Swann AMI Phosphate-II User manual

AMI Phosphate-II

Version 5.01 and higher

A-96.250.641 / 290312

Operator’

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 Phosphate-II Operator’s Manual

ID:

A-96.250.641

Revision Issue

00 July 2011 First release

01 March 2012 AMI Phosphate-II B added

AMI Phosphate II

A-96.250.641 / 230312 1

Table of Contents

1. Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1. Warning Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.2. General Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . 6

1.3. Restrictions for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

2.1. Instrument Specification. . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.2. Instrument Overview AMI Phosphate-II . . . . . . . . . . . . . . 15

2.3. Instrument Overview AMI Phosphate-II B . . . . . . . . . . . . 16

3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.1. Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.2. Mounting of Instrument Panel . . . . . . . . . . . . . . . . . . . . . 18

3.3. Connecting Sample and Waste . . . . . . . . . . . . . . . . . . . . 18

3.4. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.5. Connection Diagram Phosphate-II . . . . . . . . . . . . . . . . . . 21

3.6. Connection Diagram Phosphate-II B . . . . . . . . . . . . . . . . 22

3.7. Install the Cleaning Module . . . . . . . . . . . . . . . . . . . . . . . 23

3.8. Install 2nd Sample Stream. . . . . . . . . . . . . . . . . . . . . . . . 24

3.9. Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.10. Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.11. Relay Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.11.1 Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.11.2 Relay Contacts 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.12. Signal Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.12.1 Signal Output 1 and 2 (current outputs) . . . . . . . . . . . . . . 29

3.12.2 Signal Output 3 (optional) . . . . . . . . . . . . . . . . . . . . . . . . 29

3.13. Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4. Instrument Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.1. Establish Sample Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.2. Fill / Flush Reagent System . . . . . . . . . . . . . . . . . . . . . . . 33

4.3. Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.1. Function of the Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.2. Measured Values and Symbols on the Display . . . . . . . . 35

5.3. Software Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.4. Changing Parameters and Values . . . . . . . . . . . . . . . . . . 38

2 A-96.250.641 / 230312

AMI Phosphate II

6. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.1. Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.2. Stop of Operation for Maintenance . . . . . . . . . . . . . . . . . 40

6.3. Refill / replace Reagents . . . . . . . . . . . . . . . . . . . . . . . . . 41

6.3.1 Reagents for Measuring Phosphate. . . . . . . . . . . . . . . . . 41

6.4. Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.5. Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.6. Cleaning the protective Filter . . . . . . . . . . . . . . . . . . . . . . 45

6.7. Cleaning the Photometer . . . . . . . . . . . . . . . . . . . . . . . . . 46

6.8. Cleaning the Flow Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.8.1 Disassemble the Flow Cell . . . . . . . . . . . . . . . . . . . . . . . . 47

6.8.2 Assemble the Flow Cell . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.9. Cleaning the solenoid valve . . . . . . . . . . . . . . . . . . . . . . . 50

6.10. Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6.10.1 Changing Pump Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6.10.2 Tube Numbering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

6.11. Replacing Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

6.12. Longer Stop of Operation . . . . . . . . . . . . . . . . . . . . . . . . . 56

7. Error List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

8. Program Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

8.1. Messages (Main Menu 1). . . . . . . . . . . . . . . . . . . . . . . . . 61

8.2. Diagnostics (Main Menu 2). . . . . . . . . . . . . . . . . . . . . . . . 62

8.3. Maintenance (Main Menu 3). . . . . . . . . . . . . . . . . . . . . . . 63

8.4. Operation (Main Menu 4) . . . . . . . . . . . . . . . . . . . . . . . . . 64

8.5. Installation (Main Menu 5) . . . . . . . . . . . . . . . . . . . . . . . . 65

9. Program List and Explanations . . . . . . . . . . . . . . . . . . 67

1 Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

2 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

10. Material Safety Data sheets. . . . . . . . . . . . . . . . . . . . . . 82

10.1. OXYCON ON-LINE phosphate reagent 1 . . . . . . . . . . . . 82

10.2. OXYCON ON-LINE phosphate reagent 2 . . . . . . . . . . . . 86

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

12. Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

13. Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

AMI Phosphate-II

Safety Instructions

A-96.250.641 / 290312 3

AMI Phosphate-II - 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.

4 A-96.250.641 / 290312

AMI Phosphate-II

Safety Instructions

1.1. Warning Notices

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

nificance:

WARNING

Symbols

WARNING

Generally, the triangular warning symbol indicates the possibili-

ty of personal injury or even loss of life if instructions are not fol-

lowed,. e.g electrical shock hazard

Electrical shock hazard

Corrosive

Harmful to health

Flammable

Warning general

AMI Phosphate-II

Safety Instructions

A-96.250.641 / 290312 5

ATTENTION

Symbols

ATTENTION

The attention symbol indicates the possibility of equipment

damage, malfunctions or incorrect process results if instructions

are not followed.

Attention general

Safety goggles

Safety gloves

6 A-96.250.641 / 290312

AMI Phosphate-II

Safety Instructions

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.

Electrical

Shock Hazard

WARNING

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

disconnected from all power lines, and measures must be taken

to prevent inadvertent operation.

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

ground wire is connected.

 Service shall be performed by authorized personnel only.

 Whenever electronic service is required, disconnect

instrument power and power of devices connected to

– relay 1,

– relay 2,

– alarm relay

WARNING

For safe instrument installation and operation you must read

and understand the instructions in this manual.

WARNING

Only SWAN trained and authorized personnel shall perform the

tasks described in this document.

AMI Phosphate-II

Safety Instructions

A-96.250.641 / 290312 7

1.3. Restrictions for use

The sample must not contain any particles, which may block the

flow cell. Sufficient sample flow is coercive for the correct function

of the instrument.

If the sample contains only little disinfectant concentrations, or

there is the danger of biological growth, we recommend to use the

optional Cleaning module from Swan which is available as an op-

tion for the AMI Phosphate-II.

WARNING

For safe instrument installation and operation you must read

and understand the instructions in this manual, as well as the

Material Safety Data Sheets (MSDS)

 Oxycon On-line Phosphate 1

 Oxycon On-line Phosphate 2

ATTENTION

Never loosen pump tubes when flow is on. Otherwise you pol-

lute the reagents.

8 A-96.250.641 / 290312

AMI Phosphate-II

Product Description

2. Product Description

Application This manual describes the functions of the analyzers:

 AMI Phosphate-II

 AMI Phosphate-II B

Both analyzers are complete monitoring systems for the automatic

continuous measurement of ortho-Phosphate. ortho-Phosphate

can be found in many applications like corrosion protection in sani-

tary systems and boilers or as additive to detergents. On-line mea-

surement is used in quality control of drinking water, waste water

plants and thermal power plants.

Measuring

principle

The measurement is based on the molybdenum blue colorimetric

method according to APHA 4500-P E. and on EN ISO 6878. When

the reaction product of o-phosphate with ammonium-molybdate is

reduced with ascorbic acid, the intensely colored molybdenum blue

is formed. The color intensity is proportional to the o-phosphate

concentration of the sample and is measured photometrically at

815 nm.

Programmable

Measuring

Intervals

The duration of a measuring interval can be set to:

 10 min (not available if “2 Channels” is selected)

 15 min

 20 min

 30 min

Independent of the programmed measuring interval, the measure-

ment time of a sample takes 7 minutes.

Signal

Outputs

Two signal outputs programmable for measured values (freely scal-

able, linear or bilinear) or as continuous control output (control pa-

rameters programmable).

Current loop: 0/4–20 mA

Maximal burden: 510 

Third signal output with the same specifications as option.

(Only possible if no communication interface is used.)

Relay Two potential-free contact programmable as limit switches for mea-

suring values, controllers or timer for system cleaning with auto-

matic hold function.

Maximum load: 1 A/250 VAC

AMI Phosphate-II

Product Description

A-96.250.641 / 290312 9

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 instrument faults.

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

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

The potential-free contact is located:

 at the AMI Phosphate-II in the AMI Transmitter

 at the AMI Phosphate-II B in the peristaltic pump

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)

RS232 for logger download with HyperTerminal or RS485 with

Fieldbus protocol Modbus or Profibus DP. Webserver connection

via Modbus.

2

nd

Sample

Stream

AMI Phosphate-II B

As an option an inlet for two sample streams with a sample switch-

ing valve can be installed onto the panel of the AMI Phosphate-II B

Cleaning

Module

AMI Phosphate-II

As an option a cleaning module is available which can be connect-

ed to the AMI Phosphate-II.

WARNING

The drain of the photometer outlet contains Hexammonium

heptamolybdate 4-hydrate.

At no means recirculate it into the water system.

10 A-96.250.641 / 290312

AMI Phosphate-II

Product Description

On-line

operation

The sample flows through the sample inlet [K] and the filter vessel

[J] into the constant head [A]. Adjust the flow regulating valve so

that always a small part of the sample flows through the overflow

tube [B] into the drain [R]. This adjustment ensures a sufficient

sample flow through the measuring chamber of the photometer [M].

If no measurement takes place, the sample flows through the outlet

of the photometer where it will be aerated through air inlet [H] to

generate bubbles. Then the sample flows through the bubble coun-

ter [P] into the waste [Q].

If a measuring cycle starts:

1 A zero measurement with the sample is performed before the

reagents are added.

2 The peristaltic pump [C] pumps the reagents [N] and [O] into the

mixing chamber [G] where they are mixed together with the

sample and then flowing through the photometer [M].

3 The solenoid valve [I] will be activated to close the inlet of the

photometer.

4 The sample remains in the photometer for 7 minutes. During

this time a reaction with the reagents takes place.

5 After the 7 min have elapsed a second measurement is carried

out and the o-phosphate concentration is calculated.

6 If the measurement has been finished, the solenoid valve will be

deactivated to open the inlet of the photometer.

7 The sample flows through the outlet of the photometer where it

will be aerated to generate bubbles.

8 The sample flows through the bubble detector [P] and into the

waste [Q].

Calibration Close the flow regulating valve to drain the constant head. Prepare

a standard solution with deionized water and fill it into the constant

head. A normal measuring cycle is then initialized, the measured

value is used to calculate the photometer's slope. For details see

Calibration, S. 44.

AMI Phosphate-II

Product Description

A-96.250.641 / 290312 11

Fluidics

A

B

C

D

E

F

G

H

I

Constant head

Overflow tube

Peristaltic pump

Flow cell block

Sample flow to mixing

chamber

Flow regulating valve

Mixing chamber

Air inlet

Solenoid valve

J

K

L

M

N

O

P

Q

R

Filter vessel

Sample inlet

Reagent level detectors

Photometer

Oxycon on-line Phosphate 1

Oxycon on-line Phosphate 2

Bubble detector

Waste

Drain

E

B

C

A

D

G

HI

JK

LL M

NO P

QR

F

3

4

3

4

1

2

12 A-96.250.641 / 290312

AMI Phosphate-II

Product Description

2.1. Instrument Specification

Power Supply Voltage: 100–240 VAC (± 10%)

50/60 Hz (± 5%)

or 24 VDC, isolated, (± 15%)

Power consumption: max. 20 VA

Sample

requirements

Flow rate: min. 10 l/h

Sample pressure inlet: 0.15–2 bar (2–28 PSI)

Temperature: 5–50 °C (41–122 °F)

ATTENTION

No oil, no grease, no sand.

On-site

requirements

The analyzer site must permit connections to:

Sample inlet: Tube 4 x 6 mm

2 Drains: each 15 x 20 mm

(1/2”) hose nozzle which must end in convenient atmospheric

waste of sufficient capacity.

Electronics

housing

Aluminum

with a protection degree of IP 66 / NEMA 4X

Ambient temperature: -10 to +50 °C

Limit range of operation: -25 to +65 °C

Storage and transport: -30 to +85 °C

Humidity.: 10 to 90 % relative non condensing

Display: backlit LCD, 75 mm x 45 mm

AMI Phosphate-II

Product Description

A-96.250.641 / 290312 13

Dimensions

Phosphate-II

Panel PVC: 400 x 850 mm

Mounting hole distance: 374 x 824 mm

Screws: 5 mm or 6 mm diam.

Weight: 9.0 kg /19.9 lbs

AMI Phosphate-II

824 mm / 32

7

/

16

”

850 mm / 33½”

13 mm / ½”

400 mm / 15¾”

374 mm / 14¾”

13 mm / ½”

4 x dia. 6.5 mm / ¼”

30 mm / 1 ”

3

16

/

14 A-96.250.641 / 290312

AMI Phosphate-II

Product Description

Dimensions

Phosphate-II B

Panel stainless steel: 400 x 850 mm

Mounting hole distance: 374 x 824 mm

Screws: 5 mm or 6 mm diam.

Weight: 14.0 kg /30.85 lbs

AMI Phosphate-II

824 mm / 32

7

/

16

”

850 mm / 33½”

13 mm / ½”

400 mm / 15¾”

374 mm / 14¾”

13 mm / ½”

4 x dia. 6.5 mm / ¼”

AMI Phosphate-II

Product Description

A-96.250.641 / 290312 15

2.2. Instrument Overview AMI Phosphate-II

A

B

C

D

E

F

G

H

Panel PVC

Transmitter

Constant head

Air inlet pipe

Flow cell block

Sample inlet with filter vessel

Solenoid valve

Photometer

I

J

K

L

M

N

O

Bubble detector

Waste funnel for sample

Drain

Oxycon on-line Phosphate 1

Oxycon on-line Phosphate 2

Reagent level detectors

Peristaltic pump

A

B

C

D

E

N

O

M

L

K

J

I

H

G

F

16 A-96.250.641 / 290312

AMI Phosphate-II

Product Description

2.3. Instrument Overview AMI Phosphate-II B

A

B

C

D

E

F

G

H

Panel stainless steel

Transmitter

Constant head

Air inlet pipe

Flow cell block

Sample inlet with filter vessel

Solenoid valve

Photometer

I

J

K

L

M

N

O

Bubble detector

2

nd

sample stream (option)

Waste

Oxycon on-line Phosphate 1

Oxycon on-line Phosphate 2

Reagent level detectors

Peristaltic pump

A

B

C

D

E

N

O

M

L

K

J

I

H

G

F

AMI Phosphate-II

Installation

A-96.250.641 / 290312 17

3. Installation

3.1. Installation Check List

Check Instrument’s specification must conform to your AC power ratings.

Do not turn on power until instructed to do so.

On site require-

ments

100–240 VAC ( 10%), 50/60 Hz ( 5%) or 24 VDC (±15%),

isolated power outlet with ground connection and 20 VA.

Sample line with min. 10 l/h and 0.15–2 bar.

Waste line with atmospheric drain.

Installation Mount the instrument in vertical position.

Display should be at eye-level.

Mount the filter, filter vessel, and constant head.

Connect the sample and waste line. See Connecting Sample and

Waste, S. 18

Electrical Wiring Connect all external devices like limit switches, current loops and

pumps.

Connect power cord; do NOT switch on power yet!

See Electrical Connections, S. 19

Reagents Prepare reagents. See 6.3.1,  41

Insert suction lance/level detectors.

Power-up Perform exactly in this order:

– Lock the occlusion frames of the peristaltic pump.



The peristaltic pump is ready

– Turn on the sample flow and wait until the flow cell is completely

filled. Fill system. See 4.2.,  33

– Switch on power.

Instrument

Setup

Program all parameters for external devices (interface, recorders,

etc.). Program all parameters for instrument operation (limits,

alarms).

Run-in period Let the instrument run continuously for 1 h.

18 A-96.250.641 / 290312

AMI Phosphate-II

Installation

3.2. Mounting of Instrument Panel

Mount the instrument in vertical position. For ease of operation

mount it so that the display is at eye-level. For dimensions see pic-

ture Dimensions Phosphate-II, S. 13

3.3. Connecting Sample and Waste

Sample inlet Use plastic tube (FEP, PA, or PE 4 x 6 mm) to connect the sample

line. See also , S. 30

Mounting of

SERTO fitting

Waste Connect the 1/2” tubes to the nozzle of the waste funnels and place

them into an atmospheric drain of sufficient capacity.

WARNING

the sample which flows after the measurement through the out-

let of the photometer contains Hexammonium heptamolybdate

4-hydrate.

At no means recirculate it into the water system.

A

B

C

D

Screw connection

Compression ferrule

Knurled nut

Flexible tube

B

C

D

A

B

C

D

Tube from photometer

Waste (photometer)

Tube from constant head

Drain (constant head)

A

B

C

D

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Swann AMI Phosphate-II User manual

Swann AMI Phosphate-II User manual

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