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AMI Hydrazine Version 4.00 and later

A-96.250.501 / 070606

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SWAN sets the standard

Customer SupportSWAN and its representatives maintain a fully trained staff of technical specialists around the world. For any technical question, contact your nearest SWAN representative, or the manufacturer:

SWAN ANALYTISCHE INSTRUMENTE AGTuricaphonstrasse 298616 RiedikonSwitzerland

Internet: www.swan.ch

E-mail: [email protected]

Document Status

Title: Monitor AMI Hydrazine Operator’s Manual

ID: A.96.250.501

Revision Issue

01 June 2007

© 2007, SWAN ANALYTISCHE INSTRUMENTE AG, Switzerland, all rights reserved

subject to change without notice

AMI HydrazineTable of Contents

Table of Contents1. Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 Warning Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.3 General Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . 61.3.1 Legal Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . 61.3.2 General Inspection and Maintenance Duties . . . . . . . . 61.3.3 Spare Parts and Disposables . . . . . . . . . . . . . . . . . . . 61.3.4 Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.3.5 Electrical shock hazard . . . . . . . . . . . . . . . . . . . . . . . . 61.4 Restrictions for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2. Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1 Description of the system. . . . . . . . . . . . . . . . . . . . . . . . . 82.2 Instrument Specification. . . . . . . . . . . . . . . . . . . . . . . . . . 102.3 Instrument Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.4 Display, Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.5 Software Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162.6 Changing parameters and values . . . . . . . . . . . . . . . . . . 17

3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183.1 Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183.2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193.3 Connecting sample and waste. . . . . . . . . . . . . . . . . . . . . 193.4 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 193.4.1 Electrical connection scheme . . . . . . . . . . . . . . . . . . . 213.4.2 Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223.5 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223.6 Relay Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233.6.1 Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233.6.2 Relay Contacts 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . 233.7 Signal Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253.7.1 Signal Outputs 1 and 2 (Current Outputs) . . . . . . . . . . 253.7.2 Signal Output 3 (Optional) . . . . . . . . . . . . . . . . . . . . . . 253.8 Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.8.1 Interface RS232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.8.2 Interface RS485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.9 Installation of Filter Vessel, Electrode and

Diisopropylamine Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . 27

A-96.250.501 / 070606 1


4. Instrument Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.1 Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . 305.2 Stop Operation before Maintenance . . . . . . . . . . . . . . . . 305.3 Cleaning of Sample Supply/Filters . . . . . . . . . . . . . . . . . . 305.4 Cleaning of Protective Filter . . . . . . . . . . . . . . . . . . . . . . . 305.5 Maintenance of Hydrazine Sensor . . . . . . . . . . . . . . . . . . 315.6 Maintenance of Reference Electrode. . . . . . . . . . . . . . . . 325.7 Changing Diisopropylamine Bottle . . . . . . . . . . . . . . . . . . 325.8 Changing the Diffusion Tube . . . . . . . . . . . . . . . . . . . . . . 335.9 Maintenance of Flow Cell. . . . . . . . . . . . . . . . . . . . . . . . . 345.9.1 Longer Stop of Operation. . . . . . . . . . . . . . . . . . . . . . . 36

6. Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376.1 Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 376.2 Hydrazine Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7. Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407.1 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407.2 Error List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

A. Programm Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

B. Profibus (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46B.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46B.2 Cyclic Data Telegram. . . . . . . . . . . . . . . . . . . . . . . . . . . . 47B.3 Customizing the Cyclic Data Telegram . . . . . . . . . . . . . . 48B.4 Data Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49B.5. Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53B.5.1 Device Master Files (GSD). . . . . . . . . . . . . . . . . . . . . . 53B.5.2 GSD File Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53B.6. Acyclic Data Communication . . . . . . . . . . . . . . . . . . . . . . 54

C. Modbus (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55C.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55C.2. Data and Control Functions . . . . . . . . . . . . . . . . . . . . . . . 57C.3. Function Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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D. Programm List and Explanations. . . . . . . . . . . . . . . . . 631 Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

E. Default Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

F. Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

A-96.250.501 / 070606 3

AMI HydrazineAMI Hydrazine - Operator’s Manual

AMI Hydrazine - Operator’s ManualThis document describes the main steps for instrument setup, operation and maintenance.

1. Safety InstructionsThis chapter contains general information assuring safe operation of the instrument. More safety instructions are given throughout this manual, at the respective locations where observation is most important.Strictly follow all safety instructions in this publication.

1.1 GeneralThe instructions included in this section explain the potential risks associated with instrument operation and provide important safety practices designed to minimize these risks.If you carefully follow the information contained in this section, you can protect yourself from hazards and create a safer work environment.

Target audience

Operator: Qualified person who uses the equipment for its intended purpose.

Instrument operation requires thorough knowledge of applications, instrument functions and software program as well as all applicable safety rules and regulations.

Qualification, Training

To be qualified for instrument operation, you must read and understand the written instructions in this operator’s manual, have appropriate training (by SWAN Service Technician), and know the safety rules and regulations.

Operator’s Manual Location

The AMI Powercon Operator’s Manual shall be kept in proximity of the instrument.

4 A-96.250.501 / 070606

AMI HydrazineSafety Instructions

1.2 Warning NoticesThe symbols used for safety-related notices have the following significance:

WARNINGSymbols

Warning

Generally, the triangular warning symbol indicates the possibility of personal injury or even loss of life if instructions are not followed, e.g.

electrical shock hazard

harmful to health

inflammable

AttentionSymbols

AttentionThe attention symbol indicates the possibility of equipment damage, malfunctions or incorrect process results if instructions are not followed.

WarningFor safe instrument installation and operation you must read and understand the instructions in this manual, as well as the Material Safety Data Sheets (MSDS) of diisopropylamine.Only SWAN trained and authorized personnel shall perform the tasks described in this document.

A-96.250.501 / 070606 5


1.3 General Safety Regulations1.3.1 Legal Requirements

The user is responsible for proper system operation. All precautions must be followed to ensure safe operation of the instrument.

1.3.2 General Inspection and Maintenance DutiesThe SWAN instrument shall only be operated in optimal running condition. The preventive maintenance procedures listed in this manual must be performed.In case of safety relevant deficiencies, SWAN must immediately be informed.

1.3.3 Spare Parts and DisposablesUse only official SWAN spare parts and disposables. If other parts are used during the normal warranty period, the manufacturer’s warranty is voided.

1.3.4 ModificationsModifications and instrument upgrades shall only be carried out by an authorized Service Technician. SWAN will not accept responsibility for any claim resulting from unauthorized modification or alteration.

1.3.5 Electrical shock hazardWARNING

If proper operation is no longer possible, the instrument must be disconnected from all power lines, and measures must be taken to prevent inadvertent operation.

To prevent from electrical shock, always make sure thatthe ground wire is connected.Service shall be performed by authorized personnel only.Whenever electronic service is required, disconnectinstrument power and power of devices connected to

• relay 1,• relay 2,• alarm relay.

6 A-96.250.501 / 070606


1.4 Restrictions for useAlcalizing

ReagentPlease correct the pH of the sample only with Diisopropylamine, p.a. However, Diisopropylamine is not included in delivery. Please buy it from your local supplier: E.g. VWR Merck (6x 1l: 803646), Fluka (1x 1l: 38300) or Riedel-de Haen (1x 1l: 62580).

SampleRequire-

ments

No sand (or other polishing material) or oil are allowed in the sample.The instrument is specified for a max. pressure of 2 bar (28 psi). If the sample pressure exceeds 2 bar, please mount a pressure reduction in front of the instrument inlet.Phosphates may interfere with the hydrazine measurement.The pH value of the sample must be equal or higher than pH 7.

FlowInterruption

High concentrations of Diisopropylamine reagent may attack the acrylic material of the flow cell. This can cause cracks and render the flow cell completely unusable. This will not happen during normal operation. However, if the sample flow is stopped, undiluted diisoproylamine will diffuse through the diffusion tube and can cause damage. Therefore, the following rules should be observed if the sample flow is stopped for more than one day:

Remove diisopropylamine bottle and close it. Keep it in a safe place for further use.Note: Diisopropylamine is highly inflammable and toxic. Wear googles and protective clothing! Do not breathe vapours! Avoid contact with skin! Read the safety data sheet carefully before useScrew an empty reagent bottle on the holder.Let the sample flow for another 30 minutes to rinse out the Diisopropylamine dissolved in the diffusion tubing material.Stop sample flow.

A-96.250.501 / 070606 7

AMI HydrazineProduct Description

2. Product Description

2.1 Description of the systemApplication Hydrazine is used in power plants as an oxygen scavenger. It helps

to remove oxygen, which may cause corrosion in the power plant. The reaction of hydrazine with oxygen produces nitrogen and water.

Measuringprinciple

3-electrode amperometry:The sensor consists of two platinum electrodes and a reference electrode. A voltage is applied to the platinum electrodes and kept on a optimum level by the reference electrode. The hydrazine in the sample generates a small current on the platine pin electrode, which is proportional to the hydrazine concentration. For an optimal sensitivity and stability, a rotor continuously cleans the surfaces of the platinum electrodes (hydrodynamic cleaning). The flow sensor measures the rotations of the rotor to detect sufficient flow.The signal of amperometric systems depends on flow. The constant head guarantees a constant flow if the sample always overflows into the longer constant head tube.Temperature compensation is done automatically.

On-lineoperation

The measurement of hydrazine requires a high pH of the sample. The AMI Hydrazine buffers the pH to pH>10.5 by adding diisopropylamine. The diisopropylamine is dissolved in the water while flowing through a diffusion tube.The sample enters at the sample inlet, passes the filter and the needle valve, where sample flow is adjusted and flows through the diffusion tube in the diisopropylamine bottle, picking up diisopropylamine and reaching pH>10.5. Afterwards, the sample fills the constant head. Sample must always overflow into the longer constant head tube (waste) to ensure constant flow and pressure at the hydrazine sensor.

8 A-96.250.501 / 070606


A large part of the sample flows into the shorter overflow tube to the hydrazine sensor, turns on the rotor and leaves it into waste. A small part of the sample leaves thje instrument by the longer constant head tube.The rotation of the rotor is monitored with a flow detector to assure sufficient sample flow. An inconsistent sample flow causes the rotor to turn slowly (or stop) and produces a system error.

3

1

2

4

8

7

6

5

9

10

2

11

1 sample inlet2 filter3 needle valve4 sample flow to

hydrazine sensor5 hydrazine sensor 6 flow measurement7 temperature

measurement8 constant head overflow9 sample outlet/waste10 grab sample11 Diisopropylamine

bottle with diffusion tube

A-96.250.501 / 070606 9


2.2 Instrument SpecificationSample

Require-ments

Flow rate: approx. 15 l/hSample pressure inlet: 0.15 - 2 bar (3 - 28 PSI)Sample outlet: pressure-freeTemperature range: 15 - 45 °C (41 - 113 °F)No oil, no grease, no sand.pH value of the sample must be equal or higher than pH 7.Reagent consumption: < 1l Diisopropylamine per month (25 °C).

On-siteRequire-

ments

Sample inlet: Tube 4x6 mm. Drain: 14x20 mm (1/2”) hose nozzle which must end

in convenient atmospheric waste of sufficient capacity.

Power: 85-265 VAC, 47-63 Hz or 24 VDC, isolated, power consumption max. 20 VA.

MeasuringRange

Hydrazine

Range: 0.1 - 600ppbAccuracy: ±5% of reading up to 200 ppb,±15% up to 600ppb, or ±2ppbStability: ±5% of reading per month, or ±2ppb per monthResponse time: 90% of change in 60 sec after the sample entered the flow cell.

MeasuringRange

Temperature

Measuring range: up to 60°CResolution: 0.1°C

Sample FlowMeasurement

With Swan sample flow meter and alarm in cases of insufficient sample flow

SafetyFeatures

No data loss after power failure, all data is saved in non-volatile memory. Overvoltage protection of in- and outputs. Galvanic separation of measuring inputs and signal outputs.

AlarmRelay

One potential free contact for summary alarm indication for programmable alarm values and instrument faults.Maximum load: 1A / 250 VAC

Input One input for potential-free contact. Programmable hold or remote off function.

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Relays Two potential-free contacts programmable as • limit switches for measuring values• controllers• timer for system cleaning with automatic hold functionRated load: 1A / 250VAC

SignalOutputs

Two programmable signal outputs for measured values (freely scaleable, linear, bilinear or logarithmic) or as continuous control output (control parameters programmable).Current loop: 0/4 - 20mAMaximum burden: 510ΩThird signal output with the same specifications as option available.

Communi-cation Inter-

face (option)

RS232 interface for logger download with HyperTerminal or RS485 interface with Fieldbus protocol Modbus or Profibus DP V1.

ControlFunction

Relays or current outputs programmable for 1 or 2 pulse dosing pumps, solenoid valves or for one motor valve. Programmable P, PI, PID or PD control parameters

A-96.250.501 / 070606 11


Dimensions

Mounting: Panel: Distance between mounting holes: 254x824 mmScrews: 6 mm in diameter

E nter

ppb

RUN

Ø 10

Exit

*

*

*

13

AMI Hydrazine

24.8°C

14:36:15

13

254280

15.3

850

824

12 A-96.250.501 / 070606


2.3 Instrument Overview

Enter

ppb

14: 36:15

AMI Hydrazine

RUN

Exit

*

*

24. 8°C

15.3

*

Mounting panel

Bottle holder

Diisopropylaminebottle with diffusiontube

Diffusion tube

Reference electrode

Grab sample valve

Grab sampleoutlet

Needlevalve

Hydrazine sensor with rotor

Transmitter

Temperature sensor

Constant head cover

Constant head

Constant head tube long

Constant headtube short

Flow cell block

Flow sensor(behind inlet)

Sample inlet

Filter vessel and filter

Waste

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2.4 Display, KeysDisplay ofMeasured

Value backlit LCD

Menu navigation keys

upper / lower limit not yet reachedupper / lower limit reachedcontrol upw. / dnw.: no action

control upw. / dnw.: active, dark bar indicates control intensity

timertimer: timing active (hand rotating)

Relay Status

motor valve: valve closed

rpm

motor valve: open, dark bar indicates approx. position

°C

Status Time

R1 ProcessValuesR2

blinking: fatal errorerror

HOLD input closed or cal delay: Instrument on hold (shows status of signal outputs). Add. info see Programm List and Explanations, p. 63.

OFF input closed: Control/limit is interrupted (shows status of signal outputs). Add. info see Programm List and Explanations, p. 63.

RUN normal operation

sample temperature

sampleflow

Hydrazine xx.x ppb

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Keys

ProgramAccess, Exit

to exit a menu or command (without accepting)to move back to the previous menu level

to move DOWN in a menu list and to decrease digits

to move UP in a menu list and to increase digits

to open a selected sub-menuto accept an entry

Exit

Enter

25.4°C

RUN

305 rpm

14:10:45R1

15.3 ppbR2

1

InstallationOperation

DiagnosticsMessages

Maintenance

Main MenuEnter

Exit

A-96.250.501 / 070606 15


2.5 Software Structure

1

Messages

OperationMaintenanceDiagnostics

Main Menu

Menu 4: OperationSubset of menu 5 - installation, but process-related. User relevant parameters that might need to be modified during daily routine. Normally password protected and used by the process-operator.

Menu 1: MessagesReveals pending errors as well as an event history (time and state of events that have occurred at an earlier point of time). It contains user relevant data.

Menu 2: DiagnosticsProvides user relevant instrument and sample data.

Menu 5: InstallationFor initial instrument set up by SWAN authorized persons, to set all instrument parameters. Can be protected by means of a password.

Menu 3: MaintenanceFor instrument calibration, relay and signal output simulation, to set the instrument time. It is used by the service personnel.

Installation

1.1

Pending ErrorsMessage List

Messages

2.1

InterfaceI/O StateSample

IdentificationSensors

Diagnostics

3.1

CalibrationSimulation

Maintenance

Set Time 01.01.05 16:30:00

4.1

LoggerRelay ContactsSensorsOperation

5.1

InterfaceMiscellaneousRelay Contacts

SensorsSignal Outputs

Installation

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2.6 Changing parameters and valuesChanging

para-metersThe following example shows how to change the current loop from 4-20 mA to 0-20 mA (see Programm Overview, p. 43 Installation):

Changingparameter

values

Highlight the menu item indicating the parameter you want to change.

Press .

Press or to highlight the required parameter.

Press to confirm the selection (or [Exit] to keep the previous parameter).

The selected parameter is indicated (but not saved yet).

Press .Yes highlighted, press to save the new parameter. The system reboots, the new parameter is set.

Enter

Enter

Exit

Enter

5.2.1Signal output 1

Current loop.Parameter x Sec

Scaling 1 MinFunction Free chlorine

Curr. loop.

4-20 mA


Current loop 0-20 mAParameter Hydrazine

Function linNo

Save ?Yes


Function lin

Parameter HydrazineCurrent loop 4-20 mA


Function lin

Parameter HydrazineCurrent loop 0-20 mA

Scaling

0-20 mA

Scaling

Scaling

5.3.1.1

Alarm High 1000 ppbAlarm Dis

Alarm Low 0.00 ppbHysteresis 1.0 ppbDelay 5 Sec

5.3.1.1Alarm Dis

Alarm Low 0.00 ppbHysteresis 1.0 ppbDelay 5 Sec

Alarm High 30.0 ppb

Select parameter and press .

to set required value.

to confirm new value.

to exit the menu.

Enter

Enter

Exit

A-96.250.501 / 070606 17

AMI HydrazineInstallation

3. InstallationThe first part of this chapter describes the preparing and placing of the system in position for use.Restrictions on useIf exposed to weather, install a cover to protect the instrument from insolation and precipitation. Please see also Restrictions for use, p. 7. See Instrument Specification, p. 10 for temperature limitations.

3.1 Installation Checklist

Check Instrument’s specification must conform to your AC power ratings. Do not turn on power until instructed to do so.

On site requirements

85-265 VAC, 47-63 Hz or 24 VDC power outlet with ground connection and 20 VA.Sample line with 15 l/h and 0.15 - 2 bar (3 - 28 psi).Waste line with atmospheric drain.See Connecting sample and waste, p. 19 and Electrical Connec-tions, p. 19

Installation Mount the instrument in vertical position. Display should be at eye level.Mount the filter vessel. Connect the sample and waste line.

Electrical Wiring

Connect all external devices like limit switches, current loops and pumps. Connect power cord; do NOT switch on power yet!

Electrodes Install reference electrode. Connect to cable TR.Insert temperature sensor into small opening of cover.

Diiso-proplyamine

Wear safety gloves and safety glasses. Add 20 ml high purity water to full Diisopropylamine bottle. Slide bottle over diffusion tubes and fix on holder.

Power-up Turn on the sample flow and wait until the rotor on the Hydrazine sensor starts turning.Switch on power.

Instrument set-up

Program all parameters for external devices (interface, etc.). Program all parameters for instrument operation (limits, alarms).

Run-in period Let the instrument run-in for approximately 30 min continuous operation (flow on, power on). The Diisopropylamine needs roughly 30 min to penetrate the walls of new diffusion tubes.

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3.2 MountingFor ease of operation mount the instrument so that the display is on eye level. For the panel size, see Dimensions, p. 11

3.3 Connecting sample and waste

Sample inlet:Use plastic tube (4x6 mm) to connect the sample line.

Waste:Connect the 1/2” tube to the waste nozzle and place it into the atmospheric drain.

3.4 Electrical ConnectionsWarningAlways turn off AC power before manipulating electric parts.Grounding requirements: Only operate the instrument from an power outlet which has a ground connection.Make sure the power specification of the instrument corresponds to the power on site.

inlet

outlet/waste

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Cablethick-

nesses

In order to comply with IP66, use the following cable thicknesses:

Wire Power, RelaysUse max. 1.5 mm2 / AWG 14 stranded wire with end sleeves.

Signal Outputs, InputUse 0.25 mm2 / AWG 23 stranded wire with end sleeves.

WARNINGMake sure that the devices to be connected to

relay 1relay 2alarm relay

are disconnected from the power before resuming installation.

WARNING

To prevent from electrical shock, do not connect the instrument to the power unless the ground wire (PE) is connected.Do not connect unless specifically instructed to do so.

PG 9 fittings: Cable Øouter 4 - 8 mm

PG 11 fitting: Cable Øouter 5 - 10 mm

PG 7 fittings: Cable Øouter 3 - 6.5 mm

Protect unused glands.

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3.4.1 Electrical connection scheme

Use only the terminals shown in this diagram, and only for the men-tioned purpose. Use of any other terminals will cause short circuits withpossible damage to material and personnel.

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3.4.2 Power Supply

Terminal 1 Phase LTerminal 2 Neutral N

Attention: It is not allowed to power external loads out of the AMI transmitter.

3.5 InputNote: Use only potential-free (dry) contacts.Terminals 16/42For programming see Programm Overview, p. 43 Menu Installation

power supply connector

Neutral

Power

The protective earth cable (ground) MUST be connected to the provided grounding screw.

22 A-96.250.501 / 070606


3.6 Relay Contacts3.6.1 Alarm Relay

Note: Max. load 1 A / 250 VACAlarm output for system errors. Error codes see Maintenance, p. 30.Open during normal operation. Closed on error and loss of power.Terminals 10/11.

3.6.2 Relay Contacts 1 and 2

Note: Rated load 1 A / 250 VACRelay 1: Terminals 6/7Relay 2: Terminals 8/9For programming see Programm Overview, p. 43, Menu Installation

AttentionHeavy inductive or directly controlled loads (solenoid valves, dosing pumps) must be switched by external power relays. In this case, use the AMI relaybox which is available as an option.Small inductive loads (max 0.1 A) as for example the coil of a power relay can be switched directly. To avoid noise voltage in the AMI it is mandatory to connect an snubber circuit in parallel to the load (this procedure is not necessary if a AMI Relaybox is used)

A-96.250.501 / 070606 23


Resistive loads (max. 1 A) and control signals for PLC, impulse pumps and so on can be connected without further measures..

Actuators are using both relays: One relay contact is used for opening (relay 1), the other for closing (relay 2) the valve, i.e. with the 2 relay contacts available, only one motor valve can be controlled.Motors with loads bigger than 0.1 A must be controlled via external power relais or an AMI Relaybox.

24 A-96.250.501 / 070606


3.7 Signal Outputs3.7.1 Signal Outputs 1 and 2 (Current Outputs)

Note: Max. burden 510 Ω.If signals are sent to two different receivers, use signal isolator (loop isolator).

Signal output 1: Terminals 14 (+) and 13 (-)Signal output 2: Terminals 15 (+) and 13 (-)For programming see Programm Overview, p. 43, Menu Installation

3.7.2 Signal Output 3 (Optional)Requires the additional board for the third signal output 0/4 - 20 mA PCB Max. burden: 510 Ω.The third signal output is installed in the holder on the main board. You can operate either 3. signal output OR communication interface, not both!Terminal 38 (+) and 37 (-).For programming see Installation Signal output 3 in Programm Overview, p. 43.

Third signal output 0/4 - 20 mA PCBinstalled on main board

A-96.250.501 / 070606 25


3.8 Interface3.8.1 Interface RS232

Terminal 50, 52, 53The AMI Interface RS232 Print Circuit Board (=PCB) is used for Logger download and Firmware upload. For detailed information see the corresponding manual “AMI RS232 Interface”.

RS232 Interface PCB

3.8.2 Interface RS485Terminal 37 PB, Terminal 38 PATo connect several instruments by means of a network or to configure a PROFIBUS DP connection, consult the PROFIBUS section in this manual (Profibus (Option), p. 46). Use appropriate network cable.Note: Bus termination only by means of ON/OFF switch on the RS485 PCB. If only one instrument is installed, or on the last instrument in a bus, the switch must be ON.

RS485 PCB

on/off switch

26 A-96.250.501 / 070606


3.9 Installation of Filter Vessel, Electrode and Diisopropylamine Bottle

Position ofSensors in

the Flow Cell

ConstantHead

Mount the filter vessel.

Enter

ppb

14:36:15

AMI Hydrazine

RUN

Exit

*

*

24.8°C

15.3

*

Temperature sensor

Reference electrode, cable marked TR

Hydrazine sensor, cable with BNC plug marked H

Filter and filter vessel

Diisoproplyamine bottle

Holder for Diiso-proplyamine bottle

Diffusion tube

Grab sample valve and outlet

Screw cap

Fixing screw

A-96.250.501 / 070606 27


ReferenceElectrode

1 Cautionally pull off the rubber cap from the reference electrode tip.

2 Loosen the fixing screw and insert the electrode until it stops.3 Tighten fixing screw hand tight, take off plug cap, and connect

to cable marked TR.4 Store the plug cap and the rubber cap for interruption of

operation.

TemperatureSensor

Fragile! Handle with care!Insert the temperature sensor into the small opening in the cover ofthe flow cell.

Check all sensor connections between AMI Hydrazine and sensors.

Diisopropyl-amine Bottle

Only install the diisopropylamine bottle if you intend to start operation immediately. Do NOT install if no sample in available!Attention!Diisopropylamine is a highly inflammable and toxic compound. Read the safety data sheet carefully before use. Avoid contact with skin! Do not inhale!You can fill the Diisopropylamine into the glass bottle (G45 thread), delivered with the instrument.If you want to connect a Merck bottle directly, you need a thread adapter (to be ordered at Merck).Add 20 ml high purity water into the full Diisopropylamine bottle to limit the consumption of Diisopropylamine at the beginning. Slide the Diisopropylamine bottle over the diffusion tubes and fix it to the holder by the screw cap.

28 A-96.250.501 / 070606

AMI HydrazineInstrument Setup

4. Instrument SetupAfter the analyzer is installed according to the previous instructions, connect the power cord. Do not switch on power, yet!

BeforeStarting

Sample Flow

Ensure the grab sample valve is closed.Ensure the sample outlet is pressure-free.

Open SampleFlow

Open the flow regulating valve to allow sample flow into the constant head and into the waste. Sample must always overflow into the longer constant head tubeWatch the rotor of the Hydrazine sensor. As soon as it starts turning, switch on power.First, the analyzer performs a self test, displays the firmware version and then starts normal operation.

Programming Program all parameters for external devices (interface, etc.). Set all parameters for instrument operation (limits, alarms).

Run-in Period Let the instrument run-in for approximately 30 min continuous operation (flow on, power on). The Diisopropylamine needs roughly 30 min to penetrate the walls of new diffusion tubes.

Correction ofHydrazine

Sensor

If necessary, correct the instrument after at least 30 min running-in. A calibration (zero and slope) is NOT necessary.To correct the instrument the concentration of hydrazine in the sample has to be known. Hydrazine reacts with dimethylaminobenzaldehyde in an acid solution and forms a yellow colour. The colour intensity can be measured by a photometer. Refer to an appropriate standard method (e.g. DIN 38413). The manual sample must be taken from the grab sample outlet of the flow cell. Let the sample flow out for roughly 1 minute before grabbing the sample for the manual analysis.

Do not calibrate.

A-96.250.501 / 070606 29

AMI HydrazineMaintenance

5. MaintenanceMaintenance frequency depends strongly on the water quality.

5.1 Maintenance Schedule

5.2 Stop Operation before MaintenancePut on safety gloves and wear safety glasses!Take off diisopropylamine bottle and close well. Screw an empty bottle on the holder. Let the sample run for 30 min.Stop sample flow. Wait until rotor stops and hydrazine reading is 0 ppb.Shut off power of the instrument.Empty the constant head by opening the grab sample tap.

5.3 Cleaning of Sample Supply/FiltersDepending on the water quality, the sample supply and its filter may need cleaning from time to time.

5.4 Cleaning of Protective FilterIf the protection filter shows deposits, proceed as follows:

Close flow regulating valve.Stop the sample supply before the filter.Screw out the filter vessel.Screw out the filter (must be held at the top).Backwash the filter under pressure of tap water. Clean the outside of the filter.Mount the filter and filter vessel again.Open sample supply and flow regulating valve again.

Weekly Check sample supply for dirt.Check sample flow.Make manual measurement. If necessary, correct.

Monthly Exchange Diisopropylamine bottle if there is less than 150 ml (half of the diffusion tube has to be covered with Diisopropylamine).

Yearly Exchange diffusion tubes

30 A-96.250.501 / 070606


5.5 Maintenance of Hydrazine SensorImportant

Run-in PeriodAfter cleaning, the sensor is very sensitive. Do not correct the value! Let the instrument run in for at least 24 h!

Cleaning Shut down the instrument as described in chapterStop Operation before Maintenance, p. 30.Take off the sensor cable and put it to the side to prevent wetting it.Unscrew the two white knurled fastening screws.

Attention:The sensor will glide easily out of the cell. Do not let it drop to the floor. Any mechanical damage will make it unfit for further use. Do not touch the platinum parts with your fingers or metallic objects.

Take the hydrazine sensor out of the flow cell.

There is always some water left in the sensor chamber. When taking off the hydrazine sensor, this water will pour down. Prevent the connector on the cable and on the sensor from getting wet.

Take off the rotor.Clean the two orifices with a pipe cleaner or a toothpick.Clean the rotor with a pipe cleaner. Wipe the sensor with a soft tissue, mainly the platinum parts and the whole area which is in contact with water.Rinse all parts thoroughly with clean water.Put rotor on the sensor.Mount sensor. Fasten screws hand-tight. Connect sensor cable.Open sample flow.As soon as the rotor is turning, switch on power.

A-96.250.501 / 070606 31


5.6 Maintenance of Reference ElectrodeCleaning Shut down the instrument as described in chapter Stop Operation

before Maintenance, p. 30.Disconnect the electrode from the cableLoosen the fixing screw and pull out the electrode of the sample chamber. Wipe sensor tip carefully with a soft tissue. Grease and oily films only may cause problems: Clean the tip cautiously with alcohol using a soft tissue. Rinse with water. Do not use acid!Remount the electrode into the sample chamber, push it down till it stops and connect the electrode to the cable.

5.7 Changing Diisopropylamine BottleShut down the instrument as described in Stop Operation before Maintenance, p. 30Attention! Wear safety gloves and safety glasses! Please note the warnings in the safety data sheet of Diisopropylamine! Do not inhale!

Put on safety gloves and safety glasses!Fill roughly 750 ml high purity water into a 1 l beaker.Screw off the almost empty Diisopropylamine bottle. Take out diffusion tube. Close bottle immediately.Dip the diffusion tube into the beaker (filled with high purity water). Rinse some seconds. Take out.Open new Diisopropylamine bottle, add 20 ml of high purity water and insert diffusion tube. Fasten bottle to holder.(If you fill up Diisopropylamine into the almost empty bottle, no high purity water needs to be added).The liquid in the almost empty Diisopropylamine bottle must be discharged as chemical waste.

32 A-96.250.501 / 070606


5.8 Changing the Diffusion TubeShut down the instrument as described in chapter Stop Operation before Maintenance, p. 30.Attention! Wear safety gloves and safety glasses! Please note the warnings in the safety data sheet of Diisopropylamine! Do not inhale!

Put on safety gloves and wear safety glasses!Fill roughly 750 ml high purity water into a 1 l beaker.Screw off Diisopropylamine bottle. Take out diffusion tube. Close bottle immediately.Dip the diffusion tube into the beaker filled with high purity water. Rinse some seconds. Take out.Take off the old diffusion tube.Slide on the new diffusion tube.Open Diisopropylamine bottle, insert diffusion tube, and fasten bottle to the holder.

The correct measuring value will appear after 30 min of continuous operation (flow and power on). Diisopropylamine needs roughly 30 min to penetrate the walls of the new diffusion tube.

A-96.250.501 / 070606 33


5.9 Maintenance of Flow Cell For technical details see the component drawing on the next page.Attention!Never use organic solvents or scrubbing materials to clean acrylic glass parts.Use soft detergent and rinse well.

Cleaning Shut down the instrument as described in section Stop operation before maintenance. Remove all sensors. See also drawing on the following page.Put the rubber cap on the tip of the reference electrode and plug cap on sensor plug. For longer interruptions see Longer Stop of Operation, p. 36. Take off the protection filter, the tabs and the fittings. Do not allow water on the sensor plugs!Loosen fastening screws, take off the cover of the constant head, and take out all tubes. Remove also the the tubes, leading to the Diisopropylamine bottle.The flow cell block must not be taken from the panel during cleaning. All acrylic parts are cleaned with a soft brush (bottle cleaner) using soapy water. All gasket have to be replaced before reassembling the flow cell. A film of teflon paste (e.g. Fomblin from Solvay Solexis) on the gaskets improves tightness and life time. Wrap teflon tape around the threads of the sample inlet and outlet.

The tube, leading to the diisoproplyamine bottle, is pushed into the hole before the small overflow tube. The tube coming from the diisopropylamine bottle is put into the small overflow tube.

Bottleholder

from flow cell

toflow cell

into smaller over-flow tube (closest to stainless steel panel

34 A-96.250.501 / 070606


Component Drawing

cover

outer tube

smaller overflow tube

longer overflow tube

hydrazine sensor chamber

tap / outlet for

tap of sample inletsample

inlet

hydrazine sensor

rotor

filter

filter vessel

sampleoutlet

to diisoprop. bottletemp. sensor

from diisoprop. bottle

flowsensor

fastening ref. electrode

grab sample

flow cell block

A-96.250.501 / 070606 35


5.9.1 Longer Stop of OperationDo not switch the instrument off if your operation is suspended for less than a week. Power consumption is very low, and the sensors remain ready for use.Do not spill water on connectors! Ensure they remain dry!

Shut-down the instrument as decribed in chapter Stop Operation before Maintenance, p. 30.Switch off power of all connected devices.Remove filter vessel, empty, and remount.Dismount the reference electrode, fill water in the rubber cap and put the cap on the electrode tip to preserve it from drying out! Disconnect from cable and put plug cap on the electrode plug. Store in dry and frost protected place with tip pointing downwards.Remove cable from hydrazine sensor. Dismount sensor, dry it with a soft, clean tissue, and store dry.

36 A-96.250.501 / 070606

AMI HydrazineCalibration

6. Calibration

6.1 Calibration ProcedureManual

MeasurementHydrazine reacts with dimethylaminobenzaldehyde in an acid solution and forms a yellow colour. The colour intensity is proportional to the concentration and can be determined by a photometer. Refer to an appropriate standard method.

Correction The adjustment of the slope is called correction. The zero remains unchanged. A calibration (changing slope and zero) is not necessary. The zero point is very stable and no change is necessary.

6.2 Hydrazine SensorProcess

CalibrationThe sample must always overflow into the longer overflow tube of the constant head. Only perform process calibration if the difference is significant.

Grab Sample Grab sample directly on the flow cell (grab sample valve and tap). Open the grab sample valve and let the water flow out for a minute before taking the sample.Note the displayed value of the AMI Hydrazine while taking the grab sample. The reading has to be stable . Determine the hydrazine concentration of the sample by manual analysis.Compare the result to the reading of the AMI.If the reading of the AMI has changed while performing the manual analysis, enter the difference between the reading of the AMI.For example: Displayed measurement value at AMI during grab sample: 10 ppbDisplayed measurement value at AMI after concentration determination: 15 ppb.Determined hydrazine concentration: 8 ppbThere is a change of the measurement value of 50% during the concentration determination. This means, you have to correct the determined hydrazine concentration also with a factor of 50%.This will result in a value of 8ppm+ (50% of 8 ppb) = 12ppbFinally, you have to enter 12ppb as a process value at the AMI transmitter

A-96.250.501 / 070606 37


During calibration, control is interrupted. The signal outputs are frozen if hold after calibration has been programmed (menu 4.3.4.2). Otherwise the outputs track the measuring value. Hold after calibration is indicated by Hold in the display.

Enter Process HydrazineCurrent Value 18.8 ppbRaw value x nA

Save <Enter>Process Value 24.0 ppb

3.1.2.5

3.1.2.5Process HydrazineCurrent Value 15.0 ppbRaw value x nA

Calibration successfulpress Enter

3.1.2.5Process HydrazineCurrent Value 18.8 ppbRaw value x nA

Process Value 24.0 ppbSave <Enter>

Enter

Process Hydrazine

Raw value x nA

Save <Enter>Process Value 18.8 ppb

3.1.2.5EnterCurrent Value 18.8 ppb

3.1

CalibrationSimulation

Maintenance

Set Time 01.01.05 16:30:00

3.1.2CalibrationEnter Zero Hydrazine

Process HydrazineCalibration

Enter correct value with arrow keys.

38 A-96.250.501 / 070606


PossibleError

Message

Current value too low or no sample flow. Possible reasons:

For additional explanations see Trouble Shooting, p. 40 and Error List, p. 41

ZeroHydrazine

A zero point calibration is NOT necessary. If your quality procedure specifies a zero point calibration, please proceed as described below:During a zero calibration, the sample flow is turned off and the residual hydrazine in the small water volume around the sensor is consumed within 15-20min. 0 ppb remains and after 30min., a zero calibration is done.Let the instrument run continuously for AT LEAST 5 DAYS in normal operation before doing a zero point calibration!Choose Menu 3.1.3. The instrument guides you through the complete calibration process. If you have completed the required action press <Enter> to proceed.

Close tap of the water inlet. Wait 30 min. (Timer counts down).Current value / offset (Progress of zero cal. is shown). Wait until finished.Open tap of the water inlet and regulate flow.

Sample flow low

Low sample flow resulting in no signal difference to zero.

Check rpm on main display.

Process value too low

ppb-value is too low to provide enough current difference from the calibrated zero current.

Process value used for calibration should be higher. Check the diagnostic value of the zero point.

Contami-nated sensor

Sensor does not pro-vide enough current for the value measured with the manual analy-sis.

Clean sensor. In case of repeated sensor contamination, check for water treatment chemicals such as phosphates.

A-96.250.501 / 070606 39

AMI HydrazineTrouble Shooting

7. Trouble ShootingThis chapter provides some hints to make trouble shooting easier. For any detailed information how to handle/clean parts please see Maintenance, p. 30.For any detailed information how to program the instrument please see Display, Keys, p. 14.Attention: The sample for the manual analysis must be taken directly from the flow cell!If you need further help please contact your dealer. Note serial number of instrument and all diagnostic values before.

7.1 Error messagesThe menu 1 - Messages - reveals pending errors as well as the message list with text, time and state of errors that have occured before.Error Nonfatal error. The system continues to operate normally, except for the defective part.

Fatal error (blinking symbol)If used for control relay 1, 2 as well as the Signal Outputs are deactivated, i. e. any control is interrupted. The indicated measured values are incorrect. Depending on the error the system may stop operating.To solve the problem, please consult Error List, p. 41

If an error is corrected, by intervention or by the system itself, it is listed in the the Message List (Menu 1.2). The symbol disappears.The last 64 messages are stored for viewing. They are deleted if SET Default Values (Menu 5.4.2) is carried out.

1.1.5Pending ErrorsError Code E010

Sample Flow low

<Enter> to Acknowledge

Errors remain in the Pending Errors window until corrected, even if acknowledged.Acknowledging the error only deactivates the Alarm Relay, i.e. it switches off an alarm device if available.

40 A-96.250.501 / 070606


7.2 Error ListE0xx (bold and red) are fatal errors.

Error Error text Corrective action

E001 Hydrazine Alarm high check process

E002 Hydrazine Alarm low check process

E007 Sample Temp. high check sample temperature

E008 Sample Temp. low check sample temperature

E009 Sample Flow high check sample inlet pressure, check sample flow, check alarm value in Installation/Relays/Alarm relay/Sample

E010 Sample Flow low establish sample flow, check sample inlet pressure, check alarm value in Installation/Relays/Alarm relay/Sample,clean instrument

E011 Temp. shorted check wiring of temperature sen-sor, check temp. sensor

E012 Temp. disconnected check wiring of temperature sen-sor, check temp. sensor

E013 Case Temp. high check environment temperature

E014 Case Temp. low check environment temperature

E015 Reference electrode Check conductivity value of sample (must be > 5 μS/cm)Check gain of hydrazine sensor. If too small, clean hydrazine sensor.Exchange reference electrode.

E017 Control time-out check control device or program-ming in Installation, Relay con-tact, Relay 1/2

A-96.250.501 / 070606 41


E024 Input active Information that the Input is active (see programming Instal-lation, Input, Fault “Yes”)

E025 IC MK41T56 call service

E026 IC LM75 call service

E027 IC PCF8574 call service

E028 EEProm Microcon call service

E029 EEProm Motherboard call service

E030 EEprom Front-End call service

E031 Calibration RecOut call service

E032 Wrong Front-End call service

E033 Power-on none, status message

E034 Power-down none, status message

Error Error text Corrective action

42 A-96.250.501 / 070606

AMI HydrazineProgramm Overview

A. Programm Overview

Menu Messages may be protected by a password. Menu Diagnostics is always accessible for everybody. No password protection. In both menus, no settings can be modified.

Pending Errors 1.1* Messages Message List 1.2*(Main Menu 1)

Designation AMI Hydrazine 2.1.1* Version 3.81-04/07 2.1.2*

Instrument 2.1.3.1* Identification Factory Test Motherboard 2.1.3.2*2.1* 2.1.3* Frontend 2.1.3.3*

Years 2.1.4.1* Operating Time Days 2.1.4.2*2.1.4* Hours 2.1.4.3*

Minutes 2.1.4.4* Seconds 2.1.4.5*

Current Value 2.2.1.1* Raw Value 2.2.1.2*

Hydrazine Sensor Ref. Voltage 2.2.1.3*Sensors 2.2.1* Cal. History 2.2.1.5*2.2*

Miscellaneous Case Temp. 2.2.2.1* Diagnostics 2.2.2*(Main Menu 2)

Sample ID 2.3.1*Temperature (°C) 2.3.2*

Sample Nt5k (Ohm) 2.3.3* 2.3* Sample Flow (rpm) 2.3.4*

Raw Value (Hz) 2.3.5*

Alarm Relay 2.4.1* Relay 1 2.4.2*

I/O State Relay 2 2.4.3* 2.4* Input 2.4.4*

Signal Output 1/2 2.4.5/2.4.6*

Interface Protocol 2.5.1* 2.5* Device address/Baud rate 2.5.2* (depends on

Baud rate/ID No. 2.5.3* chosen protocol) Local operation/Parity 2.5.4*

* Menu numbers

A-96.250.501 / 070606 43


Menu Maintenance is for service: Calibration, simulation of outputs and set time/date. Please protect with password.Menu Operation is for the user, allowing to set limits, alarm values, etc. The presetting is done in the menu Installation (only for the System engineer). Please protect with password.

Calibration Zero Hydrazine 3.1.1* 3.1* Process Hydrazine 3.1.2*

Alarm Relay 3.2.1*Maintenance Simulation Relay 1/2 3.2.2/3.2.3*(Main Menu 3) 3.2* Signal Output 1/2 3.2.4/3.2.5*

Set Time3.3*

Sensors Filter Time Const. 4.1.1* 4.1* Hold after Cal. 4.1.2*

Alarm Relay Alarm Hydrazine 4.2.1.1* 4.2.1*

Operation Relay Contacts Relay 1/2 Limit value depends on pre-(Main Menu 4) 4.2* 4.2.2/4.2.3* or setpoint setting in Menu 5:

or timer Installation

Input 4.2.4* depends on presetting in Menu 5: Installation

Logger Log Interval 4.3.1* 4.3* Clear Logger 4.3.2*

* Menu numbers

44 A-96.250.501 / 070606


Menu Installation: Defining assignment of all inputs and outputs, measuring param-eters, interface, passwords, etc. Menu for the system engineer. Password stronlgy recommended

Sensors Temp. Compensation 5.1.1* 5.1*

HydrazineParameter Temperature

Signal Output 1 5.2.X.1* Sample FlowSignal Outputs Signal Output 2

5.2* Signal Output 3 Current Loop (0/4 – 20 mA) 5.2.X.2* (only with optional 3rd Signal Output) Function 5.2.X.3* 5.2.1-5.2.3*

Scal./Contr.par. (depends on chosen Function) 5.2.X.4*

Alarm highAlarm Hydrazine Alarm low

5.3.1.1* HysteresisDelay

Flow alarm Alarm Relay Sample Flow Flow alarm high5.3.1* 5.3.1.2* Flow alarm low

Sample temp 5.3.1.3* Temp. highTemp. low

Case Temp. high 5.3.1.4*Installation Case Temp. low 5.3.1.5*(Main Menu 5)

Function 5.3.2.1*Relay Contacts Relay 1/2 Parameter 5.3.2.2*5.3* 5.3.2/5.3.3* Limit/Set contr./Timer (depends on chosen Function)

5.3.2.3*

Active 5.3.4.1*Input Signal Outputs 5.3.4.2*5.3.4* Output/Control 5.3.4.3*

Fault 5.3.4.4*Delay 5.3.4.5*

Language 5.4.1*Miscellaneous Set defaults 5.4.2* 5.4* Load Firmware 5.4.3*

Password 5.4.4* (for Messages, Maint., Operation, Installation)Sample ID 5.4.5*

Interface Protocol 5.5.1* (only with optional additional board)5.5* Device Address/Baud Rate 5.5.2*

Baud Rate/ID No. 5.5.3* (depends on chosen protocol) Local operation/Parity 5.5.4*

* Menu numbers

A-96.250.501 / 070606 45

AMI HydrazineProfibus (Option)

B. Profibus (Option)

B.1. IntroductionThe AMI family of transmitters provides a common base for a number of analytical instruments with application specific sensor interfaces. Each instrument has a basic structure with identical functionality.

AMI instruments can (optionally) be equipped with a PROFIBUS DP-V1 interface. The interface supports the PROFIBUS-PA Profile 3.0. This part of the manual describes the functionality of the interface and the integration of the AMI family of transmitters into an automation system.

Hardware Wiring, bus terminals and connectors are not part of this manual. It should, however, be noted that the observation of the corresponding standards is of paramount importance to proper operation. Setting the transmission rate to reasonable values will help avoid communication errors.

GSD file forAMI

Hydrazine

The PROFIBUS system requires a description of the device parameters, e. g. output data, input data, data format, data volume and supported transmission rate, so that it can integrate the field devices into the bus system. These data are contained in a Device Master File (GSD file) which is placed at the disposal of the PROFIBUS master while communication system is being commissioned.

Device bitmaps can also be integrated. These appear as icons in the network tree.The manufacturer-specific GSD file SW17C6.gsd is available for download from http://www.swan.ch

46 A-96.250.501 / 070606

http://www.swan.ch

http://www.swan.ch


B.2 Cyclic Data Telegram AMI Hydrazine makes the following modules available as input data for the cyclic data exchange:

1 Main Process Value2 Main Temperature3 Main Flow4 Control AMI5 Diagnostic Values (5 values)

a Raw value in nAb Counter Electrode Voltage in mVc Offset in nAd Slope in nAe Case Temperature in °C

The input data is transferred from AMI Hydrazine in the following structure :

Table 1: Input data structure of AMI Hydrazine Index input data

Data Access Data format / comments Configuration data

0 ... 4 Analog Input block 1 Main Process Value

read Measured value (32-bit floating point number) Status byte

0x42, 0x84, 0x08, 0x05 or 0x42, 0x84, 0x81, 0x81 or 0x94

5 ... 9 Analog Input block 2 Main Temperature


0x42, 0x84, 0x08, 0x05 or 0x42, 0x84, 0x81, 0x81 or 0x94

10 ... 14 Analog Input block 3 Main Flow


0x42, 0x84, 0x08, 0x05 or 0x42, 0x84, 0x81, 0x81 or 0x94

15 ... 34 Diagnostic Values read 5 Measured values (32-bit floating point numbers)

0x45, 0x93, 0x08, 0x08, 0x08, 0x08, 0x08, 0xE9

A-96.250.501 / 070606 47


The output data is transferred to AMI Hydrazine in the following structure:

B.3 Customizing the Cyclic Data TelegramYou can customize the cyclic telegram to better meet the requirements of a process. The tables above represent the maximum contents of the cyclic data telegram. If you do not want to use all the cyclic data of AMI Hydrazine, you can use the device configuration (Chk_Cfg) to eliminate individual data blocks from the cyclic telegram via the PLC software. Shortening the telegram improves the data throughput rate of a PROFIBUS system. You should only keep those blocks active which you process further in the system. You can do this by means of a "negative" selection in the configuration tool. To achieve the correct structure of the cyclic data telegram, the PROFIBUS master must send the identification FREE_PLACE (00h) for the non-active blocks.

Index output data

Data Access Data format / comments Configuration data

0 ... 1 Control AMI (SP_D)

write Byte 0 Bit Description 0 Relay 1

0 = open 1 = close

1 Relay 2 0 = open 1 = close

2..7 Not used Byte 1

Bit Description 0 Hold 1 Control Off 2..7 Not used

0x82, 0x81, 0x05, 0x05 or 0x82, 0x81, 0x84, 0x82 or 0xA1

48 A-96.250.501 / 070606


B.4 Data FormatsEach measured value has the same format: one four-byte (32-bit) floating-point value in IEEE 754 Short Real Number format and a status code byte referring to the measured value. There are four quality states, 16 sub-status values (not all defined) for each quality state, and four limit states for the measured value indicated in its associated status byte (See Figures 2 ,3, 4 and 5).

Figure 2: Out Value + Status

Figure 3: IEEE 754 floating point number:

Formula: Value = (-1) sign * 2(exponent - 127) * (1 + mantissa) Example: 40 F0 00 00 h = 0100 0000 1111 0000 0000 0000 0000 0000 b Value = (-1)0 * 2(129 - 127) * (1 + 2-1 + 2-2 + 2-3) = 1 * 22* (1 + 0.5 + 0.25 + 0.125) = 1 * 4 * 1.875 = 7.5

Figure 4: Status Code Byte

Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Analog values in IEEE 754 Format Status

Byte n Byte n+1 Byte n+2 Byte n+3 Bit 7 Bit 6 Bit 0 Bit 7 Bit 6 Bit 0 Bit 7 Bit 0 Bit 7 Bit 0 Sign 27 26 25 24 23 22 21 20 2–1 2–2 2–3 2–4 2–5 2–6 2–7 2–8 2–9 2–10 2–11 2–12 2–13 2–14 2–15 2–16 2–17 2–18 2–19 2–20 2–21 2–22 2–23

Exponent Mantissa Mantissa Mantissa

7 6 5 4 3 2 1 0 Quality Sub-status Limits Meaning

0 0 bad 0 1 uncertain 1 0 good

0 0 ok

0 1 low limited 1 0 high limited

The sub-status has a different quality

depending on the coding

1 1 constant

A-96.250.501 / 070606 49


Figure 5: Status codes of the measured value

Figure 6: DP Diagnostics

Status code

Device status Meaning Limits

0x08 BAD Not connected (Temp Sensor not connected)

0x0C BAD device failure 0x10 BAD sensor failure (Temp Sensor Short

Circuit)

0x47 UNCERTAIN last usable value (HOLD) CONST 0x50 UNCERTAIN sensor conversion not accurate (No

Flow) OK

0x64 0x67

UNCERTAIN sensor calibration sensor calibration, hold

OK CONST

0x80 GOOD ok OK 0x89 0x8A

GOOD Warning Low Warning High

LOW_LIM HIGH_LIM

0x8D 0x8E

GOOD Alarm Low Alarm High

LOW_LIM HIGH_LIM

Byte Description 0 Status 1 1 Status 2 2 Status 3 3 Master address 4 Ident number (high byte) 5 Ident number (low byte)

Standard DP Diagnostics

6 Header (block length incl. Header byte) = 14 7 Status Type (0x81) 8 Slot Number (0x00) 9 Status Specifier

Status coding according to DP/V1

10 ..13 Diagnosis 14 ..19 Diagnosis Extension

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The diagnosis object consists of 4 Bytes

Byte Bit Meaning when “1” Abbreviation 0 0 Hardware failure electronics DIA_HW_ELECTR 1 Hardware failure mechanics DIA_HW_MECH 2 - 3 Electronic temperature too high DIA_TEMP_ELECTR 4 - 5 Measurement failure DIA_MEASUREMENT 6 - 7 -

1 0 - 1 - 2 - 3 - 4 - 5 Maintenance required DIA_MAINTENANCE 6 - 7 -

2 0 - 1 - 2 - 3 - 4 - 5 - 6 - 7 -

3 0 - 1 - 2 - 3 - 4 - 5 - 6 - 7 Extension Available EXTENSION_AVAILABLE

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The diagnosis extension object consists of 6 Bytes.

Bytes 4 and 5 are reserved for future extensions.

Byte Bit Meaning when “1” 0 0 Hyd. Alarm high - 1 Hyd. Alarm low - 2 - - 3 - - 4 - - 5 - - 6 Sample Temp. high DIA_MEASUREMENT 7 Sample Temp. low DIA_MEASUREMENT

1 0 Sample Flow high DIA_MEASUREMENT 1 Sample Flow low DIA_MEASUREMENT 2 Temp. shorted DIA_HW_ELECTR 3 Temp. disconnected DIA_HW_ELECTR 4 Case Temp. high DIA_TEMP_ELECTR 5 Case Temp. low DIA_TEMP_ELECTR 6 Counter Electrode Reference DIA_MEASUREMENT 7 -

2 0 Control Timeout - 1 - - 2 - - 3 - - 4 - - 5 - - 6 Cleaning Reagent DIA_MAINTENANCE 7 Input Active DIA_HW_ELECTR

3 0 IC MK41T56 DIA_HW_ELECTR 1 IC LM75 DIA_HW_ELECTR 2 IC PCF8574 DIA_HW_ELECTR 3 EEprom Microcon DIA_HW_ELECTR 4 EEprom Motherboard DIA_HW_ELECTR 5 EEprom Front-end DIA_HW_ELECTR 6 Cal. Recout DIA_HW_ELECTR 7 Wrong Front-end DIA_HW_ELECTR

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B.5. Configuration

B.5.1 Device Master Files (GSD)The device is ready for system integration once commissioning has been effected via the local display or the Class 2 master. The PROFIBUS system requires a description of the device parameters, e.g. output data, input data, data format, data volume and supported transmission rate, so that it can integrate the field devices into the bus system. These data are contained in a Device Master File (GSD file) which is placed at the disposal of the PROFIBUS master while the communication system is being commissioned. Device bitmaps can also be integrated. These appear as icons in the network tree. The Profile 3.0 Device Master File (GSD) allows field devices from various manufacturers to be exchanged without having to reconfigure.

B.5.2 GSD File TypesPrior to configuration, decide which GSD you want to use to operate the system.You can change the setting by means of a Class 2 master (under Physical Block-Parameter Ident_Number_Selector).

The following two Device Master Files with different functionalities are available:

Manufacturer-specific GSD with Profile 3.0 functionality (default setting): This GSD guarantees the unlimited functionality of the field device. Device-specific process parameters and functions are therefore available. Profile GSD's: If a system is configured with profile GSD's, it is possible to exchange devices that are supplied by various manufacturers. It is, however, essential that the cyclic process values follow the same sequence. The transmitter supports the profiles Analyzer and Multivariable (IEC 61158-2). These GSD's comprise Analog Input blocks (AI).

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GSD files for AMI Hydrazine:

Working with GSD files The GSDs must be integrated into the automation system. Depending on the software that is being used, the GSD files can be copied to the program-specific directory or can be read into the database using the import function within the configuration software.

B.6. Acyclic Data CommunicationThe AMI Series of analytical instruments is available for a wide range of parameters. Instrument configuration depends on connected sensors and application. Therefore, configuration must be performed by trained personnel with a background in analytical methods.

It should be noted that there is a clear distinction between instruments that are configured and calibrated in an application (flow, level, pressure) and instruments that are calibrated with a known standard (pH, chlorine). AMI instruments are of the second type.

To ensure reliability and consistency of the measurement, remote configuration has not been enabled at this time.

Device name Ident_number_ Selector

ID number GSD Bitmaps

Manufacturer-specific GSD with Profile 3.0 functionality:

AMI Hydrazine 1 17C6Hex SW17C6.gsd SW17C6_D.bmp SW17C6_N.bmp SW17C6_D.bmp

Profile 3.0 GSD Analyzer:

AMI Hydrazine 0 9750 Hex PA139750.gsd PA_9750n.bmp

Profile 3.0 GSD Multivariable:

AMI Hydrazine 3 9760 Hex PA139760.gsd PA_9760n.bmp

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AMI HydrazineModbus (Option)

C. Modbus (Option)

C.1. IntroductionThe AMI Hydrazine is a Microprocessor controlled electronic transmitter & controller for the conductivity measurement in power cycles. It can be operated as an intelligent Slave device on the Modbus/JBUS using twisted pair RS485 lines.

Modbus/Jbus The Modbus / Jbus Protocol communicates using a master-slave technique, in which only one device (the master) can initiate transactions (queries). The other devices (the slaves) respond by supplying the requested data to the master, or by taking the action requested in the query. Typical master devices include host processors, PLCs etc. Typical slaves can be PLCs or intelligent transmitter/controller like the AMI family of the instruments.

The Query The function code in the query tells the addressed slave device what kind of action to perform. The data bytes contain any additional information the slave will need to function. For example, function code 03 will query the slave to read holding registers and respond with their contents. The data field must contain the information telling the slave which register to start at and how many registers to read.

TheResponse

If the slave makes a normal response, the function code in the response is an echo of the function code in the query. The data bytes contain the data collected by the slave.

SerialTransmission

Modes

Modbus supports two transmission modes: ASCII or RTU. The AMI Instruments support Modbus RTU (Remote Terminal Unit) mode only.

RTU Mode In RTU mode, each 8-bit byte in a message contains two 4-bit hexadecimal characters. The main advantage of this mode is that its greater character density allows better data throughput than ASCII for the same baud rate. Each message must be transmitted in a continuous stream. Users select the desired serial port communication parameters (baud rate, parity mode, etc). The serial parameters must be the same for all devices on a Modbus network.

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Coding SystemEight bit binary1 start bit8 data bits, least significant bit sent first1 bit for even / odd parity, no bit for no parity1 stop bit if parity is used, 2 bits if no parityCyclic Redundancy Check (CRC)RTU framing: messages start with a silent interval of at least 3 ½ character times. A similar interval of at least 3 ½ character times marks the end of the message.

A typical message frame is shown below

Start Slave Address Function Data CRC END

T1-T2-T3-T4 8 Bits 8 Bits n x 8 Bits 16 Bits T1-T2-T3-T4

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C.2. Data and Control FunctionsData Address Data Addresses in Modbus Messages

All data addresses in Modbus Messages are referenced to zero. The first occurrence of a data item is addressed as item number zero. For example:

Holding Register 40001 is addressed as register 0000 in the data address field of the message. The function code field already specifies a holding register operation. Therefore the 4x reference is implicit.

FunctionCodes

Modbus Function CodesThe list below shows the function codes supported by the AMI Instruments. Codes are listed in decimal. Function codes not supported return an exception response 02 to the master.Table 1: Modbus function codes

Data Re-presentation

Data RepresentationThe process- and parameter data of the AMI Instruments are represented by float (IEEE 754), signed- or unsigned integer values. Depending on the range of the value, float, integer8, unsigned8, integer16, unsigned16, integer32 or unsigned32 representation is used.

Code Name Description 02 Read Input Status Read Alarm & Status Bits 03 Read Holding Registers Read Parameter Data 04 Read Input Registers Read Process Data 05 Force Single Coil Set Relays, fake Keystrokes etc. 16 Preset Multiple Registers Preset Parameter Data (SWAN Use only)

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Discrete InputsAlarm &Status bits are packed as one input per bit of the data field.

Definition: big-endian and little-endianBig-endian and little-endian are terms that describe the order in which a sequence of bytes are stored in computer memory. Big-endian is an order in which the "big end" (most significant value in the sequence) is stored first (at the lowest storage address). Little-endian is an order in which the "little end" (least significant value in the sequence) is stored first. For example, in a big-endian computer, the two bytes required for the hexadecimal number 4F52 would be stored as 4F52 in storage. In a little-endian system, it would be stored as 524F.Attention: big-endian format is used !!!

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C.3. Function DescriptionInput Status Read Input Status (Alarm &Status Bits), Function 02

Up to 32 bits of Alarm are available as summarised in the table below:Table 2: Alarm and Status addresses

Addr. Type Description 0 Alarm Hyd. Alarm high 1 Alarm Hyd. Alarm low 2 Alarm - 3 Alarm - 4 Alarm - 5 Alarm - 6 Alarm Sample Temp. high 7 Alarm Sample Temp. low 8 Alarm Sample Flow high 9 Alarm Sample Flow low 10 Alarm Temp. shorted 11 Alarm Temp. disconnected 12 Alarm Case Temp. high 13 Alarm Case Temp. low 14 Alarm Reference 15 Alarm - 16 Alarm Control Timeout 17 Alarm - 18 Alarm - 19 Alarm - 20 Alarm - 21 Alarm - 22 Alarm Cleaning Reagent 23 Alarm Input Active 24 Alarm IC MK41T56 25 Alarm IC LM75 26 Alarm IC PCF8574 27 Alarm EEprom Microcon 28 Alarm EEprom Motherboard 29 Alarm EEprom Front-end 30 Alarm Cal. Recout 31 Alarm Wrong Front-end

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InputRegister

Read Input Registers (Process data): Function 04The process data are made up of the measuring values of the AMI Hydrazine. Table 3: Input registers

Single CoilFunction

Force Single Coil: Function 05This function is used to set relays and reset the instrument. Relays can only be forced if set to fieldbus function. Table 4: single coil function

Read Holding Registers (Parameter data): Function 03Read Parameter data (see Parameter Table). All objects of type Record are defined in the Manufacturer specific tables following the parameter table. Note: The Address is used in a proprietary way to select the designated record.see parameter table on the next page.

Byte-Offset

Data type Description Range of physical value

0 Float Hydrazine 0.. 1000 ppb4 Float Temperature -30 … 120 ºC 8 Float Flow 0.. 600 rpm

12 Float Counter Electrode Voltage mV16 Float Raw Hydrazine 0.. 100’000 nA 20 Float Raw Temp. (NT5k) 150 …

66’000Ω

24 Float Raw Flow 0.. 100 Hz 28 Float Case Temperature -55... 125 ºC 32 Float Signal Output 1 0.. 20 mA36 Float Signal Output 2 0.. 20 mA40 INSTRUMENT_

STATUS Instrument Display Status

Addr. Description OFF (0) ON (1) 0.. 1 Relay Contacts 1..2 open close

2 Hold no yes

3 Remote Off no yes

4 Channel Select Channel 0 Channel 1

15 Reset Instrument (like hardware reset) reset

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Table 5: parameter table

Specific Data Manufacturer-specific Data Types & RecordsDATE_STAMP Format

Address Modbus Addr Parameter Object Type Data Type Description Acc. 2300 1151 Version Record FIRMWARE_REC Firmware Version r 2400 1201 Num_Evt Simple Unsigned16 Number of Event Records r 2402 1202 Num_Log Simple Unsigned16 Number of Log Records r 3000 1501 Cal_History Array Array of CAL_HIST_1[15] Cal. History 1 r 3001 1502 Cal_History Array Array of CAL_HIST_2[15] Cal. History 2 r 4000.. 4126 2001.. 2064 Event_Rec Record EVENT_REC Get Event Record

64 Records max. r

5000.. 8070 2501.. 4036 Log_Rec Record LOG_REC Get Logger Record

1536 Records max. r

31.. 26 25..22 21..17 16..12 11.. 6 5.. 0

YYYYYY MMMM DDDDD HHHHH MMMMMM SSSSSS

Year 0... 63

Month 1... 12

Date 1... 31

Hour 0... 23

Minutes 0... 59

Seconds 0... 59

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Parameter Size Data Type Description Range

INSTRUMENT_STATUS 32 Record Instrument Display Status

Language 1 Unsigned8 Language Selection

0 = German 1 = English 2 = French 3 = Spanish

RunMode 1 Unsigned8 Run Mode

0 = Run 1 = Hold 2 = Off 3 = Grab

AlaMode 1 Unsigned8 Alarm Mode 0 = Off 1 = on 2 = Blinking

MaintMode 1 Unsigned8 Maintenance Mode 0 = Off 1 = on 2 = Blinking

RelMode1 1 Unsigned8 Relais 1 Display Mode 0 = None 1 = Limit Hi On 2 = Limit Hi Off 3 = Limit Lo On 4 = Limit Lo Off 5 = Timer Off 6 = Timer On 7 = Percent Control 8 = Valve 9 = Bus

RelMode2 1 Unsigned8 Relais 2 Display Mode 0 = None 1 = Limit Hi On 2 = Limit Hi Off 3 = Limit Lo On 4 = Limit Lo Off 5 = Timer Off 6 = Timer On 7 = Percent Control 8 = Valve 9 = Bus

PercDos1 2 Unsigned16 Percent Dosage Relais 1 0.. 100 % PercDos2 2 Unsigned16 Percent Dosage Relais 2 0.. 100 % MaintValue 2 Unsigned16 Maintenance Value 0.. 100 % AlarmsActive 4 Unsigned32 Alarms Pending AlarmsActive AlarmsLatched 4 Unsigned32 Alarms no Acknowledged AlarmsLatched AlarmsActiveE 4 Unsigned32 Extended Alarms Pending AlarmsActiveE AlarmsLatchedE 4 Unsigned32 Extended Alarms not Acknowledged AlarmsLatchedE

TimeStamp 4 DATE_STAMP Current Time end Record

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AMI HydrazineProgramm List and Explanations

D. Programm List and Explanations

1 Messages1.1 Pending Errors

Provides the list of active errors with their status (active, acknowledged). If an active error is acknowledged, the alarm relay opens again. Cleared errors are moved to the Message list.

1.2 Message ListShows the error history: Error code, date and time of issue, and status (active, acknowledged, cleared).65 errors are memorized. Then the oldest error is cleared to save the newest error (circular buffer).

2 DiagnosticsIn diagnostics mode, the values can only be viewed, not modified.

2.1 Identification2.1.1 View the Designation of instrument: Always AMI Hydrazine

2.1.2 Version: Firmware of instrument, e.g. V4.00-05/07

2.1.4 Factory test of the instrument; date of mother board and front-end QC test

2.1.5 Operating time: years, days, hours, minutes, seconds

2.2 Sensors2.2.1 Hydrazine sensor

Current value: in ppbRaw value: Uncompensated current in nA.Ref. voltage: Applied voltage at the counter electrode (CE) in mV

2.2.1.5 Cal. history:Review the diagnostic values of the last calibrations of the hydrazine sensor. Only for diagnostic purpose.Max. 65 data records are memorized.

2.2.5 MiscellaneousCase Temp.: Actual temperature in °C of electronics housing.

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2.3 Sample2.3.1 Sample ID

Sample ID: Review the programmed code. The code is defined by the user to identify the sample point in the plant.

Sample TemperatureReview the actual temperature in °C and in Ohm.

Sample flowReview if sample flows (detection: rpm and raw value in Hz)

2.4 I/O State2.4.1- 2.4.2 Reveals the actual status of all in and outputs:

Alarm relay: Open or closedRelay 1 and Relay 2: Open or closedInput: Open or closedSignal output 1, 2 (and 3, if option is installed): Actual current in mA.

2.5 InterfaceOnly available if optional interface is installed. Review programmed communication settings.

3 Maintenance3.1 Calibration

3.1.1 Zero Hydrazine:Zero calibration (0 ppb). See Zero Hydrazine, p. 39 for more details.

3.1.2 Process Hydrazine:For a process calibration of the hydrazine sensor. Follow the commands on the screen. Save the value with the <enter> key.

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3.2 Simulation3.2.1-3.2.6 Select relay or signal output to be tested with the <Enter> key and

press the up/down key to change the value. After confirming the setting with the Enter key, the value is simulated by the relay/signal output.At the absence of any key activities, the instrument will switch back to normal mode after 20 min. If you quit the menu, all simulated values will be reseted.

3.3 Set TimeTo adjust date and time.

4 Operation4.1 Sensors

4.1.1 Filter time constant: Used to damp noisy signals. Constant definition: 99% of measurement value change in a given time (t99)Range: 5-300 sec

4.1.2 Hold after cal: To allow the instrument to stabilize again after calibration. During cal. and hold time the signal outputs are frozen, alarms and limits are not active.Range: 0 - 6000 sec

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4.2 Relay Contacts 4.2.1 Alarm Relay

The alarm relay is used as cumulative error indicator. Under normal operating conditions, the contact is open. The contact closes upon:

power lossdetection of system faults like defective sensors or electronic parts high case temperatureprocess values out of programmed ranges

See chapter 5 for a complete list of parameters. Program process value alarm levels here or in menu 5.3.1

4.2.1.1 Alarm Hydrazine4.2.1.1.1 Alarm high: If the measured value rises above the alarm high

value, the alarm relay closes and E001 is displayed in the message list. Range: 0-1000 ppb

4.2.1.1.28 Alarm low: If the measured value falls below the alarm low value, the alarm relay closes and E002 is displayed in the message list. Range: 0-1000 ppb

4.2.1.1.36 Hysteresis: Within the hysteresis range, the relay does not switch. This prevents damage of relais contacts when the measured value fluctuates around the limit value. Range: 0-1000 ppb

4.2.1.1.46 Delay: During run time plus the delay time the signal and control outputs are held in the operating mode. Range: 0-28800 sec

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4.2.2 and4.2.3

Relay 1 and 2 The function of relay contacts 1 or 2 are defined by the user:Start by defining the function of each relay in menu 5.3.2 and 5.3.3.These functions may be selected: limit switch, controller, timer or fieldbus driven.Then enter the necessary data in this menu or in the submenus of 5.3.2 / 5.3.3.

Limit upper/lower: 4.2.X.100 Set-point: User-defined process value (Hydrazine, temperature or

or sample flow).Range: depends on the chosen parameter.

4.2.X.200 Hysteresis: Within the hysteresis range, the relay does not switch. This prevents damage of relais contacts when the measured value fluctuates around the alarm value. Range: depends on the chosen function.

4.2.X.30 Delay: During run time plus the delay time the signal and control outputs are held in the operating mode. Range: 0-28800 sec

Control upw/dnw: 4.2.X.120 Set-point: User-defined process value (Hydrazine, temperature or

or sample flow).Range: depends on the chosen parameter

4.2.X.220 P-Band: Range below (upwards control) or above (downwards control) the set-point, within the dosing intensity is reduced from 100% to 0% to reach the set-point without overshooting.Range: depends on the chosen parameter

Timer 4.2.X.14 Operation mode: Select the operation mode (interval, daily, weekly)

of the signal outputs.

4.2.X.240 Interval: Set interval time. Range 1-1440 min.

4.2.X.34 Run Time: Time the relay stays closed. Range: 5-6000 sec.

4.2.X.44 Delay: During run time plus the delay time the signal and control outputs are held as programmed below. Range: 0-28800 sec

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4.2.X.54 Signal Outputs:Continuous: Signal output continues normally.Hold: Signal output continuous on the last valid value.Off: Signal output is switched off and goes to 0/4 mA.

4.2.X.6 Output / Control: Continuous: Controller continues normally.Hold: Controller continuous on the last valid value.Off: Controller is switched off.

4.2.X.15 Fieldbus:Relay can be switched by external signal.

4.2.4 Input: The functions of the relays and signal outputs can be defined depending on the position of the input contact, i.e. no function, closed or open.

4.2.4.2 Signal output: Select the operation mode of the signal outputs when the input is active (closed or open):Continuous: Signal outputs continue to issue the measured value.Hold: Signal outputs issue the last valid measured value.Off: Set to 0 or 4 mA respectively.

4.2.4.3 Output/Control (relay or signal output): Continuous: Controller continuous normally..Hold: Controller continuous on the last valid value.Off: Controller is switched off.

4.2.4.4 Fault: No: No message is issued and the alarm relay does not close when input is active.Yes: Message E024 is issued and alarm relay closes when input is active.

4.2.4.5 Delay: Time which the instrument waits, after the input is deactivated,before returning to normal operation. Range: 0 - 6000 s

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4.3 LoggerThe instrument is equipped with an internal logger. The data can be downloaded to a PC by Hyperterminal if option “HyperTerminal interface” is installed.The logger can save approx. 1500 data records. Records consists of: Date, time, alarms, measured value, measured value uncompensated, temperature, flow.

4.3.1 Log Interval: Select a convenient log interval. Consult the table below to estimate the max logging time. When the loggin buffer is full, the oldest data record is erased to make room for the newest one (circular buffer).

4.3.2 Clear logger: If confirmed with yes, all data is erased and a new data serie is started.

5 Installation5.1 Sensors

5.1.1 Temp. comp.: Temperatur compensation in %. Range: 0.0-5.0%

5.2 Signal outputs5.2.1 - 5.2.3 Signal output 1, Signal output 2, Signal output 3:

Signal output 3 is only available if option 3rd signal output has been installed.Assign process value, the current loop range and a function to each signal output.

5.2.X.1 Parameter: Assign one of the process values to the signal output.Available values: Hydrazine, Temperature or Sample Flow.

5.2.X.2 Current loop: Select the current range of the signal output. Make sure the connected device works with the same current range. Available ranges: 0-20 mA or 4-20 mA.

Interval 1 s 5 s 1 min 5 min 10 min 30 min 1 h

Time 25 min 2 h 25 h 5 d 10 d 31 d 62 d

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5.2.X.3 Function: Define if the signal output is used to transmit a process value or to drive a control unit:As process values:The process value can be represented in 3 ways: linear, bilinear or logarithmic. See graphs below.

.

5.2.X.40 Scaling: Enter beginning and end point of the linear or logarithmic scale. In addition, the midpoint for the bilinear scale.

0.0 0.1 0.2 0.3 0.4 0.5 0.6 unit

0-20 mA: 104-20 mA: 12

0/4

20

mA

meas. value

bilinear

linear

reso

l. 0.

0002

mA20

0-20 mA:104-20 mA: 12

0/41 10 100 1000 100002 3 6 30 value0 1 2 3 4 log

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As control output:Signal outputs can be used for driving control units. We distinguish different kinds of controls:P-controller: The controller action is proportional to the deviation from the setpoint. The controller is characterized by the P-Band. In the steady-state, the setpoint will never be reached. The deviation is called steady-state error.Parameters: Setpoint, P-BandPI-controller: The combination of a P-controller with an I-controller will minimize the steady-state error. If the reset time is set to zero, the I-controller is switched off.Parameters: Setpoint, P-Band, Reset timePD-controller:The combination of a P-controller with a D-controller will minimize the response time to a fast change of the process value. If the derivative time is set to zero, the D-controller is switched off.Parameters: Setpoint, P-Band, Derivative time.PID-controller:The combination of a P-, an I- and a D-controller allows a proper control of the process.Parameters: Setpoint, P-Band, Reset time, Derivative time

Ziegler-Nichols method for the optimization of a PID controller:

The point of intersection of the tangent with the respective axis will result in the parameters a and L.Consult the manual of the control unit for connecting and programming details. Choose control upwards or downwards.

parameters: setpointP-Band: Xp = 1.2 / areset time: Tn = 2 Lderivative time: Tv = L / 2

L

response on maximumcontrol output

time

tangent on the inflection

a

mea

sure

parameters: setpointP-Band: Xp = 1.2 / areset time: Tn = 2 Lderivative time: Tv = L / 2

L

response on maximumcontrol output

time

tangent on the inflection

a

mea

sure

LL

response on maximumcontrol outputresponse on maximumcontrol output

time

tangent on the inflectiontangent on the inflection

aa

mea

sure

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Control upwards/downwardsSet the control parameters:

5.2.X.43.10 Setpoint: User-defined process value (Hydrazine, temperature or flow). Range:depends on chosen parameter

5.2.X.43.20 P-Band: Range below (upwards control) or above (downwards control) the set-point, within the dosing intensity is reduced from 100% to 0% to reach the set-point without overshooting.Range: depends on chosen parameter

5.2.X.43.3 Reset time: The reset time is the time till the step response of a single I-controller will reach the same value as it will be suddenly reached by a P-controller.Range: 0-9000 sec.

5.2.X.43.4 Derivative time: The derivative time is the time till the ramp response of a single P-controller will reach the same value as it will be suddenly reached by a D-controller.Range: 0 - 9000 sec.

5.2.X.43.5 Control timeout: If a controller action (dosing intensity) is constantly over 90% during a defined period of time and the process value does not come closer to the setpoint, the dosing process will be stopped for safety reasons. Range: 0 - 720 min.

5.3 Relay contacts5.3.1 Alarm Relay

The alarm relay is used as cumulative error indicator. Under normal operating conditions the contact is open. The contact closes upon:

power lossdetection of system faults like defective sensors or electronic parts high case temperatureprocess values out of programmed ranges.

Program alarm levels, hysteresis values and delay times for the following parameters:Hydrazine, sample flow, sample temp. and case temp.

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5.3.1.1.1-5.3.1.1.46

Alarm Hydrazine high (E001) and low (E002) (these values may also be programmed in menu 4.2.)Range alarm high: 0-1000 ppbRange alarm low: 0-1000 ppbRange hysteresis: 0-1000 ppbRange delay: 0-28800 sec

5.3.1.2.1-5.3.1.2.36

Flow Alarm high (E009) and low (E010)Range alarm high: 150-300 rpmRange alarm low: 150-300 rpm

5.3.1.3.1-5.3.1.3.26

Sample Temperature Alarm high (E007) and low (E008): Range alarm high: 30-70 °CRange Alarm low: 0-20 °C

5.3.1.4-5.3.1.5 Case temperature alarm high (E013) and low (E014)Range alarm high: 30-75 °CRange alarm low: 10-20 °C

5.3.2 - 5.3.3 Relay 1 and 2The function of relay contacts 1 or 2 are defined by the user:First select one of the following functions: limit switch, controller, timer or fieldbus driven.Then enter the necessary data depending on the selected function. The same values may also be entered in menu 4.2.2 and 4.2.3.

5.3.X.1 FunctionLimit upper / lower: When the relays are used as upper or lower limit switches, program the following:

Parameter: Select a process value (Hydrazine, Temperature or Sample Flow)

Setpoint User-defined process value.Hysteresis: Within the hysteresis range, the relay does not

switch. This prevents damage of relais contactswhen the measured value fluctuates around thealarm value. Range: depends on chosen parameter.

Delay During run time plus the delay time the signal and control outputs are held in the operating mode. Range: 0-28800 sec

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Control upwards / downwards:The relay may be used to drive control units such as solenoid valves, membrane dosing pumps or motor valves. When driving a motor valve both relays are needed, relay 1 to open and relay 2 to close the valve.

5.3.X.22 ParameterSelect the process parameter to be controlled.

5.3.X.32 SettingsChoose the respective actuator:Time proportionalExamples of metering devices that are driven time proportional are solenoid valves, peristaltic pumps.Dosing is controlled by the operating timeParameters: Cycle time: dDuration of one control cycle (on/off change).Range: 10-600 sec.Response time: Minimal time the metering device needs to reactRange: 0-240 sec.

Frequency Examples of metering devices that are puls frequency driven are the classic membrane pumps with a potential free triggering input. Dosing is controlled by the repetition speed of dosing shotsParameters:Pulse frequency: Max. pulses per minute the device is able to respond to. Range: 20-300/min.

Motor valveDosing is controlled by the position of a motor driven mixing valve. Parameters: Run time: Time needed to open a completly closed valve.Range: 5-300 sec.Neutral zone: Minimal response time in % of the of the run time. If the requested dosing output is smaller than the response time, no change will take place. Range: 0-240 sec.

Control Parameters: For details and explanations see menu 5.2.1

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Timer:The relay will be closed repetitively depending on the programmed time scheme.This function is intended mainly to drive Swan's cleaning modules or to program an automatic filter flush.

Operation mode (interval, daily, weekly)Mode specifics parametersRun Time: (time the relay stays closed)Delay: During run time plus the delay time the signal and

control outputs are held as programmed below.Signal Outputs: Select the behavior of the signal outputs

when the relay closesOutput/Control: Select the behavior of the control outputs

when the relay closes

Fieldbus:The relay will be switched via the Profibus input. No further parameters are needed.See section Profibus (Option), p. 46 for more details

5.3.4 InputSee menu 4.2.4 for parameter description.

5.4 Miscellaneous5.4.1 Language: Set the desired language.

Available settings: Deutsch / English / Français / Español

5.4.2 Set default values: Reset the instrument to factory default values in three different ways:Calibration: Sets calibration values back to default. All other values are kept in memory.In parts: Communication parameters are kept in memory. All other values are set back to default values.Completely: Sets back all values including communication parameters.

5.4.3 Load firmware: Firmware updates should be done by instructed service personnel only.

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5.4.4 Password: Select a password different from 0000 to prevent unauthorized access to the menus “Messages”, “Maintenance”, “Operation” and “Installation”. Each menu may be protected by a different password.If you forgot the passwords, contact the closest SWAN representative.

5.4.5 Sample ID: Identify the process value with any meaning full text, such as KKS number.

5.5 Interface5.5.1 Select one of the following communication protocols. Depending on

your selection, different parameters must be defined.Profibus: Device Address: 0 - 126ID Number: Analyzer, Manufacturer, MultivariableLocal operation: Enable, disablesee Profibus operation manual for details.Modbus RTU: Device Address: 0 - 126Baud Rate: 2400 - 115200Parity: none, even, oddsee Modbus operation manual for detailsHyperTerminal: Baud Rate: 2400 - 115200see separate RS232 Operation Manual for Logger downloadWebserver: Device Address: 0-126see separate Webserver Manual.

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AMI HydrazineDefault Values

E. Default ValuesOperation:

Sensors: Filter time constant: 30sHold after cal: 300 s

Relay 1,Relay 2, Input:

same as in Installation

LoggerInterval:

Clear Logger30 minno

Installation:

Sensor: Temp. comp. : 3.0 %

SignalOutputs:

Parameter: HydrazineCurrent loop: 4-20 mAFunction: linearScaling:Hydrazine range low: 0.00 ppbHydrazine range high: 100 ppbTemperature range low: 0.0 °CTemperature range high: 50.0 °CFlow range low: 0 rpmFlow range high: 300 rpm

Alarm Relay: Alarm Hydrazine high: 1000ppbAlarm Hydrazine low: 0.00 ppbHysteresis: 10.0 ppbDelay: 5 sFlow alarm: yesFlow alarm high: 300 rpmFlow alarm low: 150 rpmSample Temperature alarm high: 55 °CSample Temperature alarm low: 5 °CCase temp. high: 65 °CCase temp. low: 0 °C

Relay1/2 Function: limit upperParameter: Hydrazine Setpoint: 1000 ppbHysteresis: 10 ppbDelay: 30 sControl: Actuator: Frequency

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AMI HydrazineDefault Values

Control: Frequency: Frequency: 120/minControl: Time prop.: Cycle time: 60s, Response time: 10 sControl: Motor valve: Run time: 60s, Neutral zone: 5%Control: Control parameter Setpoint: 1000 ppbControl: Control parameter P-band: 10 ppbControl: Control parameter Reset time: 0 sControl: Control parameter Derivative time: 0 sControl: Control parameter Control time-out: 0 minTimer: Mode: IntervalTimer: Interval: 1 minTimer: Mode: daily/weekly: Starting time: 00.00.00 Timer: Run time: 10sTimer: Delay: 5sTimer: Signal output: cont.Timer: Output/Control: cont.

Input Active: when closedSignal output: holdOutp./contr.: offFault: noDelay: 10 s

Miscellaneous Language: EnglishSet default: noLoad firmware: noPassword: for all modes 0000Sample ID: --

Interface Protocol: HyperterminalBaud Rate: 115200 Baud

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AMI HydrazineIndex

F. IndexAAlarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9, 65Alcalizing Reagent . . . . . . . . . . . . . . . . . . . . . . . . . 6

CCalibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Changing Diisopropylamine Bottle . . . . . . . . . . . . . 31Changing the Diffusion Tube . . . . . . . . . . . . . . . . . 32Cleaning of Protective Filter . . . . . . . . . . . . . . . . . . 29

DData Communication, acyclic . . . . . . . . . . . . . . . . . 53Data Communication, cyclic . . . . . . . . . . . . . . . . . . 46Data logger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Default Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

FFilter time constant . . . . . . . . . . . . . . . . . . . . . . . . . 64Flow Interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

GGrab Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

HHysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

IInput. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 67Instrument Specification . . . . . . . . . . . . . . . . . . . . . 9

MMaintenance of Flow Cell . . . . . . . . . . . . . . . . . . . . 33Maintenance of Hydrazine Sensor . . . . . . . . . . . . . 30Maintenance of Reference Electrode . . . . . . . . . . . 31Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . 29Measuring principle . . . . . . . . . . . . . . . . . . . . . . . . . 7Measuring Range . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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AMI HydrazineIndex

OOn-line operation . . . . . . . . . . . . . . . . . . . . . . . . . 7On-site Requirements . . . . . . . . . . . . . . . . . . . . . . 9Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

PProcess Calibration . . . . . . . . . . . . . . . . . . . . . . . . 36

RRelay Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,22, 65, 66

SSample Requirements . . . . . . . . . . . . . . . . . . . . . 6, 9Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Signal Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 68, 71

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AMI HydrazineNotes

Notes

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AMI Hydrazine

SWANis represented worldwide by subsidiary companies and distributors.

cooperates with independent representatives all over the world.

SWAN Products

Analytical Instruments for:

High Purity Water

Feedwater, Steam and Condensate

Potable Water

Pool and Sanitary Water

Cooling Water

Waster Water and Effluents

Made in Switzerland.

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