Ion-Selective Instruction Manual

Electrode Monitor
Model 8231 Fluoride

Fluoride 8231
 ABB AUTOMATION
The Company BS EN ISO 9001

ABB Automation is an established world force in the design and manufacture of

D
RE
GI

E
STER
instrumentation for industrial process control, flow measurement, gas and liquid analysis and
St Neots, U.K. – Cert. No. Q5907
environmental applications. Stonehouse, U.K. – Cert. No. FM 21106

As a part of ABB, a world leader in process automation technology, we offer customers

application expertise, service and support worldwide.
EN 29001 (ISO 9001)
We are committed to teamwork, high quality manufacturing, advanced technology and
unrivalled service and support.
Lenno, Italy – Cert. No. 9/90A
The quality, accuracy and performance of the Company’s products result from over 100 years
experience, combined with a continuous program of innovative design and development to
incorporate the latest technology.

The NAMAS Calibration Laboratory No. 0255 is just one of the ten flow calibration plants Stonehouse, U.K.
operated by the Company, and is indicative of ABB Automation’s dedication to quality
and accuracy. 0255

Use of Instructions

Warning. ✶ Note.
An instruction that draws attention to the risk of injury or Clarification of an instruction or additional information.
death.

Caution. Information.
An instruction that draws attention to the risk of damage to Further reference for more detailed information or
the product, process or surroundings. technical details.

Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or property damage,
it must be understood that operation of damaged equipment could, under certain operational conditions, result in degraded
process system performance leading to personal injury or death. Therefore, comply fully with all Warning and Caution notices.

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

Health and Safety

To ensure that our products are safe and without risk to health, the following points must be noted:
1. The relevant sections of these instructions must be read carefully before proceeding.
2. Warning labels on containers and packages must be observed.
3. Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel and in accordance with the
information given.
4. Normal safety precautions must be taken to avoid the possibility of an accident occurring when operating in conditions of high pressure
and/or temperature.
5. Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry. Normal safe handling procedures
must be used.
6. When disposing of chemicals ensure that no two chemicals are mixed.
Safety advice concerning the use of the equipment described in this manual or any relevant hazard data sheets (where applicable) may be
obtained from the Company address on the back cover, together with servicing and spares information.
CONTENTS
Section Page Section Page
1 INTRODUCTION .......................................................... 2 7 CALIBRATION ........................................................... 28
1.1 Description ......................................................... 2 7.1 Calibration Sequence ...................................... 28
1.2 Training .............................................................. 2
8 MAINTENANCE ......................................................... 29
1.3 Location and Function of
8.1 Chemical Solutions .......................................... 29
Main Components ............................................. 2
8.1.1 Reagent Solutions .............................. 29
2 INSTALLATION ............................................................ 3 8.1.2 Standard Solutions ............................. 30
2.1 Accessories ....................................................... 3 8.1.3 First Aid Treatment for Accidents
2.2 Location ............................................................. 3 Involving Soluble Fluoride Salts ......... 30
2.3 Mounting ............................................................ 3 8.1.4 Reference Salt Bridge Solution .......... 30
2.4 Sampling Requirement ...................................... 3 8.2 Scheduled Servicing ........................................ 30
2.5 Sample Connections ......................................... 3 8.2.1 Regular Visual Checks ....................... 30
2.6 External Electrical Connections ......................... 4 8.2.2 Four Weekly ....................................... 30
2.7 Relay Contact Protection and 8.2.3 Twelve Monthly .................................. 31
Interference Suppression .................................. 5 8.2.4 Consumables Spares Kit ................... 31
3 SETTING UP ................................................................ 6 8.2.5 Fitting the Electrodes ......................... 31
8.2.6 Peristaltic Pump ................................. 32
4 LIQUID HANDLING SECTION ..................................... 7 8.2.7 Replacement of Plumbing Tubing ...... 32
4.1 Principle of Operation ........................................ 7 8.3 Shutdown Procedure ....................................... 33
4.2 General Operation ............................................. 8 8.3.1 Short Term .......................................... 33
5 ELECTRONICS SECTION ........................................... 8 8.3.2 Long Term .......................................... 33
5.1 Electronic Layout ............................................... 8 8.4 Unscheduled Servicing .................................... 33
5.2 User Junction Box ............................................. 8 8.4.1 Malfunction of the Monitor .................. 33
5.3 Microprocessor Unit ........................................... 8 8.4.2 Monitor Diagnostic Information .......... 34
5.4 Front Panel Controls .......................................... 9 8.4.3 Malfunction of the Electrode .............. 34
5.5 Displays ............................................................. 9 8.5 Microprocessor Unit Error Messages .............. 35
5.6 L.E.D. Indication ................................................ 9 9 SPECIFICATION ........................................................ 36
6 PROGRAMMING ........................................................ 10 10 SPARES LIST ............................................................. 37
6.1 Normal Operation ............................................ 11
6.2 Programming Pages ........................................ 11 APPENDIX A – REPLACING SOFTWARE EPROM ........... 39
6.2.1 Operating Page 1 ............................... 12 A.1 Access the Transmitter Unit ............................. 39
6.2.2 Operating Page 2 ............................... 13 A.2 Access the PCB ............................................... 39
6.2.3 Security Code Page ........................... 14 A.3 Removing the PCB .......................................... 40
6.2.4 Set Up Input Page .............................. 15 A.4 Changing the EPROM ..................................... 40
6.2.5 Current Output Page .......................... 16 A.5 Completing the Procedure ............................... 40
6.2.6 Set Up Alarms Page ........................... 19
6.2.7 Set Up Clock Page ............................. 21
6.2.8 Calibration User Code Page .............. 23
6.2.9 Set Up Temperature Control Page ..... 24
6.2.10 Electrical Calibration .......................... 24
6.2.11 Electrical Calibration Page ................. 25

1
1 INTRODUCTION
1.1 Description constant head unit and any excess is allowed to overflow. This
The Model 8231 Fluoride Monitor is a microprocessor based allows sample, under controlled pressure conditions, to be
analyzer using a fluoride ion-selective electrode in conjunction presented to a multichannel peristaltic pump which proportions
with a silver-silver chloride reference electrode. This equipment is sample and reagent solutions through the monitor to the mixing
used for environmental water monitoring. point. The resulting combined solution is then temperature
controlled to remove the effects of sample and ambient
temperature variations. The conditioned solution is then delivered
1.2 Training to the flowcell, under constantly flowing conditions, where the ion
Due to the specialized nature of the above instrument, it is measurement takes place. This measurement is carried out using
recommended that, where the end users personnel have had no an ion-selective sensing electrode.
previous experience of maintaining this equipment, training be
provided by this Company. The sensor generates a millivolt output which is proportional to
the ion concentration. This output is processed by the
Such training is available via the local Company in the UK, or microprocessor-based electronics section to calculate the actual
Overseas Agent elsewhere and may be carried out either on the sample concentration.
users premises or at the factory.
To maintain optimum measurement accuracy it is necessary to
introduce standard solutions of known concentration for
1.3 Location and Function of Main Components – calibration purposes. The monitor utilizes solenoid valves to
Fig. 1.1 introduce these standard solutions automatically, at
Monitoring of any sample by ion-selective electrodes usually predetermined intervals, under the control of the microprocessor.
requires certain conditioning to be performed on the sample to
allow accurate, trouble-free measurement. Such conditioning The electronics section consists of the main Microprocessor Unit
involves regulating flow, controlling temperature and adjusting situated at the top left and a User Junction Box at the top right
chemical composition prior to presentation of the sample to the behind the hinged case.
point of measurement. This monitor carries out these
adjustments for each parameter in simple and easily understood
steps. The sample is presented from the user's pipework to a

Hinged Case Case Lock

Microprocessor
Unit
Cable Entry Glands

Fluoride EIL8231
User Junction Box
Kent-Taylor (behind case)
Solenoid Valves
(behind case)

Electrodes and
Temperature
Sensor
(cover removed)

Case Lock
Push-to-Release
Latch

Hinged Door

Calibration Constant Head Unit Peristaltic Heated

Solution (behind case) Pump Sensor
Containers with Sample Inlet and Flow Cell
Drain Connections

Fig. 1.1 Location of Instrument Components

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

2.3 Mounting – Fig. 2.1 2.5 Sample Connections – Fig. 2.2 (overpage)
The monitor has a moulded plastic case, mounted onto a flat The inlet and outlet pipe connections are both located at the
metal panel. To provide access, the case is hinged on the left bottom of the case. A 6 mm (1/4") hose adaptor is provided for the
hand side and has two lockable catches on the right hand to hold sample inlet and a 9 mm (3/8") hose connection for the drains. It is
the case in position in normal operation. recommended that the pipes used should be of inert material,
e.g., silicone rubber or p.v.c. The inlet pipe must incorporate a
One keyhole slot is provided at the top of the flat panel to provide shut-off valve at its upstream end, while the drain outlet pipes
easy mounting on a wall or framework. Two further fixing holes should be short, venting to atmosphere as soon as possible.
are provided at the bottom of the flat panel. All holes are designed
to take 8 mm bolts or studs.

Mains and signal cables are connected through cable glands in

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

8mm Keyhole
Moulded Case Slot
Shown in 278 60 Top of Case
Open Position

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

550

Sample Inlet Top View

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

Fig. 2.1 Overall Dimensions and Mounting Details

3
…2 INSTALLATION

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

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

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

g) Optional serial interface – connected into the Micro-

Caution. Slacken the terminal screws fully before
processor Unit. See supplementary instruction manual for
making connections.
details.

Constant-head unit
Monitor Case

Push-on hose connectors

Case Hinge Line

150mm
(approx) 250mm (approximate) length
tubing
to allow the case
to open through 90°

Tube wall fixing clips

Contaminated Drain pipe

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

Fig. 2.2 Suggested Layout

4
 2 INSTALLATION…

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

Mains Voltage Selector

110V to120V 220 to 240V
Mains 'ON'
Indicator
MAINS
Mains
ON / OFF
OFF Switch
MAINS

ON Mains Fuse
Mains
240V

F1 2A
Transformer
OFF

PUMP Pump
ON / OFF
ON Switch

Cable Gland
Relay
Board

L
MAINS
N INPUT
E

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

N/O
2
User
N/C
CAL
Cable
C

Solenoid Valves N/O

Entry
Glands
STD1 STD2

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

N/C
OUT
OF

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

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

Fig. 2.3 Location of User Junction Box Components

5
…2 INSTALLATION 3 SETTING UP

Note. Before proceeding any further, ensure that all

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

a) Ensure that all external electrical and plumbing connections

have been made correctly.

0 to 1mA 0 to 10mA 0 to 20mA 4 to 20mA b) Fill reagent and standard solution bottles and connect them to
the monitor. (See Section 8.1 for details of these solutions.)
Link for the Current
Output required c) Fit the probe according to the instructions in Section 8.2.5.

d) Connect the electrical supply and switch on.

Note. The temperature controlled block requires up to

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

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

monitor constant head unit.

Protection f) Fit the pump platen on the peristaltic pumps (see Section
Plate 8.2.6) and switch the pumps on with the switch on the side of
Input
the monitor. Ensure that the peristaltic pumps rotate, and
Module check that sample and reagents are being drawn into the
Output Module 2 monitor by observing the progress of any small bubbles
Temperature Input (if fitted)
Module Output present in the inlet tubes.
Module 1
g) Run the monitor for at least one hour to allow the temperature
Fig. 2.4 Selecting The Current Output Range
to stabilize, solutions to be pumped into the system and to
purge the air from the pipework. Check for any leaks around
the pipe connections and rectify as necessary.
NC C NO Relay Contacts
h) If the monitor exhibits good stability, i.e. ±2% of reading, carry
out a calibration – see Programming Page.

i) Check the condition of the sample filter and replace it if

R C necessary. Ensure that new filters are fitted correctly by taking
note of the flow directions indicated on the filter bodies.
Load
L N

External a.c. supply

A – a.c. Applications

NC C NO Relay Contacts

Diode

+ Load
–

External d.c. supply

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

6
4 LIQUID HANDLING SECTION
4.1 Principle of Operation – Fig. 4.1
The monitor uses an ABB Fluoride Ion-selective Electrode in Connection
conjunction with a silver-silver chloride reference electrode. The Cable
sensing tip of the fluoride electrode comprises a single crystal of
lanthanum fluoride, an ionic conductor in which fluoride ions are
mobile. The electrode is connected to the main electronic unit via
a screened cable. When the electrode is in contact with a sample
fluoride solution, fluoride ion activity causes a potential to develop
across the crystal. It is useful to remember that the output from the
sensor is logarithmic with respect to the fluoride ion
concentration.

The electrochemical cell is completed by the reference electrode,

which generates a stable reference potential and is also
connected to the main electronic unit. It comprises a reference
element in a salt bridge container which is in contact with an outer
electrolyte via a porous ceramic junction. The outer electrolyte
then contacts the sample via another ceramic junction. This
double junction arrangement protects the inner element from
Ag/AgCl Wire
contamination.

Range of measurement can be set to any two consecutive Wick

decades of concentration between 0.1 to 1000 mg l–1.

Under typical circumstances, with appropriate standard solutions Lanthanum

and calibration frequencies, accuracies better than ±5% of Fluoride
reading or ±0.05 mg l–1 whichever is the greater, can be achieved. Crystal

Fig. 4.1 Fluoride Electrode

To Electronics Section

Temperature
Reference Sensor
Two Channel Electrode
Peristaltic Pump

Out of Sample Constant Head Unit Electrode

Float Switch Flowcell
From
Flowcell Drain via
Sample / Calibrate Constant
Solenoid Valves Head Unit Fluoride
SV1 SV2 Electrode

Contaminated Overflow Sample

Drain Drain Inlet

Heater
Sample
Heater Coil

Standard Standard Reagent Solution

Solution 1 Solution 2 Container
(Low) (High)

Fig. 4.2 Flow Schematic

7
…4 LIQUID HANDLING SECTION 5 ELECTRONICS SECTION
4.2 General Operation – Fig. 4.2 5.1 Electronic Layout – Fig. 5.1
The sequence of events is: The electronic section comprises two separate sections:
a) The sample enters the constant head unit from below and any
excess is allowed to overflow to drain. • The User Junction Box at the top right hand side.
The constant head unit is fitted with a float switch to signal an • The Microprocessor Unit at the top left hand side.
'Out of Sample' condition. This switch is used by the monitor to
initiate the 'Out of Sample' alarm.
5.2 User Junction Box
b) From the constant head unit the sample is drawn through the The User Junction Box contains the relays for the heater, solenoid
normally open ports of the solenoid valves SV1 and SV2 by valves and alarms, and all the user external connection terminals,
one channel of the peristaltic pump. with the exception of the serial interface (if fitted).

c) The reagent is drawn through another channel of the Once installed there should be no need to remove the junction
peristaltic pump, and is then mixed with the sample. The tube box cover on a regular basis. However, to assist in any fault
diameters are arranged so as to obtain the correct ratio of finding procedure, there are l.e.d.'s on the p.c.b. to indicate if the
sample and reagent. relays and heater are being energized.

d) The electrodes are housed in a temperature controlled Switches for the mains and pump/heater are situated on the right
flowcell which includes a heat exchanger to remove the hand side of the junction box, together with a mains indication
effects of sample and ambient temperature variations. The lamp and mains fuse – see Fig. 2.3.
electrode pair generates an electrical potential when exposed
to the reacted sample which changes in proportion to
changes in concentration of the ion being measured. The 5.3 Microprocessor Unit
sensors are connected to the electronic section where, after The Microprocessor Unit contains the analogue input processing,
digital conversion, the signal is processed by the microprocessor, alarm and current output generation, and (if
microprocessor. fitted) the serial interface output.

e) After measurement the sample flows to waste via the The program controls, digital and dot-matrix displays, alarm
contaminated drain connection. indication and status l.e.d.'s are all mounted on the front panel of
the microprocessor unit.
f) During calibration the monitor introduces two calibration
solutions sequentially in place of the sample by means of the
solenoid valves SV1 and SV2.

Microprocessor Unit User Junction

Box
Mains Supply 115 to 230V

Concentration Alarm Relays

Calibration Mode Relay External

User
Out of Service Relay Connections
Out of Sample Relay

Current Outputs

External
Serial
Interface
Connections
Interconnection
Cables

Reference Out of Sample Pump and

Electrode Float Switch Stirrer Motors

Heater Ion-Selective Sample/Calibrate Flow Cell

Control Electrode Soleniod Valves Heater Block
Liquid Handling
Section
Fig. 5.1 Electrical Connections Layout

8
 5 ELECTRONICS SECTION

5.4 Front Panel Controls – Fig. 5.2

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

When programming, the switches are used to sequence through

a programming procedure as detailed. The procedure is set out in Alarms
programming pages for Input, Current Output, Alarms, Real Time 1 2 Hold Cal Fail

Clock and Monitor Calibration. Each program page contains the

program functions, the values or parameters of which are
programmable. Mode Cal Hold Enter

Switch functions are as follows:

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

Used to enable or disable the automatic calibrations,

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

Used to inhibit any change in the alarm relay/l.e.d.

Hold status and the start of any auto calibration. The feature
is used during maintenance ('Hold' l.e.d. illuminated). Connections
Cover
Note. If the 'Hold' facility is inadvertently
left switched-in, it is automatically cancelled after Fig. 5.2 Location of Controls, Displays and L.E.D.s
a period of approximately 3 hours has elapsed.
5.5 Displays – Fig. 5.2
Used for storing the programmed function parameters Two blue vacuum fluorescent displays are provided:
Enter
and values in the instrument's nonvolatile memory.
a) The upper is a 5-digit 7-segment type display which indicates
Note. The instrument responds instantly to the measured variable.
any program change but the new value is lost in
the event of a power interruption if it has not been b) The lower is a 20-character dot matrix type which provides
'Entered'. user information during setting up and in normal operation.

Parameter Advance – used for selecting a particular

parameter from a program page. 5.6 L.E.D. Indication – Fig. 5.2
There are 5 l.e.d.'s (indicators situated between the two displays)
Used for increasing or decreasing a parameter value which provide information on the current status of the monitor.
or stepping up or down through a selection of From left to right the indicators are as follows:
parameters applicable to a particular function.
Used to indicate a concentration alarm state (either

Note. Continued pressure on the 'Raise' A1 or A2 high or low). This indicator is used in association with
an external alarm relay output.
or 'Lower' switches causes the rate of change of
the displayed value to increase. To make small Used to indicate when the 'Hold' button has been
adjustments, operate the switches momentarily. operated.
Hold
Page Advance – used, via the security code, for Indicates when a calibration sequence is taking place.
selection of individual program pages. Cal
Indicates when the monitor was unable to carry out a
Fail successful calibration.

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

Test Output FSD A2 Hysteresis –%

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

CALIBRATION SET UP TEMP. CONTROL CAL USER CODE 0 SET UP CLOCK

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

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

Fig. 6.1 Overall Programme Chart

 6 PROGRAMMING…

6.1 Normal Operation 6.2 Programming Pages

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

11
…6 PROGRAMMING

6.2.1 Operating Page 1

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

Fluoride <Unit> Measurement Units

The measurement units are displayed, e.g. Fluoride mg l–1

or Mode Advance to next parameter.

Millivolts xx•xmV Sensor Output

The sensor output is displayed in millivolts.

or Mode Advance to next parameter.

Control Temp xx • x °C Control Temperature

The heater block control temperature is displayed in degrees Celsius.

or Mode Advance to next parameter.

Slope xxx • x% Slope Check Value

The slope value should be between 70 and 110%. If the value is outside these
limits check the electrode.

or Mode Advance to next parameter.

Date DD:MM:YY Date

The date is displayed.

or Mode Advance to next parameter.

Time HH:MM:SS Time

The time is displayed.

or Mode Advance to next parameter.

Next AutCal DD:MM:YY Next Calibration Date

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

or Mode
Advance to next parameter.

Last Calibration Date

Last Cal DD:MM:YY
The date of the last automatic or manual calibration is displayed.

Return to top of Operating Page.

or Mode

or
or
Advance to Security Page (Section 6.2.3).

SECURITY CODE -----

12
 6 PROGRAMMING…

6.2.2 Operating Page 2

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

Enable Auto Cals Yes Enable Automatic Calibrations

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

Enter Store.
Cal Advance to next parameter.

MANUAL CAL SEQUENCE Page header.

Cal Advance to next parameter.

Ion Std 1 –•– – Ion Standard 1

Set the value of the 'Low' standard solution (Std 1).
or

Enter Store.

Cal Advance to next parameter.

Ion Std 2 – –•– – Ion Standard 2

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

Enter Store.

Cal Advance to next parameter.

Initiate Cal Yes Initiate Calibration (manual)

Select 'Yes' to carry out a manual calibration or 'No' to return to the top of the page.
No or
No Enter Enter must be pressed to initiate a manual calibration.
Yes
Calibrating Std 1 Calibrating Standard 1
The upper display shows the fluoride concentration value. The display remains
until a stable output is obtained from the sensor.

Toggle between the two displays.

Electrode mV – –•– Electrode Millivolts

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

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

Continued on next page.

13
…6 PROGRAMMING

…6.2.2 Operating Page 2

Continued from previous page.

Calibrating Std 2 Calibrating Standard 2

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

Toggle between the two displays.

Electrode mV – –•– Electrode Millivolts
The sensor output can also be displayed during calibration.

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

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

Calibration Passed
CALIBRATION PASSED A satisfactory calibration has been carried out.

or
or
Calibration Failed (slope)
CAL FAILED (SLOPE) The monitor was unable to obtain an adequate slope value during calibration. The
slope value required is 70 to 110%.

or or

Calibration Failed (slow)

CAL FAILED (SLOW)
The monitor was unable to obtain a stable output from the sensor during calibration.

Return to top of Operating Page 2.

or or

Mode Return to Operating Page 1.

Fluoride <units>

6.2.3 Security Code Page

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

Security Code ----- Security Code

or Set the correct security code.

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

SET UP INPUT

Fluoride <Units> Return to Operating Page 1.

14
 6 PROGRAMMING…

6.2.4 Set Up Input Page

Page header.
SET UP INPUT

Advance to next parameter.

Control Temp – – • – °C Control Temperature

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

Advance to next parameter.

Ion Units mg/kg Ion Units

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

Advance to next parameter.

Display Zero –– •– Display Zero

Set the required value for display within the range 0.1 to 10.0.
Enter
Store.

Advance to next parameter.

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

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

Return to top of Set Up Input Page.

or or

Advance to Current Output Page.

CURRENT OUTPUT

15
…6 PROGRAMMING

6.2.5 Current Output Page

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

CURRENT OUTPUT Page header.

Advance to next parameter.

OP1 Cal Hold Yes Output 1 Calibration Hold

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

Enter Store.

Advance to next parameter.

OP1 Law Log Output 1 Law

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

Enter Store.

Advance to next parameter.

OP1 FSD ––– •– Output 1 Full Scale

Current Output 1 full scale range: 1.0 to 1000 mg l–1 fluoride, i.e. minimum span is
1 decade.

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

Enter Store.

Lin Advance to next parameter.

Log
OP1 Zero – •–– Output 1 Zero

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

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

Enter
Store.

Advance to next parameter.

Continued on next page.

16
 6 PROGRAMMING…

…6.2.5 Current Output Page

Continued from previous page.

OP2 Cal Hold Yes Output 2 Calibration Hold

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

Enter Store.

Advance to next parameter.

OP2 Law Log Output 2 Law

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

Enter Store.

Advance to next parameter.

OP2 FSD ––– • – Output 2 Full Scale

Current Output 2 full scale range: 1.0 to 1000 mg l–1 fluoride, i.e. minimum span is
1 decade.

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

Enter
Store.

Lin Advance to next parameter.

Log
– •–– Output 2 Zero
OP2 Zero

Set the required concentration value for Current Output 2 zero.

or

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

Enter Store.

Advance to next parameter.

Continued on next page.

17
…6 PROGRAMMING

…6.2.5 Current Output Page

Continued from previous page.

Test Output Zeros Test Current Output Zeros

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

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

Advance to next parameter.

Test Output FSD Test Current Output Full Scale

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

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

Advance to next parameter.

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

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

Enter Store.

Advance to next parameter.

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

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

Return to top of Current Output Page.

or or

Advance to Set Up Alarms Page.

SET UP ALARMS

18
 6 PROGRAMMING…

6.2.6 Set Up Alarms Page

Alarm l.e.d. indication and relay output can be assigned either to the fluoride concentration or switched off.
SET UP ALARMS Page header.

Advance to next parameter.

A1 Enabled Yes Alarm A1 Enable

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

Enter Store.

No
Advance to next parameter.
Yes
A1 Action High Alarm A1 Action
Select the alarm action required, 'High' or 'Low' – see Table 6.1.
Low or

Enter Store.

Advance to next parameter.

A1 Failsafe Yes Alarm A1 Fail-safe

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

Enter Store.

Advance to next parameter.

A1 Hysteresis –% Alarm A1 Hysteresis

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

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

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

Enter Store.

Advance to next parameter.

A1 Delay Alarm A1 Delay

– –m
If required, relay actuation and alarm l.e.d. indication can be delayed in the event of an
alarm condition. If the alarm condition clears within the programmed delay time, the
alarm function is not activated and the delay time is reset.
or
Set the required delay time between 0 and 60 minutes in 1 minute increments.

Enter
Store.

Advance to next parameter.

(a) Continued on next page.

(b)

19
…6 PROGRAMMING

…6.2.6 Set Up Alarms Page

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

or Set the required setpoint value.

Enter Store.

Advance to next parameter.

A2 Enabled Yes A2 Enabled

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

A2 Setpoint ––– • – A2 Setpoint

or Set the required set point value.

Enter Store.

Return to top of Set Up Alarms Page.

or or

Advance to Set Up Clock Page.

SET UP CLOCK

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

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

High NO Above Setpoint Energised Flashing

Below Setpoint De-energised Off

Low YES Above Setpoint Energised Off

Below Setpoint De-energised Flashing

Low NO Above Setpoint De-energised Off

Below Setpoint Energised Flashing

Table 6.1 Relay Action and Alarm Indication

20
 6 PROGRAMMING…

6.2.7 Set Up Clock Page

SET UP CLOCK Page header.

Advance to next parameter.

No Set Up Real Time Clock

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

Enter Store.

Advance to next parameter.

Set Year –– Set Year

or Set the appropriate year.

Enter Store.

Advance to next parameter.

Set Month –– Set Month

or Set the appropriate month.

Enter Store.

Advance to next parameter.

Set Day of Month –– Set Day

or Set the appropriate day of the month.

Enter
Store.

Advance to next parameter.

Set Hours
Set Hours ––

Set the appropriate hour – (24 hour clock).

or

Store.
Enter

Advance to next parameter.

(a) Continued on next page.

(b)

21
…6 PROGRAMMING

…6.2.7 Set Up Clock Page

Continued from previous page.
(a)
(b)
Set Minutes –– Set Minutes

or Set the appropriate minutes.

Enter Store.

Advance to next parameter.

Set Seconds –– Set Seconds

or Set the appropriate seconds.

Enter Store.

Advance to next parameter.

Flashing

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

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

Enter Store and advance to next parameter.

Flashing

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

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

Enter Store and advance to next parameter.

Flashing

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

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

Enter Store and advance to next parameter.

Continued on next page.

22
 6 PROGRAMMING…

…6.2.7 Set Up Clock Page

Continued from previous page.

Flashing

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

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

Enter Store and advance to next parameter.

Flashing

Cal Time HH:MM Calibration Time (minutes)

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

Enter Store and advance to next parameter.

Cal Interval – Days Calibration Interval

or Set the calibration interval required between automatic calibrations, starting

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

Enter Store.

Return to top of Set Up Clock Page.

or or

Advance to Calibration User Code Page.

CAL USER CODE -----

6.2.8 Calibration User Code Page

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

CAL USER CODE ----- Calibration User Code

or Set the correct user code.

Incorrect Code
Advance to next programming page.
Correct Code

SET UP TEMP. CONTROL Set Up Temperature Control Page.

or or

Fluoride <Unit> Return to Operating Page 1.

23
…6 PROGRAMMING

6.2.9 Set Up Temperature Control Page

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

SET UP TEMP. CONTROL Page header.

Advance to next parameter.

Cycle Time 20 Cycle Time

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

Advance to next parameter.

Prop. Band 5 Proportional Band

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

Advance to next parameter.

Integral Time 200 Integral Action Time

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

Return to top of Set Up Temperature Control Page.

or or

Advance to Calibration Page.

CALIBRATION

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

Electrical calibration is carried out prior to despatch and should identify the output range.
require no subsequent adjustment. However, if measurements
become suspect or if the contents of the 'CALIBRATION' page Preparation
are inadvertently altered, calibrate as detailed in the following a) Switch off the supply and disconnect the temperature sensor
sections. leads from terminals 1, 2 and 3 in the Microprocessor Unit.
Make the following connections:
Note. The calibration procedure involves modifying
part of the original program but, provided that changed values 1 & 3 (temperature sensor)
2 (temperature sensor) decade box
are not stored using the 'Enter' switch, the original program,
which was stored in the nonvolatile memory, can easily be
reinstated at the end of calibration by switching off the b) Insert the coaxial plug into the ISE socket above the flowcell
instrument and switch on again. and connect the millivolt source (inner +ve, outer –ve).

If there is thought to be any risk that the original program could be c) Connect the milliammeter in place of the appropriate current
lost, it is advisable to make a note of the normal parameter output connections in the junction box – see Section 2.6.
settings. If the changed program values are inadvertently
'Entered', the instrument can be reprogrammed on completion of d) Switch on the supply and allow two minutes (30 minutes from
the calibration procedure. cold) for the circuits to stabilize.

Equipment Required e) Select the appropriate Cal User Code to gain access to the
• Millivolt source, range –400 to +400 mV. programming pages – see Section 6.2.8.
• Electrode coaxial plug/lead assembly – supplied with
monitor;
• Decade resistance box†, 0 to 1 kΩ in 0.01 Ω increments.

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

24
 6 PROGRAMMING…

6.2.11 Electrical Calibration Page

CALIBRATION Page header.

Advance to next parameter.

mV Zero –––– Millivolt Input Zero

Set the millivolt source to –400 mV.

or Set the display to '–400' mV.

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

Advance to next parameter.

mV FSD –––•– Millivolt Input Full Scale

Set the millivolt source to +400 mV.

or Set the display to '+400' mV.

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

Advance to next parameter.

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

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

Set the display to '–10°C'.

or

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

Advance to next parameter.

Temperature Full Scale

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

Set the display to '110°C'.

or

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

Enter

Advance to next parameter.

Continued on next page.

25
…6 PROGRAMMING

…6.2.11 Electrical Calibration Page

Continued from previous page.

Adjust Output 1 Zero Adjust Current Output 1 Zero

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

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

Enter Store.

Advance to next parameter.

Adjust Output 1 FSD Adjust Current Output 1 Full Scale

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

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

Enter Store.

Advance to next parameter.

Adjust Output 2 zero Adjust Current Output 2 Zero

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

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

Enter
Store.

Advance to next parameter.

Adjust Output 2 FSD

Adjust Current Output 2 Full Scale
The monitor transmits a span signal, e.g. for a 4 to 20 mA output range, 20 mA is
transmitted.

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

Store.
Enter

Advance to next parameter.

Continued on next page.

26
 6 PROGRAMMING

…Electrical Calibration Page

Continued from previous page.

Cal Time 1 10 m Calibration Time 1

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

Advance to next parameter.

Cal Time 2 10 m Calibration Time 2

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

Advance to next parameter.

Cal Time 3 10 m Calibration Time 3

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

Advance to next parameter.

Alter Cal Code ----- Alter Calibration Code

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

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

Enter Store.

Return to top of Electrical Calibration Page.

or or

Return to Operating Page 1.

Fluoride <unit>

27
7 CALIBRATION
7.1 Calibration Sequence relay is energized. Two solenoid valves, SV1 and SV2 operate
Calibration of the monitor is carried out by replacing the sample sequentially to shut off the sample and admit standard solutions
solution sequentially with two standard solutions of known of known concentration, one low and one high (STD1 and STD2),
concentration. This calibration sequence (see Table 7.1) can be to the sample path.
initiated automatically at preset times, or manually on demand.
Once a valve is energized, sufficient time (preset to suit the
The sensor outputs obtained during calibration are used to sensor response time) is allowed for the previous solution to be
calculate the calibration graph for the monitor and the accuracy of displaced, and for the sensor to respond to the new solution,
the standard solutions will, therefore, have a direct effect upon the before the sensor output is evaluated for stability by the
overall accuracy of the monitor. Given accurate standards, it is microprocessor. When a stable output is achieved the next stage
clear that the best accuracy would be expected at the two in the sequence is initiated.
calibration points. Ideally, the concentrations of the two standards
should bracket the expected sample concentration closely, but After calibration the sensor outputs corresponding to the two
the latter often varies quite widely. In practice, in potable water standard solutions are used to calculate a new calibration graph
applications where the fluoride is being controlled at 1 mg l-1 the for the monitor, thus compensating for any drift in sensor or liquid
instrument range would normally be set to 0.2 to 2.0 mg l-1. In this handling performance characteristics since the last calibration,
situation the recommended standard solution values would be and the new slope value can be displayed in Operating Page 1
0.4 and 1.2 mg l-1. On applications such as effluent treatment, the (100% slope is the theoretical value).
standard solution values could differ by a factor of 10 and bracket
the expected range of sample concentration. If the values are within limits, 'CALIBRATION PASSED' is
displayed.
Note. The concentrations of the two standard solutions
must differ from each other by a factor of at least three. 'CAL FAILED (SLOPE)' is displayed if the slope value is outside
acceptable limits and 'CAL FAILED (SLOW)' is displayed if the
On initiation of the calibration sequence, either manual or sensor output failed to stabilize within 15 minutes after the end of
automatic, the 'Cal' l.e.d. is illuminated and the Calibration Mode Cal Time 1 or Cal Time 2.

Introduce Sensor Introduce Sensor Introduce Normal

Activity
STD1 Stabilises STD2 Stabilises Sample Operation

Valve Open SV1 SV1 SV2 SV2 None None

Preset Preset Preset

Timing Variable * Variable * None
(Cal Time 1) (Cal Time 2) (Cal Time 3)
*15 min. max.

Table 7.1 Calibration Sequence Summary

28
8 MAINTENANCE
8.1 Chemical Solutions Reagent 2 –
In general, the pH of the sample and standard solutions should lie Where an acetate based reagent of the TISAB (Total Ionic
above 5 pH to prevent complexation of fluoride with hydrogen Strength Adjustment Buffer) type is preferred, reagent 2 may be
ions and below 7 pH to avoid hydroxide ion interference. Addition used. The reagent has the advantage that it is much less
of a buffer reagent solution ensures constant ionic strength expensive than the usual laboratory TISAB reagent, but shows
between samples and standards and adjusts the pH between 5.0 equal performance in terms of aluminium and iron masking ability.
and 6.5. The solution will complex iron or aluminium in the sample at
concentrations of up to 1 mg l–1, (separately or combined), and
The reagent and standard solutions described below are required the Nernstian performance is maintained to very low fluoride
to maintain the monitor in operation. Instructions are given for levels.
making up 1 liter quantities of these solutions; where possible,
they should be freshly made and stored in plastic (e.g. polythene) a) Dissolve 128 (±2) g sodium hydroxide (Na0H) (analytical
bottles. reagent grade), 960 (±10) g sodium chloride (NaCl)
(analytical reagent grade) and 16 (±2) g trisodium citrate
Typical reagent solution consumption for a continuously (Na3C6H507.2H2O) (analytical reagent grade) in approximately
operating monitor is approximately 10 liters per month. The 8 litres of high purity water.
monitor uses 50 to 80 ml of each standard solution each
calibration cycle; consumption of the standard solutions, also b) Carefully add 690 (±2) ml of 5 M acetic acid* (CH3C00H)
depends on the frequency with which this cycle is carried out. (analytical reagent grade) to this solution with stirring.

8.1.1 Reagent Solutions *5 M acetic acid can be prepared from concentrated glacial acetic
acid (analytical reagent grade, 1.05 s.g.) by diluting 287 (±2) ml to
Potable Water Applications 1 litre with high purity water.
There is a choice of two reagent solutions for use in these
applications; one based on hexametaphosphate and one on
acetate. The latter provides pH adjustment of the sample such Warning. Carry out this operation under a fume
that monitor performance is maintained to a very low fluoride hood and observe appropriate precautions when handling
concentration (typically 0.1 mg l–1). The hexametaphosphate concentrated acids.
reagent is inexpensive and simple to prepare, but because it has
a slightly higher pH, 0.2 mg l–1 F– is the minimum recommended c) Dissolve 48 (±1) g calcium chloride (CaCl2.2H2O) (analytical
standardizing concentration. Both solutions will complex iron and reagent grade) separately in approximately 100 ml of high
aluminium preferentially, releasing fluoride from complexes with purity water and then add to the bulk solution.
these metal ions.
d) Finally (since the acetate content is a nutrient, encouraging
Reagent 1 – biological growth), add 20 g of microbiocide Myacide Pharma
This is probably the most suitable in the majority of cases. It is BP (Bronopol)** making the solution up to 10 litres with more
simple to prepare and is effective in complexing aluminium and high purity water. The solution should have a pH value of 5.5
iron when these are present in the sample up to a total ±0.2.
concentration of 1 mg l–1 (either singly or in combination).
**Myacide Pharma BP is available worldwide from BASF
Dissolve 480 (±10) g sodium hexametaphosphate flake Micro Check. If you are unable to locate your local supplier,
(Na(PO3)6), 160 (±5) g sodium chloride (NaCl) and 40 (±5) g contact the Company for advice.
disodium EDTA (all of laboratory reagent grade) in approximately
8 litres of high purity water, using an efficient stirring system. Note. Reagent 2 should be found suitable for sample
Make up to 10 litres with more high purity water. The pH should be waters of total hardness up to 300 mg l–1 CaC03. For total
6.0 ±0.5. hardness in the range 300 to 600 mg l–1, the amount of
calcium chloride in reagent 2 should be reduced to 2.4 g l–1.
Note.
• Reagent 1 is suitable for sample waters with total hardness Fluoride Effluent Applications
levels up to 300 mg l–1 calcium carbonate (CaCO3). For To ovecome pH effects in these effluents (see Section 8.1) a
hardness in the range 300 to 600 mg l–1, the sodium concentrated reagent solution is used. Prepare this solution
hexametaphosphate concentration should be increased to (using laboratory grade chemicals) by following this procedure .
56 g l–1.
Warning. This procedure involves the handling of
• In certain applications air bubbles from sample degassing concentrated chemicals and should be carried out under a
may collect on the electrode membrane. To remove these fume hood observing appropriate precautions according to
bubbles add 5(±1) ml of 10% 'Brij 35' solution to each liter the safety information provided by the chemical suppliers.
of reagent 1. 'Brij 35' (polyoxyethylene lauryl ether, a non–
ionic surfactant) is available as a solid or as a 30% solution a) Dissolve 600 (±5) g sodium hydroxide (NaOH) in
from Merck Ltd. approximately 7 litres of high purity water in a plastic
container. Allow the solution to cool to room temperature
before proceeding.

29
…8 MAINTENANCE

b) Carefully add 920 (±5) ml glacial (concentrated 1.05 s.g.) 8.1.4 Reference Salt Bridge Solution
acetic acid (CH3COOH) to this solution with stirring. Allow the The reference electrode contains a salt bridge solution of 3.5 M
solution to cool to room temperature before proceeding. potassium chloride. Prepare as follows:

c) Dissolve 40 (±1) g di-sodium EDTA in approximately 1 litre of a) Dissolve 26.0 (±0.5) g analytical grade, potassium chloride
high purity water and add to the solution in b). Mix the (KCl), in approximately 90 ml of high purity water.
solutions thoroughly and make up to 10 litres with high purity
water. The pH should be 5.5 ±0.3. b) Dilute the solution to 100 ml with more high purity water.

8.1.2 Standard Solutions c) Store the solution in a tightly stoppered plastic bottle.
Two standard solutions of known fluoride concentration
appropriate to the measuring range are required for calibration of
the monitor. These are best prepared by diluting a stock solution 8.2 Scheduled Servicing
(1000 mg l–1) with high purity water. (These standard solutions The following servicing schedule has been produced as a general
should always be stored in plastic labware for long term stability.) guide only. Because the monitor has been designed for a very
wide range of applications, where the nature of the sample can
The procedure is as follows: vary considerably, it may be necessary to amend the schedule to
suit the particular installation and sample conditions.
a) Dissolve 2.211 (±0.001) g analytical reagent grade sodium
fluoride (NaF) in high purity water, making the solution up to 8.2.1 Regular Visual Checks
one liter with more high purity water. Store in a polythene It is recommended that the monitor and the sampling system is
bottle. visually inspected on a regular basis to assure correct functioning
of the system and to check the integrity of the readings.
b) Dilute the stock solution appropriately with more high purity a) Check for leaks, particularly around the sample and drain
water to make the two standard solutions for the measuring pipework connections.
range of the monitor, and store in plastic bottles.
b) Confirm sample flow by checking delivery to the constant
8.1.3 First Aid Treatment for Accidents Involving head unit and effluent from the drain.
Soluble Fluoride Salts
c) Check liquid flow through sensor flowcell.
The following notes outline the first aid procedures to be observed
if an accident occurs when handling fluoride salts. The d) Check for excessive build-up of air in the flowcell.
concentrated salts are a toxic hazard and should always be
handled with great care. Avoid inhalation of dust from dry crystals e) Check liquid levels in the reagent and standard solution
or powders and prevent contact with eyes and skin at all times, containers.
since the dust is extremely irritating to the eyes, skin and
respiratory tract. f) Check for malfunction indications on the instrument display.

a) Skin Contact Note. The mains and pump/heater switches are

Drench thoroughly with water. situated on the right hand side of the User Junction Box.

b) Splashed Eyes 8.2.2 Four Weekly

Irrigate eyes thoroughly with water. In severe cases, obtain a) Inspect all tubing and flowcell for leaks and deterioration.
medical attention.
b) Examine all tubing and flowcell for signs of accumulation of
c) Inhalation of Dust solid deposits. These tend to accumulate in the reference
Remove from exposure, rest and keep warm. In severe electrode compartment of flowcells and may be cleaned to
cases, obtain medical attention. drain by squirting high purity water from a 'squeezy' bottle into
the de-bubbler vent on top of the flowcell, and the use of small
d) Ingestion (Solutions) bottle brush.
Wash out mouth thoroughly with water and give water to
drink. In severe cases, obtain medical attention. c) Clean monitor pipework if there are signs of algae visible.

e) Disposal of Spillages (Solutions) d) Check the salt bridge solution in the reference electrode and
Wear a face-shield or goggles as protection and rubber top-up if necessary.
gloves. Mop up the spillage with plenty of water and run to
waste, diluting greatly with running water. e) Discard old reagent and standard solutions. Clean containers
thoroughly before refilling with fresh solutions – see Section
8.1.

Note. It is vital that the containers are not topped up.

30
 8 MAINTENANCE…

f) Examine the sample input pipe for leaks and deterioration. 8.2.5 Fitting the Electrodes
The fluoride electrode is supplied with a protective end cap to
g) Ensure the drain is in good order and free from obstruction. prevent the crystal, forming its tip, from being scratched or
chipped. To prepare for use, remove the end cap and carefully
8.2.3 Twelve Monthly rinse the tip in distilled water.
a) Service pump, tubing and capstans – see Section 8.2.6.
a) Fit the fluoride electrode into the plastic holder supplied, slide
b) Replace all internal plumbing tubing – see Section 8.2.7. the retaining 'O' ring over the end of the electrode body and
insert it into the sloping aperture of the flowcell. Screw down to
c) Carry out the normal 4 weekly schedule not already covered compress the 'O' ring.
above.
b) Connect the electrode lead to the coaxial socket above the
flowcell on the right hand side.
8.2.4 Consumables Spares Kit
If one is not supplied, it should be ordered before the end of the c) Remove the teat from the reference electrode and the stopper
first year of operation. This kit includes all the components which from the refill aperture. Top up with salt bridge solution if
are recommended for replacement annually (see Section 10). required.
This annual refurbishment ensures a high level of reliability from
the monitor over a period of many years. A new kit should be d) Fit the 'O' ring supplied over the reference electrode body and
ordered when used so that all the items are available throughout insert the electrode into the left hand chamber of the flowcell,
the following year's operation. so that the ceramic plug is between 5 and 10 mm from the
bottom.
The kit contains the following:
e) Connect the electrode lead into the co-axial socket above the
a) one set of pump tubing flowcell on the left hand side.

b) one set of pump capstans Section 8.2.6 overpage…

c) a complete set of plumbing tubing

d) sundry items – 'O' rings, tube connectors, pump tube bungs

and fuses.

e) plastic syringe and bottle brush – for cleaning pipework,

valves, flowcell and constant-head unit.

31
…8 MAINTENANCE

8.2.6 Peristaltic Pump – Fig. 8.1

It is recommended that the pump tubing and pump capstans, supplied in the Consumable Spares Kit, are replaced after one year of
operation. Carry out the following procedure steps 1 to 8:

Apply downward force 1 Remove the pump platen by applying

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

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

3 Remove the retaining screw on the

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

7 Locate the tubes centrally on the pup rollers.

6
Pass new pump tubes, from the
kit, through the tube bungs and
case grommets. Connect to the
appropriate tube connector at the
rear of the case.
Fig. 8.1 Peristaltic Pump

8.2.7 Replacement of Plumbing Tubing d) Clean the constant head unit, solenoid valves and sample
All necessary items are included in the Consumable Spares Kit. heating coil in the flowcell with a syringe filled with sodium
hypochlorite solution.
a) Remove sensors for short term storage.
e) It is recommended that the sample and drain tubing to and
b) Remove each section of the sample and reagent plumbing from the monitor is inspected and replaced if the tubing is in
tubing in turn and replace with new tubing of the same length. poor condition or shows evidence of any build-up of solids.

c) Remove drain tubing and replace with new tubing of the same
length.

32
 8 MAINTENANCE…

8.3 Shutdown Procedure 8.4 Unscheduled Servicing

8.3.1 Short Term The monitor indicates abnormal operation by means of signals on
The monitor can be left with the power switched off for up to 24 the 20 character dot matrix display and l.e.d.'s. The indications
hours without any detrimental effects. When returned to normal are listed in Table 8.1.
monitoring mode, the monitor should be run on sample for 30
minutes, followed by a calibration – see Section 7. 8.4.1 Malfunction of the Monitor
It should always be remembered that any unpredictable problems
The fluoride electrode can be stored dry or immersed in a dilute may be due to the standard or reagent solutions, or their flow
fluoride solution. through the flowcell. If any doubts exist regarding the integrity of
the solutions, they should be replaced with freshly prepared
The reference electrode may be stored in high purity water or salt solutions in the early stages of the fault finding investigations.
bridge solution with the electrolyte level above the storage
solution level. Ensure that the electrode cannot dry out; failure to Note. The accuracy of the monitor is governed by the
observe this results in a blocked ceramic junction, causing condition of these solutions which may be incorrectly made
considerable delay when restarting the monitor. or contaminated.

If the fluoride electrode is likely to be out of service for more than In general, any problems are likely to be due to the electrodes,
one day, remove the electrode from the monitor and store it dry which may require refurbishment (see Section 8.4.3), but may be
with the protective end cap replaced to prevent the crystal being due to other parts of the liquid handling section of the monitor.
scratched or damaged. The reference electrode is stored with its
ceramic junction covered by a protective teat filled with salt bridge Mechanical components which are involved with the liquid
solution. Fit the stopper into the salt bridge solution refill aperture. handling, for example, pumps, valves, tubing and tubing
connections etc., should be systematically checked for correct
8.3.2 Long Term operation, and for leaks or blockages which change the chemical
When the monitor is required to be shut down for more than 24 conditions around the sensor. The majority of all problems are
hours, proceed as follows: found to be associated with the chemistry and the liquid handling
a) Switch off the monitor. section.

b) Close the sample valve upstream of the monitor.

c) Remove the electrodes and store – see Section 8.3.1.

d) Clean sample pipework both inside and outside the monitor,

constant head unit, and filtration system (if used).

e) Remove pressure plate from peristaltic pump.

Display Possible Cause

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

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

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

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

33
…8 MAINTENANCE

8.4.2 Monitor Diagnostic Information h) Check operation of the Microprocessor Unit by following the
Out of Service Alarm procedure in Section 6.2.10, Electrical Calibration.
This alarm relay output is a normally energized relay which de-
energizes in the following circumstances: Noisy, unstable response or slow response
a) Loss of mains supply. a) Check for air bubbles trapped on fluoride electrode crystal
surface.
b) Calibration Failed – the calculated electrode slope value is
outside the acceptable limits or the response of the electrode b) Check for surface deposits on fluoride electrode membrane –
is too slow. The 'CAL FAIL' l.e.d. on the front panel is wipe with methanol or lightly polish with fine (e.g. 0.3 micron
illuminated with the appropriate text on the 20-character particle size) aluminium powder, replace if no improvement
display. made.

c) Block temperature out of limits – the measured temperature of c) Check level of salt bridge solution in reference electrode.
the Block is not within 5°C of the Control Temperature. 'TEMP.
CONTROL ERROR' is indicated on the 20-character display. d) Check that the stopper has been removed from the salt bridge
solution refill aperture in the reference electrode.
d) 'OUT OF SAMPLE' alarm – a float switch in the constant head
unit detects the loss of sample. 'OUT OF SAMPLE' is e) Reference electrode liquid junction partially or completely
indicated on the 20-character display. blocked, replace if required.

e) 'OUT OF SERVICE' alarm – displayed when the pump is Caution. A suspected faulty fluoride electrode
switched off. cannot be disassembled to investigate any problems.

Note. The heater is switched off by the software when In the 'CAL. FAILED (SLOW)' case the failure is usually due to
an 'OUT OF SAMPLE' condition is detected. slow sensor response, but may be due to an unstable (noisy or
drifting) sensor output:
Calibration Fail Alarm a) Check sensor connections in the coaxial plugs and sockets,
A calibration failed condition occurs after a two point calibration if and inside the microprocessor unit.
the calculated slope value is less than 80% or if the sensor output
is unstable. The failure could be caused by a number of factors b) See Malfunction of the Electrode Section 8.4.3.
which should be investigated.
8.4.3 Malfunction of the Electrode
In the 'CAL. FAILED (SLOPE)' case some indication of the
problem may be obtained from the slope value. Slope value just below 80%
a) Check for surface deposits on crystal membrane. If dirty, wipe
Slope Value Just Below 80% with methanol or lightly polish with fine (e.g. 0.3 µm particle
a) Check the reagent solution flows. size) aluminium powder, replace if no improvement made.

b) Check condition of the reagent solutions. b) Check performance of fluoride electrode by substitution.

c) Check condition of the standard solutions. Slope value grossly abnormal

a) Check for surface deposits on fluoride electrode membrane –
d) See Malfunction of the Electrode Section 8.4.3. wipe with methanol or lightly polish with fine (e.g. 0.3 µm
particle size) aluminium powder, replace if no improvement
Slope Value Grossly Abnormal made.
a) Check operation of the solenoid valves and flow of the
standard solutions. b) Check performance of fluoride electrode by substitution.

b) Check condition of the standard solutions. c) Check level of salt bridge solution in reference electrode.

c) Check the reagent solution flows. d) Check that the silicone rubber sleeve has been moved away
from the salt bridge solution refill aparture in the reference
d) Check condition of the reagent solutions. electrode.

e) Check liquid levels in sensors – see Malfunction of the e) Reference electrode liquid junction partially or completely
Electrode Section 8.4.3. blocked, replace if required.

f) Check sensor connections in the coaxial plugs and sockets,

and inside the microprocessor unit.

g) See Malfunction of the Electrode Section 8.4.3.

34
 8 MAINTENANCE

Air bubble build-up in the flowcell 8.5 Microprocessor Unit Error Messages
Air bubble build-up in the flowcell around the fluoride electrode The instrument incorporates an automatic self-diagnostic
sensing tip and the temperature sensor causes considerable checking facility for detection of input and output errors. If such a
noise on the monitor output. This normally occurs when an fault occurs, one of the error messages detailed below is shown
aerated and often very cold sample, is presented to the monitor on the dot matrix display.
where it is heated before entering the flowcell. Heating the
sample will cause dissolved air to come out of the solution to form 'CHAN 1 INPUT ERROR'
air bubbles. Water at 35°C can only support 50% of the air that This error message is usually caused by an open circuit
can be dissolved in water at around 0°C sensor input allowing the input to drift outside the range of
The build-up of air masks the sensing surface of the fluoride ±400 mV. This may be due to any of the following:
electrode and eventually causes an open circuit between the
electrodes. Air will also collect around the temperature sensor, a) Loss of solution flow through the flowcell breaking the
again potentially causing an open circuit. electrical connection between the electrode pair.
If this problem occurs, proceed as follows:
b) Low level of salt bridge solution in the reference electrode.
a) Reduce the block temperature.
The flowcell temperature is controlled to remove the effects of c) Open circuit electrode internally, e.g. broken connection,
temperature on the measurement. On leaving the factory, blocked liquid junction in reference electrode etc.
control is set to 35°C, which is appropriate for most
installations where the ambient temperature ranges to 30°C. d) Broken electrical connections between the sensor and the
If the ambient temperature is low, while ensuring that a +5°C Microprocessor Unit sensor input.
temperature differential is maintained between the flowcell
temperature setting and ambient, reduce the flowcell e) Sensor coaxial plugs not correctly inserted.
temperature as low as possible.
'TEMP INPUT ERROR'
Change the flowcell temperature setting with seasonal variations 'PRT OUT OF LIMITS'
if necessary. 'TEMP REF. ERROR'
'THIRD LEAD ERROR'
b) Check bubble venting The above four error messages refer to electrical problems with
Ensure that the temperature sensor is not positioned too low. the temperature sensor input – usually an open or short-circuited
Raise the temperature sensor by 10 mm to allow any bubbles connection.
to escape into the sensor chamber and up through the
flowcell.

35
9 SPECIFICATION
Range: .................... Fluoride 0.1 to 1000 mg l–1. Concentration Alarm
Adjustment: ............ Programmable over range.
Repeatability: ......... ±2% of reading.
Concentration Alarm
Reproducibility: ...... ±3% of reading. Differential: ............. 0 to 5%.

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

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

Retention: ............... 3 years.
Millivolt Resolution: ±0.1 mV.
Calibration: ............. Fully automatic two point, plus manual
Control Temperature initiation on demand.
Range: .................... 30 to 45°C
Routine Maintenance:
Temperature Four weekly: .... Replenish reagents, clean flow system.
Resolution: ............. ±0.1°C Twelve monthly: .... Replace plumbing and pump tubing, and
pump capstans. Refurbish sensors
Displays: depending on application.
Concentration .... 5 digit blue fluorescent.
Information .... 20 character dot matrix blue fluorescent. Power Supply: ........ 115 or 240 V, 50/60 Hz, 100 VA.
Status indication .... Two flashing l.e.d.'s in alarm state.
Single l.e.d. lit when 'Hold' switch Power Supply
operated. Tolerance: ............... +6% to –20%.
Single l.e.d. lit when calibration is in
progress. Isolation Voltage: ... Input, Output and power supply 1.5 kV.
Single l.e.d. lit when the monitor is 'Out of
Service' Dimensions:
Height: .... 890 mm (35.04").
Current Outputs: .... As standard one isolated current output Width: .... 542 mm (21.34").
0 to 1, 0 to 10, 0 to 20 or 4 to 20 mA, Depth: .... 220 mm (8.68").
selectable via plug in links. Maximum
voltage load 15 V. Weight .... 30 kg (66 lb).

Current Output Degree of Protection:

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

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

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

36
10 SPARES LIST
Consumable Spares

Part No. Description Qty

Consumable spares kit comprising pump tubes, pump capstans, plumbing
8230 020 1
tubing, tube connectors and 'O' rings etc.

Refurbishment Spares

Part No. Description Qty

8001 150 Fluoride electrode 1
1436 830 Reference electrode – silver-silver chloride 1
8231 242 Electrode retaining sleeve 1
8231 235 Sample heater coil 1
8236 260 Reagent solution container assembly 1
8230 221 Standard solution container assembly – 'High' 1
8230 220 Standard solution container assembly – 'Low' 1
8063 710 Container tube sinker 3
0214 514 Hose connector – sample inlet 6 mm i.d. 1
0214 526 Hose connector – monitor drain 9 mm i.d. 1
8022 990 Tube connector – 9 mm i.d. flowcell drain 1
8231 240 Flowcell stirrer magnet 1
8230 240 Temperature sensor assembly 1
0234 019 Solenoid valve ('Burkert' type)* 1

*This valve replaces 'Fluid Automation Systems' valve (part number 0232 092).
To convert to the Burkert valve, order solenoid valve assembly, part number 8230 207, which
includes the valve and mounting bracket.

Strategic Spares

Part No. Description Qty

8232 280 Constant head unit 1
8061 864 Float switch – 'Out of Sample' 1
8230 208 Pump motor including 10 µF capacitor (4 r.p.m. @ 50 Hz)* 1
0232 033 Stirrer motor 1
8035 870 Pump motor coupling assembly 1
0216 244 Heater assembly 1
0234 712 Heater thermal cut-out 1
8231 239 Flowcell assembly 1
0232 325 Mains transformer – User Junction Box 1
0234 713 Toggle switch – mains and pump switch 2
0234 714 Toggle switch boot 2
8230 130 P.C.B. assembly – User Junction Box 1
0239 117 Electrode coaxial plug 2
0239 118 Electrode coaxial socket 2
4500 0845 Processor Board (without EPROM) 1

*This motor replaces 0232 069 (5 r.p.m. @ 50 Hz), thus reducing reagent consumption.

37
…10 SPARES LIST

Specify EPROM below as required

N.B. EPROM's require a special PLCC extraction tool
Part No. Description Qty
8231 170 EPROM (English) 1
8231 171 EPROM (German) 1
8231 175 EPROM Serial Comm (English) 1
8231 176 EPROM Serial Comm (German) 1

4500 0817 Power supply board assembly 1

4500 0140 Display board pack assembly 1
4500 0245 Serial I/O board 1
4500 0255 Current O/P board 1
8230 055 mV input board 1
4500 0265 Temp. input board 1
4500 0625 Output module 1
4500 0285 Power supply board 1
4500 0275 5–digit 7–segment display board 1
4500 0443 5–digit display flexi-circuit 1
4500 0603 Display flexi-circuit 1
4500 0395 Membrane switch 1

4500 0715 Power supply board assembly (Fitted to pre CE marked monitors only) 1

38
APPENDIX A – REPLACING SOFTWARE EPROM

Warning. Switch off the monitor and electrically A.2 Access the PCB – Fig. A.2
isolate it before carrying out the following steps.

Unlock and open cover plate and 1

A.1 Access the Transmitter Unit – Fig. A.1 hinge out to expose captive
screws.

Caution. Employ normal antistatic precautions

while handling chips and PCBs.

Caution. To avoid damaging EPROM, base or

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

Remove processor PCB.

3 See Fig. A.3

Fluoride EIL8231
Fig. A.2 Procedure to Access the Processor PCB

Undo locks and

swing open the case
1 to reveal the Continued over…
microprocessor unit.

Open microprocessor unit –

2 see Fig. A.2.

Fig. A.1 Procedure to Open the Enclosure

39
…APENDIX A

A.3 Removing the PCB – Fig. A.3

Remove the four screws attaching the PCB to

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

2 Withdraw the PCB and turn it over to

reveal the component side.

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

Fig. A.3 Procedure to Remove the PCB

A.4 Changing the EPROM – Fig. A.4 A.5 Completing the Procedure
1) Fit the PCB using the reverse
procedure in Fig. A.3.

1 Extract IC1 using an approved tool

– see Caution in Section A.1. 2 Fit the replacement IC – press home firmly.
Important Note. Ensure that
the washers are fitted between the
3 Go to Section A.5 for reassembly instructions. PCB cover and the PCB.

2) Close the microprocessor section

using the reverse procedure in
Fig. A.2.
3) Close and lock the hinged cover –
Fig. A.1.
IC5 IC4
IC2
4) The monitor may now be put into
service.
5) Check program parameters – see
IC3 IC1 IC11
Section 6.
BAT1

6) Carry out a routine 2-point

calibration.

Fig. A.4 Replacing the Software EPROM

40
 PRODUCTS & CUSTOMER SUPPORT
Products Customer Support
Automation Systems
• for the following industries: ABB Automation provides a comprehensive after sales service
– Chemical & Pharmaceutical via a Worldwide Service Organization. Contact one of the
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– Manufacturing Centre.
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Flexible Automation the Company's published specification. Periodic checks must be
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In the event of a failure under warranty, the following
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Flow Measurement
1. A listing evidencing process operation and alarm logs at time
• Electromagnetic Magnetic Flowmeters
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alleged faulty unit.
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sensors
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 Issue 6
IM/8231

The Company’s policy is one of continuous product

improvement and the right is reserved to modify the information
contained herein without notice.
© ABB 2001 Printed in UK (04.01)

ABB Automation Ltd ABB Automation Inc.

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UK USA in over 100 countries worldwide
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