Swann AMI Oxytrace QED User manual

AMI Oxytrace

AMI Oxytrace QED

Version 6.20 and higher

A-96.250.531 / 300617

Operat

or’s Manual

subject to change without notice.

Customer Support

SWAN and its representatives maintain a fully trained staff of technical specialists

around the world. For any technical question, contact your nearest

SWAN representative, or the manufacturer:

SWAN ANALYTISCHE INSTRUMENTE AG

Studbachstrasse 13

8340 Hinwil

Switzerland

Internet: www.swan.ch

E-mail: [email protected]

Document Status

Title:

Monitor AMI Oxytrace QED Operator’s Manual

ID:

A-96.250.531

Revision Issue

00 Jan. 2008 First Edition

01 Nov. 2008 Including AMI Oxytrace QED

02 July 2011 Chapter Quality Assurance added

03 Oct. 2013 New mainboard V2.4, update to FW Release 5.4

04 Sept. 2016 New mainboard V2.5, update to FW Release 6.20

AMI Oxytrace QED

A-96.250.531 / 300617 1

Table of Contents

1. Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1. Warning Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2. General Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2. Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1. Description of the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.2. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.3. Instrument Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.4. Single Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.4.1 AMI Oxytrace Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.4.2 Sensor OXYTRACE G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.4.3 QV-Flow PMMA OTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.4.4 B-Flow SS316L OTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.1. Installation Check List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.2. Mounting of Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.3. Connecting Sample Inlet and Outlet. . . . . . . . . . . . . . . . . . . . . . . 23

3.3.1 Swagelok Fitting Stainless Steel at Sample Inlet . . . . . . . . . . . . . 23

3.3.2 FEP Tube at Sample Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.4 Install the Swansensor Oxytrace G . . . . . . . . . . . . . . . . . . . . . . . 24

3.5. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.5.1 Electrical Connection Diagram AMI Oxytrace . . . . . . . . . . . . . . . 27

3.5.2 Electrical Connection Diagram AMI Oxytrace QED . . . . . . . . . . . 28

3.5.3 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.6. Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.7. Relay Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.7.1 Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.7.2 Relay 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.8. Signal Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.8.1 Signal output 1 and 2 (current outputs) . . . . . . . . . . . . . . . . . . . . 33

3.9. Interface Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.9.1 Signal Output 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.9.2 Profibus, Modbus Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.9.3 HART Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.9.4 USB Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4. Instrument Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4.1. Establish Sample Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4.2. Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2 A-96.250.531 / 300617

AMI Oxytrace QED

5. Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.1. Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.2. Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

5.3. Software Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.4. Changing Parameters and values. . . . . . . . . . . . . . . . . . . . . . . . . 40

6. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6.1. Maintenance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6.2. Stop of Operation for Maintenance. . . . . . . . . . . . . . . . . . . . . . . . 41

6.3. Maintenance of the Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . 42

6.3.1 Electrolyte exchange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6.3.2 Clean Swansensor Oxytrace G and Flow Cell . . . . . . . . . . . . . . . 44

6.4. Maintenance of the Faraday electrode . . . . . . . . . . . . . . . . . . . . . 45

6.5. Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.6. Zero-Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.7. Faraday Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6.8. Quality Assurance of the Instrument. . . . . . . . . . . . . . . . . . . . . . . 51

6.8.1 Activate SWAN Quality assurance procedure . . . . . . . . . . . . . . . 52

6.8.2 Pre-test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

6.8.3 Connect the sample lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

6.8.4 Carry out comparison measurement. . . . . . . . . . . . . . . . . . . . . . . 55

6.8.5 Completion of the measurement. . . . . . . . . . . . . . . . . . . . . . . . . . 56

6.9. Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.10. Longer Stop of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

7. Error List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

8. Program Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

8.1. Messages (Main Menu 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

8.2. Diagnostics (Main Menu 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

8.3. Maintenance (Main Menu 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

8.4. Operation (Main Menu 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

8.5. Installation (Main Menu 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

9. Program List and Explanations. . . . . . . . . . . . . . . . . . . . . . . . . 69

1 Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

2 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

10. Material Safety Data sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

10.1. Reagents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

AMI Oxytrace QED

A-96.250.531 / 300617 3

11. Default Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

12. Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

13. Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

4 A-96.250.531 / 300617

AMI Oxytrace QED

Safety Instructions

AMI Oxytrace QED -

Operator’s Manual

This document describes the main steps for instrument setup, oper-

ation and maintenance.

1. Safety Instructions

General The instructions included in this section explain the potential risks

associated with instrument operation and provide important safety

practices designed to minimize these risks.

If you carefully follow the information contained in this section, you

can protect yourself from hazards and create a safer work environ-

ment.

More safety instructions are given throughout this manual, at the

respective locations where observation is most important.

Strictly follow all safety instructions in this publication.

Target

audience

Operator: Qualified person who uses the equipment

for its intended purpose.

Instrument operation requires thorough knowledge of applications,

instrument functions and software program as well as all applicable

safety rules and regulations.

OM Location The AMI Operator’s Manual shall be kept in proximity of the instru-

ment.

Qualification,

Training

To be qualified for instrument installation and operation, you must:

 read and understand the instructions in this manual as well as

the Material Safety Data Sheets.

 know the relevant safety rules and regulations.

AMI Oxytrace QED

Safety Instructions

A-96.250.531 / 300617 5

1.1. Warning Notices

The symbols used for safety-related notices have the following sig-

nificance:

DANGER

Your life or physical wellbeing are in serious danger if such

warnings are ignored.

 Follow the prevention instructions carefully.

WARNING

Severe injuries or damage to the equipment can occur if such

warnings are ignored.

 Follow the prevention instructions carefully.

CAUTION

Damage to the equipment, minor injury, malfunctions or incor-

rect process can be the consequence if such warnings are ig-

nored.

 Follow the prevention instructions carefully.

Mandatory

Signs

The importance of the mandatory signs in this manual.

Safety goggles

Safety gloves

6 A-96.250.531 / 300617

AMI Oxytrace QED

Safety Instructions

Warning Signs The importance of the warning signs in this manual.

Electrical shock hazard

Corrosive

Harmful to health

Flammable

Warning general

Attention general

AMI Oxytrace QED

Safety Instructions

A-96.250.531 / 300617 7

1.2. General Safety Regulations

Legal

Requirements

The user is responsible for proper system operation.

All precautions must be followed to ensure safe operation

of the instrument.

Spare Parts

and

Disposables

Use only official SWAN spare parts and disposables. If other parts

are used during the normal warranty period, the manufacturer’s

warranty is voided.

Modifications Modifications and instrument upgrades shall only be carried out by

an authorized Service Technician. SWAN will not accept responsi-

bility for any claim resulting from unauthorized modification or alter-

ation.

WARNING

Risk of Electrical Shock

If proper operation is no longer possible, the instrument must be

disconnected from all power lines, and measures must be taken

to prevent inadvertent operation.

 To prevent from electrical shock, always make sure that the

ground wire is connected.

 Service shall be performed by authorized personnel only.

 Whenever electronic service is required, disconnect instru-

ment power and power of devices connected to.

– relay 1,

– relay 2,

– alarm relay

WARNING

For safe instrument installation and operation you must read

and understand the instructions in this manual.

WARNING

Only SWAN trained and authorized personnel shall perform the

tasks described in this document.

8 A-96.250.531 / 300617

AMI Oxytrace QED

Product Description

2. Product Description

This manual describes the functions of the following monitors

 AMI Oxytrace

 AMI Oxytrace QED

Both monitors are mainly identical except that AMI Oxytrace QED

includes a faraday verification.

2.1. Description of the System

Application AMI Oxytrace is used to measure low levels of oxygen in high-puri-

ty water. Especially in power plant water cycles (e.g. feedwater), a

very low level of oxygen is needed to prevent corrosion.

Measuring

principle

Clark principle:

The sensor consists of one noble metal electrode (e.g. platinum or

gold), a reference electrode (mostly Ag/AgCl) and optionally a met-

al guard electrode.

The Clark-type electrode is the most widely used oxygen sensor for

measuring oxygen dissolved in a liquid. The basic principle is that

there is a cathode and an anode submersed in an electrolyte and a

voltage is applied between the two parts. Oxygen enters the sensor

through a permeable membrane by diffusion, and is reduced at the

cathode according to

O

2

+ 4e

-

+ 2 H

2

O --> 4 OH

-

This reaction creates a measurable current. There is a linear cor-

relation between the oxygen concentration and the electrical cur-

rent.

The guard electrode is on the same voltage level as the cathode

but there is no current measurement. Oxygen which diffuses from

the electrolyte to the cathode is consumed by the guard electrode.

As a consequence, residual oxygen in the electrolyte will no more

disturb the measurement signal and the response time to low oxy-

gen levels will be shorter.

Temperature

compensa-

tion

The measuring signal depends on temperature, but is automatically

compensated to 25 °C. The sample temperature is determined con-

tinuously by a temperature sensor inside the oxygen electrode.

AMI Oxytrace QED

Product Description

A-96.250.531 / 300617 9

Faraday

Verification

For AMI Oxytrace QED only.

When a direct current is passed through water by means of two

electrodes, electrolysis of the liquid takes place, according to the

laws of Michael Faraday. Water is converted to molecular oxygen

and hydrogen.

Thus, by controlling the current, a fixed, known amount of oxygen,

which is independent of temperature and pressure, may be gener-

ated. If the sample flow is known, an exact oxygen concentration

increment can be generated at low levels. This increment is used to

verify the flawless operation of the whole system. Thereby the re-

sponse characteristics (incremental change and response time) of

the sensor are taken into account. Sensor failures (loss of electro-

lyte etc.) can be detected very easily as shown in the plot below.

Unusual sensor performance is recognized immediately and gives

also a maintenance indication to the operator/user. The faraday

verification is therefore an excellent QA/QC tool.

0

5

10

15

20

25

30

Time [Sec]

defective sensor

operational sensor

Dissolved Oxygen [ppm]

60 90 120 150 180 210 240 270 300 330

35

40

10 A-96.250.531 / 300617

AMI Oxytrace QED

Product Description

Signal

Outputs

Two signal outputs programmable for measured values (freely

scaleable, linear or bilinear) or as continuous control output (control

parameters programmable).

Current loop: 0/4–20 mA

Maximal burden: 510 

Third signal output available as an option.

Relay Two potential-free contacts programmable as limit switches for

measuring values, controllers or timer for system cleaning with au-

tomatic hold function. Both contacts can be used as normally open

or normally closed.

Maximum load: 1 A/250 VAC

Alarm Relay One potential free contact.

Alternatively:

 Open during normal operation, closed on error and loss of

power.

 Closed during normal operation, open on error and loss of

power.

Summary alarm indication for programmable alarm values and in-

strument faults.

Input For potential-free contact to freeze the measuring value or to inter-

rupt control in automated installations (hold function or remote-off)

Safety

Features

No data loss after power failure. All data is saved in non-volatile

memory. Over voltage protection of in- and outputs.Galvanic sepa-

ration of measuring inputs and signal outputs.The analyzer is facto-

ry tested and ready for installation and operation.

Communica-

tion Interface

(optional)

 USB Interface for logger download

 RS485 with Fieldbus protocol Modbus or Profibus DP.

 HART interface

AMI Oxytrace QED

Product Description

A-96.250.531 / 300617 11

Fluidics AMI Oxytrace

Swansensor oxygen combined with QV-flow PMMA OTG flow cell.

The sample flows via sample inlet [G] through the flow regulating

valve [D], where the flow rate can be adjusted. Then the sample

flows into the measuring cell [C] were the Oxygen concentration

and temperature of the sample is measured.

The sample leaves the measuring cell via flow sensor [B] through

the sample outlet [E] and the drain funnel [F].

A

B

C

D

Oxygen sensor

Flow sensor

Flow cell

Flow regulating valve

E

F

G

Sample outlet

Drain funnel

Sample inlet

A

B

C

D

E

F

G

12 A-96.250.531 / 300617

AMI Oxytrace QED

Product Description

Fluidics AMI Oxytrace QED

Swansensor oxygen combined with QV-flow PMMA OTG flow cell.

The sample flows via sample inlet [H] through the flow regulating

valve [E], where the flow rate can be adjusted. Then the sample

flows through the faraday electrode [D] into the measuring cell [C]

were the Oxygen concentration of the sample is measured.

The sample leaves the measuring cell via flow sensor [B] through

the sample outlet [F] and the drain funnel [G].

A

B

C

D

Oxygen sensor

Flow sensor

Flow cell

Faraday electrode

E

F

G

H

Flow regulating valve

Sample outlet

Drain funnel

Sample inlet

A

B

C

D

F

E

G

H

AMI Oxytrace QED

Product Description

A-96.250.531 / 300617 13

2.2. Technical Data

Power Supply Voltage:

Power consumption:

100–240 VAC (± 10%)

50/60 Hz (± 5%)

or 24 VDC (± 10%)

max. 30 VA

Electronics Aluminium with a protection degree of IP 66 / NEMA 4X

housing Ambient temperature:

Humidity:

Display:

-10 to +50 °C

10–90% rel., non condensing

backlit LCD, 75 x 45 mm

Sample

requirements

Flow rate:

Temperature:

Inlet pressure:

Outlet pressure

pH:

Suspended solids:

8–25 l/h

15–45 °C

0.2 to 1 bar

pressure free

not lower than pH 4

less than 10 ppm

Flow cell and

connection

Flow cell made of acrylic glass with built-in flow adjustment valve

and digital sample flow meter

Sample inlet:

Sample outlet:

1/4” Swagelok tube adapter

for flexible tube 15x20 mm

On-Site

requirements

Sample inlet:

Sample outlet:

Swagelok connection for stainless steel

tube 1/4”.

15x20 mm (1/2”) hose nozzle which

must end in a pressure free waste of suf-

ficient capacity.

Accuracy

Reproducibility

± 1.5% of measured value or ± 0.2 ppb

±1% of measured value or ± 0.15 ppb

Measuring

Range

Temperature

up to 60°C

Resolution: 0.1°C

Sample Flow

Measurement

With Swan sample flow meter and alarm in case of insufficient

sample flow.

14 A-96.250.531 / 300617

AMI Oxytrace QED

Product Description

Dimensions

(Oxytrace and

Oxytrace QED)

Panel:

Mounting hole distance

Screws:

Weight:

Stainless steel

280x850x150 mm

254x824

8 mm diameter

12.0 kg

AMI Oxytrace

850 mm / 33½”

13 mm / ½”

4 x dia. 10 mm / ⅜”

254 mm/ 10”

280 mm/ 11”

824 mm / 32

7

/

16

”

AMI Oxytrace QED

Product Description

A-96.250.531 / 300617 15

2.3. Instrument Overview

AMI Oxytrace

A

B

C

D

E

Panel

AMI Transmitter

Oxygen sensor

Flow sensor

Flow cell

F

G

H

I

Flow regulating valve

Sample outlet

Drain funnel

Sample inlet

A

B

C

D

E

F

G

H

I

16 A-96.250.531 / 300617

AMI Oxytrace QED

Product Description

AMI Oxytrace QED

A

B

C

D

E

F

Panel

AMI Transmitter

Faraday control unit

Oxygen sensor

Sample outlet

Flow sensor

G

H

I

J

K

Flow cell

Flow regulating valve

Faraday electrode

Drain funnel

Sample inlet

A

B

C

D

E

F

G

H

I

J

K

AMI Oxytrace QED

Product Description

A-96.250.531 / 300617 17

2.4. Single Components

2.4.1 AMI Oxytrace Transmitter

Electronic transmitter and controller for oxygen measurement.

140

4.5

180

165

103

18.5

7.5

Dimensions Width:

Height:

Depth:

Weight:

140 mm

180 mm

70 mm

1.5 kg

Specifications Electronics case:

Protection degree:

Display:

Electrical connectors:

Cast aluminum

IP 66 / NEMA 4X

backlit LCD, 75 x 45 mm

screw clamps

18 A-96.250.531 / 300617

AMI Oxytrace QED

Product Description

2.4.2 Sensor OXYTRACE G

Sensor for the measurement of dissolved oxygen in ultra pure wa-

ter. Precise oxygen measuring cell with integrated temperature

sensor and guard electrode for faster initial response time after

maintenance.

100

59

31.9

38.3

Technical data

:

Clark oxygen electrode

Cathode gold, anode silver, guard silver

Zero current-free electrode system

Robust 25 µm fluoropolymer diaphragm

Measuring

range

:

0–20 ppm O

2

(25 °C)

Automatic range switching

Range

0.1–9.99 ppb

10–199.9 ppb

200–1999 ppb

2–20 ppm

0 – 200% saturation

Resolution

0.01 ppb

0.1 ppb

1.0 ppb

0.01 ppm

Temp. sensor

:

NT5K

Accuracy

:

0,3 % if calibration temperature = measuring temp.

1,5 % at ± 10 °C deviation to cal. temperature

Precision

Response time

Minimal flow

Operating temp.

:

± 1 % of reading or ±0.15 ppb

t

90

< 30 seconds (rising concentration)

50 cm/s Pressure resistance: 3 bar

max. 50 °C

Material

Protection

Weight

:

shaft: polyacetal copolymer

cathode/anode/guard: gold/silver/silver

membrane: fluoropolymer

IP 68

150 g

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