consists of a cell cap (5), sample inlet, sample outlet, desiccators, and
throttle. The sample chamber assembly contains the measuring cell and is a sealed
unit set to the right hand side of the enclosure. The inlet pipe is situated on the
bottom of the cell (8) and the outlet pipe is situated on the top right hand side of
the cell (3). A desiccator (7) to eliminate moisture around the outside of the glass
tube and a throttle (6) to regulate flow and maintain pressure are also fitted to the
cell. The electronic control unit contains two printed circuit boards; the display
board (2) is mounted to the front cover, which provides the PPM display (4) and
the six light emitting diodes. The motherboard (1) is mounted to the back of the
enclosure and contains the power supply, alarm relays, digital to analog and
amplification circuitry. The front of the monitor is fitted with a membrane user
interface containing three push buttons (9), and windows for the LED displays.
L.L.C

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Section 2. Installation and Mounting

AI-2410
2.1 Mounting and Location
• Mount the sensor and transmitter units in a clean, vibration-free area, avoiding
direct radiant heat, sunlight and drafts. Avoid areas containing chlorinating
equipment.
• Mount the µAI-2410 by means of 4 x M4 screws on to a rigid vertical surface
and preferably with the display panel of the monitor at eye level.
• The location of the monitor should be located in close proximity to the sample
point to minimize response delays.
SAMPLE
L.L.C

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Section 2. Installation and Mounting
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AI-2410
2.2 Wiring (refer to figure 2.2)
• This unit must be connected to the power supply via a suitably rated and
approved double pole fused isolator unless such fusing/isolation is provided by
associated equipment. When fitted, the isolator should be close by, readily
accessible and marked as to function.
• Cable entries can accept cables from 6 to 12 mm diameter. The terminal block
will accept cable cores of up to 4mm2 and cables carrying hazardous voltages
must be at least .75mm2 csa. When terminating mains cabling at monitor and
electrical source, the ground conductor must be made longer than the live and
neutral conductors.
• To select between 230V and 115V supply a link (or two in case of 110V), is
attached on JP1 and JP2 in the relative formations shown on figure 2.2. The link
must be electrically insulated and at least .50 mm csa.
• Note to make connections to J11, J12, JP1, and JP2 terminals may be pulled out
of PCB connections via tags or links provided.
• Connections to the cables should be made as shown on Figure 2.2.
• Precise wiring details will vary depending upon the control system to be
employed but the most frequently used systems employ Alarm relay 1 for
control purposes and Alarm relay 2 for alarm annunciation only.
WARNING.
Although some instruments have internal fuse protection, you must use a suitably rated
external protection device, such as a fuse or miniature circuit breaker (MCB).
Switch OFF the power supply and high voltage power-operated control circuits before
making any connections.
This equipment operates on alternating current electricity. Always take suitable safety
precautions to avoid the posiblility of an electric shock.

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Section 2. Installation and Mounting

AI-2410
Figure 2.2: Terminal Connections and Wiring

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Section 2. Installation and Mounting

AI-2410
2.3 External Piping Connections
WARNING.
Do not exceed the maximum pressures and temperatures specified. If you use
pressure-reducing equipment, install a pressure relief valve between your
equipment and the sample inlet to the monitor for safety purposes.
√ Install piping (10mm) according to sample requirements from sample line into a “T-
Valve” with clean water (oil-free) as second source
√ From output of T-valve, install piping to inlet of sample chamber (bottom)
√ From outlet of sample chamber, install drain-entrainment loop as shown in Figure
2.1 to appropriate drain
√ Check all piping connections for leaks and rectify as appropriate
IMPORTANT!
Clean Water (Free of any Hydrocarbons) will be used to calibrate the instrument
and for cleaning purposes and therefor is imperative to have clean water piped into
the T-Valve for this procedure.

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Section 3. Start-Up

AI-2410
3.1 Commissioning Figure
3.1: User Interface Guideline

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Section 3. Start-Up

AI-2410
3.11 Pre-Commissioning
On completion of the installation, wiring and piping carry out the following checks:
Electrical:
√ Check that the power supply voltage on cables 1 and 2 are within limits
√ Check to confirm that a good connection to ground has been made.
Piping:
√ Check all piping connections for leaks and rectify as appropriate. Functional
Tests (refer to Fig 3.1)
√ Turn the supply voltage to the Monitor on, the display (1) should read FC
(Factory Calibration) for 3 Seconds. (*Note this will only change to CC if a
full-scale calibration is performed outside factory conditions).
√ The monitor will then run through a self-diagnostics and initialization routine.
During this time the display will count down from 40 to 0 and back up to 40
again. Alarm LED’s will extinguish & illuminate at alarm set points.
√ Run oil-free water through the instrument for a short period to purge the
system of air and dirt.
√ Adjust the throttle screw in the cell cap so that the flow rate through the cell is
between 0.5 and 2 liters/min. Note: the flow rate should be checked on both
the clean water supply and the separator sample supply. If the clean water
supply is obtained from a high pressure source, it may be necessary to restrict
this at a point up-stream of the clean water/sample 3 way selector valve.
√ Switch the clean water supply to the instrument and after 2 minutes set zero
in accordance with the Operating Instructions (see sect 3.4).
√ Set-up the monitor to give a 0 –5V analog output and connect a voltmeter
(see sect 3.5). The reading should not vary by more than + 0.25v above zero
(equivalent to + 1.5ppm). If the reading varies by a greater amount, air
entrapment is almost certainly present and changes to the sample piping or
sampling take-off point may be necessary.

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Section 3. Start-Up

AI-2410
3.2 Setting Alarm points (refer to Fig 3.1)
Alarm 1 and alarm 2 are both factory set to 15 PPM. To adjust these points the
following procedure should be followed.
To adjust alarm 1 set point:
√ Press & release the DOWN or UP KEY (10 or 9) repeatedly until the PPM
LED (3) and the ALARM 1 ADJUST LED (6) are both on, the alarm 1 PPM
set point is now displayed.
√ Press & release the SET/ZERO KEY (8). Adjust the PPM value by pressing
the UP or DOWN KEY (10 or 9) until the desired value is displayed.
Acknowledge the desired value by pressing and releasing the SET/ZERO
KEY (8)
To adjust alarm 2 set point:
√Press & release the DOWN or UP KEY (10 or 9) repeatedly until the PPM
LED (3) and the ALARM 2 ADJUST LED (7) are both on, the alarm 2 PPM
set point is now displayed.
√ Press & release the SET/ZERO KEY (8). Adjust the PPM value by pressing
the UP or DOWN KEY (10 or 9) until the desired value is displayed.
Acknowledge the desired value by pressing and releasing the SET/ZERO
KEY (8)
3.3 Setting Alarm delays (refer to Fig 2.2.)
Alarm 1 and alarm 2 delays are factory set to 0 and 10 seconds respectively. To
adjust these delays the following procedure should be followed.
To adjust alarm 1 delay:
√ Press & release the DOWN or UP KEY (10 or 9) repeatedly until the
SECONDS LED (2) and the ALARM 1 ADJUST LED (6) are both on. The
alarm 1 delay is now shown on the display (1).
√ Press & release the SET/ZERO KEY (8). Adjust the SECONDS value by
pressing the UP or DOWN KEY (10 or 9) until the desired value is
displayed. Acknowledge the desired value by pressing and releasing the
SET/ZERO KEY (8)
To adjust alarm 2 delay:
√ Press & release the DOWN or UP KEY (10 or 9) repeatedly until the
SECONDS LED (2) and the ALARM 2 ADJUST LED (7) are both on. The
alarm 2 delay is now shown on the display (1).
√ Press & release the SET/ZERO KEY (8). Adjust the SECONDS value by
pressing the UP or DOWN KEY (10 or 9) until the desired value is
displayed. Acknowledge the desired value by pressing and releasing the
SET/ZERO KEY (8)

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Section 3. Start-Up

AI-2410
3.4 Calibrating for clean water (refer to Fig 3.1)
√ Insure that there is no flow through the cell. Remove the cell cap and clean the
inside of the cell tube with bottlebrush provided. Replace the cell cap
√ To calibrate the monitor to local clean water ensure that clean water is
passing through the measuring cell then press & hold the SET/ZERO KEY
(8) for 3 seconds in PPM monitor mode (i.e. LEDS 2,4,5,6 and 7 are all off)
√ The display (1) will flash alternately CL and blank for 8 seconds after
which the display will read 0 PPM
√ If calibration was not successful bC will appear on the display. To clear this
error simply press the SET/ZERO KEY, and the original calibration will be
retained.
3.5 Output range Selection (refer to Fig 2.2)
√ To select the output range, the correct cable connections should be made first
√If an output range of 0 –20 mA or 4 –20 mA is required wires I OUT and
24V should be connected on J11 (see section 2 fig 2.2)
√If an output range of 0 –5 V or 1 –5 V is required wires V OUT and GND
should be connected on J12 (see section 2 fig 2.2)
√Using the user interface press & release the DOWN or UP KEY (10 or 9)
repeatedly until the display (1) shows OP for output range selection
√ To adjust the output press & release the SET/ZERO KEY (8)
√ The present range is now shown (r0 or r4). Refer to table below to see which
output range is selected with different combinations of connections.
Table 3.1 Output Range Selection Reference

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Section 4. Operating Instructions

AI-2410
4.1 Operating Instructions (Refer to Fig. 3.1)
√ Switch on the power supply
√ Allow 2 minutes for the instrument to warm up
√ Flow oil-free water through the system for a few minutes. If the display
is greater than zero, then a clean water calibration will need to be
performed (see section 3.4)
√ Switch the instrument sample supply valve from the clean water supply
to the sampling point connection.
THE INSTRUMENT IS NOW READY FOR USE
√ When the sample is flowing through the monitor the display will adjust to
show the current oil content of the sample.
√ If the oil concentration exceeds any of the alarm set points (PPM), the Alarm
1 or 2 indicators (4 & 5) will be illuminated and the corresponding alarm relay
will operate as soon as the set delay time for each alarm has expired.
√ If an error code is displayed on the screen. The fault relay and both alarm
relays will be activated. See Section 6.1 for troubleshooting and error code
translations.

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Section 5. Routine Maintenance

AI-2410
5.1 Operator Maintenance (Refer to Fig.1.2)
At WEELKLY intervals:
√Check the zero with oil-free water flowing through the instrument and reset if
necessary (see section 3.4)
√ Flush the cell with oil-free water.
√Isolate the instrument from both sample and oil-free water supply
√Unscrew and remove the cell cap (5)
√Insert a bottlebrush into the cell using an upward and downward motion.
√Remove the bottle brush and replace the cap (5)
√Re-connect the oil free water supply and allow this to flow through the
instrument for a few minutes
√ Re-check the zero calibration again
√ Re-connect the instrument to the separator sampling point
AT MONTHLY intervals:
√ Check the color of the DESSICATOR window (7) to ensure it is blue,
indicating correct moisture content of cell. Replace dessicator if color is
either PINK or WHITE.
√ Install new dessicator by unscrewing the old dessicator unit (7) and
inserting a new one. DO NOT OVERTIGHTEN DESSICATOR –
Finger tight is sufficient. Ensure the O-ring seats properly against the cell
housing.

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Section 6. Troubleshooting

AI-2410
Table 6.1 Error code translation table
Error
Code
Meaning
Or
PPM value out of range
SH
Excessive solids content
bC
Bad clean water cal see page 15 sect.5
E1
No scatter signal
E2
No transmission signal
E3
Scatter signal out of range
E4
Transmission signal out of range
6.1 Troubleshooting Guideline
♦ Error Or:
Oil concentration is out of selected range
Check the range wiring (See Section 3.5)
Change the programmed range (See Section 3.5)
♦Error SH:
Excessive solids content
Perform flush and cleaning (See Section 5.1)
♦ Error BC:
Bad clean water cal
Perform flush and cleaning (See Section 5.1)
Perform Clean Water Calibration (See Section 3.4)
♦ Error E1:
No Scatter Signal
Receiver has faulted, attempt cleaning (See Section 5.1), if problem persists
contact Waltron
♦ Error E2:
No Transmission Signal
Light emitter has faulted, power off /on to attempt reset, if error persists contact
Waltron
♦ Error E3 and E4
Scatter and Transmission signal out of range
Component calibration required at manufacture, contact Waltron Service
department for Return Authorization