CAL-CLEAN AUTOMATED ph MEASUREMENT SYSTEM

Transcription

1 Manual No. Cal-Clean Revision CAL-CLEAN AUTOMATED ph MEASUREMENT SYSTEM (uses Model P63B ph Analyzer)

2 TABLE OF CONTENTS PART ONE - INTRODUCTION SECTION 1 SECTION 2 GENERAL INFORMATION 1.1 Description Operating Precautions SPECIFICATIONS 2.1 Model RP6300A Auto-positioner Optional ph Electrode Model RP6300C Control Box Model P63B ph Analyzer...9 PART TWO - INSTALLATION SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 MOUNTING RP6300C CONTROL BOX...10 MOUNTING RP6300A AUTO-POSITIONER 2.1 In-line Applications: 1-1/2 inch NPT Process Connection /4 inch BSP Process Connection /2 inch Sanitary Tee Process Connection inch Sanitary Tee Process Connection Immersion Mounting (requires GLI immersible accessory RP6300M3G ): Disassembling Immersible Accessory Installing Auto-positioner Anchoring Immersible Accessory...16 PLUMBING FOR CLEANING SOLUTIONS/BUFFERS 3.1 Cleaning Solution and Buffer Supply Lines Auto-positioner Solution Line Auto-positioner Drain Line...18 CONNECTING PRESSURIZED INSTRUMENT AIR 4.1 Air Supply Line Air Insert Line Air Retract Line...19 INSTALLING/REMOVING ELECTRODE FROM AUTO-POSITIONER Cal-Clean Automated ph Measurement System

3 TABLE OF CONTENTS (Continued) SECTION 6 SECTION 7 WIRING SYSTEM WITH INTEGRAL MOUNT ANALYZER 6.1 ph Electrode Electrode Position Indication Sensors Line Power Analog Outputs (optional -- using control box terminals) Remote Start Connections (optional -- using control box terminals)...26 WIRING SYSTEM WITH REMOTE MOUNT ANALYZER 7.1 ph Electrode Electrode Position Indication Sensors P63B ph Analyzer-to-RP6300C Control Box Connections Line Power Remote Start Connections (optional -- using control box terminals)...31 PART THREE - OPERATION SECTION 1 SECTION 2 ADJUSTING ELECTRODE INSERT AND RETRACT SPEEDS...32 SETTING P63B ph ANALYZER FOR AUTOMATIC WASH/CAL OPERATION...33 PART FOUR - SERVICE AND MAINTENANCE SECTION 1 SECTION 2 CALIBRATING PERIODICALLY...34 LUBRICATING AUTO-POSITIONER SHAFT...34 SECTION 3 REPLACING AUTO-POSITIONER O-RINGS...35 SECTION 4 REPLACING CONTROL BOX PUMP TUBING SECTION 5 SECTION 6 REPLACING CONTROL BOX MANIFOLD SOLENOID TROUBLESHOOTING SECTION 7 CUSTOMER ASSISTANCE...40 PART FIVE - SPARE PARTS AND ACCESSORIES Cal-Clean Automated ph Measurement System 2

4 TABLE OF CONTENTS (continued) ILLUSTRATIONS Figure 2-1 Model RP6300C Control Box Mounting Details Figure 2-2 Mounting 1-1/2 inch NPT Process Connection Style Auto-positioner into Pipe Tee/Fitting 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 Figure 2-5 Mounting 1-1/2 inch Sanitary Tee Process Connection Style Auto-positioner into Pipeline Figure 2-6 Mounting 2 inch Sanitary Tee Process Connection Style Auto-positioner into Pipeline Figure 2-7 Immersion Mounting 1-1/2 inch NPT Process Connection Style Auto-positioner Figure 2-8 Auto-positioner Cleaning Ports and External Temperature Sensor Port Figure 2-9 Electrode Installation Details Figure 2-10 Cable Details of Electrode With Built-in Temperature Sensor Figure 2-11 Cable Details of Electrode Without Built-in Temperature Sensor Figure 2-12 Cal-Clean System with Integral Mount Analyzer -- Wiring Arrangement Figure 2-13 Cal-Clean System with Remote Mount Analyzer -- Wiring Arrangement Figure 4-1 Control Box Manifold Solenoid Replacement Details Figure 5-1 Auto-positioner Exploded View of Parts TABLES Table A Troubleshooting Common Problems 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 RP6300G 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 International, 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. 3 Cal-Clean Automated ph Measurement System

5 Cal-Clean Automated ph Measurement System 4

6 PART ONE - INTRODUCTION SECTION 1 - GENERAL INFORMATION PART ONE - INTRODUCTION SECTION 1 GENERAL INFORMATION 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 (important maintenance tasks) without user intervention. The system is designed for applications in which the process flow cannot be stopped but frequent cleaning and calibration 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 autopositioner 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 installed 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 RP6300M3G ) Pressurized air actuates the auto-positioner to insert and retract the ph electrode. Two electrode position indication 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 entire Cal-Clean System. It must be configured for automatic wash/cal operation. For details, see Operating Instruction Manual No. P63. 5 Cal-Clean Automated ph Measurement System

7 PART ONE - INTRODUCTION SECTION 1 - GENERAL INFORMATION Versatile Scheduling 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 Manual No. P63 for details on scheduling. 1.2 Operating Precautions 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 autopositioner is glass which can easily break. Do not subject 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 sterilization 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 electrode. If KCl solution is unavailable, use dilute ph 4 buffer, or as a last choice, distilled water. This keeps the ph sensitive glass and reference junction of the electrode moist and avoids slow response when the electrode is put back into operation. Cal-Clean Automated ph Measurement System 6

8 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 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. 7 Cal-Clean Automated ph Measurement System

9 PART ONE - INTRODUCTION SECTION 2 - SPECIFICATIONS SECTION 2 SPECIFICATIONS 2.1 Model RP6300A Auto-positioner Wetted Materials stainless steel, and Viton O-rings Non-wetted Materials...Acetal electrode holder, stainless steel body, anodized aluminum air control valves, and Buna-N seals Temperature Range...14 to 212 F (-10 to +100 C) Process Press. Range psi (0-6.8 bar) Solution Chamber: Pressure Range psi (0-2 bar) Inlet/Outlet Ports...1/8 inch female NPT Air Pressure Control: Pressure Range 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) operating temperature Maximum Process Flow Rate...10 ft. (3m) per second Positioner-to- Analyzer Distance 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 F (0-60 C) Installed Depth ft. (0-2 m) 2.2 Optional ph Electrode (with or without temperature sensor) Wetted Materials...Glass ph electrode with PTFE junction Measuring Range ph Temperature Range: Normal Operation...14 to 212 F (-10 to +100 C) Steam Sterilization 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 2.3 Model RP6300C Control Box Ambient Temp. Range...14 to 140 F (-10 to 60 C); 0-100% relative humidity, non-condensing Power Requirements...Std: VAC, 50/60 Hz. single fused Opt: VAC, 50/60 Hz. single or dual fused Cal-Clean Automated ph Measurement System 8

10 PART ONE - INTRODUCTION SECTION 2 - SPECIFICATIONS 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 lbs. (11.7 kg) approx. w/ Separate Analyzer lbs. (8.9 kg) approx. Electrical Certifications (optional -- pending)...csa: FM: CE: Class I and II, Div. 2, Groups A thru G Class I and II, Div. 2, Groups A thru G General Purpose (safe area use only) 2.4 Model P63B ph Analyzer 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 complete analyzer specifications 9 Cal-Clean Automated ph Measurement System

11 SECTION 1 - MOUNTING RP6300C CONTROL BOX PART TWO - INSTALLATION SECTION 1 MOUNTING RP6300C CONTROL BOX The control box may have the P63B ph analyzer integrally mounted into its enclosure door, or be supplied with a separate 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 temperature limits (14 to 140 F; -10 to 60 C) may be exceeded. FIGURE 2-1 Model RP6300C Control Box Mounting Details Cal-Clean Automated ph Measurement System 10

12 SECTION 2 - MOUNTING RP6300A AUTO-POSITIONER SECTION 2 MOUNTING RP6300A AUTO-POSITIONER 2.1 In-line Applications The auto-positioner may be mounted into the top or side of a vessel, or directly into a process line. When side mounting 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 pressure, 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 arrangement. 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. 1-1/2 inch NPT Process Connection An auto-positioner with a 1-1/2 inch NPT process connection 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 11 Cal-Clean Automated ph Measurement System

13 SECTION 2 - MOUNTING RP6300A AUTO-POSITIONER 1-1/4 inch BSP Process Connection An auto-positioner with a 1-1/4 inch BSP process connection 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 Cal-Clean Automated ph Measurement System 12

14 SECTION 2 - MOUNTING RP6300A AUTO-POSITIONER 1-1/2 inch Sanitary Tee Process Connection 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 2 inch Sanitary Tee Process Connection An auto-positioner with a 2 inch sanitary tee process connection 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 2.2 Immersion Mounting (requires GLI immersible accessory) Only the 1-1/2 inch NPT process connection style autopositioner can be immersion mounted using the GLI immersible accessory RP6300M3G (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. 13 Cal-Clean Automated ph Measurement System

15 SECTION 2 - MOUNTING RP6300A AUTO-POSITIONER 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. Disassembling Immersible Accessory 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 Cal-Clean Automated ph Measurement System 14

16 SECTION 2 - MOUNTING RP6300A AUTO-POSITIONER 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. Installing Auto-positioner After disassembling the immersible accessory, install the auto-positioner, and connect all required tubing and electrical cables. NOTE: Use Teflon tape on all threads wetted by the process 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 terminals. 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 radial 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. 15 Cal-Clean Automated ph Measurement System

17 SECTION 2 - MOUNTING RP6300A AUTO-POSITIONER 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 details. 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. Anchoring Immersible Accessory 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 brackets attached to a railing or similar object, or mooring cables. Cal-Clean Automated ph Measurement System 16

18 SECTION 3 - PLUMBING FOR CLEANING/BUFFER SOLUTIONS SECTION 3 PLUMBING FOR CLEANING SOLUTIONS/BUFFERS The Cal-Clean System requires these plumbing connections: 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. 3.1 Cleaning Solution and Buffer Supply Lines Using metal or plastic tubing, plumb up to five cleaning solution and buffer supply lines into appropriate manifold inlets. Each inlet is clearly identified from left to right by solution type: BUFFER 1, BUFFER 2, RINSE, AUXILIARY WASH, and MAIN WASH. Using appropriate tubing and fittings, 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 connection to the barbed fitting. 3.2 Auto-positioner Solution Line 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. 17 Cal-Clean Automated ph Measurement System

19 SECTION 3 - PLUMBING FOR CLEANING SOLUTIONS/BUFFERS FIGURE 2-8 Auto-positioner Cleaning Ports and External Temperature Sensor Port 3.3 Auto-positioner Drain Line Using metal or plastic tubing, plumb a drain line to the autopositioner s other cleaning port which is opposite the solution line connection (Figure 2-12). The connection for the cleaning port is 1/8 inch female NPT. NOTE: The drain line must be plumbed with a trap or include a check valve to ensure that solutions are retained inside the auto-positioner s integral solution chamber. Otherwise, gravity feed will siphon off the solution that is immersing the ph electrode. Cal-Clean Automated ph Measurement System 18

20 SECTION 4 - CONNECTING PRESSURIZED INSTRUMENT AIR SECTION 4 CONNECTING PRESSURIZED INSTRUMENT AIR 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 Recommendation: 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. 4.1 Air Supply Line Using metal or plastic tubing, connect an air supply line to the RP6300C control box air inlet on the left side of the enclosure. The connection for the air supply line is 1/8 inch female NPT. 4.2 Air Insert Line 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. 4.3 Air Retract Line 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. 19 Cal-Clean Automated ph Measurement System

21 SECTION 5 - INSTALLING/REMOVING ELECTRODE FROM AUTO-POSITIONER SECTION 5 INSTALLING/REMOVING ELECTRODE FROM AUTO-POSITIONER 5.1 Installing Electrode 1. Remove the electrode s protective plastic cap. Avoid scratching the ph glass bulb when handling the electrode. 2. Perform a first time calibration with the electrode not yet installed in the auto-positioner. Refer to the P63 instruction 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 autopositioner s internal O-rings. Carefully insert the electrode into the electrode 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 electrode. To ease installation, gently twist the electrode while inserting it past the front O-ring seals. When fully inserted, the ph glass bulb should be visible approximately 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. 5.2 Removing Electrode Before removing the electrode from the auto-positioner, always 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. Cal-Clean Automated ph Measurement System 20

22 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 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. FIGURE 2-9 Electrode Installation Details 21 Cal-Clean Automated ph Measurement System

23 SECTION 6 - WIRING SYSTEM WITH INTEGRAL MOUNT ANALYZER SECTION 6 WIRING SYSTEM WITH INTEGRAL MOUNT ANALYZER For Cal-Clean Systems equipped with an integrallymounted P63B ph analyzer, make all required electrical connections to terminals in the RP6300C control box. 6.1 ph Electrode With Built-in Temperature Sensor 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 TB 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. Cal-Clean Automated ph Measurement System 22

24 SECTION 6 - WIRING SYSTEM W/INTEGRAL MOUNT ANALYZER Without 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. With Separate, External Temperature Sensor Some applications may require a separate external temperature sensor to be used with the ph electrode. (Since GLI offers ph electrodes with an integral temperature sensor, 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 autopositioner. 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. 23 Cal-Clean Automated ph Measurement System

25 SECTION 6 - WIRING SYSTEM W/INTEGRAL MOUNT ANALYZER FIGURE 2-12 Cal-Clean System with Integral Mount Analyzer -- Wiring Arrangement Cal-Clean Automated ph Measurement System 24

26 SECTION 6 - WIRING SYSTEM WITH INTEGRAL MOUNT ANALYZER 6.2 Electrode Position Indication Sensors Sensors on the auto-positioner indicate the extreme positions 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 electrode 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 colors as indicated. 2. In the control box, connect the RETRACT sensor s three wires to the RETRACT terminals on TB1, matching colors as indicated. 6.3 Line Power 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. 25 Cal-Clean Automated ph Measurement System

27 SECTION 7 - WIRING SYSTEM W/SEPARATE MOUNT ANALYZER 6.4 Analog Outputs (optional -- using control box terminals) With the analyzer integrally mounted, convenience terminals 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 analyzer Operating Instruction Manual No. P Remote Start Connections (optional -- using control box terminals) The Cal-Clean System can be remote started by applying 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. Cal-Clean Automated ph Measurement System 26

28 SECTION 7 - WIRING SYSTEM WITH REMOTE MOUNT ANALYZER SECTION 7 WIRING SYSTEM WITH REMOTE MOUNT ANALYZER 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. 7.1 ph Electrode With Built-in Temperature Sensor 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. Without Temperature Sensor An electrode without a built-in temperature sensor has an integral, shielded coaxial cable (see Figure 2-11). 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. 27 Cal-Clean Automated ph Measurement System

29 SECTION 7 - WIRING SYSTEM WITH REMOTE MOUNT ANALYZER With Separate, External Temperature Sensor Some applications may require a separate external temperature sensor to be used with the ph electrode. (Since GLI offers ph electrodes with an integral temperature sensor, 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 autopositioner. 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. 7.2 Electrode Position Indication Sensors Sensors on the auto-positioner indicate the extreme positions 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 electrode 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 colors as indicated. 7.3 P63B Analyzer-to- RP6300C Control Box Connections TTL Input Wiring 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. Cal-Clean Automated ph Measurement System 28

30 SECTION 7 - WIRING SYSTEM WITH REMOTE MOUNT ANALYZER FIGURE 2-13 Cal-Clean System with Remote Mount Analyzer -- Wiring Arrangement 29 Cal-Clean Automated ph Measurement System

31 SECTION 7 - WIRING SYSTEM WITH REMOTE MOUNT ANALYZER TTL Outputs/ Pullouts 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. Relay A, B, and C Wiring The RELAY A, RELAY B, and RELAY C terminals in the P63B analyzer must be connected to control box terminals 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. Cal-Clean Automated ph Measurement System 30

32 SECTION 7 - WIRING SYSTEM WITH REMOTE MOUNT ANALYZER 7.4 Line Power P63B ph Analyzer Connect line power to the analyzer by following the steps described in Operating Instruction Manual No. P63. RP6300C Control Box 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 TB Remote Start Connections (optional -- using control box terminals) The Cal-Clean System can be remote started by applying a TTL signal for at least 300 milliseconds to REMOTE INPUT terminals 1 and 2 on TB2 in the analyzer, matching polarity as shown. 31 Cal-Clean Automated ph Measurement System

33 PART THREE - OPERATION SECTION 1 - ADJUSTING ELECTRODE INSERT AND RETRACT SPEEDS PART THREE - OPERATION SECTION 1 ADJUSTING ELECTRODE INSERT AND RETRACT SPEEDS You can independently adjust the electrode insert and retract 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. Recommendation: 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. Cal-Clean Automated ph Measurement System 32

34 PART THREE - OPERATION SECTION 2 - SETTING P63B ph ANALYZER FOR AUTOMATIC WASH/CAL OPERATION SECTION 2 SETTING P63B ph ANALYZER FOR AUTOMATIC WASH/CAL OPERATION 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, select 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 integral-mounted analyzer or in analyzer when it is remote-mounted). 33 Cal-Clean Automated ph Measurement System

35 PART FOUR - SERVICE AND MAINTENANCE SECTION 1 - CALIBRATING PERIODICALLY PART FOUR - SERVICE AND MAINTENANCE SECTION 1 CALIBRATING PERIODICALLY Normally, all ph electrodes age with time. Aging is characterized 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 recondition the electrode and then retest it. If reconditioning does not restore performance, the electrode should be replaced. 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 characteristics 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. SECTION 2 LUBRICATING AUTO-POSITIONER SHAFT The auto-positioner is shipped with a light silicone grease covering the shaft components. This lubricant protects internal sliding surfaces while in storage and aids operation when in use. Under normal conditions this lubricant should last the life of the auto-positioner. However, if the autopositioner 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 retract (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 assembly s materials of construction (acetal, Viton, and 316 stainless steel). Cal-Clean Automated ph Measurement System 34

36 PART FOUR - SERVICE AND MAINTENANCE SECTION 3 - REPLACING AUTO-POSITIONER O-RINGS SECTION 3 REPLACING AUTO-POSITIONER O-RINGS NOTE: If any internal seals are replaced or the autopositioner is disassembled for any reason, the GLI auto-positioner warranty is voided. Recommendation: 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. SECTION 4 REPLACING CONTROL BOX PUMP TUBING Important Recommendation: Routinely inspect the peristaltic 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. 35 Cal-Clean Automated ph Measurement System

37 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. SECTION 5 REPLACING CONTROL BOX MANIFOLD SOLENOID 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 assembly 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 solenoid 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 backing ring are in place. 5. Route the solenoid coil wires through the enclosure, and slide the solenoid coil assembly over the solenoid valve assembly. Cal-Clean Automated ph Measurement System 36

38 PART FOUR - SERVICE AND MAINTENANCE SECTION 5 - REPLACING CONTROL BOX MANIFOLD SOLENOID 6. Route the solenoid coil wires through the cord grip gasket and bushing. Place the cord grip bushing through the enclosure hole, and screw the bushing into the solenoid 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. FIGURE 4-1 Control Box Manifold Soleniod Replacement Details 37 Cal-Clean Automated ph Measurement System

39 PART FOUR - SERVICE AND MAINTENANCE SECTION 6 - TROUBLESHOOTING SECTION 6 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 Electrode wiring connection is faulty. No electrode response. Slow electrode response. Noisy electrode response. Auto-positioner jams periodically. Leaking autopositioner seals. Ineffective electrode cleaning. Electrode is cracked or internally damaged. Replace electrode. Check electrode cable connections at the control box or analyzer (see Part Two, Sect. 6.1 or 7.1). Electrode is not inserted. Insert electrode. 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. Electrode is contaminated with proteinaceous material. Electrode is contaminated from previous use. Clean junction by flushing solution chamber or removing electrode and manually cleaning. Soak electrode in pepsin solution (0.5% HCl and 1% pepsin) for 5 minutes. Clean thoroughly by flushing solution chamber. Wash and cal events are improperly timed. Re-evaluate times and scheduling. 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. Front seals are clogged by crystalline Remove auto-positioner and clean seals. material. Large particulate material is stuck in the solution chamber. Air pressure is too low. Air control valves are not adjusted properly or are inoperative. Air cylinder is contaminated. Seals are worn or damaged. Wash solution pressure is too low. Wash solution is not effective. TROUBLESHOOTING Re-evaluate the placement of the autopositioner in the process line or vessel. Increase control air pressure (up to 50 psi/3.45 bar maximum). Adjust air valves (see Part Three, Section 1) or replace them. Contact GLI Customer Service Department. Return to GLI for repair, or replace seals (see Part Four, Section 3). Increase pressure (up to 30 psi). Try a different wash solution (possibly a detergent-based cleaner). Cal-Clean Automated ph Measurement System 38