Model A15/66 Residual Sulfite Monitor Home Office Analytical Technology, Inc. 6 Iron Bridge Drive Collegeville, PA 19426 Ph: (800) 959-0299 (610) 917-0991 Fax: (610) 917-0992 Email: sales@analyticaltechnology.com European Office ATI (UK) Limited Unit 1 & 2 Gatehead Business Park Delph New Road, Delph Saddleworth OL3 5DE Ph: 0800-018-4020 + 44 (0) 1457-873-318 Fax: + 44 (0) 1457-874-468 Email: sales@atiuk.
PRODUCT WARRANTY Analytical Technology, Inc. (Manufacturer) warrants to the Customer that if any part(s) of the Manufacturer's products proves to be defective in materials or workmanship within the earlier of 18 months of the date of shipment or 12 months of the date of start-up, such defective parts will be repaired or replaced free of charge. Inspection and repairs to products thought to be defective within the warranty period will be completed at the Manufacturer's facilities in Collegeville, PA.
TABLE OF CONTENTS UNPACKING .............................................................................................................................................................. 2 INTRODUCTION ....................................................................................................................................................... 3 SPECIFICATIONS .............................................................................................................................................
TABLE OF FIGURES Figure 1 - Typical Res. SO2 Monitoring System ........................................................................... 4 Figure 2 - Panel Mount Dim. & Installation ................................................................................... 6 Figure 3 - Nexa 4X Wall Mount Dim. & Installation ....................................................................... 7 Figure 4 - Chemistry Module Dimensions ...............................................................................
ATI A15/66 Residual Sulfite Monitor UNPACKING When you receive your A15/66 Residual Sulfite Monitor, open the shipping packages and inspect the contents to be sure that all items have been received. The following items should be included: Quantity 1 - Model A15/66 Sulfite Monitor Electronics (panel mount or NEMA 4X) Quantity 1 - Sulfite Monitor Chemistry Module Quantity 1 - 20 ft.
ATI A15/66 Residual Sulfite Monitor INTRODUCTION The Model A15/66 is an on-line monitoring system designed for the continuous measurement of sulfite ion (SO3-) in solution. The full scale operating range of the system may be selected by the user for 0-2.000 PPM or 0-20.00 PPM, and the sensing system will operate on water streams with temperatures from 0 to 50C.
ATI A15/66 Residual Sulfite Monitor Figure 1 - Typical Res.
ATI A15/66 Residual Sulfite Monitor SPECIFICATIONS ELECTRONICS UNIT Range: Repeatability: Linearity: Response Time: Display: Temperature: Control Relays: Control Mode: Alarm Relay: Analog Output: Operating Conditions: Power: Enclosure: 0-2.000 or 0-20.00 PPM ± 0.01 PPM 0.1% of F.S. 90% in 5 Minutes 16 character alphanumeric backlit LCD 0-50°C with 100 ohm Pt. RTD Two SPDT relays, 5A @ 220 VAC resistive. Programmable deadband and time delay.
ATI A15/66 Residual Sulfite Monitor INSTALLATION The main installation requirements of ATI's sulfite monitor are mechanical installation, connection of power to the electronics, connection of sample and drain lines to the constant head flowcell, and connection of reagents to the reagent pump. Figure 2 provides details on the mechanical installation of the standard panel mounted electronic monitor.
ATI A15/66 Residual Sulfite Monitor The NEMA 4X wall mount enclosure is a Molded Plastic ABS unit that bolts directly to a wall or other flat surface. The enclosure is supplied with special mounting brackets for convenience in mounting the enclosure. A hinged door on the front of the enclosure provides access to operating controls, and a hinge on the back section for convenience in wiring the unit. Figure 3 - Nexa 4X Wall Mount Dim.
ATI A15/66 Residual Sulfite Monitor The chemistry module consists of an ABS enclosure housing sample and reagent pumps plus the air supply and reactor system used to measure sulfite concentration. The chemistry module is designed for wall mounting in a protected location. Although the enclosure is suitable for outdoor use, it is best to provide an additional enclosure around this module if mounted outdoors. Dimensions of this unit are shown in Figure 4.
ATI A15/66 Residual Sulfite Monitor ELECTRICAL CONNECTIONS AC power must be connected to both the monitor and the chemistry module. Refer to Figure 5 below for the proper connections. A power cord is supplied with each unit for AC connection and a 6- conductor interconnect cable (20 ft.) is supplied for connection of the chemistry module to the monitor. Note that the terminal blocks at the rear of the monitor unplug for wiring convenience.
ATI A15/66 Residual Sulfite Monitor To wire the chemistry module, you need to open the center compartment of the assembly. On the left side of the enclosure is a slot for releasing the latch. Slide a small screwdriver into the slot and push the screwdriver handle toward the side of the enclosure. The latch will snap open and you can release the catch, allowing the front part of the chemistry module to swing open on the right hand hinge.
ATI A15/66 Residual Sulfite Monitor CHEMISTRY MODULE The chemistry module is the heart of the sulfite monitor. Inside this module are the pumps, air supply, air control instruments, and sensor element required to make an accurate sulfite measurement. All items are housed in an ABS enclosure, with the main components mounted on the front panel inside the clear cover.
ATI A15/66 Residual Sulfite Monitor In operation, sample flows to the inlet chamber of the overflow assembly. Most of the sample overflows to waste. A small amount of sample (5 cc/min.) is pumped out of the inlet chamber. Sulfuric acid solution is supplied by the second pump and mixed with the sample in the mixing “T”, converting the sulfite ion to molecular sulfur dioxide gas as follows. SO3= + 2 H+ SO2 + H2O The reacted sample then moves to the air stripping chamber.
ATI A15/66 Residual Sulfite Monitor CHEMISTRY MODULE REAGENTS The sulfite monitor uses a sulfuric acid solution with a strength of 15-20%. The exact strength is not critical, provided it is sufficiently strong to bring the sample pH to 2.0 or below. A one-liter bottle of 50% sulfuric acid will be shipped separately to customers within the 48 continuous states.
ATI A15/66 Residual Sulfite Monitor Figure 8 - Reagent Bottle Mounting Bracket PURCHASING REAGENT SUPPLIES Additional supplies of sulfuric acid should be purchased directly from a chemical supplier of your choice. One liter bottles of 50% sulfuric acid are convenient for dilution in the gallon containers supplied, but you can also have this solution prepared in your own lab from concentrated sulfuric acid if your lab has the materials.
ATI A15/66 Residual Sulfite Monitor ACID PICKUP TUBING CONNECTION A special rubber stopper with a ceramic support tube is supplied for the acid bottle. After the acid bottle has been filled, insert the stopper into the bottle and press in securely. A length of pickup tubing is also supplied for the stopper assembly. One end of this tubing should extend to the bottom of the acid bottle inside the ceramic tube.
ATI A15/66 Residual Sulfite Monitor SAMPLE INLET OVERFLOW The water sample supplied to the monitor is connected to a special overflow chamber. This is done to insure that the sample flowrate to the monitor is sufficient to insure that fresh sample is always available at the sample pickup point. Most of the sample flowing to this assembly will simply go directly to the drain. Figure 10 shows the sample overflow assembly on its aluminum mounting bracket.
ATI A15/66 Residual Sulfite Monitor START-UP Prior to operation, recheck electrical connections to be sure that everything is in accordance with Figures 5 & 6 on pages 12 & 13. If everything is in order, power may be applied to the instrument. When power is turned on, the display will come up with a program and version number, which will remain on the display for a few seconds. The display will then change to a display of sulfite concentration and an indication of the status of control relays.
ATI A15/66 Residual Sulfite Monitor OPERATING MODE The A15/66 is provided with 3 programmable modes of operation. The default mode is AUTO. In this mode of operation, the display indicates both sulfite concentration and alarm status as described above. The second mode of operation is MEAS. (Measure Only). In this mode, the display indicates only residual sulfite, and the control relays are deactivated. This would be the mode to use if relays are not being used for alarm or control functions.
ATI A15/66 Residual Sulfite Monitor CHEMISTRY MODULE STARTUP Prior to operating the chemistry module, connect inlet sample and drain tubing to the hose barbs provided on inlet overflow assembly. Recheck to be sure that the sample pickup tube from the sample pump and the drain tube from the stripping chamber are inserted into the proper chambers of the overflow assembly.
ATI A15/66 Residual Sulfite Monitor CONFIGURATION The electronics for the sulfite system are designed to be as flexible as possible. A number of programming functions are provided in the CONFIGURATION menu and are protected by an access number, which must be entered to allow changes in these settings. Some settings are for factory use only, while others are used for customer selection of certain operating parameters. The access number protecting the configuration is user adjustable.
ATI A15/66 Residual Sulfite Monitor 9. TEMPERATURE: ON Factory setting. No adjustment should be made. Press ENTER to go to the next display. 10. CAL TC: 0.00%/C next display. Factory setting. No adjustment should be made. Press ENTER to go to the 11. CAL OUT1: 4-20 mA This routine allows programming of the analog output signal. Either a 4-20 or 0-20 mA output may be selected by using the UP key. The default is 4-20 mA.
ATI A15/66 Residual Sulfite Monitor 21. HOLDING T: 4.0’ After completion of a cleaning cycle, the monitor requires time to restabilize before the 4-20 mA output and alarm contacts will again function normally. Alarms and outputs are held for a fixed period of time. This holding time actually starts at the end of the cleaning time (item 19 above). You will want the holding time to add 2-3 minutes to the cycle after the air pump restarts.
ATI A15/66 Residual Sulfite Monitor OPERATION As previously discussed in the start-up section of this manual, the sensor must be given time to stabilize. Power should be turned on at least one hour before trying to zero the system. If a new sensor that was not on a keeper is installed it will take 24 hours. The sensor must be connected to the powered monitor for the sensor to stabilize.
ATI A15/66 Residual Sulfite Monitor CALIBRATION Calibration of the Sulfite Monitor can be done in one of two ways. If an accurate laboratory measurement can be made on the same sample that the sensor is measuring, the monitor can be adjusted to the laboratory result. A sulfite standard can also be prepared in accordance with the procedure on the following page, but the final value of the standard should be verified if possible by laboratory test.
ATI A15/66 Residual Sulfite Monitor POST CALIBRATION To calibrate the monitor using the "Post" procedure, proceed as follows: 1. With the display indicating PPM SO3 (second display shown on page 20), press the CAL key once and then press the ENTER key once. The display reads "SENS: XX.X%". The value of XX.X% can vary from 25% to 400%, depending on the amount of amplifier gain required to calibrate the monitor. When the UP key is used to increase the display value, the value of XX.
ATI A15/66 Residual Sulfite Monitor CONTROL & ALARM OUTPUTS The A15/66 Sulfite Monitor is equipped with two SPDT alarm/control relays, two SPST relays designated for sample system cleaning, and an isolated 4-20 mA output. The alarm/control relays may be used in a variety of ways, and the function of each relay is programmable by the operator. Relay output wiring is made at the rear of the monitor as shown in the diagram on page 12.
ATI A15/66 Residual Sulfite Monitor PULSE FREQUENCY MODULATION (PFM) CONTROL Relays A and B in the electronic monitor can be used for direct control of certain kinds of metering pumps using a pulse frequency control mode. In pulse frequency control, the relay will briefly close at a frequency linearly proportional to the deviation of the measured value from your setpoint. This type of output is used when controlling a chemical metering pump that has a pulse frequency input from an unpowered relay.
ATI A15/66 Residual Sulfite Monitor PULSE WIDTH MODULATION (PWM) CONTROL Relays A and B can also be used for control of chemical feed systems using a pulse width control mode. In pulse width control, the relay will close for a variable time period that is linearly proportional to the deviation of the measured value from your setpoint. This type of output is not as common as PFM, but can be used when controlling a solenoid feed valve or for running a pump for variable time periods.
ATI A15/66 Residual Sulfite Monitor ANALOG OUTPUT A programmable isolated analog output signal is provided for interface with recorders, data loggers, or controllers. The analog output may be programmed for either 0-20 mA or 4-20 mA output. This output signal will be linearly proportional to the measured sulfite concentration, and may be scaled over ranges of 0-0.1 to 0-20.00 PPM. Also, the output may be spanned for non-zero based ranges as well.
ATI A15/66 Residual Sulfite Monitor SAMPLE SYSTEM CLEANING Dechlorination systems often suffer from sampling system contamination that changes the sulfite concentration in the sample during transport to the monitor. This occurs because sulfur reducing bacteria grow in the sample lines. When the amount of bacterial fouling is high, the sulfite in the sample is consumed by the bacteria during the time it is flowing through the system.
ATI A15/66 Residual Sulfite Monitor The cleaning cycle may also be started manually when Auto mode is selected. To do this, press the UP or DOWN key when the display reads “CLEAN CYCLE: WAITING” in the previous paragraph. The display will change to “CLEAN C: START” and then press ENTER. The cleaning cycle will be activated. If Manual mode is selected, the cleaning cycle must be started by the operator. To do so, again start at display D6 (see page 20). The display will indicate “MANUAL CLEAN”.
ATI A15/66 Residual Sulfite Monitor MAINTENANCE The A15/66 Sulfite Monitor will generally provide unattended operation over long periods of time. With proper care, the system should continue to provide measurements indefinitely. For reliable operation, maintenance on the system must be done on a regular schedule. Keep in mind that preventive maintenance on a regular schedule is much less troublesome than emergency maintenance that always seems to come at the wrong time.
ATI A15/66 Residual Sulfite Monitor PUMP TUBING REPLACEMENT Peristaltic pump tubing should be changed every 6 months. One set of replacement tubing is supplied with the unit and additional tube sets are available in packages of 5 (see spare parts list). If tubing wear or leakage is noted in less than 6 months, tubing should also be replaced immediately.
ATI A15/66 Residual Sulfite Monitor Figure 11 - Pump Head Assembly Exploded View AIR FILTER REPLACEMENT The air pump that supplies stripping air to the reactor assembly contains a small inlet filter. Over time, this filter will accumulate dirt and dust removed from the air used by the pump. This filter should be replaced once a year. Open the rear compartment of the chemistry module to access the pump.
ATI A15/66 Residual Sulfite Monitor TROUBLESHOOTING If you experience problems during the operation of a sulfite monitor, refer to the information below to isolate the source of the problem. During calibration, monitor indicates “Sensitivity < 20 %” and calibration does not update. 1. Check sensor membrane for fouling or excessive water accumulation. Clean the sensor membrane with distilled water and dry with a Q-Tip or lint free wipe if fouling is observed. Replace sensor if necessary. 2.
ATI A15/66 Residual Sulfite Monitor MONITOR RESET The electronic unit can be reset to factory defaults if you wish to quickly get the monitor back to its original operating configurations. To do this, go to step 1 of the configuration menu (page 23). Use the UP arrow to change to H2S. Then press ENTER. Press mode once and then go back into step one of the configuration menu and press the DOWN key to return to SO3. Press ENTER and the unit will be reset to the factory defaults for sulfite.
ATI A15/66 Residual Sulfite Monitor SPARE PARTS LIST - MODEL A15/66 PART NO.
ATI A15/66 Residual Sulfite Monitor SPARE PARTS LIST –(Cont’d) 44-0091 44-0115 44-0167 44-0184 44-0185 44-0112 Barb Fitting, 1/8” Tube Tee Connector, 1/8” Barb Fitting, 1/8” NPT Luer Adapter, 1/8” NPT Luer Female Cap Reagent Feed Tubing 38 O&M Manual Rev-W (8/10)
