Hach 5500sc Maintenance And Troubleshooting Manual

DOC023.98.80475

5500sc

Ammonia/Monochloramine

03/2019, Edition 6

Maintenance and Troubleshooting

Maintenance et dépannage

Mantenimiento y solución de problemas

Техническое обслуживание и устранение неполадок

English..............................................................................................................................3

Français......................................................................................................................... 21

Español.......................................................................................................................... 39

Русский..........................................................................................................................57

2

Table of contents

General information on page 3 Clean the sample holder on page 10

Maintenance schedule on page 4 Clean the grab sample funnel on page 13

View maintenance information on page 6 Replace the analyzer bottles on page 14

Put the analyzer in shutdown mode on page 7 Replace the fuses on page 14

Put the analyzer back into operation on page 7 Prepare for storage or shipping on page 15

Clean the instrument on page 7 Update the firmware on page 16

Clean spills on page 7 Troubleshooting and diagnostics on page 16

Sample line and valve cleanup on page 7 Replacement parts and accessories on page 19

Clean the stir bar and sample cells on page 9

General information

In no event will the manufacturer be liable for direct, indirect, special, incidental or consequential

damages resulting from any defect or omission in this manual. The manufacturer reserves the right to

make changes in this manual and the products it describes at any time, without notice or obligation.

Revised editions are found on the manufacturer’s website.

Safety information

N O T I C E

The manufacturer is not responsible for any damages due to misapplication or misuse of this product including,

without limitation, direct, incidental and consequential damages, and disclaims such damages to the full extent

permitted under applicable law. The user is solely responsible to identify critical application risks and install

appropriate mechanisms to protect processes during a possible equipment malfunction.

Please read this entire manual before unpacking, setting up or operating this equipment. Pay

attention to all danger and caution statements. Failure to do so could result in serious injury to the

operator or damage to the equipment.

Make sure that the protection provided by this equipment is not impaired. Do not use or install this

equipment in any manner other than that specified in this manual.

Use of hazard information

D A N G E R

Indicates a potentially or imminently hazardous situation which, if not avoided, will result in death or serious injury.

W A R N I N G

Indicates a potentially or imminently hazardous situation which, if not avoided, could result in death or serious

injury.

C A U T I O N

Indicates a potentially hazardous situation that may result in minor or moderate injury.

N O T I C E

Indicates a situation which, if not avoided, may cause damage to the instrument. Information that requires special

emphasis.

Precautionary labels

Read all labels and tags attached to the instrument. Personal injury or damage to the instrument

could occur if not observed. A symbol on the instrument is referenced in the manual with a

precautionary statement.

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3

This is the safety alert symbol. Obey all safety messages that follow this symbol to avoid potential

injury. If on the instrument, refer to the instruction manual for operation or safety information.

This symbol indicates the need for protective eye wear.

This symbol 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.

This symbol indicates that a risk of electrical shock and/or electrocution exists.

This symbol indicates that the marked item can be hot and should not be touched without care.

This symbol indicates that a risk of fire is present.

This symbol identifies the presence of a strong corrosive or other hazardous substance and a risk of

chemical harm. 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 domestic or public

disposal systems. Return old or end-of-life equipment to the manufacturer for disposal at no charge to

the user.

Maintenance

C A U T I O N

Multiple hazards. Only qualified personnel must conduct the tasks described in this section of the

document.

Maintenance schedule

Table 1 shows the recommended schedule of maintenance tasks. Refer to Figure 1 to identify the

maintenance items. Facility requirements and operating conditions may increase the frequency of

some tasks.

Table 1 Maintenance schedule

Task 1 month 3 months 6 months 1 year

Clean the instrument on page 7 X

Clean the stir bar and sample cells

on page 9

X or as needed

Clean the sample holder on page 10 X or as needed

Replace the analyzer bottles on page 14 X

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Table 1 Maintenance schedule (continued)

Task 1 month 3 months 6 months 1 year

Replace the standards (Replace the

analyzer bottles on page 14)

X

1

Replace the cleaning solution (Replace the

analyzer bottles on page 14)

X

2

Replace the internal filter X or as needed

Clean the screen in the 40-mesh external

filter (Y-strainer)

X or as needed

Clean the screen of the optional 100-µm

external filter

X or as needed

Replace the fan filter

3

X or as

needed

Replace the reagent air filter X

Replace the tubing

3

X

Replace the stir bar X

Replace the check valves on the

colorimeters (if applicable)

4

X

Replace the sample pump

3

X

1

With one calibration per week (default)

2

For one cleaning per 6 hours (default)

3

Refer to the documentation supplied with the replacement part.

4

Not applicable to newer instruments.

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Figure 1 Maintenance items overview

1 Grab sample input funnel 5 Internal sample line filter(s)

2 Sample cells 6 Fan

3 Stir bar (one for each sample cell) 7 Sample holder

4 Reagent air filter 8 Sample pump

View maintenance information

Use the service menu to view or reset the service history for the instrument parts.

1. Push diag.

2. Select SERVICE.

3. Select an option.

Option Description

SERVICE PART Shows a list of parts and the date of the last service, the date of the next service and

the number of days before the next service is due. Restart the counter for the next

service.

PART INFORMATION Shows the date when each part was put into service and the total time that each part

has been in use. Some parts include additional information.

UPCOMING SERVICE Shows the name of the service part, the date of the last service, the date of the next

service and the number of days before the next service is due.

SERVICE HISTORY Shows the type, date and time of the last service.

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Put the analyzer in shutdown mode

Put the analyzer in shutdown mode before maintenance tasks are started. When the analyzer is

stopped, the two colorimeter cells are flushed in sequence, then the sample flow, sample pump and

air pump are set to off. The controller menus stay active.

1. Push menu.

2. Select STOP ANALYZER, then YES to confirm.

Note: If START ANALYZER is shown, the analyzer is already in shutdown mode.

3. Wait for the status to show 100% completion.

4. Close the shut-off valves in the sample lines, then complete the maintenance task(s).

Put the analyzer back into operation

After maintenance tasks are complete, start the analyzer as follows:

1. Make sure that all the tubing is connected and that the lower door is closed and latched.

2. Open the shut-off valves in the sample lines.

3. If power was removed, start power again.

4. Push menu.

5. Select START ANALYZER.

The analyzer starts normal operation.

Clean the instrument

N O T I C E

Never use cleaning agents such as turpentine, acetone or similar products to clean the instrument including the

display and accessories.

Clean the exterior of the instrument with a moist cloth and a mild soap solution.

Clean spills

C A U T I O N

Chemical exposure hazard. Dispose of chemicals and wastes in accordance with local, regional and

national regulations.

1. Obey all facility safety protocols for spill control.

2. Discard the waste according to applicable regulations.

Sample line and valve cleanup

C A U T I O N

Chemical exposure hazard. Obey laboratory safety procedures and wear all of the personal protective

equipment appropriate to the chemicals that are handled. Refer to the current safety data sheets

(MSDS/SDS) for safety protocols.

English 7

New tubing, valves and other sample conditioning equipment can be contaminated with oils or dust.

These may contribute to slightly high readings until they are cleaned.

1. Flush the sample line with sample for one to two hours.

Clean the sample components

C A U T I O N

Chemical exposure hazard. Obey laboratory safety procedures and wear all of the personal protective

equipment appropriate to the chemicals that are handled. Refer to the current safety data sheets

(MSDS/SDS) for safety protocols.

Put the analyzer in shutdown mode. Refer to Put the analyzer in shutdown mode on page 7.

Clean the sample cells, the stir bar and the sample holder as necessary. Refer to Maintenance

schedule on page 4. Refer to the illustrated steps in Clean the stir bar and sample cells on page 9

and to Clean the sample holder on page 10.

8 English

Clean the stir bar and sample cells

Items to collect: Cotton swabs, cleaning solution, T10 Torx driver and protective gloves.

English 9

Clean the sample holder

Items to collect: Soft cloth, T20 and T25 Torx drivers.

1. Put the analyzer in shutdown mode. Refer to Put the analyzer in shutdown mode on page 7.

2. Select DIAG/PERFORMANCE TEST>SAMPLE HOLDER DRAIN.

3. Set the time to 50 seconds to drain the sample holder.

4. Do the illustrated steps that follow.

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English 11

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Clean the grab sample funnel

Clean the grab sample funnel before and after each use. Refer to to the illustrated steps that follow.

English 13

Replace the analyzer bottles

C A U T I O N

Chemical exposure hazard. Obey laboratory safety procedures and wear all of the personal protective

equipment appropriate to the chemicals that are handled. Refer to the current safety data sheets

(MSDS/SDS) for safety protocols.

C A U T I O N

Chemical exposure hazard. Dispose of chemicals and wastes in accordance with local, regional and

national regulations.

Replace the reagent(s), standard(s) or cleaning solution before the level in the analyzer bottle(s) is

less than 10%.

1. Put the analyzer in shutdown mode. Refer to Put the analyzer in shutdown mode on page 7.

2. When the status shows 100% completion, open the lower door.

3. Remove the cap from the reagent(s), standard(s) or cleaning solution, then remove the bottle(s)

from the analyzer.

4. Install the new analyzer bottle(s) and close the lower door. Refer to the operations manual.

5. Push menu and go to REAGENTS/STANDARDS.

6. Select RESET REAGENT LEVELS or RESET STANDARD LEVELS or RESET CLEANING

SOLUTION LEVELS.

7. For reagents, select PRIME REAGENTS and confirm.

8. When the reagent prime is complete, start the analyzer. Refer to Put the analyzer back into

operation on page 7.

Replace the fuses

D A N G E R

Electrocution hazard. Always remove power to the instrument before making electrical connections.

D A N G E R

Fire hazard. Use the same type and current rating to replace fuses.

Refer to Figure 2 and Figure 3 to replace the fuses.

Fuse specifications:

Relay fuse: T 5.0 A, 250 V

Output power fuse: AC: T 5.0 A, 250 VAC; DC: T 1.6 A, 250 VAC

Input power fuse: AC: T 1.6 A, 250 VAC; DC: T 6.3 A, 250 VAC

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English

Figure 2 Access cover removal

Figure 3 Replace the fuses (continued)

1 Relay fuse (4x) 2 Output power fuse (2x) 3 Input power fuse (2x)

Prepare for storage or shipping

C A U T I O N

Chemical exposure hazard. Obey laboratory safety procedures and wear all of the personal protective

equipment appropriate to the chemicals that are handled. Refer to the current safety data sheets

(MSDS/SDS) for safety protocols.

Remove all the fluids and the power from the analyzer for long-term storage.

1. Push menu and then go to SETUP SYSTEM>DECOMISSIONING.

2. Select YES to stop the analyzer and start the decommissioning cycle.

3. Remove the reagents, the standards and the cleaning solution bottles for disposal in accordance

with local, state, and federal regulations.

4. Flush and then fill the bottles with deionized water.

5. Install the bottles.

6. Make sure that all of the liquid is drained from the colorimeter, sample holder and tubing.

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15

7. Set the power switch to off.

8. Clean the bottom enclosure.

Update the firmware

Use an SD card with an upgrade file to update the firmware for the analyzer or network card. The

upgrade menu is shown only when the SD card contains an upgrade file.

1. Install the SD card into the SD card slot.

2. Select SD CARD SETUP from the MAIN MENU.

Note: The SD CARD SETUP option shows only when an SD card is installed.

3. Select UPGRADE SOFTWARE and confirm. Select the device and upgrade version, if applicable.

Note: UPGRADE SOFTWARE is only shown when the software version number on the SD card is higher than

the one installed on the analyzer.

4. When the upgrade is complete, the display shows TRANSFER COMPLETE. Remove the SD

card.

Note: More steps may be necessary to complete the firmware update. Refer to the instructions supplied in the

software package.

5. Restart the instrument for the upgrade to take effect.

Troubleshooting and diagnostics

Diagnostic indicators

The display background and the status indicator light will change to red when an error occurs and to

yellow when a warning occurs.

• Error—red display background and status indicator light. A significant problem occurred that

affects the instrument operation. The current measurement stops and the analyzer goes into

shutdown mode.

• Warning—yellow display background and status indicator light. An event occurred that can cause

a future problem. The analyzer continues to operate.

• Reminders—wrench symbol shows on the display and yellow status indicator light. The time for a

maintenance task has passed.

1. Push diag to access the DIAG/TEST menu.

2. Select an option.

Option Description

DIAGNOSTICS Shows the errors and warnings that currently are on the instrument or on the installed

modules. The analyzer is in operation with the active warnings or reminders until they

are acknowledged or reset. Then, the display background will return to white.

PROGNOSYS Shows the variables which trigger the service indicator and the measurement health

indicator on the display.

CURRENT STATUS Shows the current instrument statuses that follow: OPERATION—Current

measurement mode. SAMPLE CHANNEL—Current sample channel. STEP STATUS

—Current step in the measurement cycle. STEP TIME—Step time remaining.

MINUTES LEFT—Minutes left in current step. COMPLETION—% completed of the

measurement cycle.

ANALYZER HELP Shows all possible errors, warnings and reminders with troubleshooting hints.

PERFORM TEST Examines individual parts of the analyzer. Refer to Start an analyzer test on page 18

for more details about the individual test options.

OUTPUTS Shows the current status of the 4–20 mA and relay outputs with the options to

examine, hold and simulate the outputs. Refer to Output options on page 17 for more

information.

16 English

Option Description

MODBUS STATS Shows the status of the Modbus ports: sensor, controller, network and service. Shows

the number of good and bad transmissions.

SERVICE Shows the service parts information and the history. SERVICE PART—shows the last

and the next service date and the remaining days. PART INFORMATION—Shows the

replaced part and the current run time. UPCOMING SERVICE—Shows the next part

which needs to be replaced. SERVICE HISTORY—Shows the date and time of the

replaced parts.

SYSTEM DATA Shows the system information. TEMPERATURE—Shows the measured temperature

of the A/D device in Celsius (C). POWER SOURCE FREQUENCY—Shows the line

power frequency (Hz). 12 V VOLTAGE—Shows the measured power supply voltage

(V DC). 3.3 V VOLTAGE—Shows the measured regulated 3.3 V supply (V DC). 12 V

CURRENT—Shows the measured 12 V power supply current (Amps).

I2C DATA Shows the display information (I

2

C) and the version number.

OVERFEED RESET Resets the overfeed timer.

Output options

The output menu shows the current status of the 4–20 mA and relay outputs with the options to

examine, hold and simulate the outputs.

1. Push diag and select OUTPUTS.

2. Select an option.

Option Description

TEST 4–20 mA Examines the 4–20 mA outputs from 1–4.

TEST RELAY Examines the relays A–D. Sets the relays to on or off.

HOLD OUTPUTS Sets the value that the controller sends to an external system for a defined period of

time. After this time period, the instrument reports again real time values. ACTIVATION

—Launches or releases. SET OUTMODE—Hold Outputs (default) or Transfer Outputs.

SET CHANNELS—All (default) or analyzer.

OUTPUT STATUS Shows the current status outputs 1–4.

SIMULATE

MEASURE

After the sim value is entered, the controller outputs this value as if it was the value sent

from the sensor. The simulation stops after the user exits the screen. SELECT SOURCE

—Select the module. The footer shows the current selected source. SET PARAMETER

—Sets the parameter for the source measurement. The footer shows the current

selected source. SET SIM VALUE—Enter the sim value. The footer shows the entered

value.

Diagnostic messages

The analyzer has two different types of diagnostic messages:

• Warnings that tell the user about potential problems.

• Errors that tell the user to immediately make a repair or to set the instrument power to off and then

on again.

1. When an indicator is shown, push diag, select DIAGNOSTICS, then push enter.

2. Select the error message. The user can acknowledge the error or go to the help screen.

3. To acknowledge the error:

1. Push diag, then select DIAGNOSTICS.

2. Select the error, then push enter.

3. Select ACKNOWLEDGE, then push enter.

4. To go to the help screen:

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1. Push diag, then select DIAGNOSTICS.

2. Select the error, then push enter.

3. Select VIEW HELP, then push enter.

Get troubleshooting help

The help screen gives a definition of error, warning or reminder messages and can give associated

tasks to correct the problem.

1. Push diag, then select ANALYZER HELP.

2. Select ERRORS, WARNINGS or REMINDERS.

3. Select one of the topics from the help menu.

Start an analyzer test

The user can complete tests to check the analyzer operation.

1. Push diag, then select PERFORM TEST.

2. Select an option.

Option Description

REAGENT DELIVERY Set each reagent valve to on for a time delivery (50 milliseconds to 65 seconds) or

for a volume delivery (20 to 9,999 µL). Set the AIR PUMP option to 4 psi to supply

the air pressure for the reagent delivery.

SAMPLE DELIVERY Set each sample valve to on for a sample delivery of 1 to 9999 seconds. The

sample pump is set to on during this function.

CAL SOL. DELIVERY Set the cal std valve to on for a calibration solution delivery into the colorimeter

cell. Set the duration on from 1 to 9999 seconds. Set the AIR PUMP option to

4 psi to supply the air pressure for the standard solution delivery.

CLEANING DELIVERY Set the cleaning valve to on for cleaning solution delivery into the colorimeter cell.

Set the duration to on from 1 to 9999 seconds. Set the AIR PUMP option to 4 psi

to supply the air pressure for the cleaning solution delivery.

SAMPLE HOLDER

INPUT

Set the sample holder input valve to on for sample delivery into the sample holder.

Set the duration to on from 1 to 9999 seconds.

SAMPLE HOLDER

DRAIN

Set the sample holder drain valve to on to drain the sample holder. Set the

duration to on from 1 to 9999 seconds.

MIXER Set to on for one cell mixing. Set the time from 1 to 9999 seconds.

STIR BAR The colorimeter senses if the stir bar is installed and is found by the analyzer.

COLORIMETER

HEATER

Set the colorimeter heater settings from 20 to 50 °C (68 to 122 °F). The measured

value is shown.

STATUS LED Examine the front panel status LED indicator. The test cycles continuously until

interrupted: off, red, green, yellow.

A2D Set the colorimeter LED intensity to examine the cell transmittance for the A2D

output.

AIR PUMP Change and control the air pressure. SET SETPOINT—Range: 1–9.99 psi. LOW

and HIGH DEADBAND—Range: 0–1 psi. SET LOW and HIGH VALUE—Range:

5–99.99 psi. START—Start the air pump with the entered settings.

SELECT SCRIPT Toggle between normal instrument script and test script.

SET CHANNELS For use by manufacturer technical support only.

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Replacement parts and accessories

W A R N I N G

Personal injury hazard. Use of non-approved parts may cause personal injury, damage to the

instrument or equipment malfunction. The replacement parts in this section are approved by the

manufacturer.

Note: Product and Article numbers may vary for some selling regions. Contact the appropriate distributor or refer to

the company website for contact information.

Replacement parts

Description Item no.

Air pump filter 2718

Capillary assembly 6786900

Capillary, black subassembly 9568601

Capillary, red subassembly 9568602

Colorimeter assembly, ammonia/monochloramine 9568500

Colorimeter check valve 9560800

Grab sample out cover 9566400

Fan filter plug 6789300

Fan filter replacement kit 6789100

Funnel 9566100

Funnel cover 6773500

Fuse, 1.6 A, 250 V, 5 x 20 mm 5208300

Fuse, 5 A, 250 V, slow-blow, 5 x 20 mm 4693800

Kit, Installation, single channel 9565501

Kit, Installation, two channel 9565502

Kit, Maintenance, ammonia/monochloramine, single channel 9560501

Kit, Maintenance, ammonia/monochloramine, two channel 9560502

Power cord, North American 9179700

Pressure regulator 4557500

Reagent bottle tray 9640400

Sample pump assembly 9713300

Stir bar 9563900

Y strainer 9560400

Internal sample filter, 40 µm 9566000

External sample filter, 100 µm 9623400RF

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Accessories

Description Quantity Item no.

Ammonia/monochloramine colorimeter cleaning kit, includes:

Cleaning solution with dropper, 15 mL (2x), cotton swab

1 25224000

Ammonia/monochloramine reagent kit, includes:

Reagent 1, 2 and 3, standard 1 and 2, cleaning solution

1 25233000

Reagent 1 ammonia/monochloramine, 5500sc 1 L 25234000

Reagent 2 ammonia/monochloramine, 5500sc 1 L 25235000

Reagent 3 ammonia/monochloramine, 5500sc 1 L 25236000

Standard 1 ammonia/monochloramine, 5500sc 2 L 25237000

Standard 2 ammonia/monochloramine, 5500sc 2 L 25238000

Cleaning solution ammonia/monochloramine, 5500sc 2 L 25239000

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