Waltron AQUALERT mAI-9070 Series User manual

Waltron LLC AQUALERT® DIVISION
___________________________________________
Water Chemistry Measurement & Control
µAI-9070 SERIES
HYDRAZINE MONITOR
INSTRUCTION MANUAL

TABLE OF CONTENT
9
1INTRODUCTION................................................................................................................................1
1.1 GENERAL ..................................................................................................................................... 1
1.2 DESCRIPTION.............................................................................................................................. 1
1.2.1 SENSOR UNIT........................................................................................................................ 1
1.2.2 TRANSMITTER UNIT ............................................................................................................ 1
2INSTALLATION ................................................................................................................................. 3
2.1 MOUNTING OF UNIT.................................................................................................................. 3
2.1.1 LOCATION AND LAYOUT.................................................................................................... 3
2.1.2 TRANSMITTER UNITS .......................................................................................................... 4
2.2 SAMPLE REQUIREMENTS......................................................................................................... 6
2.3 EXTERNAL PIPING CONNECTIONS......................................................................................... 6
2.3.1 INLET..................................................................................................................................... 6
2.3.2 DRAIN .................................................................................................................................... 6
2.4 ELECTRICAL CONNECTIONS................................................................................................... 7
2.5 SENSOR UNIT .............................................................................................................................. 7
2.5.1 TRANSMITTER UNIT ............................................................................................................ 7
2.5.2 WIRING OF BOARDS................................................................................................................ 8
Chassis.................................................................................................................................................. 10
2.6 REMOTE EQUIPMENT.............................................................................................................. 10
2.6.1 RECORDERS........................................................................................................................ 10
2.6.2 RANGE INDICATION.......................................................................................................... 10
3START UP .......................................................................................................................................... 12
4PRINCIPLE OF OPERATIONS...................................................................................................... 14
4.1 SENSOR UNIT ............................................................................................................................ 14
4.1.1 A flow schematic is shown in Fig. 4.1................................................................................... 14
4.2 QA/QC JUNCTION BOX SWITCH............................................................................................ 15
4.2.1 Normal Calibration .............................................................................................................. 15
4.2.2 Process Calibration.............................................................................................................. 15
4.2.3 QA/QC.................................................................................................................................. 15
4.3 TRANSMITTER UNIT................................................................................................................ 16
4.3.1 ELECTRONICS CHASSIS.................................................................................................... 16
4.3.2 CIRCUIT BOARD FUNCTION............................................................................................ 16
4.3.3 FRONT PANEL CONTROLS ............................................................................................... 17
4.3-4 ALARMS..................................................................................................................................... 20
4.4 ANALOG OUTPUTS................................................................................................................... 20
5CALIBRATION PROCEDURE....................................................................................................... 22
5.1 SINGLE POINT CALIBRATION USING STANDARD SOLUTION....................................... 22
5.2 CALIBRATION USING PROCESS SAMPLE AS ASTANDARD SOLUTION....................... 23
6MAINTENANCE ............................................................................................................................... 24
6.1 CHEMICAL SOLUTIONS .......................................................................................................... 24
6.1-1 BUFFER SOLUTION........................................................................................................... 24
6.1.1 Concentrated ammonia solution - 2 liters ............................................................................ 24
6.1-2 STANDARD SOLUTIONS........................................................................................................... 24
6.1-3 NITRIC ACID CLEANING SOLUTION............................................................................... 26
Note: Waltron L.L.C. offers Nitric Acid in a 2 ounce size part number H1234-556 ........................... 26
6.1-4 HYDRAZINE SENSOR RECHARGE GEL................................................................................. 26
6.2 SCHEDULED SERVICING ........................................................................................................ 26
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TABLE OF CONTENT
9
6.2-1 BI- WEEKLY......................................................................................................................... 26
6.2-2 BI-MONTHLY....................................................................................................................... 27
6.2-3 QUARTERLY........................................................................................................................ 27
6.2-4 REFURBISHING THE SENSOR.......................................................................................... 27
6.3 SHUT DOWN PROCEDURE...................................................................................................... 28
6.3.1 STORAGE OF THE SENSOR..................................................................................................... 29
6.4 UNSCHEDULED SERVICING................................................................................................... 29
6.4.1 Display shows “CAL”:......................................................................................................... 29
6.4.2 Display flashes (reading) - “out”:........................................................................................ 30
6.4.3 Display shows “CF”:........................................................................................................... 30
6.4.4 Display flashes “reading” continuously............................................................................... 30
6.4.5 Display shows “Hot”: .......................................................................................................... 30
6.4.6 CALIBRATION FAIL ALARM.............................................................................................. 30
6.4.7 MALFUNCTIONS OF THE MONITOR............................................................................... 31
REPLACEMENT OF PLASTIC TUBING............................................................................................. 31
7SPRARE PARTS................................................................................................................................33
8SPECIFICATIONS............................................................................................................................ 34
8.1 INSTALLATION INFORMATION ....................................................................................................... 34
9OPERATOR’S NOTES ..................................................................................................................... 36
10 OUR COMMITMENT TO OUR CUSTOMERS........................................................................ 37
11 OBSERVING SAFETY............................................................................................................. 38
12 WARRANTY AGREEMENT....................................................................................................... 39
13 CHECK LIST OF MATERIALS.................................................................................................. 41
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1INTRODUCTION 9070
1INTRODUCTION
1.1 GENERAL
The µAI-9070 Hydrazine Analyzer is a continuous on-line monitor for direct
measurement of Hydrazine in boiler feedwater. The 9070 features low
maintenance, semi-automatic process or standard calibration; and high
accuracy, auto ranging and external (“grab”) sample analysis.
1.2 DESCRIPTION
1.2.1 SENSOR UNIT
The sensor unit is in a metal case, which also houses the liquid handling
equipment. Pipework carrying the sample is mounted on a panel, and bolted
to the back of the unit with four M6 bolts.
Mounted on the sensor unit door are the Buffer container and the junction box.
The junction box for the electrode’s connection is also mounted on the door.
A user-controlled switch in the junction box allows for either calibration on a
process sample, or a quality analysis/ quality control (QA/QC) test.
The liquid handling section contains a machined PVC head chamber. As
sample flows to the vapor entrainment “T,” the head chamber controls its rate
and pressure. (Pretreat the sample with an alkaline vapor to achieve the
correct pH value.)
The sample is then collected in a standpipe that forces sample flow through
the Hydrazine Sensor.
Use a standard solution of a known value under the control of the transmitter
unit to calibrate the sample.
The drain cup collects used sample and overflow, allowing for a single drain
connection.
1.2.2 TRANSMITTER UNIT
The transmitter unit is in a metal case similar to the construction of the sensor
unit’s, with a chassis unit supporting circuit boards and other electrical sub-
assemblies.
Microprocessor electronics control the functions of the transmitter. The three
main functions of the Hydrazine Analyzer are:
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1INTRODUCTION 9070
9To interpret and to display a reading of hydrazine received from the
sensor unit,
9To control the calibration sequence,
9To provide various outputs to the remote equipment.
Displays are three-digit, seven-segment, light emitting diodes (l.e.d.), which
show the level of hydrazine and operational information as well. The operator
can see when the instrument is in the calibration mode, and when the
calibration has not been successful.
On the left-hand side of the transmitter unit are six access holes. These holes
are sized to accept cable glands for the interconnect cable, alarm signals,
current outputs and an alternating current (a/c.) power cable
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2INSTALLATION 9070
2INSTALLATION
2.1 MOUNTING OF UNIT
2.1.1 LOCATION AND LAYOUT
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 sensor unit no more than 33 feet (10 meters) from its associated
sample coolers.
Mount the sensor unit on the wall using four 5/16” or ¼” bolts on 9.06” by
13.00” centers.
Refer to Figure 2.1 for the correct positioning of transmitter and sensor units.
FIGURE 2.1 MOUNTING ARRANGEMENTS
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2INSTALLATION 9070
FIGURE 2.2 SENSOR UNIT DIMENSIONS AND INSTALLATION
2.1.2 TRANSMITTER UNITS
Wall mount using four 5/16” or ¼” bolts on 9.06” by 9.06” centers. Sufficient
access space, as detailed previously, must be left for making cable
connections to the transmitters and for the mounting of standard solution
containers.
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2INSTALLATION 9070
FIGURE 2.3 TRANSMITTER UNIT DIMENSIONS AND INSTALLATION
For access and fitting of the transmitter unit, proceed as follows:
9Unlock the door and open fully.
9To release the face panel, use a small coin or similar tool to turn
the four plastic fasteners ¼ turn in either direction.
9Remove the chassis.
9Secure the transmitter case to the wall by four 5/16” or ¼” bolts.
Note. Before fitting the chassis unit and connecting it to the main
power supply, check that the voltage selector is set to the correct value.
Refer to Section 3 for procedures required before start-up.
Caution. When replacing the connection terminal blocks, make sure
that the blocks are aligned correctly to cover all of the associated
connecting pins.
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2INSTALLATION 9070
9With the transmitter case secured to a wall or panel, open the
chassis to the case and wire the main power connection. Fit the
connection blocks onto the circuit boards.
9Fit the chassis unit, secure it with the captive screws and replace
any ground (earth) bonding leads.
9Position the face panel and secure it with the four plastic fasteners.
2.2 SAMPLE REQUIREMENTS
[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.
Bring the sample to the temperature and pressure suitable for measurement,
using sample coolers and pressure-reducing equipment (see Section 8)
2.3 EXTERNAL PIPING CONNECTIONS
2.3.1 INLET
The sample should be connected to the sensor unit using ¼” o.d. tubing of
stainless steel or rigid plastic. Connect this to the sample inlet coupling on the
right hand side of the case’s bottom piece.
The inlet tube should be of sufficient wall thickness to withstand the highest
sample pressure, and pipe lengths should be kept short.
Where particulate matter is present (e.g. magnetite in boiler samples), fit a 60-
micron sample filter to the sample line.
A shut-off valve (not supplied with the monitor) is necessary in the sample
unit.
2.3.2 DRAIN
The drain from the cup at the bottom of the sensor unit case consists of a hose
barb suitable for 3/8” bore plastic or rubber tubing. Alkaline
effluent from the monitor and overflowing sample drains through this single
connection.
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2INSTALLATION 9070
2.4 ELECTRICAL CONNECTIONS
[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 any high-voltage operated control circuits before
making any connections.
The equipment operates on alternating current electricity. Always take suitable safety precautions to
avoid the possibilities of an electric shock.
2.5 SENSOR UNIT
The prefabricated, eight-conductor cable connecting the sensor unit to the
transmitter unit arrives in place from our factory. We’ve provided this
service to assist you to avoid opening the junction box, which could admit
moisture.
You may mount the transmitter either next to the sensor unit or up to 330 feet
(100 meters) away. Also allow sufficient space on the transmitter unit’s left-
hand side. The access plate and holes on the left side allow room for the
connection of cables to the unit.
Extend the cable by placing a junction box adjacent to the sensor unit, and by
using the required length of 8-conductor cable. You can specify the length of
interconnect cable you’ll need at the time of order.
2.5.1 TRANSMITTER UNIT
9Remove the four screws securing the access plate to the left-hand side
of the transmitter case. Fit suitable cable glands through the 7/8”
diameter holes. Insert the cables necessary for the power supply,
output signals, alarms and the remote function, if used.
9Open the transmitter’s door and remove the face panel.
7