ServiceXX L Tailored Services Easy Clean 400 Training.
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Transcript of ServiceXX L Tailored Services Easy Clean 400 Training.
ServiceXXLTailored Services
Easy Clean 400 Training
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Welcome
Your Trainer is Raymond Augustine- Service Technician & Training Specialist
- Background In Electronics
- Housings, Sensors, Transmitters & Cleaning Systems Specialist
Contact Information- Mettler-Toledo Ingold, Technical Services 1-888-687-7687
- Web site for technical information & manuals mtpro.com
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Agenda
System Overview
Installation
Configuration
Programming
Calibration
Maintenance
Troubleshooting
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Objectives
To learn the function and importance of the Easy Clean 400
To learn why is it important to regularly clean and calibrate pH electrodes
To learn about the methods of control that can be interfaced with the Easy Clean 400
To learn about the valves and safety features of the Easy Clean 400 system
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The EasyClean 400
Introducing the EasyClean 400- Total flexibility to fit your application
Offers multiple control possibilities and can be programmed extensively
Version for applications in explosion hazardous areas is available
Connection to a supervisory process control system can easily be realized in a conventional way or via Profibus PA
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Benefits of EasyClean
Automatically cleaning and calibrating the electrode reduces maintenance effort
Proper and periodic cleaning substantially increases electrode lifetime
Cleaning and calibration of electrodes means continuous accurate measurement
Regular cleaning ensures less downtime
Maintenance Contamination Accuracy Downtime
Reduced costs for maintenance
Reduced replacement costs
Higher yield due to better accuracy
Better production efficiency
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EasyClean 400 System Layout
The complete EasyClean 400 system
consists of:
Transmitter M 700
Module EC 700 (pH measuring and EC 400 control)
InTrac housing (with pneumatic check- back position indicators)
pH electrode and cable
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Components of the EC 400(x)
Just like the M 700, the EC 400(x) is available in either Stainless Steel or
MT blue powder coat
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Components of the EC 400(x)
Filter, water trap
Water pressuregauge
Add valve
Purge air
Water valve
Air valve
Piezo valve
Air pressure-regulator
Air pressure-gauge
PLC
TerminalsFree place for add valveo
pti
on
al
Double valve technology
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Leak sensor
Water pressure manometer asabsorber and switch with warning
Double secured pressure monitor
(Piezo valve in sequence & as switch)
Monitor of pH and temperature recognize false media / buffer (Done by the M700 EC400 module)
Fully encapsulated electronics
Components of the EC 400(x)
All tubing is color coded and sized for Easy setup
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RS 485
PS 6.8V
Emergency stop (optional)
M 700
Media Island
EC400
EC700
InTrac7XX
Components of the EC 400(x)
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Components of the EC 400(x)
Buffer and cleaning agent container (3,5 l / 0.92 gal)
Self-sustaining assembly with integrated pump
Media adaptor for connecting the container island with the EasyClean 400
Connection for external cleaning agent, for example
The media adaptor offers up to three ports
Classic media island for two buffer and one cleaning agent container
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NO moving mechanical parts
NO wear out
All wetted parts are chemical resistant
NO stored energy according to
ATEX 94/9/EG
Floating body for level indication
Suction pipe
Expansion pump
Connection to the media adapter
All materials are made of PEEK or PVDF !
Components of the EC 400(x)
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Components of the EC 400(x)
How the Expansion Pump works
Air/Liquid is drawn out of a main cylinder. This causes a
flexible membrane tube in
the center to expand. During this expansion,
the media is drawn from the bottom of the
membrane tube. Check valves
maintain proper direction of flow.
Air/Liquid is forced into main
cylinder. This causes a flexible membrane tube in the center to
constrict. During this constriction,
the media is pushed out of the
top of the membrane tube.
Check valves maintain proper direction of flow.
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RS 485
PS 6.8V
Emergency stop (optional)
M 700
Media Island
EC400
EC700
InTrac7XX
Components of the EC 400(x)
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Components of the EC 400(x)
The M 700 EasyClean 400 Module
Integrates in to the M 700. Communication with the EasyClean 400 via RS 485 interface
Has an integrated pH measurement Module
Provides the power supply for EasyClean 400
Module design allows for easy interfacewith M 700 and PROFIBUS© technology
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pH probe interfaces with the EC 400(x) module like a standard 2700 pH Module
EC 400(x) communication is established through these two lines
Power for the EC 400(x) is supplied through these lines
Components of the EC 400(x)
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Interface and control of the EC 400(x) is done through the M 700 and the pH EC400 Module
Components of the EC 400(x)
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Components of the EC 400(x)
RS 485
PS 6.8V
Emergency stop (optional)
M 700
Media Island
EC400
EC700
InTrac7XX
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Any InTrac housing can be used as long as it is pneumatically controlled and has pneumatic indicators
Components of the EC 400(x)
Pneumatic Insert/retract ports
Pneumatic Position Indicators
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Components of the EC 400(x)
Tip: Orient this module opposite the pneumatic connections as shown in insert
Housing adapter distributes buffer, cleaning agent, control air and air for indicators
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Components of the EC 400(x)
The EC 400(x) comes with a housing conversion kit
This kit is used to convert the proper housing so it can be used with the EC 400(x) system
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Components of the EC 400(x)
RS 485
PS 6.8V
Emergency stop (optional)
M 700
Media Island
EC400
EC700
InTrac7XX
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Components of the EC 400(x)
Buffer Island End
• Unique shape for error free connection
Buffer Island End
• Unique shape for error free connection
Tubing Connection End
• Unique size and colors for easy connection
Tubing Connection End
• Unique size and colors for easy connection
InTrac Interface End
• Unique shape for error free connection
InTrac Interface End
• Unique shape for error free connection
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System Integration Architecture
The EC 400(x) is designed to
integrate into existing systems
in one of two ways
PLC/DCS Control
Digi Com (Profibus)
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Digital Communications
System Integration Architecture
PFB PA
Complete system control via M 700 or PROFIBUS communications
RS 485
Profibus PA
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PLC/DCS Control
System Integration Architecture
Complete remote system control via digital inputs and outputs
RS 485
4.. 20 mAPFB PA
Digital Inputs
Digital Outputs
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Safety & Diagnostics Features
Media monitoring- Actual media in the flushing chamber can be checked related to process value
or temperature
Level monitoring- Buffers and cleaning agent will be monitored with the level indicator which is a
part of the pump
Sensor detection- The insertion of the sensor in the housing can be detected (cable removed
from the sensor). Function is only available with electrodes with temperature probe
Air and water pressure monitoring- Supplying air and water is monitored via pressure switches
Flooding monitoring- A leak sensor, mounted on the bottom of the EasyClean 400, detects a
floating of the box.
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Questions
What is the function of the Easy Clean 400?
Why is it important to regularly clean and calibrate pH electrodes?
What will happen if one of the valves within the Easy Clean (gating fluid) fails?
Can the buffer island run properly with only two bottles attached?
How does the Easy Clean communicate with the M700 transmitter?
What methods of control can be interfaced with the Easy Clean 400?
Can the umbilical cord for this unit be incorrectly installed?
Are their any moving mechanical serviceable parts on the buffer island?
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Agenda
System Overview
Installation
Configuration
Programming
Calibration
Maintenance
Troubleshooting
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Objectives
To understand the requirements for air pressure/ water pressure and filtration for the system
To understand the 4-20milliamp outputs and the difference between the various grounding points
To understand how the Easy Clean 400 always knows the position of the housing and probe
To learn about the various diagrams and wiring color codes
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Assembling the EC 400(x)
Getting StartedTools you will need:
Screw Drivers:• 1 small flat head• 1 regular Philips
Adjustable Wrench(Medium)
Utility Knife
EasyClean 400(x) BoxesQty=2
Quick Start Guide
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Assembling the EC 400(x)
Remove all the parts from the boxes and layout on the floor how you would like to mount the unit.
Check with the minimum requirements to make sure your layout meets those requirements.
Make sure all cables and connections will be easily accessible after mounting.
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Water- To hook up a water supply both a ¼” threaded female
connection and a ¾” male connection is provided. Choose the fitting that fits your needs and install.
- The EasyClean 400(X) is operated with a water pressure of 2 ... 6 bars.
- The water supply lines shall not contain a check valve.
- Water: filtered 100 μm, temperature 5 ... 65°C.
Air- To hook up an air supply a ¼” female connection is
provided. Choose a fitting that fits your needs and install.
- The EasyClean 400(X) is operated with an air pressure of 4 ... 10 bars.
- Adjust the pressure regulator so that the internal operating pressure is kept within 4 and 7 bars. The air must be condensate- and oil-free. Maximum air consumption during probe activation is 300 L/min.
- Air quality to ISO 8573-1 Quality class 5.3.3
Assembling the EC 400(x)
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Assembling the EC 400(x)
Start by installing the tubing side of the umbilical
cable in the EC 400(x)
1. Unscrew the retaining nut from the cable and place the end into the EC 400(x)
2. Unscrew the retaining nut from the cable and place the end into the EC 400(x)
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Assembling the EC 400(x)
Insert all the push connect tubing into the appropriate size fitting.
Note: Along with the tubing being sized for the correct fitting they are also color coded (i.e. red with red, green with green).
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Assembling the EC 400(x)
Place the blue tube into the threaded “L” fitting and tighten using an adjustable wrench.
Do not over tighten!
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Assembling the EC 400(x)
When installing the Probe Position Cable, make note of color and terminal from the callout label mounted on top of the terminal block. Then locate the number on the terminal below the callout label and install. Tighten terminals with a small flathead screwdriver.
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Assembling the EC 400(x)
Unscrew the cable gland and remove the yellow plug. Place the cap on the cable and feed the cable into the EC 400(x) case. Using an adjustable wrench, tighten down the gland nut until it is tight around the cable casing.
Anytime a cable must be inserted through a gland this procedure must be used.
Using the color coding and terminal assignment on the callout label, install each wire as indicated.
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Assembling the EC 400(x)
Install the Buffer Island electrical connection. This connecter is keyed so lightly push the connector on to island connector and twist slowly until the connector falls into its seat.
Twist and hand tighten the locking ring.
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Assembling the EC 400(x)
The connector for the Buffer Island on the umbilical cord is keyed for easy assembly.
Simply line-up the flat on the connector with the flat on the island connection.
Push to seat the connector and tighten the screws with a Philips screwdriver.
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Assembling the EC 400(x)
The bottle connection on the Buffer Island comes with blind plates. Remove the plate and place the bottles on to the connectors. Tighten screws with a Philips screw driver.
NOTE: If a bottle is not connected you must have the blind plate installed!
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Assembling the EC 400(x)
Standard connections should look like this. 1. Media connection to rinsing chamber
2. Rinsing chamber outlet
3. Feedback of “SERVICE” position
4. Feedback of “MEASURE” position
5. Control air for “SERVICE” position and supply for “SERVICE” position feedback unit
6. Control air for “MEASURE” position and supply for “MEASURE” position feedback unit
7. Holding bracket for strain relief of media connection
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Assembling the EC 400(x)
Attach the Housing Adapter connection to the housing.
Use a Philips screwdriver to tighten it down.
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Clear – Measure (Terminal 2)Red – Ref. Elec. (Terminal 8)Green – RTD (Terminal 13)White – RTD (Terminal 14) Green &Yellow – Shield (Terminal 15)Blue – Sol. Ground (Terminal 12)
PT100 - Remove Jumper Term. (18 & 19) connect Gray wire.
Assembling the EC 400(x)
Wire the EC400(x) Module with a VP cable according the diagram.
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Wire the BASE Module of the M 700 as follows:- Power Lead 1* – Terminal 18
- Power Lead 2* – Terminal 19
- Earth Ground – Terminal 17
- Output 1 (+) – Terminal 7
- Output 1 (-) – Terminal 8
- Output 2 (+) – Terminal 9 “if required”
- Output 2 (-) – Terminal 10 “if required”
* There is no polarity for power on the M 700
1 1 2 2
Assembling the EC 400(x)
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Questions
Why is it very difficult to incorrectly tube the Easy Clean 400?
What are the requirements for air pressure/water pressure for the system?
What grade of filter is required for the water supply to the Easy Clean 400?
What distance/height limits must be respected when mounting the Easy Clean 400 system?
Why is it important not to connect a digital ground to Earth ground?
How many 4-20milliamp outputs does the M700 transmitter have?
How does the Easy Clean 400 know if the housing/ probe is in the correct
position?
What is the most important rule when making screw and bolt connections?
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Agenda
System Overview
Installation
Configuration
Programming
Calibration
Maintenance
Troubleshooting
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Objectives
To gain a working knowledge of the “Sensoface” feature
To be able to set Calibration and cleaning cycles for weekly or daily intervals
To understand the importance of configuring the voltage limits for the system when using a DCS to remotely control the Easy clean 400
To gain an understanding of the “sealing water” feature, and why is it important
To understand the “start up “ function feature and why it is important
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EC400 /M 700
Now that we have our EasyClean 400(x) assembled we need to set up our M 700 for use with the EC 700(x) module and the pH probe we have selected.
This is done by configuring the system and each “Module” of the M 700.
1. SYSTEM Control
2. FRONT Module
3. BASE Module
4. EC 700 Module
a. pH 2700 module
b. EasyClean 400
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SYSTEM Module
1. Call up parameter setting. Select Administrator level. Enter passcode (1989).
2. Select System control using arrow keys, confirm with Enter.
3. Select Time/date using arrow keys, confirm with Enter.
4. Select date format, and adjust time and date.
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FRONT Module
1. Press Menu key to select menu. Select parameter setting using arrow keys, confirm with Enter. Select: “Administrator level”: Passcode 1989
2. Select “M 700 FRONT”
3. Select “Measurement display”
4. Set the number of primary values (large display) to be displayed
5. Select process variable(s) to be displayed and confirm with Enter. Pressing the Meas key returns to measurement.
Notice the Module Icons for each variable!
Make sure you are displaying the variable that you really want.
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BASE Module
1. Call up parameter setting. Enter passcode.
2. Select M 700 BASE
3. Select “Output Current I1”
4. Select your measured variable
5. Select Curve, e.g. “Linear”: The measured variable is represented by a linear output current curve. The desired range of the measured variable is specified by the values for “Start” and “End”.
6. Enter your “Start” 4(0)mA value
7. Enter your “End” 20mA value
8. Press Meas to return to main display.
If you’re using a second output, follow the same steps but when
choosing the Output Current choose I2 instead of I1.
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pH 2700 / EC400 Module
Setup the EC 400 Module
To begin, press the Meas button on the front of the M 700.
Choose par from the menu and then Module pH 2700 / EC 400.
This is where we will set-up the type of sensor used and its limits.
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pH 2700 / EC400 Module
Sensor Data
Sensor Type:- The default for this is standard. All
MT sensors use the Standard setting.
Temperature Detection:- Default setting is a PT1000. Choose
the RTD that fits your sensor.
Sensoface:- Default setting is on. Sensoface is the
M 700 live diagnostics feature.
Slope, Zero Point, and Sensocheck Ref El are setting for use with diagnostics.
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Calimatic buffer-For automatic calibration, you must define the buffer set you want to use.
-For calibration, you must then use buffer solutions from this buffer set in any order.
-The selected buffer set with the nominal values of the individual buffer solutions is displayed in gray. The “Calimatic buffer” menu shows all buffer sets available.
pH 2700 / EC400 Module
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Sensoface provides information on the sensor condition (evaluating the sensor data). Great deviations are signaled.
The following parameters are monitored:- Slope
- Zero
- Reference impedance (for ISFET sensors)
- Glass impedance (pH electrodes)
- Response time
- Calcheck
The use of smiley faces give the user the ability to gauge the state of the sensor at a glance.
Sensoface
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Parameter Setting – Sensoface
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Now we need to set up the EC400 program.
Press the Return softkey twice this will bring you out to the Parameter setting menu. Scroll down the EC 400 folder. This is just below the Module M 700 EC 400.
This will bring up the Module EC 400 Menu
pH 2700 / EC400 Module
Setting up the EC400 Module
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EC 400 Control - This is a software switch
for the EC 400. It consists of 2 states.
Off: The M 700 will default to a standard pH 2700 Module.
On: The EC 400 will take over all calibration functions.
pH 2700 / EC400 Module
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Cal Preset Values Menu- In this menu we can set up which module to
monitor, whether or not we want to use predefined values or Calimatic for our buffers, and what calibration mode we will be using.
- Measuring Module If you have more than one pH module,
select which module will be monitored by the EC 400.
- Cal Buffer 1 and 2 Specify Calimatic for auto buffer
recognition or choose the value of the buffer you want for buffer bottle one or two (respectively).
- Cal Mode Adjustment: Values determined by a
calibration are used immediately. Check: Values that are determined by
calibration are logged but do not take over.
pH 2700 / EC400 Module
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Time Control
Fixed Interval:- Fixed interval timing control allows
you to set up three independent time programs. Any of the 7 programs can be chosen.
From the EC 400 menu, choose the time control fixed interval and then choose the fixed interval folder to setup each of the three programs
Specify times (000.0 h ... xxx.x h)(Please note: 000.1 h = 6 min)
pH 2700 / EC400 Module
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Week Program
Allows selection of up to ten programs per day and you can choose between “Individual start” or “Interval” (the program is executed within a start and an end time at a specified interval).
From the Timing interval option choose Week Program. In the week folder you find each day of the week. After a day is chosen you are taken to the view screen. From this screen you can see each program and the interval they will run. You can also edit, copy, or create program from this screen
pH 2700 / EC400 Module
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Installation Menu
Measuring procedure - two different measuring procedures available
Continuous measurement- Electrode is normally in measurement position
- Electrode will be only retracted for cleaning, calibrating or servicing
- Used for continuous processes
Short time measurement- Electrode is normally in service position
- Electrode will be only inserted to the process for a specified measurement time
- Can be used for continuous process with abrasive media or batch processes
NOTE:
Program flows for continuous and short time measurement are different and will be loaded, depending on the chosen measuring procedure.
pH 2700 / EC400 Module
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External DCS Menu- If Control via a DCS or PLC is planned, use
this menu to setup how the DCS inputs and outputs will functions.
- Control On: Enables control through the DCS
inputs Off: Disables control through the DCS
inputs
- Inputs DCS, M/S, and A/M Active 10…30V: Contact will activate
between 10 and 30 Volts. Active < 2V: Contact will activate if a
voltage drops below 2 volts.
- Output DCS (34) Measure: Contact will activate when the
housing is in the Measurement position. Alarm: Contact will activate when the EC
is in an alarm state.
- Outputs DCS (31…34) Specify desired contact type. Either N/O
or N/C
pH 2700 / EC400 Module
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Sensor Detection
Sensor detection “On” prevents accidental probe movement when the electrode has been removed. This is done by checking whether the temperature probe integrated in the sensor is connected.
Note: The default for this is “Off”
pH 2700 / EC400 Module
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Probe Menu- From this menu you can select the style of
housing, set the amount of time to set for movement, whether or not to use the sealing water function and set the wear counter.
- Probe Type Select the retractable housing to be used.
Here, the max. move time is automatically adjusted (depending on model).
- Max. Move Time A default value will be set for predefined
housings. If required you can alter this value to fit your application.
- Sealing Water When set to on, sealing water is switched
on shortly before the probe movement is started to keep the rinsing chamber free from medium.
- Max Wear Counter Permits the specification of the max
number of movement cycles to help aid in maintenance of the housing.
pH 2700 / EC400 Module
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Rinse Water Menu- In this menu we can specify whether
or not to monitor the rinse water. You can choose to monitor either process value or temperature.
-Monitoring Off: No monitoring Process Value: Monitor the pH
value of the rinse water Temperature: Monitor a defined
temperature of the rinse water
-Setpoint Set this to the value that will be
monitored
-Adm. Deviation This is the acceptable deviation
to the setpoint. This is a plus or minus value.
pH 2700 / EC400 Module
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Media Adapter Menu- In this menu we can specify the way we
want the media port to be used and if we want monitoring of the port.
Port I, II, and III
- Metering Pump: Sets the port to be used as a buffer pump
- Cleaning Agent: Sets the pump to be used for metering a cleaning agent
- Off: Turns off the pump Medium
- Used for entering a name for the port. This value will be displayed during all functions of the port.
Displaced Volume
- Choice of 50, 75, or 100mL. This is housing dependent and is defaulted to the 77Xe series.
pH 2700 / EC400 Module
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Residual Volume- This feature allows for a custom
alarm setting indicating the level of unused buffers and/or cleaning solution
Monitoring- Off: No monitoring
- Process Value: Monitor the pH value of the bottle media
- Temperature: Monitor a defined temperature of the rinse water
Setpoint- Set this to the value that will be
monitored
Adm. Deviation- This is the acceptable deviation
to the setpoint. This is a plus or minus value.
pH 2700 / EC400 Module
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Start-Up-When you are sure to have set all
parameters, select “Yes” to confirm. The pumps will perform the number of stroke movements required for filling the media tubes completely. The necessary rinsing cycles are automatically started and the EC400 will return to the state it was at prior to the Start-Up.
pH 2700 / EC400 Module
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Questions
Why is it important to configure the time and date on the M700 transmitter?
What does the “Sensoface” icon tell you at a glance?
What will the M700 system default to if “system control” is switched off?
Can you set the Easy Clean system to perform a Calibration and cleaning at
weekly or daily intervals?
Why is it important to configure the voltage limits for the system when using a DCS to remotely control the Easy clean 400?
What is the function of the “sealing water” feature, and why is it important?
What is the function of the “start up “feature and why is it important?
How does the M700 transmitter know when the incorrect buffers are being used for calibration?
What is the default code for the administrator?
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Agenda
System Overview
Installation
Configuration
Programming
Calibration
Maintenance
Troubleshooting
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Objectives
To learn about the binary bit sequence used to initiate the various easy clean programs
To learn about the important “park” feature
To gain an understanding of the different program sequences
To gain an understanding of how to edit the systems programs
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Programming
Control Programs of EasyClean 700(X)
Six programs and one service program can be called up. Five program flows are preset. Two further programs can be entered by the user (User 1, User 2).The programs are called up- for manual operation via the M 700(X)
- Remote via DCS or switch with passive input Bin 1…3 (24 V must be supplied externally, see specs)
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Programming
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The Park Program- The park program includes the programming step “Wait position”. When the
program is started via the DCS inputs BIN 1 ... BIN 3 on the EC 400, the program will be executed until the “Wait position” is reached. There it stops until the signal status at the DCS inputs changes.
- The program is started by a short signal at the DCS inputs: Wait position is skipped.
Programming
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Program sequences – 5 programs predefined, 2 User specific 2-point calibration
- Executes a two-point calibration
1-point calibration- Executes a one-point calibration
Cleaning- Rinse with water and clean with cleaning agent
Parking- Cleaned electrode will be stored in the flushing chamber (can only be activated via
DCS)
Service- Housing will be retracted to service position
User defined 1- Can be defined to the customer’s need
User defined 2- Can be defined to the customer’s need
Programming
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Cleaning
Two- point calibration
One- point calibration
User program (1)
User program (2)
Park
Service program
The EasyClean 400(x) uses seven programs. Of these programs, four are pre-installed.
Three of the programs are defaulted to a two-point calibration. These are meant to be defined by the user.
Note: Even though five programs are pre-installed, they are also capable of being modified to meet the customers needs.
01: probe in SERVICE
02: Cleaning agent 0003 s
03: Rinse on 0010 s
04: Rinse off 0002 s
05: Buffer 1 0000 s
06: Cal Buffer 1
07: Rinse on 0010 s
08: Rinse off 0002 s
09: Buffer 2 0000 s
10: Cal Buffer 2
11: Rinse on 0010 s
12: Rinse off 0002 s
13: Probe in MEASURE
14: Latency 0010 s
15: Program End
Programming
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Program EC 400…
Rin
se O
ff
Rin
se o
n
Rin
se o
n
RetractC
lean
Pum
p 1
Wai
t tim
e
Pum
p 2
Cal
Buf
f. 2
Insert Measure
Cal 2 point Default
All program sequences are alterable.
This allows for total customization of the 5 installed default programs and the 2 user programs to meet your, the customer, needs.
Rin
se o
n
Cal
Buf
f. 1
Rin
se O
ff
Rin
se O
ff
Programming
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Adjusting the programs to the customers need
32 program steps possible
Max. time per step: 9999s
Change order of the program flow by inserting new steps Valve function
Pump function
Programming
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Editing a Program- Every program can be edited. To
begin, choose the program you would like to edit and press the enter key to bring up the options menu. Scroll to desired option and press enter.
Enter program name- A new program name can be entered
using the arrow keys.
Programming
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Edit program step- Select the program step you want to edit
using the arrow keys. Press enter: Now you can choose between “Edit, Insert, Delete”.
Edit: Allows selecting a function Insert: Inserts an empty step above
the selected program steps and then allows selecting a function – by “editing” empty step –
Delete: The program step is deleted.
Programming
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Activate monitoring-With several functions, you can monitor
the media used (e.g. cleaning agent, buffers, rinsing water) in the calibration chamber. (“Monitoring: On” must have been enabled in the Installation menu.) A minimum response time > 2 s is required. The respective program step is then marked with “Chk”.
-Note: In any case, it is necessary that you select the monitoring function for the respective medium in the “Installation” menu and specify valid tolerance limits for temperature or process value; otherwise the respective line is not displayed.
Programming
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Questions
How many different programs can be initiated via the Binary bit inputs?
What will happen if a program is initiated via the Binary inputs with a
continuous signal?
Which of the programs can be altered by the customer?
When adding a step to an existing program such as “purge air on” what is the next mandatory step that must be added to avoid an error?
What does the term “exposure time” refer to?
The active monitoring function can be activated when editing a program line, but where must it have been enabled first?
How many steps are allowed for any given program?
What does the Latency feature refer to and why is it important?
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Agenda
System Overview
Installation
Configuration
Programming
Calibration
Maintenance
Troubleshooting
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Objectives
To understand the inner workings of the combination pH electrode
To understand the importance of regular calibration
To understand the effect of temperature on pH measurement
To learn about the various types of calibration offered by the Easy Clean 400 system
To understand the various types of calibration available to the user
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Calibration
pH is a measure of the hydrogen ion activity of a solution resulting in a mV signal
Acids = Positive mV Signal
Base = Negative mV Signal
7.0 pH = 0 mV Output
Sensor Output Changes with Temperature- 0o C ~ 54.2 mV/pH
- 25oC ~ 59.2 mV/pH
- 50oC ~ 64.1 mV/pH
Sensor Output is Corrected to 25oC with Automatic Temperature Compensation
-500
-400
-300
-200
-100
0
100
200
300
400
500
0 2 4 6 8 10 12 14
pHm
V
0C 25C 50C
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Why do we measure and control pH?- to produce products with defined properties
- to produce products with less costs
- to avoid damage to people, materials and environment
- to fulfil regulatory requirements
- Proper control will optimize yield
Opt
imal
pH
con
trol
Yieldkg/batch
pH
Calibration
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Why Calibration is Important
Every Electrode is different
Electrodes “live” and age in process or storage
Parameters change after cleaning
Aging accelerates if stored dry
-450
-350
-250
-150
-50
50
150
250
350
450
0 7 14
Ideal
85% slope
0.5pH offset
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pH VALUE is measured by POTENTIOMETRY
The measuring chain consists of a:- pH (also called glass) electrode
- reference electrode
The difference between the potentials of the pH and reference electrodes is a function of the solution being measured.
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pH is a Potentiometric Measurement
The Measuring System consists of a pH Measuring Electrode and Reference Electrode
The Potential Difference Between the Two Electrodes is a Function of the pH Value of the Measured Solution
The Solution Must Be Conductive and is Part of the Electrical Circuit
pH Measuring Electrode Reference Electrode
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pH Sensor Components
pH Measuring Electrode- Purpose is to develop a millivolt
potential directly proportional to the free hydrogen ion concentration in an aqueous solution
Reference Cell- Purpose is to maintain a constant
reference potential regardless of ph change or other ionic activity in the solution
Reference Cell Liquid Junction- Purpose is to maintain electrical
contact between the reference electrode and the measuring electrode by way of the solution
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How the pH Sensitive Glass Works
Positive charged free hydrogen ions (H+) develop positive mV Potential relative to inner buffer- Acidic solutions
Fewer hydrogen ions relative to inner buffer produce a negative mV potential- Alkaline solutions
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Temperature Compensation
Corrects for slope change with temperature
Performed automatically by the transmitter
-500
-400
-300
-200
-100
0
100
200
300
400
500
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
pH
E (
mV
)
25 C
77 C
)7(303.2
pHnF
RTEE O
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M 700 Calibration
Parameters by Calibration- Zero Point
pH Value exhibits a millivolt output of zero millivolts. The zero millivolt reading will change with age and wear.
- Temperature: Temperature is a critical value for pH since the pH value is
dependent on temperature. Most probes today have an integrated temperature probe.
- Slope: The voltage change per pH unit. The theoretical pH slope is
-59.2mV/pH.
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Calibration
Calibration Methods- One-point calibration
The electrode is calibrated with one buffer solution only. Here, only the electrode zero point is detected and taken into account by the M 700 after an adjustment. One-point calibration is appropriate and permissible whenever the measured values lie near the electrode zero point so that slope changes do not have much of an impact.
- Two-point calibration The electrode is calibrated with two buffer solutions. In that case, zero point and
slope of the electrode can be detected and taken into account by the M 700 after an adjustment. Two-point calibration is required if:- the electrode has been replaced- the measured pH values cover a wide range,- there is great difference between the measured pH value and the electrode
zero,- the pH measurement must be very accurate,- the electrode is exposed to extreme wear.
- Three-point calibration (only for manual calibration) The electrode is calibrated with three buffer solutions. Zero and slope are
calculated using a line of best fit according to DIN 19268.
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Calibration
Sensor Replacement- When an electrode is replaced, a calibration must be done on the probe
initially.- All data of the electrode is input into the Statistics menu in the Diagnostics
section of the M 700.- Here is where zero, slope, glass and reference impedance, and response time
of last three calibrations will be stored in reference to the first calibration.- This will enable data trends for drift and aging of the electrode.
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pH Module EC700
Calibration
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Calibration
You have 6 options for calibration. This allows for maximum accuracy and calibrations that will be relative to the process- EC 400 - Calibration with the EC700 module
- Calimatic: Automatic Cal - Cal with auto buffer recognition
- Manual: Entry of Buffers - Cal with manual buffer values
- Product Calibration - Cal in-situ
- Data Entry - Cal using sensor data
- ORP Calibration - Cal for ORP Measurement
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Calibration
Select Calibration Method and Probe goes into service mode
Start the calibration of the probe
Use “End Service” to move probe Back into process at position it started
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Calibration
Manual Calibration- For a manual calibration to be
performed, the electrode must be withdrawn from the process.
- Once the housing is moved into the service mode, the calibration menu is activated.
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Calibration
Manual calibration is performed with one or two buffer solutions.
The analyzer automatically detects the nominal buffer value on the basis of the electrode potential and the measured temperature.
Any sequence of buffer solutions is possible, but they must belong to the buffer set defined during parameter setting
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Calibration
If only doing one point calibration, then press “End” .
For two point calibration, rinse probe then press “Start”
Once a calibration has taken place you have the option to end and disregard the calibration data or to accept it and make an adjustment to the calibration data.
Press adjust for the calibration to be stored into memory
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Questions
How many options does the Easy Clean 400/ M700 have for calibration?
When would it be most important to do a two point calibration?
What is the electrode measuring when it takes a pH reading?
How does temperature effect pH?
What ideally forms on the pH glass of an electrode during measurement?
Is it possible to trend your calibration data with the M700 transmitter?
What is the term “in situ” imply?
What is the default code for calibration?
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Agenda
System Overview
Installation
Configuration
Programming
Calibration
Maintenance
Troubleshooting
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Objectives
To learn about the serviceable parts of the Easy clean400 system and the interval at which they should be changed
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Maintenance
Replacing seals in contact with the process medium- All seals that come in contact with the process medium should be replaced at least
every six months for reason of safety.
- With aggressive media the seals may need to be changed at correspondingly shorter intervals.
- Medium–wetted seals must be examined at least monthly, as well as during normal maintenance procedures to check for dirt or damage.
- Frequent insertion and retraction motion of the immersion tube can also have an influence on the necessary maintenance intervals
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Maintenance
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pH Module EC700
Maintenance
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MC 700 Maintenance
Start probe maintenance- Here you can select a preset
program (Cleaning, Cal 2point, Cal1point, etc.) or one of the 2 user-specific programs. Select using arrow keys confirm with enter.
Probe maintenance- With the EC 400 “SERVICE”
program, the probe is moved into SERVICE position. The individual program steps are indicated in the display. After having terminated the servicing work, press the “End Service” softkey to move the probe back to “Measuring” position (PROCESS).
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Maintenance
Reset wear counter - The wear counter indicates the
number of probe movements.
Manual control (requires access code*)- Select function using arrow keys.
Symbol flashes, activate with enter. “ON” appears below the icon. Terminate function with enter. (“ON” disappears again.)
* The access code is specified in the “Parameter setting / EC 400 / Installation” menu.
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Maintenance
It is recommended that a service visit be scheduled once a year. This check-up will ensure that the Easy Clean 400 is maintained properly. Site visits will include inspection and maintenance of O rings, seals, pumps, filters, hosing and armature. These visits will also provide an opportunity for additional training as required.
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Questions
Why is it important to replace the orings in a retractable housing?
What is the “wear counter” and why is it important?
How often should you inspect the orings in a retractable housing for abnormalities?
What is the default code for the maintenance/ manual control menus?
How often should a Mettler Toledo service Technician be scheduled for preventative maintenance?
What position should the probe housing be in before starting any maintenance and why is that important?
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Agenda
System Overview
Installation
Configuration
Programming
Calibration
Maintenance
Troubleshooting
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Objectives
To get an overview of the powerful troubleshooting tools in line with the Easy Clean 400
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Diagnostics
Troubleshooting
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Sensor Monitor- The Sensor Monitor function
shows the millivolt value directly measured by the sensor. Also displayed is the glass and reference impedance along with the RTD resistance and temperature value.
- All are very important functions for diagnostics and validation!
Troubleshooting
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EC 400 status-The media / ports at the media adapter. The texts for the media are entered by the user during the installation (here, for example “Buffer 7.00”)
Troubleshooting
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Sensor Network Diagram- The Sensor Network Diagram is a
great tool for visualizing, in one graphic, the over all state of the loop. Because the measured values are continuously monitored during the measurement process, you can quickly determine where a possible problem might be and affect quicker troubleshooting techniques.
- If a tolerance limit has been exceeded, the respective parameter is flashing.
- Values in gray: Monitoring is switched off.
Troubleshooting
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Troubleshooting Matrices
Extensive troubleshoot guide for the EC 400 and the M 700 are included in their respective manuals.
EasyClean 400 Troubleshooting Matrix M 700 Troubleshooting Matrix
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Questions
Why is the sensor monitoring screen excellent for validation of the electrode?
Where do you initiate the self check function for the Easy Clean 400?
What does it mean (in the network diagram window) when the lines are touching the innermost circle?
What is your instructor’s name?
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