Operator Manual ORBISPHERE

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1 Operator Manual ORBISPHERE Revision C - 28/02/2008

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3 3626/36 Analyzer - Important Information Product Recycling Information ENGLISH Electrical equipment marked with this symbol may not be disposed of in European public disposal systems after 12 August In conformity with European local and national regulations (EU Directive 2002/96/EC), 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 manufacturer or supplier for instructions on how to return end-of-life equipment for proper disposal. GERMAN Elektrogeräte, die mit diesem Symbol gekennzeichnet sind, dürfen in Europa nach dem 12. August 2005 nicht mehr über die öffentliche Abfallentsorgung entsorgt werden. In Übereinstimmung mit lokalen und nationalen europäischen Bestimmungen (EU-Richtlinie 2002/96/EC), müssen Benutzer von Elektrogeräten in Europa ab diesem Zeitpunkt alte bzw. zu verschrottende Geräte zur Entsorgung kostenfrei an den Hersteller zurückgeben. Hinweis: Bitte wenden Sie sich an den Hersteller bzw. an den Händler, von dem Sie das Gerät bezogen haben, um Informationen zur Rückgabe des Altgeräts zur ordnungsgemäßen Entsorgung zu erhalten. FRENCH A partir du 12 août 2005, il est interdit de mettre au rebut le matériel électrique marqué de ce symbole par les voies habituelles de déchetterie publique. Conformément à la réglementation européenne (directive UE 2002/96/EC), les utilisateurs de matériel électrique en Europe doivent désormais retourner le matériel usé ou périmé au fabricant pour élimination, sans frais pour l'utilisateur. Remarque: Veuillez vous adresser au fabricant ou au fournisseur du matériel pour les instructions de retour du matériel usé ou périmé aux fins d'élimination conforme. ITALIAN Le apparecchiature elettriche con apposto questo simbolo non possono essere smaltite nelle discariche pubbliche europee successivamente al 12 agosto In conformità alle normative europee locali e nazionali (Direttiva UE 2002/96/EC), gli utilizzatori europei di apparecchiature elettriche devono restituire al produttore le apparecchiature vecchie o a fine vita per lo smaltimento senza alcun costo a carico dell utilizzatore. Nota: Per conoscere le modalità di restituzione delle apparecchiature a fine vita da riciclare, contattare il produttore o il fornitore dell apparecchiatura per un corretto smaltimento. DANISH Elektriske apparater, der er mærket med dette symbol, må ikke bortskaffes i europæiske offentlige affaldssystemer efter den 12. august I henhold til europæiske lokale og nationale regler (EUdirektiv 2002/96/EF) skal europæiske brugere af elektriske apparater nu returnere gamle eller udtjente apparater til producenten med henblik på bortskaffelse uden omkostninger for brugeren. Bemærk: I forbindelse med returnering til genbrug skal du kontakte producenten eller leverandøren af apparatet for at få instruktioner om, hvordan udtjente apparater bortskaffes korrekt. Operator Manual ORBISPHERE

4 Important Information /36 Analyzer SWEDISH Elektronikutrustning som är märkt med denna symbol kanske inte kan lämnas in på europeiska offentliga sopstationer efter Enligt europeiska lokala och nationella föreskrifter (EU-direktiv 2002/96/ EC) måste användare av elektronikutrustning i Europa nu återlämna gammal eller utrangerad utrustning till tillverkaren för kassering utan kostnad för användaren. Obs! Om du ska återlämna utrustning för återvinning ska du kontakta tillverkaren av utrustningen eller återförsäljaren för att få anvisningar om hur du återlämnar kasserad utrustning för att den ska bortskaffas på rätt sätt. SPANISH A partir del 12 de agosto de 2005, los equipos eléctricos que lleven este símbolo no deberán ser desechados en los puntos limpios europeos. De conformidad con las normativas europeas locales y nacionales (Directiva de la UE 2002/96/EC), a partir de esa fecha, los usuarios europeos de equipos eléctricos deberán devolver los equipos usados u obsoletos al fabricante de los mismos para su reciclado, sin coste alguno para el usuario. Nota: Sírvase ponerse en contacto con el fabricante o proveedor de los equipos para solicitar instrucciones sobre cómo devolver los equipos obsoletos para su correcto reciclado. DUTCH Elektrische apparatuur die is voorzien van dit symbool mag na 12 augustus 2005 niet meer worden afgevoerd naar Europese openbare afvalsystemen. Conform Europese lokale en nationale wetgegeving (EU-richtlijn 2002/96/EC) dienen gebruikers van elektrische apparaten voortaan hun oude of afgedankte apparatuur kosteloos voor recycling of vernietiging naar de producent terug te brengen. Nota: Als u apparatuur voor recycling terugbrengt, moet u contact opnemen met de producent of leverancier voor instructies voor het terugbrengen van de afgedankte apparatuur voor een juiste verwerking. POLISH Sprzęt elektryczny oznaczony takim symbolem nie może być likwidowany w europejskich systemach utylizacji po dniu 12 sierpnia Zgodnie z europejskimi, lokalnymi i państwowymi przepisami prawa (Dyrektywa Unii Europejskiej 2002/96/EC), użytkownicy sprzętu elektrycznego w Europie muszą obecie przekazywać Producentowi stary sprzęt lub sprzęt po okresie użytkowania do bezpłatnej utylizacji. Uwaga: Aby przekazać sprzęt do recyklingu, należy zwrócić się do producenta lub dostawcy sprzętu w celu uzyskania instrukcji dotyczących procedur przekazywania do utylizacji sprzętu po okresie użytkownia. PORTUGESE Qualquer equipamento eléctrico que ostente este símbolo não poderá ser eliminado através dos sistemas públicos europeus de tratamento de resíduos sólidos a partir de 12 de Agosto de De acordo com as normas locais e europeias (Directiva Europeia 2002/96/EC), os utilizadores europeus de equipamentos eléctricos deverão agora devolver os seus equipamentos velhos ou em fim de vida ao produtor para o respectivo tratamento sem quaisquer custos para o utilizador. Nota: No que toca à devolução para reciclagem, por favor, contacte o produtor ou fornecedor do equipamento para instruções de devolução de equipamento em fim de vida para a sua correcta eliminação. ORBISPHERE Operator Manual

5 3626/36 Analyzer - Important Information Product Disposal Note: The following only applies to European customers. Hach Ultra is committed to ensuring that the risk of any environmental damage or pollution caused by any of its products is minimized as far as possible. The European Waste Electrical and Electronic Equipment (WEEE) Directive (2002/96/EC) that came into force on 13 August 2005 aims to reduce the waste arising from electrical and electronic equipment; and improve the environmental performance of all those involved in the life cycle of electrical and electronic equipment. In conformity with European local and national regulations (EU Directive 2002/96/EC stated above), electrical equipment marked with the above symbol may not be disposed of in European public disposal systems after 12 August Hach Ultra will offer to take back (free of charge to the customer) any old, unserviceable or redundant analyzers and systems which carry the above symbol, and which were originally supplied by Hach Ultra. Hach Ultra will then be responsible for the disposal of this equipment. In addition, Hach Ultra will offer to take back (at cost to the customer) any old, unserviceable or redundant analyzers and systems which do not carry the above symbol, but which were originally supplied by Hach Ultra. Hach Ultra will then be responsible for the disposal of this equipment. Should you wish to arrange for the disposal of any piece of equipment originally supplied by Hach Ultra, please contact your supplier or our After Sales Service department in Geneva for instructions on how to return this equipment for proper disposal. Operator Manual ORBISPHERE

6 Important Information /36 Analyzer ORBISPHERE Operator Manual

7 3626/36 Analyzer - Table of Contents 1 of 68 Table of Contents 1 Installation 1.1 Indicating Instrument Installation Power Input Electrical Signal Connections Wiring Identification User-Supplied Cabling Requirements Junction Box Installation Power Input Electrical Signal Connections Wiring Identification LEMO Connector Assembly Instructions Cable Gland Wiring Instructions Analog Outputs Gas Concentration Output User Defined Output Serial Outputs Alarm Outputs Installation Completion Check List Check Voltage and Line Power Check Instrument Mounting and Connections Check Junction Box Mounting and Connections Check Sensor Mounting Check Oxygen Sensor Check Purge Gas Supply Maintain Instrument Power at all Times Operating Information 2.1 Instrument Controls Junction Box Program Menus Entering Numerical Values Measure Menu Measurement Displays Shutting Down the System Options Setup 3.1 Options Menu Standby Mode Display Mode Coefficients Membranes Gas Units Partial Pressure Gas Measurement...34 Operator Manual ORBISPHERE

8 2 of 68 Table of Contents /36 Analyzer Fraction Gas Measurement Dissolved Gas Measurement Temperature Units Alarm Outputs Alarm Output Test Analog Outputs Analog Output Test Serial Output Continuous Purge Mode Rolling Average Offset Corrections Hydrogen Correction Humidity Correction Calibrations 4.1 Calibrate Menu Barometric Pressure Sensor Calibration External Pressure Sensor Calibration H 2 /He Sensor Calibration In Air Calibration In Hydrogen Calibration In Helium Calibration O 2 Sensor Calibration O 2 In Air Calibration O 2 Direct Calibration Calibration Tables Oxygen Concentrations in ppm (in air-saturated water) Accessories and Attachments 5.1 Model Purge Backup Unit Model External Pressure Sensor Maintenance and Troubleshooting 6.1 General Maintenance Filament Current Adjustment Internal Fuse Replacement AC Voltage Switch Analog Current/Voltage Output Jumper Settings Alarm and Analog Output Testing Instrument and Sensor Maintenance Troubleshooting Measurement Troubleshooting Warning Messages Specifications ORBISPHERE Operator Manual

9 3626/36 Analyzer - Table of Contents 3 of System Specifications General Technical Data Instrument Configurations Standard Sensor Cable Specifications Part Lists 8.1 Accessories Spare Parts...61 Appendix A: Glossary A.1 Common Units...63 A.2 Terms and Definitions...63 Operator Manual ORBISPHERE

10 4 of 68 Table of Contents /36 Analyzer ORBISPHERE Operator Manual

11 3626/36 Analyzer - Manual Overview 5 of 68 Manual Overview About this Manual The information in this manual has been carefully checked and is believed to be accurate. However, Hach Ultra assumes no responsibility for any inaccuracies that may be contained in this manual. In no event will Hach Ultra be liable for direct, indirect, special, incidental, or consequential damages resulting from any defect or omission in this manual, even if advised of the possibility of such damages. In the interest of continued product development, Hach Ultra reserves the right to make improvements in this manual and the products it describes at any time, without notice or obligation. Published in Europe. Copyright 2006 by Hach Ultra. All rights reserved. No part of the contents of this manual may be reproduced or transmitted in any form or by any means without the written permission of Hach Ultra. Revision History Initial Release, June 1998, Orbisphere Revision A, April 2002, Orbisphere Revision B, October 2003, Hach Ultra Analytics Revision C, February 2006, Hach Ultra Safety Conventions WARNING A warning is used to indicate a condition which, if not met, could cause serious personal injury and/or death. Do not move beyond a warning until all conditions have been met. CAUTION: A caution is used to indicate a condition which, if not met, could cause minor or moderate personal injury and/or damage to the equipment. Do not move beyond a caution until all conditions have been met. Note: A note is used to indicate important information or instructions that should be considered before operating the equipment. Operator Manual ORBISPHERE

12 6 of 68 Manual Overview /36 Analyzer Safety Precautions Please read the entire manual before unpacking, setting up, or operating this instrument. Pay particular attention to all warning and caution statements. Failure to do so could result in serious injury to the operator or damage to the equipment. To ensure the protection provided by this equipment is not impaired, do not use or install this equipment in any manner other than that which is specified in this manual. Your 3626/36 analyzer measures hydrogen (H 2 ) and helium (He) gas concentrations, with the 3636 instrument additionally measuring oxygen (O 2 ) gas concentrations. Measurements can be made in either fraction or partial pressure in dry or humid gas at a pressure of 0-4 bar and a room temperature of between 10 C and 40 C (50 F to 104 F). WARNING This analyzer is not certified for use in explosive areas. For this environment, the gas should be sampled in the dangerous area and supplied to the analyzer via a suitable flame arrester (washing bottle for example). Safety Recommendations For safe operation, it is imperative that these service instructions be read before use and that the safety recommendations mentioned herein be scrupulously respected. If danger warnings are not heeded to, serious material or bodily injury could occur. WARNING In accordance with safety standards, it must be possible to disconnect the power supply of the instrument in its immediate vicinity. WARNING The installation of the instrument should be performed exclusively by personnel specialized and authorized to work on electrical installations, in accordance with relevant local regulations. Service and Repairs None of the instrument s components can be serviced by the user. Only personnel from Hach Ultra or its approved representative(s) is (are) authorized to attempt repairs to the system and only components formally approved by the manufacturer should be used. Any attempt at repairing the instrument in contravention of these principles could cause damage to the instrument and corporal injury to the person carrying out the repair. It renders the warranty null and void and could compromise the correct working of the instrument and the electrical integrity or the CE compliance of the instrument. If you have any problems with installation, starting, or using the instrument please contact the company that sold it to you. If this is not possible, or if the results of this approach are not satisfactory, please contact the manufacturer s Customer Service. ORBISPHERE Operator Manual

13 3626/36 Analyzer - Manual Overview 7 of 68 Precautionary Labels Read all labels and tags attached to the instrument. Personal injury or damage to the instrument could occur if not observed. 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 that the marked item can be hot and should not be touched without care. 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 the product, identifies a risk of chemical harm and indicates that only individuals qualified and trained to work with chemicals should handle chemicals or perform maintenance on chemical delivery systems associated with the equipment. 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. This symbol, if noted on the product, indicates the need for protective eye wear. This symbol, when noted on the product, identifies the location of the connection for protective earth (ground). Acknowledgements Dacron, Delrin, Tedlar, Tefzel, and Viton are registered trademarks of DuPont. Halar is a registered trademark of Ausimont U.S.A., Inc. Hastelloy is a registered trademark of Haynes International. Kynar is a registered trademark of The Pennwalt Corporation. Monel is a registered trademark of IMCO Alloys International, Inc. Saran is a registered trademark of Dow Chemical Co. Swagelok is a registered trademark of Swagelok Co. Microsoft and Windows are registered trademarks of Microsoft Corporation. Operator Manual ORBISPHERE

14 8 of 68 Manual Overview /36 Analyzer ORBISPHERE Operator Manual

15 3626/36 Analyzer - Installation 9 of 68 1 Installation This section provides all the necessary information to prepare for and install your 3626 or 3636 analyzer. If you still have any questions or encounter any difficulties, contact your Hach Ultra representative. The diagram illustrated in Fig 1-1 below is a typical on-line configuration for the 3636 instrument, with both gas sensors mounted in flow chambers (but without an optional external pressure sensor). CAUTION: A purge gas supply must be connected and flowing through the sensor before exposing the sensor to a sample, otherwiae the sensor could be damaged. Fig 1-1: Typical Installation (components not to scale) Detailed instructions for installing these and other individual components are in the sections that follow. Operator Manual ORBISPHERE

16 10 of 68 Installation /36 Analyzer 1.1 Indicating Instrument Installation Note: Include at least 100 mm additional rear clearance for cable protrusion. The standard panel mount instrument configuration is illustrated in Fig 1-2 below. Use the model panel mount template as a guide for the necessary panel cutting and drilling. To use, place the template where you wish to mount the instrument, and mark the drill holes and cut lines. Your mounting hardware includes a drill bit. Use this to drill the 5.4 mm holes required, then cut the mm wide by mm high panel holes. Fig 1-2: Instrument Mounting Four self-clinching bolts secure the instrument to the panel. It is easiest to attach the bottom two bolts first, guide the instrument into place, and then fix the top two bolts to finish the procedure. Once tightened, the self-clinching bolts ensure that only one person is required to remove the instrument. A retrofit panel mount (model 32201) is also available. This enables users of existing Orbisphere analyzers to replace their instruments with the 3626/36 instruments, without additional drilling or panel cutting, as shown in Fig 1-3. Fig 1-3: Retrofit Panel Mount Configuration ORBISPHERE Operator Manual

17 3626/36 Analyzer - Installation 11 of 68 The instrument can also be mounted in a 19" rack, either one across (model illustrated in Fig 1-4) or two across (model illustrated in Fig 1-5). Note: Include at least 400 mm additional frontal clearance for front panel access, and at least 100 mm bottom clearance for cable protrusion. Fig 1-4: 19 Rack Mount - One Across (Model 32202) Fig 1-5: 19 Rack Mount - Two Across (Model 32203) Four self-clinching bolts secure the instrument to the rack panel. Operator Manual ORBISPHERE

18 12 of 68 Installation /36 Analyzer Power Input WARNING The installation of a 3626/36 instrument should only be performed by personnel specialized and authorized to work on electrical installations, in accordance with relevant European and/or national regulations. In accordance with safety standard EN , it must be possible to disconnect the power supply of the instrument in its immediate vicinity. While the instrument electronics are well shielded, it is still advisable to locate the instrument as far as possible from any source of electromagnetic perturbation. AC Power Input Note: Use a power supply cable type H05VV-F 3 X 0.75 mm2 (supplied with the instrument). The length of the cable should be three meters maximum and it should have a separable plug (with three connectors, L+N+PE), without a locking device, to mate with a socket outlet in the building. The cable and the plug must conform to an appropriate European or national standard. AC power connections use a standard detachable power cable on the rear panel of the instrument (as illustrated in Fig 1-7) VDC Power Input DC powered instruments have a Male Binder connector on their rear panel. It accepts VDC power as follows: Pin 1: DC Return Pin 2: Earth (Chassis) Pin 3: Not connected Pin 4: Volts DC The necessary DC power wiring connections must be made using the Female Binder connector supplied. User-supplied power cable can have an outer diameter of between 5mm and 8mm. Fig 1-6: Female Binder Connector - Exploded View Disassemble the plug by squeezing the two clips located in the middle of the plug (position C in Fig 1-6). This reveals numbered wiring connections inside, to be matched one-to-one with the Male Binder connector diagram above. ORBISPHERE Operator Manual

19 3626/36 Analyzer - Installation 13 of Electrical Signal Connections Connections for the oxygen sensor (on the 3636 instrument), the junction box (for the H 2 /He sensor), the RS 232 connection and the external pressure sensor use prewired, snap-in LEMO receptacles on the rear panel of the instrument. The LEMO connector pin assignments are identified in Wiring Identification on page 14. Instructions for wiring the LEMO plugs can be found in LEMO Connector Assembly Instructions on page 19. WARNING Disconnect power from the instrument before opening the rear panel, and ground each cable shield properly to ensure proper operation. Fig 1-7: Instrument Rear View (Model 3636 Illustrated) Connections for analog (recorder) output and alarm relays are through stainless steel watertight glands on the instrument rear panel. These connections must be hard-wired to a terminal strip inside the instrument. To make any of these connections, remove the rear instrument panel. First, make sure the power supply is unplugged, and then remove the front-panel key. Then place the instrument facedown and remove the four 3mm Allen-head screws. Carefully pull off the rear panel, taking care not to disconnect any wires, to expose the terminal block (illustrated in Fig 1-8) and the wiring diagram label. Fig 1-8: Instrument Terminal Block Operator Manual ORBISPHERE

20 14 of 68 Installation /36 Analyzer Wiring Identification H 2 /He Sensor (junction box) Wiring Identification Fig 1-9: H 2 /He Sensor Wiring Sensor Signal LEMO-10 Pin GND for Power Pin 1 Not Used Pin 2 Solenoid Pin 3 Relay Coil Pin 4 +12V Power Pin 5 +24V Power Pin 6 V3 Signal Pin 7 GND for Signal Pin 8-5V Power Pin 9 Temperature Pin O 2 Sensor Wiring Identification Fig 1-10: O 2 Sensor Wiring Sensor Signal LEMO-10 Pin Guard Pin 1 TH1.B Pin 3 Anode Pin 4 TH1.A Pin 6 Cathode Pin External Pressure Sensor Input Wiring Identification Fig 1-11: External Pressure Sensor Wiring Sensor Signal LEMO-4 Pin Voltage (+) Pin 1 Ground Pin 2 Input (+) Pin 3 Input (-) Pin 4 ORBISPHERE Operator Manual

21 3626/36 Analyzer - Installation 15 of Analog (recorder) Output Wiring Identification Fig 1-12: Analog (recorder) Output Wiring Analog Output Terminal Strip Position H 2 Gas Out J13.1 -> H 2 Gas In He Gas Out J13.2 -> He Gas In O 2 Gas Out J13.3 -> O 2 Gas In User Recorder Signal User Defined J13.4 -> User Defined H 2 Gas Ground J14.1 <- H 2 Gas Ground He Gas Ground J14.2 <- He Gas Ground O 2 Gas Ground J14.3 <- O 2 Gas Ground User Defined Ground J14.4 <- User Ground Alarm Output Wiring Identification Fig 1-13: Alarm Output Wiring Alarm Relay Terminal Strip Position User Alarm Signal High Relay, Sensor 0 J High, Sensor 0 Low Relay, Sensor 0 J Low, Sensor 0 High Relay, Sensor 1 J14.5 High, Sensor 1 Low Relay, Sensor 1 J Low, Sensor 1 Common J Common Serial (RS-232) Wiring Identification Fig 1-14: Serial (RS232) Output Wiring RS232 Signal LEMO-6 Pin Transmitted data (TXD) Pin 1 Received data (RXD) Pin 2 Ground Pin 6 Operator Manual ORBISPHERE

22 16 of 68 Installation /36 Analyzer User-Supplied Cabling Requirements Cables for the recorder output and alarm relays should be control cables (i.e. not power cables) with twisted copper wires and shield, meeting the specifications in Table 1-1. Table 1-1: Alarm and Analog Output Cable Specifications Description External Diameter Alarms Output: Recorder Output: Wire (core) Area Insulation Nominal Voltage Absolute Maximum Voltage Absolute Maximum Current Wire Resistance Wire 800 Hz Shield 800 Hz Specification 4-6 mm 6-8 mm mm² PVC 250 V 1200 V A Ω/km 100 pf/m 240 pf/m Note: Ground the cable shield securely to the instrument case to ensure proper operation. The maximum cable length for the RS-232 connection is 20 meters. For installations that require connection distances up to 1 km, use RS-232/RS-485 converters at each end of the cable. ORBISPHERE Operator Manual

23 3626/36 Analyzer - Installation 17 of Junction Box Installation The model junction box is installed between the H 2 /He sensor and the 3626/36 instrument. The junction box wall mount enclosure has the following dimensions: Fig 1-15: Junction Box Dimensions Note: Include at least 200 mm additional frontal clearance for front panel access, and at least 100 mm bottom clearance for cable protrusion Power Input WARNING The installation of a model junction box should only be performed by personnel specialized and authorized to work on electrical installations, in accordance with relevant European and/or national regulations. In accordance with safety standard EN , it must be possible to disconnect the power supply of a junction box in its immediate vicinity. Although the box electronics are well shielded, locate the instrument as far as possible from any source of electromagnetic perturbation. Note: Use a flexible cable of the recommended type H05VV-F 3 X 0.75 mm2. The length of the cable should be three meters maximum and it should have a separable plug (with three connectors, L+N+PE), without a locking device, to mate with a socket outlet in the building. The cable and the plug must conform to an appropriate European or national standard. Operator Manual ORBISPHERE

24 18 of 68 Installation /36 Analyzer The VAC power connection for the junction box uses the leftmost waterproof cable gland. Wire according to the label inside the cabinet. To access this connection, unlock the front panel of the unit to expose the instrument electronics inside. 1) Remove the exterior insulation of the cable for a length of about 50 mm. 2) Insert the cable through the leftmost cable gland. 3) Strip the wires for a length of about 8 mm. 4) Put a Wago (spade type) connector on each of two wires (L and N). 5) Put the live and neutral wires on the corresponding spade plugs of the mains filter, as indicated on the label affixed to the bottom of the wall mount box, opposite the filter. Crimp the earth wire in the provided eyelet and screw it on the wall of the box. 6) Slide the cable farther through its cable gland until its external insulation penetrates about 6 mm inside the measurement box, blocking the cable gland Electrical Signal Connections The model junction box makes all connections using LEMO connectors and stainless steel watertight glands at the bottom of the instrument housing Wiring Identification H 2 /He Sensor Wiring Identification Fig 1-16: H 2 /He Sensor Wiring Sensor Signal LEMO-10 Pin GND for Power Pin 1 Filament 1 Pin 2 Solenoid Pin 3 Filament 2 Pin 4 +12V Power Pin 5 +24V Power Pin 6 V3 Signal Pin 7 GND for Signal Pin 8-5V Power Pin 9 Temperature Pin Instrument Wiring Identification Connection from the junction box to the 3626/36 instrument is hard-wired through a cable gland at the bottom of the junction box. The cable has a snap-in LEMO-10 connector to interface to the instrument Sensor TC receptacle (see illustration in Fig 1-7 on page 13). The instrument LEMO-10 connector wiring and pin identification is the same as the H 2 / He sensor wiring shown in Fig 1-16 above. ORBISPHERE Operator Manual

25 3626/36 Analyzer - Installation 19 of LEMO Connector Assembly Instructions Disassemble the LEMO connector, referring to Fig Fig 1-17: LEMO Connector - Exploded View 1) Slide the pieces over the cable in the following order: boot, back nut, collet, ring (beveled edge down), rubber seal, and reducer (narrow edge down). 2) Strip off 8 mm of the insulation and 6 mm of the shield from the cable. 3) Fan out the remaining wires and the shield. 4) Remove the clear plastic wrap from the wires. 5) Strip off about 1 mm of insulation from the wires. 6) Slide the mid piece up over the wires to the shield. Make sure the shield is pinched between the mid piece and the reducer to ensure proper grounding. 7) Place the pin assembly in a vice and solder the wires to the numbered pins. 8) Slide all the pieces down into the shell (note: the key in the mid piece must match the notch in the pin assembly) and secure the entire connector assembly by tightening the back nut. 1.4 Cable Gland Wiring Instructions The nickel-plated, brass cable glands are EMC-types, designed so that the cable shields attach directly to the instrument box. Typical cable wiring through one of these glands is illustrated in Fig Fig 1-18: Cable Gland Wiring - 1 1) Unscrew the cable gland nut. You will find a rubber gasket, then a metal washer with an interior diameter of 8.3 mm, and then another metal washer with an interior diameter of 7.5 mm. 2) Pass the cable through the nut, the gasket, and the 8.3-mm washer. Operator Manual ORBISPHERE

26 20 of 68 Installation /36 Analyzer 3) Strip off 110 mm of external insulation, and 85 mm of shielding (see Fig 1-19). 1.5 Analog Outputs Fig 1-19: Cable Gland Wiring - 2 4) Pass the cable prepared in this fashion through the 7.5-mm washer. 5) Pinch the shield so that its entire circumference is pressed between the two washers (as shown in Fig 1-18). 6) Pass the cable into the box, blocking the cable gland. 7) Reattach and tighten the cable gland nut. 8) Strip the wires about 8 mm from their ends. 9) Attach the wires to the corresponding terminal block connections by using a small-bladed flat screwdriver to gently push back the spring-loaded plastic lever on top of the terminal strip connector. Insert the wire into the connector opening and release the lever to hold the wire firmly in place. During measurement the instrument provides four analog outputs of measurement results. These outputs are available as 0-5 Volts, 0-20 ma, or 4-20 ma signals. There are six potential measurement values that can be output - H 2, He, and O 2 gas concentrations, temperature from both sensors, and external pressure. H 2, He, and O 2 gas concentrations are pre-assigned to three of the analog outputs. Thus, you have a choice under the Analog Output/User options menu, to choose Temp. 0, Temp. 1 or Pressure for the User defined output. Instructions for selecting these analog output options can be found in Options Setup on page 31. The analog outputs are generated using a 12-bit digital converter; thus, the minimum increment of any output can be determined by dividing the output range by For example, you could set the gas concentration range to ppm for 4-20mA, and your recorder would still pick up changes of ppm. The accuracy of each increment is 1% Gas Concentration Output The instrument rescales outputs for each of the three signals (4-20mA, 0-20mA and 0-5V) between any Low (L) and High (H) limits that are defined in the Modify Options Menu (See Analog Outputs on page 37). The relationship between the analog output signal V (voltage V) or I (current, ma), and the measurement M is represented in Table 1-2. Table 1-2: Custom Analog Output Enabled Analog Output Gas Concentration Measurement (M) 4-20mA M = L + ((H - L) * ((I - 4) / 16)) 0-20mA M = L + ((H - L) * (I / 20)) 0-5V M = L + ((H - L) * (V / 5)) ORBISPHERE Operator Manual

27 3626/36 Analyzer - Installation 21 of 68 Using Table 1-2, the following is an example of the measurement calculation for a 16mA analog signal (I) (on a 4-20mA configuration) and where the low and high limits are defined as 10 (L) and 20 (H): M = L + ((H - L) * ((I - 4) / 16)) M = 10 + ((20-10) * ((16-4) / 16)) M = 10 + (10 * 0.75) M = M = 17.5 This same calculation can also be represented graphically as illustrated in Fig Fig 1-20: Analog Output - Graphical Representation The output upper limit is fixed at 20mA or 5V whenever the displayed concentration is equal to or exceeds the defined High limit value. Similarly, the output lower limit is fixed at 4mA, 0mA or 0V if the concentration is equal to or less than the defined Low limit value. The output also shows these extreme upper and lower limit values under other conditions as summarized in Table 1-3. Table 1-3: Analog Output - Additional Upper and Lower Limit Conditions Analog Output 4-20mA 0-20mA 0-5V Menu, sensor thermal cutoff, negative gas concentration value, custom analog output low level or display under range Normal Operating Condition Display over range, custom analog output high level or sensor disconnected 4mA 0mA 0V 4mA < signal < 20mA 0mA < signal < 20mA 0V < signal < 5V 20mA 20mA 5V Operator Manual ORBISPHERE

28 22 of 68 Installation /36 Analyzer User Defined Output If you select Temp. 0 or Temp. 1 for the user output, the output signal varies linearly with temperature in the range -20 to 100 C, as illustrated in Table 1-4. Table 1-4: Analog Output - Temperature Calculations Analog Output 4-20mA 0-20mA 0-5V Temperature C = (7.5 * (I - 4)) F = -4 + (13.5 * (I - 4)) K = (7.5 * (I - 4)) C = (6 * I) F = -4 + (10.8 * I) K = (6 * I) C = (24 * V) F = -4 + (43.2 * V) K = (24 * V) If you select Pressure for the user output, the output signal varies linearly with the sample pressure from 0 to 5000 mbar as illustrated in Table 1-5. Table 1-5: Analog Output - Pressure Calculations Analog Output Pressure (P) 4-20mA P = * (I - 4) 0-20mA P = 250 * I 0-5V P = 1000 * V 1.6 Serial Outputs The instrument serial output provides formatted text for an RS-232 compatible printer, monitor, or computer interface (see Serial (RS-232) Wiring Identification on page 15 for serial output wiring connections). This output provides a running log of gas concentrations plus sample temperature and pressure for each measurement cycle. It also includes specific information on conditions that affect gas measurement, such as offsets. The serial output also generates a tabular report when you calibrate the sensor. Instructions for selecting the serial output options are in the Modify Options menus section. The output generates a new row of headings every sixteen measurement cycles. Concentration, Temperature, and Alrm values are as seen on the instrument's display. External pressure Pext is displayed in bars and barometric pressure Patm is displayed in mbars. If an offset has been entered (see Offset on page 39), the Offset column shows the value. An A code appearing in the Status column signifies the Rolling Average is enabled. ORBISPHERE Operator Manual

29 3626/36 Analyzer - Installation 23 of Alarm Outputs Low and High alarm relay contacts are available from the instrument. The instrument activates these alarm relays in response to various system or measurement conditions. You can set your own measurement limits - if the measured gas concentration is outside of these limits, the instrument activates the appropriate alarm relay. Instructions for setting the alarm limits are in the Modify Options menus section. The internal alarm relays of the instrument can be set for normally open (NO) or normally closed (NC) operation - the factory default setting is normally open. The Alarm Outputs options menu gives you the choice of selecting either the standard Low/High alarm condition, or a High/High-High alarm. Table 1-6 and Table 1-7 list all alarm conditions and alarm relay responses for your options settings. Table 1-6: Low/High Alarm Relay Responses Condition Low Relay Set For NO* High Relay Set for NO* Low Relay Set For NC* High Relay Set For NC* No alarm: LL < measured gas < HL Low alarm: measured gas < LL Low test: After entering LL in Options menu High alarm: measured gas > HL High test: After entering HL in Options menu System alarm: In Calibration or Modify Options menu, or instrument power off * Low and High refer to the alarm relays identified in the instrument wiring labels Table 1-7: High/High-High Alarm Relay Responses Condition Low Relay Set For NO* High Relay Set for NO* Low Relay Set For NC* High Relay Set For NC* No alarm: measured gas < HL High alarm: HL < measured gas < HH High test: After entering HL in Options menu Operator Manual ORBISPHERE

30 24 of 68 Installation /36 Analyzer Table 1-7: High/High-High Alarm Relay Responses Condition Low Relay Set For NO* High Relay Set for NO* Low Relay Set For NC* High Relay Set For NC* High-High alarm: measured gas > HH High-High test: After entering HH in Options menu Instrument Power Off System alarm: In Calibration or Modify Options menu * Low and High refer to the alarm relays identified in the instrument wiring labels Note: The High-High alarm condition does not correspond to a single alarm relay response, rather, it sets both alarm relays. Fig 1-21 shows a graphical representation of when the alarms are triggered. Fig 1-21: Alarm Conditions - Graphical Representation The High or HighHigh alarm is initially activated, once the measurement goes above the limits set. The Low alarm is activated when the measurement falls below the low limit. The instrument clears the Low alarm when the gas concentration rises to 1% above the low limit, or clears the High or High-High alarm when the gas concentration drops to 1% below the high or high-high limit. ORBISPHERE Operator Manual

31 3626/36 Analyzer - Installation 25 of Installation Completion Check List Check Voltage and Line Power The indicating instrument is available in 115 VAC and 230 VAC versions. A sticker on the rear panel indicates which voltage you have. Make sure that it is correct before connecting to a power supply, and make sure that the ground of the AC supply is connected. The model junction box requires a VAC power supply. Note: While the instrument case is watertight, the detachable power cable connection is not Check Instrument Mounting and Connections The instrument provides connections for power input, O 2 Sensor, TC Sensor (via the model junction box), serial RS-232 communication, recorder (analog) output, and alarm relay contacts. In addition, the instrument includes a connector for optional external pressure sensor input. CAUTION: Connect the oxygen sensor to the correct receptacle, because you could damage it if you plug it into the wrong socket Check Junction Box Mounting and Connections The junction box provides two cables with LEMO connectors for the H 2 /He sensor and the instrument Check Sensor Mounting The gas sensors can be placed in a sensor socket or ProAcc for measurements directly in a sampling pipe, in a flow chamber for on-line sampling or calibration, or directly into liquid or gas-phase samples. Check the recommendations in the Installation Guidelines Check Oxygen Sensor Shipping conditions can adversely affect Orbisphere oxygen sensors. If you intend to make measurements with the sensor as shipped, first examine the sensor head. Carefully, remove the protection cap, using the wrench supplied in your recharge kit, and check the sensor head to see that: The membrane mounting ring is firmly in place, The membrane surface is smooth and wrinkle-free, The electrolyte beneath the membrane is free of bubbles, and The electrodes appear clear, clean, and bright. Operator Manual ORBISPHERE

32 26 of 68 Installation /36 Analyzer Check Purge Gas Supply The H 2 /He TC sensor must have a cylinder of clean, dry air running as a purge gas before operating the system. CAUTION: The TC sensor, when exposed to a liquid sample, could easily become damaged if the purge gas is not running. The model regulator ensures a steady, dry purge gas supply to the sensor. See section entitled Purge Gas System in the TC Sensor Operator Manual, for instructions on connecting and using the purge gas regulator Maintain Instrument Power at all Times The TC sensor must be purged continuously. The instrument does this automatically; thus make certain that power is supplied constantly to the instrument. If it is desirable to be able to shut off the instrument while leaving the sensor installed in a liquid sample, install a model purge backup unit as described in Model Purge Backup Unit on page 51. ORBISPHERE Operator Manual

33 3626/36 Analyzer - Operating Information 27 of 68 2 Operating Information 2.1 Instrument Controls The front panel of the 3626/36 instrument (as illustrated in Fig 2-1) has several displays and controls associated with it. Fig 2-1: Instrument Controls The Key Switch should be turned to the horizontal unlocked position to start the instrument in measurement mode. The function keys (see Fig 2-2) are only active if the key switch is in the unlocked position. Use the vertical locked position to avoid accidental modifications. The Display has a two-line liquid crystal display (LCD) with 16 characters per line. A Light Button, when pressed, provides illumination to the LCD for three minutes. Four Function Keys provide simple operator control over the instrument functions: Fig 2-2: Function Keys ESC jumps back a step within a program menu or to a previous character when inputting numerical data values. The UP/DOWN ARROW keys are used to scroll through screen displays and increase or decrease numerical data values. ENTER is used to select a highlighted item from a menu, input data into the system and validate or accept data values. Operator Manual ORBISPHERE

34 28 of 68 Operating Information /36 Analyzer 2.2 Junction Box The model junction box has an on-off switch and a seven-digit counter (with reset button) accessible behind its front door. The junction box has two LEMO connectors - a snap-in receptacle for the TC sensor cable and a pre-wired cable with a snap-in connector to the instrument. AC power between V is supplied through the left gland. 2.3 Program Menus Fig 2-3: Model Junction Box The operator controls the instrument by menu-selectable commands using the four function keys. When switched on, the instrument goes automatically into measurement mode. To bring up the Main Menu, you must first press ESC to put the instrument on standby. The message indicated left will be displayed, to confirm the instrument is now in standby mode. Press the ESC key again to bring up the Main Menu. The main menu has three choices: MEASURE to start the measurement sequence (for full instructions refer to Measure Menu on page 29) OPTIONS to enable the instrument to be customized (for full instructions refer to Options Menu on page 31) CALIBRATE to provide a choice of sensor calibration procedures (for full instructions refer to Calibrate Menu on page 41) Note: If you are using alarm outputs and you press the ESC key while your instrument is in measurement mode, then a system alarm is engaged. ORBISPHERE Operator Manual

35 3626/36 Analyzer - Operating Information 29 of Entering Numerical Values When entering numerical values in any of the instrument menus, a value is displayed with the ^ symbol below the first digit. 2.5 Measure Menu Use the UP/DOWN ARROWS to increase/decrease the value of the digit (0-9, a decimal point and in some cases a plus or minus sign) until you reach your required target value. Then press ENTER to accept that digit and shift the highlight symbol one digit to the right. Repeat the process until the entire value has been entered. Pressing ENTER after the last digit saves the value. Pressing ESC during the data entry process will shift the highlight symbol one digit to the left. The following flow chart depicts the instrument measurement process. The flow lines are keyed to specific instrument actions. Fig 2-4: Instrument Measurement Menu Flow Diagram Your instrument is pre-set with certain default values to anticipate your measurement conditions, such as measurement display units, etc. You may, however, change these using the Instrument Modify Options Menus described in Options Setup on page 31. The instrument procedures for the 3626 and the 3636 are operationally identical. However, the 3626 instrument does not measure oxygen gas concentrations. As such, users of the 3626 instrument will not see any menus, or menu options, related to oxygen sensors and measurements. Operator Manual ORBISPHERE

36 30 of 68 Operating Information /36 Analyzer 2.6 Measurement Displays With the instrument, sensor, and purge gas supply connected, switching the instrument on first reveals the software version and the date, followed by a Please wait message to indicate the start of a measurement cycle, which takes about 90 seconds. When complete, the instrument switches to a continuous gas and temperature Measurement Display. Fig 2-5: Measurement Display Use the display mode option (see Display Mode on page 33) to select among several different measurement displays, each showing various combinations of sensor measurements: H 2 / He sensor gas and temperature measurements, O 2 sensor gas and temperature measurements, External and internal (barometric) pressure sensor measurements. Depending on the Number of Ranges configured for the instrument, the display resolution changes automatically to reflect gas and temperature measurement value changes. To make changes to the display resolution, refer to Gas Units on page 34. Press the ESC key twice to exit from the measurement display and move to the Main Menu to access additional options (MEASURE, OPTIONS and CALIBRATE). 2.7 Shutting Down the System In general, for inactive periods of up to one month, it is recommended to leave the instrument in standby mode with purge gas supplied, as this will increase the H 2 and O 2 sensor lifespan. For inactive periods of greater than one month, it is better to extract the sensors from the line (see instructions in the respective Sensors - Maintenance and Installation Manuals) and switch the instrument off. Since the instrument has a non-volatile memory, important parameters remain memorized even when the instrument power is off. CAUTION: The H 2 /He sensor should never be left in water or humid gas without power and purge gas, as water condensation could take place in the sensing area under the membrane, damaging the expensive thermal conductivity element. ORBISPHERE Operator Manual

37 3626/36 Analyzer - Options Setup 31 of 68 3 Options Setup 3.1 Options Menu Your instrument includes a full set of programmable outputs, and the ability to specify different units of measurement, sample media and sampling conditions. The flow charts illustrated in Fig 3-1 and Fig 3-2 outline these routines. Note: The flow charts illustrated are for the 3636 analyzer. The 3626 analyzer will have the same options, but without any references to oxygen measurements or displays. Fig 3-1: Modify Options Menu - Part 1 Operator Manual ORBISPHERE

38 32 of 68 Options Setup /36 Analyzer Fig 3-2: Modify Options Menu - Part 2 All of the menus require user input of one form or another. This is done by using the four function keys on the Instrument Panel (see Instrument Controls on page 27). You should ensure you are familiar with the use of these keys in entering and modifying numeric values (see Entering Numerical Values on page 29), before accessing these menus. ORBISPHERE Operator Manual

39 3626/36 Analyzer - Options Setup 33 of Standby Mode During standby, the purge cycle is activated every 10 minutes, the O 2 sensor is switched off, and no filament heating takes place. This is the recommended mode for periods of short-term inactivity (up to one month). For periods of inactivity greater than one month, it is better to extract the sensors from the line and switch the instrument off. To put your instrument in Standby Mode, ensure it is currently in Measurement Mode and then press the ESC key. The message indicated left will appear to inform you that the instrument has been placed in standby. To exit from Standby Mode, press the ESC key again to bring up the Main Menu (indicated left). 3.3 Display Mode 3.4 Coefficients 3.5 Membranes With your instrument in the Main Menu, highlight OPTIONS and press ENTER to bring up the MODIFY OPTIONS menu, then select DISPLAY MODE. This option determines which measurement values will be displayed. For example, if you select H2/He, then hydrogen and helium gas concentrations will be displayed on screen during the measurement process. Note: This option is reserved for qualified Hach Ultra Service Representatives only. As such, if you feel that any of the coefficient values need changing, please contact your local Hach Ultra Service Representative to perform this operation for you. The O 2 and H 2 sensors can be fitted with different membranes, each having individual sensitivity and flow requirements. To change your type of membrane, highlight MEMBRANES and press ENTER to display the screen. Select the sensor and then press ENTER to bring up the membrane choices. The membrane choices are M2956A, M29552A, M2958A, M2952A, M2995A and M2935A for O 2 sensors and M29561A, M2952A, M2935A and M2995A for H 2 /He sensors. Select the correct membrane and press ENTER. Operator Manual ORBISPHERE

40 34 of 68 Options Setup /36 Analyzer 3.6 Gas Units For detailed specifications regarding sensors and associated membranes, please refer to the accompanying Sensors - Maintenance & Installation Manual(s). Note: If you select any membrane (even if you reselect the same membrane and press ENTER), you must re-calibrate the sensor. In addition, you must reset any CORRECTIONS you may be using. This option allows you to specify your type of measurement (fraction, partial pressure or dissolved), the unit of measurement to be displayed, the display resolution (i.e. decimal point placement) and the number of display ranges desired for each of the gases being measured. Highlight GAS UNITS and press ENTER. You have the choice of selecting the display units for hydrogen (H2), helium (He) and oxygen (O2) measurements. Select the gas and press ENTER Partial Pressure Gas Measurement For each gas, the initial menu provides a choice between FRACTION, DISSOLVED and PARTIAL PRESSURE gas measurement. Highlight your choice and press ENTER. The menu for display units comes up. Table 3-1 shows the available choices of partial pressure display units (certain specialized applications may have additional units available as well). Select the units you want displayed. Table 3-1: Partial Pressure Gas Units bar mbar kpa psia Atm Gas pressure in bar Gas pressure in millibars Gas pressure in kilopascals Gas pressure in pounds per square inch, absolute Gas pressure in atmosphere ORBISPHERE Operator Manual

41 3626/36 Analyzer - Options Setup 35 of 68 Next choose one of the formats to set the decimal point placement of the LOWEST RANGE to display Fraction Gas Measurement Next, choose the NUMBER OF RANGES. This menu limits the number of measurement ranges that can be displayed (see Measurement Displays on page 30). For example, if your measurement values displayed are only from XX.XX to XXX.X with the XX.XX value as the lowest, select 2 as the number of ranges. You may also fix on a single range - that is, maintain a specific number of digits past the decimal point - by selecting 1 as the number of ranges. Highlight your choice and press ENTER to take you back to the DISPLAY UNITS menu. The menu for display units comes up. Table 3-2 shows the available choices of fraction display units. Note: Not all of the display unit choices are available for all gases. Table 3-2: Fraction Gas Units %vbar, ppmvb, ppmvb:%vbar %vext, ppmve, ppmve:%vext Percentage of gas volume, calculated at barometric pressure using the instrument's internal pressure sensor ([partial pressure / internal pressure] * 100), and/or also expressed as parts per million (ppm) Percentage of gas volume, calculated at external pressure using an external pressure sensor ([partial pressure / external pressure] * 100), and/or also expressed as parts per million (ppm) The instrument corrects fraction measurement for pressure. The %Vbar and ppmvb choices use the instrument's barometric pressure sensor. For %Vext or ppmve, it is necessary to have the model external pressure sensor connected and calibrated properly (see External Pressure Sensor Calibration on page 42). Next choose the LOWEST RANGE, and NUMBER OF RANGES in the same way as described above for Partial Pressure Gas Measurement Dissolved Gas Measurement The menu for dissolved display units comes up. Table 3-3 shows the available choices of display units. Note: Not all of the display unit choices are available for all gases. Next choose the LOWEST RANGE, and NUMBER OF RANGES in the same way as described above for Partial Pressure Gas Measurement. Operator Manual ORBISPHERE

42 36 of 68 Options Setup /36 Analyzer Table 3-3: Dissolved Gas Units cc/kg ml/l ppb ppm ppb:ppm Cubic centimeters per kilogram Milliliters per liter Parts per billion Parts per million Composite units, which will switch from parts per billion to parts per million depending on display resolution 3.7 Temperature Units This menu defines the display units for temperature. Choose between degrees Centigrade, Fahrenheit and Kelvin. 3.8 Alarm Outputs The ALARM menu configures the instrument's internal relays for alarm outputs. Separate limits can be set for each gas measurement, and if the measured gas concentration is outside of these limits the instrument activates the appropriate alarm relay. Alarm Outputs on page 23 describes the outputs in more detail. Connector and wiring identification for these outputs are in Wiring Identification on page 14. Under the MODIFY OPTIONS menu, highlight ALARM and press ENTER. Then highlight the gas combination required and press ENTER. Next highlight the gas and press ENTER. This menu gives you the choice of disabling alarms for the selected gas, or choosing the standard Low/High or the High/High-High alarms. For the LowHigh alarm selection, first enter a low limit. Enter the complete numeric value, including the decimal point. Once the last digit is set, press ENTER to save your selection. The instrument then proceeds to the second limit menu (High Limit in this example). After you enter the second limit, the instrument returns to the ALARM menu. For the High/High-High alarm selection, menu operation is the same, except that the menus use the applicable terms in place of the Low Limit and High Limit illustrated. ORBISPHERE Operator Manual

43 3626/36 Analyzer - Options Setup 37 of Alarm Output Test When you set each alarm limit in the menus, the associated instrument alarm relay provides a test contact at the Alarm Relay pins. The Alarm Limit menus provide test relay outputs at the Alarm Relay pins (see Table 1-6, Low/High Alarm Relay Responses, on page 23 and Table 1-7, High/High-High Alarm Relay Responses, on page 23). The test analog signal remains on the associated output pins until you press ESC to return to the main menu. Refer to Alarm Outputs on page 23, for further description and use of these diagnostic outputs. 3.9 Analog Outputs The instrument provides several analog output signals representing sample measurements. The ANALOG OUTPUT menus scale the gas concentration output signals between any two concentration levels, for use with external equipment such as recorders. Analog Outputs on page 20 describes the outputs in more detail. Connector and wiring identification for these outputs are in Wiring Identification on page 14. Highlight ANALOG OUTPUT and press ENTER. Then highlight the output required and press ENTER. For the User selection, you can choose between TEMP TC, TEMP O2, and external PRESSURE as the user defined output. For H2, He, and O2 selections, you must enter the analog low and high levels. First, enter the low level analog output value, including decimal point. Once the last digit is set, press ENTER to save your selection. The instrument then proceeds to the high level menu. Enter the high level, after which the instrument returns to the ANALOG OUTPUT menu Analog Output Test When you set each analog limit in the menus, the associated instrument analog output provides a test current (or voltage) at the recorder output Gas Concentration pins. For example, after you press ENTER to save the new levels, the instrument provides a 20 ma (or 5 V) test signal at the Gas Concentration pins of the Recorder connector. The test analog signal remains on the associated output pins until you press ESC to return to the main menu. Refer to Analog Outputs on page 20, for further description and use of these diagnostic outputs. Operator Manual ORBISPHERE

44 38 of 68 Options Setup /36 Analyzer 3.10 Serial Output The instrument serial output provides formatted text for an RS-232 compatible printer, monitor, or computer interface. When ENABLED, the output provides a running log of gas concentration, sample temperature measurement and pressure information. It also includes information on conditions that affect gas measurement, such as offsets. This output, also generates a report when you calibrate the sensor. The DIAGNOSTICS selection provides lines of hexadecimal codes indicating how your instrument is performing. In addition, when you return to Measurement mode the RS-232 output subsequently provides a running log of diagnostic results for every measurement cycle Continuous Purge Mode Under the MODIFY OPTIONS menu, highlight SERIAL OUTPUT and press ENTER. The RS-232 menu gives you a choice of DISABLED, ENABLED and DIAGNOSTICS. It may be useful, particularly when seeing a Prg message on your instrument LCD, to view the Purge voltage. Choose CONTINUOUS PURGE from the MODIFY OPTIONS menu. The H 2 sensor voltage (top line) and temperature details are displayed. The voltage should be in the range of 2.0V to 3.0V and preferably around 2.5V. The O 2 sensor current (bottom line) will vary with the membrane model selected. Press ESC to exit this option. Note: Pressing the UP ARROW key on the instrument, while this menu is displayed, will trigger a FILAMENT IGNITION with the details being displayed for about 15 seconds. The sensor is continually purged whenever you exit the measurement mode (unless the instrument is placed in standby mode, in which case the purge cycle is invoked every 10 minutes). ORBISPHERE Operator Manual

45 3626/36 Analyzer - Options Setup 39 of Rolling Average The rolling average feature causes the instrument to average measurements over successive measurement cycles. It suppresses sharp peaks and troughs, while retaining reasonably fast response to real concentration changes. Choose ROLLING AVERAGE from the MODIFY OPTIONS menu. Highlight the gas measurement you wish to specify and press ENTER. Select DISABLED if rolling averages are not required, or select the number of successive measurement cycles over which the average will be taken (3,5,7 or 9) Offset It may be advantageous to apply a specific offset value (negative or positive) to the displayed gas measurement. Choose OFFSET from the MODIFY OPTIONS menu to bring up the data entry screen. This menu gives you the choice of applying an offset to the H2, He or O2 measurement. Highlight the choice and press ENTER to set your offset. To set an offset, highlight ENABLED, and press ENTER to bring up the offset data entry screen. Enter the offset value, including sign and decimal point (a negative offset of 0.1 is illustrated). Once the last digit is set, press ENTER to save your selection and return to the OFFSET menu. The display, analog output, and RS-232 output of gas concentration will reflect this offset value. However, the RS-232 output also lists the offset value in a separate column, in case you want to calculate the true measured value. Operator Manual ORBISPHERE

46 40 of 68 Options Setup /36 Analyzer 3.14 Corrections Note: This option is reserved for qualified Hach Ultra Service Representatives only. As such, if you feel that corrections are required, please contact your local Hach Ultra Service Representative to perform this operation for you Hydrogen Correction The instrument can compensate O 2 measurements for the presence of high H 2 levels in samples (over 20% H 2 ). To use this option, choose CORRECTIONS from the MODIFY OPTIONS menu and then select H2->O2. This menu provides a choice of DISABLED, ENABLED and CALIBRATE. Choose ENABLED to apply the H 2 correction to O 2 measurements using previously stored correction parameters. To determine and apply a new correction, choose CALIBRATE from this menu. The next screen reminds you to expose the O 2 sensor to a sample containing pure H Humidity Correction The instrument will ask you to wait until the O 2 sensor current signal is stable and slightly negative (for a freshly installed sensor, which has not been conditioned to measure at low levels, this stabilization could take several hours). When stable, press ENTER to store this setting, and return to the MODIFY OPTIONS menu. Note: If the displayed current is positive, then no H 2 correction is required. In this instance, press ESC to disable the H 2 correction. In AUTO mode, a correction will be applied when measuring dissolved gas. The correction can be manually enabled for measurement in humid gas. ORBISPHERE Operator Manual

47 3626/36 Analyzer - Calibrations 41 of 68 4 Calibrations 4.1 Calibrate Menu Note: The flow chart illustrated is for the 3636 analyzer. The 3626 analyzer will have the same options, but without any references to oxygen calibrations. Fig 4-1: Instrument Calibration Menu Flow Diagram Operator Manual ORBISPHERE

48 42 of 68 Calibrations /36 Analyzer The instrument has been calibrated before shipment and should not require further calibration until the next maintenance service. The calibration menu is depicted in the flow chart shown in Fig 4-1 above, and allows you to calibrate the gas sensor(s), the internal barometric pressure sensor and the optional external pressure sensor. Note: When you select the Calibration menu, the instrument discontinues all measurement operations. Most applications will find it simplest to calibrate the O 2 sensor in air, and to calibrate the H 2 sensor only if necessary (for example, a membrane change or unrealistic measurement values). The external pressure sensor calibration is only necessary for volume fraction measurements in pressurized gas. All of the menus require user input of one form or another. This is carried out using the four function keys on the Instrument Panel (see Instrument Controls on page 27). You should ensure you are familiar with the use of these keys in entering and modifying numeric fields (see Entering Numerical Values on page 29), before accessing these menus. 4.2 Barometric Pressure Sensor Calibration You can verify or calibrate the internal barometric pressure sensor against your local atmospheric pressure. Select CALIBRATE from the main menu followed by BAROM. PRESSURE. 4.3 External Pressure Sensor Calibration The instrument first displays the current barometric pressure reading. Press ESC if this agrees with your known atmospheric pressure, or ENTER to modify and bring up the next screen. Enter the new value and press ENTER to calibrate. After a few seconds the instrument displays the message CALIBRATION Pb COMPLETE before returning to the BAROM. PRESSURE display. Press ESC to accept the value. The instrument can be fitted with an external pressure sensor, model 28117, capable of measuring up to 3.5 bar (50 psi). This pressure sensor is mounted on the model multi-parameter flow chamber, and interfaces with the instrument via a 4-pin LEMO connector section. An accurate pressure gauge is required to calibrate this sensor. To calibrate your external pressure sensor against a known pressure, select CALIBRATE from the main menu followed by EXTERN. PRESSURE. The instrument first displays the current external pressure sensor measurement. If you agree with this reading then press ESC. If you do not agree with this measurement, and you wish to re-calibrate, press ENTER to display the menu for selection of pressure measurement units. Choose the desired units to bring up the calibration Method menu. ORBISPHERE Operator Manual

49 3626/36 Analyzer - Calibrations 43 of 68 There are two methods of calibrating this sensor: ONE POINT permits you to calibrate at one pressure value TWO POINT requires that you calibrate against high and low pressure values (generally required only for high-pressure applications) The TWO POINT calibration method differs from ONE POINT in that it requires you to apply and enter a HIGH and LOW pressure. This is usually required for a more precise measurement. The TWO POINT calibration method also requires that you enter the absolute pressure (gauge plus atmospheric). 4.4 H 2 /He Sensor Calibration If your measurements do not match expected values, check the accuracy of the analyzer in pure H 2 and in pure He. If the value for the pure gas is between 95% and 105%, no recalibration is needed. Otherwise, calibrate the sensor using pure hydrogen, pure helium, and air. H 2 /He sensor calibration may be performed either in-line, with the sensor left in its mounting (such as sensor socket or flow chamber), or off-line with the sensor removed and using a separate flow chamber. To start calibration, highlight CALIBRATE from the main menu and press ENTER In Air Calibration Choosing ONE POINT allows you to enter the absolute (gauge plus atmospheric) pressure currently applied to the external pressure sensor. Press ENTER when the new value has been entered. The instrument then calibrates the sensor. After a few seconds the instrument displays the message CALIBRATION Pe COMPLETE before returning to the EXTERN. PRESSURE display. Press ESC to accept the value. For the H 2 /He sensor, you have a choice of IN AIR, IN H2 or IN He calibration routines. Select each of these routines in sequence to completely calibrate the H 2 /He sensor. Expose the H 2 /He sensor to air, and then select TC IN AIR from the calibration menu to start the process. After a few minutes, the instrument displays the message CALIBRATION AIR COMPLETE. Press ENTER to return to the calibration menu for the next selection. Note: if you press ESC during the calibration process, the calibration will abort. Operator Manual ORBISPHERE

50 44 of 68 Calibrations /36 Analyzer In Hydrogen Calibration In Helium Calibration Expose the H 2 /He sensor to pure hydrogen at atmospheric pressure, and then select TC IN H2 from the calibration menu. This menu provides a choice between PARTIAL PRESSURE and FRACTION measurement. Select the type of measurement you wish, and press ENTER to bring up the menu for choosing calibration units. Select the appropriate units from the list displayed. The available units depends on your choice of Partial Pressure or Fraction. Note: Fraction display units include the composite ppmvb:%vbar and ppmve:%vext units, which will switch from parts per million to percentage depending on the display resolution. The instrument corrects fraction measurements for pressure. The %Vbar choice uses the instrument's barometric pressure sensor. For %Vext it is necessary to have the model external pressure sensor connected and correctly calibrated. Note: Partial Pressure display units also include psia and Atm. Select your preferred calibration units and press ENTER. Enter the hydrogen concentration of the calibration gas, in percent (99.5% shown in this example). Once the last digit is set, press ENTER to start calibrating. After a few minutes, the instrument displays the message CALIBRATION H2 COMPLETE. Press ENTER to return to the preceding calibration menu for the next selection. Note: If you press ESC during the calibration process, the calibration will abort. Expose the H 2 /He sensor to pure helium at atmospheric pressure, and then select TC IN He from the calibration menu. Now proceed as in In Hydrogen Calibration above, to select between PARTIAL PRESSURE and FRACTION measurement. The menus for helium calibration are the same as for hydrogen, substituting He for H2 and helium for hydrogen where applicable. ORBISPHERE Operator Manual

51 3626/36 Analyzer - Calibrations 45 of O 2 Sensor Calibration The O 2 sensor can be accurately calibrated in air, or against a sample containing a known level of the gas. The O 2 sensor should be calibrated before it is used for the first time, or after a sensor service. Remember to wait at least 30 minutes after mounting a new membrane before re-calibrating the sensor. Verify that the barometric pressure sensor is functioning properly (and, if you are making Volume measurements that depend on an external pressure sensor, that the external pressure sensor is properly calibrated) before attempting the O 2 sensor calibration. Please also refer to the tables in Calibration Tables on page 47, as these tables are useful for verifying your results O 2 In Air Calibration In order to calibrate the sensor in air, you will need to extract it from its mounting or flow chamber, and wipe dry the sensor protection grille (if applicable). Calibration is best achieved using the storage cap that protected the sensor during shipment. Put several drops of tap water in the cap, shake out the excess, and then attach it to the sensor by means of its collar. It is best to leave the cap slightly loose, to avoid compressing the air inside. The cap and sensor should be about the same temperature. To calibrate in air, highlight O2 in Air from the calibration menu and press ENTER. The instrument displays the sensitivity of the sensor as a percentage of the sensitivity determined when calibration was last performed. If, for example, 95% OF LAST CALIBRATION is displayed (as shown left), then sensitivity has drifted downwards by 5% since calibration was last performed. The displayed percentage must be between 50% and 150% in order to calibrate. If this is the case, press ENTER to finish the calibration, and display the completion message. However, if you press ENTER when the displayed percentage is outside the permitted range, you will see the OUT OF BOUNDS message. If this occurs, the sensor will probably need to be serviced. In the Calibration flow chart, you will see the notes First calibration and After first calibration. The system considers a first calibration to be performed whenever a membrane is selected in the Membranes option menu. For a first calibration, instead of getting a message with a percentage of the last calibration (as above), you will see a 95% OF EXPECTED CURRENT message as the system compensates for the change in parameters. Pressing ENTER will then give you either a calibration COMPLETE or OUT OF BOUNDS message, as described above. Operator Manual ORBISPHERE

52 46 of 68 Calibrations /36 Analyzer O 2 Direct Calibration Use this calibration routine when calibrating the oxygen sensor against a sample with a known oxygen content (i.e. a span gas). To calibrate, choose O2 DIRECT from the Calibration menu to bring up the GAS CALIBRATION menu. You have a choice of FRACTION or PARTIAL PRESSURE calibration routines. Select the type of calibration to bring up the menu for calibration units. Highlight your preferred units and press ENTER. Note: If you choose FRACTION with %Vbar units, the exit port of the flow chamber or sensor mounting must be open to the atmosphere. Enter the oxygen content of the calibration sample (8.123% of oxygen in this example), and press ENTER to record this value. The next screen will relate this calibration to the previous one with a percentage of the LAST CALIBRATION, as described above in O 2 In Air Calibration. If the value is not within 50 to 150% of the previous calibration, the message CALIBRATION OUT OF BOUNDS prompts you to take corrective action ORBISPHERE Operator Manual

53 3626/36 Analyzer - Calibrations 47 of Calibration Tables Oxygen Concentrations in ppm (in air-saturated water) Table 4-1: Oxygen Concentrations - Table 1 of 4 Barometric Pressure [mbar] T [ C] T [ F] Operator Manual ORBISPHERE

54 48 of 68 Calibrations /36 Analyzer Table 4-2: Oxygen Concentrations - Table 2 of 4 Barometric Pressure [mbar] T [ C] T [ F] ORBISPHERE Operator Manual

55 3626/36 Analyzer - Calibrations 49 of 68 Table 4-3: Oxygen Concentrations - Table 3 of 4 Barometric Pressure [mbar] T [ C] T [ F] Operator Manual ORBISPHERE

56 50 of 68 Calibrations /36 Analyzer Table 4-4: Oxygen Concentrations - Table 4 of 4 Barometric Pressure [mbar] T [ C] T [ F] ORBISPHERE Operator Manual

57 3626/36 Analyzer - Accessories and Attachments 51 of 68 5 Accessories and Attachments Certain applications may require the use of one or more of the items described below. 5.1 Model Purge Backup Unit Since it is necessary to continuously purge the sensor to prevent the ingress of moisture, normally you would want to leave the instrument switched on at all times even when gas analysis is not required. If it is more practical to be able to switch off an analyzer for several days at a time (without removing the sensor), a purge backup unit is recommended. Install the model Purge Backup Unit directly between the 3626/36 instrument and the junction box. It is powered by internal batteries which recharge automatically when the instrument is switched on. When the instrument is switched off, the purge backup unit continues to leave the sensor's solenoid in the open position (enabling purge gas entry) for up to four days. Note: A green LED indicates the purge backup unit s rechargeable battery is adequately charged, and a red LED indicates the battery needs recharging. However, it is important to note that the LED only functions when the instrument is switched on. 5.2 Model External Pressure Sensor The 3626/36 instrument can be fitted with an external pressure sensor (model 28117) which is capable of measuring up to 3.5 bar (50 psi), This sensor should be mounted on a multi-parameter flow chamber (model 32002), and interfaces with the instrument via a 4-pin LEMO connector, situated at the rear of the instrument. Operator Manual ORBISPHERE

58 52 of 68 Accessories and Attachments /36 Analyzer ORBISPHERE Operator Manual

59 3626/36 Analyzer - Maintenance and Troubleshooting 53 of 68 6 Maintenance and Troubleshooting 6.1 General Maintenance While unauthorized opening of the instrument normally voids the Hach Ultra warranty, it is necessary to open the process instrument for output wiring connections. Fuse replacement and AC voltage changes can also be performed by the user. WARNING Disconnect power before opening the instrument. To open an instrument, remove the front panel key and place the instrument face down. Remove the four 3-mm Allen head screws on the rear, and carefully pull off the rear panel, taking care not to disconnect any wires Filament Current Adjustment During the lifetime of the two TC filaments, it may be necessary to adjust the current. This is done inside the junction box, but should only be attempted by qualified Hach Ultra Service personnel. Should you feel the current needs adjusting (e.g. the FILAMENT CURRENT DRIFT message appears on the instrument LCD), please contact your local Hach Ultra representative Internal Fuse Replacement The power supply is attached to the inside of the rear panel. At position F1 on the power supply is a black plastic fuse holder. Remove the fuse cover using a thin coin or a small flat-bladed screwdriver to push down and turn. The 230 VAC power supply uses a T 100 ma fuse. The 115 VAC power supply uses a T 250 ma fuse. The VDC power supply uses a T 1.25 A fuse AC Voltage Switch A rotary 115/230 VAC switch is located next to the fuse holder (see Internal Fuse Replacement above). You can change this with a turn from a small flat-bladed screwdriver. Check to see that the correct fuse for your voltage is installed before connecting the instrument to a power supply Analog Current/Voltage Output Jumper Settings The printed circuit board closest to the rear, number 1121, contains the jumpers for analog current/voltage output. To remove this board, remove the screws on either side that hold the board in place, and carefully lift it out. Oriented so the board's electronic connectors are down, locate positions J2, J4, J6 and J8 by looking for the red-colored jumpers in the center of the board. To convert the analog output from current to voltage, or from voltage to current, move the red jumpers in the positions as illustrated in Fig 6-1 for all four positions (J2, J4, J6 and J8). Operator Manual ORBISPHERE

60 54 of 68 Maintenance and Troubleshooting /36 Analyzer Fig 6-1: Jumper Pin Number Identification Replace the board by placing it back into position and gently pushing it a final 2 mm to make the electrical connection. Then reattach the two holding screws. Note: You can alternate between a Current and Voltage output simply by re-setting the appropriate jumpers as outlined above. However, If you need to change the Current output from 0-20 ma to 4-20 ma (or vice versa), contact your Hach Ultra Service Representative first Alarm and Analog Output Testing When connecting the alarm or recorder (analog) outputs to user-supplied equipment, it may be helpful to verify the connections using a test signal from the instrument. For this purpose, the instrument provides diagnostic signals for both the alarm output pins and the recorder current (or voltage) gas concentration output pins. When you set alarm and analog output limits using the MODIFY OPTIONS menus (see Alarm Outputs on page 36 and Analog Outputs on page 37), the instrument generates an associated alarm or analog output test signal at the pin connections. The alarm limit menu selections set the high and low alarm relays. The analog output menu selections apply a test current (or voltage) output at the recorder output gas concentration pins. The diagnostic outputs provided from the Modify Options menu procedures are: Alarm, Low Limit Alarm, High Limit M odify Options Selection Alarm, High-High Limit Analog, Low Level Analog, High Level Output Provided Closure (*) of Low Alarm relay, Low Alarm pin to Common Closure (*) of High Alarm relay, High Alarm pin to Common Closure (*) of both High Alarm relay and Low Alarm relay, High Alarm pin and Low Alarm pin to Common 4 ma (or 0 ma, or 0 Volts) applied to Gas concentration pins 20 ma (or 5 Volts) applied to Gas concentration pins * These alarm relay outputs are for Normally Open alarm relays, if the relays are set to Normally Closed, these relay outputs are the opposite, Opening instead of Closure. The test alarm relay closure remains on the alarm output pins until you return to the main menu (MEASURE, OPTIONS, CALIBRATE). ORBISPHERE Operator Manual

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