CAL-CLEAN AUTOMATED ph MEASUREMENT SYSTEM

Manual No. Cal-Clean Revision 3-1099

CAL-CLEAN™ AUTOMATED

pH MEASUREMENT SYSTEM

(uses Model P63B pH Analyzer)

T A B L E O F C O N T E N T S

P A R T O N E - I N T R O D U C T I O N

SECTION 1 GENERAL INFORMATION

1.1 Description ...5-6 1.2 Operating Precautions ...6-7

SECTION 2 SPECIFICATIONS

2.1 Model RP6300A Auto-positioner ... 8

2.2 Optional pH Electrode ... 8

2.3 Model RP6300C Control Box ...8-9 2.4 Model P63B pH Analyzer ... 9

P A R T T W O - I N S T A L L A T I O N

SECTION 2 MOUNTING RP6300A AUTO-POSITIONER 2.1 In-line Applications: 1-1/2 inch NPT Process Connection... 11

1-1/4 inch BSP Process Connection ... 12

1-1/2 inch Sanitary Tee Process Connection... 13

2 inch Sanitary Tee Process Connection... 13

2.2 Immersion Mounting (requires GLI immersible accessory RP6300M3G5000-101): Disassembling Immersible Accessory...14-15 Installing Auto-positioner ...15-16 Anchoring Immersible Accessory... 16

SECTION 3 PLUMBING FOR CLEANING SOLUTIONS/BUFFERS 3.1 Cleaning Solution and Buffer Supply Lines... 17

3.2 Auto-positioner Solution Line ...17-18 3.3 Auto-positioner Drain Line... 18

SECTION 4 CONNECTING PRESSURIZED INSTRUMENT AIR 4.1 Air Supply Line ... 19

4.2 Air Insert Line ... 19

4.3 Air Retract Line ... 19

SECTION 5 INSTALLING/REMOVING ELECTRODE FROM

T A B L E O F C O N T E N T S ( C o n t i n u e d )

SECTION 6 WIRING SYSTEM WITH INTEGRAL MOUNT ANALYZER

6.1 pH Electrode...22-24

6.2 Electrode Position Indication Sensors... 25

6.3 Line Power ... 25

6.4 Analog Outputs (optional -- using control box terminals) ... 26

6.5 Remote Start Connections (optional -- using control box terminals) ... 26

SECTION 7 WIRING SYSTEM WITH REMOTE MOUNT ANALYZER 7.1 pH Electrode...27-28 7.2 Electrode Position Indication Sensors... 28

7.3 P63B pH Analyzer-to-RP6300C Control Box Connections ...28-30 7.4 Line Power ... 31

7.5 Remote Start Connections (optional -- using control box terminals) ... 31

P A R T T H R E E - O P E R A T I O N

SECTION 2 SETTING P63B pH ANALYZER FOR AUTOMATIC WASH/CAL OPERATION... 33

P A R T F O U R - S E R V I C E A N D M A I N T E N A N C E

SECTION 2 LUBRICATING AUTO-POSITIONER SHAFT... 34

SECTION 3 REPLACING AUTO-POSITIONER O-RINGS ... 35

SECTION 4 REPLACING CONTROL BOX PUMP TUBING ...35-36 SECTION 5 REPLACING CONTROL BOX MANIFOLD SOLENOID...36-37 SECTION 6 TROUBLESHOOTING ...38-39 SECTION 7 CUSTOMER ASSISTANCE ... 40

P A R T F I V E - S P A R E P A R T S A N D A C C E S S O R I E S

T A B L E O F C O N T E N T S ( c o n t i n u e d )

ILLUSTRATIONS

Figure 2-1 Model RP6300C Control Box Mounting Details ... 10

Figure 2-2 Mounting 1-1/2 inch NPT Process Connection Style Auto-positioner into Pipe Tee/Fitting ... 11

Figure 2-3 Mounting 1-1/4 inch BSP Process Connection Style Auto-positioner into Vessel Wall ... 12

Figure 2-4 Mounting 1-1/4 inch BSP Process Connection Style Auto-positioner into Pipeline ... 12

Figure 2-5 Mounting 1-1/2 inch Sanitary Tee Process Connection Style Auto-positioner into Pipeline ... 13

Figure 2-6 Mounting 2 inch Sanitary Tee Process Connection Style Auto-positioner into Pipeline ... 13

Figure 2-7 Immersion Mounting 1-1/2 inch NPT Process Connection Style Auto-positioner ... 14

Figure 2-8 Auto-positioner Cleaning Ports and External Temperature Sensor Port ... 18

Figure 2-9 Electrode Installation Details ... 21

Figure 2-10 Cable Details of Electrode With Built-in Temperature Sensor... 22

Figure 2-11 Cable Details of Electrode Without Built-in Temperature Sensor ... 23

Figure 2-12 Cal-Clean™ System with Integral Mount Analyzer -- Wiring Arrangement ... 24

Figure 2-13 Cal-Clean™ System with Remote Mount Analyzer -- Wiring Arrangement ... 29

Figure 4-1 Control Box Manifold Solenoid Replacement Details... 37

Figure 5-1 Auto-positioner Exploded View of Parts... 42

TABLES

Table A Troubleshooting Common Problems ... 38-39

CAL-CLEAN™ SYSTEM WARRANTY/REPLACEMENT PLAN

GLI International, Inc. warrants the primary elements of the Cal-Clean™ System to be free from defects in material or workmanship for a period of:

■ One year (12 months) for Model RP6300C Control Box. ■ One year (12 months) for Model RP6300A Auto-positioner. ■ Two years (24 months) for Model P63B pH Analyzer.

■ 90 days for Model RP6300G2130 pH electrode with temperature sensor. ■ One year (12 months) for GLI Immersible Accessory RP6300G5000-101.

This period starts from the date of shipment from our facility. A warranty claim will not be honored if defects are not reported within the warranty period, or if GLI International determines that defects or damages are due to normal wear, misapplication, lack of maintenance, abuse, improper installation, alteration or abnormal conditions. GLI International’s obligation under this warranty shall be limited to, at its option, replacement or repair of this product. The product must be returned to GLI Interna-tional, freight prepaid, for examination. The product must be thoroughly cleaned and any process chemicals removed before it will be accepted for replacement or repair. GLI International’s liability shall not exceed the cost of the product. Under no circumstances will GLI International be liable for any incidental or consequential damages, whether to person or property. GLI International will not be liable for any other loss, damage or expense of any kind, including loss of profits, resulting from the installation, use, or inability to use this product.

PART ONE - INTRODUCTION SECTION 1 - GENERAL INFORMATION

P A R T O N E - I N T R O D U C T I O N

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1.1 Description

System Elements The Cal-Clean™ System, and its full-featured Model P63B

pH analyzer, is a fully-automated, highly reliable pH measurement system that substantially reduces overall maintenance costs. This unique system can regularly and automatically clean and calibrate the pH electrode (impor-tant maintenance tasks) without user intervention. The system is designed for applications in which the process flow cannot be stopped but frequent cleaning and calibra-tion is required. The Cal-Clean™ system consists of three primary components:

„ Model RP6300C Control Box -- This prewired and plumbed component is controlled by the Model P63B pH analyzer. The control box operates the auto-positioner to automatically insert and retract the pH electrode, and automatically dispenses up to five cleaning, rinse, and buffer solutions to the electrode.

„ Model RP6300A Auto-positioner -- This component, controlled by the Model RP6300C control box, is in-stalled into the process line or vessel wall. (The 1-1/2 inch NPT process connection style auto-postioner can be immersion mounted in a vessel or pond using GLI’s immersible accessory RP6300M3G5000-101.) Pres-surized air actuates the auto-positioner to insert and retract the pH electrode. Two electrode position indi-cation sensors on the positioner verify when the electrode is fully inserted or fully retracted. When fully retracted, the auto-positioner isolates the electrode from the process. The integral solution chamber of the positioner holds a small volume of solution, immersing the electrode for cleaning and calibration.

„ Model P63B pH Analyzer -- This component can be integrally mounted into the RP6300C control box door or separately mounted. The analyzer controls the en-tire Cal-Clean™ System. It must be configured for automatic wash/cal operation. For details, see Oper-ating Instruction Manual No. P63.

PART ONE - INTRODUCTION SECTION 1 - GENERAL INFORMATION

Versatile Scheduling

1.2 Operating Precautions

The analyzer enables independent scheduling for cleaning and calibration events. Each scheduled event can contain from a few to up to 15 functional steps. Each step can last from 1 to 999 seconds, enabling cleaning and calibration events to be easily configured in hundreds of ways to suit specific application needs. See Operating Instruction Man-ual No. P63 for details on scheduling.

WARNING:

UNUSUAL SYSTEM OPERATING CONDITIONS SUCH AS EXCESSIVE CYCLE TIME, POWER SURGES, ETC. MAY CAUSE THE MANIFOLD ASSEMBLY ON THE BOTTOM OF THE RP6300C CONTROL BOX TO BECOME HOT.

1. The combination pH electrode used in the

auto-positioner is glass which can easily break. Do not sub-ject it to impact or other mechanical abuse.

WARNING:

A BROKEN GLASS ELECTRODE CAN CAUSE SERIOUS CUTS IF NOT HANDLED CAREFULLY.

2. The optional combination pH electrode supplied with the auto-positioner can withstand typical steam sterili-zation CIP cleaning, or the electrode can be cleaned when it is fully retracted from the process.

3. Before placing the electrode into operation, remove the

protective plastic cap. Store this cap for future use. NOTE: If electrode is to be out of solution for more

than a day or two, put a few drops of 3M KCl solution in the cap and replace it on the elec-trode. If KCl solution is unavailable, use dilute pH 4 buffer, or as a last choice, distilled water. This keeps the pH sensitive glass and refer-ence junction of the electrode moist and avoids slow response when the electrode is put back into operation.

PART ONE - INTRODUCTION SECTION 1 - GENERAL INFORMATION

WARNING:

BEFORE REPLACING AN ELECTRODE, ALWAYS DE-PRESSURIZE THE PROCESS LINE. DO NOT ATTEMPT TO REMOVE THE ELECTRODE FROM THE AUTO-POSITIONER WHILE THE AUTO-POSITIONER IS INSTALLED IN A PRESSURIZED LINE. WHEN THE ELECTRODE IS RETRACTED, THE SOLUTION CHAMBER IN THE POSITIONER IS NORMALLY SEALED. HOWEVER, IF THE FRONT ELECTRODE SEAL BREAKS WHILE REMOVING THE ELECTRODE, PRESSURIZED SOLUTION CAN FLOW PASSED IT AND OUT OF THE BACK OF THE POSITIONER.

PART ONE - INTRODUCTION SECTION 2 - SPECIFICATIONS

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2.3 Model RP6300C Control Box

Wetted Materials ... 316 stainless steel, and Viton O-rings

Non-wetted Materials... Acetal electrode holder, stainless steel body, ano-dized aluminum air control valves, and Buna-N seals

Temperature Range ... 14 to 212°F (-10 to +100°C) Process Press. Range ... 0-100 psi (0-6.8 bar)

Solution Chamber:

Pressure Range ... 0-30 psi (0-2 bar) Inlet/Outlet Ports ... 1/8 inch female NPT

Air Pressure Control:

Pressure Range ... 15-50 psi (1-3.4 bar) or one-half process pressure Insert/Retract Fittings .. 1/8 inch female NPT w/ adj. air pressure valves

Position Indication

Sensors... Two normally “off” Hall-effect sensors; open collector output; sinks 20 mA at 24 VDC maximum; 5-24 VDC operating voltage; -40 to 125°C (-40 to 257°F) oper-ating temperature

Maximum Process

Flow Rate... 10 ft. (3m) per second

Positioner-to-Analyzer Distance ... 100 ft. (30 m) max. for combination pH electrode with electrode cable capacitance of less than 30 pF per foot (includes positioner-to-control box and control box-to-analyzer distances)

Optional Immersion Accessory:

Wetted Materials ... PVC, 316 stainless steel, and Viton O-rings Operating Temp.

Range... 32-140°F (0-60°C) Installed Depth ... 0-6 ft. (0-2 m)

Wetted Materials ... Glass pH electrode with PTFE junction

Measuring Range ... 0-14 pH

Temperature Range:

Normal Operation... 14 to 212°F (-10 to +100°C)

Steam Sterilization ... 266°F (130°C) maximum for 30 minutes

Temp. Compensation ... 14 to 230°F (-10 to 110°C), Pt 1000 RTD (DIN 385) Electrode Cable... Integral, 10 ft. (3m), with stripped and tinned wires

Ambient Temp. Range... 14 to 140°F (-10 to 60°C); 0-100% relative humidity, non-condensing

Power Requirements ... Std: 105-127 VAC, 50/60 Hz. single fused Opt: 207-250 VAC, 50/60 Hz. single or dual fused

PART ONE - INTRODUCTION SECTION 2 - SPECIFICATIONS

2.4 Model P63B pH Analyzer

Plumbing Connections: Type of Fitting Wetted Mat’l Max. Pressure Manifold Solution

Inlets (five)... 1/8” male NPT 316 SS or PVDF 30 psi (2.0 bar) Pump Solution

Outlet... 1/8” female NPT 316 SS 20 psi (1.4 bar) Air Retract Outlet

(to positioner)... 1/8” female NPT Ni-plated brass 50 psi (3.4 bar) Air Insert Outlet

(to positioner)... 1/8” female NPT Ni-plated brass 50 psi (3.4 bar)

Peristaltic Pump:

Wetted Materials ... Tygon LFL

Max. Pressure ... 20 psi (1.4 bar) cont.; 25 psi (1.7 bar) intermittent Max. Suction Lift ... 28 ft. (8.5 m) of water

Enclosure... NEMA 4X; PPO structural foam; with hardware for surface or pipe mounting

Net Weight:

w/ Integral Analyzer... 25.9 lbs. (11.7 kg) approx. w/ Separate Analyzer .. 19.7 lbs. (8.9 kg) approx.

Electrical Certifications

(optional -- pending) ... CSA: Class I and II, Div. 2, Groups A thru G FM: Class I and II, Div. 2, Groups A thru G CE: General Purpose (safe area use only)

Cal and Wash Cycle

Software Steps... The available steps, shown below in their order of sequence, can be bypassed and their durations changed to create custom cal or wash cycles. Steps highlighted by an asterisk are only available for a calibration cycle.

1. Abort Position (insert or retract) *2. Cal Timeout (0-999 seconds)

3. Hold Release (0-999 seconds) 4. Aux. Wash 1 (0-999 seconds) 5. Aux. Wash 1 Delay (0-999 seconds) 6. Main Wash (0-999 seconds) 7. Main Wash Delay (0-999 seconds) 8. Rinse (0-999 seconds)

9. Rinse Delay (0-999 seconds) *10. Buffer 1 (0-999 seconds) *11. Buffer 1 Delay (0-999 seconds) *12. Buffer 2 (0-999 seconds) *13. Buffer 2 Delay (0-999 seconds)

14. Aux. Wash 2 (0-999 seconds) 15. Aux. Wash 2 Delay (0-999 seconds)

Additional Specs ... See Operating Instruction Manual No. P63 for com-plete analyzer specifications

PART TWO - INSTALLATION SECTION 1 - MOUNTING RP6300C CONTROL BOX

P A R T T W O - I N S T A L L A T I O N

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The control box may have the P63B pH analyzer integrally mounted into its enclosure door, or be supplied with a sepa-rate pH analyzer. In either case, locate the analyzer within 100 feet (30 m) from where the electrode is to be installed. (When using a non-GLI electrode with a cable capacitance of more than 30 pF per foot, decrease this distance as needed for best measurement results.)

Mount the control box where there is minimal mechanical vibration. Mounting hardware is supplied to surface mount the control box, or to pipe mount it to a vertical or horizontal 1-1/2 inch or 2 inch diameter pipe. Refer to Figure 2-1 for enclosure and mounting dimension details.

NOTE: Avoid locations where control box ambient

tem-perature limits (14 to 140°F; -10 to 60°C) may be exceeded.

FIGURE 2-1 Model RP6300C Control Box Mounting Details

PART TWO - INSTALLATION SECTION 2 - MOUNTING RP6300A AUTO-POSITIONER

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The auto-positioner may be mounted into the top or side of a vessel, or directly into a process line. When side mount-ing the auto-positioner, orient it at least 15° above

horizontal to ensure that the electrode performs properly.

In all cases, make adequate clearance allowances for: „ Fully retracting the electrode

„ Connecting two pressurized air lines from the control box to the auto-positioner control valves

„ Connecting a solution line from the control box to one of the auto-positioner cleaning ports

„ Connecting a solution drain line to the auto-positioner’s other cleaning port

NOTE: When retracting the electrode under process

pres-sure, process solution may vent from the open cleaning ports shown in Figure 2-8. If the process solution is hot or in any way dangerous, consider this condition when designing the plumbing ar-rangement.

The auto-positioner is available in one of four connection styles. Each connection style requires specific mounting hardware to mount the positioner into the process pipe or vessel wall. Refer to the appropriate subheading for mounting details.

An auto-positioner with a 1-1/2 inch NPT process connec-tion style requires GLI’s stainless steel RP6300A3F1005 adapter shown in Figure 2-2 for mounting into a standard 1-1/2 inch NPT pipe tee or fitting.

FIGURE 2-2 Mounting 1-1/2 inch NPT Process Connection Style Auto-positioner into Pipe Tee or Fitting

PART TWO - INSTALLATION SECTION 2 - MOUNTING RP6300A AUTO-POSITIONER

1-1/4 inch BSP Process Connection

An auto-positioner with a 1-1/4 inch BSP process connec-tion style requires a 1-1/4 inch BSP weld-in socket fitting, available from GLI, for vessel wall or pipeline mounting (Figure 2-3 or Figure 2-4 respectively).

FIGURE 2-3 Mounting 1-1/4 inch BSP Process Connection Style Auto-positioner Into Vessel Wall

FIGURE 2-4 Mounting 1-1/4 inch BSP Process Connection Style Auto-positioner into Pipeline

PART TWO - INSTALLATION SECTION 2 - MOUNTING RP6300A AUTO-POSITIONER 1-1/2 inch Sanitary Tee Process Connection 2 inch Sanitary Tee Process Connection 2.2 Immersion Mounting (requires GLI immersible accessory)

An auto-positioner with a 1-1/2 inch sanitary tee process connection style requires a 1-1/2 inch sanitary tee and its associated gasket and heavy duty clamp for pipeline mounting (Figure 2-5).

FIGURE 2-5 Mounting 1-1/2 inch Sanitary Tee Process Connection Style Auto-positioner into Pipeline

An auto-positioner with a 2 inch sanitary tee process con-nection style requires a 2 inch sanitary tee and its associated gasket and heavy duty clamp for pipeline mounting (Figure 2-6).

FIGURE 2-6 Mounting 2 inch Sanitary Tee Process Connection Style Auto-positioner Into Pipeline

Only the 1-1/2 inch NPT process connection style auto-positioner can be immersion mounted using the GLI im-mersible accessory RP6300M3G5000-101 (Figure 2-7). This accessory must be partially disassembled to enable installation of the auto-positioner and its connections for the air “insert” and “retract” lines, solution line, drain line, and electrical cables.

PART TWO - INSTALLATION SECTION 2 - MOUNTING RP6300A AUTO-POSITIONER

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Disassembling Immersible Accessory

NOTE: The auto-positioner may be submerged below the

surface of the vessel or pond to a depth of 6 ft. (2 m). Depending on the desired depth, it may be necessary to replace the immersible accessory’s short pipeway pipe with a longer pipe. Since the cable and tubing grips at the top of the accessory’s pipeway are not waterproof, keep them at least 12 inches (305 mm) above the surface. Leakage through the grips will damage the auto-positioner and its electrode positioner indication sensors.

1. Unfasten the three retaining nuts holding the top cover/ pipeway assembly of the immersible accessory.

FIGURE 2-7 Immersion Mounting 1-1/2 inch NPT Process Connection Style Auto-positioner

PART TWO - INSTALLATION SECTION 2 - MOUNTING RP6300A AUTO-POSITIONER

Installing Auto-positioner

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2. If it is desired to submerge the immersible accessory to a greater depth, replace the short pipeway pipe with a longer pipe. Unfasten the short pipeway pipe from the chamber cover and radial grip piece. Then, fasten the new, longer replacement pipe in the same way.

After disassembling the immersible accessory, install the auto-positioner, and connect all required tubing and electri-cal cables.

NOTE: Use Teflon tape on all threads wetted by the

proc-ess to avoid leaks.

1. Fasten the 1-1/2 inch NPT adapter onto the end of the auto-positioner.

2. Hand tighten the 1-1/2 inch NPT adapter (attached to the auto-positioner) into the bottom chamber cover of the immersible accessory.

3. Plumb a solution line from the RP6300C control box

pump outlet, through one of the grips on the radial grip piece, to one of the RP6300A auto-positioner cleaning ports. See Part Two, Section 3.2 for details.

4. Plumb a drain line from the auto-positioner’s opposite cleaning port, through one of the grips on the radial grip piece, to a drain. See Part Two, Section 3.3 for details.

5. Connect the air “insert” and “retract” lines from the RP6300C control box, through grips on the radial grip piece, to the RP6300A auto-positioner. See Part Two, Sections 4.2 and 4.3 respectively for details.

6. Connect the pH electrode cable wires, through one of the grips on the radial grip piece, to terminals in the RP6300C control box. Refer to Part Two, Section 6.1 for details. (If the P63B pH analyzer is separately mounted, connect the pH electrode to the analyzer ter-minals. See Part Two, Section 7.1 for details.)

7. Connect the electrode position indication sensors on the auto-positioner, through one of the grips on the ra-dial grip piece, to terminals in the RP6300C control box. See Part Two, Section 6.2 (or Section 7.2) for details.

8. Calibrate and install the electrode into the RP6300A auto-positioner. See Part Two, Section 5.1 for details.

PART TWO - INSTALLATION SECTION 2 - MOUNTING RP6300A AUTO-POSITIONER

Anchoring Immersible Accessory

9. Check to make sure that all tubing and electrical cable lengths inside the immersible accessory chamber have sufficient slack. If not, re-adjust to appropriate lengths.

10. Check the auto-positioner for proper insert and retract operation. If necessary, adjust the electrode insert and retract speeds. See Part Three, Section 1 for details.

11. Set up the P63B pH analyzer for the desired automatic wash/cal operation. See Part Three, Section 2 for de-tails. Run the system through a test cycle to confirm operation.

12. Before reinstalling the top cover/pipeway assembly onto the immersible accessory, make sure that the two cover O-ring seals are in place and properly seated. Fasten the three retaining nuts to secure the cover.

After the auto-positioner is installed and all its tubing and wiring is connected, position the immersible accessory in a suitable location. Then anchor it in position by using brack-ets attached to a railing or similar object, or mooring cables.

PART TWO - INSTALLATION SECTION 3 - PLUMBING FOR CLEANING/BUFFER SOLUTIONS

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3.1 Cleaning Solution and Buffer Supply Lines

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3.2 Auto-positioner Solution Line

The Cal-Clean™ System requires these plumbing connec-tions:

„ Supply lines for cleaning solutions and buffers to the RP6300C control box manifold inlets.

„ A solution line from the control box pump outlet to one of the RP6300A auto-positioner cleaning ports.

„ A drain line to the auto-positioner’s other cleaning port.

Using metal or plastic tubing, plumb up to five cleaning so-lution and buffer supply lines into appropriate manifold inlets. Each inlet is clearly identified from left to right by so-lution type: BUFFER 1, BUFFER 2, RINSE, AUXILIARY WASH, and MAIN WASH. Using appropriate tubing and fit-tings, connect each supply line to its respective check valve inlet (1/8 inch NPT male) on the manifold.

NOTE: The GLI optional manifold plumbing hardware kit

enables using plastic tubing. In this case, fasten the supplied couplings to the check valve inlets, and attach the supplied 1/8 inch barbed fittings. Hose clamps may be used to secure the tubing connec-tion to the barbed fitting.

When the auto-positioner is fully retracted, it isolates the pH electrode from the process with a positive seal, and forms an integral solution chamber. This enables the electrode to be immersed in cleaning solutions and buffers for cleaning and calibration without contaminating the process.

Using metal or plastic tubing, plumb a solution line from the control box pump outlet to one of the cleaning ports on the auto-positioner (see Figures 2-8 and 2-12). Connections for the solution line are 1/8 inch female NPT.

PART TWO - INSTALLATION SECTION 3 - PLUMBING FOR CLEANING SOLUTIONS/BUFFERS

3.3 Auto-positioner Drain Line

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FIGURE 2-8 Auto-positioner Cleaning Ports and External Temperature Sensor Port

Using metal or plastic tubing, plumb a drain line to the auto-positioner’s other cleaning port which is opposite the solu-tion line connecsolu-tion (Figure 2-12). The connecsolu-tion for the cleaning port is 1/8 inch female NPT.

NOTE: The drain line must be plumbed with a trap or

in-clude a check valve to ensure that solutions are retained inside the auto-positioner’s integral solu-tion chamber. Otherwise, gravity feed will siphon off the solution that is immersing the pH electrode.

PART TWO - INSTALLATION SECTION 4 - CONNECTING PRESSURIZED INSTRUMENT AIR

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4.1 Air Supply Line

4.2 Air Insert Line

4.3 Air Retract Line

NOTE: Use only instrument quality (filtered and dried)

pressurized air to operate the Cal-Clean™ System. Control air pressure must be between 15 and 50 psi (1.03 and 3.45 bar). General

Recommenda-tion: Use air pressure that is one-half the process

pressure. The auto-positioner is rated for use in processes having up to 100 psi (6.8 bar) pressure.

The Cal-Clean™ System requires these pressurized air line connections:

„ Air supply line to the RP6300C control box air inlet on left side of enclosure.

„ Air insert line from the RP6300C control box “INSERT” outlet to the auto-positioner “INSERT” air valve.

„ Air retract line from the RP6300C control box “RETRACT” outlet to the auto-positioner “RETRACT” air valve.

Using metal or plastic tubing, connect an air supply line to the RP6300C control box air inlet on the left side of the en-closure. The connection for the air supply line is 1/8 inch female NPT.

Connect an air insert line from the control box “INSERT” outlet to the auto-positioner “INSERT” air valve (farthest from electrode tip). Connections for the air insert line are 1/8 inch female NPT.

Connect an air retract line from the control box “RETRACT” outlet to the auto-positioner “RETRACT” air valve (closest to electrode tip). Connections for the air retract line are 1/8 inch female NPT.

PART TWO - INSTALLATION SECTION 5 - INSTALLING/REMOVING ELECTRODE FROM AUTO-POSITIONER

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5.1 Installing Electrode

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5.2 Removing Electrode

1. Remove the electrode’s protective plastic cap. Avoid scratching the pH glass bulb when handling the elec-trode.

2. Perform a first time calibration with the electrode not yet installed in the auto-positioner. Refer to the P63 in-struction manual (Part Three, Sections 4.3 and 4.4) and perform a two-point calibration using the arbitrary buffer method.

3. Install the electrode. Lubricate its glass body with water so that it slides more easily against the auto-positioner’s internal O-rings. Carefully insert the elec-trode into the elecelec-trode holder (item H33 in Figure 5-1) at the rear of the positioner.

NOTE: Make sure the plastic washer and O-ring

(shipped with electrode) are in place on the glass electrode body. If not, the electrode could be inserted too deeply, damaging the elec-trode.

To ease installation, gently twist the electrode while in-serting it past the front O-ring seals. When fully inserted, the pH glass bulb should be visible approxi-mately 1/8 inch from the bottom of the protector (Figure 2-9). Hand-tighten the electrode retaining nut onto the electrode holder; then tighten 1/4 turn more with a wrench or pliers.

Before removing the electrode from the auto-positioner, al-ways retract it by:

1. Pressing the MAINT key.

2. Selecting “Sensor Maintenance” line and pressing

ENTER key.

3. Selecting “Manual Retract” line and pressing ENTER key.

PART TWO - INSTALLATION SECTION 5 - INSTALLING/REMOVING ELECTRODE FROM AUTO-POSITIONER

WARNING:

BEFORE REPLACING AN ELECTRODE, ALWAYS DE-PRESSURIZE THE PROCESS LINE. DO NOT ATTEMPT TO REMOVE THE ELECTRODE FROM THE AUTO-POSITIONER WHILE THE AUTO-POSITIONER IS INSTALLED IN A PRESSURIZED LINE.

WHEN THE ELECTRODE IS RETRACTED, THE SOLUTION CHAMBER IN THE POSITIONER IS NORMALLY SEALED. HOWEVER, IF THE FRONT ELECTRODE SEAL BREAKS WHILE REMOVING THE ELECTRODE, PRESSURIZED SOLUTION CAN FLOW PASSED IT AND OUT OF THE BACK OF THE POSITIONER.

PART TWO - INSTALLATION SECTION 6 - WIRING SYSTEM WITH INTEGRAL MOUNT ANALYZER

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6.1 pH Electrode

With Built-in Temperature Sensor

For Cal-Clean™ Systems equipped with an integrally-mounted P63B pH analyzer, make all required electrical connections to terminals in the RP6300C control box.

The GLI pH electrode with built-in temperature sensor has an integral, shielded cable containing a coaxial electrode cable and two temperature sensor wires (Figure 2-10).

FIGURE 2-10

Cable Details of Electrode with Built-in Temperature Sensor

To connect this type of electrode, refer to Figure 2-12 and follow these steps:

1. In the control box, connect the electrode cable’s clear insulated wire (active signal) to “ACT.” terminal 1 on TB14. (Do not remove the factory-connected wire from this terminal.)

2. In the control box, connect the electrode cable’s black shield wire (reference signal) to “REF.” terminal 3 on TB13.

3. In the control box, connect the electrode cable’s red and white temperature sensor wires to “TC” terminals 1 and 2 on TB13, attaching either wire to either terminal.

PART TWO - INSTALLATION SECTION 6 - WIRING SYSTEM W/INTEGRAL MOUNT ANALYZER

Without Temperature Sensor

With Separate, External Temperature Sensor

An electrode without a built-in temperature sensor has an integral, shielded coaxial cable (Figure 2-11).

FIGURE 2-11

Cable Details of Electrode without Built-in Temperature Sensor

To connect this type of electrode, refer to Figure 2-12 and follow these steps:

1. In the control box, connect the electrode cable’s clear insulated wire (active signal) to “ACT.” terminal 1 on TB14. (Do not remove the factory-connected wire from this terminal.)

2. In the control box, connect the electrode cable’s black shield wire (reference signal) to “REF.” terminal 3 on TB13.

Some applications may require a separate external tem-perature sensor to be used with the pH electrode. (Since GLI offers pH electrodes with an integral temperature sen-sor, separate temperature sensors are not available.) The Cal-Clean™ System can be used with either a Pt100 or Pt1000 RTD sensor. Install the temperature sensor into the plugged 1/8 inch NPT port (Figure 2-8) of the auto-positioner. Do not use the two cleaning ports.

1. Unplug the port and install the temperature sensor.

2. In the control box, connect the temperature sensor

wires to the “TC” terminals 1 and 2 on TB13, attaching either wire to either terminal.

PART TWO - INSTALLATION SECTION 6 - WIRING SYSTEM W/INTEGRAL MOUNT ANALYZER

PART TWO - INSTALLATION SECTION 6 - WIRING SYSTEM WITH INTEGRAL MOUNT ANALYZER 6.2 Electrode Position

Indication Sensors

6.3 Line Power

Sensors on the auto-positioner indicate the extreme posi-tions of the electrode to the control system. One position sensor indicates when the electrode is fully retracted. This ensures that the process media will not be contaminated by solutions being pumped into the auto-positioner’s integral solution chamber. The other position sensor indicates when the electrode is fully inserted. This ensures that the elec-trode is actually in the process, and that the auto-positioner is maintaining a positive seal with the process.

To connect these sensors, refer to Figure 2-12 and follow these steps:

1. In the control box, connect the “INSERT” sensor’s three wires to the “INSERT” terminals on TB1, matching col-ors as indicated.

2. In the control box, connect the “RETRACT” sensor’s

three wires to the “RETRACT” terminals on TB1, matching colors as indicated.

Connect line power to “MAINS” terminals on TB4 and TB5 in the control box using the standard three-wire connection arrangement. Use wiring practices that conform to local codes (example: National Electric Code Handbook in USA).

WARNING:

MAKE SURE THAT LINE POWER IS NOT PRESENT WHILE CONNECTING LINE POWER WIRES TO THE “MAINS” TERMINALS IN THE CONTROL BOX. ALSO, USE ONLY THE STANDARD THREE-WIRE GROUND-ED WIRING ARRANGEMENT TO PREVENT AN UNSAFE CONDITION, AND TO ENSURE PROPER INSTRUMENT OPERATION.

1. In the control box, connect the ground wire to the green grounding screw (at lower left of TB5, Figure 2-11).

2. In the control box, connect the neutral (white) wire to one of the “N” terminals on TB5.

3. In the control box, connect the hot (black) wire to one of the “L1/HOT” terminals on TB4.

PART TWO - INSTALLATION SECTION 7 - WIRING SYSTEM W/SEPARATE MOUNT ANALYZER 6.4 Analog Outputs

(optional -- using control box terminals)

6.5 Remote Start Connections (optional -- using control box terminals)

With the analyzer integrally mounted, convenience termi-nals for the analog outputs are provided on TB15 in the control box. Use the TB15 terminals instead of terminals in the analyzer to make output connections. For details on the analog outputs, refer to Part Two, Section 3.5 in the ana-lyzer Operating Instruction Manual No. P63.

The Cal-Clean™ System can be “remote started” by apply-ing a TTL signal for at least 300 milliseconds to “REMOTE INPUT” terminals 9 and 10 on TB15 in the control box, matching polarity as shown.

PART TWO - INSTALLATION SECTION 7 - WIRING SYSTEM WITH REMOTE MOUNT ANALYZER

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For Cal-Clean™ systems with a remote-mounted P63B pH analyzer, electrical connections must be made to terminals in the analyzer and RP6300C control box.

The GLI pH electrode with built-in temperature sensor has an integral, shielded cable containing a coaxial electrode cable and two temperature sensor wires (see Figure 2-10). To connect this type of electrode, refer to Figure 2-13 and follow these steps:

1. In the P63B analyzer, connect the electrode cable’s clear insulated wire (active signal) to “ACTIVE” terminal 1 on TB1.

2. In the P63B analyzer, connect the electrode cable’s black shield wire (reference signal) to “REFERENCE” terminal 3 on TB1.

3. In the P63B analyzer, connect a jumper between

“REFERENCE” terminal 3 and “GND” terminal 7 on TB1.

4. In the P63B analyzer, connect the electrode cable’s red and white temperature sensor wires to terminals 8 and 10 on TB1, attaching either wire to either terminal.

An electrode without a built-in temperature sensor has an integral, shielded coaxial cable (see Figure 2-11). To con-nect this type of electrode, refer to Figure 2-13 and follow these steps:

1. In the P63B analyzer, connect the electrode cable’s clear insulated wire (active signal) to “ACTIVE” terminal 1 on TB1.

2. In the P63B analyzer, connect the electrode cable’s black shield wire (reference signal) to “REFERENCE” terminal 3 on TB1.

3. In the P63B analyzer, connect a jumper between

“REFERENCE” terminal 3 and “GND” terminal 7 on TB1.

PART TWO - INSTALLATION SECTION 7 - WIRING SYSTEM WITH REMOTE MOUNT ANALYZER

With Separate, External Temperature Sensor 7.2 Electrode Position Indication Sensors 7.3 P63B Analyzer-to-RP6300C Control Box Connections TTL Input Wiring

Some applications may require a separate external tem-perature sensor to be used with the pH electrode. (Since GLI offers pH electrodes with an integral temperature sen-sor, separate temperature sensors are not available.) The Cal-Clean™ System can be used with either a Pt100 or Pt1000 RTD sensor. Install the temperature sensor into the plugged 1/8 inch NPT port (Figure 2-8) of the auto-positioner. Do not use the two cleaning ports.

1. Unplug the port and install the temperature sensor.

2. In the P63B analyzer, connect the temperature sensor wires to terminals 8 and 10 on TB1, attaching either wire to either terminal.

Sensors on the auto-positioner indicate the extreme posi-tions of the electrode to the control system. One position sensor indicates when the electrode is fully retracted. This ensures that the process media will not be contaminated by solutions being pumped into the auto-positioner’s integral solution chamber. The other position sensor indicates when the electrode is fully inserted. This ensures that the elec-trode is actually in the process, and that the auto-positioner is maintaining a positive seal with the process.

To connect these sensors, refer to Figure 2-13 and follow these steps:

1. In the control box, connect the “INSERT” sensor’s three wires to the “INSERT” terminals on TB1, matching col-ors as indicated.

2. In the control box, connect the “RETRACT” sensor’s

three wires to the “RETRACT” terminals on TB1, matching colors as indicated.

The “TTL INPUTS” terminals in the P63B analyzer must be connected to control box terminals on TB2:

1. Connect the P63B analyzer “X” terminal 11 on TB1 to control box terminal “TTLX” on TB2.

2. Connect the P63B analyzer “Y” terminal 12 on TB1 to control box terminal “TTLY” on TB2.

3. Connect the P63B analyzer “LO” terminal 13 on TB1 to control box terminal “ICOM” on TB2.

PART TWO - INSTALLATION SECTION 7 - WIRING SYSTEM WITH REMOTE MOUNT ANALYZER

PART TWO - INSTALLATION SECTION 7 - WIRING SYSTEM WITH REMOTE MOUNT ANALYZER

TTL Outputs/ Pullouts Wiring

Relay A, B, and C Wiring

The “TTL OUTPUTS” and “PULLUPS” terminals in the P63B analyzer must be connected to control box terminals on TB2:

1. In the P63B analyzer, connect a jumper between “LO” terminal 1 and “COM” terminal 2 on TB3.

2. In the P63B analyzer, connect a jumper between “TTL OUTPUT A” terminal 3 and “+5A” terminal 6 on TB3.

3. In the P63B analyzer, connect a jumper between “TTL OUTPUT B” terminal 4 and “+5B” terminal 7 on TB3.

4. In the P63B analyzer, connect a jumper between “TTL OUTPUT C” terminal 5 and “+5C” terminal 8 on TB3.

5. Connect the P63B analyzer “LO” terminal 1 on TB3 to control box terminal “LO” on TB3.

6. Connect the P63B analyzer “TTL OUTPUT A” terminal

3 on TB3 to control box terminal “TTLA” on TB3.

7. Connect the P63B analyzer “TTL OUTPUT B” terminal

4 on TB3 to control box terminal “TTLB” on TB3.

8. Connect the P63B analyzer “TTL OUTPUT C” terminal

5 on TB3 to control box terminal “TTLC” on TB3.

The “RELAY A”, “RELAY B”, and “RELAY C” terminals in the P63B analyzer must be connected to control box termi-nals on TB2:

1. In the P63B analyzer, jumper “RELAY A, B, and C

COM” terminals together (terminals 2, 5, and 8 on TB4).

2. Connect the P63B analyzer “RELAY A COM” terminal 2

on TB4 to control box terminal “+24V” on TB3.

3. Connect the P63B analyzer “RELAY A N.O.” terminal 1 on TB4 to control box terminal “RLYA” on TB3.

4. Connect the P63B analyzer “RELAY B N.O.” terminal 4 on TB4 to control box terminal “RLYB” on TB3.

5. Connect the P63B analyzer “RELAY C N.O.” terminal 7 on TB4 to control box terminal “RLYC” on TB3.

PART TWO - INSTALLATION SECTION 7 - WIRING SYSTEM WITH REMOTE MOUNT ANALYZER 7.4 Line Power P63B pH Analyzer RP6300C Control Box 7.5 Remote Start Connections (optional -- using control box terminals)

Connect line power to the analyzer by following the steps described in Operating Instruction Manual No. P63.

Connect line power to the control box to “MAINS” terminals on TB4 and TB5 using the standard three-wire connection arrangement. Use wiring practices that conform to local codes (example: National Electric Code Handbook in USA).

WARNING:

MAKE SURE THAT LINE POWER IS NOT PRESENT WHILE CONNECTING LINE POWER WIRES TO THE “MAINS” TERMINALS IN THE CONTROL BOX. ALSO, USE ONLY THE STANDARD THREE-WIRE GROUND-ED WIRING ARRANGEMENT TO PREVENT AN UNSAFE CONDITION, AND TO ENSURE PROPER INSTRUMENT OPERATION.

1. In the control box, connect the ground wire to the green grounding screw (at lower left of TB5, Figure 2-13).

2. In the control box, connect the neutral (white) wire to one of the “N” terminals on TB5.

3. In the control box, connect the hot (black) wire to one of the “L1/HOT” terminals on TB4.

The Cal-Clean™ System can be “remote started” by apply-ing a TTL signal for at least 300 milliseconds to “REMOTE INPUT” terminals 1 and 2 on TB2 in the analyzer, matching polarity as shown.

PART THREE - OPERATION SECTION 1 - ADJUSTING ELECTRODE INSERT AND RETRACT SPEEDS

P A R T T H R E E - O P E R A T I O N

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You can independently adjust the electrode insert and re-tract speeds by turning the small screw in the end of each auto-positioner air control valve.

• Turning counterclockwise (left): Moves the electrode at a faster speed (increases control valve opening). • Turning clockwise (right): Moves the electrode at a

slower speed (decreases control valve opening).

Adjust these valves to optimize the electrode insert and retract speeds to the application requirements.

Recom-mendation: Adjust the valves equally to produce a smooth

electrode movement. (Note that the insert and retract speeds cannot be adjusted to be dramatically different.)

NOTE: Never adjust the air control valves fully open, since

the abrupt movement of the auto-positioner mechanism may cause the electrode to break.

PART THREE - OPERATION SECTION 2 - SETTING P63B pH ANALYZER FOR AUTOMATIC WASH/CAL OPERATION

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After installing and wiring the Cal-Clean™ System, and connecting the solution and pressurized air lines to the control box and auto-positioner, you must set the P63B pH analyzer for automatic wash/cal operation:

1. Press the CONFIG key. If a passcode was assigned,

enter the correct passcode to access the configuration menus.

2. Select the “Wash/Cal System” submenu and enable the wash/cal feature to set the analyzer for automatic wash/cal operation. All relays, TTL inputs, and TTL outputs are now re-assigned to operate the Cal-Clean™ System.

3. Define and schedule wash and cal events. For details on events (shown as “cycles” on the P63B display and referred to as “cycles” in the P63B instruction manual), see Part Three, Section 5.4 in the “Establishing Wash/Cal System Operation” subsection.

4. Start system operation in one of two ways:

■ Locally at the analyzer:

A. Press the CAL key, and select “pH.” From the “pH Calibration” submenu, select “Wash/Cal.”

B. With the “Wash/Cal” submenu displayed, se-lect “RUN” and press the ENTER key twice to.

■ From a remote location:

Apply a TTL signal for at least 300 milliseconds to “REMOTE INPUT” terminals (in control box for in-tegral-mounted analyzer or in analyzer when it is remote-mounted).

PART FOUR - SERVICE AND MAINTENANCE SECTION 1 - CALIBRATING PERIODICALLY

P A R T F O U R - S E R V I C E A N D M A I N T E N A N C E

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Normally, all pH electrodes “age” with time. Aging is char-acterized by shortened span and slower speed of response. A span or slope adjustment can compensate for electrode span error, but not for slower speed of response. Aging is best detected by calibrating the electrode in, for example, pH 7 buffer and then rinsing the electrode and placing it in pH 4 buffer. Generally, if the span error is 10% or more (a reading of 4.3 or higher for this example), clean and/or re-condition the electrode and then retest it. If rere-conditioning does not restore performance, the electrode should be re-placed.

Perform calibration periodically with pH buffers to maintain measurement accuracy. Establish a maintenance program to keep the electrode clean and the measurement system calibrated. The time intervals (hours, days, weeks) between performing maintenance will be influenced by the charac-teristics of the process solution and can only be determined by operating experience. Usually, a process that fouls the sensor more quickly requires more frequent cleaning.

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The auto-positioner is shipped with a light silicone grease covering the shaft components. This lubricant protects in-ternal sliding surfaces while in storage and aids operation when in use. Under normal conditions this lubricant should last the life of the positioner. However, if the auto-positioner is operated continuously at temperatures above 70°C, it may become necessary to periodically re-apply lubricant. If the electrode becomes difficult to insert and re-tract (excluding any resistance from the process solution pressure), you can lubricate the entire shaft with any high temperature silicone grease that is compatible with the as-sembly’s materials of construction (acetal, Viton, and 316 stainless steel).

CALIBRATING PERIODICALLY

PART FOUR - SERVICE AND MAINTENANCE SECTION 3 - REPLACING AUTO-POSITIONER O-RINGS

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☞

auto-positioner is disassembled for any reason, the GLI auto-positioner warranty is voided.

Recommenda-tion: Return the entire auto-positioner to GLI for

servicing. All major components are listed in the Part Five -- Spare Parts section.

The auto-positioner’s front external O-ring seals (shown as HO3 and HO9 in Figure 5-1 in Part Five -- Spare Parts) can be easily replaced without disassembling the positioner.

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Important Recommendation: Routinely inspect the

peri-staltic pump tubing for wear. Tubing life is dependent upon the solutions used and the frequency of pump operation. If pump tubing leaks or becomes deteriorated, immediately replace the tubing. Follow the instructions below. (A pump spare tubing kit RP6300M5G4050 is available from GLI.) 1. Disconnect line power from the control box.

2. Loosen both hose clamps from the manifold plumbing

and disconnect old pump tubing.

3. Unfasten the four small screws (not the three larger screws) and remove the pump cover.

4. Remove old pump tubing and discard it.

5. Wipe both pump rollers with a clean, water-dampened cloth to remove any particles that could damage the new tubing. 6. Position rollers vertically by turning the roller assembly. 7. Push new tubing onto the manifold’s left barb fitting,

and secure this end with the hose clamp.

8. Position new tubing into the left pump slot. Then rotate the roller assembly clockwise (right) to work the tubing around it and down through the right pump slot.

CAUTION: DO NOT ROTATE ROLLER ASSEMBLY BY TURNING THE PUMP FAN. THIS MAY DAMAGE THE GEARTRAIN.

REPLACING AUTO-POSITIONER O-RINGS

PART FOUR - SERVICE AND MAINTENANCE SECTION 5 - REPLACING CONTROL BOX MANIFOLD SOLENOID

9. Push the other tubing end onto the manifold’s right barb fitting, and secure it with the hose clamp.

10. Replace the pump cover and tighten the fours screws.

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Removing Inoperative Solenoid (refer to Figure 4-1):

1. Disconnect line power from the control box.

2. Disconnect both wires of the inoperative solenoid from the circuit board terminals.

3. Remove the cord grip cap. Then pry out the cord grip insert.

4. Remove the solenoid nut.

5. Unscrew and remove the cord grip bushing and cord

grip gasket.

6. Remove the solenoid coil assembly by lifting it straight up from the solenoid valve assembly.

7. Remove the solenoid gasket and solenoid backing ring. 8. Remove the solenoid valve assembly from the manifold

by unscrewing its knurled base. Avoid turning the as-sembly’s slotted valve stem when removing. This disassembles the valve assembly into all of its parts.

Installing New Solenoid (refer to Figure 4-1):

1. Remove the new solenoid nut to disassemble the sole-noid into two pieces: its coil assembly and its valve assembly.

2. Make sure the new solenoid valve assembly O-rings

are properly seated. Also, check the manifold port for any damage.

3. Thread the solenoid valve assembly into the manifold port. Using a screwdriver in its slotted valve stem, tighten the assembly until it is fully seated.

4. Make sure that the solenoid gasket and solenoid back-ing rback-ing are in place.

5. Route the solenoid coil wires through the enclosure, and slide the solenoid coil assembly over the solenoid valve assembly.

PART FOUR - SERVICE AND MAINTENANCE SECTION 5 - REPLACING CONTROL BOX MANIFOLD SOLENOID

6. Route the solenoid coil wires through the cord grip gas-ket and bushing. Place the cord grip bushing through the enclosure hole, and screw the bushing into the so-lenoid coil assembly. Tighten the cord grip bushing until the cord grip gasket is compressed and the solenoid coil assembly is tight against the enclosure.

7. Replace the solenoid nut and tighten. 8. Trim the solenoid wire lengths as needed.

9. Route the solenoid wires through the cord grip insert, recessed side first, and push the insert into the cord grip bushing.

10. Replace the cord grip cap and tighten.

11. Connect the solenoid wires to appropriate terminals on the circuit board.

PART FOUR - SERVICE AND MAINTENANCE SECTION 6 - TROUBLESHOOTING

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The following table lists symptoms, their possible causes and remedies to aid in correcting common problems.

TABLE A - TROUBLESHOOTING COMMON PROBLEMS

Symptom Possible Cause Remedy

No electrode response.

Electrode wiring connection is faulty. Check electrode cable connections at the control box or analyzer (see Part Two, Sect. 6.1 or 7.1). Electrode is cracked or internally damaged. Replace electrode.

Electrode is not inserted. Insert electrode. Slow electrode

response.

Reference junction is dehydrated. Hydrate in 3M KCl solution (or dilute pH 4 buffer) for several hours or until next use. Soak electrode up to 24 hours in extreme cases. Reference junction is clogged. Clean junction by flushing solution chamber or

removing electrode and manually cleaning. Electrode is contaminated with

proteinaceous material.

Soak electrode in pepsin solution (0.5% HCl and 1% pepsin) for 5 minutes.

Electrode is contaminated from previous use.

Clean thoroughly by flushing solution chamber. Wash and cal events are improperly timed. Re-evaluate times and scheduling.

Noisy electrode response.

Electrode wiring connection is faulty. Check electrode cable connections at the control box or analyzer (see Part Two, Sect. 6.1 or 7.1). Reference junction is clogged. Clean junction by flushing solution chamber or

removing electrode and manually cleaning. Electrode pH glass bulb is dehydrated. Hydrate in 3M KCl solution (or dilute pH 4

buffer). for several hours or until next use. Soak electrode up to 24 hours in extreme cases. Wash and cal events are improperly timed. Re-evaluate times and scheduling.

Auto-positioner jams periodically.

Front seals are clogged by crystalline material.

Remove auto-positioner and clean seals. Large particulate material is stuck in

the solution chamber.

Re-evaluate the placement of the auto-positioner in the process line or vessel.

Air pressure is too low. Increase control air pressure (up to 50 psi/3.45 bar maximum).

Air control valves are not adjusted properly or are inoperative.

Adjust air valves (see Part Three, Section 1) or replace them.

Air cylinder is contaminated. Contact GLI Customer Service Department. Leaking

auto-positioner seals.

Seals are worn or damaged. Return to GLI for repair, or replace seals (see Part Four, Section 3).

Ineffective elec-trode cleaning.

Wash solution pressure is too low. Increase pressure (up to 30 psi).

Wash solution is not effective. Try a different wash solution (possibly a detergent-based cleaner).

PART FOUR - SERVICE AND MAINTENANCE SECTION 7 - CUSTOMER ASSISTANCE

TABLE A - TROUBLESHOOTING COMMON PROBLEMS (continued)

Symptom Possible Cause Remedy

P63 analyzer dis-plays: “WASH/CAL ERROR -- Sensor not inserted”* or “WASH/CAL ERROR -- Sensor not retracted”*.

Electrode position indication sensor connections are faulty or the sensors are improperly powered.

Electrode position indication sensor magnet position is not adjusted properly.

Electrode indication position sensor magnet is missing.

Check electrode cable connections at the control box or analyzer (see Part Two, Sect. 6.2 or 7.2). Check sensor supply voltage.

In Figure 5-1, loosen nuts H25, slide shaft H12 in/out slightly, and re-tighten H25 nuts.

In Figure 5-1, verify that magnet H10 is mounted to the end of shaft H12. If not, install new magnet.

Air pressure to the auto-positioner is not sufficient.

Check auto-positioner inlet air pressure. It must be at least one-half of the process pressure (pressure range: 15-50 psi).

*To clear the “WASH/CAL ERROR -- Sensor not inserted” or “WASH/CAL ERROR -- Sensor not retracted” message after resolving the cause of the problem, follow this procedure:

1. With the “Clear Alarm” field highlighted, press the ENTER key.

2. Press the MAINT key and, with the “Hold/Xfer Outputs” highlighted, press the ENTER key. 3. Select “Active” and press the ENTER key.

4. Press the MEAS key to return to the measuring screen.

If the WASH/CAL ERROR message is not cleared, the analyzer will be in an abort/hold condition. NOTE: To clear the error, the auto-positioner must be in the proper position. That is, if the error occurred

when the positioner was inserted, the positioner has to be manually placed in the inserted position. Analyzer runs the

wash/cal cycle but solutions are not pumped to the auto-positioner.

The fuse in the control box is blown. Loss of suction from loose connection, or solution leaking from cracked pump tubing.

Replace the fuse.

Replace the tubing (see Part Four, Section 4).

Manifold solenoid(s) are inoperative. Replace the solenoid (see Part Four, Section 5). Relay in the control box is inoperative. Observe the LED in the control box to ensure

power is being supplied to the relay. Relays are not field-serviceable -- call GLI Service Dept. P63 analyzer dis-plays “WASH/CAL ERROR -- pH calibration unkown buffer”.

Incorrect or contaminated buffers are used. Buffer is not being pumped through the auto-positioner solution chamber due to an inoperative manifold solenoid or empty buffer container.

Replace the buffers.

Check and fill the buffer container, or replace the solenoid (see Part Four, Section 5).

Scheduled wash/cal times are not sufficient for buffer to be pumped between the control box and auto-positioner in the allotted time.

PART FOUR - SERVICE AND MAINTENANCE SECTION 7 - CUSTOMER ASSISTANCE

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If you need spare parts, assistance in troubleshooting, or repair service, please contact your local GLI representative, or the GLI Customer Service Department at:

GLI International, Inc. Telephone: [800] 543-8907

9020 West Dean Road Telefax: [414] 355-8346

Milwaukee, Wisconsin 53224

 GLI SERVICE DEPARTMENT HOURS  Eastern Std. Time Central Std. Time Mountain Std. Time Pacific Std. Time Monday through Thursday 8:30 a.m. to 5:30 p.m. 7:30 a.m. to 4:30 p.m. 6:30 a.m. to 3:30 p.m. 5:30 a.m. to 2:30 p.m. Friday 8:30 a.m. to 4:00 p.m. 7:30 a.m. to 3:00 p.m. 6:30 a.m. to 2:00 p.m. 5:30 a.m. to 1:00 p.m. When ordering spare or replacement parts, be sure to use the complete assembly part number.

All Cal-Clean™ system parts returned for repair must be freight prepaid and include the following information:

1. A clearly written description of the malfunction.

2. Name of person to contact and the phone number where they can be reached.

3. Proper return address for shipping Cal-Clean™ system parts back. Include preferred shipping method (UPS, Federal Express, etc.) if applicable.

4. A purchase order if Cal-Clean™ system parts are out of warranty to cover costs of repair.

NOTE: If Cal-Clean™ system parts are damaged during

return shipment because of inadequate packaging, the customer is responsible for any resulting repair costs. (Recommendation: Use the original GLI shipping carton or an equivalent.)

Also, GLI will not accept Cal-Clean™ system parts returned for repair or replacement unless they are thoroughly cleaned and all process material is re-moved.

PART FIVE - SPARE PARTS AND ACCESSORIES

P AR T F I V E - S P AR E P AR T S AN D AC C E S S O R I E S

pH Buffers for Calibration and Operating Checks

Spare pH Electrode

Cal-Clean™ System Hardware Accessories

RP6300C Control Box Spare Parts

Description Part Number

pH 4 Buffer (20 liter collapsible container) ...3A1031 pH 7 Buffer (20 liter collapsible container) ...3A1032 pH 10 Buffer (20 liter collapsible container)...3A1033

Gel-filled pH Electrode (with temp. sensor) ... RP6300G2130 Liquid-filled pH Electrode (with temp. sensor) ... RP6300G2130-002

Air Fitting Hardware Kit ...RP6300G4060 Includes four 1/8 inch NPT compression fittings.

Spare Pump Tubing Kit ...RP6300G4050 Includes one 12 inch (305 mm) long replacement

tubing for peristaltic pump, and two hose clamps.

Solution Fitting Hardware Kit (all stainless steel)...RP6300G4070 Solution Fitting Hardware Kit (all PVDF) ...RP6300G4080

Each kit includes five 1/8 inch NPT manifold cou-plings, and eight 1/8 inch barbed fittings.

Air Tubing* ...2M1031-025-XXX 1/4 inch O.D. polyethylene tubing for transferring

pressurized air from the control box to the auto-positioner. Separate air lines are required for in-sert and retract operation.

Solution Tubing*...2M1033-043-XXX 1/4 inch O.D. Tygon tubing for supply lines, and

for transferring cleaning and buffer solutions from the control box to the auto-positioner.

*To order tubing, substitute required length in whole feet for “-XXX” in part number suffix. Immersible Mounting Accessory ...RP6300G5000-101

Common Parts for All Control Boxes

Fuse (5 amp, 250 VAC, 5 mm x 20 mm) ...7F1050 Fuse (1/4 amp, 250 VAC, 5 mm x 20 mm) ...1F1048 Muffler Filter, 1/8 inch NPT...4H1324 Check Valve, 1/8 inch NPT, stainless steel ...4H1304 Four-way Pneumatic Valve, 115 VAC ...4H1319 Four-way Pneumatic Valve, 230 VAC ...4H1318

Main Circuit Board, 115 VAC, single-fused ...RP6300G4001-101 Main Circuit Board, 230 VAC, single-fused ...RP6300G4001-102 Main Circuit Board, 230 VAC, dual-fused...RP6300G4001-104

Control Box with 316 Stainless Steel Manifold

Manifold Pipe Plug, 1/8 inch NPT, 316SS ...2P2217-100 Manifold Solenoid Valve, 115 VAC ...4H1325 Manifold Solenoid Valve, 230 VAC ...4H1326

Control Box with PVDF Manifold

Manifold Pipe Plug, 1/8 inch NPT, PVDF ...8P2117-100 Manifold Solenoid Valve, 115 VAC ...4H1416 Manifold Solenoid Valve, 230 VAC ...4H1415

PART FIVE - SPARE PARTS AND ACCESSORIES

RP6300A Auto-positioner Spare Parts

Refer to Figure 5-1 below for an exploded view with item number call-outs for the following spare parts:

Item H01 Retainer Lock Nut ... RP6300A2F0030 Item H02 Lock Nut... RP6300A2F0021 Item H03 O-ring, 0.020 dia., Viton 70 ... 5H1018

Item H04 O-ring, 18mm x 2.5mm, Viton 70 ... 5H1286

Item H05 Shaft Holder... RP6300B2F0027 Item H06 O-ring, 18mm x 2.5mm, Viton 70 ... 5H1286

Item H07 O-ring, 0.032 dia., Nitrile 70 ... 5H1292

Item H08 Shaft ... RP6300B2F0024 Item H09 O-ring, 0.111 dia., Viton 75 ... 5H1272

Item H10 Magnet... 7T1027 Item H11 Seal, Nitrile ... 5H1293

Item H12 Alignment Rod ... RP6300A2F0036 Item H13 Tube Holder ... RP6300A2F0034 Item H14 Screw, No. 6-32 ... 8H1293-031 Item H15 Plate ... RP6300A2F0035 Item H16 Nut, #4 ... 8H1112

Item H17 Lock Washer, #4 ... 8H1312 Item H18 Position Indication Sensor (opt.)... 3D1001 Item H19 Screw, No. 4-40 ... 8H1292-038 Item H20 Tube ... RP6300A2F0033 Item H21 Body ... RP6300B2F0025 Item H22 Seal, Nitrile ... 5H1294

Item H23 O-ring, 0.032 dia., Nitrile 70 ... 5H1292

Item H24 Body End ... RP6300B2F0032 Item H25 Nut, 1/4 inch... 8H1116

Item H26 Rod Holder Plate... RP6300A2F0037 Item H27 Lock Washer, 1/4 inch... 8H1326

Item H28 Set Screw, No. 6-32 ... 8H1203-038 Item H29 Screw, No. 6-32 ... 8H1293-038 Item H30 Pipe Plug, 1/8 inch NPT ... 2P2217-100 Item H31 Set Screw, No. 6-32 ... 8H1203-038 Item H32 O-ring, Viton 75... 5H1238

Item H33 Electrode Holder ... RP6300A2F0031