Instruction Manual Ion-Selective Electrode Monitor

IM/8232–SO1_2
Model 8232 Ammonia Monitor
Special Range 0.05 to 2000 mg l–1

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 ABB
The Company EN ISO 9001:2000

We are an established world force in the design and manufacture of instrumentation for industrial
process control, flow measurement, gas and liquid analysis and environmental applications.

As a part of ABB, a world leader in process automation technology, we offer customers Cert. No. Q05907

application expertise, service and support worldwide.

EN 29001 (ISO 9001)
We are committed to teamwork, high quality manufacturing, advanced technology and unrivalled
service and support.

The quality, accuracy and performance of the Company’s products result from over 100 years
Lenno, Italy – Cert. No. 9/90A
experience, combined with a continuous program of innovative design and development to
incorporate the latest technology.
Stonehouse, U.K.
The UKAS Calibration Laboratory No. 0255 is just one of the ten flow calibration plants operated
by the Company, and is indicative of our dedication to quality and accuracy.

0255

Electrical Safety
This equipment complies with the requirements of CEI/IEC 61010-1:2001-2 'Safety Requirements for Electrical Equipment for
Measurement, Control and Laboratory Use'. If the equipment is used in a manner NOT specified by the Company, the protection
provided by the equipment may be impaired.

Symbols
One or more of the following symbols may appear on the equipment labelling:

Warning – Refer to the manual for instructions Direct current supply only

Caution – Risk of electric shock Alternating current supply only

Protective earth (ground) terminal Both direct and alternating current supply

The equipment is protected

Earth (ground) terminal through double insulation

Information in this manual is intended only to assist our customers in the efficient operation of our equipment. Use of this manual for
any other purpose is specifically prohibited and its contents are not to be reproduced in full or part without prior approval of the
Technical Publications Department.

Health and Safety

To ensure that our products are safe and without risk to health, the following points must be noted:
1. The relevant sections of these instructions must be read carefully before proceeding.
2. Warning labels on containers and packages must be observed.
3. Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel and in accordance with the
information given.
4. Normal safety precautions must be taken to avoid the possibility of an accident occurring when operating in conditions of high pressure and/
or temperature.
5. Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry. Normal safe handling procedures
must be used.
6. When disposing of chemicals ensure that no two chemicals are mixed.
Safety advice concerning the use of the equipment described in this manual or any relevant hazard data sheets (where applicable) may be
obtained from the Company address on the back cover, together with servicing and spares information.

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 CONTENTS
Section Page Section Page

1 INTRODUCTION .......................................................... 2 7 CALIBRATION ........................................................... 28

1.1 Description ......................................................... 2 7.1 Calibration Sequence ...................................... 28
1.2 Training .............................................................. 2
1.3 Location and Function 8 MAINTENANCE ......................................................... 29
of Main Components ......................................... 2 8.1 Chemistry ......................................................... 29
8.1.1 Reagent Solutions .............................. 29
2 INSTALLATION ............................................................ 3 8.1.2 Standard Solutions ............................. 29
2.1 Accessories ....................................................... 3 8.2 Scheduled Servicing ........................................ 29
2.2 Location ............................................................. 3 8.2.1 Regular Visual Checks ....................... 29
2.3 Mounting ............................................................ 3 8.2.2 Four Weekly ....................................... 30
2.4 Sampling Requirement ...................................... 3 8.2.3 Two Monthly ....................................... 30
2.5 Sample Connections ......................................... 3 8.2.4 Twelve Monthly .................................. 30
2.6 External Electrical Connections ......................... 5 8.2.5 Cleaning Sample Pipework ................ 30
2.7 Relay Contact Protection 8.2.6 Consumables Spares Kit ................... 31
and Interference Suppression ........................... 5 8.2.7 Assembling/Refurbishing
the Probe ........................................... 31
3 SETTING UP ................................................................ 6 8.2.8 Peristaltic Pump ................................. 32
8.2.9 Replacement of
4 LIQUID HANDLING SECTION ..................................... 7 Plumbing Tubing ................................ 32
4.1 Principle of Operation ........................................ 7 8.3 Shutdown Procedure ....................................... 34
4.2 General Operation ............................................. 8 8.3.1 Short Term .......................................... 34
5 ELECTRONICS SECTION ........................................... 8 8.3.2 Long Term .......................................... 34
5.1 Electronic Layout ............................................... 8 8.4 Unscheduled Servicing .................................... 34
5.2 User Junction Box ............................................. 8 8.4.1 Malfunction of the Monitor .................. 34
5.3 Microprocessor Unit ........................................... 8 8.4.2 Monitor Diagnostic Information .......... 35
5.4 Front Panel Controls .......................................... 9 8.4.3 Malfunction of the Probe .................... 35
5.5 Displays ............................................................. 9 8.5 General Maintenance of the Probe .................. 35
5.6 L.E.D. Indication ................................................ 9 8.5.1 Ageing of the Glass Electrode ........... 35
8.5.2 Checking the Performance
6 PROGRAMMING ........................................................ 10 of the Glass Electrode ........................ 35
6.1 Normal Operation ............................................ 11 8.5.3 Reference Element ............................ 36
6.2 Programming Pages ........................................ 11 8.5.4 Procedure for Chloridising
6.2.1 Operating Page 1 ............................... 12 the Reference Element ...................... 36
6.2.2 Operating Page 2 ............................... 13 8.6 Microprocessor Unit Error Messages .............. 36
6.2.3 Security Code Page ........................... 14
9 SPECIFICATION ........................................................ 37
6.2.4 Set Up Input Page .............................. 15
6.2.5 Current Output Page .......................... 16 10 SPARES LIST ............................................................. 38
6.2.6 Set Up Alarms Page ........................... 19
6.2.7 Set Up Clock Page ............................. 21 APENDIX A – REPLACING SOFTWARE EPROM ............. 39
6.2.8 Calibration User Code Page .............. 23 A.1 Access the Transmitter Unit ............................. 39
6.2.9 Set Up Temperature Control Page ..... 24 A.2 Access the PCB ............................................... 39
6.2.10 Electrical Calibration .......................... 24 A.3 Removing the PCB .......................................... 40
6.2.11 Electrical Calibration Page ................. 25 A.4 Changing the EPROM ..................................... 40
A.5 Completing the Procedure ............................... 40

1
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 1 INTRODUCTION
1.1 Description understood steps. The sample is presented from the user's
The Model 8232 Ammonia Monitor is a microprocessor based pipework to a constant head unit and any excess is allowed to
analyser using an ABB ammonia ion-selective probe. This overflow. This allows sample, under controlled pressure
equipment is used for environmental water monitoring. conditions, to be presented to a multi-channel peristaltic pump
which proportions sample and reagent solutions through the
monitor to the mixing point. The resulting combined solution is
1.2 Training then temperature controlled to remove the effects of sample
Due to the specialised nature of the above instrument, it is and ambient temperature variations. The conditioned solution
recommended that, where the end users personnel have had is then delivered to the probe, under constantly flowing
no previous experience of maintaining this equipment, training conditions, where the ion measurement takes place.
be provided by this Company.
The probe generates a millivolt output which is proportional to
Such training is available via the local Company in the UK, or the ion concentration. This output is processed by the
Overseas Agent elsewhere and may be carried out either on microprocessor-based electronics section to calculate the
the users premises or at the factory. actual sample concentration.

To maintain optimum measurement accuracy it is necessary to

1.3 Location and Function of Main Components – introduce standard solutions of known concentration for
Fig. 1.1 calibration purposes. The monitor utilises solenoid valves to
Monitoring of any sample by ion-selective electrodes usually introduce these standard solutions automatically, at
requires certain conditioning to be performed on the sample to predetermined intervals, under the control of the
allow accurate, trouble-free measurement. Such conditioning microprocessor.
involves regulating flow, controlling temperature and adjusting
chemical composition prior to presentation of the sample to The electronics section consists of the main Microprocessor
the point of measurement. This monitor carries out these Unit situated at the top left and a User Junction Box at the top
adjustments for each parameter in simple and easily right behind the hinged case.

Hinged Case Case Lock

Microprocessor
Unit
Cable Entry Glands

Ammonia 8232
User Junction Box
(behind case)
Solenoid Valves
(behind case)

Ammonia Probe

Case Lock
Push-to-Release
Latch

Hinged Door

Calibration Constant Head Unit Peristaltic Temperature

Solution (behind case) Pump Controlled
Containers with Sample Inlet and Block
Drain Connections (cover removed)

Fig. 1.1 Location of Instrument Components

2
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 2 INSTALLATION
2.1 Accessories 2.4 Sampling Requirement
2 x reagent bottles 1 x ammonia probe kit In addition to being as close as possible to the monitor, the
4 x calibration bottles 1 x spares kit sampling point must provide a thoroughly mixed
representative sample. The sample must also conform to the
following conditions:
2.2 Location
The monitor should be installed in a clean, dry, well ventilated a) Sample flow rates must be between 5 ml min–1 and
and vibration-free location giving easy access, and where 1250 ml min–1.
short sample lines can be used. Rooms containing corrosive
gases or vapours (e.g., chlorination equipment or chlorine gas b) Sample temperature should be within 20 °C of the ambient
cylinders) should be avoided. It is also advisable to have temperature and within the range 0 to 40°C.
adjacent drains near ground level, so that the waste outlet
from the monitor can be as short as possible, together with c) Particles must be less than 10 mg l–1 and the size must not
maximum fall. Power supplies should also be adjacent. exceed 60 μm. Above these levels it is essential that the
Ambient temperature: within the range 5 to 40°C. filter supplied is fitted in both the sample and emergency
inlets.

2.3 Mounting – Fig. 2.1

The monitor has a moulded plastic case, mounted onto a flat 2.5 Sample Connections – Fig. 2.2 (overpage)
metal panel. To provide access, the case is hinged on the left The inlet and outlet pipe connections are both located at the
hand side and has two lockable catches on the right hand to bottom of the case. A 6 mm (1/4") hose adaptor is provided for
hold the case in position in normal operation. the sample inlet and a 9 mm (3/8") hose connection for the
drains. It is recommended that the pipes used should be of
One keyhole slot is provided at the top of the flat panel to inert material, e.g., silicone rubber or p.v.c. The inlet pipe must
provide easy mounting on a wall or framework. Two further incorporate a shut-off valve at its upstream end, while the drain
fixing holes are provided at the bottom of the flat panel. All outlet pipes should be short, venting to atmosphere as soon as
holes are designed to take 8 mm bolts or studs. possible.

Mains and signal cables are connected through cable glands

in the User Junction Box on the right hand side with the
exception of the optional serial interface which connects
directly into the Microprocessor Unit. Sample and drain
pipework are brought in through the bottom of the case.

Moulded Case 8mm Keyhole

Shown in Slot
278 60 Top of Case
Open Position

188 Open
235
Position
Junction
Box
Cable
780 Entry 95° Max.
Fixing 890 Point
Centres angle of Closed
Position 542
opening

550

Sample Inlet Top View

8mm Fixing 220
& Drain
Tubes Holes
30
Edge of
482
Case 110mm minimum clearance
Fixing Centres All dimensions in mm
required for access to locks

Fig. 2.1 Overall Dimensions and Mounting Details

3
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 …2 INSTALLATION

2.6 External Electrical Connections – Fig. 2.3 The connections are as follows:

a) Mains input 115 V or 240 V. The mains voltage is selected

Warning.
by means of the voltage selector – see Fig. 2.3.
• Although certain instruments are fitted with internal fuse
protection, a suitably rated external protection device,
b) Current outputs 1 and 2 – two independent current outputs
e.g. a 3 A fuse or miniature circuit breaker (m.c.b.),
for external recording or control. One output is supplied as
must also be fitted by the installer.
standard, the second is supplied as an optional extra – see
Fig. 2.4 for details of current output range.
• Before making any connections, ensure that the power
supply , any high voltage-operated control circuits, high
Information. Because the current output is isolated, the
common mode voltage, including externally powered
negative terminal must be connected to earth (ground) if
alarm circuits, are switched off.
connecting to the isolated input of another device.
• The power supply earth (ground) must be connected to
c) Relay 1 and 2 – two concentration alarms.
ensure safety to personnel, reduction of effects of radio
frequency interference (r.f.i.) and correct operation of
d) Relay 3 – calibration mode indication. This indicates when
the power supply interference filter.
the instrument is off line during a calibration.
The external electrical connections are to be found in the User
e) Relay 4 – instrument 'OUT OF SERVICE' indication. This
Junction Box with the exception of the optional serial interface
indicates that the monitor readings are suspect and it is in
which is connected directly into the Microprocessor Unit. The
need of attention.
cables are passed through the cable glands on the right hand
side of the junction box which are adjacent to the internal
f) Relay 5 – 'OUT OF SAMPLE' – indication of loss of sample.
electrical terminals.
g) Optional serial interface – connected into the
Caution. Slacken the terminal screws fully before making Microprocessor Unit. See supplementary instruction
connections. manual for details.

Note. It is essential that all

sample pipework to the monitor
Constant-head unit
Monitor Case is kept as short as possible to
reduce the effects on the
sample due to the presense of
algæ which can build up. This
Push-on hose connectors problem is particularly acute in
Case Hinge Line the pipework between the filter
and the monitor because of the
small sample flow. Small bore
tubing is essential, e.g. 6 mm
i.d.
150 mm
(approx) 250 mm (approximate) length
tubing to allow the case
to open through 90°

Tube wall fixing clips

Contaminated Drain pipe

(9 mm i.d.)
Sample Inlet Pipe
(6 mm i.d.)
Drain Tundish N.B. Sample, drain and overflow pipework
Overflow in flexible silicone rubber or PVC
Drain

Fig. 2.2 Suggested Layout

4
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 2 INSTALLATION…

2.7 Relay Contact Protection and Interference (part no. B9303) as shown in Fig. 2.5A. If the instrument
Suppression – Fig. 2.5 malfunctions the value of the RC network is too low for
If the relays are used to switch loads on or off the relay suppression and an alternative value must be used. If the
contacts can become eroded due to arcing. Arcing also correct RC suppressor unit cannot be obtained, contact the
produces radio frequency interference (r.f.i.) which can cause manufacturer of the switched device for details of the RC unit
instrument malfunctions and incorrect readings. To minimize required.
the effects of r.f.i., arc suppression components are required;
these are resistor/capacitor networks for a.c. applications, or For d.c. applications fit a diode as shown in Fig. 2.5B. For
diodes for d.c. applications. These components can be general applications use an alternative IN5406 type (600 V
connected either across the load or directly across the relay peak inverse voltage at 3 A – part no. B7363).
contacts.
Note. For reliable switching the minimum voltage must be
For a.c. applications the value of the resistor/capacitor greater than 12 V and the minimum current greater than
network depends on the load current and inductance that is 100 mA.
switched. Initially fit a 100 R/0.022 μF RC suppressor unit

115V Position Mains Voltage Selector 230V Position

110V min. to 120V max. AC 110V to120V 220V to 240V 220V min. to 240V max. AC
50/60Hz 50/60Hz
Mains 'ON'
Indicator
MAINS
Mains
ON / OFF
OFF Switch
MAINS

ON Mains Fuse –
Mains 1A, 250V AC (T)
230V

F1 250V 1A
Transformer
OFF

PUMP Pump
ON / OFF
ON Switch

Cable Gland
Relay
Board F3 F2

0.5A (T) 5A (F) L

MAINS
N INPUT

N/C
C RELAY
1
N/O
N/C
C RELAY

N/O
2
User
N/C
CAL
Cable
C

Solenoid Valves N/O

Entry
Glands
STD1 STD2

N/C
and Heater C
OUT
OF
SERVICE
Indicators N/O

N/C
C
OUT
OF
Note. The mains and pump ON/
SAMPLE
HEATER N/O
OFF switches are situated on the
+
- O/P 1 right hand side of the junction box.
+ O/P 2
-

External
User
Internal Connection
Interconnection Terminals
Cable Terminals
Interconnection Cable from/to
Microprocessor Unit and Instrument
Components (wet section)

Fig. 2.3 Location of User Junction Box Components

5
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 …2 INSTALLATION 3 SETTING UP

Note. Before proceeding any further, ensure that all

1 8 1 8 1 8 1 8 switches are set to OFF on the right hand side of the
electronics unit – see Fig. 2.3.

a) Ensure that all external electrical and plumbing

connections have been made correctly.
0 to 1mA 0 to 10mA 0 to 20mA 4 to 20mA
b) Fill reagent and standard solution bottles and connect
them to the monitor. (See Section 8.1 for details of these
Link for the Current solutions.)
Output required
c) Fit the probe according to the instructions in Section 8.2.7.

d) Connect the electrical supply and switch on.

Note. The temperature controlled block requires up to half

an hour to reach the normal control temperature. During
Captive this time, 'Temp. Control Error' is indicated on the display.
Screws Any calibrations are prevented by the microprocessor
during this time.

e) Verify that there is an adequate supply of sample to the

monitor constant head unit.
Protection
Plate
f) Fit the pump platen on the peristaltic pumps (see Section
Input 8.2.8) and switch the pumps on with the switch on the side
Module of the monitor. Ensure that the peristaltic pumps rotate,
Output Module 2
Temperature Input and check that sample and reagents are being drawn into
Output (if fitted)
Module the monitor by observing the progress of any small bubbles
Module 1
present in the inlet tubes.
Fig. 2.4 Selecting The Current Output Range
g) Run the monitor for at least one hour to allow the
temperature to stabilize, solutions to be pumped into the
system and to purge the air from the pipework. Check for
any leaks around the pipe connections and rectify as
NC C NO Relay Contacts
necessary.

h) If the monitor exhibits good stability, i.e. ±2% of reading,

carry out a calibration – see Programming Page.
R C
i) Check the condition of the sample filter and replace it if
necessary. Ensure that new filters are fitted correctly by
Load
L N taking note of the flow directions indicated on the filter
bodies.
External a.c. supply
A – a.c. Applications

NC C NO Relay Contacts

Diode

+ Load
–

External d.c. supply

B – d.c. Applications
Fig. 2.5 Relay Contact Protection

6
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 4 LIQUID HANDLING SECTION
4.1 Principle of Operation – Fig. 4.1
The monitor uses an ABB Ammonia Probe. This contains a
glass pH electrode, whose pH-sensitive glass membrane forms
a slightly convex tip, and a robust, long-life reference electrode.
The two electrodes are combined into a single assembly, and
are connected as a pH measuring pair through an internal
reservoir of filling solution containing ammonium ions.

The filling solution is 0.1 M ammonium chloride saturated with Filling Body
silver chloride and is separated from the sample by a gas- Solution Body
permeable hydrophobic membrane fitted in the tip of the Aperture Seal
probe. Sample is caused to flow past the probe membrane,
whereupon the partial pressures of ammonia gas in the two
Washer
solutions on either side of the membrane equilibrate,
transferring gas across the membrane. At equilibrium, the
Membrane
concentration of ammonia in the thin film of filling solution
between the probe membrane and the glass electrode pH
membrane equals that in the sample. The resultant change in Electrode
pH value of the thin film is measured by the pH electrode pair End Cap
which thus develops an output potential related to the
Reference
ammonia concentration in the sample. Like most ion-selective Element
electrodes, the Ammonia Probe produces an output which is
Filling
logarithmic with respect to concentration.
Solution

Range of measurement can be set to any two consecutive

Washer
decades of concentration between 0.05 to 2000 mg l–1 as N,
NH3, or NH4+. Membrane

Under typical circumstances, with appropriate standard

solutions and calibration frequencies, accuracies better than
±5% of reading or 0.1 mg l–1 whichever is the greater, can be Fig. 4.1 Ammonia Probe
achieved.

To Electronics Section

Three Channel
Peristaltic Pump Heat Exchanger Ammonia
Block Probe
Out of Sample Constant Head Unit Heater
Float Switch Mat
From Reaction
Flowcell Sample / Calibrate Coils
Solenoid Valves
SV1 SV2

Sample
Contaminated Overflow Sample Orange Heater Coil Temperature
Drain Drain Inlet Channel Drain via
Red Sensor
Constant
Channel Head Unit

Standard Standard EDTA NaOH

Solution 1 Solution 2 Reagent Reagent
(Low) (High) Solution Solution Note. In applications in the power
Orange Red industry where hardness is very low, the
Channel Channel first reagent (EDTA) is not required.

Fig. 4.2 Flow Schematic

7
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 …4 LIQUID HANDLING SECTION 5 ELECTRONICS SECTION
4.2 General Operation – Fig. 4.2 5.1 Electronic Layout – Fig. 5.1
The sequence of events is: The electronic section comprises two separate sections:
a) The sample enters the constant head unit from below and
any excess is allowed to overflow to drain. • The User Junction Box at the top right hand side.
The constant head unit is fitted with a float switch to signal • The Microprocessor Unit at the top left hand side.
an 'Out of Sample' condition. This switch is used by the
monitor to initiate the 'Out of Sample' alarm.
5.2 User Junction Box
b) From the constant head unit the sample is drawn through The User Junction Box contains the relays for the heater,
the normally open ports of the solenoid valves SV1 and solenoid valves and alarms, and all the user external
SV2 by one channel of the peristaltic pump. connection terminals, with the exception of the serial interface
(if fitted).
c) The reagents are drawn through another channel of the
peristaltic pump, and then mixed with the sample. The tube Once installed there should be no need to remove the junction
diameters are arranged so as to obtain the correct ratio of box cover on a regular basis. However, to assist in any fault
sample and reagents. finding procedure, there are l.e.d's on the p.c.b. to indicate if
the relays and heater are being energised.
d) The probe is housed in a temperature controlled block
which includes a heat exchanger to remove the effects of Switches for the mains and pump/heater are situated on the
sample and ambient temperature variations. The probe right hand side of the junction box, together with a mains
produces an electrical potential when exposed to the indication lamp and mains fuse – see Fig. 2.3.
reacted sample which changes in proportion to changes in
concentration of the ion being measured. The probe is
connected to the electronic section where, after digital 5.3 Microprocessor Unit
conversion, the signal is processed by the microprocessor. The Microprocessor Unit contains the analogue input
processing, microprocessor, alarm and current output
e) After measurement the sample flows to waste via the generation, and (if fitted) the serial interface output.
contaminated drain connection.
The programme controls, digital and dot-matrix displays,
f) During calibration the monitor introduces two calibration alarm indication and status l.e.d's are all mounted on the front
solutions sequentially in place of the sample by means of panel of the microprocessor unit.
the solenoid valves SV1 and SV2.

User Junction
Microprocessor Unit
Box
Mains Supply 115 to 230 V

Concentration Alarm Relays

Calibration Mode Relay External

User
Out of Service Relay
Connections
Out of Sample Relay

Current Outputs

External
Serial
Interface Interconnection
Connections Cables

Reference Out of Sample Pump and

Electrode Float Switch Stirrer Motors

Heater Ion-Selective Sample/Calibrate Flow Cell

Control Electrode Soleniod Valves Heater Block
Liquid Handling
Section

Fig. 5.1 Electrical Connections Layout

8
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 5 ELECTRONICS SECTION

5.4 Front Panel Controls – Fig. 5.2

The programme controls comprise eight tactile membrane 20-character Alarm and Status 5-digit Display
switches. These switches are situated behind a hinged door Dot-Matrix Display L.E.D.s (Concentration)
below the display, access is via a screwdriver-operated catch.
In normal operation the switches are used to view the
measured ion concentration value, initiate a manual
calibration, or to activate the 'alarm hold' facility.

When programming, the switches are used to sequence

through a programming procedure as detailed. The procedure Alarms
1 2 Hold Cal Fail
is set out in programming pages for Input, Current Output,
Alarms, Real Time Clock and Monitor Calibration. Each
programme page contains the programme functions, the
values or parameters of which are programmable. Mode Cal Hold Enter

Switch functions are as follows:

Used for viewing the fluoride concentration,
Mode
electrode mV output, flowcell control temperature,
sensor slope, date, time, the time to the next
calibration and the time from the last calibration.

Used to enable or disable the automatic

Cal
calibrations, enter the standard solution values and
manually initiate a calibration sequence. Operating
'Cal' during a calibration aborts the sequence and
returns to normal operation.

Hold
Used to inhibit any change in the alarm relay/l.e.d.
status and the start of any auto calibration. The
feature is used during maintenance ('Hold' l.e.d. Connections
illuminated). Cover

Note. If the 'Hold' facility is inadvertently left Fig. 5.2 Location of Controls, Displays and L.E.D.s
switched-in, it is automatically cancelled after
a period of approximately 3 hours has elapsed. 5.5 Displays – Fig. 5.2
Two blue vacuum fluorescent displays are provided:
Enter
Used for storing the programmed function
parameters and values in the instrument's a) The upper is a 5-digit 7-segment type display which
nonvolatile memory. indicates the measured variable.

Note. The instrument responds instantly to b) The lower is a 20-character dot matrix type which provides
any programme change but the new value is user information during setting up and in normal operation.
lost in the event of a power interruption if it has
not been 'Entered'.
5.6 L.E.D. Indication – Fig. 5.2
Parameter Advance – used for selecting a particular There are five l.e.d's (indicators situated between the two
parameter from a programme page. displays) which provide information on the current status of the
monitor. From left to right the indicators are as follows:
Used for increasing or decreasing a parameter
value or stepping up or down through a selection of Used to indicate a concentration alarm state
parameters applicable to a particular function. (either high or low). This indicator is used in
A1 or A2
association with an external alarm relay output.
Note. Continued pressure on the 'Raise' or
'Lower' switches causes the rate of change of Used to indicate when the 'Hold' button has been
the displayed value to increase. To make small operated.
Hold
adjustments, operate the switches
momentarily. Indicates when a calibration sequence is taking
Cal place.
Page Advance – used, via the security code, for
selection of individual programme pages. Indicates when the monitor was unable to carry
Fail out a successful calibration.

9
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 10
Operating Page 1
Ammonia <unit> SECURITY CODE 0 SET UP INPUT CURRENT OUTPUT SET UP ALARMS
Millivolts xx.xmV Control Temp. – – • –°C OP1 Cal Hold (Yes/No) A1 Enabled (Yes/No)
Control Temp xx.x°C Display as N Op1 Law. (Log/Lin) A1 Action (High/Low) No
Slope xxx.x% Ion Units (Units) OP1 FSD –– •–– A1 Failsafe (Yes/No)
or Date DD:MM:YY Display Zero – • – –°C OP1 Zero – • – – Lin A1 Hysteresis –%
Mode Time HH:MM:SS Display FSD – – • – –°C OP2 Cal Hold (Yes/No) A1 Delay ––m
Next AutCal DD:MM:YY Note 4 Incorrect OP2 Law (Log/Lin) A1 Setpoint –– •––
Code (Yes/No)
Last Cal DD:MM:YY Note 5 OP2 FSD –– •–– A2 Enabled
OP2 Zero – • – – Lin A2 Action (High/Low)
No
Test Output Zeros A2 Failsafe (Yes/No)
6 PROGRAMMING

Test Output FSD A2 Hysteresis –%

Alter Sec. Code 0 A2 Delay ––m
% Output –––•– A2 Setpoint –– •––
Incorrect Code

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CALIBRATION SET UP TEMP. CONTROL CAL USER CODE 0 SET UP CLOCK
mV Zero –– •– Cycle Time –– Set Clock? (Yes/No)
mV FSD –– •– Prop. Band ––– Set Year ––
Temp. Zero – – • –°C Integral Time –––– Set Month ––
Temp. FSD – – • –°C No Set Day of Month ––
Adjust Output 1 Zero Set Hours ––
Adjust Output 1 FSD Set Minutes ––
Adjust Output 2 Zero Cal Date – – Note 1
Adjust Output 2 FSD Operating Page 2 Cal Time – – Note 2
Cal Time 1 – –m Cal Interval – Days
Cal
Cal Time 2 – –m
Cal Time 3 – –m
Cal User Code 0
Enable Auto Cals (Y/N)
Note 1. MANUAL CAL SEQUENCE
No Ion Std 1 – •–– Cal
‘Cal Date’ is the date when the first calibration is due and is updated every time an automatic
calibration is carried out, i.e ‘Cal Date’ = autocal date + ‘Cal Interval’. Ion Std 2 –– •––
Initiate Cal. (Yes/No)
Note 2.
‘Cal Time’ is the time of the day when the autocalibration is required. Calibrating Std 1 Electrode mV – – •–
Calibrating Std 2 * Electrode mV – – •–
Note 3.
Operating Cal during a calibration aborts the sequence and returns the system to normal operation.
CALIBRATION PASSED
Note 4. or Calibration Std 1 Cal
‘Next AutCal’ is the date of the last automatic calibration + the calibration interval ‘Cal interval’. If CAL. FAILED (SLOPE) * Calibrating Std 2
the instrument has been switched off, the next ‘AutCal’ is the present date + the ‘Cal interval’. If the or
‘AutCal’ is switched off, ‘OFF’ is displayed on the 20-character display. See Note 3
CAL. FAILED (SLOW)

Note 5.
‘Last Cal’ is the date of the last automatic or manual calibration.

Fig. 6.1 Overall Programme Chart

 6 PROGRAMMING…

6.1 Normal Operation 6.2 Programming Pages

In normal operation (Operating Page 1) the lower, dot matrix, Operation of the switch enables a series of 'programming'
display gives indication of the units of measurement, millivolt pages to be displayed. Unauthorised entries to this page are
value, sensor slope and time. Selection is made using the inhibited by a 5-digit security code which is displayed
switch. Operation of the Cal switch gives access to a second immediately after the page header.
Operating Page (Operating Page 2) in which the standard
solution values can be set and a manual calibration can be In the programming pages, displayed values indicated 'xxxxx'
initiated. Either page can be selected at any time by using the are for viewing only and cannot be altered by the operator.
Mode
or Cal switches. Displayed values indicated '– – –' can be altered using the
and switches. When the desired reading is displayed,
operate the Enter switch. The l.e.d's flash momentarily, to
indicate that the value has been stored in the nonvolatile
memory. Although the instrument appears to operate
satisfactorily, if the Enter switch is not operated, in the event of
power interruption, the programmed values are lost. If
previously programmed values are to be viewed only, it is
unnecessary to operate the Enter switch.

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 …6 PROGRAMMING

6.2.1 Operating Page 1

The values displayed in Operating Page 1 are for viewing only and cannot be altered in this page.

Nitrate <Unit> Measurement Units

The measurement units are displayed, e.g. Ammonia ppm.

or Mode Advance to next parameter.

Millivolts xx•xmV Sensor Output

The probe output is displayed in millivolts.

or Mode Advance to next parameter.

Control Temperature
Control Temp xx • x °C
The heater block control temperature is displayed in degrees Celsius.

or Mode Advance to next parameter.

Slope xxx • x% Slope Check Value

The slope value should be between 80 and 110%. If the value is outside these
limits check the electrode.

or Mode Advance to next parameter.

Date DD:MM:YY Date

The date is displayed.

or Mode Advance to next parameter.

Time HH:MM:SS Time

The time is displayed.

or Mode Advance to next parameter.

Next AutCal DD:MM:YY Next Calibration Date

The date when the next automatic calibration is to be carried out is displayed. If the
automatic calibration is disabled, 'OFF' is displayed in place of the date.

or Mode Advance to next parameter.

Last Cal DD:MM:YY Last Calibration Date

The date of the last automatic or manual calibration is displayed.

or Mode Return to top of Operating Page.

or or

Advance to Security Page (Section 6.2.3).

SECURITY CODE -----

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 6 PROGRAMMING…

6.2.2 Operating Page 2

To gain access to the Calibration Page (Operating Page 2), operate the Cal
switch.

Enable Auto Cals Yes Enable Automatic Calibrations

Select 'Yes' to enable or 'No' to disable the automatic calibrations.
No or

Enter
Store.

Cal
Advance to next parameter.

MANUAL CAL SEQUENCE

Page header.

Cal Advance to next parameter.

Ion Std 1 –•– –

Ion Standard 1
Set the value of the 'Low' standard solution (Std 1).
Low value ammonia standard solutions should be avoided. For example, at
or ambient temperatures of about 25 °C, and under normal light conditions, a
0.5 mg -1 NH3 solution is expected to lose at least 10% of its concentration over a
seven day period. Because of the instability of such solutions, it is not possible to
programme a standard solution of lower concentration than 0.2 mg l–1 NH3 on this
monitor. Solutions as low as 0.2 mg l–1 can be prepared with care, but must be
used immediately, making it an unsuitable concentration for long term use with the
monitor.

Enter
Store.

Cal
Advance to next parameter.

Ion Standard 2
Ion Std 2 – –•– –

Set the value of the 'High' standard solution (Std 2). The concentrations of the two
or standard solutions must differ from each other by a factor of at least four.

Enter
Store.

Cal
Advance to next parameter.

Initiate Calibration (manual)

Initiate Cal Yes
Select 'Yes' to carry out a manual calibration or 'No' to return to the top of the page.
No or
No Enter
Enter must be pressed to initiate a manual calibration.

Yes
Calibrating Std 1 Calibrating Standard 1
The upper display shows the ammonia concentration value. The display remains
until a stable output is obtained from the probe.

Toggle between the two displays.

Electrode Millivolts
Electrode mV – –•–

Cal Note. Pressing Cal during a calibration aborts the sequence and returns to
normal operation.

When a stable probe output is detected the display automatically advances to the
next parameter.

Continued on next page.

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 …6 PROGRAMMING

…6.2.2 Operating Page 2

Continued from previous page.

Calibrating Std 2 Calibrating Standard 2

The upper display shows the ammonia concentration value. The display remains
until a stable output is obtained from the probe.

Toggle between the two displays.

Electrode mV – –•– Electrode Millivolts

The probe output can also be displayed during calibration

Note. Pressing Cal during a calibration aborts the sequence and returns to
Cal
normal operation.

When a stable probe output is detected the display automatically advances to the
next parameter.

CALIBRATION PASSED Calibration Passed

A satisfactory calibration has been carried out.

or or

CAL FAILED (SLOPE) Calibration Failed (slope)

The monitor was unable to obtain an adequate slope value during calibration. The
slope value required is 80 to 110%.

or or

CAL FAILED (SLOW) Calibration Failed (slow)

The monitor was unable to obtain a stable output from the probe during calibration.

Return to top of Operating Page 2.

or or
Mode
Return to Operating Page 1.

Nitrate <units>

6.2.3 Security Code Page

A security code is required to gain access to all subsequent programming pages. The code is preset at the factory to '0' but can
be changed if required in the Current Output Page – see Section 6.2.5.

Security Code ----- Security Code

or Set the correct security code.

Incorrect code. Advance to the first of the programming pages – Set Up Input Page.

SET UP INPUT

Nitrate <Units> Return to Operating Page 1.

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 6 PROGRAMMING…

6.2.4 Set Up Input Page

SET UP INPUT Page header.

Advance to next parameter.

Control Temp – – • – °C Control Temperature

or Set the required block control temperature within the range 5 to 45 °C in 0.1 °C
increments.

Enter Store.

Advance to next parameter.

Display as
Display Type (Ammonium, Ammonia or Nitrogen)
NH4?
Select display as ammonium (NH4+), ammonia (NH3) or nitrogen (N).
N? or
NH3?
Enter Store.

Advance to next parameter.

Ion Units mg/kg Ion Units

Select the required display units for ammonia concentration.
mg/l or
ppm
Enter Store.

Advance to next parameter.

Display Zero –– •– Display Zero

Set the required value for display within the range 0.05 to 20.00.
Enter Store.

Advance to next parameter.

Display Full Scale

Display FSD –– •– The full scale value is automatically set at two decades above Display Zero.

Example– If the setting is 1.0 the full scale is automatically set to 100.0.
Enter
Store.

Return to top of Set Up Input Page.

or or

Advance to Current Output Page.

CURRENT OUTPUT

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 …6 PROGRAMMING

6.2.5 Current Output Page

The current output is assigned to the ammonia concentration but is only operative if the relevant output modules are fitted – see
Fig. 2.4.

CURRENT OUTPUT Page header.

Advance to next parameter.

OP1 Cal Hold Yes Output 1 Calibration Hold

Current Output 1 can be held during calibration, if required. Select 'YES' or 'NO'.
No or

Enter Store.

Advance to next parameter.

OP1 Law Log Output 1 Law

Current Output 1 can be either logarithmic or linear. Select 'Log' or 'Lin'.
Lin or

Enter Store.

Advance to next parameter.

OP1 FSD ––– •– Output 1 Full Scale

Current Output 1 full scale range: 0.5 to 2000 mg l–1 ammonia, i.e. minimum span
is 1 decade.

or Set the required concentration value for Current Output 1 full scale.

Enter Store.

Lin Advance to next parameter.

Log
OP1 Zero – •–– Output 1 Zero

or Set the required concentration value for Current Output 1 zero.

Note. If the output 1 Law is linear (Lin), this parameter is omitted and the zero
current output is automatically set to '0'.

Enter Store.

Advance to next parameter.

Continued on next page.

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 6 PROGRAMMING…

…6.2.5 Current Output Page

Continued from previous page.

OP2 Cal Hold Yes Output 2 Calibration Hold

Current Output 2 can be held during calibration, if required. Select 'YES' or 'NO'.
No or

Enter Store.

Advance to next parameter.

OP2 Law Log Output 2 Law

Current Output 2 can be either logarithmic or linear. Select 'Log' or 'Lin'.
Lin or

Enter Store.

Advance to next parameter.

OP2 FSD ––– • – Output 2 Full Scale

Current Output 2 full scale range: 0.5 to 2000 mg l–1 ammonia, i.e. minimum span
is 1 decade.

or Set the required concentration value for Current Output 2 full scale.

Enter Store.

Lin Advance to next parameter.

Log
OP2 Zero – •–– Output 2 Zero

or Set the required concentration value for Current Output 2 zero.

Note. If the Output 2 Law is linear (Lin), this parameter is omitted and the zero
current output is automatically set to '0'.

Enter Store.

Advance to next parameter.

Continued on next page.

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 …6 PROGRAMMING

…6.2.5 Current Output Page

Continued from previous page.

Test Output Zeros Test Current Output Zeros

The instrument automatically transmits a current output zero test signal on both
outputs.

Example – For a 4 to 20 mA current output range, 4 mA is transmitted.

Advance to next parameter.

Test Output FSD Test Current Output Full Scale

The instrument automatically transmits a current output full scale test signal on
both outputs.

Example – For a 4 to 20 mA current output range, 20 mA is transmitted.

Advance to next parameter.

Alter Sec. Code ––––– Alter Security Code

Set the Security Code required, between 0 and 19999. This value must then be
or
entered again to access the secure parameters from Operating Page 1.

Enter
Store.

Advance to next parameter.

% Output xxx•x% Proportional Output Percentage (to heater)

Used as a diagnostic check to indicate the proportionally controlled current output
(%) to the heater.

Return to top of Current Output Page.

or or

Advance to Set Up Alarms Page.

SET UP ALARMS

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 6 PROGRAMMING…

6.2.6 Set Up Alarms Page

Alarm l.e.d. indication and relay output can be assigned either to the ammonia concentration or switched off.

SET UP ALARMS Page header.

Advance to next parameter.

A1 Enabled Yes Alarm A1 Enable

Select 'YES' to enable or 'NO' to disable.
No or

Enter Store.

No Advance to next parameter.

Yes
A1 Action High Alarm A1 Action
Select the alarm action required, 'High' or 'Low' – see Table 6.1.
Low or

Enter Store.

Advance to next parameter.

A1 Failsafe Yes Alarm A1 Failsafe

If failsafe action is required select 'Yes', otherwise select 'No' – see Table 6.1.
No or

Enter Store.

Advance to next parameter.

A1 Hysteresis –% Alarm A1 Hysteresis

A differential set point can be set as a percentage of the set point value. The
differential setting operates about the set point.

or Example – A 5% differential setting operates 2.5% above and below the setpoint.

Select the differential required, between 0 and 5% in 1 % increments.

Enter Store.

Advance to next parameter.

A1 Delay – –m Alarm A1 Delay

If required, relay actuation and alarm l.e.d. indication can be delayed in the event
of an alarm condition. If the alarm condition clears within the programmed delay
or time, the alarm function is not activated and the delay time is reset.

Set the required delay time between 0 and 60 minutes in 1 minute increments.

Enter Store.

Advance to next parameter.

(a)
Continued on next page.
(b)

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 …6 PROGRAMMING

…6.2.6 Set Up Alarms Page

Continued from Previous page.
(a)
(b)
A1 Setpoint – – –•– A1 Setpoint

or Set the required setpoint value.

Enter Store.

Advance to next parameter.

A2 Enabled Yes A2 Enabled

No or Repeat the programming procedures as for Alarm Relay 1.

A2 Setpoint ––– • – A2 Setpoint

or Set the required set point value.

Enter Store.

Return to top of Set Up Alarms Page.

or or

Advance to Set Up Clock Page.

SET UP CLOCK

Action Failsafe Measured Value Relay Status L.E.D. Indication

High YES Above Setpoint De-energised Flashing
Below Setpoint Energised Off

High NO Above Setpoint Energised Flashing

Below Setpoint De-energised Off

Low YES Above Setpoint Energised Off

Below Setpoint De-energised Flashing

Low NO Above Setpoint De-energised Off

Below Setpoint Energised Flashing

Table 6.1 Relay Action and Alarm Indication

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 6 PROGRAMMING…

6.2.7 Set Up Clock Page

SET UP CLOCK Page header.

Advance to next parameter.

No Set Up Real Time Clock

Set Clock? No Select 'Yes' to set up the clock, otherwise select 'No'.
or
Yes
Yes

Enter Store.

Advance to next parameter.

Set Year –– Set Year

or Set the appropriate year.

Enter Store.

Advance to next parameter.

Set Month –– Set Month

or Set the appropriate month.

Enter Store.

Advance to next parameter.

Set Day of Month –– Set Day

or Set the appropriate day of the month.

Enter Store.

Advance to next parameter.

Set Hours –– Set Hours

or Set the appropriate hour – (24 hour clock).

Enter Store.

Advance to next parameter.

(a)
Continued on next page.
(b)

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…6.2.7 Set Up Clock Page

Continued from previous page.

(a)
(b)
Set Minutes –– Set Minutes

or Set the appropriate minutes.

Enter Store.

Advance to next parameter.

Set Seconds –– Set Seconds

or Set the appropriate seconds.

Enter Store.

Advance to next parameter.

Flashing

Cal Date DD:MM:YY Calibration Date (day of the month)

or Set the day of the month when the first automatic calibration is to be carried out.

Enter Store and advance to next parameter.

Flashing

Cal Date DD:MM:YY Calibration Date (month)

or Set the month when the first automatic calibration is to be carried out.

Enter Store and advance to next parameter.

Flashing

Cal Date DD:MM:YY Calibration Date (year)

or Set the year when the first automatic calibration is to be carried out.

Enter Store and advance to next parameter.

Continued on next page.

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 6 PROGRAMMING…

…6.2.7 Set Up Clock Page

Continued from previous page.

Flashing

Cal Time HH:MM Calibration Time (hour – 24 hour clock)

or Set the hour of the day when the first automatic calibration is to be carried out.

Enter Store and advance to next parameter.

Flashing

Cal Time HH:MM Calibration Time (minutes)

or Set the minute of the hour when the first automatic calibration is to be carried out.

Enter Store and advance to next parameter.

Cal Interval – Days Calibration Interval

Set the calibration interval required between automatic calibrations, starting

or
from the calibration date (6 hours, 12 hours or 1 to 7 days in 1 day increments).

Enter Store.

Return to top of Set Up Clock Page.

or or

Advance to Calibration User Code Page.

CAL USER CODE -----

6.2.8 Calibration User Code Page

The calibration user code is required to gain access to the Set Up Temperature Control and Calibration Pages. The access code
can be altered in the Calibration Page, if required – see Section 6.2.11.

CAL USER CODE ----- Calibration User Code

Set the correct user code.

or

Incorrect Code
Advance to next programming page.

Correct Code

SET UP TEMP. CONTROL Set Up Temperature Control Page.

or or

Ammonia <Unit> Return to Operating Page 1.

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 …6 PROGRAMMING

6.2.9 Set Up Temperature Control Page

The parameters within this page are factory preset and should not require any adjustment.

SET UP TEMP. CONTROL Page header.

Advance to next parameter.

Cycle Time 20 Cycle Time

The cycle time is adjustable between 5 and 60 seconds in 1 second increments.

Advance to next parameter.

Prop. Band 2 Proportional Band

The proportional band is adjustable between 1 and 500% in 1% increments.

Advance to next parameter.

Integral Time 200 Integral Action Time

The integral action time is adjustable between 1 and 1800 seconds in 1 second
increments (1801 = 'OFF').

Return to top of Set Up Temperature Control Page.

or or

Advance to Calibration Page.

CALIBRATION

6.2.10 Electrical Calibration • Digital milliammeter, 0 to 20 mA – refer to Fig. 2.4 to

Electrical calibration is carried out prior to despatch and identify the output range.
should require no subsequent adjustment. However, if
measurements become suspect or if the contents of the Preparation
'CALIBRATION' page are inadvertently altered, recalibrate as a) Switch off the supply and disconnect the temperature
detailed in the following sections. sensor leads from terminals 1, 2 and 3 in the
Microprocessor Unit. Make the following connections:
Note. The calibration procedure involves modifying part of
the original programme but, provided that changed 1 & 3 (temperature sensor)
decade box
values are not stored using the 'Enter' switch, the 2 (temperature sensor)
original programme, which was stored in the nonvolatile
memory, can easily be reinstated at the end of calibration b) Insert the coaxial plug into the ISE socket above the
by switching off the instrument and switch on again. flowcell and connect the millivolt source (inner +ve, outer –
ve).
If there is thought to be any risk that the original programme
could be lost, it is advisable to make a note of the normal c) Connect the milliammeter in place of the appropriate
parameter settings. If the changed programme values are current output connections in the junction box – see
inadvertently 'Entered', the instrument can be reprogrammed Section 2.6.
on completion of the calibration procedure.
d) Switch on the supply and allow two minutes (30 minutes
Equipment Required from cold) for the circuits to stabilise.
• Millivolt source, range –400 to +400 mV.
• Electrode coaxial plug/lead assembly – supplied with e) Select the appropriate Cal User Code to gain access to the
monitor; programming pages – see Section 6.2.8.
• Decade resistance box†, 0 to 1 kΩ in 0.01 Ω increments.

†
Resistance boxes have an inherent residual resistance
which may range from a few milliohms to one ohm. This
value must be taken into account when simulating input
levels, as must the overall tolerances of the resistors within
the box.

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 6 PROGRAMMING…

6.2.11 Electrical Calibration Page

CALIBRATION Page header.

Advance to next parameter.

mV Zero –––– Millivolt Input Zero

Set the millivolt source to –400 mV.

Set the display to '–400' mV.

or

Enter
Store. New value is accepted only when input is stable.

Advance to next parameter.

mV FSD –––•– Millivolt Input Full Scale

Set the millivolt source to +400 mV.

Set the display to '+400'mV.

or

Enter
Store. New value is accepted only when input is stable.

Advance to next parameter.

Temp. Zero – – – • –°C Temperature Zero

Set the resistance box to 96.09 Ω (resistive equivalent of –10 °C).

Set the display to '–10°C'.

or

Enter
Store. New value is accepted only when input is stable.

Advance to next parameter.

Temp. FSD – – – • –°C Temperature Full Scale

Set the resistance box to 142.29 Ω (resistive equivalent of 110 °C).

Set the display to '110°C'.

or

Enter
Store. New value is accepted only when input is stable.

Advance to next parameter.

Continued on next page.

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 …6 PROGRAMMING

…6.2.11 Electrical Calibration Page

Continued from previous page.

Adjust Output 1 Zero Adjust Current Output 1 Zero

The monitor transmits a zero signal, e.g. for a 4 to 20 mA output range, 4 mA is
transmitted.

Set the milliammeter reading to the current output 1 zero level, i.e. 0 mA (zero-
or based ranges) or 4 mA (4 to 20 mA range).

Enter Store.

Advance to next parameter.

Adjust Output 1 FSD Adjust Current Output 1 Full Scale

The monitor transmits a span signal, e.g. for a 4 to 20 mA output range, 20 mA is
transmitted.

Set the milliammeter reading to the current output 1 full scale level, i.e. 1 mA,
or 10 mA or 20 mA as applicable.

Enter Store.

Advance to next parameter.

Adjust Output 2 zero Adjust Current Output 2 Zero

The monitor transmits a zero signal, e.g. for a 4 to 20 mA output range, 4 mA is
transmitted.

Set the milliammeter reading to the current output 2 zero level, i.e. 0 mA (zero-
or based ranges) or 4 mA (4 to 20 mA range).

Enter Store.

Advance to next parameter.

Adjust Output 2 FSD Adjust Current Output 2 Full Scale

The monitor transmits a span signal, e.g. for a 4 to 20 mA output range, 20 mA is
transmitted.

Set the milliammeter reading to the current output 2 full scale level, i.e. 1 mA,
or 10 mA or 20 mA as applicable.

Enter
Store.

Advance to next parameter.

Continued on next page.

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…6.2.11 Electrical Calibration Page

Continued from previous page.

Cal Time 1 10 m Calibration Time 1

The displayed value is preset at the factory and must not be altered.
See Table 7.1.

Advance to next parameter.

Cal Time 2 10 m Calibration Time 2

The displayed value is preset at the factory and must not be altered.
See Table 7.1.

Advance to next parameter.

Cal Time 3 10 m Calibration Time 3

The displayed value is preset at the factory and must not be altered.
See Table 7.1.

Advance to next parameter.

Alter Cal Code ----- Alter Calibration Code

The calibration user code inhibits access to the Set Up Temperature Control
Page and the Calibration Page – see Section 6.2.8.

or Set a suitable user code, between 0 and 19999.

Enter Store.

Return to top of Electrical Calibration Page.

or or

Return to Operating Page 1.

Ammonia <unit>

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 7 CALIBRATION
7.1 Calibration Sequence On initiation of the calibration sequence, either manual or
Calibration of the monitor is carried out by replacing the automatic, the 'Cal' l.e.d. is illuminated and the Calibration
sample solution sequentially with two standard solutions of Mode relay is energised. Two solenoid valves, SV1 and SV2
known concentration. This calibration sequence (see Table operate sequentially to shut off the sample and admit standard
7.1) can be initiated automatically at preset times, or manually solutions of known concentration, one low and one high (STD1
on demand. and STD2), to the sample path.

The sensor outputs obtained during calibration are used to Once a valve is energised, sufficient time (preset to suit the
calculate the calibration graph for the monitor and the sensor response time) is allowed for the previous solution to
accuracy of the standard solutions will, therefore, have a direct be displaced, and for the sensor to respond to the new
effect upon the overall accuracy of the monitor. Given accurate solution, before the sensor output is evaluated for stability by
standards, it is clear that the best accuracy would be expected the microprocessor. When a stable output is achieved the next
at the two calibration points. Ideally, the concentrations of the stage in the sequence is initiated.
two standards should bracket the expected sample
concentration closely, but the latter often varies quite widely. In After calibration the probe outputs corresponding to the two
practice it is convenient, and often the best compromise, to standard solutions are used to calculate a new calibration
use standards whose concentrations are one decade apart, graph for the monitor, thus compensating for any drift in probe
i.e. differ by a factor of 10, and bracket the expected range of or liquid handling performance characteristics since the last
sample concentrations. For example, if the range of sample calibration, and the new slope value can be displayed in
concentrations is expected to be 5 to 10 ppm, then standards Operating Page 1 (100% slope is the theoretical value).
of 2 and 20 ppm could be used – see Section 8.1.2 concerning
low concentration ammonia standards. If the values are within limits, 'CALIBRATION PASSED' is
displayed.
Note. The concentrations of the two standard solutions
must differ from each other by a factor of at least four. 'CAL FAILED (SLOPE)' is displayed if the slope value is
outside acceptable limits and 'CAL FAILED (SLOW)' is
displayed if the sensor output failed to stabilise within 15
minutes after the end of Cal Time 1 or Cal Time 2.

Introduce Sensor Introduce Sensor Introduce Normal

Activity
STD1 Stabilises STD2 Stabilises Sample Operation

Valve Open SV1 SV1 SV2 SV2 None None

Preset Preset Preset

Timing Variable * Variable * None
(Cal Time 1) (Cal Time 2) (Cal Time 3)
*15 min. max.
Table 7.1 Calibration Sequence Summary

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 8 MAINTENANCE
8.1 Chemistry 8.1.2 Standard Solutions
Neither ammonium ion content nor total ammonia can be Two standard solutions of known concentration appropriate to
measured directly in an untreated sample, since the probe can the measuring range are required for calibration of the monitor.
respond only to free ammonia gas. The ammonium ions must To prepare a stock solution of 10,000 mg l–1 follow instructions
therefore be converted to free ammonia by adjusting the pH of below:
the sample solution to a value greater than 11. This is effected
by addition of a sodium hydroxide solution to the sample a) Ammonia as N – Dissolve 38.21 (±0.01) g analytical
before it is presented to the probe. This reagent also has a reagent grade ammonium chloride (NH4Cl) (dried) in
second function, i.e., to fix the total concentration of dissolved approximately 200 ml of high purity water.
species in the final solution at approximately 0.2M.
Ammonia as NH3 – Dissolve 31.47 (±0.01) g analytical
reagent grade ammonium chloride (NH4Cl) (dried) in
In water industry applications a water softener, EDTA, is
approximately 200 ml of high purity water.
added prior to the sodium hydroxide addition. Besides
preventing hardness precipitation, this also overcomes Ammonia as NH4+ – Dissolve 29.72 (±0.01) g analytical
inaccuracies caused by complexing of ammonia with some reagent grade ammonium chloride (NH4Cl) (dried) in
metal ions. In power applications where the hardness levels approximately 200 ml of high purity water.
are very low this second reagent is not required, so the bottle
tube, pump tube and first reaction coil can be removed. b) Transfer the solution to a one litre volumetric flask and
make up to the mark with more high purity water.
The reagent and standard solutions described below are
required to maintain the monitor in operation. Where possible, c) Dilute the appropriate stock solution with more high purity
they should be freshly made and stored in plastic (e.g. water to make the two standard solutions for the measuring
polythene) bottles. Typical reagent solution consumption for a range of the monitor. Store in plastic bottles.
continuously operating monitor is approximately 10 litres per
month. The monitor uses 50 to 80 ml of each standard solution Note. Low value ammonia standard solutions should be
each calibration cycle; consumption of the standard solution, avoided. For example, at ambient temperatures of about
also depends on the frequency with which this cycle is carried 25 °C, and under normal light conditions, a 0.5 mg -1 NH3
out. solution is expected to lose at least 10% of its
concentration over a seven day period. Because of the
8.1.1 Reagent Solutions instability of such solutions, it is not possible to
Two reagent solutions are used in the ammonia monitor. Care programme a standard solution of lower concentration
must be exercised to ensure that the correct reagent is fed into than 0.2 mg l–1 NH3 on this monitor. Solutions as low as
each channel. They are prepared as follows: 0.2 mg l–1 can be prepared with care, but must be used
immediately, making it an unsuitable concentration for
Reagent 1 – Orange Channel long term use with the monitor.
Dissolve 315 (±5) g laboratory reagent grade di-sodium EDTA
in approximately 8 litres of high purity water and make up to 10
litres with more high purity water. Note. The mass relationship of ammonium (NH4+) to
ammonia (NH3) is 18/17 and ammonia (NH3) to nitrogen
Note. If the monitor is to be used on power plant (N) is 17/14.
applications the reagent will not be required due to the
insignificant concentration of hardness in the sample.
8.2 Scheduled Servicing
Reagent 2 – Red Channel The following servicing schedule has been produced as a
Dissolve 1000 (±10) g analytical reagent grade sodium general guide only. Because the monitor has been designed
hydroxide (NaOH) in approximately 8 litres of high purity for a very wide range of applications, where the nature of the
water. Allow the solution to cool and then make up to ten litres sample can vary considerably, it may be necessary to amend
with more high purity water. the schedule to suit the particular installation and sample
conditions.
Warning. This solution is extremely caustic; avoid
8.2.1 Regular Visual Checks
contact with the skin and eyes. If contact occurs, wash
It is recommended that the monitor and the sampling system is
with plenty of clean water.
visually inspected on a regular basis to assure correct
functioning of the system and to check the integrity of the
readings.
a) Check for leaks, particularly around the sample and drain
pipework connections.

b) Confirm sample flow by checking delivery to the constant

head unit and effluent from the drain.

c) Check liquid flow over the probe membrane.

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 …8 MAINTENANCE

d) Check liquid levels in the reagent and standard solution Note. Once growth is visible the problem is already
containers. serious.

e) Check for malfunction indications on the instrument The recommended agent for cleaning tubing and pipework is
display. sodium hypochlorite solution containing about 0.1%
(1000 mg l–1) available chlorine.
Note. The mains and pump/heater switches are situated
on the right hand side of the User Junction Box. Cleaning Solution
To prepare 500 ml of cleaning solution, dilute 5 ml of
8.2.2 Four Weekly concentrated sodium hypochlorite (NaOCl) solution
a) Inspect all tubing and flowcell for leaks or deterioration, (containing approximately 10% available chlorine) with de-
and for signs of accumulation of solid deposits. ionised water and make up to 500 ml with more de-ionised
water.
b) Clean monitor pipework if there are signs of algae visible.
Note. The solution is unstable. Make only enough for
c) Check the level of the filling solution in the probe and immediate requirements and discard any surplus after
top-up if necessary. use.
d) Discard old reagent and standard solutions. Clean
containers thoroughly before refilling with fresh solutions – Warning. Sodium hypochrorite is an irritant. Contact with
see Section 8.1. acids liberates toxic gas. Avoid contact with skin and eyes.
If contact occurs, wash with plenty of clean water.
Note. It is vital that the containers are not topped up.
Method
e) Examine the sample input pipe for leaks and deterioration. Where an Ultrafilter is used, clean according to the manual
with a 0.05% (500 mg l–1) chlorine solution (i.e. half the
f) Ensure the drain is in good order and free from obstruction. concentration of the above solution). Tubing between the
Ultrafilter and the analyser should also be flushed through,
8.2.3 Two Monthly along with the constant head tank.
Refurbish the probe – see Section 8.2.7.
a) Remove sensors for short-term storage before cleaning –
8.2.4 Twelve Monthly see Section 8.3.1
a) Service pump, tubing and capstans – see Section 8.2.8.
b) Remove the reagent and calibration solution take-up tubes
b) Replace all internal plumbing tubing – see Section 8.2.9. from their respective containers. Fill a calibration container
with the sodium hypochlorite cleaning solution, place it in
c) Carry out the normal 4 weekly schedule not already the calibration container recess and immerse the take-up
covered above. tubes in the solution.
8.2.5 Cleaning Sample Pipework c) Operate 'Cal' to initiate a calibration sequence to draw the
A common problem in measuring water samples from rivers, solution through the solenoid valves tubing and flowcell.
treatment works, etc., is the presence of bacteriological
growth in the sample. d) Remove any dislodged debris from the flowcell and clean
the constant-head unit with the cleaning solution using the
In the form of algae it creates a problem by growing inside bottle brush provided. The tube between the constant-
tubing supplying sample to analysers, as well as in the head unit and SV1 can be cleaned with the cleaning
monitors and associated ABB Kent-Taylor Ultrafilters, if used. solution using the syringe.
If severe, this growth may cause blockages in tubing or valves
and/or fouling of flowcells and sensors. e) Repeat the process using high purity water to flush out the
sodium hypochlorite solution.
In addition, the algae may affect the concentration of the
measured parameter in the sample. This is particularly severe If, after cleaning, there are still signs of discoloration or
in ammonia monitors, where algal growth in supply lines deposits in the monitor tubing, it should be discarded and
causes 'ammonia stripping' and a reduction in the measured replaced with new tubing throughout. In cases where the
concentration. Other parameters, however, may also be monitor tubing is blocked or very heavy deposits are found, it
affected. may be necessary to simply replace the tubing without
attempting to clean it.
It is therefore essential to maintain sterile conditions. This
requires periodic cleaning, at a frequency dependent on
sample conditions. It is suggested that a regular maintenance
programme is introduced, rather than wait for visible signs of
the presence of algal growth.

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 8 MAINTENANCE…

Cleaning Solution Containers 8.2.7 Assembling/Refurbishing the Probe

Great care should be taken to ensure that reagent and The ammonia probe is a gas sensing combination electrode
standard solution containers are thoroughly cleaned assembly. It is supplied in kit form and must be assembled or
whenever their contents are changed, as algal growth can also refurbished using one of the appropriate procedures below:
occur in them. Under normal circumstances thorough rinsing
of the containers with high purity water may be adequate. Refurbishing
However, if there is any evidence of algal growth, the a) Dismantle the probe and rinse off the filling solution with
containers should be rinsed with sodium hypochlorite solution dimineralised water.
(containing about 0.1% available chlorine) and thoroughly
flushed out with water afterwards. A bottle brush may be useful b) Remove the membrane from the end cap and retain the
to remove stubborn deposits. sealing washer; use a new washer if it is damaged.

It is advisable when changing standard or reagent solutions to c) Proceed from step c) in Assembling the Probe below.
replace the container and remove the empty/used one for
thorough cleaning. Assembling the Probe
a) Unscrew the end cap from the probe body. Rinse the probe
Note. It must be emphasised that containers which are to body with distilled or de-ionised water. Allow to drain.
be used for ammonia standard solutions must be very
thoroughly washed out after chlorine treatment because b) Remove the teat from the glass electrode. Rinse the
any residual chlorine will react with ammonia and hence electrode with distilled or de-ionised water. Dry with a
change the standard concentration. In addition to paper tissue.
thorough washing with water, it is suggested that the
containers are rinsed with a portion of the ammonia c) Screw the glass electrode into the body until the tip of the
standard before finally filling. electrode is flush with the end face of the probe. Note the
number on the electrode cap in line with the mark on the
8.2.6 Consumables Spares Kit body. Unscrew the electrode cap four full turns.
If one is not supplied, it should be ordered before the end of the
first year of operation. This kit includes all the components d) Drop a membrane (coloured white) into the end cap and
which are recommended for replacement annually (see place the sealing washer centrally upon it.
Section 10). This annual refurbishment ensures a high level of
reliability from the monitor over a period of many years. e) Screw the end cap firmly onto the body, taking care not to
Another kit should be ordered when the old one is used so that wrinkle the membrane. Ensure that the body seal and the
all the items are available throughout the following year's membrane sealing washer are both under compression.
operation. The consumable spares kit is in addition to the
electrode spares kit. f) Holding the probe upright, inject the filling solution
provided through the filling hole until there is a 50 to 60 mm
The kit contains the following: depth of solution inside so that the reference element is
immersed in the solution. Wipe any excess filling solution
• one set of pump tubing from the body.
• one set of pump capstans
• a complete set of plumbing tubing g) Tap the end of the probe with the finger to dislodge any air
• sundry items – 'O' rings, tube connectors, pump tube bubbles which have been trapped between the end of the
bungs and fuses glass electrode and the membrane. Screw the glass
• plastic syringe and bottle brush – for cleaning pipework, electrode down four turns to the flush position again and
valves, flowcell and constant-head unit. then a further 1.0 ±0.1 turns. The tip of the electrode should
now be pressing against the membrane. In some
circumstances, particularly if the electrode response is
sluggish, the screw may be given a further 0.2 to 0.3 turn.
Beware of overtightening, which can puncture the
membrane.

h) Push the probe cap onto the top of the probe body so that
it covers the filling hole.

Note. A newly assembled probe should be run on sample

for 2 to 4 hours before a calibration is attempted.

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 …8 MAINTENANCE

…8.2.7 Assembling/Refurbishing the Probe 8.2.8 Peristaltic Pump – Fig. 8.2

Fitting the Probe – Fig. 8.1 It is recommended that the pump tubing and pump capstans,
When the Ammonia Probe has been prepared for use in supplied in the Consumable Spares Kit, are replaced after one
accordance with steps a) to h) proceed as follows: year of operation. Carry out the following procedure 1 to 8:

i) Hinge down the temperature controlled block cover to gain 8.2.9 Replacement of Plumbing Tubing
access to the block. Fit the assembled probe into the All necessary items are included in the Consumable Spares
recess in the temperature controlled block, ensuring that Kit.
the probe sits at the bottom of the recess. Rotate the
retaining clip to hold the probe in position. Do not touch the a) Remove probe for short term storage.
delicate membrane with any hard or sharp objects.
b) Remove each section of the sample and reagent plumbing
j) With sample and reagents flowing, ensure that liquid is tubing in turn and replace with new tubing of the same
delivered on to the membrane, flows over its surface and length.
drips off the lower edge of the probe end cap into the drain
recess, as shown. c) Remove drain tubing and replace with new tubing of the
same length.
k) Replace the cover on the temperature controlled block.
d) Clean the constant head unit, solenoid valves and sample
l) Connect probe lead to the coaxial socket above the heating coil in the flowcell with a syringe filled with sodium
temperature controlled block. hypochlorite solution.

e) It is recommended that the sample and drain tubing to and

from the monitor is inspected and replaced if the tubing is
in poor condition or shows evidence of any build up of
solids.

Probe Retaining Clip

Ammonia
Probe
Recess in
Block

Sample
Delivery
Tube

Sample Delivery Temperature

and Drain Moulding Controlled
Block
Probe Membrane Sample Director Moulding

Fig. 8.1 Fitting the Probe

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 8 MAINTENANCE…

Apply downward force. 1 Remove the pump platen by applying

gentle downward force to the platen
while turning the catch mechanism
to the vertical position and pulling the
catch forward.
Lower the pump platen, only from
8
directly above, on to the pump tubes
until the catch mechanism locates in
the hole in the case, and turn the
catch lever to the horizontal position.

5
If required, fit new pump tube 2 Disconnect each pump tube from its
bungs and shims, from the kit, to respective tube connector at the rear
the left hand side of the pump. of the case, pull through the
grommets and discard.

3 Remove the retaining screw on the

Note. The bungs are pump shaft and remove the capstans.
designed to grip the pump
tube when compressed by 4 Fit all three new capstans, from the
the platen. Two sizes of tube kit, on the hexagonal shaft so the
are used so it is essential rollers are offset from one another.
that the correct size of bung Fit retaining screw.
is fitted. The sample tube,
which is the larger of the two,
is fitted at the front of the
pump. It is important that the
shims are always fitted.

6
Pass new pump tubes, from the 7
kit, through the tube bungs and Locate the tubes centrally on the pump rollers.
case grommets. Connect to the
appropriate tube connector at the
rear of the case.

Fig. 8.2 Peristaltic Pump

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 …8 MAINTENANCE

8.3 Shutdown Procedure d) Clean sample pipework both inside and outside the
8.3.1 Short Term monitor, constant head unit, and filtration system (if used).
The monitor can be left with the power switched off for up to 24
hours without any detrimental effects. When returned to e) Remove pressure plate from peristaltic pump.
normal monitoring mode, the monitor should be run on sample
for 30 minutes, followed by a calibration – see Section 7.
8.4 Unscheduled Servicing
If the probe is left in the monitor with no liquids flowing, the The monitor indicates abnormal operation by means of signals
internal filling solution becomes more concentrated by on the 20 character dot matrix display and l.e.d's. The
evaporation of water through the membrane. The probe output indications are listed in Table 8.1.
drifts when normal operation is resumed and many hours may
be required to re–establish stability. In such cases normal 8.4.1 Malfunction of the Monitor
performance can sometimes be restored by unscrewing the It should always be remembered that any unpredictable
glass electrode 2 to 3 turns and then returning it to its original problems may be due to the standard or reagent solutions, or
position, thus allowing fresh filling solution to flow between it their flow through the flowcell. If any doubts exist regarding the
and the membrane. If this procedure is not successful replace integrity of the solutions, they should be replaced with freshly
the membrane and filling solution. prepared solutions in the early stages of the fault finding
investigations.
If the probe is likely to be out of use for more than one day,
remove from the monitor and store with the lower part of the Note. The accuracy of the monitor is governed by the
body immersed in a small quantity of liquid in a beaker or other condition of these solutions which may be incorrectly
suitable vessel. 0.1M ammonium chloride is the best storage made or contaminated.
solution (but it is essential that all traces of the storage solution
are rinsed away with clean water before use); otherwise, a In general, any problems are likely to be due to the electrodes,
small amount of the EDTA reagent (Reagent 1) is suitable. which may require refurbishment (see Section 8.4.3), but may
be due to other parts of the liquid handling section of the
8.3.2 Long Term monitor.
When the monitor is required to be shut down for more than 24
hours, proceed as follows: Mechanical components which are involved with the liquid
a) Switch of the monitor. handling, for example, pumps, valves, tubing and tubing
connections etc., should be systematically checked for correct
b) Close the sample valve upstream of the monitor. operation, and for leaks or blockages which change the
chemical conditions around the sensor. The majority of all
c) Dismantle the probe and return to its box. First the glass problems are found to be associated with the chemistry and
electrode is unscrewed, then the rest of the probe emptied, the liquid handling section.
rinsed and drained. Store the glass electrode with its end in
a teat containing a neutral buffer solution, taking care not to
cover the reference element.

Display Possible Cause

'CALIBRATING Std 1 (or 2)' Normal when calibration is taking place. 'Std 1' or 'Std 2'
Cal L.E.D. flashing refers to the standard solution being admitted at the time.
'CALIBRATION PASSED' A recent two point calibration has been successfully carried out.

'CAL. FAILED (SLOPE)' The slope value calculated from the probe outputs in the two
Fail L.E.D. flashing standard solutions was outside the acceptable limits.

'CAL. FAILED (SLOW)' The monitor was unable to achieve a stable output from the
Fail L.E.D. flashing probe.
'TEMP. CONTROL ERROR' The sensor flowcell temperature is significantly different from the
Control Temperature.
'OUT OF SAMPLE' Indicates loss of sample.

Hold L.E.D. 'ON' This indicates the Hold button has been pressed to freeze the
concentration alarm states and to activate the Out of Service
alarm relay. Pressing the button again returns the monitor to
normal operation after a period of 3 hours.
Table 8.1 Unscheduled Servicing Messages

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 8 MAINTENANCE

8.4.2 Monitor Diagnostic Information b) Clean membrane by washing with a jet of clean water from
Out of Service Alarm a wash–bottle or syringe.
This alarm relay output is a normally energised relay which de-
energises in the following circumstances: c) Check, and top up as necessary, the filling solution in the
a) Loss of mains supply. probe. There should be a 50 to 60 mm depth inside the
probe so that the reference element is immersed in the
b) Calibration Failed – the calculated electrode slope value is solution.
outside the acceptable limits or the response of the probe
is too slow. The 'CAL FAIL' l.e.d. on the front panel is d) Osmotic effects, i.e. total concentration of dissolved
illuminated with the appropriate text on the 20-character species in samples too high.
display.
e) Puncture of the membrane (usually visible), disassemble
c) Block temperature out of limits – the measured probe and reassemble – see Section 8.2.7.
temperature of the Block is not within 5 °C of the Control
Temperature. 'TEMP. CONTROL ERROR' is indicated on f) Interference (from for example high concentrations of
the 20-character display. anionic detergents).

d) 'OUT OF SAMPLE' alarm – a float switch in the g) Check glass electrode – see Section 8.5.
constant head unit detects the loss of sample. 'OUT OF
SAMPLE' is indicated on the 20-character display. h) Check reference element – see Section 8.5.

e) 'OUT OF SERVICE' alarm – displayed when the pump is In the 'CAL. FAILED (SLOW)' case the failure is usually due to
switched off. slow sensor response, but may be due to an unstable (noisy or
drifting) sensor output:
Note. The heater is switched off by the software when an a) Check sensor connections in the coaxial plugs and
'OUT OF SAMPLE' condition is detected. sockets, and inside the microprocessor unit.

Calibration Fail Alarm b) See Malfunction of the Electrode/Probe – see Section

A calibration failed condition occurs after a two point 8.4.3.
calibration if the calculated slope value is less than 80% or if
the probe output is unstable. The failure could be caused by a 8.4.3 Malfunction of the Probe
number of factors which should be investigated. Internal Filling Solution
The internal filling solution incorporates a coloured indicator
In the 'CAL. FAILED (SLOPE)' case some indication of the which is normally yellow. The indicator changes to blue if the
problem may be obtained from the slope value. probe membrane, or membrane seal, allows alkaline reagent
to leak into the probe. If this occurs the membrane should be
Slope Value Just Below 80% replaced, and care taken to tighten the end cap sufficiently to
a) Check liquid delivery on to the probe membrane – see provide a good seal. The solution keeps indefinitely.
Section 8.2.7 (j).

b) Clean membrane by washing with a jet of clean water from 8.5 General Maintenance of the Probe
a wash–bottle or syringe.
8.5.1 Ageing of the Glass Electrode
c) Disassemble probe and reassemble – see Section 8.2.7. After the probe has been in use for some months, the
performance of the glass electrode may eventually deteriorate
d) Check glass electrode – see Section 8.5. due to its continued use in weakly buffered solutions at near
neutral pH. The response of the probe becomes sluggish and
Slope Value Grossly Abnormal the response slope drops. The electrode may frequently be
a) Check, and top up as necessary, the filling solution in the restored to its initial condition by soaking for 12 hours in 0.1M
probe. There should be a 50 to 60 mm depth of solution hydrochloric acid. The performance of the electrode may be
inside the probe. checked as described below.

b) Disassemble probe and reassemble – see Section 8.2.7. 8.5.2 Checking the Performance of the Glass
Electrode
c) Check glass electrode – see Section 8.5. The glass electrode may be checked independently of the
probe with a laboratory calomel reference electrode by testing
d) Check reference element – see Section 8.5. the pair in pH buffer solutions.

Noisy, unstable response or slow response Immerse the glass electrode to a depth of 5 to 10 mm. There
a) Check liquid delivery on to the probe membrane – see must be no liquid contact with the reference element.
Section 8.2.7 (j).

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 …8 MAINTENANCE

Connect the electrodes to a pH meter and calibrate with pH c) If the element is not uniform in colour repeat the ammonia/
buffers in the usual way. The glass electrode may be found to nitric acid process.
be somewhat slower in response than a conventional bulb–
type electrode, but adequate scale length should be obtained, d) When clean, rinse with distilled water and immediately
typically better than 98% of the theoretical slope value. transfer to the plating solution such that the reference
element is completely immersed.
8.5.3 Reference Element
During the lifetime of the probe, the internal reference element Chloridisation –
may show signs of deterioration, indicated by the removal of a) Attach the screen of the combination electrode cable to the
the grey/brown silver chloride coating, exposing the buff/light negative terminal of the constant current supply and
grey silver element beneath. This is a normal process, the rate immerse the lower 50 mm of the electrode in the plating
of removal depending on probe operating conditions and solution so that the reference element is covered. Immerse
maintenance. a silver counter electrode in the plating solution and
connect to the positive terminal of the supply.
When new and in good condition this element is completely
and evenly coated. Loss of a large part of this coating causes b) Pass a current of 2 mA for approximately 30 seconds.
probe drift, but can be restored by re–chloridising the element, Carefully tap the electrode to remove all bubbles and then
using the following procedure: reverse the connections to the supply (i.e. the electrode to
be plated is connected to the positive terminal).
8.5.4 Procedure for Chloridising the Reference
Element c) Pass a current of 2 mA for 30 minutes after which
time the electrode will be a dark brown or grey colour. A
Requirements – more uniform coating may be obtained by employing
• Plating solution – hydrochloric acid (HCl) 0.1M, 500 ml. moderate stirring during the process.

Note. Do not use acid preserved with mercuric ions. d) Remove the electrode from the plating solution, rinse
with distilled water and dry with a tissue.
• Cleaning solutions – Ammonia solution (NH3) 50% vol./
vol., 200 ml.
To prepare, dilute 100 ml analytical reagent grade 8.6 Microprocessor Unit Error Messages
concentrated ammonia solution, s.g. 0.88, with 100 ml The instrument incorporates an automatic self-diagnostic
distilled water and stir. checking facility for detection of input and output errors. If such
a fault occurs, one of the error messages detailed below is
• Nitric acid (HNO3), 25% vol./vol. 200 ml. shown on the dot matrix display.
To prepare; cautiously pour 50 ml analytical reagent
grade, concentrated nitric acid, s.g. 1.42, into 150 ml 'CHAN 1 INPUT ERROR'
distilled water, stirring continuously. Allow to cool before This error message is usually caused by an open circuit
use. sensor input allowing the input to drift outside the range of
±400 mV. This may be due to any of the following:
Warning. Stored ammonia solutions and concentrated
a) Low level of filling solution in the probe.
nitric and hydrochloric acids are irritants and very
corrosive. Take great care not to inhale the fumes of either
b) Open circuit electrode internally, e.g. broken
or to get any on the skin or clothing. Any slight spillage on
connection.
skin, clothing or working surface must be washed away
with plenty of water.
c) Broken electrical connections between the probe and
the Microprocessor Unit sensor input.
• Constant current supply, 2 mA d.c. output.
d) Sensor coaxial plugs not correctly inserted.
• Silver wire (counter electrode).
'TEMP INPUT ERROR'
• 1 beaker.
'PRT OUT OF LIMITS'
'TEMP REF. ERROR'
Cleaning –
'THIRD LEAD ERROR'
a) Immerse the lower 50 mm of the combination electrode
(i.e. so that the silver reference element is covered) in the
The above four error messages refer to electrical problems
ammonia solution for about 1 minute. Remove and rinse
with the temperature sensor input – usually an open or short-
with distilled water.
circuited connection.
b) Immerse the electrode to the same depth in the 25% nitric
acid until the silver element is a uniform creamy white. This
process usually takes about 1 minute, but the element
must be inspected frequently as prolonged immersion is
detrimental.
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 9 SPECIFICATION
Range: .................... Ammonia 0.05 to 2000 mg l–1. Concentration Alarm
Adjustment: ........... Programmable over range.
Repeatability: ........ ±2% of reading.
Concentration Alarm
Reproducibility: .... ±3% of reading. Differential: ............ 0 to 5%.

Response Time: .... Less than 10 minutes for 90% step Concentration Alarm
change. Delay: ..................... 0 to 60 minutes.

Millivolt Range: ..... –400 to +400 mV. Programmable Data

Retention: .............. 3 years.
Millivolt Resolution: ±0.1 mV.
Calibration: ............ Fully automatic two point, plus manual
Control Temperature initiation on demand.
Range: .................... 30 to 45 °C
Routine Maintenance:
Temperature Four weekly: ...... Replenish reagents, clean flow system.
Resolution: ............ ±0.1 °C Twelve monthly: Replace plumbing and pump tubing, and
pump capstans. Refurbish sensors
Displays: ................ depending on application.
Concentration .... 5 digit blue fluorescent.
Information ........ 20 character dot matrix blue fluorescent. Power Supply: ....... 115 or 240 V, 50/60 Hz, 100 VA.
Status indication Two flashing l.e.d's in alarm state.
Single l.e.d. lit when 'Hold' switch Power Supply
operated. Tolerance: .............. +6% to –20%.
Single l.e.d. lit when calibration is in
progress. Isolation Voltage: .. Input, Output and power supply 1.5 kV.
Single l.e.d. lit when the monitor is 'Out of
Service' Dimensions:
Height: ............... 890 mm (35.0").
Current Outputs: ... As standard one isolated current output Width: ................ 542 mm (21.3").
0 to 1, 0 to 10, 0 to 20 or 4 to 20 mA, Depth: ................ 220 mm (8.7").
selected via plug in links. Maximum
voltage load 15 V. Weight ............... 30 kg (66 lb)

Current Output Degree of Protection:

Span: ...................... Minimum 1 decade of display range, Electronic Section:IP65
logarithmic or linear. Liquid Handling: .. Case IP31, critical internal components
IP65.
Computer Interface: Optional second current output or
RS422/RS423 serial interface.

Alarms: ................... Two high or low concentration alarms.

Remote calibration mode indication.
Remote monitor 'OUT OF SERVICE'
indication.
Remote 'OUT OF SAMPLE' indication.
All voltage free 250 V, 5 A noninductive
changeover relay contacts.

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 10 SPARES LIST
Consumable Spares Strategic Spares

Part No. Description Qty Part No. Description Qty

Consumable spares kit comprising 8232 280 Constant head unit 1
pump tubes, pump capstans, plumbing
8230 020 1 8061 864 Float switch – 'Out of Sample' 1
tubing, tube connectors and 'O' rings
etc. Pump motor including 10 μF capacitor
8230 208 1
(4 r.p.m. @ 50 Hz)*
8002 240 Ammonia probe internal filling solution 1
8035 870 Pump motor coupling assembly 1
8002 260 Ammonia probe membrane kit 1
8232 254 Heater mat 1
0234 712 Heater thermal cut-out 1
Refurbishment Spares
8232 250 Heater plate assembly 1
Part No. Description Qty 0232 325 Mains transformer – User Junction Box 1
8002 805 Ammonia probe kit 1 0234 713 Toggle switch – mains and pump switch 2
8002 701 Ammonia probe inner electrode 1 0234 714 Toggle switch boot 2
8002 780 Electrode body 1 8230 130 P.C.B. assembly – User Junction Box 1
8002 820 Probe clamp 1 0239 117 Electrode coaxial plug 1
8232 262 Sample heater tube 1 0239 118 Electrode coaxial socket 1
8232 270 EDTA reagent bottle assembly 1 4500 0845 Processor Board (without EPROM) 1
8232 275 NaOH reagent bottle assembly 1
*This motor replaces 0232 069 (5 r.p.m. @ 50 Hz), thus
8232 269 Mixer coil 2
reducing reagent consumption.
Standard solution container assembly –
8230 221 1
'High'
Standard solution container assembly – Specify EPROM below as required
8230 220 1
'Low' N.B. EPROM's require a special PLCC extraction tool
8063 710 Container tube sinker 4 Part No. Description Qty
Hose connector – sample inlet 6 mm 8232 170 EPROM (English) 1
0214 514 1
i.d. 8232 170 SP01 EPROM (English, range 0.05 to 2000 mg–1) 1
Hose connector – monitor drain 9 mm
0214 526 1 8232 171 EPROM (German) 1
i.d.
Tube connector – 9 mm i.d. flowcell 8232 175 EPROM Serial Comm (English) 1
8022 990 1
drain
8232 176 EPROM Serial Comm (German) 1
8230 240 Temperature sensor assembly 1
8232 261 Sensor probe receptacle 1
8232 289 Sample drain director moulding 1 4500 0817 Power supply board assembly 1
0234 019 Solenoid valve ('Burkert' Type)* 1 4500 0140 Display board pack assembly 1
4500 0245 Serial I/O board 1
*This valve replaces 'Fluid Automation Systems' valve (part
4500 0255 Current O/P board 1
number 0232 092).
To convert to the Burkert valve, order solenoid valve 8230 055 mV input board 1
assembly, part number 8230 207, which includes the valve 4500 0265 Temp. input board 1
and mounting bracket. 4500 0625 ISE Output Module (valve drive etc.) 1
4500 0285 Power supply board 1
4500 0275 5–digit 7–segment display board 1
4500 0443 5–digit display flexi-circuit 1
4500 0603 Display flexi-circuit 1
4500 0395 Membrane switch 1

Power supply board assembly (Fitted to

4500 0715 1
pre CE marked monitors only)

38
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 APENDIX A – REPLACING SOFTWARE EPROM

Warning. Switch off the monitor and electrically isolate it A.2 Access the PCB – Fig. A.2
before carrying out the following steps.
Unlock and open cover plate and 1
hinge out to expose captive
A.1 Access the Transmitter Unit – Fig. A.1 screws.

Caution. Employ normal antistatic precautions while

handling chips and PCBs.

Caution. To avoid damaging EPROM, base or PCB, it is

essential that you use an approved IC extractor in this
procedure. 2
For example, a PLCC Extractor, RS Stock Number:
404-727 Unscrew captive screws and
swing front cover upwards. Lock
into position using the hinged
Hinged Case stay on the right hand side.
Microprocessor Unit

Remove processor PCB.

3
See Fig. A.3

Fluoride 8231
Fig. A.2 Procedure to Access the Processor PCB

Undo locks and

swing open the case
1 to reveal the
microprocessor unit.

2 Open microprocessor unit –

see Fig. A.2.

Fig. A.1 Procedure to Open the Enclosure

39
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 …APPENDIX A

A.3 Removing the PCB – Fig. A.3

Remove the four screws attaching the PCB to

1
the assembly.
Note that there are washers between the PCB
cover and the PCB.

2 Withdraw the PCB and turn it over to

reveal the component side.

3 Locate and change the EPROM IC1 – see Fig. A.4.

Fig. A.3 Procedure to Remove the PCB

A.4 Changing the EPROM – Fig. A.4 A.5 Completing the Procedure
1) Fit the PCB using the reverse procedure in
Fig. A.3.
Extract IC1 using an approved tool Fit the replacement IC
1 2
– see Caution in Section A.1. – press home firmly. Important Note. Ensure that the washers
are fitted between the PCB cover and the
See Section A.5 for
3 PCB.
reassembly instructions.

2) Close the microprocessor section using the

reverse procedure in Fig. A.2.
3) Close and lock the hinged cover – Fig. A.1.
4) The monitor may now be put into service.
5) Check program parameters – see Section 6.
IC5 IC4
IC2 6) Carry out a routine 2-point calibration.

IC3 IC1 IC11

BAT1

Fig. A.4 Replacing the Software EPROM

40
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 PRODUCTS & CUSTOMER SUPPORT
Products Customer Support
Automation Systems
• for the following industries: We provide a comprehensive after sales service via a Worldwide
– Chemical & Pharmaceutical Service Organization. Contact one of the following offices for
– Food & Beverage details on your nearest Service and Repair Centre.
– Manufacturing
– Metals and Minerals United Kingdom
– Oil, Gas & Petrochemical ABB Limited
– Pulp and Paper Tel: +44 (0)1453 826661
Fax: +44 (0)1453 829671
Drives and Motors
• AC and DC Drives, AC and DC Machines, AC Motors to 1kV United States of America
• Drive Systems ABB Inc.
• Force Measurement Tel: +1 (0) 775 850 4800
• Servo Drives Fax: +1 (0) 775 850 4808

Controllers & Recorders

• Single and Multi-loop Controllers
• Circular Chart and Strip Chart Recorders
• Paperless Recorders
• Process Indicators

Flexible Automation
• Industrial Robots and Robot Systems

Flow Measurement
• Electromagnetic Flowmeters
• Mass Flow Meters
• Turbine Flowmeters
• Flow Elements

Marine Systems & Turbochargers

• Electrical Systems
• Marine Equipment
• Offshore Retrofit and Refurbishment

Process Analytics
• Process Gas Analysis
• Systems Integration

Transmitters
• Pressure
• Temperature
• Level
• Interface Modules

Valves, Actuators and Positioners

• Control Valves Client Warranty
• Actuators
Prior to installation, the equipment referred to in this manual must
• Positioners
be stored in a clean, dry environment, in accordance with the
Company's published specification.
Water, Gas & Industrial Analytics Instrumentation Periodic checks must be made on the equipment's condition. In
• pH, Conductivity and Dissolved Oxygen Transmitters and the event of a failure under warranty, the following documentation
Sensors must be provided as substantiation:
• Ammonia, Nitrate, Phosphate, Silica, Sodium, Chloride, 1. A listing evidencing process operation and alarm logs at time of
Fluoride, Dissolved Oxygen and Hydrazine Analyzers failure.
• Zirconia Oxygen Analyzers, Katharometers, Hydrogen Purity 2. Copies of all storage, installation, operating and maintenance
and Purge-gas Monitors, Thermal Conductivity records relating to the alleged faulty unit.

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 ABB has Sales & Customer Support The Company’s policy is one of continuous product
expertise in over 100 countries worldwide improvement and the right is reserved to modify the
information contained herein without notice.
www.abb.com Printed in UK (01.07)
© ABB 2007
Issue 2
IM/8232–SO1

ABB Limited ABB Inc.

Oldends Lane, Stonehouse 125 E. County Line Road
Gloucestershire Warminster
GL10 3TA PA 18974
UK USA
Tel: +44 (0)1453 826661 Tel: +1 215 674 6000
Fax: +44 (0)1453 829671 Fax: +1 215 674 7183

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