Polymetron 9582 Dissolved Oxygen: User Manual
Polymetron 9582 Dissolved Oxygen: User Manual
93067
Table of Contents
Additional information ............................................................................................. 3
Specifications .............................................................................................................. 3
General information .................................................................................................. 3
Safety information ........................................................................................................ 3
Use of hazard information .................................................................................... 4
Precautionary labels ............................................................................................ 4
EMC compliance statement (Korea) ..................................................................... 5
Product overview ......................................................................................................... 5
Product components .................................................................................................... 5
Installation ..................................................................................................................... 5
Startup ............................................................................................................................. 9
User navigation ........................................................................................................... 9
Operation ....................................................................................................................... 9
System configuration ................................................................................................... 9
Configure the sensor ................................................................................................. 10
Calibrate the sensor ................................................................................................... 10
About sensor calibration ..................................................................................... 10
Temperature calibration ...................................................................................... 10
Zero calibration ................................................................................................... 10
Calibration in air .................................................................................................. 11
Calibration with the process sample ................................................................... 12
Exit calibration procedure ................................................................................... 13
Change calibration options ................................................................................. 13
Standby function ........................................................................................................ 13
Maintenance ............................................................................................................... 13
Troubleshooting ....................................................................................................... 16
Table of Contents
Additional information
Additional information is available on the manufacturer's website.
Specifications
Specifications are subject to change without notice.
Sensor
Specification
Details
Sensor body
Noryl
Dimensions
Weight
Electrode
Membrane
PFA
Membrane holder
Noryl
410 liters/hour
Sample temperature
-2060 C (-4120 F)
Sample pressure
Atmospheric pressure
Relative humidity
090%
Certifications
Sensor module
Specification
Details
Measuring range
02 ppm
Sensitivity
Repeatability
Detection limit
1 ppb
Response time
045 C (32113 F)
General information
In no event will the manufacturer be liable for direct, indirect, special, incidental or consequential
damages resulting from any defect or omission in this manual. The manufacturer reserves the right to
make changes in this manual and the products it describes at any time, without notice or obligation.
Revised editions are found on the manufacturers website.
Safety information
NOTICE
The manufacturer is not responsible for any damages due to misapplication or misuse of this product including,
without limitation, direct, incidental and consequential damages, and disclaims such damages to the full extent
permitted under applicable law. The user is solely responsible to identify critical application risks and install
appropriate mechanisms to protect processes during a possible equipment malfunction.
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Please read this entire manual before unpacking, setting up or operating this equipment. Pay
attention to all danger and caution statements. Failure to do so could result in serious injury to the
operator or damage to the equipment.
Make sure that the protection provided by this equipment is not impaired. Do not use or install this
equipment in any manner other than that specified in this manual.
DANGER
Indicates a potentially or imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially or imminently hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION
Indicates a potentially hazardous situation that may result in minor or moderate injury.
NOTICE
Indicates a situation which, if not avoided, may cause damage to the instrument. Information that requires special
emphasis.
Precautionary labels
Read all labels and tags attached to the product. Personal injury or damage to the product could
occur if not observed. A symbol on the instrument is referenced in the manual with a precautionary
statement.
This symbol, when noted on a product, indicates a potential hazard which could cause serious
personal injury and/or death. The user should reference this instruction manual for operation and/or
safety information.
This symbol, when noted on a product enclosure or barrier, indicates that a risk of electrical shock
and/or electrocution exists and indicates that only individuals qualified to work with hazardous
voltages should open the enclosure or remove the barrier.
This symbol, when noted on the product, indicates the presence of devices sensitive to electrostatic
discharge and indicates that care must be taken to prevent damage to them.
This symbol, when noted on a product, indicates the instrument is connected to alternate current.
Electrical equipment marked with this symbol may not be disposed of in European public disposal
systems. In conformity with European local and national regulations, European electrical equipment
users must now return old or end-of-life equipment to the manufacturer for disposal at no charge to
the user.
Note: For return for recycling, please contact the equipment producer or supplier for instructions on how to return
end-of-life equipment, producer-supplied electrical accessories, and all auxiliary items for proper disposal.
Products marked with this symbol indicates that the product contains toxic or hazardous substances
or elements. The number inside the symbol indicates the environmental protection use period in
years.
Products marked with this symbol indicates that the product conforms to relevant South Korean
EMC standards.
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Additional information
A
( )
(A )
,
.
Class A equipment
(Industrial Broadcasting and Communication
Equipment)
Product overview
This single-channel analyzer is used for the measurement of dissolved oxygen in boiler feedwaters,
economizers, condensers and in general all thermal equipment using water as a heat transfer liquid.
Product components
Make sure that all components have been received. If any items are missing or damaged, contact the
manufacturer or a sales representative immediately.
Components:
Installation
CAUTION
Multiple hazards. Only qualified personnel must conduct the tasks described in this section of the
document.
Installation guidelines
Put the instrument in a location that has access for operation, service and calibration.
Make sure that there is good view of the display and controls.
Keep the instrument away from a heat source.
Keep the instrument away from vibrations.
Keep the sample tubing as short as possible to minimize the response time.
Make sure that there is no air in the sample supply line.
Electrolyte must be added to the sensor before use. Refer to the steps that follow and Figure 1.
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1. Install the membrane on the sensor body by hand as far as it will go.
2. Use the syringe to add 5 mL of electrolyte to the sensor body. Make sure that there are no
impurities or bubbles in the electrolyte.
3. Gently push the electrode into the sensor body until there is resistance. Do not force the
electrode.
4. Install and tighten the holding nut by hand.
5. Install the gasket and filling screw to prevent electrolyte leakage or external contamination from
the sample. Carefully tighten the screw with a screwdriver without using excessive force.
Figure 1 Sensor assembly
Refer to the steps that follow and Figure 2 to mount the sensor in the flow chamber.
1. Connect the sensor cable to the sensor and tighten the connector by hand. Do not turn the cable
or the sensor.
2. Put the sensor into the flow chamber and tighten the sensor clamping nut by hand.
3. Connect the sample line to the sample input connector.
4. Connect the sample output to the sample output connector.
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5 Flow chamber
3 Assembled sensor
4 Gasket
WARNING
Electrocution Hazard. High voltage wiring for the controller is conducted behind the high voltage barrier in the
controller enclosure. The barrier must remain in place except when installing modules, or when a qualified
installation technician is wiring for power, relays or analog and network cards.
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NOTICE
Potential Instrument Damage. Delicate internal electronic components can be damaged by static
electricity, resulting in degraded performance or eventual failure.
Signal
Sensor wire
Temp +
Black
Temp
Blue
34
Ground
Green
Earth
Yellow
78
Working electrode
White
10
Counter electrode
Red
1112
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Startup
Make sure that the flow rate and pressure do not exceed the values in Specifications on page 3.
1.
2.
3.
4.
5.
Open the valve on the sample line to let sample flow through the analyzer.
Turn the knob on the flow meter to set the flow rate.
Examine the plumbing for leaks and stop any leaks if found.
Apply power to the controller.
Make the applicable menu selections when the controller starts.
User navigation
Refer to the controller documentation for keypad description and navigation information.
Operation
System configuration
Refer to the controller documentation for system configuration, general controller settings and setup
for outputs and communications.
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Description
EDIT NAME
Changes the name that corresponds to the sensor on the top of the measure screen.
The name is limited to 16 characters in any combination of letters, numbers, spaces or
punctuation.
SENSOR S/N
Allows the user to enter the serial number of the sensor, limited to 16 characters in any
combination of letters, numbers, spaces or punctuation.
MEAS UNITS
Changes the measurement unitsSelect the unit from the list available.
PRESSURE UNITS
Sets the units for atmospheric pressureSelect the unit from the list available.
TEMP UNITS
FILTER
Sets a time constant to increase signal stability. The time constant calculates the
average value during a specified time0 (no effect, default) to 60 seconds (average of
signal value for 60 seconds). The filter increases the time for the sensor signal to
respond to actual changes in the process.
LOG SETUP
Sets the time interval for data storage in the data log5, 30 seconds, 1, 2, 5, 10,
15 (default), 30, 60 minutes.
RESET DEFAULTS Sets the configuration menu to the default settings. All sensor information is lost.
Temperature calibration
It is recommended to calibrate the temperature sensor once a year. Calibrate the temperature sensor
before calibrating the measurement sensor.
1. Put the sensor in a container of water that is at a known temperature. Under agitation, measure
the temperature of the water with an accurate thermometer or independent instrument.
2. Push the menu key and select SENSOR SETUP>CALIBRATE.
3. If the pass code is enabled in the security menu for the controller, enter the pass code.
4. Select 1 PT TEMP CAL and push enter.
5. The raw temperature value is displayed. Push enter.
6. Enter the correct value if different from that displayed and push enter.
7. Push enter to confirm the calibration. The temperature offset is displayed.
Zero calibration
Because of the stability of the electrode, for most applications this calibration is not required but can
be used to define the unique zero point of the sensor.
1. Remove the sensor from the process and rinse in distilled water.
2. Push the menu key and select SENSOR SETUP>CALIBRATE.
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3. If the pass code is enabled in the security menu for the controller, enter the pass code.
4. Select ZERO CAL and push enter.
5. Select the option for the output signal during calibration:
Option
Description
ACTIVE
The instrument sends the current measured output value during the calibration procedure.
HOLD
The sensor output value is held at the current measured value during the calibration procedure.
TRANSFER A preset output value is sent during calibration. Refer to the controller user manual to change
the preset value.
The sensor was not calibrated previously with this controller. The days of operation and previous
calibration curves for the sensor are reset.
NO
12. Return the sensor to the process and push enter. The output signal returns to the active state
and the measured sample value is shown on the measure screen.
Note: If the output mode is set to hold or transfer, select the delay time when the outputs return to the active
state.
Calibration in air
Air calibration is recommended for best accuracy and repeatability.
1.
2.
3.
4.
5.
Description
ACTIVE
The instrument sends the current measured output value during the calibration procedure.
HOLD
The sensor output value is held at the current measured value during the calibration procedure.
TRANSFER A preset output value is sent during calibration. Refer to the controller user manual to change
the preset value.
6. Using a precision certified barometer, measure the atmospheric pressure where the analyzer is
located. Use the arrow keys to enter this value if different from the value displayed and push
enter.
7. Moisturize the wadding in a calibration cap with a few drops of water. Place the sensor vertically
in the calibration cap with the membrane downwards. Tighten the calibration cap and push enter.
8. Wait for the value to stabilize and push enter.
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The sensor was not calibrated previously with this controller. The days of operation and previous
calibration curves for the sensor are reset.
NO
Description
ACTIVE
The instrument sends the current measured output value during the calibration procedure.
HOLD
The sensor output value is held at the current measured value during the calibration procedure.
TRANSFER A preset output value is sent during calibration. Refer to the controller user manual to change
the preset value.
5. With the sensor in the process sample, push enter. The measured value is shown. Wait for the
value to stabilize and push enter.
6. With a certified secondary verification instrument measure the concentration value of the sample.
To avoid impurities in the sample take the measurement before the sample enters the flow
chamber. Use the arrow keys to enter this value if different from the value displayed and push
enter.
7. Review the calibration result:
PASSthe sensor is calibrated and the calibration factor is displayed.
FAILthe calibration is outside of accepted limits. Clean the sensor and retry. Refer to
Troubleshooting on page 16 for more information.
8. If the calibration passed, push enter to continue.
9. If the option for operator ID is set to YES in the CAL OPTIONS menu, enter an operator ID. Refer
to Change calibration options on page 13.
10. On the NEW SENSOR screen, select whether the sensor is new:
Option Description
YES
The sensor was not calibrated previously with this controller. The days of operation and previous
calibration curves for the sensor are reset.
NO
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11. With the sensor still in the process push enter. The output signal returns to the active state and
the measured sample value is shown on the measure screen.
Note: If the output mode is set to hold or transfer, select the delay time when the outputs return to the active
state.
Description
QUIT CAL
Stop the calibration. A new calibration must start from the beginning.
Exit the calibration temporarily. Access to other menus is allowed. To return to the
calibration, push the menu key and select SENSOR SETUP.
2. Use the arrow keys to select one of the options and push enter.
Description
CAL REMINDER Sets a reminder for the next calibration in days, months or yearsselect the required
delay from the list.
OP ID ON CAL
Standby function
The measuring range of the 9582 is up to a maximum of 2 ppm. If measurements exceed this value
for more than 2.5 minutes the standby function is enabled and no more measurements are taken. To
exit standby mode push the menu key and select SENSOR SETUP>EXIT STANDBY.
Maintenance
WARNING
Multiple hazards. Only qualified personnel must conduct the tasks described in this section of the
document.
Membrane replacement
CAUTION
Chemical exposure hazard. Obey laboratory safety procedures and wear all of the personal protective
equipment appropriate to the chemicals that are handled. Refer to the current material safety data
sheets (MSDS) for safety protocols.
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NOTICE
Always remove the electrolyte filling plug before removal of the electrode. Do not touch the membrane with the
hands. Do not use a worn membrane.
Unscrew the filling screw and remove along with the gasket.
Unscrew the holding nut.
Carefully remove the electrode from the sensor body.
Empty any electrolyte left in the sensor body.
Unscrew the old membrane from the sensor body.
Install the new membrane. Refer to Assemble the sensor on page 5.
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Electrode rejuvenation
After some months of operation (3 to 12 depending on sample oxygen concentration, plant shutdown
frequency, etc.), a dark coating of silver bromide (AgBr) may cover part of the silver anode. This
coating does not affect the measurement unless more than 90% of the surface is contaminated.
When changing the electrolyte and membrane, visually check the silver anode. If more than 2/3 of
the surface is coated with silver bromide then an electrode rejuvenation is required. To do this, very
softly polish the areas coated with the deposit using a soft abrasive (N 400 to 600). After polishing,
rinse with demineralized water and wipe dry with a soft cloth. Some of the dark coloring may be left
to improve sensor stabilization time.
After cleaning, replace the sensor in the sample and leave for 30 minutes for the measurement to
stabilize. Once stable, the sensor must be calibrated.
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Troubleshooting
General troubleshooting
Problem
No significant
current increase
when the sensor is
in the air for the
calibration.
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Probable cause
Resolution
Problem
Important instability
in measuring mode.
Probable cause
Resolution
Incorrect connection.
Electrolyte pollution.
Electrolyte leaking.
Lack of accuracy.
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Problem
The sample
temperature is out of
specification.
The displayed
reading is not
numeric.
Probable cause
Resolution
Description
MODULE INFORMATION Shows the version and the serial number for the sensor module.
SENSOR INFORMATION Shows the name and serial number that was entered by the user.
CAL DAYS
CAL HISTORY
Resets the calibration history for the sensor (requires service-level passcode). All
previous calibration data is lost.
SENSOR SIGNALS
MEMBRANE DAYS
Shows the number of days that the sensor has been in operation.
RESET MEMBRANE
Resets the number of days that the sensor has been in operation.
Warning list
A warning icon consists of an exclamation point within a triangle. Warning icons appear on the right
of the main display below the measurement value. A warning does not affect the operation of menus,
relays and outputs. To view warnings, push the menu key and select DIAGNOSTICS. Then select
the device to view any problems associated with that device. The warning icon will no longer be
displayed once the problem has been corrected or acknowledged.
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Description
Resolution
DO TOO HIGH
DO TOO LOW
CAL OVERDUE
REPLACE SENSOR
NOT CALIBRATED
CAL IN PROGRESS
Return to calibration.
Error list
Errors may occur for various reasons. An error icon consists of an exclamation point within a circle.
When an error occurs, the error icon and the measurement screen flash alternately in the main
display. All outputs are held when specified in the controller menu. To view errors, push the menu
key and select DIAGNOSTICS. Then select the device to view any problems associated with that
device.
A list of possible errors is shown in Table 4.
Table 4 Error list for dissolved oxygen sensors
Error
Description
Resolution
ADC FAILURE
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Item no.
09185=A=3500
Calibration cap
09182=A=1200
09078=C=1020
09078=C=1030
09182=A=1000
09078=C=1010
Reference electrolyte 25 mL
09181=A=3600
09078=A=2000
Syringe
460150,21951
3. HAZARDS IDENTIFICATION
Hazardous components which must be listed on the label: Caustic potash; Potassium hydroxide
R34: Causes burns.
S26: In case of contact with eyes, rinse immediately with plenty of water and seek medical advice.
S45: In case of accident or if you feel unwell, seek medical advice immediately (show the label where possible).
S36/37/39: Wear suitable protective clothing, gloves and eye/face protection.
Additional advice on labelling: Classification according to European directive on classification of hazardous
preparations 1999/45/EC.
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UN number: 1814
UN proper shipping name: POTASSIUM HYDROXIDE SOLUTION
Transport hazard class(es): 8
Packing group: II
Hazard label: 8
Classification code: C5
Limited quantity: LQ22
Hazard No: 80
Tunnel restriction code: E
Excepted Quantities: E2
Transport Category: 2
Inland waterways transport (ADN):
UN proper shipping name: Not tested
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UN number: 1814
UN proper shipping name: POTASSIUM HYDROXIDE SOLUTION
Transport hazard class(es): 8
Packing group: II
Hazard label: 8
Limited quantity: 1 L
EmS: F-A, S-B
Excepted Quantities: E2
Air transport (ICAO):
UN number: 1814
UN proper shipping name: POTASSIUM HYDROXIDE SOLUTION
Transport hazard class(es): 8
Packing group: II
Hazard label: 8
Limited quantity - Passenger: 0.5 L
IATA-packing instructions - Passenger: 809
IATA-max. quantity - Passenger: 1 L
IATA-packing instructions - Cargo: 813
IATA-max. quantity - Cargo: 30 L
Excepted Quantities: E2
Passenger-LQ: Y809
Special Provisions A3
The above-mentioned data correspond to our current state of knowledge. They serve as a description of the
products in regard to necessary safety measures and do not guarantee the described chemical properties. These
indications describe the safety precautions to take against the related product and they are not a guaranty of the
described product properties.
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Hach, 2013-2015.
All rights reserved. Printed in Europe.