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RC400G Residual Chlorine Analyzer [Style: S3]

1. Detector Sand filter Sand filter CELL F1 F2 Solenoid Solenoid vave SVI valve SV3 4 Power terminal Ball valve Ball valve Solenoid box 1 V15 olenoi x 1 v2 valve SV1 2 5 Metering ojo Meas Std solution pump switching valve PU Drain VP40 pipe v7 Activated Ball valve Pressure reducing charcoal filter 11 12 i valve PR F11 2 2 Ball valve 3 way solenoid gf Measuring v4 valve SV6 f sample inlet 5 2 VP16 pipe O Tap water inlet VP16 pipe 7 1 Option ARS applies to model with arrestors 2 Option AZC applies to model with auto zero calibration 3 Option APO applies to model with air pump F040102 ai Figure 4 1 Component Identification and Functions and Residual Chlorine Analyzer 1 m Converter Analyzer operation display lt Fail gt indicator Data display Operation status indicator Mode display Data set keys Unit indicator ji Function code display X 9 5 Sian mp Sreoceam 1 P mimin Srrosram 2 toio om dasu Function key DATASET p d Fuse 1 A C SEEEREEEEEREGEE 6 eelere Fuse 3 A Q Handling outline description Mode change key Function code list Terminal boa
2. Item Part No Qty Description 1 1 Converter 2 A1109EF 1 Fuse 1A 3 A1113EF 1 Fuse 3A CMPL 12F04A01 03E 1st Edition Mar 2013 YK DETECTOR Part No L9804UK K9332JP K9334VA 3 a K9334JY K9334VQ K9334VR K9334VS 4 K9334LK K9332JS A2022CF K9332WA K9332JX K9332JZ K9334LM K9334LL K9332MJ K9332MK 11 K9334JP a SOMNAD 1st Edition Mar 2013 YK EN 1 25 26 23 24 21 22 Description Drive Belt Gear Head For 100 110 V AC power supply For 200 220 V AC power supply Motor Assembly For 100 V AC power supply For 110 V AC power supply For 200 V AC power supply For 220 V AC power supply Capacitor For 100 V AC power supply For 110 V AC power supply For 200 220 V AC power supply Cable Brush Slip Ring Plate Plate Counter Electrode For general type Item 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 For combined chlorine insensitive type Indicator Electrode Part No K9334JV K9334LN Y9500ET L9805BG K9332LQ K9334JW Y9115XB L9831HC L9831HE K9332KQ Y9114XB K9332KR Y9110XB L9831KL L9831KN K9332KZ K9332ZJ K9332KX K9332KL K9332MS Description Shaft Assembly Shaft Retainer ring E Bearing
3. amp bd Oo Kx Oo Power fuse kepppepepeepppa OE n Figure 3 9 Wiring Terminals of Converter IM 12F4A1 01E 8th Edition Aug 2014 3 3 2 3 3 3 lt 3 Installation Tubing and Wiring gt 3 1 4 Wiring for Analog Output Signals This is for transmitting output signals of 1 to 5 V DC or 4 to 20 mA DC by the respective range to receives such as a recorder Use a two conductor shielded cable of 6 to 12 mm finished O D When the analyzer is equipped with arrestors when option code ARS is specified connect terminals L1 and L2 to the power terminal box a circuit breaker is incorporated Refer to Figures 3 5 to 3 7 NOTE For lt remote gt range switching use a four conductor including this wiring shielded cable Treat the cable at its end to be connected to the converter terminal in the following manner 1 Strip of the insulation covering of the cable at its end approx 60 mm and solder a lead wire to the base of the exposed shield Protect the soldered part by wrapping with insulation tape or other means 2 Cut the lead wire and each conductor to equal length and attach to the lead wire and con ductors tips crimping type terminal lugs which fit M4 screws 3 Connect the cable to and terminals of the converter Connect the positive pole conductor to the terminal OUTPUT at and the negative pole conductor to respec
4. l Wiring terminal board Eoi O o BESS gppegp a O Wiring cable inlet port 3 or 4 ports for external wiring F3 5 ai Figure 3 8 External Wiring Terminal Board and Cable Inlet Port in Converter Whereas the converter has 8 cable inlet ports 5 out of the 8 ports have been assigned to internal wiring and only 3 ports are available for external wiring A NOTE In the RC400G 1 analyzer which has no air pump 4 ports are available for external wiring Use one cable for each wiring The analog output wiring and contact input wiring are collected together in one cable as a rule but they can be assigned separate cables if cable ports are avail able A NOTE Stop cable ports not in use with plugged cable glands IM 12F4A1 01E 8th Edition Aug 2014 lt 3 Installation Tubing and Wiring gt 3 1 3 3 3 1 Wiring for Power Supply and Grounding This is for supplying power of voltage and frequency meeting the specification of the analyzer and for grounding the converter case Connect the terminals L1 and L2 of the converter to power supply with a two conductor cable of 6 to 12 mm finished O D
5. 9 10 9 3 2 Cleaning is not Conducted Properly cccccesceeeeeeeeeeeeesteeeeaees 9 10 9 3 3 Remote Range Switching does not Work rrrrrrrnrrnnnrnnrnrnnrnnnnnn 9 10 10 Spare Parts and Consumables rrnnvvnnnnnnnvvnnnnnnvnnnnnnnnnnnnnnnnvnnnnnnnnnnnnnnner 10 1 10 1 Spare Parts and Consumables List c cccseceeseeeeseeeeseeeeseneeeseeeeseeeeseees 10 1 10 2 Complementary Description rrrnvrnnnnrnnnnvnnnnvnnnnvnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 10 2 10 2 1 Reagent K9041TH K9041TG K9041TJ K9041TQ e eee 10 2 10 2 2 Lubricating oil K9041RA rernrernvernvernvernvernvernvrrnrernrernvernvernrernnenrnn 10 2 10 2 3 Polishing Powder K9088PE rrrrnvrrnvrrnvrrnvrrnvrrnvrrnvernvrrnvrrnvrrnvernne 10 2 10 2 4 Glass Beads K9332Z J rrnrrnnvrrnvernvrrnvrrnvernvrrnvernvrrnvernvernrrrnvrrnnernne 10 2 10 2 5 Sand K9720FZ rernrernrrrnvernvernvernvernvernrernvernrernrernrernrernrernrernnernnernne 10 2 10 2 6 Valve Sheet K9041HC n rnrernvernvernvernvernvernvernrernvernvernrernvernrernnernne 10 2 10 2 7 Bellofram L9819AA L9819AB rrrnrernrernvernvernvernversversversrersvernn 10 3 10 2 8 Indicator Electrode K9334JP mnnnnvnnnvnnnvrnnvrnnnrnrnrnnnrnenrnenrrenreennr 10 3 10 2 9 Counter Electrode K9332M J for Combined Chlorine K9332MK 10 3 10 2 10 Fuse A1113EF A1109EF J renrnrernrernvernvernrernvernvernvernvernrernvernvernnernne 10
6. 2 Reference Sensitivity Setting Function code 4 A NOTE Products which can be set using this function code are those of version 1 02 or later In prod ucts earlier than version 1 02 use the function code 7 in service mode The reference sensitivity set on shipment is the value of 2 62 uA mg l at 20 C based on am perometric titration IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 23 In span calibration if standard solution residual chlorine concentration measured by manual analytical methods other than amperometric titration such as chlorimetry and iodometric titration is entered great variance may occur between the sensitivity calculated from this value meas ured sensitivity and the set reference sensitivity In particular this trend is stronger when residual chlorine concentration is low or a sample water is used as the standard solution The RC400G residual chlorine analyzer detects an error Err22 when the measured sensitivity is less than 50 of the reference sensitivity and makes that span calibration invalid If it is found that inconvenience such as calibration is not performed because of the error Err22 occurrence is caused by the difference between the employed method and manual analytical methods set a reference sensitivity conforming to the employed manual analytical method NOTE If Err22 is not detected on adopting a manual
7. Item PartNo Qty Description 1 K9332NH 1 Filter Assembly for Model RC400G 2 1a K9332PG 1 Filter Assembly for Model RC400G 3 1b K9332PH Filter Assembly for Model RC400G 3 2 K9720FZ 1 Sand 1 liter 3 1 Solenoid Valve K9332RN For 100 V AC power supply K9332RP For 110 V AC power supply K9332RQ For 200 V AC power supply K9332RR For 220V AC power supply 4 1 Solenoid Valve K9332RW For 100 V AC power supply K9332RX For 110 V AC power supply K9332RY For 200 V AC power supply K9332RZ For 220 V AC power supply 5 1 Solenoid Valve K9332RS For 100 V AC power supply K9332RT For 110 V AC power supply K9332RU For 200 V AC power supply K9332RV For 220 V AC power supply CMPL 12F04A01 03E e Model RC400G AZC with Auto Zero Calibration Option CMPL 12F04A01 03E Item Part No K9726EG L9862AY A1029MV Qty 1 1 1 Description Filter Element Solenoid Valve Filter Assembly 1st Edition Mar 2013 YK Customer Model RC401G Maintenance Reagent Tank Parts List Model RC401G A 3 4 e Model RC401G C Item Part No 1 K9041ZN 2 K9725GQ 3 K9725GY 4 G9303NV 5 K9725HA 6 K9332XA L9869FJ Qty ee M M Model RC401G B Description Cap Pipe Plug O Ring Needle Valve Stand Pump
8. Reagent Rc1 4 Deaq t Air Ro1 4 ap EEE We ee Air pump Vat Drain VP40 es V R I l Figure 3 2 2 Tubing Diagram of RC400G 2 F1_4_2E ai Tubing materials eer polyethylene tube Converter 98x 06 polyethylene tube r 22 x 15 braided wire reinforced soft PVC tube e 933 x 025 braided wire reinforced soft PVC tube aa os VZ ive SV6 Ino away solenoid v2 val as O COM i NC vee PU a ing jeharcoal filter Ball ll O ae lI Measuring sample VP16 Pressure reducing valve Solenoid gvn 1 V4 Tap water VP16 Dex Standard solution Rc1 4 BANE EE EEE ENE Strainer b Reagent Rc1 4 so ace ae Gia a Air Rc1 4 E VP16 pipe VP40 pipe mt option os o S Sa ZA Air pump a Vat Drain VP40 F1 4 5E ai Figure 3 2 3 Tubing Diagram of RC400G 2 AZC IM 12F4A1 01E 8th Edition Aug 2014 lt 3 Installation Tubing and Wiring gt 3 5 3 RC400G 3 Residual Chlorine Analyzer for Treated Water Drain VP40 pipe Standard solution inlet For air purge inlet 8 Reagent inlet Measuring sample inlet VP16 pipe Tap water inlet VP16 pipe F3 3 1E ai Figure 3 3 1 Piping of RC400G 3 Residual Chlorine Analyzer for Treated Water Tubing materials 6 x 4 polyethylene tube Sand Biter 98x 6 i
9. When the analyzer is equipped with arrestors when option code ARS is specified connect terminals L1 and L2 to the power terminal box a circuit breaker is incorporated Refer to Figures 3 5 to 3 7 A NOTE The converter does not have a power switch A double pole switch should be installed in the power line A power switch for the converter is necessary to prevent electric shock or damage to the instrument when inspection or maintenance of electric system is performed with power sup plied Treat the end of cable to be connected to the converter terminal in the following manner 1 Strip of the insulation covering from the cable at its end approx 80 mm 2 Attach to the tip of the conductor a crimping type terminal lug which fits an M4 screw L For grounding use the grounding terminal marked at the bottom of the converter case Provide grounding by connecting the end treated for sufficient conduction grounding lead to the M5 screw of the grounding terminal grounding resistance must be 100 Q or less A NOTE When the grounding terminal of the converter case cannot be used connect the grounding lead to terminal G M4 screw inside the converter and ground the lead at the power supply For this use a two or three conductor shielded cable for power supply and grounding wiring R1 R 11 12 01 02 p1 p2 mi m2
10. Indicator Electrode Polishing Since the indicator electrode rotates at a constant speed or 600 rpm at 50 Hz its gold alloy sur face is constantly and automatically polished by the glass beads However although the polish ing effect is significant contamination adhesion is not completely prevented and contamination gradually increases with time lapse Contamination of the gold alloy surface causes a meaning error which increases corresponding to the amount of contamination increase Thus it is necessary to remove contamination by pol ishing the gold alloy surface with polishing agent alumina before this measuring error exceeds the permissible value Polishing frequency varies with sample water quality and could extend to possibly once every several months In principle it is recommended that polishing be implemented once a month For the polishing procedure refer to subsection 4 3 10 Also perform calibration after polishing completion IM 12F4A1 01E 8th Edition Aug 2014 8 4 lt 8 Maintenance gt 8 2 Glass Beads and Measuring Tank Cleaning If the glass beads are contaminated polishing effect is reduced and the indicator electrode is likely to be contaminated Periodically clean the glass beads At the same time clean the measuring tank Conduct cleaning in the following procedure 1 Press CELL key in lt MAINT gt mode to stop indicator electrode revolution When electrode rotation stops lt CELL
11. Tap water inlet 1 A y VP16 pipe 1 Option AZC applies to model with auto zero calibration F3_1_1E ai Figure 3 1 1 Piping of RC400G 1 Residual Chlorine Analyzer for Tap Water Tubing materials C 26x04 polyethylene tube 22 x 15 braided wire reinforced soft PVC tube 33 x 25 braided wire reinforced soft PVC tube Converter Head tank VP16 pipe VP40 pipe i option 3 Metering Ball valve v2 Laa Roon l 7 l 4 4 Measuring sample VP16 _Pec Standard solution Ret 4 e L_f_ l V3 Strainer l C Reagent Rc1 4 E DX M 7 Air Rc1 4 E gt q t Vat Air pump os pr Drain VP40 F1 4 1E ai Figure 3 1 2 Tubing Diagram of RC400G 1 IM 12F4A1 01E 8th Edition Aug 2014 lt 3 Installation Tubing and Wiring gt 3 3 Tubing materials 26x04 polyethylene tube 22 x 15 braided wire reinforced soft PVC tube 1 01 Hi 33 x 25 braided wire reinforced soft PVC tube Converter VP16 pipe VP40 pipe Measuring tank option ae solenoid Pa valve Activ ted chardoal filter Metering pump V Measuring sample VP16 D84 Pressure reducing valve O SS ee V13 Calibration solution VP16 4 Stan
12. Function code g 4 5 6 TT 8 and 97 Figure 5 14 shows the cleaning sequence for sand filter two cylinder type applied to the RC400G 3 residual chlorine analyzers for treated water IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 35 Fn to Ta T1 pia T1 mie T1 pia T1 SV4 OFF LINE 2 4 T6 T5 T6 T5 T6 Sand UNE n OE oyin 4 2 sec 5 sec 3 T5 GU p cleaning fm operation SV1 FILTER 1 EE he 4 2 sec 5 sec C e ON ON SV5 FILTER 2 Eam 1 sv2 Measuring WASH OFF tank 4 A cleaning operation 2 Output hold OFF Output hold a T1 Sand filter cylinder T2 Measuring tank cleaning time 1 Symbols in _ show the relevant external connection T3 Sand filter cylinder cleaning time terminal names T4 Relaxation time 2 If the measuring tank cleaning function is in stopping T5 Substitution time status No operation is performed T6 Cross time 3 In the T7 period immediately after the mode is switched to T7 Measuring tank cleaning cycle the lt MEAS gt mode cleaning operation is not performed F5 14 ai Figure 5 14 Cleaning Sequence Time Chart for Sand Filter Two Cylinder Type In the sand filter two cylinder type cleaning sequence the sand filter cylinder cleaning se quence and the measuring tank cleaning sequence operate independently Acleaning sequence starts at the time when mode is switched t
13. Time settings for cleaning sequence can be performed setting items are selected 1toF using FUNC key e Operations using data set keys or operation command keys are available PROGRAM 2 e Failure detecting function execution stop can be selected setting items are 1 to F selected using FUNC key e Operations using data set keys or operation command keys are available 5 2 1 Function Codes and Their Description in lt MEAS gt Mode Table 5 3 shows types of function code in lt MEAS gt mode and their description Table 5 3 Functions List in lt MEAS gt Mode age i Display Initial F Description Display Range example Value 1 Remarks i 1 00 to 12 00 mg l 1 Jente chlorine concentration O L is displayed 0 35 mg l _ pe Hr is p ay for out of range i 5 0 to 55 0 C 2 Sample water temperature display O L is displayed 20 0 C for out of range 3 Applied voltage display 1 50 to 1 50 V 0 40 V 0 40 2 15 00 to 65 00 pA 4 Diffusion current display O L is displayed 2 62 pA for out of range 5 Display for FS of output signal 10 0 to 110 0 50 0 Display for sample water metering F F 6 pump flow 0 0 to 100 0 ml min 50 0 ml min 0 0 7 Risplay for reagent metering PUMP 0 00 to 3 00 ml min 1 50 ml min 0 00 8 Zero point error display 1 00 to 1 00 pA 0 02 pA 0 00 9 Slope display 50 0 to 120 0 100 0 100 0 A Cannot be sel
14. 0 1 to 25 0 min 0001 0 min 1 0 are i 5 0 The value in is for 5 Setting relaxation time after cleaning 0 1 to 25 0 min 0005 0 min 3 0 RC400G 3 analyzer Setting and filter cylinder cleaning 2 0 The value in is for 6 cycle 0 1 to 24 0 hours 0002 0 hours 0 5 RC400G 3 analyzer 7 dd sand filter cylinder cleaning 0 1 to 25 0 min 0001 0 min 1 0 8 Setting substitution time 0 1to0 25 0 min 0006 0 min 60 ee analyzer only 9 Setting cross time 0 10 25 0min 0001 0 min pr analyzer only A re automatic Zero calibration 0 1 to 99 9 days 0010 0days 10 0 b Setting automatic zero calibration 1 to 100 min 0010 min 10 preparation time Setting automatic zero calibration 1 to 100 min 0010 min 10 relaxation time d E F 1 2 3 Temperature compensation range 4 exceeding detection function execu on oFF on tion stop 5 Residual chlorine concentration upper orilo FF n limit alarm function execution stop 6 7 8 9 A b c d E F Note 1 If an unused function code is selected is displayed Note 2 Ifa value outside the setting range is set not is displayed pressing gt key returns the display to data display Note 3 Values shown in the initial value column are those to be shown when the memory that stores data is initialized IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 7 5 3 Key Operation 5 3 1 Operation Key Types and Functions 1 Mode Key
15. 4 2 Preparation for Operation 4 2 1 Reagent Preparation Reagent used for measurement differs in free available chlorine measurement and residual chlo rine total chlorine measurement Also in total chlorine measurement the component amounts in the reagent must be changed depending on the chlorine concentration in the solution to be measured Prepare reagents using the following procedure for each case Keep prepared reagents in rea gent tanks Preparation of Reagent for Free Available Chlorine Measurement max con centration 10 mg l As reagent components use potassium bromide KBr which reacts with the free available chlo rine present in a measuring sample to liberate bromine acetic acid CH3COOH for maintaining measuring sample pH at 4 5 to 5 0 and sodium acetate CH3COONa If a reagent solution of 100 liter is to be prepared obtain a mixed reagent solution of a total of a 100 liter by dissolving 4000 g of JIS grade 1 KBr 1000 g of sodium acetate and 1000 ml of acetic acid 95 or higher into approx 80 liter of purified water and then adding additional purified water to make 100 liter Table 4 1 Reagent Composition and Its Component Quantities Measurement Object Free Chlorine Reagent Composition Quantity in 100 I KBr 4000 g CH3COONa 1000 g CH3COOH 1000 ml Preparation for Combined Chlorine Table 4 2 Reagent Composition and Its Component Quantities Measurement Object Free Chlorine
16. Converter Detector Metering pump Front Side Back F1 1E ai Figure 1 1 Appearance of RC400G Residual Chlorine Analyzer RC400G 1 Tap Water type IM 12F4A1 01E 8th Edition Aug 2014 lt 1 Outline gt 1 2 1 1 RC400G Residual Chlorine Analyzer Configuration The RC400G Residual Chlorine Analyzer is mainly composed of a measuring system a sam pling system and an air tubing system In addition a cleaning piping system is added to raw water treated water analyzers E Measuring System Measuring System mainly consists of a detector and a converter The detector contains a measuring tank and an electrode mechanism block The electrode mechanism block incorporates two electrodes indicator electrode gold alloy electrode and counter electrode platinum electrode with built in Pt1000 temperature sensor and a drive as sembly composed of a starting motor for rotating the indicator electrode at a constant speed a drive belt etc The electrodes obtain diffusion currents by electrolytic reduction of iodine for measuring total residual chlorine or bromine for measuring free available chlorine in the plateau region which is liberated corresponding to sample water chlorine concentration in mixed solution of sample water with reagent fed into the measuring tank The electrodes also serve to obtain a signal for automatic temperature compensation
17. Immediately after converter power is turned ON the memories that are used RAM and EEPROM are checked For RAM by performing the specified data writing and reading check if both coincide When they do not agree error code Err16 lt failure gt is displayed For EEPROM check that the data items stored in two areas coincide If both do not agree by performing the specified data writing and reading check if both coincide When they do not agree error code Err17 lt failure gt is displayed When these failures are detected the converter displays error code Err16 or Err17 and stops operation key operation cannot by conducted When memory failure is detected memory contents are initialized in very rare case In this case the setting data may be lost Concentration Upper Limit Setpoint Exceeded Err25 Residual chlorine concentration measured value that exceeds the value set using function code b in lt PROGRAM 1 gt mode is handled as failure When it is detected that the measured concentration exceeds the setpoint in lt MEAS gt mode error code Err25 lt failure gt occurs and a contact signal is output This contact output can also be used as an upper limit alarm However since this contact output is shared by other lt failure gt contact outputs fully exercise care for its use as the upper limit alarm This failure detecting function execution s
18. L00 00 V c On pressing ENT key the stopping voltage is displayed H 0 80 V d On pressing ENT key the number of steps is displayed P0008 e Pressing ENT key displays Execution selection Go oF f Pressing gt key displays Executable Go on IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 1 8 g On pressing ENT key characteristic taking is executed 00 001 When a series of taking operations is completed End is displayed End During plateau data taking any step can be skipped and data taking is transferred to the next step This operation is performed using ENT key When ENT key is pressed the step display then displays the next step number and the time display is also reset to start the next step time count ing No plateau data for the skipped step is taken During plateau data taking at any step the operation can be suspended using MODE and FUNC keys In this case operations from start to the suspended step all become invalid How ever since those key operations cannot be accepted when Stor is displayed data taken is updated When plateau characteristic taking operations are completed or aborted the applied voltage to the electrode returns to the automatically set value function code 5 in lt PROGRAM 1 gt mode When this operation is complete residual chlorine concentration measured value is temporarily unstable immediately after applied
19. polyethylene tube Sand filter 22 x 15 Solenoid valve braided wire reinforced SV3 soft PVC tube 33 x 25 8 8 braided wire reinforced soft PVC tube SV4 VP16 pipe VP40 pipe option Metering pump Measuring sample VP16 Pressure reducing valve Tap water VP16 Standard solution Rc1 4 E el I a fe Reagent Rc1 4 E M8 amp H3IT gent Air Rc1 4 E t a2 l pe ME a a Air pump Er SE pr Vat Drain VP40 F1 4 3E ai Figure 3 3 2 Tubing Diagram of RC400G 3 IM 12F4A1 01E 8th Edition Aug 2014 lt 3 Installation Tubing and Wiring gt 3 6 Tubing materials _ _ 86x 24 polyethylene tube 98 x 26 polyethylene tube 22 x 15 braided wire reinforced soft PVC tube e e 933 x 625 braided wire reinforced soft PVC tube VP16 pipe VP40 pipe 3 way solenoid I valve sv6 com page L No NC Ball valve i Activated charcoal ilter Pressure reducing valve 4 V6 Tap water VP16 Standard solution Rc1 4 4 option Measuring sample VP16 Reagent Rc1 4 t l t se al aaa laa SSS SS SS a eee Air pump 1 Pad a Vat Drain VP40 p F1_4 6E ai Figure 3 3 3 Tubing Diagram of RC400G 3 AZC 3 2 1 Sample Water Tubing This is the tubin
20. 2 lt RC400G 2 gt Converter CON Detector pump 3 way solenoid valve SV6 Air pump 3 CELL Power terminal box 1 switching valve V5 Activated charcoal filter F11 2 Meas Std solution Solenoid Ball valve V2 Metering pump PU Ball valve V11 12 3 way solenoid valve SV6 Head tank HD Drain VP40 pipe Pressure reducing valve PR 2 Ball valve V1 Ball valve 2 V4 Measuring sample inlet VP16 pipe Tap water inlet VP16 pipe 2 1 Option ARS applies to model with arrestors 2 Option AZC applies to model with auto zero calibration 3 Option APO applies to model with air pump Sand filter F1 Ball valve V1 Drain VP40 pipe Pressure reducing valve PR Ball valve V3 Ball valve V4 Measuring sample inlet Tap water inlet VP16 pipe 1 Option ARS applies to model with arrestors 2 Option AZC applies to model with auto zero calibration 3 Option APO applies to model with air pump F040101 ai IM 12F4A1 01E 8th Edition Aug 2014 lt 4 Operation gt 4 2 lt RC400G 3 gt Air pump 3 Converter AP CON
21. Consult with Yokogawa for the product before April 1999 All Rights Reserved Copyright 1991 Yokogawa Electric Corporation CMPL 12F04A0 1 11E YOKOGAWA Subject to change without notice 5th Edition Mar 2013 YK Yokogawa Electric Corporation Revision Information Title Model RC400G Residual Chlorine Analyzer Style S3 Manual No IM 12F4A1 01E Aug 2014 8th Edition P 2 6 Addition of the note P 4 6 Sec 4 3 4 Addition of the explanation P 4 11 Sec 4 3 13 Correction of the note P 5 2 Sec 5 2 Addition of the explanation P 6 1 Sec 6 1 Addition of the explanation P 6 3 Sec6 1 4 Addition of the explanation P 6 4 to 6 5 Sec 6 5 Correction of contents P 9 7 and 9 8 Sec 9 1 2 5 amp 7 Addition of the explanation Mar 2014 7th Edition P 2 4 Addition of Regulatory Compliance P 2 7 Some note added for spare parts P 8 14 Addition of caution for replacement of motor assembly P 10 1 Some note added for spare parts Mar 2013 6th Edition For Style S3 P 1 2 Indicator electrode changed to gold alloy electrode of Sec 1 1 by style S3 P 1 4 Change of applied voltage of Sec 1 2 by style S3 P 2 2 Indicator electrode changed to gold alloy electrode of Sec 2 1 1 by style S3 P 2 6 Style of RC400G MS code changed to S3 P 2 7 P N change of fuse 3A for spare parts P N of indicator electrode and driven shaft assembly changed by style S3 P 2 12 Change of outline drawing for RC401G
22. Example a Select function code 8 3 to 7 9 0006 0 min b Press gt key 0006 0 min Leftmost digit flashes c Selecta digit using gt key and set a numeric value using A and v keys 0007 0 min Last set digit flashes d Press ENT key to enter the value 0007 0 min Flashes once For inputs out of the permissible range not is displayed Press gt key to reset this display and reset the time A NOTE If the time for automatic zero calibration comes during cleaning the automatic zero calibration takes precedence over cleaning The cleaning process is held at the start of automatic zero calibration and the cleaning sequence is not executed If the time for cleaning comes during automatic zero calibration the cleaning sequence is not executed 3 Failure Detecting Function Execution Stop Selection Function code 4 5 For the following two lt failure gt detection detection execution stop can be selected Table 5 22 Failure Detecting Function Execution Stop Selection Function Failure Detecting Function Kemi Initial Value Code Range 4 Temperature compensation range exceeded 0 0 to 40 0 C on 1 5 Residual chlorine concentration upper limit alarm Within setpoint 2 on 1 AE on Detection execution oFF Detection stop 2 Setpoint is set using function code b in lt PROGRAM 1 gt mode Since this func
23. F F1 F2 Solenoid eroa valve SV1 valve SV3 4 Ball valve Ball valve V2 V1 5 Solenoid i valve SV1 2 5 Power terminal i box 1 NJIJ oL je Metering um Drain Meas Std solution 4 r 2 8 VP40 pipe switching valve v7 PU S j Ball valve Pressure reducing Activated charcoal filter V11 12 valve PR 11 2 c2 v Ball valve a 4 3 way solenoid Measuring V4 E A valve SV6 sample inlet TZ VP16 pipe Tap water inlet VP16 pipe e mM D l 550 85 60 40 ll 150 150 1 Option ARS applies to model with arrestors 2 Option AZC applies to model with auto zero calibration 3 Option APO applies to model with air purge pump F2 3E ai IM 12F4A1 01E 8th Edition Aug 2014 lt 2 Specifications gt 2 11 2 2 RC401G Reagent Tank It is a tank to hold reagent to be supplied to the residual chlorine analyzer It is equipped with a stirrer manual and a level gauge Either a tank only or a tank installed on a stand are available A NOTE When the tank with a stand RC401G B is used open a needle valve gradually and stop it at the position when reagent starts to flow Don t open more otherwise leakage may happen 2 2 1 Standard specifications 1 Reagent tank RC401G A Capacity 1001 Materials Rigid PVC Weight Approx 15 kg Other With manual mixer and level gauge 2 Reagent tank with stand RC401G B Incorporates the reagent tan
24. P__00 Steps c to e can be repeated using gt key f On pressing ENT key with the step number displayed the procedure moves to the next step P__01 g Applied voltages and diffusion currents are displayed by repeating operations c to f h When the final step is reached the next step returns to step 0 IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 1 9 If no plateau characteristics have been taken noP is displayed when ENT key is pressed at step b of the operating procedure If a step is skipped in taking plateau characteristic the diffusion current display becomes no_uP because of data lack at that step Figure 5 7 shows an example of key operations for plateau characteristics display number of steps 8 Ex number of steps 8 gt key operation gt P 00 gt 00 000 V 000 00 pA gt key operation v ENT key gt P__01 gt 0 100V 001 50 pA operation gt P 08 0 800V 005 80 pA gt key operation Step display Applied voltage display Diffusion current display F5 7 ai Figure 5 7 Key Operations for Displaying Plateau Characteristics 8 Error Code Display Function code b When lt FAIL gt lamp is lit on detecting a failure during operation the generated lt failure gt contents can be confirmed by error code display Note For countermeasures when failure occurs
25. RC400G 30 the water sample or reagent appears to freeze 5 to 95 RH non condensing 30 to 70 C Indoors A separate rainproof cover is required for outdoor installa tion Avoid direct sunlight 100 110 220 V AC 10 50 60 Hz Approx 65 VA Approx 125 VA Approx 210 VA Cleaning water required with sand filter system Quality Pressure Flow Consumption clean water 100 to 500 kPa 10 to 12 I min Approx 130 I day 1 cylinder sand filter type Approx 470 I day 2 cylinder sand filter type With standard cleaning sequence factory settings IM 12F4A1 01E 8th Edition Aug 2014 lt 2 Specifications gt 2 4 Air purge using instrument air Supply pressure 140 kPa Air consumption Approx 5 l min Weight For pure water Approx 65 kg For raw water 1 cylinder Approx 70 kg For raw water 2 cylinder Approx 75 kg Optional specifications Pump for air purge if instrument air cannot be used Install to enable intake of clean air Intake discharge 5 l min at 50 Hz Intake discharge outlets Open Maximum pressure 80 kPa Power consumption Approx 23 VA Weight Approx 2 kg Regulatory Compliance EMC Regulatory Arrangement in Australia and New Zealand RCM EN 55011 Class A Group 1 Korea Electromagnetic Conformity Standard Class A Aw 717 AFTE YEE ZA o 71718 YTE AP AAA 7N i EE ALSARE 9 BAS Fa jern 7149 9 2 NA ASAE AS F4JOT FUT as agay o 7 AN E Reagent sets
26. Reagent Composition Quantity in 100 I KBr 4000 g CH3COONa 5400 g CH3COOH 200 ml Preparation of Reagent for Measuring Residual Chlorine As reagent components use potassium iodide KI which reacts with free chlorine present in a measuring sample to liberate iodine acetic acid CH3COOH for maintaining measuring sample pH at 4 5 or less and sodium acetate CH3COONa The amount of potassium iodide to be used varies with the residual chlorine concentration See Table 4 3 Table 4 3 Reagent Composition and Its Component Quantities Residual Chlorine Measurement Object and Max Con Up to 6 mg l More than 6 mg l to 10 mg l inclusive centration Quantity in 100 KI 500 g 1000 g CH3COONa 150g 150g CH3COOH 1000 ml 1000 ml IM 12F4A1 01E 8th Edition Aug 2014 lt 4 Operation gt 4 5 4 2 2 Filling Bead Case with Electrode Polishing Glass Beads Contamination adhering to the gold alloy surface of the gold alloy rotating electrode results in measured value error To prevent such error owing to contamination the gold alloy surface is continuously polished with glass beads during operation Fill the bead case in the measuring tank with glass beads which are delivered by placing in the accessory box E Glass Beads Filling Procedure 1 Remove the electrode mechanism block by loosening two fixing screws 2 Put the glass beads into the bead case Feed the glass beads up to the lowest slit p
27. electrode The glass beads should be entirely replaced once every year For optimum polishing the glass beads should be placed in the bead case so that the height of bead bed reaches the lowest slit position with the indicator electrode inserted The polishing abil ity cannot be recovered by replenishing the beads only by volume reduced by wear IM 12F4A1 01E 8th Edition Aug 2014 8 5 8 6 8 7 lt 8 Maintenance gt 8 3 8 Reinstall the electrode mechanism block and fix it to the bracket using two screws 9 Turn on the power switch to restart operation Calibration It is recommended that calibration be conducted every month When the indicator electrode has been polished or operation is restarted after being stopped for a long period of time calibrate zero point and span in the procedure described in Chapter 7 Metering Pump Driving Section Oiling Oil only the lever support block bearing parts shown in Figure 8 1 Apply two or three drops of the attached lubricant engine oil into each block oiling port Perform oiling at the approximate rate of once a month Sample water metering pump driving lever support block Reagent metering pump driving lever support block F8 1 ai Figure 8 1 Metering Pump Driving Section Replacement of Bellofram and Valve Sheet in Metering Pump In principle replace the metering pump Bellofram and valve sheet with new ones at the rate of once every six mo
28. execution stop of part of failure detecting functions indicated in Table 5 6 are performed Function codes 1 to F gt Cleaning sequence operation time setting Function codes 1 to F gt Failure detecting function execution stop selection This subsection describes key operations to be performed by specifying function codes in lt PRO GRAM 2 gt mode and displays associated with the key operations 1 Cleaning sequence and time setting for sand filter One cylinder type Function code 4 5 6 and 7 2 Cleaning sequence and time setting for sand filter Two cylinder type Function code 3 4 5 6 7 8 and 9 6b 3 Failure detecting function Execution Stop selection Function code 4 5 IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 33 1 Cleaning Sequence and Time Setting for Sand Filter One Cylinder Type Function code 4 5 6 and 7 Figure 5 13 shows the cleaning sequence for sand filter one cylinder type applied to the RC400G 2 residual chlorine analyzers for raw water Ti 4 T1 4 T1 SV2 WASH 3 Measuring tank cleaning operation 1 2 sec 5 sec T3 SV1 FILTER 1 3 Sand filter cylinder cleaning operation Hold time 2 LS Hold time 2 ON ON Output hold T1 Sand filter cylinder and measuring 1 If the meas
29. for one year For free chlorine Potassium bromide extra pure 64 containers 500 g each Anhydrous sodium acetate extra pure 16 containers 500 g each Acetic acid extra pure 17 containers 500 ml each For residual chlorine Total chlorine Potassium iodide extra pure 8 containers 500 g each Anhydrous sodium acetate extra pure 3 containers 500 g each Acetic acid extra pure 17 containers 500 ml each For high concentration of residual chlorine Total chlorine Potassium iodide extra pure 16 containers 500 g each Anhydrous sodium acetate extra pure 3 containers 500 g each Acetic acid extra pure 17 containers 500 ml each For combined chlorine insensitive version Free chlorine Potassium bromide extra pure 64 containers 500 g each Anhydrous sodium acetate extra pure 87 containers 500 g each Acetic acid extra pure 4 containers 500 ml each Note These reagents sets are not imported from Japan because of both safety and transportation cost issues Purchase them directly in your local reagent supplier IM 12F4A1 01E 8th Edition Aug 2014 lt 2 Specifications gt 2 5 2 1 2 Characteristics Percent display is computed with respect to whichever of output range 1 or output range 2 has the highest upper range value Repeatability 2 Linearity 3 Drift Zero drift 1 month Max Span drift 5 month Max Response time Displayed as 90 response time For pure water Approx 3 min For raw water
30. tion of the brush mounting bracket so as to bring the brush contacts into contact with the slip ring Adjustment of the Brush Contact Pressure Slightly loosen the two screws holding the brush mounting bracket and then further loosen the lock screw adjacent to the contact pressure adjusting screw Screw in the contact pressure adjusting screw while drawing the brush mounting bracket toward you by hand until the optimum brush contact pressure is achieved This is achieved when the contact pressure adjusting screw is turned by three and half turns more after the brush has contacted with the slip ring Confirm the contact of the brush with the slip ring by for example measuring the resistance using a tester After positioning tighten the lock screw Also tighten the fixing screw for the brush mounting bracket Supply power to the RC400G Check that drive shaft drive belt and driven shaft rotate smoothly Also check that abnormal sounds such as resonant sound or discontinuous sound are not heard Check the resistance between the brush wiring terminal and the driven shaft using a tester The resistance must be 500 Q or less Replacement of the brush and slip ring is now complete 8 10 2 Inspection Maintenance and Replacement of Drive Belt Inspection and Maintenance Procedure The following inspections should be performed in time with other maintenance work which is per formed with the cover of the electrode mechanism blo
31. 2 Press PUMP key to once stop the metering pump operation 3 Close the ball valve 1 in the reagent flow line Remove the tubing connected to the rea gent metering pump suction tubing joint 1 RC400G 1 For tap water V3 RC400G 2 For raw water V6 RC400G 3 For treated water V8 4 Connect the prepared soft PVC tube to the burette and fill the tube and burette with water alternative of reagent Connect the opposite end of the PVC tube to the reagent metering pump suction tube joint and then set the burette as shown in Figure 4 5 Consumption measuring range 10 cm Detector 10 cm 50ml burette Burette stand Metering pump Soft PVC tube UO Reagent metering pump 6 mm O D x 4 mm I D suction tubing joint F4 5 ai Figure 4 5 Burette Setting IM 12F4A1 01E 8th Edition Aug 2014 5 6 7 4 3 7 lt 4 Operation gt 4 8 Measure the delivery flow rate using the method for measuring a time interval in which water in the burette is consumed by a definite volume 4 5 ml Consumption should be measured in the range of 10 cm at the upper end position reference of the detector Press PUMP key and again operate the metering pump Press ENT key the instant when the water level inside the burette lowers to the reference graduation arbitrarily specified within the limited burette range At this moment the data display indication changes to sec count Since water level in the
32. 5 10 summarizes error messages displayed in zero point and span calibration and their detecting conditions for reference Table 5 10 Error Messages displayed in Zero and Span Calibration Error Message Error Contents Permissible Range Range Setting Resetting Err21 Zero point failure 1 0 to 1 0 pA Fixed ENT key Sensitivity failure 50 or more of reference Err22 Note sensitivity Fixed ENT key Err23 Response failure Setpoint Variable ENT key Calibration value not setting failure 0 00 to 10 00 mg l Fixed gt key The reference sensitivity set on shipment is the value of 2 62 uA mg l at 20 C based on amperometric titration In the case that for example a standard solution whose residual chloric concentration is low is measured by manual analytical methods other than amperometric titration colorimetry iodometric titration an error may occur even if sensitivity is normal because of the difference in sensitivity owing to manual analysis If calibration is impossible because of error automatically update the reference sensitivity using the next operation 3 or change the reference sensitivity according to the manual analysis adopted using the method shown in subsection 5 3 4 2 Note 3 Span Calibration Reference Sensitivity Updating Function code d If span calibration is executed with function code set to d the reference sensitivity set in function code 4 in lt PR
33. Corporation e Model RC400G 2 Item a A O N CMPL 12F04A01 03E Part No K9087XA K9087XF K9087XG K9087XH K9326VG Qty Description Converter see page 4 Detector see page 5 Metering Pump Assembly see page 6 Sand Filter Assembly see page 7 _ ok kk Air Pump Option For 100 V AC power supply For 110 V AC power supply For 200 V AC power supply For 220 V AC power supply 1 Pressure Reducing Valve 1st Edition Mar 2013 YK e Model RC400G 3 1st Edition Mar 2013 YK Item ao A O N Part No K9087XA K9087XF K9087XG K9087XH K9326VG Qty Description Converter see page 4 Detector see page 5 Metering Pump Assembly see page 6 Sand Filter Assembly see page 7 Air Pump Option For 100 V AC power supply For 110 V AC power supply For 200 V AC power supply For 220 V AC power supply Pressure Reducing Valve CMPL 12F04A01 03E CONVERTER 1 T o 16 m svi SV2 SV3 SV4 SV amp SVG E ves sea co mar E PROGRAM 1 E Procram2 DATASET pr T O MANUAL OPERATION
34. Counter electrode K9332MJ Reference electrode Glass beads Polishing ponder Amina K9omePe For poistingindcatoreecrode Jaf id msn _KO202 K_ Pantforelecrode mechanism 1 ayes siping Kossz Pantorelecrodemechanism 1 eves Ar pump OOW 1 Replacement intervals vary depending on the application 2 At the time of damage 3 30 ml for lubricating the metering pump drive assembly 4 P N changed by style S3 5 Fuse may be used more than one year we recommend periodical replace for planning maintenance IM 12F4A1 01E 8th Edition Aug 2014 lt 2 Specifications gt 2 1 5 Flow diagrams and outline drawings m RC400G 1 Residual chlorine analyzer for tap water unit mm Standard solution inlet Air purge inlet Rc1 4 female Re1 4 female Maintenance Maintenance space space Reagent inlet Rc1 4 female 4 915 holes Approx 200 530 7 Approx 200 for anchor bolt 3 E 4 0 Stand 8 Ball valve V3 Te a oe y S 8 Strainer S1 x Maintenance rat Front S pace OO Ty Ea 20 490 20 Cross section A A Air pump 3 Converter CON m Detector CELL Power terminal n Head tank box 1 HD Metering Meas ee sauren pump Drain switching
35. K9332ZJ These are for replenishing or replacing the glass beads used for automatic polishing of the indi cator electrode as beads are gradually lost or become so contaminated they cannot be clean able The quantity required for replenishment and replacement depends on the operating conditions in general one to two packs per year Two packs of glass beads are supplied as the accessory 10 2 5 Sand K9720FZ This is a spare part required for raw water type and treated water type analyzers and used in the following situations 1 When sand in the sand filter has decreased Flocks etc depositing in the sand filter are flushed and discharged from the sand filter by automatic water jet at regular intervals If the frequency of the automatic cleaning is im proper sand can be discharged with the flocks and sand in the sand filter decreases As the sand filter must retain sand to a certain level making up for sand decrease is required 2 When the entire sand in the sand filter has discolored Although manganese and iron contained in sample water are contaminants of the elec trodes sand adsorbs most of the metals in the sample water minimizing the contamination of the electrodes When the sand has adsorbed a quantity of metals such as to discolor the entire sand layer the sand loses adsorption power and needs to be freshly replaced 10 2 6 Valve Sheet K9041HC It is recommended to replace the valve sheets on the suction a
36. MAINT gt mode and displays associated with the key operations 1 2 3 4 Zero calibration Function code 1 Span calibration Function code 2 Span calibration reference sensitivity updating Function code d ee r u i tank cleaning and sand filter cylinder cleaning Function code 4 5 and 6 Measurement of sample water and reagent metering pump flow Function code 7 and 8 oa 6 7 8 Taking plateau characteristics Function code 9 9 lt failure gt display contact output resetting Function code c 0 1 Plateau characteristics display Function code A Error code display Confirmation of lt FAIL gt contents Function code b 10 Version number display 11 Password input for transferring to the service mode Function code F 1 Zero Calibration Function code 1 There are two methods for calibrating the residual chlorine analyzer one is the method to be performed with input open circuit and the other is the method to be conducted using chlorine free water For details see section 7 2 Zero Calibration In this subsection the key operation for it is described Calibration operation starts at key operation The procedure for key operation is as follows Example a Select function code 1 in lt MAINT gt mode gt 000 24 mg l b Press ENT key lt CAL gt lam
37. MODE By pressing MODE key the operation mode changes The current operation mode is known through a mode lamp which is lit Mode is transferred in the order shown in Figure 5 2 every time the MODE key is pressed How ever when a function code other than 1 is selected in each mode mode does not change for the first key operation and only the function code returns to 1 PC lt MEAS gt p lt MAINT gt lt PROGRAM 1 gt lt PROGRAM 2 gt J F5 2 ai Figure 5 2 Mode Transfer by MODE Key Operation 2 Function Key FUNC When FUNC key is pressed the function code is transferred The transferred function code is displayed in the function code display Function code contents vary in each mode see section 5 2 The number of selectable codes also varies in each mode Figure 5 3 shows how the function codes are transferred by FUNC key operation For lt MEAS gt For lt MAINT gt For lt PROGRAM 1 gt or lt PROGRAM 2 gt Note By pressing MODE key with the function code set to other than 1 the function code returns to 1 F5 3 ai Figure 5 3 How the Function Codes are Transferred by FUNC Key Operation 3 Data Set Keys Operation using data set keys is valid in modes other than lt MEAS gt mode There are the follow ing four types of data set key a gt key digit selection key This is used when a digit to be changed displayed in the data
38. Option AZC applies to auto zero calibration 2 Option ARS applies to version with arrestor 3 Option APO applies to version with air purge pump Figure 3 5 RC400G 1 ARC AZC IM 12F4A1 01E 8th Edition Aug 2014 lt 3 Installation Tubing and Wiring gt 3 1 0 RC400G 2 Residual Chlorine Analyzer for Raw Water Converter Dedicated cable Detector CON K9332WA CELL DR Bk ME Fail contact output W RE Bw T1 Maintenance contact output Gn Wired by customer i Terminal Range switching output Rd mounting gt C1 screw BI D D C2 Remote range switching input Power terminal box 2 Pump Analog output Dedicated cable PU utpu dl ET A K9332WB P1C P1 Bk O7 P2 P2 S e W C G G AR2x2 z E i I ORE Solenoid valve Lre Go G Dedicated cable SV1 K9332W 2 4 L2 B1 0 9 Q La 1 a Lota B20 0 G 2 Solenoid valve L1 i SV2 g Dedicated cable SV2 G K9332WD CB1 Er ean J1 Q 01 G Bk E J2 y 2 2 F W hoo a 1 AR1 Solenoid valve ii Dedicated cable SV6 1 Case ground terminal must be o EN K9460CN grounded 5 l vig Bk 1 If this is not possible connect to 5 ERI V2
39. P 4 3 Indicator electrode of Figure 4 3 changed to gold alloy electrode by style S3 P 4 5 Indicator electrode changed to gold alloy electrode of Sec 4 2 2 by style S3 P 4 9 Indicator electrode changed to gold alloy electrode of Sec 4 3 10 by style S3 P 4 10 Indicator electrode of Figure 4 8 changed to gold alloy electrode by style S3 P 5 3 Change of applied voltage display of Table 5 3 by style S3 P 5 5 Change of applied voltage setting of Table 5 5 by style S3 some addition of Table 5 5 Function codes of E F added see below Function code E Selection of negative below zero display in lt MEAS gt mode Function code F Selection of below 4 mA output hold in lt MEAS gt mode P 5 21 Addition of description for function codes of E F P 5 31 to 5 36 Addition of operation for function codes of E F and following pages layout changed P 6 2 Change of applied voltage in Figure 6 1 by style S3 P 7 1 Indicator electrode changed to gold alloy electrode of Sec 7 2 by style S3 P 8 1 Indicator electrode changed to gold alloy electrode of Sec 8 3 by style S3 P 9 2 Indicator electrode changed to gold alloy electrode by style S3 P 9 9 Change of applied voltage in Table 9 3 by style S3 P 10 1 P N change of fuse 3A for spare parts P N of indicator electrode and driven shaft assembly changed by style S3 P 10 3 Indicator electrode changed to gold alloy elect
40. Routine maintenance work for keeping good operating conduction was described in Sec tion 8 Maintenance work for failures is described in this section Failure conditions are divided into the following three patterns 1 Only error messages are indicated in the operations of calibration plateau character istics collection or data setup 2 On lt failure gt detection lt FAIL gt lamp is lit and lt failure gt contact signal is sent 3 lt failure gt is not detected but normal measurement is hampered When lt failure gt is Indicated Indication of Error Message or Error Code During Operation Types of lt failure gt during operation and respective error messages error codes are listed in Table 9 1 Except for Err16 and Err17 these lt failure gt s are indicated only by error messages or error codes without accompanying lt FAIL gt light or lt failure gt contact signal Table 9 1 lt failure gt during Operation Operation Error Code Type of lt failure gt lt fallure gt Indication Reset Action Zero calibration Err21 Zero point failure Press ENT key See subsection 7 2 Err23 Response failure Press ENT key Err22 Sensitivity failure Press ENT key Span calibration Err23 Response failure Press ENT key See subsection 7 3 not Calibration input value out of Press gt key allowable range Metering pump flow rate meas ti i FOER urement Error R operationin om Press ENT key
41. Water and Adjusting Flow 1 Feed sample water with the ball valve 1 in the sample water line at the rear of the ana lyzer fully closed 1 RC400G 1 For tap water V1 see subsection 3 2 RC400G 2 For raw water V3 see subsection 3 2 RC400G 3 For treated water V3 V4 see subsection 3 2 2 Gradually open the ball valve described in 1 to feed the sample water at the predetermined rate 2 2 RC400G 1 For tap water 1 to 4 I min RC400G 2 For raw water 5 to 10 I min RC400G 3 For treated water 10 to 20 I min 5 to 10 l min for one stream Adjust valve opening so that the sample water flows out of the drain port on the side of the head tank or sand filter keeping the drain water at the level of one quarter of the drain port diameter 4 3 3 Supplying Cleaning Water This step is necessary only for an analyzer for raw water the RC400G 2 or treated water the RC400G 3 measurement Supply cleaning water at a pressure of 100 to 500 kPa to the analyzer In so doing leave the ball valve in the cleaning water line V4 for raw water V6 for treated water at the rear of the analyzer open Also keep the ball valves in the filter sand cleaning line located under the sand filter and in the glass bead cleaning line V1 V2 for raw water V1 V2 V5 for treated water fully closed after confirming that no cleaning water leaks from the solenoid valve in the closed state 4 3 4 Turning on Power First confirm that the pow
42. a measured value of residual chlorine concentration decrease below the predetermined value set using function code c in lt PROGRAM 1 gt mode the applied voltage changes for a very short time as shown in Figure 6 1 The diffusion current value change owing to this detecting voltage is checked When sample is not present in the measuring tank the diffusion current does not change When sample is present in the measuring tank and the state between the electrodes is not open the diffusion current changes presenting plateau characteristics Is Is Ip A Amplifier y Is Diffusion current V Applied voltage Time V Detecting Indicator Counter voltage electrode electrode Setting voltage Example 0 40 V 0 Time a When sample is present in the measuring tank Is Is A Amplifier Is Diffusion current 0 V Applied voltage Time V V Detecting voltage Setting Indicator Counter voltage electrode electrode 0 Time b When sample is not present in the measuring tank F6 1 ai Figure 6 1 Principle of Detecting Out of Sample in Measuring Tank The detecting voltage is applied periodically approx 10 min cycle when the measured concen tration value decreases below the predetermined value set using function code c in lt PRO GRAM 1 gt mode in lt MEAS gt mode As shown in Figure 6 2 the reverse voltage is applied after the detecting voltage is applied so that the diffusion current changing time becomes minimu
43. and Time Setting for Sand Filter One Cylinder Type Time Chart Function Content Permissible Setpoint Value Symbol Code Setting Range on Shipment T1 6 Sand filter cylinder and measuring tank 0 1 to 24 0 hours 2 0 hours cleaning cycle T2 4 Measuring tank cleaning time 0 1 to 25 0 min 1 0 min T3 7 Sand filter cylinder cleaning time 0 1 to 25 0 min 1 0 min T4 5 Relaxation time after cleaning 0 1 to 25 0 min 5 0 min If it is necessary to change the setpoint value set on shipment reset the value in the following procedure Example a Select function code 4 5 6 7 0005 0 min b Press gt key 0005 0 min Leftmost digit flashes c Selecta digit using gt key and set a numeric value using A and v keys 0005 5 min Last set digit flashes d Press ENT key to enter the value 0005 5 min Flashes once For inputs out of the permissible range not is displayed Press gt key to reset this display and reset the time A NOTE If the time for automatic zero calibration comes during cleaning the automatic zero calibration takes precedence over cleaning The cleaning process is held at the start of automatic zero cali bration and the cleaning sequence is not executed If the time for cleaning comes during auto matic zero calibration the cleaning sequence is not executed 2 Cleaning Sequence and Time Setting for Sand Filter Two Cylinder Type
44. beads P 2 12 Correct dimensions of outline drawings P 8 5 Add notice for installation P 8 12 Change the tension of cogged belt Revise up CMPL CMPL 12F04A01 01E 8th Edition CMPL 12F04A01 11E 4th Edition May 2007 2nd Edition The overall review Computerization Dec 1992 1 st Edition Newly published E If you want to have more information about Yokogawa products you can visit Yokogawa s home page at the following web site Home page http www yokogawa com an IM 12F4A1 01E 8th Edition Aug 2014
45. belt may result Tension adjustment is relatively time consuming so it is recommended that the drive belt be replaced in time with other mainte nance work such as replacement of driven shift assembly or motor assembly unless replacement is urgently needed i e if the drive belt causes abnormal operation of the electrode mechanism block For drive belt replacement refer to Items 14 and 15 in subsection 8 10 3 8 10 3 Inspection Maintenance and Replacement of Driven Shaft Assembly Inspection and Maintenance Procedure With the electrode mechanism block working at the time of for example zero calibration the fol lowing inspections should be conducted The recommended interval is three month e Check for abnormal sounds loud sound resonant sound or discontinuous sound If abnor mal sound occurs defect bearings in the driven shaft assembly are likely Other causes such as a defect in the motor are also likely Stop the operation of the electrode mecha nism block and check for friction in the driven shaft Refer to the instructions described below in biannual inspections e Check for vibration of the driven shaft and indicator electrode If vibration occurs wear of bearings in the driven shaft assembly are most likely Stop the operation of the electrode mechanism block and check for looseness between the driven shaft and the bearings Re fer to the instructions described below in biannual inspections The following in
46. dif fused lighting Each status item of output HOLD CALibration and WASHing lights flashes and flashes respectively when actuated otherwise those extinguish 9 Mode key This is used for selecting operation mode 10 Function key This is used for selecting the function code 11 Data set keys These are used when set data is to be changed or calibrating operation is performed 12 Operation command keys 1 These are used when the cell motor pump or air pump are to be turned ON OFF Every time a key is pressed the pump cell motor or air pump relevant to that key is turned ON OFF 13 Operation command keys 2 These are used when solenoid valves are to be turned ON OFF Every time a key is pressed the solenoid valve relevant to that key is turned ON OFF 1 2 3 Operation Modes and Functions Operation of the residual chlorine analyzer is determined broadly by three operation modes modes are classified into four types Measuring mode lt MEAS gt mode Maintenance mode lt MAINT gt mode Setting mode Data setting operation setting mode lt PROGRAM 1 gt mode Cleaning sequence setting Failure detecting function selection mode lt PROGRAM 2 gt mode Data display items and setting items and command items such as calibration are determined us ing Function in each mode The setting data is stored in EEPROM Thus various oper
47. electrode operates stops every time this key is pressed When the cell motor is stopped lt CELL gt lamp which has lit during running extin guishes b PUMP key metering pump ON OFF key The sample water and reagent metering pumps operate stop every time this key is pressed When the metering pumps are stopped lt PUMP gt lamp which has lit during running extin guishes c AIR PUMP key air pump ON OFF key For an analyzer which is provided with an air pump the air pump operates stops every time this key is pressed When the air pump is stopped lt AIR PUMP gt lamp which has lit during running extinguishes Even if the air pump is not provided lt AIR PUMP gt lamp lights extinguishes every time the key is pressed A NOTE If on is selected with function code d in lt PROGRAM 1 gt mode the air pump automatically operates when lt MEAS gt mode is selected even if the air pump operation is set to be stopped 5 Operation Command Keys 2 Operation of operation command keys 2 is valid in modes other than lt MEAS gt mode Operation command keys 2 include the following six keys shown in Table 5 7 These keys are for operating stopping solenoid valves for the measuring tank and the sand filter cylinder cleaning Accordingly none of these keys are used in the the RC400G 1 residual chlorine analyzer for tap water which does not incorporate cleaning functions for measuring tank and sand filter cyli
48. in lt MAINT gt mode set the mode in lt MEAS gt mode for sequence operation However even in lt MAINT gt mode cleaning operation can be manual started though operations at the function codes 4 5 and 6 see 5 3 3 3 If setting times related to cleaning are to be changed perform setting referring to subsection 5 3 5 4 3 9 Purging Air Supplying Halogen gases are strongly corrosive To protect metallic parts from corrosion owing to intrusion of halogen gases generated from sample water purge the inside of enclosures such as the elec trode mechanism block with air If an air pump is attaches press AIRPUMP key to operate this pump If on has been selected with the function code d in lt PROGRAM 1 gt mode setting lt MEAS gt mode starts pump opera tion without pressing the key for selecting the operation status A NOTE If optionally specified for air pump addition the analyzer is shipped from the factory with the set ting on If instrument air is to be used supply it by regulating the pressure to 140 kPa Tightly close the cover of the enclosure to be air purged 4 3 10 Polishing Indicator Electrode The gold alloy surface of the indicator electrode must be kept clean Polish the gold alloy surface in the following procedure 1 Confirm that the mode is lt MAINT gt and then press CELL key on the control panel to stop revolution of the indicator electrode When the elec
49. in lt MEAS gt Mode Each data in Table 5 3 is displayed by FUNC key operation Those contents are described below in the order shown 9 3 2 1 Residual Chlorine concentration display Function code 1 2 Sample water temperature display Function code 2 3 Applied voltage display Function code 3 4 Diffusion current display Function code 4 5 Display for FS of output signal Function code 5 6 Display for sample water metering pump flow rate Function code 6 7 Display for reagent meter pump flow rate Function code 7 8 Zero point error display Function code 8 9 9 Slope display Function code 9 1 Residual Chlorine Connection Display Function code 1 Function code 1 displays residual chlorine concentration of 1 00 to 12 00 mg l or ppm oly The unit is represented by mg l or ppm selected using the function code c in lt PRO GRAM 1 gt mode 2 Sample Water Temperature Display Function code 2 Function code 2 displays sample water temperature in the range of 5 0 to 55 0 C The temperature sensor used for measuring sample temperature is a Pt 1000 RTD incorporated in the counter electrode 3 Applied Voltage Display Function code 3 Function code 3 displays an applied voltage across the electrodes The applied voltage is set using function code 5 in lt PROGRAM 1 gt mode IM 12F4A1 0
50. out of the reagent tank Press PUMP key to actuate the metering pump and confirm that pump operation is normal Metering Pump Delivery Flow Rate Confirmation and Adjustment When the Bellofram or the valve sheet is replaced confirm the metering pump delivery flow rate in principle Confirm the flow rate according to the procedure described in subsection 4 3 5 and 4 3 6 If the flow rate is outside the specified range adjust the flow rate by changing the position of the stopper located in the pump driving assembly IM 12F4A1 01E 8th Edition Aug 2014 8 9 8 9 1 8 9 2 lt 8 Maintenance gt 8 6 Sample water metering pump delivery flow rate adjusting stopper Reagent metering pump delivery flow rate adjusting stopper F8 5 ai Figure 8 5 Delivery Flow Rate Adjusting Stopper 1 Press PUMP key to stop the metering pump operation 2 Shift the relevant stopper Loosen the lock nut and turn the stopper clockwise when flow rate is to be decreased and counterclockwise when flow rate is to be increased 3 Confirm the delivery flow rate and if it is not yet in the predetermined range repeat the op eration in step 2 4 When the flow rate in the predetermined range is obtained confirm that the lock nut is fully tightened and then restart operation Inspection and Maintenance of Sand Filters The inspection and maintenance of sand filters are required when the RC400G 2 or RC400G 3 residual ch
51. q 2 power source ground wire x I Ww AR1 2 Arrestors h J CB1 Circuit breaker Air pump option Power Analog output Dedicated cable AP 3 MOO K9332WJ ve Bk A2C W A2 Note Dotted lines external wiring Use cable of 6 to 12 mm OD however when connecting via power terminal box option use cable of 9 to 11 mm OD for both power and analog output cables 1 Option AZC applies to auto zero calibration 2 Option ARS applies to version with arrestor 3 Option APO applies to version with air purge pump F17 EPS Figure 3 6 RC400G 2 ARS AZC IM 12F4A1 01E 8th Edition Aug 2014 lt 3 Installation Tubing and Wiring gt RC400G 3 Residual Chlorine Analyzer for Raw Water 3 11 Solenoid valve SV2 1 2 Solenoid valve SV6 option 1 2 Solenoid valve SV1 1 2 Solenoid valve SV5 1 2 Solenoid valve SV3 1 2 Solenoid valve SV4 1 2 Converter Dedicated cable Detector CON CELL Wired by customer SBAA Fail contact output TO EG w mM T1 T1 Mainten
52. see chapter 9 Troubleshooting Key operations for displaying error codes are shown below Example a Select function code b in lt MAINT gt mode CHEC Display b On pressing ENT key an error generated is displayed Err13 Flashing If more than one error exists these error codes are displayed flashing in turn If no error exists Good is displayed c On pressing ENT key the display returns to CHEC display CHEC Table 5 15 shows the types of lt failure gt for which lt FAIL gt lamp lights and the detecting condi tions When these lt failures gt occur a contact signal is output from the external connecting terminals F1 and F2 However as shown in Table 5 15 the contact signal is output only in the determined modes IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 20 Table 5 15 Types of lt failure gt for Which lt FAIL gt Lamp Lights Mode in which Selection Error fallure gt Contents Detecting Detectable lt failure gt Con of Detect Code Conditions Mode tact Signal is ing Func Output tion stop Err11 Concentration range exceeded purer et All modes lt MEAS gt Unavailable 11 0 mg l range Err12 Sample temperature failure Fs at All modes lt MEAS gt Unavailable ele ee lt MEAS gt lt MEAS gt Available Err14 Converter failure AD croug All modes All modes Unavailable failure Err15 Converter failure
53. valve r VP40 pipe v2 Activated Ball valve Pressure reducing charcoal filter V11 12 valve 2 PR z 2 Ball valve F114 2 V1 Ball valve 2 V 3 way solenoid v4 A valve SV6 Measuring 7 7 sample inlet Tap water inlet 2 VP16 pipe VP16 pipe De 2 F m t 3 F 50 85 60 40 150 150 1 Option ARS applies to model with arrestors 2 Option AZC applies to model with auto zero calibration 3 Option APO applies to model with air purge pump F2_1E ai IM 12F4A1 01E 8th Edition Aug 2014 lt 2 Specifications gt m RC400G 2 Residual chlorine analyzer for raw water with one cylinder sand filter unit Standard solution inlet Rc1 4 female Reagent inlet Rc1 4 female Air purge inlet Rc1 4 female 4 915 holes Maintenance unit mm Maintenance for anchor bolt shate Space Approx 200 530 Approx 200 gt gt Ball valve V6 S Stand 8 ive Strainer S1 Y oh B Maintenance Front 5 20 490 20 space lt y Cross section A A Air pump 3 Converter CON Detector Sand filter CELL Solenoid F1 valve SV1 2 P terminal Ball valve Ball valve ower terminal V1 box 1 v2 V1 o 2 Metering Meas Std s
54. voltage change If the current value fails to stabilize in the predetermined time during taking plateau characteris tics the diffusion current value at the predetermined time lapse is sampled The predetermined time described above is the same as response time limit to be described in subsection 5 3 4 3 Table 5 14 shows the possible error message that may be issued when taking plateau character istics and its contents Table 5 14 Error in Taking Plateau Characteristics Error Message Error Content Reset Starting and stopping voltage failures number of steps setpoint gt ke failure and starting and stopping voltage setting width failure y 7 Plateau Characteristics Display Function code A When function code is set to A the plateau characteristic taken by function code 9 operation is displayed The plateau characteristic display contents include each step number applied volt ages at each step and the diffusion current value Key operations for displaying plateau characteristics are shown in the following a Select function code A in lt MAINT gt mode PLt_d Display b On pressing ENT key a step number is displayed gt P 00 c On pressing gt key the applied voltage at that step is displayed 00 000 V d On pressing gt key the diffusion current at that step is displayed 000 00 HA e Next by pressing gt key the display returns to the step number display
55. 014 lt 5 Converter Operation gt 5 28 Remote Local Selecting Operation a Select function code 1 ON Remote OFF Local b Every time gt key is pressed on and oF F are alternately displayed gt on lt oFF c Select on remote or oFF local OFF d Press ENT key to enter it OFF Flashes once Output Range Selection at lt local gt a Select function code 2 ___1 Range 1 pee 2 Range 2 b Every time gt key is pressed 1and 2are alternately displayed fe 2 c Select 1 outputrange l or 2 output range 2 gt 2 d Press ENT key to enter it I _ 2 Flashes once 11 Output Mode Hold No Hold Selection in maintenance Func tion code 3 In maintenance lt MAINT gt mode lt PROGRAM 1 gt mode and lt PROGRAM 2 gt mode analog output signal hold no hold is selected The setting key operation procedure is shown below a Select function code 3 ON Hold OFF No hold b Every time gt key is pressed on and oFF are alternately displayed gt on lt gt oFF c Select on hold or oFF no hold on d Press ENT key to enter it ON Flashes once The output mode set here becomes valid immediately after the setting operation If on hold is selected lt HOLD gt lamp lights during output hold Even if no hold is selected in this function if hold or preset has been selected in function
56. 060 sec 60 9 Output signal setting in the case of lt failure gt 10 to 110 00000 0 A Line segment function output setting 0 to 100 00050 50 i God i Display in ppm is b Concentration upper limit alarm setpoint setting 0 00 to 11 00 mg l 011 00 mg l 11 00 also available Setting out of sample detection starting con Display in ppm is c centration 0 00 to 5 00 mg l 000 10 mg l 0 10 also available d Setting averaging coefficient time constant 1 to 20 00001 1 E F 1 Range transfer selection Remote local on oFF OFF oFF at local Output range type 1 or 2 when local range Range 1 Range 2 1 __ 2 1 transfer is selected 2 I 3 Provision of output signal hold in lt MAINT gt Provided not pro on oFF SR lt PROGRAM 1 gt or lt PROGRAM 2 gt mode vided 4 Output signal mode when lt FAIL gt contact Hold no hold preset 1 21 2 signal is output 3 5 Automatic Zero Calibration function Execution stop on oFF oFF 5 execution stop 6 7 Sand filter single cyl 8 Selecting cleaning sequence to be used inder double cylinders 1 __ 2 1 9 Measuring tank cleaning function execution on oFF S stop Sand filter cylinder cleaning function execu tion stop on oFF on b Out of sample detecting function execution on oFF an stop Concentration display unit mg l ppm 12 2 __1 Air pump operation in lt MEAS gt mode on oFF OFF on Always operates f NE If the value is bel E Negative below zero
57. 10 Spare Parts and Consumables 10 1 Spare Parts and Consumables List boas i Recommended JIS grade 1 anhydrous sodium 3 acetate CH COONa ed JIS grade 1 potassium bro mide KBr JIS grade 1 potassium iodide KI Indicator electrode Rotating electrode Counter electrode Counter electrode Glass beads Polishing powder Alumina Brush Slip ring Drive belt Driven shaft assembly O ring Motor assembly 100 V Motor assembly 110 V Motor assembly 200 V Motor assembly 220 V Gear head 100 V 110 V Gear head 200 V 220 V Fuse 1 A Fuse 3A Sand Air pump 100 V Air pump 110 V Air pump 200 V Air pump 220 V Lubricating oil engine oil Bellofram Bellopfram Valve sheet Activated charcoal filter Filter 500 g for reagent preparation for free available 500 g for reagent preparation for total residual K9334JP Gold alloy electrode 5 EG splid Kl ined chlor ty 1 A1109EF For electric circuit A1113EF For power supply For sand filter unit liter Replacement intervals vary depending on the application 2 Reagents are not imported from Japan because of both safety and transportation cost issues Purchase them directly in your local reagent supplier 3 Atthe time of damage 4 30m for lubricating the metering pump drive assembly 5 P N changed by style S3 6 Fuse may be used more than one year we recommend periodical replace for
58. 14 Confirmation Method Confirm sample temperature display with function code 2 in lt MEAS gt Disconnect the terminals T1 and T2 of the converter and measure resistance of the wiring Temperature sensor is Pt 1000 conforming to DIN Standard Class B Check wiring connection to the counter electrode etc Figure 9 3 lt 9 Troubleshooting gt Disposition Is sample temperature display normal Is the temperature sensor resistance normal replaced Is wiring correct connection Defective temperature sensor in the counter electrode is the cause of failure Replace the electrode End Inspection Flow Chart for Concentration Failure 9 5 Other failures should be considered the indicator electrode failure etc Failure in temperature input circuit of the converter etc is the cause of failure If defective the circuit board assembly must be Repair defective part such as loose terminal F9 3 ai If cause s of the failure is are known repair defective parts and reset lt failure gt display IM 12F4A1 01E 8th Edition Aug 2014 lt 9 Troubleshooting gt 9 6 2 Error code Err12 Sample temperature failure Error code Err24 Temperature compensation range exceeded When lt failure gt of error code Err12 is detected Err24 is also detected at the same time in many cases In such case conduct insp
59. 1E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 1 0 4 Diffusion Current Display Function code 4 Function code 4 displays a diffusion current in the range of 15 00 to 65 00 pA However if the limit of output range 1 and output range 2 whichever is greater is set at 5 00 mg l ppm or lower the maximum displayed value is approx 35 pA because the current input range is set to Low approx 5 to 35 pA When the diffusion current exceeds a value corresponding to 5 00 mg l O L is displayed A NOTE For the current input range see subsection 6 1 1 5 Display for FS of Output Signal Function code 5 Function code 5 displays what percentage of the selected output range span the current residu al chlorine concentration measured value corresponds to The display range is 10 0 to 110 0 Example For output range 0 to 3 mg l Current residual chlorine concentration measured value 0 54 mg l Display for FS of output 0 54 3 0 x 100 18 0 The analog output is sent out in the range of 10 0 to 110 0 6 Display for Sample Water Metering Pump Flow Function code 6 Function code 6 displays the sample water metering pump delivery flow rate This flow rate displayed value is that computed from the result of operation conducted using function code 7 in lt MAINT gt mode see subsection 4 3 5 Hence if operation is not
60. 2F4A1 01E 8th Edition Aug 2014 8 10 5 lt 8 Maintenance gt 8 1 4 When replacing motor assembly and gear head first remove motor mounting plate from base There are no special cautions relating to removal of or reassembly of motor assembly and gear head however the parts such as electrode brushes and drive belt removed when removing motor assembly from mounting plate should be carefully reassembled referring to 8 10 1 through 8 10 3 so as not to make any mistakes in reassembly The terminal board within motor assembly should be set same position of C1 and C2 printed on the plate which wire color of C1 is yellow green and C2 is pink black Replacement of Activated Charcoal Filter Stop supplying sample water by closing the main valve 1 a A OO N O Remove the filter case by turning it in the direction shown below Clean the inside of the case with a brush or appropriate tool Replace the filter with a new one Reverse the above steps to assemble Turn on the solenoid valve SV6 to allow chlorine free water to run for at least 30 minutes Check that there is no leakage Check that the reading approximates to zero Cover fixed by pipe Turn Filter activated charcoal BIE Spacer TJ Filter Case Figure 8 8 Replacing Activated Charcoal Filter IM 12F4A1 01E 8th Edition Aug 2014 9 1 lt 9 Troubleshooting gt 9 9 1 9 1 1 Troubleshooting
61. 3 10 2 11 Brush K9332JX and Slip Ring K9332JZ rrrnrrrnvrrnvrrnvrrnvrrnvernne 10 4 10 2 12 Driven Shaft Assembly K9334JV renrronvnonvnonrnnnrnnnrrrnrrrnrrenrrenveenr 10 4 10 2 13 Drive Belt L9O804UK rrrrrnrrrnvernvernvernvernvernvernrernrernrrrnrernrernnrrnnenne 10 4 10 2 14 MotorAssembly See CMPL for Part Number ernnrnnnnrnnnnrnnnnnn 10 4 10 2 15 Gear Head See CMPL for Part Number arrnnrnrnnnrnnnrnnnrnnnrenn 10 4 10 2 16 Activated Charcoal Filter L9862AY rranrnonrnnnrnonvnenrnnnrnnnvnenreennr 10 4 10 217 Fiter K9I332NN shes aan aia aieat annan inst 10 4 Customer Maintenance Parts List rnnrnrnnnnnvrnnnnnnnvrnnnnner CMPL 12F04A01 03E Customer Maintenance Parts List rrnnnnrnnnnnvrnnnnnnnvrnnnnnnr CMPL 12F04A01 11E Revision Information s 5 cessrccacecanncscstcpeeceeseens ta eecseeseetnestes esa nnan ennnen annene i IM 12F4A1 01E 8th Edition Aug 2014 1 lt 1 Outline gt 1 1 Outline In chlorinated tap water and industrial water the chlorination effect can be determined by measuring residual chlorine contact The RC400G Residual Chlorine Analyzer is for process use and employs rotating elec trode polarography as its measuring principle It can be used for continuous measurement of residual chlorine composed of free avail able chlorine and combined available chlorine or for free available chlorine only The RC400G Residual Chlorine Analyzer includes Tap Wa
62. Approx 4 min Within 3 min from standard liquid inlet Temperature compensation error water temperature 1 Max Temperature compensation range 0 to 40 C Effect of ambient temperature 0 5 10 C Effect of power variation 0 5 10 of rated voltage Effect of combined chlorine 5 or less of concentration of combined chlorine for combined chlorine insensitive version 2 1 3 Accessories Residual chlorine meter Name Quantity Remark Polishing powder 1 bottle For polishing electrode Lubricating oil 1 For metering pump drive Fuses 4 each 1 A and 3A for spare Glass beads 1 including for spare 2 bags Valve sheet 4 For pump for spare 1 For sample pump for spare Bellofram 1 For reagent pump for spare Special tool 1 For pump valve replacement Tool 1 For Bellofram replacement Allen wrenches 1 set 1 5 2 2 5 4 5 6 mm Reagent set For startup These reagents sets are not imported from Japan because of both safety and transportation cost issues Purchase them directly in your local reagent supplier IM 12F4A1 01E 8th Edition Aug 2014 lt 2 Specifications gt Product model and suffix codes RC400G Residual chlorine analyzer Suffix code Style S3 Option re Residual chlorine analyzer Application cleaning unit 1 For pure water for municipal water with glass bead cleaning For raw water 1 cylinder with glass beads c
63. G 3 Mode Mode Cell motor ON ON ON ON Metering pump ON ON ON ON Air pump 1 ON OFF ON OFF ON OFF ON OFF SV1 FILTER 1 OFF OFF OFF OFF SV2 WASH OFF OFF OFF OFF 2 2 SV3 LINE 1 OFF ON OFF ON SV4 LINE 2 OFF ON OFF OFF SV5 FILTER 2 OFF OFF OFF OFF SV6 SAMPLE ZERO OFF OFF OFF OFF q The air pump is turned OFF only when oFF is selected with function code d in lt PROGRAM 1 gt mode 2 In lt PROGRAM 1 gt and lt PROGRAM 2 gt modes the setting data is kept in last mode before mode change IM 12F4A1 01E 8th Edition Aug 2014 7 7 1 1 2 7 2 1 lt 7 Calibration gt 7 1 Calibration Calibration should be implemented at startup or when analyzer operation is restarted after prolonged operation suspension and also periodically during operation nearly once a month This chapter describes running in operation conducted when calibration is to be ex ecuted and the calibration procedure Running in Operation Conduct running in operation in principle when calibration is to be implemented Conduct running in operation without fail when calibration is to be performed at analyzer startup or after prolonged analyzer operation suspension or for calibration when values displayed with function code 8 or 9 in lt MEAS gt mode greatly deviate from the reference values Start running in operation at polishing of the indicator electrode For the polishing procedure con
64. G in the same attitude as it will be installed the RC400G weight exceeds 60 kg For details see subsection 2 1 1 For storing the RC400G select a place where the ambient temperature is in the range of from 30 to 70 C Humidity must be of a level that does not result in dew condensation Exposure to corrosive gases or water splash must be avoided as well Media No IM 12F4A1 01E 8th Edition Aug 2014 YK IM 12F4A1 01E 8th Edition Aug 2014 All Rights Reserved Copyright 1992 Yokogawa Electric Corporation 3 Content of User s Manual This user s manual fully describes the handling of the RC400G including installation wiring operation inspection maintenance and so forth Operating principle and specifications are also shown to help in the understanding of the RC400G Residual Chlorine Analyzer To achieve full performance of this equipment the user id recommended to peruse this manual before handling the equipment This manual also introduces various peripheral equipment prepared by Yokogawa such as the RC401G Reagent Tank which is used in combination with the RC400G analyzer Note This manual does not describe any equipment or attachments that are supplied on special order A CAUTION If this manual is used during the planning stage in advance of equipment order placement please be note that the content of this manual is subject to change without prior notice for product improvement or other reasons Wh
65. Holder Bearing O Ring Nut Sleeve Nipple O Ring Cock Assembly O Ring Nut Sleeve Beads Case Cover Beads Beads Case Measuring Cell Bracket CMPL 12F04A01 03E METERING PUMP ASSEMBLY 12 11 10 M 4 5 6 7 Item PartNo Qty Description Item PartNo Qty Description 1 K9041EA 1 Cam Assembly 11 K9041JA 2 Lever Assembly 2 K9041BT 1 Gear 12 K9041JP 2 Block Assembly 3 K9041BK 1 Bracket Assembly 13 G9303AT 2 O Ring 4 K9041DA 1 Gear 14 G9303AM 2 O Ring 5 L9805GF 1 Bearing 15 K9041HC 4 Valve Sheet 6 K9041DF 1 Gear Head Assembly 16 L9819AA 1 Bellofram for Reagent Pump 7 K9041EN 1 Motor 1 L9819AB 1 Bellofram for Sample Pump K9041EQ 1 Motor 2 17 K9041FU 1 Plate for Reagent Pump 8 K9041BP 1 Bracket Assembly K9041FP 1 Plate for Sample Pump 9 K9041JU 2 Block Assembly 18 L9800EA 4 Screw for each pump 10 K9041JK 2 Lever Assembly CMPL 12F04A01 03E 1 Manufacturing date on the nameplate Feb 2004 or later 2 Manufacturing date on the nameplate Jun 1995 to Jan 2004 1st Edition Mar 2013 YK SAND FILTER e For Model RC400G 2 e For Model RC400G 3 1st Edition Mar 2013 YK
66. IL gt lamp turns on 6 1 1 Concentration Range Exceeded Err11 This is an error which occurs when sample water residual chlorine concentration has exceeded the range of 0 5 to 11 0 mg l or the current input has exceeded the predetermined range owing to a failure in the measuring circuit system or the like Current input check is conducted based on either Low or High range and it is defines that error occurs when either the range of 7 5 to 37 5 pA or 20 to 70 pA respectively Whether Low or High range is selected is automatically determined by whichever is the large value mg l of two upper limit values in output range 1 and output range 2 If the larger upper limit value is 5 00 mg l or less the current input range Low is selected while if it is more than 5 00 mg l High is selected When plateau characteristics are taken the current input value may exceed the permissible range depending on the applied voltage to be set Thus when plateau characteristics are taken error code Err11 failure detecting function is tem porarily stopped so that no lt failure gt is detected 6 1 2 Sample Temperature Failure Err12 Err24 When the sample water temperature exceeds the temperature compensation range 0 to 40 C or the temperature input signal value exceeds the permissible range corresponding to that tem perature owing to electric circuit system failure lt failure gt of error cod
67. Leftmost numeral flashes c Selecta digit using gt key set a numeric value limit value using A and gt keys L01 00 mg l Last setting digit flashes d On pressing ENT key the upper range value is displayed H05 00 mg l If change is not required start operation at step f e Change the numeric value in the same operation as shown in step b and c H03 00 mg l f On pressing ENT key setting is performed H03 00 mg l The display once flashes On repressing ENT key the step is returned to a Confirm the set value If both the upper and lower limit values are not to be changes only confirmation operation of the set values is performed Thus when operation of step f is executed the display does not flash The permissible setting range is 0 00 to 10 00 mg l for both the upper and lower limit values However span upper limit value lower limit value must be 1 00 mg l or more If a setting that does not meet the conditions is performed not is displayed Reset this display using gt key and set again Permissible span range is checked when the upper limit value is set operation procedure step f Table 5 17 shows the initial values of output range 1 and output range 2 Table 5 17 Initial Values of Output Ranges 1 and 2 Output Range Lower Limit Initial Value Upper Limit Initial Value 1 0 00 mg l 5 00 mg l 2 0 00 mg l 10 00 mg l
68. Memory com All modes All modes Unavailable parison failure Memory R W When power When power is Err16 Converter failure failure is turned DN turned ON Unavailable i Memory R W When power When power is F Err17 Converter failure failure is turned ON turned ON Unavailable Err24 Temperature compensation range Out of 0 to 40 Allmades lt MEAS gt Available exceeded C range Err25 Concentration upper limit setpoint When setpoint All mod s lt MEAS gt Available exceeded is exceeded Types of lt failure gt to be detected include those which are only displayed without lt FAIL gt lamp lighting and lt failure gt contact signal output These types of lt failure gt are shown in Table 5 16 Table 5 16 lt failure gt Accompanied by Error Message Only Error lt failure gt Contents Detecting Conditions Operation n whch the Emor Message is Detected Err21 Zero point failure Out of 1 0 to 1 0 pA range Zero calibration Less than 50 of reference Err22 Sensitivity failure sensitivity Span calibration Err23 Response failure When setpoint is exceeded Zero and span calibration Error Flow rate failure When six minutes is exceeded Measurement anime tong pump flow rate not 1 Setpoint range exceeded MENE permissible ranges Data setting operation exceeded A For permissible range for exceeding the setpoint range see Table 5 5 and others 9 lt failure gt Displ
69. NT key to enter it The automatic zero calibration mode set in this code will be valid soon after the setting When the automatic zero calibration mode is set to execution a Zero flushing function which allows chlorine free water to pass once every 24 hours under the following conditions 1 and 2 is enabled during the zero flushing the indication is held This function is pro vided to prevent corrosion of the activated charcoal filter 1 The automatic zero calibration function is enabled 2 The automatic zero calibration cycle is longer than one day Refer to subsection 7 2 2 14 Selection of Cleaning Sequence to be used Function code 8 One sand filter is used for the RC400G 2 residual chlorine analyzer for raw water and two sand filters are used for the RC400G 3 residual chlorine analyzer for treated water Hence sand filter cylinder cleaning is performed in different cleaning sequences for the RC400G 2 and for the RC400G 3 see subsection 5 3 5 In this function code the relevant cleaning sequence must be entered for either one cylinder or two cylinders depending on the specifications for the analyzer used However since it is already entered on shipment it is usually unnecessary to specifically conduct it If entry is necessary perform key operation in the following procedure a Select function code 8 1 One cylinder 2 Two cylinders b Every time gt key is pressed 1and 2are a
70. OFF Once flashes 16 Selection of Sand Filter Cylinder Cleaning Function execution stop Function code A In this function code sand filter cylinder execution stop should be set If on execution is selected sand filter cylinder cleaning is executed through the cleaning sequence selected with function code 8 For residual chlorine analyzers of the relevant specifications cleaning execution is already set in shipment Thus since normally cleaning is executed it is unnecessary to specifically set it again If it is necessary to stop sand filter cylinder cleaning function operate keys in the following proce dure a Select function code A ON Cleaning execution OFF Cleaning stop b Every time gt key is pressed on and oF F are alternately displayed gt on lt oFF c Select on execution or oFF stop OFF d Press ENT key to enter it OFF Flashes once 17 Selection of Out of sample Detecting Function execution stop Function code b If open status occurs between the electrodes without supply of sample water in the measuring tank the diffusion current is stable even if the applied voltage is changed This analyzer has an out of sample detecting function utilizing the above fact for details see subsection 6 1 3 The out of sample detecting function operates only in lt MEAS gt mode and if out of sample is detected lt FAIL gt lamp lights a
71. OGRAM 1 gt mode is automatically updated Since the RC400G residual chlorine analyzer is calibrated for span using the amperometric titra tion in the factory the reference sensitivity on shipment is also set to 2 62 uA mg at 20 C based on amperometric titration When a problem occurs for example the error message Err22 display appears in the case of measuring residual chlorine concentration in a standard solution using a manual analysis other than amperometric titration once execute span calibration accompanied by this reference sensi tivity updating A NOTE Manual setting of reference sensitivity such as modification of updated sensitivity should be performed using function code 4 in lt PROGRAM 1 gt mode See subsection 5 3 4 Key operation procedure is as follows Example a Select function code d in lt MAINT gt mode CAL b Press ENT key 000 46 mg l Subsequent procedure is the same as operations b in 2 Span Calibration IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 1 4 4 Manual Start of Measuring Tank Cleaning and Sand Filter Cylinder Cleaning Function codes 4 5 and 6 By specifying a predetermined function code and pressing ENT key cleaning of the measuring tank and sand filter cylinder s can be executed A WARNING Electric Shock Hazard Even if the cleaning system tubing is not provided manual cleaning sta
72. RAM 1 indicated PROGRAM 2 CD MEAS TD MAINT F5 12 ai Figure 5 12 Residual Chlorine Concentration Unit Indication 19 Selection of Air Pump Action Function execution stop Function code d An air pump for air purge is added only wheni it is specified The air pump action function is that which always places the air pump in operating status in lt MEAS gt mode Hence if on execution is set with this function code the air pump automatically enters the operating status even if the mode is transferred to lt MEAS gt mode with the air pump action stopped If the air pump is added it has been set at on on shipment Thus it is unnecessary to specifically set it If it is to be changed to oFF stop set it again by the following key operation a Select function code d ON Execution OFF Stop b Every time gt key is pressed on and oF F are alternately displayed gt on lt oFF c Select on execution or oFF stop OFF d Press ENT key to enter it OFF Flashes once OFF Cleaning stop b Every time gt key is pressed on and oF F are alternately displayed c Select on execution or oFF stop d Press ENT key to enter it on OFF oFF OFF Flashes once IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 32 20 Selection of negative below zero display in lt MEAS gt mode A 21 5 3 5 Fu
73. See subsections 4 3 5 and 4 3 6 P Plateau characteristics collection Voltage etc input value out of See subsection 5 3 3 6 not allowable range not enterable Pines er key Data setup in EROS ay Obs Input value out of allowable mode not range not enterable presse See subsections 5 3 4 and 5 3 5 Power ON operation Err16 note 1 Memory lt RAM gt failure Not possible P Err17 note 1 Memory EEPROM failure Not possible Note 1 Described in subsection 9 1 2 7 When lt failure gt has occurred during operation treat as follows depending on the error message or error code indicated 1 Error message not The value input exceeds allowable setup range Re setup Note Refer to Tables 5 5 and 5 6 for allowable setup range 2 Error message Error lt On metering pump flow rate measurement operation gt When 360 seconds has passed after starting flow rate measurement time measurement by pushing ENT key the error message appears unless the ENT key is re pressed within 360 sec If the metering pump fails to deliver a specified volume in 360 seconds proceed with the inspection flow given below IM 12F4A1 01E 8th Edition Aug 2014 lt 9 Troubleshooting gt 9 2 Confirmation Method Disposition Check lt PUMP gt lamp is lit 777777777 Turn on the pump by pressing PUMP key lt PUMP gt lamp is lit Check with a tester that setup voltage is imposed between the connecting term
74. T contact Activate when analyzer is in maintenance mode Main power OFF Main power ON Not operating Operating FAIL contact Open Closed Open MAINT contact Closed Open Closed IM 12F4A1 01E 8th Edition Aug 2014 Sample conditions Temperature pH Flow Pressure Electrodes Indicator electrode Counter electrode Reagents Composition 0 to 50 C pH 3to9 lt 2 Specifications gt 1 to 4 l min for pure water or municipal water application 5 to 10 l min for raw water or sea water application 10 to 20 l min for secondary sewage treatment application 20 to 500 kPa Rotating gold alloy electrode Platinum electrode built in Pt1000 RTD the combined chlorine insensitive version uses a silver chlorine electrode The following reagents are dissolved in pure water to give 100 of solution Note Pure water should be equal to or exceed level of tap water and should not contain oxidizing and reducing substances such as chlorine For residual chlorine For free chlorine For combined chlorine extra pure measurement measurement measurement Puss Up to 6 mg l Over 6 up to 10 mg l Up to 10 mg l Up to 10 mg l EM ee 1000 g z 7 ae fe 4000 g 4000 g seg 150 g 1000 g 5400 g Glacial acetic acid 4000 ml EE aa Consumption 1 5 ml min 10 Constant flow pump Sample flow Reagent flow Converter functions 50 ml min 10 1 5 ml min 10 D
75. Table 9 2 Types and Error Codes of lt failure gt which are followed by lt FAIL gt Lamp Lighting Error Code Type of lt failure gt Resetting lt failure gt Display Err11 Concentration range exceeded Err12 Sample temperature failure Err13 Out of sample in the measuring tank Err14 Converter failure AD circuit failure dine kjede A Err15 Converter failure Memory comparison failure 1 2 Err24 Temperature compensation range exceeded Err25 Concentration upper limit setpoint exceeded A Once turn OFF and then ON power for reseting error display 1 Error code Err11 Concentration range exceeded Error code Err25 Concentra tion upper limit setpoint exceeded Reset error once using the operation of subsection 5 3 3 9 If lt FAIL gt lamp lights again after resetting the error perform the following inspection How ever on simultaneous occurrence of Err11 and Err14 conduct the inspection Err14 a Calibration of zero point or span may have been performed incorrectly Perform calibration again After calibration operate resetting of lt failure gt display b If lt FAIL gt lamp lights even after operation a above failure of the temperature sensor built in the counter electrode is considered to be the cause of the abnormally temperature is not compensated correctly Conduct inspection following the inspection flow shown in Figure 9 3 IM 12F4A1 01E 8th Edition Aug 20
76. UMP SV1 SV2 SV3 SV4 SV5 SV6 OD MEAS MAINT CD PROGRAM 1 PROGRAM 2 8 Status display 2 Function code display 9 Mode key 11 Data set keys MANUAL OPERATION a PUMP 12 Operation command keys 1 13 Operation command keys 2 10 Function key F5 1 ai Figure 5 1 Control Panel IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 2 Table 5 1 Operation Key Display Names and Functions 1 Name Data display indicated by red LEDs Function Measured values setting data message etc are displayed 2 Function code display indicated in red A selected function code is displayed 3 Mode display indicated in green lamp lights A operation mode is displayed A lamp relevant to the current mode is lit 4 Unit display indicated in green diffused lighting One of data units is displayed A unit for the data displayed in the data display is lit 5 lt Fail gt display indicated in red diffused lighting This is lit when the processor fails or a failure is detected 6 Operation display 1 indicated in green diffused lighting This goes ON OFF corresponding to turning ON OFF of the cell motor pumps and air pump 7 Operation display 2 indicated in green diffused lighting This goes ON OFF corresponding to turning ON OFF of solenoid valves 8 Status display indicated in green
77. User s EXA RC Manual Model RC400G Residual Chlorine Analyzer Style S3 IM 12F4A1 01E vigilantp ant YOKOGAM 9 IM 12F4A1 01E Yokogawa Electric Corporation Ge Introduction The RC400G Residual Chlorine Analyzer is a process analyzer for continuous measurement of free chlorine concentration and residual chlorine contained in chlorine treated water 1 Confirmation of Specifications The RC400G comprises Tap Water type RC400G 1 Raw Water type RC400G 2 and Treated Water type RC400G 3 When the RC400G has been delivered to your location carefully unpack and check the equip ment for any transportation damage and ensure that the equipment is of the correct specifica tions as ordered Confirm this by the model code indicated on the nameplate or the package tag referring to Chapter 2 of this manual Ay NOTE 1 Unpack the equipment at a location close to its installation site 2 Locate on power to read to version number of ROM loaded on the equipment Then follow the procedures as instructed in item 10 of subsection 5 3 3 after completion of the installa tion work such as wiring 2 Caution for Transfer and Storage Observe the following notices so as not to damage the RC400G on transfer and storage When transferring the RC400G to its installation site or elsewhere prevent the equipment from receiving strong impact and exercise care to minimize the vibration received CAUTION Carry the RC400
78. a well drained concrete foundation or the equivalent A NOTE Refer to the external dimension figures in Chapter 2 for the position of anchor bolting etc When using RC401G A Reagent Tank for supplying reagent to the analyzer install the tank in such a manner that its bottom is positioned about 70 cm above the floor surface where the ana lyzer is installed 3 2 Tubing Tubing for the analyzer include the following 1 Sample water tubing see subsection 3 2 1 2 Reagent tubing see subsection 3 2 2 3 Washing water tubing for raw or treated water type analyzers see subsection 3 2 3 4 Drain tubing see subsection 3 2 4 5 Purge air tubing when the analyzer is not provided with air pump see subsection 3 2 5 6 Standard solution tubing for calibration see subsection 3 2 6 7 Automatic zero calibration tubing see subsection 3 2 7 IM 12F4A1 01E 8th Edition Aug 2014 lt 3 Installation Tubing and Wiring gt 3 2 Tubing connections and flow charts for the RC400G 1 RC400G 2 and RC400G 3 are illus trated in Figure 3 1 1 to 3 1 3 Figure 3 2 1 to 3 2 3 and Figure 3 3 1 to 3 3 3 respectively 1 RC400G 1 Residual Chlorine Analyzer for Tap Water a H Drain i VP40 pipe Standard solution inlet For air purge inlet Reagent inlet Measuring sample inlet LLH VP16 pipe i
79. absorbed by the sand If the sand has absorbed manganese or iron to such an extent that the entire sand is discolored replace it with new sand by following the procedure below Sand Replacement Procedure see Figure 8 6 1 Close the sample water valve s and cleaning water valve to stop supplying sample water and cleaning water RC400G 2 Sample water valve V3 cleaning water valve V4 RC400G 3 Sample water valves V3 and V4 cleaning water valve V6 2 Remove the top cover on the sand filter and remove the sand from the sand filter by hand or using a container It is not necessarily to remove the sand completely 3 Ifthe inner wall of the filter cylinder has been stained turned black by manganese or umber by iron clean it with dilute hydrochloric acid or appropriate cleaner 4 Replenish the filter cylinder with new sand to scale marking lt 10 gt 5 Reinstall the top cover on the sand filter open the sample water valve s and cleaning water valve to start supplying sample water and cleaning water Filter Replacement Afilter is installed at the bottom of the sand filter to prevent the sand from falling off see Figure 8 6 When the filter is clogged and the specified flow rate cannot be achieved replace the filter by following the procedure below Filter Replacement Procedure see Figure 8 6 1 Close the sample water valve s and cleaning water valve to stop supplying sample water and cleaning water RC400G 2 Sam
80. alfunctioning of the solenoid valve is observed e g ir regular cleaning of the measuring tank sand filter cylinder or evidence of cleaning water mixing into sample water check the operation of each solenoid valve in lt MAINT gt mode Perform operation checking by operating each one of each Operation command keys 2 corre sponding to each solenoid valve When a solenoid valve does not work at all check with a multimeter if the supply voltage for operating the solenoid valve is applied to the connecting terminals when the operation command is sent If the voltage is applied by operation command the cause of malfunctioning is on the solenoid valve side Replace the solenoid valve after checking that wiring connection is not the cause of the failure Replace the solenoid valve also when cleaning water enters the measuring tank or the sand filter even the solenoid valve is not working The cycle of automatic zero calibration may coincide with that of cleaning If so automatic zero calibration will take precedence Change either cycle 9 3 3 Remote Range Switching does not Work This failure occurs when output range switching is performed in Remote position When the range is not switchable by the range switching command check if the command signal resistance of input contact meets requirements Refer to subsection 3 3 3 IM 12F4A1 01E 8th Edition Aug 2014 10 1 lt 10 Spare Parts and Consumables gt
81. alyzer with automatic zero calibration performs zero calibration using an activated charcoal filter In the automatic zero calibration the solenoid valve SV6 is opened and closed by a sequence signal from the converter Operating Principle of RC400G Residual Chlorine Analyzer The measuring object of the RC400G residual Chlorine Analyzer is either free available chlorine or combined available chlorine Free available chlorine exists in the forms of chlorine Cl2 hypochlorous acid HCIO or hy pochlorite ion CIO in water Combined available chlorine exists in the from of chloramines such as trichloramine NCl3 and dichloramine NHCl2 generated through reactions of chlorine with ammonia nitrogen from contaminants in polluted rivers and other sources The residual chlorine analyzer operates on the principle of rotating electrode polarography Measurement of free available chlorine content or total residual chlorine content including free and combined available chlorine contents can be performed by adequate selection of reagent electrode and applied voltage For measurement of total residual chlorine reaction of chlorine with sample water added with potassium iodide KI is implemented Since KI is dissociated into K and I in aqueous solution the iodine equivalent to the amount of residual chlorine is liberated as shown in equations 1 2 3 and 4 Free available chlorine Clo 2h elo 2Cl aisiiiieesestngsteediienee 1 NH2CI m
82. analytical method other than amperometric titra tion it is unnecessary to change the reference sensitivity Next the key operation procedure for setting the reference sensitivity is described a Select function code 4 002 62 pA b Select gt key and set a numeric value using A and v keys 002 02 pA c On pressing ENT key setting is fixed 002 00 pA Entire display flashes once When span is calibrated after resetting the reference sensitivity the slope value displayed by function code 9 in lt MEAS gt mode is updated to a value calculated based on the newly set reference sensitivity When span calibration is executed using function code d in lt MAINT gt mode the reference sensitivity is automatically updated If the reference sensitivity to be set is unclear it is convenient to use this function 3 Applied Voltage Setting Function code 5 This function sets a voltage to be applied across the electrodes The key operation procedure for setting is as follows 00 40 V 00 40 V Negative sign flashes I a Select function code 5 b Press gt key c Select the digit using gt key and set a numeric value using A and v keys 00 50 V Last setting digit flashes d Press ENT key to enter it 00 50 V Entire display once flashes The permissible applied voltage setting range is 1 50 to 1 50 V Since not is displayed fo
83. ance contact output mz2 nog l Lt r ae G L_ Terminal Range switching output ies ae Rel ci Rd op screw aeai gt O RI coop Sh Remote range switching input C 2 i Pum Power terminal box 2 ae Dedicated cable PU PP ord K9332WB ER Bk P2 7 P2 e G oH LOG AR2x2 Dedicated cable _t f R K9332WL LT OG J2 a ER L2 w Ag L1 ED O 12 Ca Dedicated cable TTS K9460CN CB1 sl V1 G L2 v Bk 2 L1 w HAR t Dedicated cable Terminal box 2 o oa K9832WK 5 Dedicated cable Sy i 1 K9332WH l k B2 foal gt J Power Analog output B3 3 B4 4 Dedicated cable a i K9332WG Case ground terminal must be Bk grounded 5 If this is not possible connect to S1 5 w power source ground wire S2 AR1 2 Arrestors R Greni Dedicated cable CB1 Circuit breaker K9332WE 3 8 Bk 84 J U Ww Dedicated cable K9332WF Air pump option Bk Dedicated cable AP 3 W K9332WJ A1 A1 Bk A20 7 0 A2 Note Dotted lines external wiring Use cable of 6 to 12 mm OD however when connecting via Figure 3 7 RC400G 3 ARS AZC power terminal box option use cable of 9 to 11 mm OD for both power and analog output cables 1 Option AZC applies to auto zero calibration 2 Option ARS applies to version with arrestor 3 Option APL applies to version with air purge pump IM 12F4A1 01E F18 EPS 8th Edition Aug 2014 lt 3 Installation Tubing and Wiring gt 3 1 2
84. ations are performed by specifying a mode and a function code Table 5 2 briefly shows each mode and function codes in that mode For specific contents of each function code see subsections 5 2 1 to 5 2 4 IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt Table 5 2 Outline of Modes and Function Codes Func Mode tion Description Code A mode for actual operation Residual chlorine concentration is measured By specifying a function code using FUNC key residual chlorine concentration MEAS 1to9 liquid temperature applied voltage diffusion current etc can be displayed If execution of cleaning function is selected sequence operation is performed for RC400G 2 or RC400G 3 This is the mode in which maintenance is performed and calibration or taking pla MAINT 1toF teau characteristics can be done execution items are selected using FUNC key e Operations using data set keys or operation command keys are available Data setting can be performed such as output range setting or applied voltage 1toF setting setting items are selected using FUNC key e Operations using data set keys or operation command keys are available PROGRAM 1 e Operating functions can be selected such as range selection remote local or 1 to F cleaning function execution stop setting items are selected using FUNC key e Operations using data set keys or operation command keys are available
85. ay Contact Output Resetting Function code c Once detected lt failure gt s shown in Table 5 15 are not automatically reset even if the cause is removed When failed parts are returned to normal reset lt FAIL gt lamp lighting and lt failure gt contact signal output through the following operations a b Press ENT key Select function code c in lt MAINT gt mode CL Er Display flashes once e lt FAIL gt lamp extinguishes When the lt failure gt contact signal is output this output is turned OFF If lt FAIL gt lamp again lights after an error is reset it indicates that the failed part is not yet re stored Take countermeasures again referring to the chapter 9 on troubleshooting IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 21 10 Version Number Display Select function code E in lt MAINT gt mode then the converter incorporated ROM version number is displayed 11 Entry of Password for Transferring to Service Mode Function code F Function codes 1 to F in lt MAINT gt mode are provided as function codes in service mode used when YOKOGAWA performs servicing These function codes can be selected by entering the password 77 in function code F However request servicing by YOKOGAWA as a rule if operations are required in service mode 5 3 4 Key Operations in lt PROGRAM 1 gt Mode In lt PROGRAM 1 gt mode se
86. bration is performed at that instant When indication is stable the sensitivity is examined and if it is out of permissible range the fol lowing message is displayed Err22 sensitivity failure in calibration If indication is not stabilized within the predetermined time the following message is displayed Err23 response failure in calibration In either case only the message is displayed and no lighting of lt FAIL gt lamp and no output of lt FAIL gt contact signal occur The error message display is reset by pressing ENT key returning to the residual chlorine con centration display The criteria for setpoint failure response failure and sensitivity failure are as shown in Table 5 9 IM 12F4A1 01E 8th Edition Aug 2014 5 13 lt 5 Converter Operation gt Table 5 9 Failures in Span Calibration and Their Criteria Failure Criteria Setpoint failure Setpoint exceeding the range of 0 00 to 10 00 mg l ppm fixed Stabilizing time exceeding the setpoint set using function code 6 in lt PROGRAM 1 gt mode Set at 7 min on shipment Ration to the reference sensitivity decreasing below 50 fixed Response failure Sensitivity failure In any stage of span calibrating operation transferring to other modes or function codes is available by pressing MODE key or FUNC key However unless calibration is completed the calibrating operation conducted before becomes invalid Table
87. burette further declines again press ENT key when the water level lowers by 4 5 ml from the reference graduation After the above operation is performed the converter computes taking the number of sec onds counted as the time per pump delivery of 4 5 ml and indicates flow rate in the data dis play If the flow rate is 1 5 0 15 ml min the reagent metering pump delivery flow is normal If incorrect make adjustment by changing the stopper position in the pump driving assembly see section 8 8 Press PUMP key and once stop the metering pump Remove the tube connected to the reagent metering pump suction tubing joint and restore the tubing Open the ball valve in the reagent flow line Also press PUMP key to operate the metering pump Confirming Indicator Electrode Operation Remove the electrode mechanism block cover and confirm that the cell motor is rotating Also confirm that there is no fluttering or eccentric deflection in the indicator electrode revolution If the cell motor is in operating status lt CELL gt lamp is lit 4 3 8 Confirming Cleaning Solenoid Valve Operation and Adjusting Ball Valve Opening There are performed only for the residual chlorine analyzer RC400G 2 or RC400G 3 for raw water or treated water Perform solenoid valve operation confirmation and ball valve opening adjustment in the following procedure 1 Adjust the flow rate of cleaning water entering the sand filter First press SV1
88. cator Electrode Operation ussrranrrnnrnnnrrnnrnrnrernreenn 4 8 4 3 8 Confirming Cleaning Solenoid Valve Operation and Adjusting Ball Valve OPENING 325i Sie Aol E eid Ann anal ene 4 8 4 3 9 Purging Air SUPPIYING ceeeeceeeeeeeeeeeeeeeeeeeeteeeeeeeseeeseneseaeseaeeeaeeaes 4 9 4 3 10 Polishing Indicator Electrode rernvnrnvnnnvnnnvvnnvvnnvnnsvnnrvensvnnsvensrennnenn 4 9 4 3 11 Filling the Zero Filter Case and Running in Operation 4 10 4 3 12 Output Range Setting ce eeceeeseeeseeeeeeeeeeesneesneesieesieesieesieesieesieees 4 11 4 3 13 Calibration ngunanutuigdruudegatnuigubnudagulnuairt 4 11 4 4 OperatlonusrsaancvquaqaaqqumJmruasaasameauanmenennmannuin 4 11 Converter Operation usvsumesnagtme nine mejniinueivdne 5 1 5 1 Component Identification and Functions on the Control Panel 5 1 5 2 Operation Modes and FunctionsS rrxwrnnnnvnnnnvnnnnvnnnnnnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnn 5 2 5 2 1 Function Codes and Their Description in lt MEAS gt Mode 5 3 5 2 2 Function Codes and Their Description in lt MAINT gt Mode 5 4 5 2 3 Function Codes and Their Description in lt PROGRAM 1 gt Mode 5 4 5 2 4 Function Codes and Their Description in lt PROGRAM 2 gt Mode 5 6 5 3 Key Operaatiot sssi 5 7 5 3 1 Operation Key Types and Functions 0 0 cc eeeeeeeneeeeeeeeeeeeeeeeeeneees 5 7 5 3 2 Key Operation in lt MEAS gt Mode srnnnvnnn
89. ce between the slip ring and the brush and furthermore in crease the contact pressure of the brush to the slip ring surface 1 Polishing and cleaning the surface of the slip ring With the RC400G being powered press sandpaper 2000 on the rotating slip ring Then press a cotton swab soaked in alcohol on the rotating slip ring to wipe off debris 2 Increasing the brush contact pressure Turn off power to the RC400G Loosen the lock screw next to the contact pressure adjusting screw and then the 2 fixing screws for the brush mounting bracket Turn the contact pres sure adjusting screw in 1 2 turn Tighten the lock screws and bracket fixing screws Make sure that the brush does not come in contact with the pulleys and does not come off the slip ring Then turn on the power 10 2 12 Driven Shaft Assembly K9334JV The two bearings in the driven shaft assembly are used to rotate the rotary shaft smoothly The bearings will be worn gradually and so should be replaced after approximately 3 year operation The replacement in principle should be conducted by Yokogawa Note It is recommended that the O ring P N Y9115XB in the electrode holder in the driven shaft assembly should also be replaced at the same time 10 2 13 Drive Belt L9804UK The drive belt will be worn or deteriorated gradually It should be replaced after approximately 3 year operation 10 2 14 Motor Assembly See CMPL for Part Number The rotor in the motor asse
90. ck if the solenoid valves function by operating SV3 and SV4 keys in lt MEAS gt mode If the valves do not operate check the voltage between the solenoid valve SV3 connecting terminals V1 and V2 or between V3 and V4 of the valve SV4 with a mul timeter if power is applied in the ON state If no power is applied in the ON state there is a failure in electric circuits in the converter such as a defective relay If the voltage is applied the solenoid valve s is are defective After repairing defective parts reset lt failure gt display Refer to subsection 5 3 3 9 Confirm the supply of sample water into the measuring tank and then the mode to lt MEAS gt 4 Error code Err14 Converter failure When lt failure gt of error code Err14 is displayed once reset lt failure gt display and confirm that lt failure gt display appears again IM 12F4A1 01E 8th Edition Aug 2014 lt 9 Troubleshooting gt 9 7 This lt failure gt detection is carried out in a slightly longer frequency Wait about 2 minutes to confirm the recurrence of lt failure gt If lt failure gt is displayed again perform the inspection following the flow chart of Figure 9 5 Is current display O L Is temperature display O L Failure in temperature input circuit Is temperature display O L Failure in AD conveter circuit Malfunctioning due to noise etc Fail
91. ck open e g polish of indicator electrode to check the condition The recommended interval is three month Check for the presence of drive belt shavings on the motor mounting plate and the vicinity If the materials have been deteriorated or if misalignment between the pulley and the drive belt has occurred more drive belt shavings will be produced Rotate the driven pulley clockwise and counterclockwise by hand Check that rotation is transmitted to the drive shaft by small play If the drive belt has lost tension large play is needed for the rotation of the drive shaft The following inspections and maintenance should be performed approximately every six months IM 12F4A1 01E 8th Edition Aug 2014 lt 8 Maintenance gt 8 1 1 e Check the drive belt for cracks due to material deterioration If significant cracks are found replacement is recommended e Check the drive belt tooth profile for abnormal trace significant wear peeling etc If abnor mal trace is found replacement is recommended e Check the pulleys of the drive shaft and driven shaft for drive belt shavings deposits If there are deposits that may interfere with the pulley operation remove and clean them Also clear away drive belt shavings fallen on the motor mounting plate and the vicinity Replacement Procedure After drive belt replacement the tension should be adjusted Without tension adjustment nega tive effects such as shorter life of the drive
92. cleaning Water jet cleaning flow 2 to 3 I min Filter sand for municipal water high speed filtering sand approx 550 ml per tube approx 500 ml min per cylinder Backwash water flow 8 to 9 l min per cylinder Standard cleaning sequence factory settings 1 cylinder system 2 cylinder system Setting range Sand filter backwash interval 2 hours 30 min 0 1 to 24 h 0 1 h steps Sand filter backwash time 1 min 1 min 0 1 to 25 min 0 1 min steps Flow cell jet cleaning interval 2 hours 1 hour 0 1 to 24 h 0 1 h steps Flow cell jet cleaning time 1 min 1 min 0 1 to 25 min 0 1 min steps Waiting time 5 min 3 min 0 1 to 25 min 0 1 min steps Output hold time 6 min 4 min Jet cleaning time waiting time In a 1 cylinder system sand filter backwash and flow cell jet cleaning are performed at the same time Finish Operating conditions Wetted part materials Measurement tank Pump Tubing piping Stand materials Paint colors Mounting stand Other parts Acrylic resin Fluorinated rubber Viton hardened PVC SUS316 Polyethylene hardened PVC Carbon steel or stainless steel Munsell 0 6GY3 1 2 0 Munsell 0 6GY3 1 2 0 and 2 5Y8 4 1 2 Baked polyurethane resin coating Ambient temperature 5 to 55 C However measure to prevent freezing are required if Ambient humidity Storage temperature Installation Utilities Power supply Power consumption RC400G 101 RC400G 2
93. code 4 in the lt PROGRAM 1 gt mode Output Signal Mode Selection in lt failure gt the latter dominates 12 Output Signal Mode Selection in lt failure gt Function code 4 This function can set analog output signal mode when lt FAIL gt lamp lights as a result of failure occurrence in any of the output modes hold no hold or preset The output mode set here is applied when lt failure gt contact signal is output The output mode selection key operation procedure is shown below a Select function code 4 __ 1 Hold _ 2 Nohold 3 Preset b Every time gt key is pressed 1 2 or 3 is repeatedly displayed in this order Pu NR Ge c Select 1 hold __ 2 no hold 3 preset gt 3 d Press ENT key to enter it __ 3 Flashes once When preset is selected the output value set in function code 9 becomes valid If hold or preset is selected in this function these dominate the output mode set in function code 3 IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 29 13 Selection of Automatic Zero Calibration Function execution stop Function code 5 Whether automatic zero calibration is performed or not can be selected The setting procedure is shown below a Select function code 5 b Each time gt key is pressed on and oF F are alternately displayed c Select on execution or oFF stop d Press E
94. conducted even once 0 00 ml min is displayed 7 Display for Reagent Metering Pump Flow Function code 7 Function code 7 displays the reagent metering pump delivery flow rate This flow rate displayed value is that computed from the result of operation conducted using function code 8 in lt MAINT gt mode see subsection 4 3 6 Hence if operation is not conducted even once 0 00 ml min is displayed 8 Zero Point Error Display Function code 8 Function code 8 displays the diffusion current uA obtained in the latest zero calibration Since the zero point reference diffusion current is 0 pA this value shows the zero point error If the diffusion current in zero calibration exceeds the range of 1 0 to 1 0 HA an error message of Err21 is issued 9 Slope Display Function code 9 Function code 9 displays the sensitivity in obtained in the latest span calibration to the refer ence sensitivity If the sensitivity decreases below 50 of the reference sensitivity in span calibration an error message of Err22 is issued IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 1 1 A NOTE The reference sensitivity which has been set on shipment is the value 2 62 uA mg l at 20 C based on the amperometric titration 5 3 3 Key Operation in lt MAINT gt Mode This subsection describes key operations to be conducted by specifying function codes in lt
95. converter supplies contact signals of either lt failure gt lt maintenance gt or lt range gt for which contact output wiring is provided For the wiring use a cable or 6 to 12 mm finished O D select a two three or four conductor cable depending on the number of contract outputs used Treat the cable end to be connected to the converter terminals in the same manner as the analog output signal cable see subsection 3 3 2 Connect each conductor of the cable to terminals F1 F2 contact output lt failure gt M1 M2 con tact output lt maintenance gt and 01 02 lt range gt switching contact respectively Contact capacity of the contact output relay is given in Table 3 2 Equipment to be connected must meet the condition shown by the table Table 3 2 Contact Capacity of Contact Output Relay with DC with AC Contact maximum allowable voltage 220 V 250 V Contact maximum allowable current 2A 2A Contact maximum allowable power 60 W 125 VA IM 12F4A1 01E 8th Edition Aug 2014 8th Edition Aug 2014 lt 4 Operation gt 4 1 4 Operation This chapter chiefly describes preparation procedures for stable analyzer operation 4 1 Component Identification and Function lt RC400G 1 gt Converter CON Detector Air pump 3 AP CELL Power terminal box 1 Meas Std solution switching valve v2 Activated charcoal filter F11
96. d bromine is liberated by reacting with chlorine as seen in equation 5 Ch OBE gt BA DCN sene snde 5 Except for the liberation of bromine the measurement of free available chlorine is the same as the measurement of total residual chlorine Figure 1 4 illustrates the principle of the RC400G Residual Chlorine Analyzer The current flowing between the indicator ME and the counter RE electrodes is measured when a specific voltage is applied across the electrodes Temperature compensation is implemented through CPU computation based on temperature signals from the temperature measuring circuit Is Amplifier Current NE voltage LED conversion indicator circuit Voltage Current O O application voltage 4 to 20 mA DC RE circuit output od or 1 to 5 V DC circuit emperature measuring circuit Counter electrode Indicator electrode Measuring tank F1 4 ai Figure 1 4 Schematic Diagram of Measuring Circuit IM 12F4A1 01E 8th Edition Aug 2014 lt 2 Specifications gt 2 1 2 Specifications In this chapter specifications are given for the RC400G Residual Chlorine Analyzer the RC401G Reagent Tank and others 2 1 RC400G Residual Chlorine Analyzer 2 1 1 Standard specifications Residual chlorine analyzer Measurement object Free chlorine or residual chlorine total chlorine in water Measurement method Rotating electrode type polarographic system Measurement rang
97. d charcoal filter in a suitable vessel Also prepare a tube O D 6 mm x I D 4 mm for supplying this chlorine water to the residual chlorine analyzer Set the vessel containing chlorine free water so that the water level satisfies the conditions shown in Figure 7 1 Chlorine free water Maximum level 35 cm or less Reagent metering pump center position cm Residual chlorine analyzer installation surface Frid Figure 7 1 Chlorine Free Water Level Connect one end of the tube for supplying chlorine free water to the residual chlorine ana lyzer standard solution tubing connecting port Rc1 4 screw Immerse the opposite end of the tube in chlorine free water Transfer the sample water standard solution selector valve to the standard solution posi tion and feed the detector with chlorine free water The measured value normally stabilizes in approx 5 to 10 min Confirm that the mode is lt MAINT gt and set the function code to 1 The content of this code is zero calibration Start calibrating operation Press ENT key During calibrating operation lt CAL gt lamp flashes Calibration is performed when the ana lyzer stabilizes to that predetermined conditions are met after measured value stability is automatically checked When calibration is executed the value displayed in the data display flashes once and at the same time flashing lt CAL gt lamp
98. d to let chlorine free water flow and the analyzer waits a preset calibration preparation time When the analyzer reads a value approximate to zero and confirms that the reading has stabilized it performs zero cali bration The analyzer checks the stability using the same criteria of manual calibration After the calibration is completed the solenoid valve SV6 is de energized to let sample water flow and the analyzer waits a preset relaxation time the time required for zero water to be replaced with sam ple water The held analog output is released and lt HOLD gt and lt CAL gt lamps turn off A NOTE 1 The automatic calibration will be aborted if the mode is changed to the one other than the lt MEAS gt mode during the calibration Upon abort the held analog output is released and lt HOLD gt and lt CAL gt lamps turn off The calibration cycle timer is reset 2 The FUNC key is valid even during automatic calibration FUNC key does not affect the automatic zero calibration sequence 3 The calibration cycle timer will start at Zero when e the automatic zero calibration is set to on upon startup e the setting of automatic zero calibration is changed to on e the automatic calibration cycle is changed only when automatic zero calibration is enabled 4 The timer continues to count regardless of operation mode 5 Automatic zero calibration is executed only when the analyzer is in lt MEAS gt mode If the t
99. d to the metering pump If the pressure of the supplied standard solution largely exceeds 10 kPa standard solution may enter the reagent line or some quantity of solution more than specified may be sent to the detector causing the measuring cell to overflow As a rule standard solution should be supplied only in the manner described in Chapter 7 3 2 7 Automatic Zero Calibration Tubing This is the tubing that is used when zero calibration using an activated charcoal filter is per formed If the option has been specified this tubing is installed at the factory before shipment IM 12F4A1 01E 8th Edition Aug 2014 lt 3 Installation Tubing and Wiring gt 3 8 3 3 Wiring The type of wiring required by the residual chlorine analyzer are as shown below All are con nected to wiring terminals M4 screw in the converter When the analyzer with arrestors connect terminals of power and analog output to the terminal box 1 Wiring for power supply and grounding 2 Wiring for analog output signals 3 Wiring for contact input lt remote gt range switching 4 Wiring for contact output lt maintenance gt lt failure gt when required Analyzer converter Receiver lt maintenance gt contact lt failure gt contact output Grounding Power supply Power supply F030401 ai Figure 3 4 External Wiring Diagram IM 12F4A1 01E 8th Edition Aug 2014 lt 3 Installation Tubing and Wiring gt 3 9 RC400G 1 Res
100. dard solution Ret4yE Land ant v3 Strainer 9 Reagent Rc1 4 DX AE reser n if Air Ret 4 amp AP EEE SEE EE J A l EE ar Vat Air pump Le Drain VP40 Figure 3 1 3 Tubing Diagram RC400G 1 AZC F1 4 4E ai 2 RC400G 2 Residual Chlorine Analyzer for Raw Water MT pic Drain VP40 pipe Standard solution inlet at r cap For air purge inlet sla Reagent inlet Measuring sample inlet SSF VR16 pipe ry Tap water inlet ol EA y 7 VR16 pipe a LF gm sit se F3 2 1E ai Figure 3 2 1 Piping of RC400G 2 Residual Chlorine Analyzer for Raw Water IM 12F4A1 01E 8th Edition Aug 2014 lt 3 Installation Tubing and Wiring gt 3 4 Tubing materials 06 x 04 polyethylene tube Convert de Sand filter eee polyethylene tube 22 x 15 _ braided wire reinforced soft PVC tube 33 x 25 8 8 braided wire reinforced soft PVC tube CELL Measuring tank VP16 pipe VP40 pipe option PU Metering O pump Measuring sample VP16 l Pressure reducing valve Solenoid valve Tap water VP16 Ball valve Standard solution Rc1 4 E V6 Strainer 9
101. display is selected The digit selected flashes Digit selection is performed in such a manner as the digit moves from the most significant digit in the leftmost position to the right by one digit every time the key is pressed and returning from the right end to the left end b A key numeric value increasing key The numeric value in the selected digit increments in turn every time this key is pressed and when it reaches 9 then next time it returns to 0 In the most significant digit minus sign is inserted next to 9 However if negative numbers do not exist in the displayed data that sign is not inserted IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 8 c v key numeric value decreasing key The numeric value in the selected digit decreases in turn every time this key is pressed and when it reaches 0 then next time it returns to 9 In the most significant digit minus sign is inserted next to 0 However if negative numbers do not exit in the displayed data that sign is not inserted d ENT key entry key This is used for entering the displayed data When data is entered the entire displayed data flashes only once 4 Operation Command Keys 1 Operation of operation command keys 1 is valid in modes other than lt MEAS gt mode Operation command keys 1 include the following three keys a CELL key cell motor ON OFF key The cell motor which operates the indicator
102. display selection in lt MEAS gt on oFF SPE ane te Ne mode PONG 6 7 ea on If the value is below 4 F Below 4 mA output hold selection in lt MEAS gt mode on oFF OFF mA itis held at4 mA 7 Note 1 If an unused function code is selected is displayed Note 2 Ifa value outside the setting range is set not is displayed pressing gt key returns the display to data display Note 3 Values shown in the initial value column are those to be shown when the memory that stores data is initialized 4 In the case of combined chlorine insensitive version the initial value is 0 6 V 5 When option code AZC is specified the initial value is on 6 If the value is below 1 00 mg l O L is displayed regardless of the setting 7 The setting can only be enabled in lt MEAS gt mode IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 6 5 2 4 Function Codes and Their Description in lt PROGRAM 2 gt Mode Table 5 6 shows the types of function code and their description in lt PROGRAM 2 gt mode Table 5 6 Functions List in lt PROGRAM 2 gt Mode SV i Display Initial F Description Setting Range example Value Remarks 1 2 3 Setting measuring tank cleaning cycle 0 1 to 24 0 hours 0001 0 hours 1 0 An ae analyzer only 4 Setting measuring tank cleaning time
103. e 0 to 10 mg l mg l used as concentration units per JIS KO101 and munici pal water test methods Output range Can be freely set within ranges with spans of 1 mg l or greater Range set when shipment No 1 0 to 5 mg l No 2 0 to 10 mg l Allows selection between 2 ranges selected with contact input signal 2 line segment output available Any desired point between 0 and 100 of measurement span can be set as the 50 point of the output range Output signal 4 to 20 mA load resistance 550 Q Max or 1 to 5 V DC output resist ance 300 Q Max isolated Display range 1 00 to 12 00 mg l Display method Digital display 4 digit LED Output contacts Voltage free dry contacts Contact rating Max 250 V AC Max 2A Max 125 VA resistive load Max 220 V DC Max 2A Max 60 W resistive load Input contacts Voltage free dry contact ON resistance 200 Q Max OFF resistance 100 KQ Min Open circuit voltage 10V Closed circuit current 100 mA Automatic zero calibration Zero calibration using activated charcoal filter optional Contact inputs Remote range switching Switching between 2 preset ranges range 1 and range 2 Contact open Range 1 Contact closed Range 2 Contact outputs FAIL contact Activate when concentration over range measurement tempera ture error no liquid in flow cell converter error temperature com pensation over range setting upper limit exceeded Range switching contact MAIN
104. e Err24 is displayed Also the sample water temperature exceeds the measuring range 0 to 50 C lt failure gt of error code Err12 is displayed similarly The detecting function for Err24 temperature compensation range exceeded execution stop can be selected using function code 4 in lt PROGRAM 2 gt mode see subsection 5 3 5 6 1 3 Out of Sample in the Measuring Tank Err13 In lt MEAS gt mode when the circuit between electrodes is open owing to decrease of sample level in the measuring tank lt failure gt of error code Err13 out of sample in the measuring tank is displayed However this detecting function does not operate for about two minutes after power is turned ON This function also does not operate when oFF stop is selected using function code b in lt PROGRAM 1 gt mode The detection principle of Err13 uses the fact that residual chlorine concentration indication reads approx 0 mg l without sample water in the measuring tank However since out of sample must be identified from the state when residual chlorine concentration in the measuring tank is close to 0 mg l the diffusion current change is also confirmed when the applied voltage is changed IM 12F4A1 01E 8th Edition Aug 2014 lt 6 Converter Operating Functions gt 6 2 Figure 6 1 shows the discriminating method between the state either sample is present or not in the measuring tank When
105. e perform measurement using amperometric titration AT method Note Yokogawa employs amperometric titration for calibration On pressing gt key the most significant digit of the displayed value flashes indicating that input is possible Select the digits whose numeric values are to be changed using gt key and change the values using A and v keys After equalizing the displayed value to the residual chlorine concentration of the calibrating standard solution execute span calibration Press ENT key During the calibrating operation lt CAL gt lamp flashes Calibration is per formed when the analyzer stabilizes so that predetermined conditions are met after meas ured value stability is automatically checked When calibration is executes the value displayed in the data display flashes once and at the same time flashing lt CAL gt lamp extinguishes Now the span calibration is completed Remove the tube used for calibration and transfer the sample water standard solution selector valve to the sample water position If error message Err22 lt failure gt is detected in span calibration this calibrating operation be comes invalid Recalibrate span exercising care for correct entry of calibration standard solution residual chlorine concentration Err22 is detected when the ratio of measured sensitivity to the reference sensitivity is less than 0 5 The reference sensitivity set on shipment is the
106. easuring tank and then introduce the sample water flowing out of the drain cock into the graduated cylinder Press ENT key the instant the sample water reaches the reference graduation of the graduated cylinder At this moment the data display indication changes to sec count e Press ENT key again the instant the sample water in the cylinder increases by 150 ml from the reference graduation After the above operation is performed the converter computes taking the number of seconds counted as the time per pump delivery of 150 ml and indicates flow rate in the data display If the flow rate is 50 5 ml min the sample water metering pump delivery flow is normal If incorrect make adjustment by changing the stopper position in the pump driving assembly see section 8 8 3 Close the drain cock next confirm the reagent metering pump delivery flow Confirming Reagent Metering Pump Delivery Flow The reagent metering pump has been adjusted to deliver the required flow Verify to ensure the flow in a similar manner to that of sample water Prepare a 50 ml burette and an approx 120 cm long soft PVC tube of O D 6 mm and I D 4 mm To facilitate the work also prepare a burette stand 1 Confirm that the analyzer is in lt MAINT gt mode and then display 8 in the function code display using the FUNC key The content of this code is measurement of reagent metering pump flow The data display indicates FLo_2
107. ected F Values shown in the initial value column are those shown when the memory that stores data is initialized In the case of combined chlorine insensitive version the initial value is 0 6 V IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 4 5 2 2 Function Codes and Their Description in lt MAINT gt Mode Table 5 4 shows the types of function code and their description in lt MAINT gt mode Table 5 4 Functions List in lt MAINT gt Mode F Description Setting Range Display Initial Remarks example Value 0 00 mg l i 1 Zero calibration Display 1 00 to 000 02 mg l eA ells 12 00 also available 0 00 to 10 00 mg l F alani Display in ppm is 2 Span calibration oy 1 00 to 004 02 mg l alkoavslsble 3 4 Manual start of measuring tank clean EE ing 5 Manual start of sand filter cylinder 1 bLo 1 cleaning 6 Manual start of sand filter cylinder 2 bLo 2 cleaning lt 7 Sample water metering pump flow ELo 1 measurement E 8 Reagent metering pump flow meas ELo 2 urement 9 Taking plateau characteristics PLt_E A Plateau characteristics display PLt_d b Error code display CHEC c lt FAIL gt display contact output reset CL_Er d Span calibration reference sensitivity CAL updating E Version number 1 02 F Entry of password for transferring to 00 Password service m
108. ection for Err24 When lt failure gt has been detected reset the error once After resetting if the error is de tected again perform inspection following the inspection flow in Figure 9 4 Confirmation Method Disposition Confirm that sample temperature is displayed as O L Disconnect the terminals T1 and T2 of the converter and measure resistance of the wiring Temperature sensor is Pt 1000 and conforms to DIN Standard Class B Is the temperature sensor resistance normal Failure in temperature input circuit of the YES converter etc is the cause of failure If defective the circuit board assembly must be replaced Check wiring connection to the counter electrode 77777 etc Repair defective part such as loose terminal Is wiring correct connection Defect of the temperature sensor in the counter electrode writing breakage short circuit etc is the cause of failure Replace the electrode End F9 4 ai Figure 9 4 Temperature Failure Inspection Flow Chart 3 Error code Err13 Out of sample in the measuring tank No sample water is supplied to the measuring tank Find out the cause by inspecting the following items a Check that tubing is securely connected b Check the metering pump operation following the inspection flow of Figure 9 1 c For the RC400G 3 analyzers for treated water check the operation of the solenoid valves SV3 and SV4 Che
109. en dried the gold alloy surface also dries uniformly No undried water drops will remain 5 Mount the indicator electrode Fully screw in the electrode while supporting the driven shaft by hand so that it does not rotate Do not touch the gold alloy surface 6 Mount the electrode mechanism block cover Return the electrode mechanism block into the measuring tank and fix it to the bracket using two screws 7 Press CELL key to rotate the electrode 4 3 11 Filling the Zero Filter Case and Running in Operation To allow smooth automatic zero calibration the zero filter case should be filled with zero water in advance Immediately after a filter is installed or when time has passes since the last calibration was performed operate the analyzer without turning on zero calibration and conduct running in operation 1 Make sure that solenoid valve SV2 is closed Then open the solenoid valve SV6 The RC400G for tap water does not have the solenoid valve SV2 2 Check that no leakage has occurred and no air bubbles have formed IM 12F4A1 01E 8th Edition Aug 2014 lt 4 Operation gt 4 11 3 Allow the analyzer to operate continuously for about 20 minutes Make sure that the residual chlorine analyzer reads approximately zero After the running in is completed set the cycle preparation time and relaxation time of automatic zero calibration to the values in accord ance with the sample water and measurement conditions Refe
110. en the manual is revised the edition number or version number in the cover of the manual changes Safety Precautions m Safety Protection and Modification of the Product e In order to protect the system controlled by the product and the product itself and ensure safe operation observe the safety precautions described in this user s manual We assume no liability for safety if users fail to observe these instructions when operating the product e If this instrument is used in a manner not specified in this user s manual the protection provided by this instrument may be impaired If any protection or safety circuit is required for the system controlled by the product or for the product itself prepare it separately e Be sure to use the spare parts approved by Yokogawa Electric Corporation hereafter simply referred to as YOKOGAWA when replacing parts or consumables e Modification of the product is strictly prohibited The following symbols are used in the product and user s manual to indicate that there are precautions for safety IM 12F4A1 01E 8th Edition Aug 2014 E Symbol Marks Throughout this user s manual you will find several different types of symbols are used to identify different sections of text This section describes these icons A CAUTION Identifies instructions that must be observed in order to avoid physical injury and electric shock or death of the operator A WARNING Identifies instruct
111. er supply voltage and frequency meet the analyzer specifications In addition verify to ensure that the converter fuse holder cap is not loose The analyzer itself has no power switch It operates by the turning On of a switch provided in the power line When the power is supplied analyzer start in lt MEAS gt mode and metering pump and cell motor which rotate indicator electrode are always turned on After starting analyzer operation press MODE key in the converter to enter in lt MAINT gt mode Note When option code ARS with flame arrester is specified there is a power switch circuit breaker in the power terminal box 4 3 5 Confirming Sample Water Metering Pump Delivery Flow The sample water metering pump has been adjusted to deliver the required flow Verify to ensure the flow using the following procedure Prepare a 200 ml graduated cylinder to be used for verifying 1 Confirm that the analyzer is in lt MAINT gt mode and then display 7 in the function code display using the FUNC key The content of this code is measurement of sample water metering pump flow The data display indicates FLo_1 IM 12F4A1 01E 8th Edition Aug 2014 4 3 6 lt 4 Operation gt 4 7 2 Drain the sample water out of the drain cock at the bottom of the measuring tank and meas ure the delivery flow rate by cylinder to a definite volume 150 ml Loosen the drain cock Drain out the water stored in the m
112. ercially available sodium hypochlorite NaClO using purified water and adjust it so that a residual chlorine concentration of around 80 of the output range can be obtained Acalibrating standard solution of approx 2 to 3 liter is required Conduct span calibration in the following procedure 1 Provide the prepared calibrating standard solution of 2 to 3 liter in a suitable vessel 2 Feed the residual chlorine analyzer with the calibrating standard solution Set the vessel containing the calibrating standard solution in accordance with Figure 7 1 Immerse the opposite end of the tube connected to the standard solution tubing connect ing port in zero calibration in the calibrating standard solution Now the calibrating standard solution can be fed to the detector ensure that the sample water standard solution selec tor valve is turned to the standard solution position The measured value displayed in the data display normally stabilizes in approx 5 to 10 min 3 After the displayed measured value has almost stabilized confirm that the mode is lt MAINT gt and then set function code to 2 This code content is span calibration IM 12F4A1 01E 8th Edition Aug 2014 4 6 lt 7 Calibration gt 7 6 Set the residual chlorine concentration value of the calibrating standard solution First measure residual chlorine concentration of the calibrating standard solution by manual analysis In principl
113. ervecte seis 7 1 7 2 Zero Cali rations sssi eras rerai iaaa Paas asas raS 7 1 7 2 1 Zero Calibration Using Open Input Circuit Method 0e 7 1 7 2 2 Zero Calibration Using Chlorine Free Water a se 7 2 7 2 3 Automatic Zero Calibration Using Chlorine Free Water 00 7 3 7 3 Span Calibration ssrin aia daan aaas aa As aaa aaa aa 7 5 Maintenarn Ce siiin Sencsn chi xesecee cd cucetnesacacucdnndecebenebsdacedendeadeeensinn 8 1 8 1 Inspection Maintenance Items and Intervals rrrrnvrnrnnnnvrnrnnnnvnnnnnnvvnrnnnnnennn 8 1 8 2 Reagent Replenishment rrnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnvnnnnnnnnnnsnnnnnnnennnenn 8 1 8 3 Indicator Electrode Polishing c sseceeseesseeseeeseeseeesseeseeeseeesenesseesenenenenenes 8 1 8 4 Glass Beads and Measuring Tank Cleaning rss rssvnnnvnnnvnnnvnnnvnnnnnnnnnnnnnnnvnnnr 8 2 8 5 041 1 pg SE MR en 8 3 8 6 Metering Pump Driving Section Oiling rxerrsvrnnnnnnvnnnvnnnvnnnvennnnnnnnnnnnnnnnnnnnnen 8 3 8 7 Replacement of Bellofram and Valve Sheet in Metering Pump 8 3 8 7 1 Bellofram ReplaceMent ccccccececeeeeeeeeeeeeeeeeaeeeeeeseneeeeieeenees 8 4 8 7 2 Valve Sheet Replacement ccccescceceeeeceeeeeeeeeeeeeeeeeeeeeeneeeeneees 8 5 8 8 Metering Pump Delivery Flow Rate Confirmation and Adjustment 8 5 8 9 Inspection and Maintenance of Sand Filters rrnvnnnnvnnnnvnnnnvvnnnnnnnnnvnnnnnnnnner 8 6 8 9 1 Ins
114. eshooting gt 4 Error code Err22 sensitivity failure Conduct inspection following the inspection flow chart shown in Figure 9 2 Confirmation Method Disposition Confirm that the calibration standard solution concentration is in the allowable range Confirm the standard solution concentration by re measurement Check the metering pump inspection flow chart in Figure 9 1 Confirm the presence of reagent in the tank Check the setpoint using the operation described in subsection 5 3 2 3 Measure the applied voltage between the connecting terminals ME and RE Figure 9 2 Is span setpoint correct Set the span again and recalibrate the analyzer standard solution concentration accurate solution concentration is carried out by manual analysis other than amperometric titration change of the reference sensitivity setup may be necessary Refer to subsection 7 3 Is the pump in normal condition Adjust or replace the pump depending on the inspection result Is reagent present in tank Replenish reagent to the tank and recalibrate the analyzer Is the applied voltage setup normal NO If setup is unsuitable change it If setting cannot be carried out properly further adjustment or replacement of respective part is necessary Is the voltage being applied ak Malfunctioning of circuit etc is the cause of the failure Defective c
115. etering pump IM 12F4A1 01E 8th Edition Aug 2014 lt 1 Outline gt 1 3 The sand filter used for the raw and treated water analyzers serves to remove from sampled wa ter flocks which contaminate electrodes and also iron and manganese ions that liberate iodine Another metering pump is incorporated in the reagent tubing to mix reagent from the reagent tank with the sample water being fed to the measuring tank at a constant flow rate E Air Tubing System The air tubing system consists of air purge tubing etc The air purge tubing is provided for preventing the components of electrode drive assembly the converter pump drive assembly etc from corrosion due to halogen gases generated from the sample water When an air pump is included in the system it supplies purging air If no air pump is attached connect the system through a regulating valve to a clean and dry air source like instrument air E Cleaning Tubing System The cleaning tubing system added to the raw treated water analyzers functions to clean filter sand in the sand filter the measuring tank and glass beads and to remove and drain flocks Cleaning is automatically carried out by opening and closing the solenoid valve in cleaning water tubing with sequence signals from the converter The cleaning water tubing is also provided with a regulating valve to adjust the cleaning water pressure m Automatic Zero Calibration Tubing System 1 2 The residual chlorine an
116. extinguishes After calibration pass chlorine free water for short period of time and confirm that indication holds the value of 0 ppm stably Now the zero calibration is completed Leave the tube for supplying chlorine free water as connected and subsequently conduct span calibration IM 12F4A1 01E 8th Edition Aug 2014 lt 7 Calibration gt 7 3 7 2 3 Automatic Zero Calibration Using Chlorine Free Water Automatic zero calibration is performed using an activated charcoal filter The parameters should be set in following the procedure o 1 Select execution on in function code 5 Automatic zero calibration function in lt PRO GRAM 1 gt The default setting is stop oFF 2 Set the automatic zero calibration sequence parameters in A b and c in lt PRO GRAM 2 gt Function code A is Setting automatic zero calibration cycle function code b is Setting automatic zero calibration preparation time and function code c is Setting automatic zero calibration relaxation time The default settings are 10 days note refer to zero filter flushing function for function code A 10 minutes for function code b and 10 TE minutes for function code c Once automatic zero calibration starts the analog output is held lt HOLD gt lamp turns on and lt CAL gt lamp flashes At the same time the solenoid valve SV6 is energize
117. for Power Supply and Grounding cccceceeeeeeeeteeeteeeees 3 13 3 3 2 Wiring for Analog Output Signals asvrrnvnnnvnnnvnnnvnnnvrnnvnnnvrnnvnnnnnnn 3 14 IM 12F4A1 01E 8th Edition Aug 2014 3 3 3 Wiring for Contact Input lt remote gt Range Switching 3 14 3 3 4 Wiring for Contact Output oe eee cece eeeeeeeseeeteeeeeeeteeeteneteneteneeeaes 3 15 PENN 4 1 4 1 Component Identification and Function rrrnvnnnnvnnnnnnnnnnvnnnnvnnnnvnnnnnnnnnnnnnnnennnn 4 1 4 2 Preparation for Operation rsernnnnvnnnnvnnnnvnnnnnnnnnnnnnnnvnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnen 4 4 4 2 1 Reagent Preparation masvnavvnnn vnr vnr vnnnvnnnvvnnvennrnnnvnnnvensvensvessreesnen 4 4 4 2 2 Filling Bead Case with Electrode Polishing Glass Beads 4 5 4 2 3 Checking the Sand in the Sand Filter asrranvnnnrnnnrnnnrnnnrnnnrnenrrrnrnennr 4 5 4 3 Startup omuaianauauainstnnhnlsnnhmngdutsslmmmnultiejinet 4 6 4 3 1 Confirming Tubing and Wiring Implementation cece eee eee 4 6 4 3 2 Feeding Sample Water and Adjusting FIOW ccccecseeeneeneeees 4 6 4 3 3 Supplying Cleaning Water rssnrsnrrnvnnnvrnnnrnnnvnnnrrnnrrrnrrrnresnreenrernreenn 4 6 4 3 4 Tuming On POWer u kusv4as ev idremeveeveieeiiervenkvrereekvnervednnn einen 4 6 4 3 5 Confirming Sample Water Metering Pump Delivery Flow 006 4 6 4 3 6 Confirming Reagent Metering Pump Delivery FIOW eeeee 4 7 4 3 7 Confirming Indi
118. form to subsection 4 3 10 After mounting the polished indicator electrode press CELL key and rotate the electrode Leave the analyzer to operate in lt MAINT gt mode Calibration should be performed after continuing this running in operation for about 30 min When new sand is used in the sand filters of the RC400G 2 or RC400G 3 residual chlorine analyzer chlorine in the sample water may be absorbed by the sand resulting in measurement errors Upon startup or after sand is replaced allow water to run for 2 to 3 hours and perform calibration after the reading has stabilized Furthermore allow water to run for about one day for complete stabilization of sand and then perform calibration again Zero Calibration Calibration methods for residual chlorine analyzer zero point include the open input circuit method and chlorine free water method The open input circuit method is a calibration method which is conducted with no current flow ing between the indicator electrode rotating gold alloy electrode and the counter electrode exposing the electrodes in the air The chlorine free water method is a calibration method which is conducted using water that does not contain chlorine In general perform zero calibration using the simple open input circuit method However when trace residual chlorine 0 1 ppm is to be usually measured conduct the zero calibration using the chlorine free water method Zero Calibra
119. g for taking sample water and feeding it to the analyzer The connection is a rigid PVC tube of nominal dia 16 0 D 22 mm Implement tubing using proper joints i e unions and flanges etc which fit the connection Note Perform tubing so that sample water pressure at the connection falls within the range of 20 to 500 kPa Sample water flow rates to the analyzer in operation are as follows In RC400G 1 1 to 4 l min In RC400G 2 5 to 10 l min In RC400G 3 10 to 20 I min 3 2 2 Reagent Tubing Residual chlorine content is determined by sample water mixed with reagent The reagent tubing supplies reagent to the measuring cell of the analyzer Connect the outlet of the reagent tank to the reagent inlet of the analyzer using Rc1 4 joint and O D 6 mm x I D 4 mm polyethylene tube There is a reagent level limit in the tank Check that the position of the reagent tank is in accordance with Figure 2 4 RC401G Reagent Tank 3 2 3 Cleaning Water Tubing This tubing is required for the raw water type and treated water type analyzers In these types of analyzers intake sample water is filtered by the sand filter For maintaining filtering capacity the sand filter is flushed with water at regular intervals to remove floccules etc deposited in the filter IM 12F4A1 01E 8th Edition Aug 2014 lt 3 Installation Tubing and Wiring gt 3 7 The cleaning water tubing leads tap water for washing to the analyzer The connection is a rig
120. git using gt key and set the numeric value using A and gt keys P0008 Pressing ENT key now fixes the numeric value Last set digit flashes k Pressing ENT key displays Execution selection Go_oF If each setpoint is to be reconfirmed press ENT key The display returns to b starting voltage display I If the displayed item is to be executed press gt key Go on IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt m On pressing ENT key characteristic taking is executed e Data taking proceeds in turn by displaying the step No and time lapse Number of steps Figure 5 5 00 001 TZ Time lapse sec F5 5 ai Display Content in Taking Plateau Characteristic Data taking at a step is over the next step display appears Time lapse display is also reset and counts up from the beginning 00 001 00 002 00 121 00 122 Figure 5 6 01 001 01 002 gt 01 150 01 151 lt qH 08 001 08 002 08 119 08 120 Status of Display Change in Taking Plateau Characteristic When the last step is completed data taken is stored in memory Several sec are required to complete string When completed End is displayed If data is to be retakes press ENT key The display returns to the status of a End F5 6 ai Stor Display The above demonstrated the plateau c
121. good operating condition are necessary such as replenishing consumed reagent at a predetermined period Determine maintenance items and periods referring to Chapter 8 Maintenance The RC400G residual chlorine analyzers have the function for displaying various data items ef fective for understanding operating conditions not limited to residual chlorine concentration see subsection 5 3 2 It is recommended that this function be fully utilized IM 12F4A1 01E 8th Edition Aug 2014 5 5 1 lt 5 Converter Operation gt 5 1 Converter Operation The converter has functions for cleaning sequence failure detection and self diagnosis by fully utilizing the incorporated microprocessor as well as the residual chlorine concen tration measuring function The converter is operated when executing various data value display solenoid valve op eration commanding and operation parameters entry etc This chapter describes key operations and display contents indicated in this displays Component Identification and Functions on the Control Panel Converter operations are all performed on the control panel The control panel includes displays for data mode function code and others in which measured values and operating conditions are displayed Figure 5 1 shows the control panel 5 lt Fail gt display 1 Data display 6 Operation display 1 l 4 Unit display 3 Mode display 7 Operation display 2 CELL PUMP AIRP
122. gt lamp extinguishes 2 Remove the electrode mechanism block Loosen two screws fixing the electrode mechanism block to the measuring tank bracket and raise the electrode mechanism block 3 Remove the bead case with glass beads contained together with the beads case cover from the measuring tank Since the beads case cover is fit rather tight take care not to break it 4 Clean the measuring tank Remove contamination adhering to the measuring tank using a brush dipped in neutral detergent If manganese or iron adheres clean the cell using diluted hydrochloric acid Finally clean out the detergent using water NOTE Do not use organic solvents for cleaning the measuring tank Otherwise the transparency may be damaged or cracks may occur 5 Transfer the glass beads to another container and wash the dirt off with dilute hydrochloric acid Then rinse well with water 6 Clean the bead case and beads case cover Clean them according to the procedure described in step 4 cleaning the measuring tank NOTE The beads case cover may become clouded in long term use which provides no harm in use 7 Install the bead case in the beads case cover and put the cleaned glass beads into the bead case If the beads have obviously become smaller in size much smaller than a diameter of 1 7 to 2 3 mm replace them with new ones NOTE Glass beads are worn in long term use thereby reducing the ability of polishing indicator
123. haracteristic taking operation including that for changing setting contents Here the notable points in setting data are summarized Permissible ranges for each setpoint are as shown in Table 5 13 Table 5 13 Permissible Ranges and Initial Values for Plateau Characteristic Taking Setpoints Setting Item Permissible Range fixed Detection Timing Initial Value Starting voltage 1 50 to 1 50 V OV Stopping voltage 1 50 to 1 50 V sl al a oe after 0 8V Number of steps 1 to 20 steps SaaS 8 When a setpoint exceeds the permissible range not is displayed Reset it by pressing gt key By resetting the display returns to the data value before change In addition the starting voltage must be set to be larger than the stopping voltage and also the setting width must be larger than 0 1 V Starting Voltage 0 1 V gt Stopping Voltage These set data are checked the instant ENT key is pressed with execution selection display set to ON If the conditions are not met an error message of not appears The error message is reset by pressing gt key By pressing gt key the display returns to Go_oF display Then change the voltage setpoint The operating procedure when taking plateau characteristic with the same setting contents as the previous time is shown below Example a Select function code 9 in lt MAINT gt mode gt PLtE b On pressing ENT key the starting voltage is displayed
124. haracteristics When execution is commanded after start and stop voltages for applied voltage and the number of steps are set applied voltage corresponding to set parameters are applied in turn and plateau characteristics voltage current characteristic taken The time required for taking a plateau char acteristic is approx 2 or 3 min per step although it varies depending on the number of steps set and the voltage A NOTE Applied voltage changes during taking of plateau characteristic Hence if analog output hold is reset in maintenance lt MAINT gt lt PROGRAM 1 gt and lt PROGRAM 2 gt the output changes corresponding to the set output range Thus the status of current change is replaced with residual chlorine concentration change and this can be output to a recorder or the like utilizing the above phenomenon Set the output range at an appropriate value depending on plateau characteristics IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 1 6 Figure 5 4 shows the relationship between start to stop voltage and the number of steps 6 Plateau characteristic example Setting example Starting voltage 0V Stopping voltage 0 8 V Number of steps 8 5 Diffusion current VA 4 Relevant to initial values 0 0 5 1 0 Applied voltage V Step 0 Step 2 Step 4 Step 6 Step 8 j Step 1 P 3 P 5 P step 7 j Step Step ee Starting Stopping voltage gt voltage Note The applied
125. he O ring should be installed in the position of approximately 4 mm from the end of the electrode holder Next mount the driven shaft assembly on the motor mounting plate taking care not to allow the O ring to protrude from the hole in the base 11 Install the plate to hold the driven shaft assembly Make sure that the four pins are installed in the plate Here temporarily tighten the two screws on the long sides 12 Install the plate for preventing drive belt shavings to enter the electrode holder With the surface with the two tabs facing downward pass the plate through the driven shaft Align the tabs with the holes in the plate installed in step 11 and temporarily tighten the two screws 13 Install the slip ring in the driven shaft NOTE The contact surface between the driven shaft and the slip ring needs an electrical connection Make sure that the contact surface is clean 14 Install the pulleys with drive belt attached to the drive and driven shafts NOTE The drive pulley should be installed so that the end of the shaft poke out 0 3 to 0 7 mm so that the drive belt is positioned horizontally 15 While adjusting the drive belt tension further tighten the screws that were tightened tempo rarily in steps 11 and 12 Hang the hook of a spring balance 1 00 kg on the hole in the IM 12F4A1 01E 8th Edition Aug 2014 lt 8 Maintenance gt 8 1 3 driven shaft Make sure that all the temporarily tighten four
126. id PVC tube of nominal dia 16 0 D 22 mm Perform tubing in the same manner as the sample water tubing using proper joints so as to al low cleaning water pressure to fall within the range of 100 to 500 kPa 3 2 4 Drain Tubing This is the tubing to discharge sample water and cleaning water from the analyzer to a drainage ditch etc The specifications of the tubing connections are given below In RC400G 1 Rigid PVC tube nominal dia 40 0 D 48 mm In RC400G 2 Rigid PVC tube nominal dia 40 0 D 48 mm In RC400G 3 Rigid PVC tube nominal dia 40 O D 48 mm Perform tubing so as to prevent sedimentation and formation of any dead spot in the tubing 3 2 5 Purge Air Tubing This is the tubing to supply clean dry air to the cases which house the converter electrode mechanism block and pump drive assembly for air purging When the RC400G is provided with an air pump extend the tubing to an area free from corro sive gases for intake of clean air If an air pump is not available employ instrument air etc and perform tubing so that air is supplied at a pressure of approx 140 kPa The connection is Rc1 4 3 2 6 Standard Solution Tubing This supplies standard solution to the analyzer for calibrating zero point or span Usually this tubing is set up every time when calibration refer to Chapter 7 is conducted The tubing connection is Rc1 4 A NOTE Standard solution supplied from the tubing connection is directly fe
127. idual Chlorine Analyzer for Tap Water Converter Dedicated cable Detector CON K9332WA CELL Bk lt F1 ME Fail contact output W q ME lt O F2 REO O RE O M1 T1O Ey T1 Maintenance contact output huer P Gn ke p Wired by customer SME Teo as lt 001 G Terminal Range switching output Rd mounting lt 0 02 C10 O C1 screw BI gt 0 R1 C20 TD TD C2 Remote range switching input gt 0 R2 Power terminal box 2 Pump PR Dedicated cable PU Analog output K9332WB D P10 EO P1 Bk J He P2 QO P2 G GC w L G mI wt 18 Solenoid valve A L2 option Q L1 Dedicated cable SVO CI K9460CN vi OS O 1 Bk V2 O wO 2 W Air pump 2 Tii option 1 ar T L Dedicated cable AP 3 1 K9332WJ IL AO Bk A1 Case ground terminal must be A2 70 A2 grounded W If this is not possible connect g lll to power source ground wire Q Note AR1 2 Arrestors 9 ko Dotted lines external wiring F16 EPS CB1 Circuit breaker G J Use cable of 6 to 12 mm OD however when connecting via power Power Analog output terminal box option use cable of 9 to 11 mm OD for both power and analog output cables 1
128. ime for automatic Zero calibration comes while the analyzer is in other modes the calibra tion will be cancelled The internal timer is reset and then starts counting 6 Ifthe time for automatic cleaning comes during automatic zero calibration the automatic cleaning will be cancelled If the time for automatic zero calibration comes during automatic cleaning the automatic cleaning is aborted and the automatic zero calibration starts In this case the sequence for switching the solenoid valves SV3 and SV4 continues but this does not affect the automatic zero calibration IM 12F4A1 01E 8th Edition Aug 2014 lt 7 Calibration gt 7 4 SV6 zero water measurement Output hold T1 Automatic zero calibration cycle Zero calibration time may vary depending on T2 Automatic zero calibration preparation time calibration condition T3 Zero calibration time Maximum time limit value of response time T4 Automatic zero calibration relaxation time F7 23 ai Figure 7 2 Automatic Zero Calibration Sequence Zero Filter Flushing Function This function is activated to prevent corrosion of the activated charcoal filter and is enabled when the following conditions are met 1 Automatic zero calibration is set to on 2 Automatic calibration cycle is longer than one day Flushing Cycle and Sequence The flushing is activated once every 24 hours and this cycle is fixed When the flushing is acti vated the analog
129. in When memory contents in EEPROM is initialized the stored setting date is also initialized 6 Error code Err25 Concentration upper limit setpoint exceeded Usually independent display of error code Err25 lt failure gt appears when chlorine concen tration in sample water exceeds the set value but does not mean equipment failure IM 12F4A1 01E 8th Edition Aug 2014 lt 9 Troubleshooting gt 9 8 Err25 lt failure gt therefore serves as a common upper limit alarm However lt failure gt output is not reset even when chlorine concentration reduces below the set value Reset the display by the error resetting operation see subsection 5 3 3 9 7 Error code Err16 or Err17 Converter failure lt failure gt of error code Err16 or Err17 is detected only a moment immediately after power has been supplied to the converter When this lt failure gt is displayed turn off power once If lt failure gt display see Figure 9 6 is observed when power is turned ON again RAM or EEPROM is defective Replace the circuit board assembly carrying these components CHEC gt Err16 defective RAM momentary indication CHEC gt dF gt Err17 defective EEPROM momentary indication indicated for about 15 sec Initial values are written Figure 9 6 Error Display in Power ON When memory contents in EEPROM is initialized the stored setting date is al
130. inals 77777777 P1 and P2 Is terminal voltage normal The relay in the converter may be defective If defective replace the relay Check visually the operation ofthe metering pump Is motor turning Defective motor or loosened motor wiring is the cause of the failure If defective replace the motor Turn off power supply to the converter before checking the wiring Confirm there is no liquid leak from the bottom hole of the metering pump body Any leak from pump Deterioration of Bellofram or valve sheet is the cause of the failure Replace the defective part referring to subsection 8 7 Adjust flow rate referring to subsection 8 8 Is it adjustable End F9 1 ai Figure 9 1 Metering Pump Inspection Flow Chart 3 Error code Err21 zero point failure Carry out the inspections described below in accordance with the zero calibration method lt Open input circuit method gt Confirm that the space between the indicator electrode rotating gold alloy electrode and the counter electrode is completely open lt Chlorine free water method gt a Check by amperometric titration etc that the zero calibration liquid in use is chlorine free water b Confirm that reagent is present in the reagent tank c Confirm the operation of the metering pump following the inspection flow chart shown in Figure 9 1 IM 12F4A1 01E 8th Edition Aug 2014 lt 9 Troubl
131. ions that must be observed in order to prevent the software or hardware from being damaged or the system from becoming faulty A NOTE Identifies information required to understand operations or functions m Notes on Handling User s Manuals Please hand over the user s manuals to your end users so that they can keep the user s manuals on hand for convenient reference Please read the information thoroughly before using the product The purpose of these user s manuals is not to warrant that the product is well suited to any particular purpose but rather to describe the functional details of the product No part of the user s manuals may be transferred or reproduced without prior written con sent from YOKOGAWA YOKOGAWA reserves the right to make improvements in the user s manuals and product at any time without notice or obligation If you have any questions or you find mistakes or omissions in the user s manuals please contact our sales representative or your local distributor m Warning and Disclaimer The product is provided on an as is basis YOKOGAWA shall have neither liability nor respon sibility to any person or entity with respect to any direct or indirect loss or damage arising from using the product or any defect of the product that YOKOGAWA can not predict in advance IM 12F4A1 01E 8th Edition Aug 2014 After sales Warranty E Do not modify the product E During the warranty period for repair under wa
132. isplay functions Data Concentration temperature applied voltage diffusion current output signal pump flow zero point slope Status indicators Measurement maintenance hold calibration in progress clean ing fail Operating status Rotating gold alloy electrode mertering pump air pump sole Diagnostic functions Setup functions noid valve ON OFF Concentration over range measurement temperature error no liquid in flow cell converter error temperature compensation over range setting upper limit exceeded zero point error slope error response error Maintenance functions MAINT mode One touch calibration flow cell and sand filter system cleaning pump flow measurement one touch plateau characteristic acquisition failure error information PROGRAM 1 mode Output Range 1 and Range 2 settings 2 line segment output setting applied voltage setting response time and stability parameter settings contact output during FAIL condition ON OFF indication hold during MAINT ON OFF remote range switching ON OFF IM 12F4A1 01E 8th Edition Aug 2014 PROGRAM 2 mode lt 2 Specifications gt 2 3 Cleaning sequence setup auto zero calibration sequence setup For pure water Automatic cleaning functions Electrode and flow cell cleaning methods Glass bead cleaning For raw sea water secondary sewage treatment Sand filter system Filter sand Filtering flow Glass bead cleaning water jet
133. ive point of view and there is no guarantee against failure The inspec tion and maintenance intervals should be determined in accordance with individual operating conditions Table 8 1 Inspection Maintenance Items and Intervals Inspection Maintenance Item Reagent replenishment Indicator electrode polishing Indicator electrode replacement Glass beads cleaning Glass beads replacement Calibration Metering pump driving section oiling Replacement of Bellofram and valve sheet in metering pump Metering pump delivery flow rate confirmation Sand inspection Electrode mechanism block inspection Brush and slip ring Drive belt Driven shaft assembly Motor assembly gear head Activated charcoal filter Recommended Intervals As needed Monthly Yearly 3 months Yearly Monthly Monthly 6 months When Bellofram is replaced Occasionally See subsection 8 10 Yearly Reagent Replenishment Reagents are consumed at the rate of 2 to 2 4 l day When there is but slight reagent left in the reagent tank replenish with reagent prepared in advance with subsection 4 2 1 Normally replenish reagent by transferring the reagent prepared in a different tank to the reagent tank If reagent is to be prepared directly in the reagent tank and purified water as accurately as possible considering the remaining reagent volume When preparing reagent do not neglect to stop the metering pump by pressing PUMP key on the control panel
134. k in item 1 with a stand and a needle valve Materials Carbon steel Stand color Munsell 2 5Y8 4 1 2 Stand finish Baked polyurethane resin coating Weight Approx 25 kg 3 Reagent mixing tank with cart RC401G C This is a tank to prepare reagent It is mounted on a cart and provided with a manual stirrer and a pump to transfer the prepared reagent to the reagent tank RC401G The pump is driven by 100 VAC A reagent mixing tank mounted on a cart With manual mixer and pump for transferring reagents Note This tank is for reagent mixing and is not a substitute for the reagent tank Tank capacity 100 L Tank materials Rigid PVC Cart materials Frame Steel pipe SPG30A Bracket Steel plate SPCC Pump Seal less Pump Discharge flow rate 14 to 35 L min Wetted part material Polypropylene resin Hastelloy ceramics fluorinated rubber Power supply 100 V AG 50 60 Hz Power consumption Approx 100 VA Power cord PVC sheathed cable 5m Weight Approx 40 kg IM 12F4A1 01E 8th Edition Aug 2014 lt 2 Specifications gt 2 12 2 2 2 Product model and suffix codes Model Suffix code Option code Description RC401G Reagent tank Type Reagent tank only Reagent tank with stand Reagent mixing tank with mobile stand With manual mixer Style A 2 2 3 Accessories Reagent tank RC401G A RC401G B Name Quantity Remark Couplings 2 sets Outside diameter 6 mm In
135. key and actuate solenoid valve SV1 valve open Confirm that solenoid valve SV1 has operated though lighting of lt SV1 gt lamp Next adjust the opening of ball valve V1 located under the sand filter Open the valve to the extent that the sand in the sand filter is not forced up above the sample water inlet After adjusting the ball valve opening again press SV 1 key to stop operation of solenoid valve SV1 If a residual chlorine analyzer for treated water is used adjust also the flow of cleaning water entering another sand filter Press SV5 key to operate solenoid valve SV5 valve open Adjust ball valve V5 to the extent that the sand in the sand filter is not forced up above the sample water inlet Adjust the flow rate of cleaning water entering the measuring tank First press SV2 key to operate solenoid valve SV2 valve open When solenoid valve SV2 operates lt SV2 gt lamp is lit Next gradually open ball valve V2 to adjust the flow Adjust it to the extent that glass beads float in the measuring tank and that the water level does not exceed the second slit of the bead case from its top IM 12F4A1 01E 8th Edition Aug 2014 lt 4 Operation gt 4 9 e After adjusting cleaning water flow rate press again SV 1 SV2 and SV5 keys to stop operation of solenoid valves SV1 SV2 and SV5 Operating times related to cleaning are already set on shipment Since these sequential opera tions become stopping states
136. le zero calibration the fol lowing inspections should be conducted The recommended interval is three month e Check there s no irregularity in rotation speed of drive shaft If there s any irregularity loose the load on the shaft by loosening the screws which fix the driven shaft pulley and recheck If there is still irregularity replace motor assembly and gear head If the irregularity doesn t reappear check the driven shaft assembly e Abnormal sound from gear head motor If there s any abnormal sound check the motor assembly gear head In principle this should be done by Yokogawa The following inspection should be performed approximately every six months Motor rated torque and drive torque In lt CELL gt mode when motor is turned ON OFF after the ON command it should quickly reach speed Confirm that the difference in speed of rotation between its normal status and when load is reduced by loosening screws fixing pulley to driven shaft is not noticeable If operation is still not satisfactory replace motor assembly and gear head Replacement Procedure Replacement of the motor assembly gear head in principle should be conducted by Yokogawa If the replacement is conducted by the user the following should be noted Inprinciple replace motor assembly and gear head at the same time as periodic replace ment of other parts Replace complete motor assembly consisting of both motor and capaci tor IM 1
137. leaning jet cleaning and one cylinder sand filter unit 6 For raw water 2 cylinder with glass beads cleaning jet cleaning and two cylinder sand filter unit 6 Output signal 1to5 VDC 4 to 20 mA DC Power supply 1 2 3 4 5 6 7 8 200 V AC 50 Hz 200 V AC 60 Hz 220 VAC 50 Hz 220 VAC 60 Hz 100 VAC 50 Hz 100 VAC 60 Hz 110 VAC 50 Hz 110 VAC 60 Hz Measurement object 2 Free chlorine Residual chlorine total chlorine Combined chlorine insensitive version free chlorine 3 Always N Always A Optional specifications With air purge pump 200 V AC 50 60 Hz 7 With air purge pump 220 V AC 50 60 Hz 7 With air purge pump 100 V AC 50 60 Hz 7 With air purge pump 110 V AC 50 60 Hz 7 Units ppm Without reagent set for start up 4 Stainless tag plate Stainless stand 5 With automatic zero calibration With arrestor power and signal lines AE Application indicates general guidelines Select the cleaning equipment appropriate for the contamination in the sample i Measurement object selection is indicated in the following 3 Less affected by combined chlorine in free chlorine measurement 4 When ordering the RC400G select NR and get reagent sets for start up from local reagent supplier These reagent sets can not be exported from Japan due to both safety and transportation issues 5 Stanchion base and bracket are stainles
138. lorine analyzer is used Follow the procedures below Inspection of Sand Filter Surface Check the surface of sand filter for the formation of mud balls Formed mud balls should be crushed using a stick Check that crushed flocks flows out at the time of back washing To pre vent recurrence the cleaning time should be set longer or the cleaning cycle shorter Checking the Sand Volume in Sand Filters Flocks and other sediment in the sand filters are discharged from the filters by water jet cleaning that is automatically performed at regular intervals Improper cleaning intervals may cause formation of thick layer of flocks In back washing entire sand is lifted by cleaning water and sand is discharged together with flocks thereby reducing the volume of sand in the sand filters When the sand is reduced inconvenience in measurement may result delayed response because the filtrate rate is reduced by floc layers larger measure ment errors because chlorine is absorbed into the flocks etc If the sand is reduced remove the top cover of the filtration cylinder and replenish the cylinder with sand to scale marking lt 10 gt in the cylinder see Figure 8 6 IM 12F4A1 01E 8th Edition Aug 2014 8 9 3 8 9 4 lt 8 Maintenance gt 8 7 Checking the Discoloration of Sand in Sand Filters Manganese or iron contained in sample water may cause contamination in the measuring tank of the residual chlorine analyzer Most of them however are
139. lternately displayed gt 1le6 2 c Select 1 one cylinder type or 2 two cylinders type gt 2 d Press ENT key to enter it 2 Flashes once When transferred to lt MEAS gt mode a cleaning sequence relevant to the one entered here is activated However if the sand filter cylinder cleaning function is set to oFF stop with function code A the cleaning sequence is not activated 15 Selection of Measuring Tank Cleaning Function execution stop Function code 9 For the RC400G 2 raw water or the RC400G 3 treated water residual chlorine analyzer automatic cleaning of the measuring tank and sand filter cylinder s using cleaning water can be executed based on the set sequences In this function code measuring tank cleaning execution stop should be set For residual chlo rine analyzers of the relevant specifications cleaning execution is set on shipment Thus since cleaning is normally executed it is unnecessary to specifically reset it IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 30 If it is necessary to stop the measuring tank cleaning function operate keys in the following pro cedure a Select function code 9 ON Cleaning execution OFF Cleaning stop b Every time gt key is pressed on and oF F are alternately displayed gt on lt oFF c Select on execution or oFF stop OFF d Press ENT key to enter it
140. ly of conductive silicone grease is enough 10 2 9 Counter Electrode K9332MJ for Combined Chlorine K9332MK The counter electrode can be used continuously without planned replacement as it is not worn unlike the indicator electrode rotating gold alloy electrode However it is recommended to have a spare electrode providing for accidental breakage of elec trode or other failures 10 2 10 Fuse A1113EF A1109EF The fuse in the converter should be renewed once a year to prevent unexpected shutdown IM 12F4A1 01E 8th Edition Aug 2014 lt 10 Spare Parts and Consumables gt 10 4 10 2 11 Brush K9332JX and Slip Ring K9332JZ A As the brush in the electrode mechanism block is used in contact with the rotating slip ring both parts are worn over a long time Generally replacement every two years is standard As a rule replacement should be made as a pair NOTE Do not touch the brush except when replacement is performed Procedures for adjusting the brush contact pressure and removing wear debris from the slip ring Wear debris generated from the sliding action of the slip ring and brush generated largely at the beginning may enter between the slip ring and the brush thereby temporarily increasing the contact resistance This may cause a drop in readings When this phenomenon occurs polish and clean the surface of the slip ring to prevent the generation of wear debris and the ingress of wear debris generated into a spa
141. m The detecting operation time in which the detecting and reverse voltages are applied is a few seconds Including this detecting operation analog output holds for three minutes after the de tecting operation Concentration indication changes IM 12F4A1 01E 8th Edition Aug 2014 6 1 4 6 1 5 lt 6 Converter Operating Functions gt 6 3 Applied coltage A A few sec Detecting gt voltage Setting voltage Reverse voltage Time F6 2 ai Figure 6 2 Detecting Voltage Waveform Converter Failure Err14 Err15 Err16 and Err17 Converter circuit failure and memory failure are detected in the following method 1 2 3 AD Circuit Failure Err14 By periodically sampling the reference resistance value and reference voltage value in the temperature input circuit check whether these values are the predetermined ranges or not If a value exceeds the predetermined range error code Err14 lt failure gt is displayed Memory Comparison Failure Err15 Each data such as setpoint is stored in two areas in the memory EEPROM During converter operation each data stored in two areas is periodically mutually com pared If data which does coincide is detected error code Err15 lt failure gt is displayed When memory failure is detected memory contents are initialized in very rare case In this case the setting data may be lost Memory R W Read Write Failure Err16 Err17
142. mbly will be worn The motor assembly should be replaced after ap proximately 3 year operation 10 2 15 Gear Head See CMPL for Part Number The rotor in the gear head will be worn The gear head should be replaced after approximately 3 year operation 10 2 16 Activated Charcoal Filter L9862AY To secure accurate zero value it is recommended that the filter be replaced once a year 10 2 17 Filter K9332NN It is recommended that the filter which used for head tank or sand filter be replaced once a year IM 12F4A1 01E 8th Edition Aug 2014 Customer Model RC400G Style 3 ENDE Maintenance Residual Chlorine Analyzer Parts List e Model RC400G 1 ad _ 2 5 o o 4 NA ny O Item Part No Qty Description 1 1 Converter see page 4 2 1 Detector see page 5 3 1 Metering Pump Assembly see page 6 4 1 Overflow Tank 5 1 Air Pump Option K9087XA For 100 V AC power supply K9087XF For 110 V AC power supply K9087XG For 200 V AC power supply K9087XH For 220 V AC power supply All Rights Reserved Copyright 1991 Yokogawa Electric Corporation CMPL 12F04A01 03E YOKOGAWA Subject to change without notice 1st Edition Mar 2013 YK Yokogawa Electric
143. n Stabilization The setting key operation procedure is common to each parameter The following shows the procedure taking response time limit setting as an example a Select function code 6 0005 0 min b Press gt key 0005 0 min Leftmost digit flashes c Select the digit using gt key and set a numeric value using A and v keys 0006 0 min Last set digit flashes d Press ENT key to enter it 0006 0 min Entire display flashes once Since not is displayed for setting out of the permissible setting range reset this display by pressing gt key and set it again 5 Output Signal Setting in the Case of lt failure gt Function code 9 Analog output when lt failure gt occurs in lt MEAS gt mode can be fixed to a preset value For se lecting preset value output see 9 Set the preset value using a span value in the output range A range of 10 to 110 can be set The following shows the setting key operation procedure a Select function code 9 00000 IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 25 b Press gt key 00000 Leftmost digit flashes c Select the digit using gt key and set a numeric value using A and v keys 00100 Last set digit flashes d Press ENT key to enter it 00100 Entire display once flashes Since not is displayed for inputs out of pe
144. nce gt 8 1 2 4 Remove the bracket which holds the brush by loosening the 2 screws which holds the bracket and remove the rock screw at side of contact pressure adjusting screw OT Remove the drive belt together with the pulleys for the driven and drive shafts O Remove the slip ring from the driven shaft Fane I r Remove the plate installed to prevent drive belt shavings to enter the electrode holder in the driven shaft assembly by loosening the 2 screws oc wm Remove two plates which holds driven shaft assembly in place Oo If driven shaft assembly is bad remove it from motor mounting plate The place where the electrode holder base is inserted contains an O ring This O ring and the counter electrode fixing clamp can be reused NOTE It is recommended that an O ring P N Y9115XB be replaced after 3 years even if no damage has occurred Step 10 and the following steps are an assembly procedure Keep the following in mind when assembling the driven shaft assembly e Before assembly clean away dirt or stains on each component e Assemble the assembly so that the drive belt tension is 4 N spring balance reading of 0 4 kgf Assemble the assembly so that the indicator electrode does not make contact with the base 10 Mount a new driven shaft assembly on the motor mounting plate First install the clamp and O ring in the electrode holder in the driven shaft assembly T
145. nction code E When this function is set to on enabled a negative value below 0 00 mg l is not displayed even if the measured residual chlorine concentration value is negative However this setting can only be enabled in lt MEAS gt mode The factory setting is disabled If the setting is to be changed perform the following key opera tion a Select function code E on enabled OFF disabled b Every time gt key is pressed on and oF F are alternately displayed gt on lt oFF c Select on enabled or oFF disabled on d Press ENT key to enter it ON Flashes once NOTE If the value is below 1 00 mg l O L is displayed regardless of the setting Selection of below 4 mA output hold in lt MEAS gt mode Function code F When the function is set to on enabled analog output does not fall below 4 mA but is held at 4 mA However this setting can only be enabled in lt MEAS gt mode The factory setting is disabled If the setting is to be changed perform the following key opera tion a Select function code F on enabled OFF disabled b Every time gt key is pressed on and oFF are alternately displayed on lt gt oFF c Select on enabled or oFF disabled on d Press ENT key to enter it on Flashes once Key Operation in lt PROGRAM 2 gt Mode In lt PROGRAM 2 gt mode each time setting in cleaning sequences and also
146. nction code 8 reagent FLo 2 c Re actuate metering pumps stopped for measurement preparation d Measure the delivery time required for 150 ml of sample water or 4 5 ml of reagent from the metering pump e When the liquid level within a metering apparatus such as graduated cylinder reaches the reference graduation press ENT key Time measurement starts data display indication changes to time indication 1 sec e When the liquid level reaches the predetermined graduation position press ENT key again Time measurement stops 186 sec The indicated time flashes once and the flow rate is calculated and displayed 48 4 ml min If the time measurement does not reach 90 sec O L is displayed If ENT key is not pressed even after 360 sec have elapsed Error is displayed These displays are reset by pressing ENT key and the message in operation step b appears e After the flow rate is displayed and confirmed normal restore tubing and the like Time to be measured and computable flow rate ranges are as shown in Table 5 12 Table 5 12 Measurement Flow Rate and Time Ranges Measuring Item Computable Flow Rate Range Measurement Time Range Sample water flow rate 25 0 to 100 0 ml min Reagent flow rate 0 75 to 3 00 ml min 90 to 360 sec 6 Taking Plateau Characteristics Function code 9 Function code 9 performs parameter setting and execution commanding for taking plateau c
147. nd a lt failure gt contact signal is output In this function code out of sample detecting function execution stop should be set Out of sample detection execution is already set on shipment If the function is to be stopped operate keys in the following procedure a Select function code b ON Detection execution OFF Detection stop b Every time gt key is pressed on and oF F are alternately displayed c Select on execution or oFF stop d Press ENT key to enter it on OFF OFF OFF Flashes once 18 Concentration Display Unit Selection Function code c Either mg l or ppm can be selected as the unit of residual chlorine concentration displayed in the converter On shipment the specified unit has been set to be displayed IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 31 If this setting is to be changed operate keys in the following procedure to set the unit again a Select function code c __ 1 mgh _ _ 2 ppm b Every time gt key is pressed 1and 2are alternately displayed gt 10 2 c Select__ 1 mg l or__ 2 ppm gt 2 d Press ENT key to enter it __ 2 Flashes once The selected unit appears to the right of data when a residual chlorine concentration is displayed see Figure 5 12 Residual chlorine concentration display Either one of the units set with function code c is PROG
148. nd delivery sides of sample water and reagent metering pumps after use for six months to prevent possible trouble even if the sheets still show no defect Determine the quantity of spare valve sheets taking this scheduled replacement into account IM 12F4A1 01E 8th Edition Aug 2014 lt 10 Spare Parts and Consumables gt 10 3 10 2 7 Bellofram L9819AA L9819AB Bellofram used in the piston sections of the metering pumps should be replaced after six months use even if no defect has developed as is the case with the valve sheet Bellofram for the sample water metering pump and that for the reagent metering pump have different sizes Bellofram for Sample Water Metering Pump Bellofram for Reagent Metering Pump Part No L9819AA Part No L9819AB EN Figure 10 1 Bellofram 10 2 8 Indicator Electrode K9334JP The indicator electrode is worn gradually by continual polishing with glass beads and becomes unusable finally Wear being a dominant factor service life of the indicator electrode is one to two years gener ally 2 te d A replacement electrode should be prepared in consideration of this life However at least one more electrode should be prepared at all times for accidental breakage or unexpected electrode failure Note 1 Electrode life can be shortened by use in an erroneous condition such as deflecting rotation Note 2 Slope Display by function code 9 in lt MEAS gt m
149. nder Also in the RC400G 2 residual chlorine analyzer for raw water although cleaning functions are provided only SV1 and SV2 keys are used When a solenoid valve is operating the relevant lamp lights If to whatever operating condition each solenoid valve state is changed using key operation the normal state is restored by select ing lt MEAS gt mode The relevant lamp to that key lights extinguishes every time the relevant key is pressed even when no solenoid valve is provided IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt Table 5 7 Operation Command Keys 2 and Relevant Solenoid Valves Operation RC400G 1 RC400G 2 RC400G 3 Command Relevant Solenoid Valve no cleaning number of number of Key function sand filters 1 sand filters 2 SV1 SV1 Solenoid valve in one sand filter x A A cylinder cleaning water line sv2 SV2 Solenoid valve in measuring tank x A A cleaning water line SV3 SV3 Solenoid valve in one sand filter A cylinder sample water line sv4 SV4 Solenoid valve in two sand filter x A cylinder sample water line SV5 Solenoid valve in two sand filter Sv5 cylinder cleaning water line a x SV6 Switching of automatic zero calibration A Note A Note A Note solution sample water A Relevant solenoid valve is provided x Relevant solenoid valve is not provided Note Provided when option code AZC is specified Key Operation
150. nnvnnnvnnnvnnnvvnnvvnnvnnnvnnsrnnsvennnnnn 2 6 2 1 5 Flow diagrams and outline drawings usrrrvvrnvnnnvvrnvvrrvnnnvrnrrnnnvnnnnen 2 8 2 2 RCA401G Reagent Tanker siccsc ccetsedesceccccescetseceseeteadeeceesedeceatecteetedeedeceetecdzecedeeseae 2 11 2 2 1 Standard specifications ccccccccscceeeceeeeeeeeeceeeeeeeeeeeeeneeeteeeseaees 2 11 2 2 2 Product model and Suffix COdes rrrrnrnrnrnnnrnnnrnnnrnnnrernrnrnrnrnrernreennr 2 12 2 2 3 ACCOSSOMNCS EEE EE PEPE 2 12 2 2 4 Outline Arawings sicsenci sc cxsccs di cabepiedeaseca A EEIE E EAEN ERRARE 2 12 3 Installation Tubing and Wiring erasnvnnnnnvnnnnvvnnnnnvnnnnnvnnnnnennnnvnnnnnvnnnnnnennnn 3 1 3 1 Installation n 3 1 3 1 1 LOCALION 00 eeeeeeeeeeeeeeeeeeeeeeeeseeeseeeseeeseceseeesneseeseneseaeseneseeeseneseneteneeeaes 3 1 3 1 2 Installation Sc pte ete ett wd vada Steeda ute vada s a vedas AE 3 1 3 2 TUBING EE EE EE 3 1 3 2 1 Sample Water Tubing mesvrrsvvnnvvnnvrnnvnnnvvnnvnnnnnnnnnrrnrernrnsnresnresnresnreennn 3 6 3 2 2 Reagent Tubing 2 nedhenenhdnenenel dkenana duane 3 6 3 2 3 Cleaning Water TUBING 0 00 ccecceeeeeeeeeteeeeeeeeeaeeeaeeeaeeeaeeeaeeeaeeeaeeeas 3 6 3 2 4 Drain TUDIN Gecenin aa a 3 7 3 2 5 Purge Alr TUDING c0heidnei nein ia 3 7 3 2 6 Standard Solution TUDING senetan 3 7 3 2 7 Automatic Zero Calibration Tubing eenvronrnnnvnnnrnnnrnnnrnnnrnrnrnrnrnenreenn 3 7 3 3 WING E E ieeteiteetnnindieaninir nities 3 8 3 3 1 Wiring
151. nths even if no failure is recognized Figure 8 2 shows metering pump construction IM 12F4A1 01E 8th Edition Aug 2014 lt 8 Maintenance gt 8 4 Pump mounting plate Pump main body O ring Ring Transparent plate ketainer Retainer mounting screw F8 2 ai Figure 8 2 Metering Pump Construction 8 7 1 Bellofram Replacement Perform Bellofram replacement work using the following procedure 1 Press PUMP key to stop metering pump operation Take measures to prevent reagent from flowing out of the reagent tank 2 Remove the transparent plate of the metering pump Loosen four screws located on the front face wo Remove the ring which forces the Bellofram flange down Remove the retainer fixed to the piston with screw Remove the Bellofram which has been used and mount a new Bellofram oa For mounting first press the Bellofram flange using the ring Fold the Bellofram so as to cover the piston using the attached jig see Figure 8 3 Bellofram Bellofram mounting jig F8 3 ai Figure 8 3 Bellofram Mounting Procedure 6 Reassemble the disassembled parts IM 12F4A1 01E 8th Edition Aug 2014 8 7 2 8 8 lt 8 Maintenance gt 8 5 Valve Sheet Replacement Perform replacement work in the following procedure 1 Remove the metering pump with the mounting plate First press PUMP key to stop metering pump o
152. o lt MEAS gt When the measuring tank cleaning starts the analog output holds at the value immediately before cleaning start Hold is reset when the relaxation time is completed During analog output hold lt HOLD gt lamp lights During cleaning lt WASH gt lamp flashes In response to operations of solenoid valves operation display lamps corresponding to each solenoid valve light extinguish Table 5 21 shows permissible time setting ranges applied to each cleaning sequence operation shown in Figure 5 14 Table 5 21 Cleaning Sequence and Time Setting for Sand Filter Two Cylinder Type Time Chart Function Content Permissible Setpoint Value Symbol Code Setting Range on Shipment T1 6 Sand filter cylinder 0 1 to 24 0 hours 0 5 hours T2 4 Measuring tank cleaning time 0 1 to 25 0 min 1 0 min T3 7 Sand filter cylinder cleaning time 0 1 to 25 0 min 1 0 min T4 5 Relaxation time after cleaning 0 1 to 25 0 min 3 0 min T5 8 Substitution time 1 0 1 to 25 0 min 6 0 min T6 9 Cross time 2 0 1 to 25 0 min 1 0 min T7 3 Measuring tank cleaning cycle 0 1 to 24 0 hours 1 0 hours MM Substitution time is the time for stabilizing water in the sand filter 2 Cross time is the time that overlaps when the sample water line is switched IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 36 If it is necessary to change the value set on shipment re set it in the following procedure
153. ode ee 77 These are usually not selected owing F to service mode Note 1 Message shown in the display example column shows the content shown first when the relevant function code is selected Note 2 If an unused function code is selected is displayed 5 2 3 Function Codes and Their Description in lt PROGRAM 1 gt Mode Table 5 5 shows the types of function code and their description in lt PROGRAM 1 gt mode IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 5 Table 5 5 Functions List in lt PROGRAM 1 gt Mode ae i Display Initial F Description Setting Range example Value Remarks A a 0 00 to 10 00 mg l L00 00 Display in ppm is 1 Output range setting for output range 1 Span 1 00 or more L00 00 mg l H05 00 also available i pr 0 00 to 10 00 mg l L00 00 Display in ppm is 2 Output range setting for output range 2 Span 1 00 or more L00 00 mg l H10 00 also available 3 4 Reference sensitivity setting 1 00 to 5 00 uA mg l 002 62 uA mg l 2 62 5 Applied voltage setting 1 50 to 1 50 V 00 40 V PN 6 Parameter setting for response checking 0 1 to 10 0 min 0007 0 min 7 0 Setting concentration for stable indication Display in ppm is 7 detection 0 01 to 2 00 mg l 000 01 mg l 0 01 alsoavailable 8 Setting time for stable indication detection 2 to 180 sec 00
154. ode can be used as a guide to the degradation of electrode characteristics Notice in evaluation however that the slope indication value can be influenced by such factors as the contamination of electrodes including the counter electrode set reference sensitivity or manual analysis method used for measuring residual chlorine concentration of standard solution etc Procedure for Applying Conductive Silicon Grease to Indicator Electrode Threaded hole An electrical connection is required between the indicator electrode and the driven shaft To ensure to secure the electrical connection conduc tive silicon grease is applied to the female thread part of the indicator electrode If not apply grease by following the procedure below Collar Apply grease taking care not to apply it to the outside gold i R isti llar alloy side in particular of the electrode AE Ge Apply a half drop of grease to the tip of a small flat head screw Gold alloy surface driver and then transfer and apply it well to the three places almost equally spaced 3 to 5 mm below the edge of the threaded hole e Insert the indicator electrode in the driven shaft once Remove it again and check that the grease does not run off to the edge If so remove the excess and clean the part with for example a cloth soaked in alcohol F10 2 ai Note Conductive silicone grease on the side of the electrode may interfere with accurate measurement One app
155. of Electrode Mechanism Block and Replacement of Damaged Parts Parts used in the detector s electrode mechanism block such as a motor assembly and rotating shaft assembly have a limited service life Their service life may be reduced unless they are used in appropriate condition The electrode mechanism block should be checked regularly to ensure proper operation The check is conducted effectively by combining full check and quick check In a full check components are checked thoroughly to ensure that no failure has occurred and a quick check is conducted at the time of calibration or other maintenance work It is recommended that components be replaced at recommended replacement intervals Table 8 2 shows items that need periodic inspection maintenance and replacement Table 8 2 Periodic Inspection Maintenance and Replacement Parts Inspection Intervals tem Full Check Quick Check Recommended Replacement Intervals Brush and slip ring 3 months 2 years or if characteristic without range Drive belt 6 months 3 months 3 years operating time Driven shaft assembly 6 months 3 months 3 years operating time Motor assembly gear head 6 months 3 montsh 3 years operating time IM 12F4A1 01E 8th Edition Aug 2014 lt 8 Maintenance gt 8 9 8 10 1 Inspection Maintenance and Replacement of Brush and Slip Ring A NOTE Do not touch the brush except when replacement is performed Inspection and Maintenance Procedure Remove the cove
156. of the diffusion current which varies with temperature The measuring tank is made of acrylic resin and the place of indicator electrode insertion houses the glass beads for polishing the electrode The measuring circuit part of the converter is housed in a sealed case of aluminium alloy together with an operating panel and an external cable connecting the terminal board The measuring circuit part serves to amplify and carry out computation based on the input dif fusion current and temperature compensating signal from the detector and to obtain output signals of 1 to 5 V DC or 4 to 20 mA DG corresponding to the output range Drive assembly N li ora ET im a Ly JE i TF TID LE VZZZ FZ rag LL Dy ft Indicator electrode Counter electrode Operating panel ale Jak fv External cable Q Measuring tank r connecting ma terminal NS A Glass beads m F1 3 ai Figure 1 2 Detector Figure 1 3 Converter Sampling System Sampling System consists primarily of sample water tubing and reagent tubing The system conditions the sample water and reagent fed to the measuring tank in the detector to a specified flow rate The sample tubing incorporates a ball valve a head tank for tap water or a sand filter for raw or treated water and a m
157. olution pump a o switching valve PU Drain VP40 pipe Ball valve Pressure reducing Activated charcoal filter V11 12 i valve PR pr ko Vi F11 2 ca v3 Ball valve V 3 way solenoid V4 A valve SV6 Measuring p sample inlet HE KO Tap water inlet VP16 pipe VP16 pipe y e E 550 1 Option ARS applies to model with arrestors 2 Option AZC applies to model with auto zero calibration 3 Option APO applies to model with air purge pump F2_2E ai IM 12F4A1 01E 8th Edition Aug 2014 lt 2 Specifications gt 2 10 m RC400G 3 Residual chlorine analyzer for treated water with two cylin der sand filter unit unit mm Standard solution inlet Air purge inlet Rc1 4 female Rc1 4 female Maintenance Maintenance Reagent inlet space space Rc1 4 fema 4 15 holes for anchor bolt Approx 200 530 Approx 200 of 3 Ball valve V8 Stand 8 3 Strainer S1 N 8 j 2 Maintenance or i Front fo 5 space Q 20 490 20 lt Cross section A A Air pump 3 Converter AP CON al Detector Sand filter Sand filter CELL
158. omponent must be replaced Polish the indicator electrode referring to subsection 4 3 10 Clean glass beads using the procedure described in subsection 8 4 If not cleanable replace them Can calibration be performed Defective indicator electrode is the cause of the failure Replace the electrode End F9 2 ai Sensitivity Failure Inspection Flow Chart IM 12F4A1 01E 8th Edition Aug 2014 lt 9 Troubleshooting gt 9 4 9 1 2 5 Error code Err23 response failure Reset the response failure detection limit at a larger value referring to subsection 5 3 4 4 and recalibrate the analyzer If error is still displayed after changing the limit value confirm the applied voltage Measure the voltage between the connecting terminals ME and RE with a voltmeter of input resistance 1 MQ or mode with ME terminal positive and RE terminal negative When the voltage is stable in the range of 20 mV it is normal If not itis attributable to a defective voltage applying circuit Replace the circuit board assembly on which the respec tive circuit is located lt FAIL gt Lamp Lit Types of lt failure gt which turn on lt FAIL gt lamp and respective error codes are listed in Table 9 2 Err13 Err24 and Err25 are detected only when execution of failure detecting function is selected When lt FAIL gt lamp is lit confirm the error codes may be displayed simultaneously
159. onochloramine 21 2H f 9 NHZCI ise tssccdeteienereees 2 Combined available chlorine NHClo 41 3H gt 212 NH4CI CF sit 3 NCl3 6l 4H 3l2 NH4Cl 2CF annann 4 IM 12F4A1 01E 8th Edition Aug 2014 lt 1 Outline gt 1 4 The iodine concentration indirectly chlorine concentration is determined by applying a voltage across the indicator and counter electrodes to conduct electrolytic reduction of the free iodine and simultaneously measuring the current Therefore the voltage to be applied is selected as a value at which the so called polarograph concentration polarization occurs that is current does not change when voltage changes For measuring total residual chlorine 0 40 V is applied The diffusion current observed under this condition is approx 2 0 uA mg I in reference to the sample water at 20 C and temperature coefficient is approx 2 2 C in the range of 0 to 40 C The effect of temperature coefficient on measurement values is compensated by processing temperature signals from the temperature sensor Pt 1000 Q built in the counter electrode In addition to potassium iodide acetic acid and sodium acetate are added to the reagent to make the reagent act as a pH buffer All the chlorine components are effectively detected by reducing the pH of sample water to 4 5 or below For measurement of free available chlorine content potassium bromide KBr is added to sample water an
160. ontact pressure adjusting screw Gear head Cell motor assembl Plate y Clamp Electrode holder Counter electrode Indicator electrode F8 7 ai Figure 8 7 Electrode Mechanism Block 2 Remove the brush by loosening the two screws one serves as a wiring terminal screw holding the brush IM 12F4A1 01E 8th Edition Aug 2014 lt 8 Maintenance gt 8 1 0 Remove the two pulleys of the drive shaft cell motor shaft and the driven shaft indicator electrode mounting shaft The driven shaft pulley can be removed by inserting an Allen wrench 2 mm nominal sup plied into the hole in the shaft which is used as a lock and unscrewing the end of the driven shaft The drive shaft pulley can be removed by loosening the two set screws using an Allen wrench 1 5 mm nominal supplied Remove the pulleys by pulling them out together with the drive belt Pull out the slip ring from the driven shaft and install a new one Reinstall the pulleys and drive belt Note Mount the drive shaft pulley so that it is 0 3 to 0 7 mm from end of the shaft Install a new brush taking care not to deform it Align the hole in the brush with the position ing pin on the bracket and fix the brush with the two screws After installing make sure that the brush contacts are in contact with the slip ring and that the brush itself is not in contact with the pulleys If the brush contacts are not in contact with the slip ring change the posi
161. osition approx 4 cm above the bottom of the bead case 3 Restore the electrode mechanism block Note The upper surface of the glass beads with the indicator electrode placed in the bead case is to be located 1 cm higher than the lowest slit position Electrode mechanism block Status in which the electrode mechanism block has been removed Fixing screws pester 2 pcs i Lowest slit I position Indicator electrode Glass beads Bead case cover F 4 2 2 ai Figure 4 4 Detector Construction 4 2 3 Checking the Sand in the Sand Filter This is a check to be performed when a residual chlorine analyzer for raw water or treated water is used Confirm that the sand filter is filled with sand up to the scale 10 position of the filter cylinder If lacking replenish the sand by opening the upper cover of the cylinder Use filter sand having an effective dia of 0 6 mm and uniformity coefficient of 1 4 as adopted in filtration plants IM 12F4A1 01E 8th Edition Aug 2014 lt 4 Operation gt 4 6 4 3 Startup Proceed with the work sequentially in accordance with subsections 4 3 1 to 4 3 12 Prior to starting work reviews chapter 5 and 6 to understand the outlines of the key operations and analyzer operation 4 3 1 Confirming Tubing and Wiring Implementation Confirm the proper connections of tubing and wiring to the residual chlorine analyzer referring to sections 3 2 and 3 3 4 3 2 Feeding Sample
162. other than lt MEAS gt mode Table 6 2 shows contact ratings of relays for contact output Contact loads which satisfy any of these conditions to the wiring terminals Table 6 2 Contact Ratings of Relays for COntact Output Resistive Load Max permissible power 60 W 125 VA Max permissible voltage 220 V 250 V Max permissible current 2A 2A Contact Input The converter is provided with a function which receives one type of contact signal input shown in Table 6 3 and executes action in response to the signal requirement However only the contact signal lt remote gt range selection is used for the RC400G residual chlorine analyzers of standard specifications Note For lt remote gt range selection action see subsection 5 3 4 10 Table 6 3 Converter Contact Input Function Connection Contact Input Judgment Application Terminal Names OFF Range selection lt remote gt RANGE Input resistance 100 kQ or more Input resistance 200 or less IM 12F4A1 01E 8th Edition Aug 2014 lt 6 Converter Operating Functions gt 6 5 6 5 Default Status When Mode Change Table 6 4 shows default status of cell motor metering pumps and solenoid valves SV1 to SV6 when mode change Table 6 4 Default Status of Pumps Solenoid Valves etc When Mode Change Equipment Name lt MEAS gt Mode lt MAINT gt Mode lt PROGRAM 1 gt lt PROGRAM 2 gt Symbol RC400G 1 2 RC400G 3 RC400G 1 2 RC400
163. output is held and the lt HOLD gt lamp turns on Chlorine free water is supplied for the preparation time of automatic zero calibration and sample water is supplied for the relaxa tion time of automatic zero calibration After the flushing is completed the held analog output is released and the lt HOLD gt lamp turns off The timer of zero filter flushing cycle is activated or deactivated in the following condition The timer is activated when e the power is turned on provided that the analyzer is preset so that it meets the conditions that enable the zero filter flushing function e the automatic calibration function is set to on provided that the automatic zero calibration cycle is preset to one longer than one day the automatic zero calibration cycle is changed to the one longer than one day provided that the automatic calibration function is preset to on When the timer is activated the counter is reset The timer is deactivated when e the automatic calibration function is changed to oFF while the zero filter flushing timer is running e the automatic zero calibration cycle is changed to one day or shorter while the zero filter flushing timer is running IM 12F4A1 01E 8th Edition Aug 2014 Ay NOTE 1 lt 7 Calibration gt 7 5 Zero filter flushing will be aborted if the mode is changed to the one other than the lt MEAS gt mode during the flushing Upon abort the held analog out
164. p starts flashing e Indication stability is checked gt 000 03 mg l When stabilized the entire display flashes once and the calibration is performed gt 000 00 mg l lt CAL gt lamp extinguishes at the same time If ENT key is pressed before stabilization is judged to be completed calibration is performed at that instant When indication is stable zero point error is examined and if it is out of permissible range the following message is displayed Err21 zero point failure in calibration If indication is not stabilized within the predetermined time the following message is displayed Err23 response failure in calibration IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 1 2 In either case only the message is displayed and no lighting of lt FAIL gt lamp and no output of lt FAIL gt contact signal occur The error message display is reset by pressing ENT key returning to the residual chlorine con centration display The criteria for zero point failure and response failure are as shown in Table 5 8 Table 5 8 Failures in Zero Calibration and Their Criteria Failure Criteria Zero point failure Diffusion current exceeding the range 1 to 1 pA fixed Stabilizing time exceeding the setpoint set using function code 6 in lt PROGRAM 1 gt mode Set at 7 min on shipment Response failure In any stage of zero point calibrating operation transferring to othe
165. pection of Sand Filter Surface ccccceeeseeeeeeeeeeeeeeeeeeteeeseaees 8 6 8 9 2 Checking the Sand Volume in Sand Filters srranrrnnrnnnrnonrnonrrrnrrenn 8 6 8 9 3 Checking the Discoloration of Sand in Sand Filters 000 8 7 8 9 4 Filter Replacement cc cccecceceeceeeeceeeeneeeeeeeeeaceeeneeeeaeeeeeeesineeeans 8 7 8 10 Inspection of Electrode Mechanism Block and Replacement of Damaged Parts 8 8 8 10 1 Inspection Maintenance and Replacement of Brush and Slip Ring 8 9 8 10 2 Inspection Maintenance and Replacement of Drive Belt 8 10 8 10 3 Inspection Maintenance and Replacement of Driven Shaft Assembly8 11 8 10 4 Inspection Maintenance and Replacement of Motor Assembly Gear alte a AEE E Gasa 8 13 8 10 5 Replacement of Activated Charcoal Filter rrrrnnrrrronnvrvrnnnnrrnnnrr 8 14 Troubleshooting ssc ceic ses cree ce ada ects erecta etre nde estate hee esc cts 9 1 9 1 When lt failure gt is Indicated rrnnvrnnnvrnnnnvnnnnvnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnner 9 1 9 1 1 Indication of Error Message or Error Code During Operation 9 1 9 1 2 lt FAIL gt Lamp Lits t t Sects aan tein ayant eyes 9 4 9 2 Operation Failures in Measurement Without lt failure gt Detection 9 8 IM 12F4A1 01E 8th Edition Aug 2014 Toc 4 9 3 Other Failures iiaa Naaa AEE aE EAEAN 9 10 9 3 1 Analog Output does not Correspond to Indicated Value
166. peration Next disconnect the tubing connected to the sample water metering pump delivery joint and the tubing connected to the reagent metering pump suction and delivery joints Loosen six screws fixing the plate When disconnecting tubing take measures to prevent reagent from flowing out of the rea gent tank 2 Remove the metering pump from the plate First remove the Bellofram in according with subsection 8 7 1 Next disconnect the tubings connected to the pump and then loosen four screws located at the rear of the plate 3 Remove the valve assembly Turn the valve assembly counterclockwise It is crowed into the pump main body using a special tool accessory Special tool Shaft Valve sheet presser foot Valve sheet F8 4 ai Figure 8 4 Valve Sheet Construction and How to Remove It 4 Remove the used valve sheet from the shaft and properly fit a new valve sheet to the shaft Mount the valve sheet so that its flange is not forced out from the valve sheet pressing foot groove 5 Fully screw the valve assembly into the pump main body 6 Incorporate the metering pump to the pump mounting plate and then mount this plate to the case When installing confirm that the drain hole of the metering pump is underneath aid I r Remount the metering pump parts such as Bellofram removed in step 2 ec wm Reconnect once disconnected tubings as before Cause reagent to flow
167. planning maintenance IM 12F4A1 01E 8th Edition Aug 2014 lt 10 Spare Parts and Consumables gt 10 2 10 2 Complementary Description 10 2 1 Reagent K9041TH K9041TG K9041TJ K9041TQ The reagent for free available chlorine measurement is prepared by acetic acid anhydrous sodium acetate and potassium bromide For making 100 liter of this reagent 1000 mL of acetic acid 1 kg of anhydrous sodium acetate and 4 kg of potassium bromide are required Reagent of 100 liter is approx 45 days supply Therefore for a year supply a quantity of 8 times the above is required K9041TH 17 bottles K9041TG 16 bottles K9041TJ 64 bottles The reagent for total residual chlorine measurement is prepared by acetic acid anhydrous so dium acetate and potassium iodide Quantities of each component vary with the measurement range Refer to subsection 2 1 10 2 2 Lubricating oil K9041RA To maintain smooth operation of the metering pump drive assembly levers use this lubricating oil on each bearing of the four lever support blocks once a month or so One bottle of lubricating oil is supplied as an accessory It can be used for some time as its use requires only about 0 4 ml at one time 10 2 3 Polishing Powder K9088PE This is used to remove contamination on the indicator electrode as contamination cannot be prevented completely by automatic polishing with glass beads One bottle of the agent is supplied as an accessory 10 2 4 Glass Beads
168. ple water valve V3 cleaning water valve V4 RC400G 3 Sample water valves V3 and V4 cleaning water valve V6 2 Remove the top cover on the sand filter and remove as much sand as possible from the sand filter by hand or using a container 3 Loosen the 4 fixing screws at the bottom of the sand filter and remove the sand filter 4 Loosen the 4 set screws at the bottom of the filter cylinder and remove the filter by pulling the part of cleaning tap water inlet downward Remaining sand in the filter cylinder if any falls together with the filter 5 Replace the filter with a new one reinstall the part of cleaning water inlet and fix the filter with the set screws Remove the remaining sand well by rinsing Otherwise scratches may occur causing leakage O Reinstall the sand filter and fix it with the fixing screws ratte FI r Replenish the filter cylinder with sand to scale marking lt 10 gt 00 lt Reinstall the top cover on the sand filter open the sample water valve s and cleaning water valve to start supplying sample water and cleaning water IM 12F4A1 01E 8th Edition Aug 2014 lt 8 Maintenance gt 8 8 4 Sample Water Inlet I fa Filter Cylinder Overflow Outlet ME KEN Filter Sand Set Screws 4 og Da Filtrate Outlet Fixing Screws 4 LETH Cleaning Water Inlet F8 6 ai Figure 8 6 Inspection and Maintenance of Sand Filter 8 10 Inspection
169. put is released and lt HOLD gt lamp turns off Also the zero filter flushing cycle timer is reset 2 Ifthe FUNC key is pressed during zero filter flushing the zero filter flushing will continue The selected item remains displayed 3 Ifan automatic zero calibration starts during zero filter flushing the zero filter flushing will be aborted 4 Ifthe time for zero filter flushing comes during automatic zero calibration the zero filter flushing will not be executed 5 Ifthe time for automatic cleaning comes during zero filter flushing the zero filter flushing will continue and the automatic cleaning will not be executed 6 Ifthe time for zero filter flushing comes during automatic cleaning the automatic cleaning will be aborted and the zero filter flushing will be executed 7 Zero filter flushing is executed only when the analyzer is in lt MEAS gt mode If the time for zero filter flushing comes when the analyzer is in the other modes the zero filter flushing will not be executed The timer is reset and then starts counting Span Calibration NOTE Before performing a span calibration make sure that the electrode mechanism block is prop erly installed in the measuring tank after the zero calibration and also that the electrode rotates smoothly in the cell Conduct span calibration using a calibrating standard solution which has a residual chlorine con centration of around 80 of the output range used Dilute comm
170. r out of range settings reset this display using gt key to set it again When an applied voltage is changed it takes some time until indication is stabilized Exercise care for this fact when transfer ring to lt MEAS gt mode 4 Parameter Setting for Response Checking Function code 6 7 and 8 This function sets parameters for detecting stability judgment and response failure automatically executed when calibration is to be performed and when plateau characteristics are to be taken IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 24 Table 5 18 shows parameters to be set When plateau characteristics are to be taken response failure Err23 detection is not conducted Table 5 18 Parameters for Response Checking Function Code Setting Content Permissible Setting Range 6 Response time limit 0 1 to 10 0 min 7 Concentration for detecting indication stabilization 0 01 to 2 00 mg l 8 Detecting time for detecting indication stabilization 2 to 180 sec Figure 5 8 shows the judgment method for indication stabilization Concentration Concentration change AS AS t Response time limit gini t Detection time for detecting indication stabilization AS Concentration change within detecting time AS Concentration for detecting indication stabilization Detection start Response failure Err24 F5 8 ai Figure 5 8 Judgment Method for Indicatio
171. r modes or function codes is available by pressing MODE key or FUNC key However unless calibration is completed the calibrating operation conducted before becomes invalid 2 Span Calibration Function code 2 Span calibration is performed using a standard calibration solution For details see section 7 3 Span Calibration In this subsection key operation for it is described First set the residual chlorine concentration in the standard calibration solution and then start the calibration operation The key operation procedure is as follows Example a Select function code 2 in lt MAINT gt mode 000 46 mg l b Press gt key 000 46 mg l The most significant digit flashes c Selecta digit to be set by pressing gt key and set the calibration concentration using A and v keys 000 57 mg l The last set digit flashes d Press ENT key lt CAL gt lamp starts flash 000 48 mg l Current concentration If calibration concentration setpoint is out of the permissible range the following message is displayed not setpoint failure The message is reset by pressing gt key and the display returns to the indication in b Indication stability is checked 000 54 mg l e When stabilized the entire display flashes once and the calibrated 000 57 mg l At the same time lt CAL gt lamp extinguishes If ENT key is pressed before stabilization judgment cali
172. r natural changes E Yokogawa does not warrant conformance with the specific application at the user site Yokogawa will not bear direct indirect responsibility for damage due to a specific application E Yokogawa Electric will not bear responsibility when the user config ures the product into systems or resells the product E Maintenance service and supplying repair parts will be covered for five years after the production ends For repair for this product please contact the nearest sales office described in this instruction manual IM 12F4A1 01E 8th Edition Aug 2014 Toc 1 Model RC400G Residual Chlorine Analyzer Style S3 IM 12F4A1 01E 8th Edition CONTENTS Tah Let e to 9 leet E ee TS re ee nr a eer eee er renner i Safety Precautions sss iio se eee eee ii After sales Warranty ssccincccnsicnrcncticitienin ction hadesawieninaneis iv 1 Outline EE EE scer EE a Ea E e ES 1 1 1 1 RC400G Residual Chlorine Analyzer Configuration cccccseseeeeeneees 1 2 1 2 Operating Principle of RC400G Residual Chlorine AnalyZet eee 1 3 2 SPECIES ar 2 1 2 1 RC400G Residual Chlorine Analyzer r rrsvrnnvnnnvnnnvnnnvnnnvnnnnnnnnnnnvnnnnnnnnnnnnnnnenn 2 1 2 1 1 Standard specifications c cccccccececeeeeeeseeeeeeeeeeeeeeeeeseaeeeseeeetens 2 1 2 1 2 Gharacleristits ee tn enmesiermidldnnm casts 2 5 2 1 3 ACCS SONOS bedende edleste kista detewee va 2 5 2 1 4 Product model and Suffix COGes rrrrnnn
173. r of the electrode mechanism block for inspection and maintenance The inspection and maintenance should be performed in time with other maintenance work such as polish of rotating gold electrode The recommended interval is three month e Visually inspect the slip ring on the driven shaft and the brush contacts that are in contact with the slip ring to ensure that no wear or failure has occurred e Measure the resistance between the brush wiring terminal a fixing screw and the driven shaft place under the slip ring using a tester With the rotating gold electrode rotating the resistance must be stable within the range of 500 or less If the resistance exceeds 500 Q wipe off dirt or stain on the slip ring using a cotton swab soaked in alcohol or by appropriate means Then re measure the resistance Replacement Procedure If any defects such as wear of the slip ring or a bend of the brush are observed or if the resist ance between the brush wiring terminal and the driven shaft still exceeds 500 Q after wiping the slip ring and brush should be replaced The replacement in principle should be conducted by Yokogawa s service person The replacement procedure is described below just in case the replacement is conducted by the user 1 Turn off the switch installed in the power line to stop the operation of the RC400G Driven shaft Drive shaft Brush Drive belt Pulleys Brush fixing screw Rock screw Slip ring Ea C
174. r to subsections 5 2 3 and 5 2 4 4 3 12 Output Range Setting There are two output ranges output range 1 and output range 2 and either of them can be output The above two ranges can be selected lt local gt or lt remote gt In lt remote gt selection output range 1 is output when the contact of the range selection contact input is open while output range 2 is output when the above contact is closed On shipment the range selection is set to lt local gt If the range is to be selected lt remote gt or output range 2 is to be output reset the range selec tion referring to 5 3 4 7 The range for output range 1 set on shipment is 0 00 to 5 00 mg l and the range for output range 2 set is 0 00 to 10 00 mg l If range change is required refer to 5 3 4 1 4 3 13 Calibration 4 4 Calibrate zero and span For practical calibration procedure see 5 3 3 1 and 2 and chapter 7 Now the startup takes are completed If the data set on shipment from the factory are changed note them The setting data is stored in EEPROM Hence the data is not lost even if power is turned OFF However if memory failure is detected and memory contents are initialized the data may be lost in this case Operation If operation conditions are arranged at startup there is no need to perform adjustment or control in actual operation However inspection and maintenance for maintaining
175. rd for wiring Wiring procedure Operation command key Error code list Terminal code indication Haa Figure 4 2 Component Identification and Functions of Residual Chlorine Analyzer 2 IM 12F4A1 01E 8th Edition Aug 2014 lt 4 Operation gt 4 3 Detector and electrode mechanism block Cover Prevents the ingress of corrosive gases Base Electrode Mechanism Block Fixing Screws Measuring Tank Glass Beads Polishes rotating indicator electrode to keep electrode surface clean Brush Drive Shaft Driven Shaft Receives power transmitted from drive shaft via drive belt and rotates indicator electrode Also transmits electrode signal to brush Gear Head Cell Motor Rotates indicator electrode at a constant speed Clamp Holds counter electrode Measuring tank Counter Reference Electrode 1 Platinum electrode with built in Pt1000 temperature sensor Sample Water Inlet Indicator Electrode Rotating Gold Alloy Electrode Drain Cock Pipe Fitting with Plug Used to drain measuring tank Pipe connection for cleaning water Not used for RC400G 1 1 In the case of combined chlorine insensitive version silver chloride electrode with built in Pt1000 temperature sensor is used F4 2 ai Figure 4 3 Component Identification and Functions of Residual Chlorine Analyzer 3 IM 12F4A1 01E 8th Edition Aug 2014 lt 4 Operation gt 4 4
176. ress ENT key to enter it 00040 Entire display once flashes For inputs out of the setting range not is displayed Reset the display by pressing gt key and set it again 7 Concentration Upper Limit Alarm Setpoint Setting Function code b If the upper limit alarm function execution is selected with function code 5 in lt PROGRAM 2 gt mode when the residual chlorine concentration indication exceeds the setpoint lt FAIL gt lamp lights and if in lt MEAS gt mode lt failure gt contact signal is output The range that can be set as the upper limit alarm value is 0 00 to 11 00 mg l The setting key operation procedure is as follows a Select function code b 011 00 mg l b Press gt key 011 00 mg l Leftmost digit flashes c Select the digit using gt key and set a numeric value using A and v keys 001 50 mg l Last set digit flashes d Press ENT key to enter it 001 50 mg l Entire display once flashes For inputs out of the setting range not is displayed Reset the display by pressing gt key and set it again 8 Out of Sample Detection Concentration Setting Function code c This concentration has been set at the value of the 0 10 mg l on shipment In this case if it is assumed that the sample residual chlorine concentration in the normal state is below 0 10 mg l an approx three minute out of sample detection in a ten min
177. ris from slip ring Refer to subsection 10 2 11 b Rreplace the brush and or slip ring Refer to subsection 8 10 1 5 Failure of the temperature sensor in the 5 Replace the counter electrode Checking counter electrode method Measure resistance between the conductors T1 and T2 of the electrode cord It should be about 1078 Q at 20 C If resistance value changes with temperature it is normal 6 Current leaks from the input circuit 6 Check the electrode mechanism block for insulation failures and fix if any Checking example between the brush and bracket Measurement 1 The electrodes especially the indicator 1 Polish the indicator electrode referring to error is large electrode is contaminated subsection 4 3 10 and clean glass beads referring to subsection 8 4 If not cleanable replace them 2 Zero point and span are not properly calibrated 2 Calibrate zero point and span 3 Sand adsorbs chlorine when filter sand in the sand filter has been replaced 3 Clean sand repeatedly before performing measurement total cleaning time About 20 minutes No response 1 The pump does not feed sample water 1 Replace Bellofram or valve sheet 2 Wire breakage between the electrodes Slow re 2 Deterioration of the filter capacity of the 2 Improve performance referring to subsection ee sand filter 8 9 Measured 1 The indicator electrode does not rotate 1 Check the se
178. rmissible range reset this display by pressing gt key and set it again 6 Line Segment Function Output Setting Function code A Analog signals can be output in the form of line segment function The setpoint value of the function for a span mg l in the output range is the break point corresponding to 50 of the output signal 4 to 20 mA or 1 to 5 V span The setting range is 0 to 100 Figure 5 9 shows a setting example Output signal mA 20 Example of setting Break point Output range 0 to 5 mg l Output 4 to 20 mA 12 Break point setting 40 2 mg l N 2 3 4 5 Output range mg l 40 setting F5 9 ai Figure 5 9 Example of Line Segment Output If the setpoint is specified at 50 the output becomes linear Also if set to 0 or 100 the output is as shown in Figure 5 10 20 20 Output Output signal signal mA mA 12 12 4 4 Lower Upper Lower Upper limit Output range mg l limit limit Output range mg l limit When set to 0 When set to 100 F5 10 ai Figure 5 10 Output when break point is set to 0 or 100 IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 26 The setting key operation procedure is shown below a Select function code A 00050 b Press gt key 00050 Leftmost digit flashes c Select the digit using gt key and set a numeric value using A and v keys 00040 Last set digit flashes d P
179. rode of Sec 10 2 9 by style S3 figure of electrode added and Sec 10 2 10 Fuse A1094EF changed to Fuse A1113EF P 10 4 P N change of Sec 10 2 12 Driven Shaft Assembly CMPL CMPL 12F04A01 03E newly published for style S3 because P N of indicator electrode and driven shaft assembly changed from CMPL 12F04A01 01 for style S2 or before and CMPL 12F04A01 11E revised to 5th edition edited by InDesign contens are same Jun 2011 5th Edition For Style S2 Remake and all pages changed P 2 6 Some revision of MS code description P 2 7 Factory wastewater deleted from applications P 4 5 Some revision of Table 4 2 P 4 7 to 4 8 Some error correction P 5 3 to 5 6 Some revision of Table 5 3 to 5 6 P 5 14 to 5 20 Some error correction and some revision of Figure 5 6 P 5 21 to 5 22 Some revision of 5 3 4 Key Operations in lt PROGRAM 1 gt Mode P 5 27 Addition of 9 Setting Averaging Coefficient and following number of items revised IM 12F4A1 01E 8th Edition Aug 2014 P 5 33 Some revision of Figure 5 14 P 6 4 to 6 5 Some revision of 6 5 Data Backup and Operation When Power is Turned ON Again P 9 6 Some revision of Figure 9 4 CMPL 12F04A01 01E revised to 9th edition some revision of P N in P 5 item 3 P 6 item 7 Jan 2010 4th Edition P 2 11 Addition of note of reagent tank Oct 2009 3rd Edition P 2 4 Change the specification Response time P 2 5 P 2 7 Change the package of glass
180. rranty carry consult local sales representative or service office Yokogawa will replace or repair any damaged parts Before consulting a product for repair un der warranty provide us with the model name and serial number and a description of the problem Any diagrams or data explaining the prob lem would also be appreciated If we replace the product with a new one we won t provide you with a repair report Yokogawa warrants the product for the period stated in the pre purchase quotation Yokogawa shall conduct defined warranty service based on its standard When the custom er site is located outside of the service area a fee for dispatching the maintenance engineer will be charged to the customer E In the following cases customer will be charged repair fee regardless of warranty period Failure of components which are out of scope of warranty stated in instruction manual e Failure caused by usage of software hardware or auxiliary equipment which Yokogawa Electric did not supply e Failure due to improper or insufficient maintenance by user e Failure due to modification misuse or outside of specifications operation which Yokogawa does not authorize e Failure due to power supply voltage frequency being outside specifications or abnormal e Failure caused by any usage out of scope of recommended usage Any damage from fire earthquake storms and floods lightning disturbances riots warfare radiation and othe
181. rt command operation is available Exercise care to prevent electric shock since solenoid valve driving power is applied to predetermined terminals by start command operation Key operations for start command are common to cleaning of each item Cleaning operation time is the same as that set in function codes in lt PROGRAM 2 gt mode Key operation procedure is shown below a Select function code 4 5 or 6 in lt MAINT gt mode The data display indicates as shown below Example Function code 4 measuring tank cleaning JEG Function code 5 sand filter cylinder 1 cleaning bLo 1 Function code 6 sand filter cylinder 2 cleaning blo 2 b Press ENT key lt WASH gt lamp starts to flash 59 sec Decreases with time lapse e Cleaning action starts and the operation display lamp corresponding to the active solenoid valve lights Data display indicates time unit sec and elapsed time is counted down When set cleaning operation time is over lt WASH gt lamp extinguishes and cleaning operation is completed End If ENT key is pressed after cleaning operation is completed the status returns to a If ENT key is pressed during cleaning operation the cleaning operation is aborted at that time Also if one of the other modes or functions is selected using MODE key or FUNC key the cleaning operation is aborted During cleaning operation of the operation command keys SV1 key or o
182. s steel 6 Please contact Yokogawa regarding the adequate number of the cylinder MT Installation of air purge is always required for all application If instrument air cannot be used select the air purge pump IM 12F4A1 01E 8th Edition Aug 2014 lt 2 Specifications gt 2 7 Measurement object Application i i Free chlorine Total chlorine Water purification raw water O 1 O Water purification mixed water sedimentation water O 1 O Water purification mains water O O Sea water x x 3 Factory wastewater treated effluent x x Factory cooling water industrial water x O 2 Factory drinking water O O Sewage secondary treatment x x 3 O Can be measured x Cannot be measured 41 If ammoniacal contaminants are present in large quantity high concentrations of combined chlorine may remain if sampling is performed soon after chlorine injection in prechlorination treatment or in intermediate treatment without prechlorination treat ment In this case combined chlorine type is recommended 2 Oxidizing or reducing agents other than chlorine may be present If so chlorine concentration measurement may not be possible 3 There are Residual chlorine analyzer for sewage secondary treatment or sea water Please ask Spare parts inti Recommended Name Partno Description QY replacement interval 1 Indicator electrode Rotating electrode K9334JP Gold alloy electrode 4
183. screws are loose Then draw the drive belt horizontally in the direction of the line that connects between the drive shaft and the driven shaft by a force of 4 N spring balance reading of 0 4 kgf With this tension kept tighten the screws completely 16 Install the indicator electrode in the driven shaft Check that the indicator electrode does not make contact with the base A NOTE If the indicator electrode makes contact with the base or if the center of the hole in the base and the center of the indicator electrode are misaligned largely loosen the four screws holding the motor mounting plate to the base and adjust the positions 17 Install the reference counter electrode make the wiring connections and fix it with the clamp 18 Install the brush and bracket which holds the brush If the screws holding the motor mount ing plate have been loosened in step 16 set the contact pressure adjusting screw so that the brush makes contact with the slip ring at an optimum contact pressure See subsection 8 10 1 Replacement is now complete After supplying power to the RC400G make sure that the drive shaft drive belt and driven shaft rotate smoothly Also check that abnormal sounds resonant sound discontinuous sound etc are not heard 8 10 4 Inspection Maintenance and Replacement of Motor Assembly Gear Head Inspection and Maintenance Procedure With the electrode mechanism block working at the time of for examp
184. side Polyethylene tubing 5m diameter A mm Note These are not included in reagent mising tank RC401G C 2 2 4 Outline drawings e RC401G A e RC401G B Unit mm Reagent tank _ Reagent output Rc1 4 Needle 3 valve i Manual mixer Approx 1600 Reagent input Level gauge Approx Reagent 700 output Approx Rc1 4 299 20 100 4 913 holes 100 e RC401G C T a Approx 1280 770 460 F0204 ai IM 12F4A1 01E 8th Edition Aug 2014 lt 3 Installation Tubing and Wiring gt 3 1 3 Installation Tubing and Wiring Instructions for installation tubing and wiring of the RC400G Residual Chlorine Analyzer are given in this chapter When transferring the RC400G from storage or in unpacking it observe the caution in the foreword in the early part of this user s manual 3 1 Installation 3 1 1 Location Install the RC400G analyzer in a location to satisfying the following conditions e A building or a cabinet free rain water Slight vibration e Substantially free from corrosive gases e Low humidity Slight temperature variation Ambient temperature should be approximately maintainable near ordinary temperatures e Sufficient and accessible space for maintenance e Provision for drainage 3 1 2 Installation Securely fix the analyzer to
185. so initialized 9 2 Operation Failures in Measurement Without lt failure gt Detection Phenomena which hamper normal measurement such as measured value fluctuation can take place without detection of lt failure gt Possible failure symptoms causes and corrective actions are described in Table 9 3 IM 12F4A1 01E 8th Edition Aug 2014 lt 9 Troubleshooting gt Table 9 3 Causes and Corrective Actions for Operation Failures in Measurement Symptoms Possible Causes Corrective Actions Measured 1 Reagent is not mixed with sample water karen a No reagent in the reagent tank 1 a Supply reagent to the reagent tank b Reagent metering pump failure 1 b Check delivery flow rate If flow rate is not in specified range adjust it Replace defective Bellofram or valve sheet if there is any damage 2 The indicator electrode is not rotating a The drive belt of the electrode drive is 2 a Tighten the set screw not turning b The cell motor does not turn 2 b Replace the motor with a new one 3 The indicator electrode is worn and 3 Replace the electrode with a new one damaged 4 Electric resistance between the rotating 4 Inspect and maintain them according to shaft and the brush is high subsection 8 10 Checking method Measure the resistance between the rotating shaft and the brush with a multimeter If the result is 500 Q or less it is normal a Adjust the brush contact pressure and remove wear deb
186. spection should be performed approximately every six months Stop the opera tion of the electrode mechanism block for the inspection Turn the driven shaft by hand and check to ensure smooth rotation without looseness If looseness occurs if the driven shaft does not rotated by inertial force with the drive belt removed or if friction sound is heard immediately replace the driven shaft assembly Replacement Procedure If failure of bearings occurs the whole driven shaft assembly including the bearings should be replaced The replacement in principle should be conducted by Yokogawa s service person The replacement procedure is described below just in case the replacement is conducted by the user Steps 1 to 9 are a disassembly procedure and steps 10 and the following steps are an assembly procedure 1 Shut off the power fed to the RC400G then place the electrode mechanism block in the maintenance position then remove the cover see Figure 4 7 2 Remove indicator electrode and counter electrode To remove the indicator electrode inset the supplied hex key wrench into the socket of the driven shaft to stop it from rotating Disconnect the three wires connected to the counter electrode next loosen and remove the clamp holding the electrode in its holder 3 Remove the brush by loosening the two screws one serves as a wiring terminal screw holding the brush IM 12F4A1 01E 8th Edition Aug 2014 lt 8 Maintena
187. t screw for loosening Replace value fluctu ata constant speed the drive belt driven shaft assembly etc if ates largely defective 2 Incomplete conduction between the 2 a Adjust the brush contact pressure and slip ring and the brush in the electrode remove wear debris from the slip ring mechanism block Refer to subsection 10 2 11 2 b Replace the brush and slip ring Refer to subsection 8 10 1 Measured 1 Out of sample in the measuring tank 1 Restore detached tubing abnormally of the value does detected by out of sample detection metering pump etc to the normal status not vary 2 Repair broken wiring Replace electrode for wire breakage in the electrode 3 No voltage is applied between the indicator and counter electrodes 3 Repair the converter Checking method Measure voltage between connecting terminals ME and RE of the 1 MQ or more A result in the range of 0 40 0 02 V is normal IM 12F4A1 01E 8th Edition Aug 2014 lt 9 Troubleshooting gt 9 1 0 9 3 Other Failures 9 3 1 Analog Output does not Correspond to Indicated Value When analog output is abnormal whereas the display of residual chlorine concentration is nor mal output circuit may have failed When an output range of 4 to 20 mA is used confirm that load resistance is 550 Q or less 9 3 2 Cleaning is not Conducted Properly This problem may appear when the RC400G 2 or RC400G 3 is used When a symptom possibly caused by m
188. ter type Model RC400G 1 suitable for measurement of tap water or filtered water Raw Water type Model RC400G 2 suitable for measurement of raw water and Treated Water type Model RC400G 3 suitable for measurement of treated water such as sewer water after secondary treatment or plant waste water Combined Chlorine Insensitive Version If raw water contains large quantities of ammonia nitrogen combined chlorine will form and re main in the reaction process even if necessary and sufficient chlorine is added at prechlorination point In particular when the pH and temperature of the water are low combined chlorine dichlo ramine remains longer and breaks down slowly In measurement of free available chlorine in sample water that contains a high concentration of combined chlorine measurement errors may occur when the previous model of residual chlorine analyzer is used To solve this problem the combined chlorine insensitive version should be used It has modified electrode and reagent composition thereby improving sensitivity to free available chlorine in the presence of combined chlorine The electrode configuration reagent composi tion and applied voltage have been changed otherwise the measurement principle equipment specifications and performance remain unchanged from the previous model In this chapter the operating principle and structural outline of the RC400G Residual Chlorine Analyzer is described E
189. the factory If the fluctuation of measured readings is large e g due to suspended matter in the measurement object change the averaging coefficient as necessary The following is the procedure for the setting operation Example a Select function code d in the lt PROGRAM 1 gt mode 00001 b Selecta digit using gt key and set a numeric value using the A or v key gt 00005 c Press the ENT key to enter the value gt 00005 Entire display once flashes If the set value is beyond the permissible range not is displayed Reset the display by pressing gt key and set it again 10 Range Switching Remote Local Selection Function code 1 2 Analog output includes both output range 1 and output range 2 Select which range is to be output by specifying lt remote gt or lt local gt When lt remote gt is selected the range to be output is determined by the contact input status see Figure 5 11 Converter external wiring terminals Converter external wiring terminals R1 R2 R1 R2 Input contact open gt Output range 1 Input contact closed P Output range 2 F5 11 ai Figure 5 11 Relationship between Contact Input and Output Range in lt remote gt Range Switching For lt local gt selection select which is to be output output range 1 or output range 2 using func tion code 2 in the lt PROGRAM 1 gt mode IM 12F4A1 01E 8th Edition Aug 2
190. thers is invalid Table 5 11 shows setting and operation items related to manual cleaning start command Table 5 11 Setting and Operation Items Related to Manual Cleaning Start Command i z Solenoid Function Cleaning Object Time Setting Time Setting Set Time on Valve tobe Code Mode Function Shipment Operated 4 Measuring tank cleaning 4 One minute SV2 5 Sand filter cylinder 1 cleaning PROGRAM 2 T One minute SV1 6 Sand filter cylinder 2 cleaning 7 One minute SV5 5 Measurement of Sample Water and Reagent Metering Pump Flow Function code 7 and 8 Metering pump delivery flow rates are measured by measuring the time Sec during which each metering pump delivers the predetermined volume When the time is measured the converter computes the flow rate ml min using this time and displays the results IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 1 5 The sample water metering pump delivery volume is measured using function code 7 and the reagent metering pump delivery volume using function code 8 Key operation for time measure ment is the same for both metering pumps Key operation procedure is described below a Prepare for measurement according to subsection 4 3 5 or subsection 4 3 6 b Select function code 7 or 8 in lt MAINT gt mode The data display indicates as shown below Example Function code 7 sample water FLo_1 Fu
191. tion Using Open Input Circuit Method Perform zero calibration using the open input circuit method in the following procedure 1 Press CELL key in lt MAINT gt mode to stop turning of the indicator electrode When the electrode rotation is in stopping status lt CELL gt lamp extinguishes Next the electrode mechanism block is removed from the measuring tank see Figure 4 7 Set the function code to 1 The content of this code is zero calibration WO N Risso a Start calibrating operation Press ENT key During calibrating operation lt CAL gt lamp flashes Calibration is performed when the ana lyzer stabilizes so that predetermined conditions see subsection 5 3 4 4 are met after measured value stability is automatically checked When calibration is executed the value displayed in the data display flashes once and at the same time flashing lt CAL gt lamp extinguishes IM 12F4A1 01E 8th Edition Aug 2014 4 7 2 2 lt 7 Calibration gt 7 2 Re mount the electrode mechanism block to the measuring tank Also press CELL key to rotate the indicator electrode Zero Calibration Using Chlorine Free Water Conduct zero calibration using the chlorine free water in the following procedure Mount the elec trode mechanism block to the measuring tank and turn the indicator electrode in advance 1 Prepare chlorine free water of approx 2 to 3 liter produced by passing sample water through activate
192. tion is set to on detection execution on shipment change it in the following procedure if necessary a Select function code 4 5 on Detection execution OFF Detection stop b Every time gt key is pressed on and oF F are alternately displayed on lt gt oFF c Select on execution or oFF stop OFF d Press ENT key to enter it OFF Flashes once If the function is set to on execution lt FAIL gt lamp lights when a failure is detected and lt failure gt contact signal is output in lt MEAS gt mode Ay NOTE In addition to the above lt failure gt out of sample detecting function execution stop can also be selected This is specified by function code b in lt PROGRAM 1 gt mode IM 12F4A1 01E 8th Edition Aug 2014 lt 6 Converter Operating Functions gt 6 1 6 Converter Operating Functions Operating functions related to converter operation were partially described in 5 Convert er Operation This chapter describes details of the already described functions and the other operating functions 6 1 lt failure gt Detecting Operation For types of lt failure gt detected see subsection 5 3 3 8 and others This section describes de tecting operations for major lt failure gt The lt failure gt status is reset by turning the power off If abnormal cause is not eliminated after turning the power on lt failure gt is detected again and lt FA
193. tion of cleaning sequence to be used Function code 8 15 Selection of measuring tank cleaning function execution stop Function code 9 16 Selection of sand filter cylinder cleaning function execution stop Function code A 17 Selection of out of sample detecting function execution stop Function code b 18 Concentration display unit selection Function code c 19 Selection of air pump action function execution stop Function code d 20 Selection of negative below zero display in lt MEAS gt mode Function code E 21 Selection of below 4 mA output hold in lt MEAS gt mode Function code F IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 22 1 Output Range Setting Function code 1 2 Analog output signals include output range 1 and output range 2 Either of them can be arbi trarily output Function code 1 sets the range of output range 1 and function code 2 sets the range of out put range 2 In the following key operations for range setting are shown The key operation procedure is the same both in output range 1 and output range 2 Example a Select function code 1 or 2 L00 00 mg l Lower limit value display b On pressing gt key the lower limit value can be entered L00 00 mg l If change is not required start operation at step d
194. tively Connect the lead wire of the shield to terminal G Do not double ground the shield con nected to terminal G at the receiver end Wiring for Contact Input lt remote gt Range Switching The two output ranges are switchable to each other arbitrarily Range switching can be per formed either lt remote gt or lt local gt The wiring herewith described is provided for switching the range with lt remote gt see subsection 5 3 4 10 Use the remainder of the cable used for the analog output signal wiring described in subsection 3 3 2 Connect the two conductors of the cable to terminals R1 and R2 NOTE When cable inlet ports are available the wiring described above can be made with two separate cables For that employ a two conductor cable of 6 to 12 mm finished O D Treat the cable end in the same manner as the analog output signal cable Contact inputs ON Output range 2 is selected and OFF Output range 1 is selected are identified by the resistance condition shown in Table 3 1 On wiring ensure that a contact meet ing this condition is used Table 3 1 Identification of ON and OFF of Contact Input for lt remote gt Range Selection Identification ON Output range 2 Identification OFF Output range 1 Resistance contact 200 Qorless 100 kQ or more IM 12F4A1 01E 8th Edition Aug 2014 lt 3 Installation Tubing and Wiring gt 3 1 5 3 3 4 Wiring for Contact Output The
195. top can be selected using function code 5 in lt PRO GRAM 2 mode IM 12F4A1 01E 8th Edition Aug 2014 6 4 lt 6 Converter Operating Functions gt 6 2 6 3 6 4 Analog Output Signal Analog output signal is either 4 to 20 mADC or 1 to 5 V DC corresponding to output range spans Their selection is performed by changing PCB jumper pin connection in the converter On ship ment either one that was required by the user has been set If change is required contact Yokogawa because service work is required to be conducted for removing the control panel Analog outputs can cover 10 to 110 of the span in the output range for bath 4 to 20 mA DC and 1 to 5 V DC output range 1 and output range 2 The load resistance is 550 Q or less for 4 to 20 mA DC output and 300 Q or less for 1 to 5 V DC output Contact Output The converter is provided with a function which outputs these types of volt free contact signal shown in Table 6 1 Table 6 1 Converter Contact Output Function Contact Status Application Wiring Terminal Names At Power OFF Energized lt failure gt contact signal F1 F2 FAIL Open Open lt maintenance gt contact signal M1 M2 MAINT Closed Closed lt Range gt contact signal SUB OUT Open Closed 41 De energized status Range 1 energized status Range 2 The contact signal lt maintenance gt in Table 6 1 is output in modes
196. trode stops rotating lt CELL gt lamp extin guishes 2 Remove the electrode mechanism block from the measuring tank and set it as shown in Figure 4 7 The electrode mechanism block is fixed with two screws to the measuring tank bracket Electrode mechanism Electrode mechanism block cover block Fixing screws F4 6 ai F 4 7 ai Figure 4 6 Electrode mechanism block fixing screws Figure 4 7 Measuring tank status in maintenance IM 12F4A1 01E 8th Edition Aug 2014 lt 4 Operation gt 4 1 0 3 Remove the indicator electrode Remove the electrode mechanism block cover of the detector Detach the rotating electrode with the end of the driven shaft supported by hand so that the driven shaft does not rotate Since the electrode is screws into the driven shaft turn the electrode counterclockwise Exercise care not to touch the brush Driven shaft a Collar CN r EN Gold alloy surface O Indicator electrode Fasial Figure 4 8 Appearance of electrode mechanism block and Indicator electrode 4 Polish the gold alloy surface of the indicator electrode Place the polishing agent alumina supplied as one of the accessories on a piece of moist gauze and carefully polish the electrode until any contamination owing to oil and grease is completely removed using clean water After polishing confirm that the contamination is completely removed The cleaned surface of the gold alloy must be uniformly wet with water Wh
197. tting operation for various data values such as output range can be performed Also selecting operation for various actions such as range selection can be conduct ed Function code 1 to F Data setting Function code 1 to F Action selection For specific contents see Table 5 5 This subsection describes key operations to be performed by specifying function codes in lt PRO GRAM 1 gt mode and displays accompanying such key operations 1 Output range setting Function code 1 2 2 Reference sensitivity setting Function code 4 3 Applied voltage setting Function code 5 4 Parameter setting for response checking Function code 6 7 and 8 5 Output signal setting in the case of lt failure gt Function code 9 6 Line segment function output setting Function code A 7 Concentration upper limit alarm setpoint setting Function code b 8 Out of sample detection concentration setting Function code c 9 Setting averaging coefficient time constant Function code d 10 Range switching remote local selection Function code 1 2 11 Output mode Hold No Hold selection in maintenance Function code 3 12 Output signal mode selection in lt failure gt Function code 4 13 Selection of automatic zero calibration function execution stop Function code 5 14 Selec
198. ure in current input circuit It will seldom occur as the equipment is well protected against noise The converter must be replaced End F9 5 ai Figure 9 5 Converter Failure Inspection Flow Chart 5 Error code Err15 Converter failure lt failure gt of error code Err15 is displayed when failure occurs in EEPROM memory storing setup data When this lt failure gt is displayed once reset the display and confirm if the lt failure gt is de tected again If lt failure gt display appears again memory content initialization is necessary Memory content initialization is carried out by the procedure given below Notice however that when memory content is initialized re setup of calibration factor for zero point and span adjustment factors for analog output and current input etc as well as setup data becomes necessary As setting except for the setup of calibration factor must be made in service mode contact Yokogawa when the lt failure gt described above has occurred a Once turn the converter power OFF b Turn power ON again Display change as shown below Power ON gt CHEC gt dFt gt with function code 1 in lt MEAS gt mode momentary indication initialization about 15 sec Note Display of Err17 when power is ON means that EEPROM itself is in an unusable condition c Reset lt failure gt display and confirm that lt failure gt is not indicated aga
199. uring tank cleaning function is in stop status No tank cleaning cycle residual chlorine operation is performed concentration measuring time 2 The hold time is the following time whichever is longer T2 Measuring tank cleaning time T2 T4 or T3 T4 7 sec T3 Sand filter cylinder cleaning time 3 Symbols in show the relevant external connection T4 Relaxation time terminal names 4 This is set function code 6 This is relevant to sand filter cylinder cleaning cycle cleaning waiting time In the T1 period immediately after the mode is switched to the lt MEAS gt mode cleaning operation is not performed p5 13 ai Figure 5 13 Cleaning Sequence for Sand Filter One Cylinder Type The cleaning sequence starts at the instant when the mode is switched to lt MEAS gt When cleaning is started the analog output holds at the value immediately before the cleaning start Hold is reset at the relaxation time completion During the analog signal holds lt HOLD gt lamp lights During cleaning lt WASH gt lamp flashes In response to operations of solenoid valves SV1 and SV2 shown in Figure 5 13 operation display lamps corresponding to each solenoid valve light extinguish Table 5 20 shows permissible time setting ranges applied to each cleaning sequence operation shown in Figure 5 13 IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 34 Table 5 20 Cleaning Sequence
200. ute cycle is per formed and the output signal is held during the detecting operation If the operating conditions are relevant to this case and if difficulty exists for output signal hold change the setpoint As the out of sample detection concentration take approximately 50 of the sample water residual chlorine concentration value The key operation procedure for out of sample detection concentration setting is shown below a Select function code c 000 10 mg l b Select the digit using gt key and set a numeric value using A and v keys 000 05 mg l c Pressing ENT key sets the data 000 05 mg l Entire display flashes once For out of sample detecting operation see subsection 6 1 3 IM 12F4A1 01E 8th Edition Aug 2014 lt 5 Converter Operation gt 5 27 9 Setting Averaging Coefficient time constant Function code d The converter display and analog output are computed for average by the program In this set ting the extent of averaging signal time constant can be changed Table 5 19 shows an approxi mate correspondence between the averaging coefficient and a 90 response time Table 5 19 Averaging Coefficient and 90 Response Time Averaging coefficient Standard for 90 response time Approx 37 se The 90 response time is about 13 the averaging coefficient 1 x 6 35 seconds This coef ficient is set at 1 about 13 seconds for a 90 response time upon shipment from
201. value of 2 62 uA mg l at 20 C based on amperometric titration When the standard solution residual chlorine concentration is measured using manual analysis other than amperometric titration colorimetry iodometric titration etc if span calibration can not be executed by more accurate measurement change the reference sensitivity to meet the manual analytical method employed Reference sensitivity changing method is two fold predetermined reference sensitivity manual entry and automatic change by span calibrating operation For reference sensitivity manual entry specify function code 4 in lt PROGRAM 1 gt mode Per form key operation for entry referring to subsection 5 3 4 2 For automatic change perform span calibration with function code d in lt MAINT gt mode See subsection 5 3 3 3 IM 12F4A1 01E 8th Edition Aug 2014 8 1 lt 8 Maintenance gt 8 8 1 8 2 8 3 Maintenance This chapter describes inspection and maintenance implemented for good operating con ditions For measures when failure occurs in operations and others see Chapter 9 Inspection Maintenance Items and Intervals Main inspection and maintenance items and recommended intervals to keep the analyzer in good operating condition are shown Tables 8 1 and 8 2 show recommended intervals for in spection and maintenance of limited life components Recommended intervals shown in Table 8 1 is set from the prevent
202. vnnnvnnnvnnnvnnsvvnnvnnnvnnsrensvnnsnnn 5 9 5 3 3 Key Operation in lt MAINT gt Mode rmanrnonvnonvvenrvnnrvenrernrnenrernrrenreennn 5 11 5 3 4 Key Operations in lt PROGRAM 1 gt Mode uanvnanvnenvnrnrvrnrnrnrrrnveennr 5 21 5 3 5 Key Operation in lt PROGRAM 2 gt Mode srranvnonrnrnrnrnrernrernrernreennr 5 32 Converter Operating FunctionsS rrnwnnnnnvnnnnnnvnnnnvennnnvnnnnnennnnvnnnnnvnnnnnnennnn 6 1 6 1 lt failure gt Detecting Operation rsrrnnvnnnvnnnvnnnvnnnvnnnnnnnvnnnnnnnnnnnennnennnnnnnnnnnnnnnnnnnn 6 1 6 1 1 Concentration Range Exceeded Err11 l es 6 1 6 1 2 Sample Temperature Failure Err12 Err24 sesser 6 1 6 1 3 Out of Sample in the Measuring Tank Err13 aorrnnnnnrnonrnonrnnnrnenr 6 1 IM 12F4A1 01E 8th Edition Aug 2014 6 1 4 Converter Failure Err14 Err15 Err16 and Err17 ennnrnnnnrnnnnnne 6 3 6 1 5 Concentration Upper Limit Setpoint Exceeded Err25 05 6 3 6 2 Analog Output Signal cicciccciccssccsecctecctecstcecterstcesueretlentencudecterstienteneedeveeseeieveeneeass 6 4 6 3 Contact Output secs cccsceiscccisececactceneciciceensdaacanscecnssiesceisscnetssceeustansstueanaetecrenesecees 6 4 6 4 Contact INpUut isisisi teen een ne reece 6 4 6 5 Default Status When Mode Change rserrnwnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnsvnnnennsennnenr 6 5 C AMD Atl OM REE ar aaan a aaide 7 1 7 1 Running in Operation c iccccceccececeeccecoeeecteceeeeceecereaceeceedecesceedeces cervectec
203. voltage changes in the direction of increasing negative voltage The number of diffusion current samples is the number of steps plus one Applied voltage at each step are computed automatically when executed T6 4 ai Figure 5 4 Example of Taking Plateau Characteristics The key operation procedure for lt taking plateau characteristic gt is as follows Example a Select function code 9 in lt MAINT gt mode PLt E Display b On pressing ENT key the starting voltage is displayed L00 00 V c To change the setting press gt key L00 00 V If no setting change is required operate from step e Leftmost digit flashes d Selecta digit using gt key and set the numeric value using A and gt keys L00 10 V Pressing ENT key now fixes the numeric value Last set digit flashes e Press ENT key to display the stopping voltage H 1 00 V f To change the setting press gt key H 1 00 V If no setpoint change is required start from step h Thenegative sign flashes 9 Select a digit using gt key and set the numeric value using A and gt keys H 0 80 V By next pressing ENT key the numeric value is fixed Last set digit flashes h On pressing ENT key the number of steps is displayed P0010 i To change the setting press gt key P0010 If no setpoint change is required start from step k Leftmost numeral flashes j Select a di

RC400G Residual Chlorine Analyzer [Style: S3]

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