5500sc 961Xsc Service Manual v3.3 Official Version October 2019

5500sc & Polymetron 961Xsc
Service manual – Edition 3.3

Last revised on October 7th, 2019
Contents
1 Theory – Measuring principle................................................................................................................ 3
1.1 Measurement cycle principle ........................................................................................................ 3
1.2 Silica (Closed) Normal Measurement Cycle .................................................................................. 4
1.3 Silica (Closed) Grab Sample Cycle.................................................................................................. 5
1.4 Silica (Closed) Slope Calibration Cycle ........................................................................................... 6
1.5 Silica (Open) Normal Measurement Cycle .................................................................................... 7
1.6 Silica (Open) Grab Measurement Cycle......................................................................................... 8
1.7 Silica (Open) Slope Calibration Cycle ............................................................................................. 9
1.8 Silica (Open) Zero Calibration Cycle ............................................................................................ 11
2 Commissioning and start-up ............................................................................................................... 12
2.1 Requirements for installation:..................................................................................................... 12
2.2 Parts assembly ............................................................................................................................. 12
2.3 Turn it on, quick startup .............................................................................................................. 13
2.4 Calibration and Auto-Cal setup ................................................................................................... 15
2.5 Basic recorder output setup ........................................................................................................ 17
2.6 Basic set point Alarm Setup: ....................................................................................................... 19
2.7 Post-setup checks ........................................................................................................................ 20
3 Menu functions ................................................................................................................................... 21
3.1 Rotations from the Home Screen ................................................................................................ 21
3.2 Menu functions - Important Internal Data .................................................................................. 22
3.3 Menu tree structure .................................................................................................................... 26
4 Software settings and codes for events and errors ............................................................................ 42
4.1 Event Log codes ........................................................................................................................... 42
4.2 Hardware errors list..................................................................................................................... 52
4.3 Analyzer default settings ............................................................................................................. 53
5 Maintenance plan................................................................................................................................ 55
6 Diagnostic tools ................................................................................................................................... 56
6.1 Prognosys Operational Description ............................................................................................. 56
6.1.1 Introduction ......................................................................................................................... 56
6.1.2 Measurement Quality ......................................................................................................... 56
6.1.3 Service Due .......................................................................................................................... 56
6.1.4 Final comment ..................................................................................................................... 57
1
6.2 Diagnostic Menu Navigation and Usage ..................................................................................... 57
6.3 Intermediate Diagnostics - Troubleshooting and Corrective Actions ......................................... 58
7 Troubleshooting charts ....................................................................................................................... 64
7.1 Reagent air leak ........................................................................................................................... 64
7.2 Calibration failure ........................................................................................................................ 65
7.3 Suspected low reading ................................................................................................................ 66
7.4 Unstable reading warning ........................................................................................................... 67
8 Electronics- Connection diagrams ....................................................................................................... 68
8.1 Mother board .............................................................................................................................. 68
8.2 ADIOB – Analogue Digital Input Output Board ........................................................................... 69
8.3 Electronic module options .......................................................................................................... 70
9 Assembly drawings & parts ................................................................................................................. 71
9.1 Assembly case ............................................................................................................................. 71
9.2 Enclosure dimensions .................................................................................................................. 71
9.3 Colorimeter assembly drawing.................................................................................................... 72
9.4 4 channels sequencer assembly drawing .................................................................................... 73
9.5 Mechanical parts ......................................................................................................................... 74
9.6 PCB Assembly .............................................................................................................................. 76
9.7 Fluidics panel assembly ............................................................................................................... 77
9.8 Valve plate assembly ................................................................................................................... 78
9.9 Analyzer plate assembly .............................................................................................................. 79
9.10 Mechanical parts multichannel version ...................................................................................... 80
9.11 Interconect PCB assembly multichannel version ........................................................................ 83
9.12 Fluidics panel assembly multichannel version ............................................................................ 84
9.13 Valve plate assembly multichannel version ................................................................................ 85
9.14 Analyzer plate assembly multi channel version .......................................................................... 87
9.15 Parts for field tech only ............................................................................................................... 88
10 Service Procedures .......................................................................................................................... 92
10.1 Filter replacement ....................................................................................................................... 92
10.2 SD Card Reader Ckt Bd replacement ........................................................................................... 93
10.3 Checking or Changing Factory Settings ....................................................................................... 94
10.4 Circuit Boards Replacement ........................................................................................................ 96
10.5 Calibration offset entry ............................................................................................................. 100
2
10.6 Change the serial number ......................................................................................................... 100
11 Others ............................................................................................................................................ 103
11.1 Training outline ......................................................................................................................... 103
1 Theory – Measuring principle
1.1 Measurement cycle principle
3
1.2 Silica (Closed) Normal Measurement Cycle
Dispence Reagent
Step Segment
Sample Flush
Time - sec's
Vent Fan
Mixer
LED
Step Segment Description
Flush Cycle Mea s a ges : 1-FLUSH MIX 2-WAIT 3-DARK 4-FLUSH MIX 5-WAIT
12 sec
115
Dark Measurement
Ful l cel l ri ns e wi th new s a mpl e. Optci a l LED turned off for 12
110 sec
110 sec
s econds a t the begi nni ng of the cycl e to mea s ure the Da rk current.
Thi s cycl e a l ows a mi ni mum of 10 vol umn cha nges of fres h s a mpl e
103 sec
i n the 10mL col ori meter cel l for the next a na l ys i s .
~12sec
Add Reagent 1 200 Mea s a ges : 1-R1 2-REACT
Moly
Rea gent 1 a dded a nd mi xed. The s i l i ca i s rea cted wi th mol ybda te
to ma ke s i l i comol ybda te. Sul furi c a ci d i s a dded to i ns ure a very
200 sec
200 sec
a ci di c s ol uti on. Thi s rea gent cons i s ts of mol ybda te a nd s ul furi c

a ci d i n one s ol uti on (R1) for the cl os ed chemi s try.
Add Reagent 2 110 Mea s a ges : 1-R2 2-MIX 3-STABILIZE

~9sec
30 sec
Citric
Addi ti on of Rea gent 2,The s econd rea gent does three thi ngs . 1) i t
provi des a s urfa cta nt for better wetti ng of the pl a s ti c s urfa ce of the
110 sec
cel l for bubbl e remova l a nd 2) the orga ni c a ci d i nhi bi ts rea cti on of

the mol ybda te wi th phos pha te. The a ci d us ed for thi s s tep i s ci tri c
a ci d i n the Ha ch cl os ed chemi s try.
LED Adjustment Mea s a ges : 1-REFERENCE

10 sec 10 sec 10 sec
10
Opti ca l LED a djus tment to keep the reference counts to ~7,600,000

10
counts . An i ni ti a l mea s urement i s ma de to determi ne how much
the LED i s to be a ddjus ted then a wa i t peri od to l et the LED s ta bl i ze.
Reference Measurement 10 Mea s a ges : 1-REFERENCE
Actua l Reference Mea s urement
~12sec
Add Reagent 3 85 Mea s a ges : 1-R3 2-MIX 3-COLOR

FAA
35 sec
The a ddi ti on of certa i n reduci ng a gents (s uch a s ANSA, As corbi c

Aci d, FAS, or FAA) ca us e the forma ti on of the heteropl ol y bl ue
compl ex whi ch needs s i l i co or phos pho mol ybda te a s a precurs or to
85 sec
85 sec
form. The a ddi ti on of the reducta nt ca us es a more i ntens e col or

tha t i s a l s o more s ta bl e chemi ca l l y. Thi s permi ts the i ncredi bl e
detecti on l i mi ts pos s i bl e wi th thi s method. The cl os ed chemi s try
us es FAA but the functi on i s the s a me i n ea ch ca s e.
Sample Measurement Mea s a ges : 1-SAMPLE

12 sec
12 sec
12
La s t mea s urement of s a mpl e a fter col or devel opment
End Flush with 30 Mea s a ges : 1-FLUSH

30 sec
30 sec
30 sec
Thi s ri nce i s to fl us h the cel l of rea cted ma teri a l tha t produces

same sample
fumes
Wait State ? Mea s a ges : 1-WAIT

Ma ke up ti me depends on l ength of Inerva l s et by opera tor
Interval Mode
Total Seconds = 582
Cycle Time Min.'s = 9.7
4
1.3 Silica (Closed) Grab Sample Cycle
Step Segment
Dispence
Sample Flush
Time - sec's
Vent Fan
Mixer
LED
Start Opera tor wi l l be a s ked to pour i n 250 mL of Gra b Sa mpl e a nd pres s
Idle enter.
Grab Sample Flush Mea s a ges : 1-WAIT 2-DARK 3-FLUSH MIX 4-WAIT
78 sec 12 sec
90
Dark Measurement
90 sec
90 sec
~12sec
Add Reagent 1 200 Mea s a ges : 1-R1 2-REACT
Moly
200 sec
200 sec


~9sec
30 sec
Citric
110 sec


10
Opti ca l LED a djus tment to keep the reference counts up to 7,600,000

10
counts

Reference Mea s urement
~12sec

FAA
35 sec

85 sec
85 sec


12 sec
12 sec
12

30 sec
30 sec
30 sec

same sample
fumes
Idle Idle Opera tor wi l l be a s ked i f they woul d l i ke to run a nother Gra b
Sa mpl e or Exi t
Total Seconds = 557

5
1.4 Silica (Closed) Slope Calibration Cycle
Step Segment
Dispence
Sample Flush
Time - sec's
Vent Fan
Mixer
LED
Flush Cycle Mea s a ges : 1-WAIT 2-DARK 3-FLUSH MIX 4-WAIT
12 sec
99
Dark Measurement
99 sec
99 sec
87 sec
i n the 10mL col ori meter cel l for the next a na l ys i s .
~12sec Mea s a ges : 1-R1 2-REACT

Add Reagent 1 200
Moly
200 sec
200 sec


~9sec
30 sec
Citric
110 sec


10
Opti ca l LED a djus tment to keep the reference counts up to 7,600,000

10
counts

Reference Mea s urement
~12sec

FAA
35 sec

85 sec
85 sec


12 sec
12 sec
12

30 sec
30 sec
30 sec

same sample
fumes
Ins trument goes ba ck to previ ous s ta te of opera ti on

Total Seconds = 566
6
1.5 Silica (Open) Normal Measurement Cycle
Dispence Reagent
Step Segment
Sample Flush
Time - sec's
Vent Fan
Mixer
LED
Flush Cycle Measages: 1-FLUSH MIX 2-WAIT 3-DARK 4-FLUSH MIX 5-WAIT
12 sec
115
Dark Measurement
Full cell rinse with new sample. Optcial LED turned off for 12 seconds at the
110 sec
110 sec
beginning of the cycle to measure the Dark current. This cycle alows a
minimum of 10 volumn changes of fresh sample in the 10mL colorimeter cell for
103 sec the next analysis.
~12sec
Add Reagent 1 & 4 200 Measages: 1-R1 2-REACT
Moly
Reagent 1 & 4 added and mixed. For the open chemistry two different reagents
are used, R1 which is molybdate and R4 which is sulfuric acid in solution. In the
200 sec
200 sec
open chemistry they are added nearly at the same time.
Add Reagent 2 110 Measages: 1-R2 2-MIX 3-STABILIZE

~9sec
30 sec
Citric
Addition of Reagent 2,The second reagent does three things. 1) it provides a
surfactant for better wetting of the plastic surface of the cell for bubble
110 sec
removal and 2) the oxalic acid inhibits reaction of the molybdate with
phosphate.
LED Adjustment Measages: 1-REFERENCE

10
Optical LED adjustment to keep the reference counts up to 7,600,000 counts

10
Reference Measurement 10 Measages: 1-REFERENCE

Reference Measurement
~12sec
Add Reagent 3 85 Measages: 1-R3 2-MIX 3-COLOR

FAS
35 sec
The addition of certain reducing agents (such as ANSA, Ascorbic

Acid, FAS, or FAA) cause the formation of the heteroploly blue
complex which needs silico or phospho molybdate as a precursor
85 sec
85 sec
to form. The addition of the reductant causes a more intense color

that is also more stable chemically. This permits the incredible
detection limits possible with this method. The open chemistry
uses FAS here.
Sample Measurement Measages: 1-SAMPLE

12 sec
12 sec
12
Last measurement of sample after color development
End Flush with 30 Measages: 1-FLUSH

30 sec
30 sec
30 sec
This rince is to flush the cell of reacted material that produces fumes
same sample
Wait State ? Measages: 1-WAIT

Make up time depends on length of Inerval set by operator
Interval Mode
Total Seconds = 582
7
1.6 Silica (Open) Grab Measurement Cycle
Step Segment
Dispence
Grab Sample
Time - sec's
Vent Fan
Mixer
LED
Start Operator will be asked to pour in 250 mL of Grab Sample and
Idle
press enter.
Grab Sample Flush Measages: 1-WAIT 2-DARK 3-FLUSH MIX 4-WAIT
78 sec 12 sec
90
Dark Measurement
90 sec
90 sec
the next analysis.
~12sec
Moly
515 sec
515 sec

~9sec
30 sec
Citric
110 sec
phosphate.

10

10

~12sec

FAA
35 sec
The addition of certain reducing agents (such as ANSA, Ascorbic

Acid, FAS, or FAA) cause the formation of the heteroploly blue
complex which needs silico or phospho molybdate as a precursor
85 sec
85 sec
to form. The addition of the reductant causes a more intense color

that is also more stable chemically. This permits the incredible
detection limits possible with this method. The open chemistry
uses FAS here.

12 sec
12 sec
12

30 sec
30 sec
30 sec
same sample
Idle Idle Operator will be asked if they would like to run another Grab
Sample or Exit
Total Seconds = 872
8
1.7 Silica (Open) Slope Calibration Cycle
Silica (Open) Slope Calibration Cycle
Segment Time
Grab Sample
Dispence
Vent Fan
Reagent
Step
- sec's
Mixer
Flush
Step
LED
Segment Description
Dark
10 sec 100 Messages: 1-WAIT 2-DARK 3-FLUSH MIX 4-
Measureme WAIT
nt
Cell rinse with Calibration solution. Optical LED turned off for
Flush Cycle 10 seconds at the beginning of the cycle to measure the Dark
current. This cycle allows a minimum of 10 volume changes
of Calibration in the 10mL colorimeter cell for the analysis.
86 sec
90 sec
90 sec
Add 515 Measages: 1-R1 & 4 2-REACT

~12sec
Reagent 1
200 uL each of Reagent 1 & 4 added and mixed. For the open
&4 chemistry two different reagents are used, R1 which is
Moly molybdate and R4 which is sulfuric acid in solution. In the
515 sec
515 sec
Add 110 Messages: 1-R2 2-MIX 3-STABILIZE

Reagent 2
~9sec
Addition of 200 uL of Reagent 2. The second reagent does

Citric two things:
30 sec
1) it provides a surfactant for better wetting of the plastic

surface of the cell for bubble removal and 2) the organic acid
inhibits reaction of the molybdate with phosphate. The acid
used for this step is citric acid in the Hach closed chemistry.
110 sec
9
LED 7 Messages: 1-REFERENCE
Adjustment
7 to 17 sec
Optical LED adjustment to keep the reference counts at
~7,600,000 counts. An initial measurement is made to
determine how much the LED is to be adjusted then a wait
period to let the LED stabilize. Nominal 7 sec. Max 17 sec
Reference 10 Messages: 1-REFERENCE
10 sec
Measureme
10 second wait for LED to stabilize before Final Reference
nt Measurement
10 sec 10
Add 85 Measages: 1-R3 2-MIX 3-COLOR

Reagent 3
~12sec
Addition of 200 uL of Reagent 3. The addition of certain
FAA
reducing agents (such as ANSA, Ascorbic Acid, FAS, or FAA)
cause the formation of the heteroploly blue complex which
needs silico or phospho molybdate as a precursor to
35 sec
form. The addition of the reductant causes a more intense

color that is also more stable chemically. This permits the
incredible detection limits possible with this method. The
open chemistry uses FAS here.
85 sec
85 sec
Sample 12 Measages: 1-SAMPLE

Measureme
nt
12 sec
12 sec
End Flush 30 Measages: 1-FLUSH

This rince is to flush the cell of reacted material that produces
with
fumes
same
sample
30 sec
30 sec
30 sec
Instrument goes back to previous state of

operation
Total Seconds = 879
10
1.8 Silica (Open) Zero Calibration Cycle
Step Segment
Dispence
Grab Sample
Time - sec's
Vent Fan
Mixer
LED
Flush Cycle Measages: 1-WAIT 2-DARK 3-FLUSH MIX 4-WAIT
12 sec
99
Dark Measurement
99 sec
99 sec
87 sec
the next analysis.
~12sec
Moly
515 sec
515 sec

~9sec
30 sec
Citric
110 sec
phosphate.

10

10

~12sec

FAA
35 sec
The addition of certain reducing agents (such as ANSA, Ascorbic Acid, FAS, or
FAA) cause the formation of the heteroploly blue complex which needs silico or
phospho molybdate as a precursor to form. The addition of the reductant
85 sec
85 sec
causes a more intense color that is also more stable chemically. This permits
the incredible detection limits possible with this method. The open chemistry
uses FAS here.

12 sec
12 sec
12

30 sec
30 sec
30 sec
same sample
Instrument goes back to previous state of operation

Total Seconds = 881
11
2 Commissioning and start-up
2.1 Requirements for installation:

AC power (110/240 VAC)
Sample (2psi minimum, sampling point accepts 6mm or ¼” OD analyzer feed tube)
Drain(s) for bypass flow and analysis waste
Wall/panel/bench with sufficient space for mounting, clearance for open doors, and access behind analyzer
for plumbing connections
2.2 Parts assembly
1. Wall/panel/bench mount the analyzer. See the 5500sc Installation Manual (DOC023.97.80240) for details.
2. Assemble/attach sample conditioning kit (shut-off valve, Y-strainer, pressure regulator), sample bypass drain
tube, and waste drain tube. The cabinet catastrophic drain tube is optional, but recommended; if installed this
drain must include a trap and air break to prevent entry of potentially corrosive fumes from the common drain.
See figs. 3-6 in the Installation Manual for details.
3. Connect AC power, 4-20mA output wiring, alarm wiring. If optional input/output cards are not already installed,
install and wire them now. See fig. 11 for access cover removal, this needs to be removed for access to hole plugs
and knockouts. See fig. 10 for wiring ports – note external cap needs removed from hole plug before plug can be
removed. Fig. 10 item 3, cover plate with knockouts – these can be easily punched out with a 3/8 nutdriver or flat
screwdriver and hammer. (Note removal of top-facing plugs/knockouts can also allow easy entry of water & dirt;
be sure to install water-tight strain relief fittings for all wire entries.) Reinstall access covers when done.
4. Install the stir bar in the sample cell. Install the grab sample funnel and covers (if not already shipped this way).
5. Turn on the sample and adjust bypass flow. (It is easiest to do this now, before installing reagents.)
6. Prepare and install the reagents. FAA is a two-part reagent and needs mixed. Be sure to reinstall the straw and
rubber stopper before capping and shaking the bottle! The cap alone will not seal, and liquid will leak out. Don’t
squeeze full uncapped bottles!
12
2.3 Turn it on, quick startup
1. Turn on the analyzer power switch. If the analyzer is being started for the first time then the language selection
screen will appear. To save time on startup, follow the steps below:
1. Select a language, then press [Enter]. 2. Select a date format, then press [Enter]. 3. Set date and time (or accept values shown),
then press [Enter].
4. Select ‘No’ at the setup guide prompt, 5. The analyzer jumps directly to the Home 6. Press [Menu] / Reagents/Standards / Prime
then press [Enter]. screen. Reagents / [Enter].
7. Press [Enter] to prime all. 8. Select ‘Yes’ to interrupt the current cycle, 9. Reagent priming requires about 3 minutes,
then press [Enter]. during which the keyboard is locked. Wait for
completion.
13
10. After priming the analyzer will return to 11. Select Enter Blank Value, then press 12. Edit the value as labeled on the Molybdate
the Main Menu. Be sure [Enter]. Reagent bottle label. Open the bottom door if
Reagents/Standards is selected. Press needed to view the label, then close and latch
[Enter]. the door. Press [Enter].
13. The analyzer will return to the 14. The analyzer is in operation, measuring
Reagents/Standards screen. Press [Home] sample. If readings appear reasonable,
to go to the Home screen. proceed to calibration.
14
2.4 Calibration and Auto-Cal setup
The following steps allow you to initiate the first auto-calibration after startup, and then set up a calibration
schedule while the calibration is being performed. This saves time because you do not need to wait ten minutes for
completion of the calibration before setting up the schedule.
1. From Home screen, press [Cal]. 2. Select Start Manual Cal, then press 3. Press [Enter] to continue.
[Enter].
------------
4. Select Yes, then press [Enter]. 5. Calibration Status screen indicates the 6. The Home screen will show the “Calibrating”
calibration is in progress. DO NOT press icon in the blue status bar at the top. You may
[Enter] or [Back], or the calibration will be now proceed with Auto-Cal setup without
cancelled. DO press [Home]. interrupting the calibration in progress.
7. From the Home screen press [Cal]. 8. Select Activate Auto Cal, then press 9. Select Yes, the press [Enter].
Select Set Auto Calibration, then press [Enter].
[Enter].
15
10. Select Time Base, then press [Enter]. 11. Select Days, then press [Enter]. 12. Select days of the week as desired, then
press [Enter].
13. Select Time, then press [Enter]. 14. Edit Time as desired, then press [Enter]. Press [Home]. When the current calibration is
complete, the result will be displayed.
16
2.5 Basic recorder output setup
1. Press [Menu], select Setup System, then 2. Select Setup Outputs, then press [Enter]. 3. Select 4-20mA Setup, then press [Enter].
press [Enter].
4. Select an output, then press [Enter]. 5. Select Select Source, then press [Enter]. 6. Select the analyzer, the press [Enter].
7. Select Set Parameter, then press [Enter]. 8. Select a sample stream, then press 9. Select Set Function, then press [Enter].
[Enter].
10. Select Linear Control, then press 11. Select Activation, then press [Enter]. 12. Select Set Low Value, then press [Enter].
[Enter].
17
13. Edit the concentration representing 14. Select high Value, then press [Enter]. 14. Edit the concentration representing 20mA
4mA output, then press [Enter]. output, then press [Enter].
15. Press [Home].
18
2.6 Basic set point Alarm Setup:
1. Press [Menu], select Setup 2. Select Setup Outputs, then press 3. Select Relay Setup, then press
System, then press [Enter]. [Enter]. [Enter].
4. Select a relay, then press [Enter]. 5. Select Select Source, then press [Enter]. 6. Select the analyzer, the press [Enter].
7. Select Set Parameter, then press [Enter]. 8. Select a sample stream, then press 9. Select Set Function, then press [Enter].
[Enter].
10. Select Alarm, then press [Enter]. 11. Select Set Transfer, then press [Enter]. 12. Select Active, then press [Enter].
19
13. Select Activation, then press [Enter]. 14. Select Low Alarm or High Alarm, then 15. Edit the alarm value, then press [Enter].
press [Enter].
16. Press [Home].
2.7 Post-setup checks
1. Open the top and bottom analyzer doors, and carefully inspect for leaks or other concerns. The analyzer will
display background will turn red with the bottom door open. The analyzer will automatically restart when the
bottom door is closed and latched, and the red display background will again turn white. (If the display background
remains red or yellow, refer to Simplest Path to Important Internal Data.doc.) link to doc
2. Test recorder outputs and relays (if used).
20
3 Menu functions
3.1 Rotations from the Home Screen
Home screen – this Press [Right] to Press [Right] to Press [Right] to Press [Right] to
is the default screen move to this screen. move to this screen; move to this screen; move to this screen.
that appears when Minimum of two one more stream is one more stream is All currently active
the analyzer is samples (if added to the display. added to the display. sample streams are
powered up. sequencing is Continue until all displayed.
installed) will be streams are
If the analyzer has displayed. displayed. Press [Home] to
sequencing access the graph
installed, then If the analyzer is Press [Up] or [Down] settings menu.
pressing [Up] or single-stream, the to highlight any Time period and full
[Down] arrow keys graph display screen selected stream. scale values can be
will rotate through will be shown. The selected stream manually set.
the sample streams. will be shown at the
Sample stream top of the graph list, Full scale for each
currently being and will be the stream is listed at
analyzed is shown in displayed stream at the far right.
the status bar, and the Home screen.
analysis progress Press [Left] from any
will be shown if this screen to move one
sample is selected in screen to the left Press [Right] again
the main display to loop back to the
area. Home screen.
21
3.2 Menu functions - Important Internal Data
Example of display with several potential service indications:
The display background

color is yellow (or red) A ‘wrench’ icon appears in
the status bar
The Prognosys graph

is less than 100%
Important data concerning the analyzer’s operating status may be found in several menu locations, depending
whether the information represents a normal operating status or whether it represents a warning or error status.
In general, normal operating status info is found in the Main Menu, and warning or error info is found in the
Diagnostic Menu.
Whenever the Home Screen background color is yellow or red, always press [Enter] first to directly go to viewing
warnings/alarms:
Diagnostics / Diagnostics screen – if the display background is yellow

or red, simply press [Enter]; if the background is white, press [Diag],
then select Diagnostics.
Current analyzer warnings, alarms, and errors are displayed on this

screen. Active sample setpoint alarms are NOT displayed.
Press [Up] or [Down] arrow keys to select an item, then [Enter] to

display additional information or to acknowledge (reset) an item.
Important Note for servicers: If a Hardware Error occurs you must

go to [Menu] / View Data / Log Data / View Event Log, in order to
view the specific Event Code corresponding to the error. The Event
Code is available only in the Event Log, whether viewed in the Log or
downloaded to SD card. Refer to Event Log Codes.xls and Hardware
Codes Event 24.xls for details. The analyzer goes into shutdown
mode when a Hardware Error occurs, so the relevant error event will
probably be very near the top of the Event Log list.
An analyzer restart is needed if a Hardware Error occurs – this is not

a bug, but by design. The intent is to turn off power, fix the problem,
turn on power again. There is no other way to reset a Hardware
Error.
22
Go to [Menu] / View Data / Analyzer Data / [Enter] to view the following:
Analyzer Data screen
Readings are real-time. Sample Flow and Fan Speed may be zero,
depending on progress in sample measurement cycle, though these
will update appropriately when actuated. The sample cycle is not
interrupted when Analyzer Data is displayed; these are
measurements of the current sample cycle in progress.
Go to [Menu] / View Data / Measurement Data / [Enter] to view the following:
Measurement Data screen
These readings are for the last completed sample cycle. The readings
are static and will be updated when the current cycle is completed.
23
Go to [Diag] / System Data / [Enter] to view the following:
System Data screen
Readings are real-time, except for source frequency and source

voltage, which are inferred by firmware. Temperature reading is
ambient temperature measured on the interconnect board.
5. Go to [Menu] / Setup System / Instrument Information / [Enter] to view the following:
Analyzer Info screen
Analyzer name, chemistry, firmware information and serial number

are displayed.
24
Go to [Diag] / Current Status / [Enter] to view the following:
Current Status screen
Similar to Output Status display (but not printout) on the Series 5000
analyzer. Current sample stream, analysis step and time remaining
are shown.
Go to [Cal] / Calibration Data / [Enter] to view the following:
Calibration Data screen
Result of last calibration is displayed.
Note: It is possible displayed information may appear incorrect or

conflicting. The Calibration menu allows manual entry of slope and
zero values, but no other displayed values are altered.
25
Press [<] or [>] from the Home screen to view the following:
Graph display screen
Graphical display shows sample trend over time. Press [Home] key
to access options for scaling time and concentration axes.
Prognosys graphs on Home screen:
The left-hand graph represents Measurement Quality. The right-hand graph represents Service Due.
Various internal data are consolidated into a single percentage reading indicating the analyzer’s operating
condition. Each of the colored areas of the graphs indicate the following:
Green – No analytical or maintenance concerns. There is very high confidence the analyzer is functioning properly,
returning accurate readings, and will continue to do so. No further attention is required.
Yellow – A performance concern has been detected (e.g. sample cell needs cleaned), or maintenance is required in
45 days or less. The analyzer is functioning properly and returning accurate readings, but the user should monitor
the Prognosys menu for items requiring attention and prepare to correct to these items.
Red – A performance concern has been detected that may compromise analyzer operation or accuracy, or a
maintenance item is past due. The analyzer is not necessarily malfunctioning, but the Prognosis menu (and
perhaps other diagnostics) should be immediately checked and the concerns corrected.
3.3 Menu tree structure
NOTE: Please refer to the user manual for the menu definitions
Starting from the Home screen
26
[menu] – go to Main Menu (click here)
[back] – return to previous screen
[cal] – go to Calibration Menu(click here)
[diag] – go to Diagnostic Menu (click here)
[enter] – go to selection or accept data entry
[home] – return to Home screen (shown above)
Up, Down, Left, Right arrows – move cursor on menu

or data entry, or select alternate Home screen
Many menus offer a list of selections in submenus. Some selections offer choices as follows:
Yes/No – “Yes” usually means “continue”; “No” usually means”Cancel”.
Radio buttons, e.g. “ppb”, “ppm”, etc. Only one radio button at a time can be selected.
Checkbox buttons, e.g. “Sample1”, “Sample2”, etc. All buttons with checks are selected at once.
Main Menu
Main Menu
Stop (or Start) Stop Analyzer
Analyzer Shutdown Interrupts Stop Analyzer
Current Select Yes to Continue Shutdown
Cycle Step Status: Flush/Mix
Minutes Left: 1.3
or Completion: 29%
Analyzer halts operation
Start Analyzer Start Analyzer

Start Analyzer Run setup Yes/No? Start Anayzer
or Yes – runs initial setup
Start Analyzer No – immediately restarts,
Pease Clear Errors unless “Please Clear Errors…”
27
Before Performing is displayed. In this case
Start Analyzer Hardware Error has occurred,
Press Enter to and power must be cycled
Continue off/on to restart.
Reagents/Standards Reagents/Standards
Set Reagent Level Select Reagent
Reagent 1 Set Fluid Level
Reagent 2 Push ^v <> to Change Value
Reagent 3 +079 %
0% - 100%. Same for all three
reagents
Set Standard Level

Reset Standard Levels
Reset All Standard Reset Standard Levels
Levels to Full? [Enter]=Yes; [Back]=No
Press Enter to
Continue
Press Back to Cancel
Reset Reagent Levels

Reset Reagent Levels
Reset All Reagent Reset Reagent Levels
Levels to Full? [Enter]=Yes; [Back]=No
Press Enter to
Continue
Press Back to Cancel
Prime Reagents
Prime Reagents
Reagent 1 Interrupt cycle to prime?
Reagent 2 Yes/No
Reagent 3 (primes all selected)
Enter Blank Value

Enter Blank Value
Push ^v <> to -999.999 to 999.999
Change Value
+2.222 ppb
Grab Sample Perform Grab Sample

Grab Sample In Interrupt cycle to
start? Yes/No Standard – prompt for std
value, then run grab sample.
Other – prompt to pour in
Grab Sample Out sample
Analyze after
measuring? Yes/No
28
No – next reading not saved
Yes – next reading saved as
grab sample value.
Setup System Setup System

see Setup System
submenu tree
on following page –
(click here)
View Data View Data

Analyzer Data Analyzer Data
Cell Temp: 0.7’ C Summary of real-time
Reagent Temp: measurements representing
25.9’ C current operating conditions.
Ambient Temp: (Example at left)
29.8’ C
Sample Temp: 52.0’
C
Air Press: 3.85 PSI
LED Duty Cycle:
6660
Heater Duty Cycle :
100%
Sample Flow:
0mL/m
Sample Press 1:
7.13 PSI
Sample Press 2:
0.02 PSI
Reagent 1: 80%
Reagent 2: 80%
Reagent 3: 80%
Std Solution: 80%
Fan Speed: 0rpm
Leak Counts: 30
Measurement Data
Last Meas Channel: 1
Last Meas Time: Summary of measurements of
15:17:16 the last completed sample is
Last Abs: 0.0068 displayed. (Example at left)
Last Conc: 5.5ppbSiO2
Next Meas Time:
15:26:37
Dark: 308
Ref: 7602214
Sample: 7484205
29
Dark Std Dev: 13
Ref Std Dev: 460
Sample Std Dev: 1024
Sample Volume: 98ml
Reagent 1: 10972ms
Reagent 2: 7993ms
Reagent 32: 10938ms
Log Data
Log Data
View Data Log Select Data Log (sample
View Event Log measurements) or Event Log
(all other data) saved by the
analyzer. Data is displayed
per choice of previous Start
Time, Number of Hours, or
Number of Readings
Link2SC Create a new job

Job to lab
Erase Job
Job List
Job ID Min
Job ID Max
SD Card Setup SD Card Setup

Reading SD Card Save Logs Save Logs
Please Wait… Analyzer_9900001 Save Logs
(This list item appears Save Logs Push  to Begin
only if SD card has Last Day Log Files Transfer
been inserted) Last Week Save Logs
Last Month Analyzer_9900001 DL
Please refer to the All Transferring Files
user manual for New Please Wait…
further information 17%
on the use of the SD Manage
card Configuration Manage
Configuration
Backup Settings Backup Settings
Select Devices Transfer Complete.
Analyzer_9900001 Analyzer_9900001:Successful
30
Restore Settings
(listed only after a Restore Settings
backup has been Transfer Complete.
performed) Analyzer_9900001:Success
Select Devices Push  to Restart Analyzer.

Push  to Exit
Analyzer_9900001
Transfer Settings
Retrieve Settings Retrieve Settings
Select Devices Transfer Complete.
Analyzer_9900001 Analyzer_9900001:Successful
Work With Devices

Read Device Files Read Device Files
Sensor Diag Read Device Files
Measurement Transferring Files
Data Sensor Diag (and etc)
Cal History From: Analyzer_9900001
Cal Data Please Wait…
Test Script 15%
Service Part
Transfer Process
Successful
Push  to Continue
Main menu / Setup System submenu

Setup System
Setup Analyzer Interrupt cycle to setup?
Yes/No,
then
Activate Channels
Sample1
Sample2
Sample3
Sample4
Sequence Channels Use ^, v direction keys to

S1---> Sample1 select step; use <,> direction
S2---> Sample2 keys to select sample
S3---> ---------- stream
S4---> ----------
S5---> ---------- (Note “S9” is ‘step 9’, not
S6---> ---------- ‘Sample9’)
31
S7---> ----------
S8---> ----------
S9---> ----------
Meas Mode Meas Mode

Continuous
Interval
Edit Interval Appears only when Meas 10-240 minutes
Mode / Interval is
selected
Meas Units Meas Units

ppb
ppm
mg/l
ug/l
Signal Average Signal Average

Push ^v to Change 1-5 (number of readings
Value that will be averaged for
+1 displayed value)
Edit Analyzer Name Edit Analyzer Name

Push ^v <> to Change Edit text as desired
Value
ANALYZER 9900001
Edit Channel Name Edit Channel Name

Channel 1 Channel 1
Channel 2 Push ^v <> to Change Edit text as desired
Channel 3 Value
Channel 4 SAMPLE1
Sample Missing Sample Missing

(available with On Delay Allows users to switch to Use ^, v direction keys
V1.07) Off Delay the next channel when a to select step; use <,>
sample is missing, direction keys to
leveraging the choice of select On or Off Delay
“on delay” and “off delay.”
Configure Configure Sequencer
Sequencer Activate Channels Activate Channels
Sample1
Sample2
Sample3
Sample4 Use ^, v direction keys
to select step; use <,>
Sequence Channels Sequence Channels direction keys to
S1---> Sample1 select sample stream
32
S2---> Sample2
S3---> ---------- (Note “S9” is ‘step 9’,
S4---> ---------- not ‘Sample9’)
S5---> ----------
S6---> ----------
S7---> ----------
S8---> ----------
S9---> ----------
Set Date/Time Set Date/Time 

Date Format Date Format
YYYY-MM-DD 24h
YYYY-MM-DD 12h
DD-MM-YYYY 24h
DD-MM-YYYY 12h
MM-DD-YYYY 24h
MM-DD-YYYY 12h
Date/Time Date/Time
Date: 2013 – 06 – 26 Edit per selected
Time: 13 : 36 format
Display Setup Display Setup

Language Select one of 15 languages
Adjust Order Adjust Order

See Current Order In sequencing
Add Measurements analyzers, these
Reorder List menus edit sample
See Default Order readings that are
Set to Default displayed and their
order of display.
Display Backlight 1 (dimmest) – 9 (brightest)
Disable Reminders Disable Reminders

Tubing Select maintenance
Stir Bar reminders to disable as
Colorimeter Cell desired
Air Filter
Stir Motor
Air Relief Valve
Pinch Valve
Air Compressor
Reagent Valve(s)
Sample Valve(s)
Standard Valve(s)
Colorimeter LED
Fan Filter
Air Check Valve
33
Manage Devices Manage Devices
Scan Devices Press [Enter]; controller will
look for new SC200/1000
devices
(If SD card is in slot it does
not appear)
Instrument Analyzer Info

Information (below are examples only) Summary of internal
Name: configuration settings and
Analyzer_9900001 software revision info.
Type: Silica Closed (Example at left)
Software Vers: 1.01
DD Firmware: 1
DD Content: 0
Script Version: 1
Script Content: 1
Bootloader Vers: 1.01
S/N: 131239900001
Calculation Calculation 
Set Variable X ANALYZER_99000001 Select analyzer if more
than one is available
Set Parameter X 1-Silica:Sample1 Select sample stream.

2-Silica:Sample2 Note six streams are
3-Silica:Sample3 shown, asterisks
4-Silica:Sample4 denote invalid
5-Silica:Sample5* selections. (Example
6-Silica:Sample6* at left is 4-stream
analyzer.)
Set Variable Y ANALYZER_99000001
Select analyzer if more

Set Parameter Y 1-Silica:Sample1 than one is available
2-Silica:Sample2
3-Silica:Sample3 Select sample stream.
4-Silica:Sample4 Note six streams are
5-Silica:Sample5* shown, asterisks
6-Silica:Sample6* denote invalid
selections.
Set Formula (Example at left is 4-
Display Format stream analyzer.)
Set Units
Set parameter
Setup Outputs Setup Outputs

4-20mA Setup
Relay Setup
34
Error Hold Mode
Security Setup Security Setup
(if passcode is Set Passcode Set Passcode If Enabled is selected,
disabled) Disabled then current passcode
Enabled is in effect after
exiting Setup menu
or
Security Setup
(if passcode is
enabled) Security Setup
Enter Passcode Set Passcode Set Passcode
Push ^v <> to Disabled Disabled
Change Value Enabled Enabled
______
Edit Passcode Edit Passcode _ _ _ _ _ _ (up to 6
Push ^v <> to Change characters,no leading
Value blank)
______
Protect Features
Protect Features
Calibrate Calibrate
Configure Configure
Diag/Test Diag/Test
Perform Grab Sample Perform Grab
Start Analyzer Sample
Stop Analyzer Start Analyzer
Stop Analyzer
Air Purge Air Purge (air purge only enables or

Off disables case fan)
On
Reset Defaults Reset Defaults

Push Enter to Reset All
Configuration Settings If Enter is pressed:
to Reset Complete
Default. Push Back to Settings Are Rest
Cancel. Push Enter to
Continue
Cal menu
Calibrate Menu Start Manual Cal
Start Manual Cal Slope Cal is Selected Cycle:Measuring 2…
Press Enter to Continue Minutes Left: 5.6
Interrupt Cycle to Start?
35
Yes/No
Set Auto Calibration Schedule Slope Cal

Activate Auto Cal No
Yes
Std Solution + 0 5 0 0 . 0 ppb SiO2
Time Base Days If Days selected, set

Hours Week Day(s) and
Time to set cal
schedule.
Week Day Checklist allows day(s) If Hours selected, set
selection for calibration. Interval between 2
and 168.
Time 00:00 – 23:59
or
Interval 2 - 255 (>255 entry is
allowed, but rolls over to
0 at 256)
Calibration Data Last Cal Type:Slope Previous calibration

Last Cal Date:2013-05-30 result and schedule.
Last Cal Time:05:17:33 (Example at left)
Absorbance:0.4280
Concentration:521.6ppb
Slope Corr:0.99
Cal Zero:0.000
Next Cal Date:3012-06-30
Next Cal Time:02:00:00
Override Calibration Changing Cal Values

Overrides and Disables Auto Set Slope 0.50-1.50
Cal Yes/No Zero -999.999-999.999
Output Calibration Output 1 Edit A/D values while

Output 2 Cal 4mA observing output
Output 3 Cal 20mA
Output 4
Reset Default Cal Are You Sure?

Push Enter to Continue
Push Back to Cancel
Diag menu
Diag/Test Menu
Diagnostics Diagnostics
36
None
or
List of currently active Errors and warnings Select an item, then press
errors & warnings is can be acknowledged Enter for help suggestions
displayed and help submenus – user-serviceable level
accessed only.
Prognosys Prognosys
Measurement
Indicator
Service Indicator
Service Indicator Days remaining in current
Stir Motor: 1825 Days maintenance cycle are
Reagent Valve 1: 2555 Days
Reagent Valve 2: 2555 Days displayed. Example at left
Reagent Valve 3: 2555 Days
Colorimeter LED: 1825 Days
Sample Valve 1: 2555 Days
Air Relief Valve: 2555 Days
Standard Valve 1: 2555 Days
Colorimeter Cell: 365 Days
Air Filter: 365 Days
Charge Valve: 2555 Days
Stir Bar: 365 Days
Tubing: 365 Days
Fan Filter: 365 Days
Air Compressor: 1825 Days
Current Status
Current Status
Operation: Measuring Progress in current
Sample Channel: 1 measurement cycle is
Step Status: Color displayed. (Example at
Step Time: 16s left)
Minutes Left: 0.5
Completion: 94%
Analyzer Help
Analyzer Help
Errors Select an item, then press
Errors Enter for help suggestions
LED Low – user-serviceable level
LED High only.
Reagent Empty
Firmware Error
Hardware Error
Lower Door Open
Reagent Pressure Low
Wrong Colorimeter
Warnings Warnings
Select an item, then press
37
High Dark Current Enter for help suggestions
Reagent Pressure – user-serviceable level
Unstable Readings only.
Low Light Level
Reagent Low
Std Solution Low
Sample Flow Low
Heater Failure
Fluid Leak
Temperature Sensor
Case Temp High
Failed Cal
Sample Missing
Shutdown Mode
Sample Pressure > X
Sample Pressure < X
Cal Standard Empty
Autocal Disabled
Analyzer Setup
Reagent Pressure High
Fan Failure
Reminders Reminders
Tubing Lifespan
Stir Bar Lifespan
Sample Cell Lifespan Select an item, then press
Air Filter Lifespan Enter for help suggestions
Stir Motor Lifespan – user-serviceable level
Air Relief Valve Lifespan
only
Pinch Valve Lifespan
Air Compressor Lifespan
Reagent Valve Lifespan
Sample Valve Lifespan
Std Valve Lifespan
Sample LED Lifespan
Fan Filter Lifespan
Perform Test Air Check Valve Lifespan
Perform Test
Stop Analyzer First In Perform Test
Order to Reagent Delivery
Run Test. Interrupt Sample Delivery
Cal Sol Delivery
Cycle?
Mixer
Yes/No Colorimeter Heater
Sample Heater Functional tests of
Colorimeter hardware & software
Status LED
A2D
Air Pump
Fan
Analyzer Type
Select Script
Set Channels
Outputs
38
Outputs
Test 4-20mA Select 4-20mA Output
Output 1
Output 2
Output 3
Output 4
Test Relay Select Relay Test 4-20mA

Relay A Push ^v <> to Change
Relay B Value
Relay C +04.01 mA
Relay D (Same for all four outputs)
Hold Outputs Hold Outputs Test Relay

Launch Energize
Release De-energize
(Same for all four relays)
Output Status Output Status
Output 1
4.10 mA
Output 2 Current recorder output
4.10 mA values are shown.
Output 3 (Example at left)
0.02 mA
Output 4
0.02 mA
Simulate Simulate
Measurement Measurement
Select Source Select Source
Analyzer_9900001
Set parameter Set Parameter

1-Silica:Sample1
2-Silica:~Sample2
3-Silica:~Sample3
4-Silica:~Sample4
5-Silica:Sample5*
6-Silica:Sample6*
(Tilde ~ indicates sample is
deactivated; asterisk *
means selection is not
valid. Four stream
analyzer example above,
only Sample1 is active.)
Set Sim Value Set Sim Value

Push ^v <> to Change
Value
39
View LED Timeout +0004.9 ppb SiO2
Push ^v <> to Change
Value 0-9999 seconds
+0060 s
Modbus Status
Modbus Status
Sensor Port
Controller Port
Network Port
Service Port
Clear Stats
Service
Service Select Part
Service Part Tubing
Stir Bar
Colorimeter Cell
Etc, list of
maintenance parts
Part Information Select Part

Tubing
Part Information
Part: Tubing
Start:2013-05-30
Run Time: 293h
Stir Bar
Colorimeter Cell
Etc, list of
maintenance parts
Upcoming Service Upcoming Service

Service Part:Stir Bar
Last Service:2013-05-
09
Next Service:2014-06-
09
Days Remaining:
343days
(First part requiring
service is shown.)
Note math for next
service & days above as
example only
Service History Select Service

2013-05-20 08:45:02
Service History
Type:Factory
Reset
40
Date:2013-05-20
Time:08:45:02
Run Days: 0days
2013-05-20 10:52:34
2013-05-20 10:52:47
2013-05-20 16:50:37
…etc
System Data
System Data (Current status. Source
Temperature: 30.2’C frequency and voltage
Power Source are implied, not
Frequency:60Hz measured)
Power Source
Voltage:120V
12V Voltage:11.98V
3.3V Voltage: 3.27V
12V Current:0.562A
I2C Data
I2C Data Internal I2C serial bus
R1: 0 data’
R2: 0 (Example at left)
PT1: 0
PT2: 0
Version:C0
Overfeed Reset
Overfeed Reset
Done Resets overfeed control
41
4 Software settings and codes for events and errors
4.1 Event Log codes

Event Code
Possible causes or action

UI Display UI Help Information Event Description Condition/Function Event Type required
0 SETTING DEFAULT No longer applies
MODBUS
1 SERIAL NUMBER SerialNumChanged Analyzer board S/N was Can only be changed from the Inform
CHANGED changed test fixture
2 LOCATION STRING LocStrChanged Analyzer system name Analyzer name was changed Inform
CHANGE change
3 CODE UPDATE STARTED AppCodeUpdateStarted Firmware update started Start of new firmware update Inform
4 CODE UPDATE AppCodeUpdateCompleted Firmware update Firmware update completed Inform

COMPLETED completed
5 CODE UPDATE FAILED AppCodeUpdateFailed Firmware update failed Corrupted firmware file or Warning -File corrupted try to
disrupted during firmware reload or update file
update
6 DEVICE DRIVER No longer applies
UPDATED
7 OUTPUT MODE No longer applies
8 SOFTWARE RESTART SoftwareRestart Watch dog timer, timed Rare: time out in firmware Warning -Firmware Bug
out and restarted
9 POWER DOWN PowerDownEvent Instrument was powered Information on action Inform
down performed
10 POWER UP PowerUpEvent Instrument was powered Information on action Inform
up performed
11 RTC UPDATE RTCUpdateEvent Real time clock was Information on action Inform
updated performed
12 ZERO CAL ZeroCalEvent An auto zero calibration Information on action Inform
was performed performed
13 SLOPE CAL SlopeCalEvent An auto slope calibration Information on action Inform
14 MANUAL ZERO ManualZeroEvent An manual zero calibration Information on action Inform
15 MANUAL SLOPE ManualSlopeEvent An manual slope Information on action Inform
calibration was performed performed
42
16 LED LOW DIRTY OR SCRATCHED LEDLowError No transmitted light LED duty cycle is @ 100% and Alarm -Colorimeter cell needs
SAMPLE CELL: through the colorimeter the reference counts are < cleaning or replacing
-CLEAN OR REPLACE cell or so low reading are 5,000,000 counts. -Colorimeter cell not
SAMPLE CELL. affected flushing out
BLOCKAGE IN LIGHT
PATH OR SAMPLE CELL
NOT INSTALLED
CORRECTLY:
-REMOVE BLOCKAGE OR
INSTALL SAMPLE CELL
AGAIN.
LED LIGHT NOT BRIGHT
ENOUGH:
-SAMPLE MAY NEED
REPLACEMENT.CALL
TECHNICAL SUPPORT.
17 LED HIGH LED HIGH: LEDHighError A to D input is saturated A to D counts = 8388608 Alarm -Optical LED is always on,
-NOT USER counts replace analyzer board
SERVICEABLE. CALL -Detector circuit in
TECHNICAL SUPPORT colorimeter is defective
replace colorimeter board.
-A to D failure, replace
analyzer board.
18 REAGENT 1 EMPTY ANALYZER INDICATES Reagent1EmptyError Instrument thinks that If there is less than 10 mL in Alarm -Replace reagent and
THAT REAGENT BOTTLE Reagent 1 is nearly empty bottle….will not attempt to reset levels
IS EMPTY: make a measurement
-REPLACE REAGENT OR
19 REAGENT 2 EMPTY Reagent2EmptyError Instrument thinks that If there is less than 10 mL in Alarm -Replace reagent and
RESET FLUID LEVEL TO
Reagent 2 is nearly empty bottle….will not attempt to reset levels
MATCH AMOUNT
make a measurement
REMAINING IN BOTTLE.
20 REAGENT 3 EMPTY Reagent3EmptyError Instrument thinks that If there is less than 10 mL in Alarm -Replace reagent and
make a measurement
21 REAGENT 4 EMPTY ReagentEmptyError Instrument thinks that If there is less than 10 mL in Alarm -Replace reagent and
make a measurement
22 SAMPLE HEATER No longer applies
23 FIRMWARE ERROR FIRMWARE ERROR: FirmwareError Firmware error, error Set from Internal firmware Alarm -Power Cycle
-NOT USER logged and system auto run time errors
SERVICEABLE. CALL [Order which checked] Error Name rebooted
code
TECHNICAL SUPPORT
24 HARDWARE ERROR HARDWARE ERROR: 0 [N/A] e_hwErr_none = 0 No Errors No Error condition
43
- NOT USER 1 [21] e_hwErrColorimeter_Type Wrong colorimeter for Colorimeter ID does not Alarm -Instrument has the wrong
SERVICEABLE. CALL instrument configuration match the instrument type colorimeter
TECHNICAL SUPPORT -Check for loose connector
-Check for a loose cable
going to the 7ckt connector
on the colorimeter
2 [20] Photo LED cable connector Colorimeter, LED connector Alarm -Colorimeter photo
e_hwErrLEDHeaterCables_Swapped and heater cable connector and Heater connector are detector cable is plugged
are swapped swapped into the heater connection
on the analyzer board.
3 [1] e_hwErrPower_12V 12v supply voltage out of 12v supply voltage is < 11.0 Alarm -Defective Power Supply
range volts replace.
4 [2] e_hwErrPower_3P3V 3.3v supply voltage out of 3.3v supply voltage < 2.8 volts Alarm -Defective regulator
range replace Interconnect
board.
5 [3] e_hwErrReagentValve_1 Reagent valve not detected Current detection < 40ma or > Alarm -Wrong device, is missing,
for this instrument 250ma shorted or instrument type
configuration configured wrong.
6 [4] e_hwErrReagentValve_2 Reagent valve not detected Current detection < 40ma or > Alarm -Check connections and
for this instrument 250ma wire integrity
configuration
7 [5] e_hwErrReagentValve_3 Reagent valve not detected Current detection < 40ma or > Alarm
for this instrument 250ma
configuration
8 [6] e_hwErrReagentValve_4 Reagent valve not detected Current detection < 40ma or > Alarm
for this instrument 250ma
configuration
9 [7] e_hwErrStandardValve_1 Standard pinch valve not Current detection < 40ma or > Alarm
detected for this 150ma
instrument configuration
10 [8] e_hwErrStandardValve_2 Standard pinch valve not Current detection < 40ma or > Alarm
11 [9] e_hwErrSamplePinchValve Sample pinch valve not For sequencer version: (one Alarm
detected tube)
current detection < 40ma or
> 200ma
For single channel: (two
tubes)
current detection < 40ma or
> 300ma
12 [10] e_hwErrSampleValve_1 Sample sequence valve not Current detection < 50ma or > Alarm
44
15 [13] e_SampleValve_4 Sample sequence valve not Current detection < 50ma or > Alarm
18 [16] e_hwErrAirPump Air pump not detected Current detection < 100 or > Alarm -Check connections and
700ma wire integrity
-Check or replace device
19 [17] e_hwErrCellHeater Colorimeter heater not Current detection < 500 or > Alarm -Check connections and
detected 2880ma wire integrity
-Check or replace device
-Check for blown thermal
fuse
20 [18] e_hwErrSampleHeater Sample pre-heater not 1-Checks for AC or DC mode Alarm -Replace heater thermal
detected 2-Checks for line frequency fuse.
(See Tab "24-20-Sample pre-
heater" below for more
detail)
21 [19] e_hwErrMixer Colorimeter mixer not Current detection < 50ma or > Alarm -Check connections and
detected 300ma wire integrity
-Check or replace mixer
motor
25 LOWER DOOR OPEN LOWER DOOR IS OPEN: LowerDoorOpenError Lower Reagent Lower door open detection Alarm -If ERROR does not go
-CLOSE LOWER DOOR compartment door is away when door is closed
DOOR DETECTOR IS opened then check connections
DEFECTIVE: and wire integrity. Replace
-CALL TECHNICAL Open Door Detector Ckt
SUPPORT Bd.
45
26 REAGENT PRESSURE AIR LEAKAGE IN THE ReagentPressureLowError Excessive leak in the Air pump duty cycle is >16.7% Alarm -Check for loose fitting,
LOW REAGENT SYSTEM: reagent air supply, air tubes and bottle caps.
-EXAMINE BOTTLE CAPS, pump life is significantly -Check air relief valve.
FITTINGS AND TUBING reduced or cannot meet -Check for restricted line
CONNECTIONS. the supply pressure to or from the air
CALL TECHNICAL requirements. compressor.
SUPPORT -Check for plugged air filter
or defective check valve.
27 A2D FAIL A2DError The A to D reported an Checks to see if error bit is set Alarm -Replace Analyzer board
error
28 FLASH FAILURE No longer used
29 WRONG COLORIMETER WRONG COLORIMETER ColorimeterError Instrument see the wrong Alarm -Check for seated
-Not user serviceable. Colorimeter for its connector on main
CALL TECHNICAL configuration type Analyzer board
SUPPORT. -Replace with correct
colorimeter
30 HIGH DARK CURRENT LIGHT LEAKAGE INTO HighDarkCurrentWarning Excessive dark counts Dark counts were greater Warning -Is the instrument in direct
THE SAMPLE: measured when optical LED than 1000 sun light with covers
- MAKE SURE THAT THE is turned off removed
LIGHT COVER IS -Colorimeter circuitry
INSTALLED damaged check for spills
- MAKE SURE THAT THE
VIEWING LED IS TURNED
OFF.
31 REAGENT PRESSURE SMALL AIR LEAKAGE IN ReagentPressureWarning Small air leak in the Air pump duty cycle is >3% <= Warning -Check the relief valve
THE REAGENT SYSTEM: Reagent air pressure 16.7% -Check the frit after the
-TIGHTEN BOTTLE CAPS, system relief valve
FITTINGS AND TUBING
CONNECTIONS.
46
32 UNSTABLE READINGS EXCESSIVE BUBBLES IN UnstableReadingWarning Readings may be unstable The reference count change Warning -Is the colorimeter cell
SAMPLE: or inaccurate, excessive between the current and cover fully seated.
-PUT THE ANALYZER IN variability in the reference previous measurements > -Is the sample highly
STANDBY MODE. counts and LED duty cycle. 1.5% aerated.
ACTIVATE EACH -Is the surfactant reagent
REAGENT VALVE TO being delivered.
LOOK FOR REAGENT -Is the sample rinse
FLOW, LIFT THE SAMPLE sufficient. Check sample
CELL COVER. IF NO pressure and flow.
FLOW, LOOK FOR -Turbidity in the sample
PINCHED TUBING OR A
DEFECTIVE VALVE.
-EXAMINE SAMPLE
SOLUTION FOR AIR
SATURATION LEAKING
VALVES:
-PUT THE ANALYZER IN
STANDBY MODE TO
LOOK FOR SAMPLE,
REAGENT OR STANDARD
VALVE LEAKS, LIFT THE
CELL LID SLIGHTLY
ABOVE THE CELL. IF A
LEAK EXISTS, CALL
TECHNICAL SUPPORT.
MOISTURE IN OPTICS:
-PUT THE ANALYZER IN
STANDBY MODE.
REMOVE AND DRY THE
SAMPLE CELL. LET THE
HEATER BLOCK DRY,
THEN INSTALL THE
SAMPLE CELL.
33 LOW LIGHT LEVEL DIRTY OR SCRATCHED LowLightLevelWarning Transmitted light through LED duty cycle is > 70% but < Warning -Colorimeter cell needs
SAMPLE CELL: the colorimeter cell has 100% cleaning or replacing
– CLEAN OR REPLACE greatly decreased Instrument Accuracy and -Colorimeter cell not
SAMPLE CELL. percussion still OK flushing out
SAMPLE CELL NOT
INSTALLED CORRECTLY:
–PUSH SAMPLE CELL
TIGHTLY INTO
COLORIMETER BLOCK
34 REAGENT LOW LOW LEVEL IN REAGENT ReagentLowWarning One or more reagents are Reagent level < 10% Warning -Time is close to replacing
BOTTLE: low reagents
- REPLACE REAGENT -Level may have been
SOON entered
35 STD SOLUTION LOW LOW LEVEL IN StdSolutionLowWarning One or more of the Standard solution < 200 mL Warning -Time is close to replacing
STANDARD SOLUTION standard solutions are low standards
BOTTLE: -Level may have been
- REPLACE STANDARD entered
47
SOLUTION SOON
36 SAMPLE FLOW LOW FLUSH VOLUME TOO SampleFlowLowWarning Sample flush volume is too Total flush Volume < 99mL Warning -If sample pressure is OK
LOW, READINGS MAY low for complete cell flush or <54 mL/min check for line restrictions
BE AFFECTED BY after the sample pre-
CARRYOVER: heater.
-MAKE SURE THAT If there is no flow, check to
SAMPLE PRESSURE IS make sure the sample
SUFFICIENT pinch valve is opening or
LINE FILTER IS BLOCKED: the pinch tube is not frozen
- REPLACE LINE FILTER. shut.
TUBING IS PINCHED:
-MOVE TUBING FROM
PINCHED AREA.
SAMPLE PRESSURE
REGULATOR IS SET
INCORRECTLY:
-ADJUST THE PRESSURE
REGULATOR
37 HEATER FAILURE CALL TECHNICAL Colorimeter heater is not heating. Colorimeter heater or Warning -Check to see if thermal
SUPPORT. Or Sample Pre-heater not fuse is blown
Sample pre-heater is not heating. coming to temperature -Check thermistor
connection and ohm value
38 FLUID LEAK LEAK FOUND IN THE FluidLeakWarning Fluid leak has been Range for leak counts is 1023, Warning -Check for fluid leaks close
UPPER OR LOWER detected in the upper or counts > than 511 will trigger to the leak detector in the
ANALYZER lower compartment a warning. upper and lower cabinet.
COMPARTMENT:- After resolving the issue,
EXAMINE TUBING AND toughly dry the areas
FITTINGS FOR LEAK AND around the leak detectors. -
REPLACE DAMAGED If this is a regular nuisance
PARTSELECTRONIC due to condensation in the
ERROR:CALL TECHNICAL lower case (Hi humid
SUPPORT conditions), this warning
can be disabled from the
menu.
39 TEMPERATURE SENSOR CALL TECHNICAL TempSensorWarning One of the three If >100 C a shorted sensor or Warning -If temperature sensor is
SUPPORT temperature sensors are If <1 C a open sensor circuit open the reading will read
defective 0.7 C
48
40 CASE TEMP HIGH AMBIENT CaseTempHighWarning Upper inside case Temperature is > 65C Warning -Ambient temperature to
TEMPERATURE IS temperature is to high high
GREATER THAN 50 ºC: -Is instrument exposed to
- PUT INSTRUMENT IN A direct sun light?
LOCATION THAT HAS AN
AMBIENT
TEMPERATURE OF 50 ºC
OR LESS.
ANALYZER IS IN DIRECT
SUNLIGHT:
-SHADE THE ANALYZER
FROM DIRECT SUNLIGHT
41 CAL FAIL STANDARD VALUE IS FailedCalWarning Instrument failed to Limits must be within: Warning
NOT CORRECT: calibrate Silica (closed)
-ENTER THE CORRECT Scorr = 1.000 +-30%
STANDARD VALUE. Zero = 0.000 to 10ppb
SAMPLE IS NOT MIXED Silica (open)
FULLY: Scorr = 1.000 +-95%
-MAKE SURE THAT THE Zero = 0.000 to 150ppb
STIR BAR IS LR Phosphate (closed)
INSTALLED.TUBING IS Scorr = 1.000 +-30%
PINCHED. Zero = 0.000 to 100ppb
LR Phosphate (open)
Scorr = 1.000 +-95%
Zero = 0.000 to 100ppb
HR Phosphate (closed)
Scorr = 1.000 +-30%
Zero = 0.000 to 1000ppb
HR Phosphate (open)
Scorr = 1.000 +-95%
Zero = 0.000 to 1000ppb
42 SAMPLE 1 MISSING NO SAMPLE PRESSURE: Sample1MissingWarning Pressure sensor indicate Pressure < 0.5 psi Warning -Verify that Sample is
-MAKE SURE THAT that Sample 1 is missing missing or check line filter
43 SAMPLE 2 MISSING SAMPLE PRESSURE IS Sample2MissingWarning Pressure sensor indicate Pressure < 0.5 psi Warning
SUFFICIENT that Sample 2 is missing
44 SAMPLE 3 MISSING Sample3MissingWarning Pressure sensor indicate Pressure < 0.5 psi Warning
that Sample 3 is missing
48 SHUTDOWN INSTRUMENT IS IN StandbyWarning Instrument is in standby Information on status Warning -Instrument is in Standby,
SHUTDOWN if this is not the intention
than restart analyzer
49
49 SAMPLE PRESSURE > X SAMPLE PRESSURE SamplePressureHighWarning Sample pressure is high Pressure is > 10 psi Warning -Defective sample pressure
REGULATOR IS regulator, replace.
DEFECTIVE:
-REPLACE SAMPLE
PRESSURE
50 SAMPLE PRESSURE < X SAMPLE PRESSURE SamplePressureLowWarning Sample pressure low Sample pressure =< 1 psi but Warning -Check sample line filter
REGULATOR IS => .5 psi -Check actual sample line
DEFECTIVE: pressure
-REPLACE SAMPLE -It is advised that line
PRESSURE pressure be at least 2 psi
51 CAL STANDARD EMPTY ANALYZER INDICATES StandardEmptyWarning Not enough calibration If the instrument thinks there Warning -Replace Standard bottle
THAT CALIBRATION solution left for another is less than 5% of the original with fresh new standards
SOLUTION BOTTLE IS calibration volume it considers it empty or set standard levels to
EMPTY: correct levels.
-REPLACE CALIBRATION
SOLUTION OR RESET
FLUID LEVEL TO MATCH
AMOUNT REMAINING IN
BOTTLE
52 AUTO CAL DISABLED AUTO CALIBRATION IS AutoCalDisabledWarning Auto Calibration is disabled Information on status Warning -Advise using Auto
DISABLED Calibration on a weekly
basis
53 ANALYZER SETUP SETUP INCOMPLETE SetupRequiredWarning Indicate that the Awareness for the operator Warning -Finish instrument setup
instrument setup is advised
incomplete
54 TEMP OUT RANGE TempOutRangeWarning Instrument cannot control Temperature reads 0.5 or 0.0 Warning -If the instrument
the Colorimeter or Sample deg C and will not try to turn measures 0.5 C the
Pre Heater on either or both; the thermistor is open circuit.
Colorimeter or Sample Pre -If the instrument
Heaters. measures 0.0 C the
thermistor is shorted.
55 OPEN HEATER CIRCUIT No longer applies

56 REAGENT PRESSURE REAGENT PRESSURE ReagentPressureHighWarning Reagent pressure is Reagent pressure > 4.2 psi Warning -Check Relief Valve and its
HIGH HIGH: excessive connection
-REPLACE THE RELIEF -Replace tubing with frit
VALVE going to the Relief Valve
CAPILLARY TUBE.
-CALL TECHNICAL
SUPPORT
57 FAN FAILURE CALL TECHNICAL FanFailureWarning Fan is not turning on at Fan RPM's = 0 Warning -Replace Vent Fan
SUPPORT appropriate time
58 LINK2SC FILE PARSE ERR Link2scFileParsingFailure Job file parsing failure in Corrupted the Link2sc job file Warning -Restart a Link2sc job
the Link2sc operation
59 LINK2SC JOB FAILURE Link2scJobFailure Job creation failure in No measurement in the job Warning -Add a measurement to
Link2sc operation file current Link2sc job
50
60 RESET DEFAULT CAL ResetDefaultCal Reset all calibration values Slope set to: 1.000 Inform
back to default values Zero set to: 0.0
Auto Calibration: DISABLED
See TAB: 60-RESET DEFAULT
CAL
61 RESET DEFAULTS ResetDefaults Reset to default values See TAB: 61-SET DEFAULTS Inform
Except Calibration
62 SCAN FAILURE ScanFail Scan for sensors failed Expected to see a Sensor Warning -Has sensor been removed
63 INSTALL FAILURE InstallFail New sensor installation Could not install new Sensor Warning -Device may be bad or
failed check for connector
alignment
64 INSTALL SENSORS AddDevice New sensor was added Sensor was added to the Inform
analyzer
65 REMOVE SENSOR RemoveDevice Sensor was removed Sensor was removed from the Inform
analyzer
66 SENSOR COMM LOSS DeviceCommLoss Communication was lost to No response from the sensor Warning #NAME?
sensor after 3 retries
67 SENSOR COMM DeviceCommRestore Communication was The communication between Inform
RESTORED restored to sensor the analyzer and sensor is
reestablished.
68 FLASH FAILURE FlashFailure Error writing to serial flash Flash on circuit board failed, Warning -Replace Analyzer board
analyzer not capable of
logging data
69 NETWORK CHANGE NetCardConfigChange A change in the network Information on action Inform
CONFIG card configuration performed
occurred
70 SET DEFAULTS ConfigInitialize A change in the analyzers Information on action Inform
configuration occurred performed
71 CHANGE CONFIG ConfigChange A change occurred to the Information on action Inform
instrument configuration performed
72 GRAB SAMPLE GrabSample Grab sample event Information on action Inform
performed
51
4.2 Hardware errors list
Error
Code Hardware Error Description
0 e_hwErr_none = 0, No Errors
1 e_hwErrColorimeter_Type, Wrong colorimeter for instrument configuration
2 e_hwErrLEDHeaterCables_Swapped, Photo LED cable and colorimeter cable are swapped
3 e_hwErrPower_12V, 12v supply voltage out of range
4 e_hwErrPower_3P3V, 3.3v supply voltage out of range
5 e_hwErrReagentValve_1, Reagent valve not detected for this instrument configuration
Standard pinch valve not detected for this instrument

9 e_hwErrStandardValve_1,
configuration
Standard pinch valve not detected for this instrument

10 e_hwErrStandardValve_2,
configuration
11 e_hwErrSamplePinchValve, Sample pinch valve not detected
Sample sequence valve not detected for this instrument

12 e_hwErrSampleValve_1,
configuration

configuration

configuration

configuration

configuration

configuration
18 e_hwErrAirPump, Air pump not detected

19 e_hwErrCellHeater, Colorimeter heater not detected
20 e_hwErrSampleHeater, Sample pre-heater not detected
21 e_hwErrMixer, Colorimeter mixer not detected
52
4.3 Analyzer default settings
- MEAS MODE CONTINUOUS

(cannot edit, in
CONTINUOUS
- EDIT INTERVAL mode)
- MEAS UNITS ppb
- SIGNAL AVERAGE +1
example:
- ANALYZER NAME ANALYZER_2030405
- CHANNEL NAME example: SAMPLE 1
- SET DATE/TIME
- DATE FORMAT YYYY-MM-DD 24h
(no change, retains
- DATE/TIME last setting)
- DISPLAY SETUP
- LANGUAGE ENGLISH
- ADJUST ORDER (only Calculation
measurement
added will be reset)
- DISPLAY
BACKLIGHT +5
- DISABLE
REMINDERS (all are disabled)
- CALCULATION
- SETUP
CALCULATION
(sets to first item on
- SET VARIABLE X the list)
- SET PARAMETER X the list)
- SET VARIABLE Y the list)
- SET PARAMETER Y the list)
- SET FORMULA NONE
- DISPLAY FORMAT AUTO
- SET UNITS units
- SET PARAMETER param
- SETUP OUTPUTS
- 4-20mA SETUP NONE
- RELAY SETUP NONE
- ERROR HOLD
MODE HOLD OUTPUTS
- SECURITY SETUP
- SET PASS CODE DEFAULT
- EDIT PASS CODE (can change pass
53
code)default is
HACH50
- PROTECT
FEATURES DISABLED
- AIR PURGE OFF
LR HR
Silica Phosphate Phosphate
- SET AUTO CALIBRATION - ACTIVATE AUTO
CAL DISABLED
- STD SOLUTION 500ppb 3000ppb 3.0ppm
- TIME BASE DAYS
- WEEK DAY SUNDAY
- TIME 2AM
The following settings are retained through Reset Defaults:

Date and Time
Calibration slope
Calibration offset
Output Holds
Multi-stream analyzer will go to 1, 2, 3, etc sample sequence, all streams activated.
54
5 Maintenance plan
 Tubings 1x/year
 Stir bar 1x/year
 Colorimeter cell 1x/year
 Air filter 1x/year
 Fan filter 1x/year
 Air check valve 1x/year
 Stir Motor 1x/4 years
 Air compressor 1x/4 years
 Colorimeter LED 1x/4 years
 Valves (reagent, std, sample, pinch, air relief) 1x/6 years
55
6 Diagnostic tools
6.1 Prognosys Operational Description
6.1.1 Introduction
The purpose of Prognosys© is to provide the customer with a graphical indication that something needs to be
done to his instrument in order for it to continue to function properly. In the 5500sc/9610\ implementation
this was provided using two colored bars, one for measurement quality, and one for service due. These two
bars are made up of other discrete measures and provide a composite estimate of measurement quality and
service interval.
6.1.2 Measurement Quality

The measurement quality progress bar indicates when a compromise in instrument analytical performance is
likely (0%) and when such a compromise is unlikely (100%). The measurement quality consists of four checked
parameters: LED DUTY CYCLE, SLOPE CAL, DARK COUNTS, and REF STD DEV. These parameters are listed
below:
Measurement Parameter Value which Measures 100% Value Which Measures 0%

LED DUTY CYCLE < 70% >100%
SLOPE CAL <+/- 50% of nominal slope >+/- 125% of nominal slope
DARK COUNTS < 500 >1000
REF STANDARD DEVIATION <1000 >5000
Table 1- Values At which The Measurement Bar will indicate 0% and 100% on the analyzer
For each of these parameters 0% would mean that the instrument’s measurement is most likely compromised,
and at 100% the instrument’s measurement quality is most likely not compromised. These four parameters are
then combined via an algorithm which takes each of the parameters into account to generate a value from 0 to
100%. If any of the individual parameters are at 0% then the instrument will reflect 0%. If none are at 0% the
scores (each of the above limits linearly related from 0 to 100%) then the total value is calculated in a manner
whereby the worst value is automatically the largest contributor to the aggregate measure. For example: If
the LED Duty was greater than 100% then the aggregate measure would yield a 0% value meaning something
must be done. If however the LED Duty cycle were at 95% its contribution to the Prognosys© value would be
approximately 15%. If this were the lowest value the quality would be dictated primarily by this value so we
would expect the graphical indicator to be coming in at about 15% which is in the red zone.
The dark line on the indicator as it passes the colored regions (red, yellow and green) indicates pictorially
where the value is and the level of concern. When the dark line is in the green region (>75%) there is nothing
to worry about. Values in the yellow area should be monitored for further problems. Anytime the aggregate
measure is between 50% and 75% the bar will be in the yellow region. Below the 50% point there is most likely
something to worry about and the individual values in the Prognosys menu should be consulted and action
taken to repair the instrument. Even if the bar is in the red the instrument may continue without
measurement impairment for a short while. This gives the customer the opportunity to see difficulties before
they become emergencies.
6.1.3 Service Due

The service due indicator simply indicates if any of the serviceable items are due to have service in the next 90
days. We do not include reagents in this list but do include such items as filters, valves, tubing, and other
56
potential wear items. If none of the serviceable items have recommended service within 90 days the bar will
be at its greatest extent and the numerical value will indicate “>90 days”. If ANY item is less than 90 days then
the overall bar will be entirely governed by that item.
6.1.4 Final comment

The purpose of Prognosys© is to alert the customer to potential upcoming problems by means of a visual
indicator. It cannot be said that it is perfectly capable of predicting all conditions, but rather evaluates the
most likely problem areas in an attempt to anticipate upcoming difficulties. It is entirely possible, and in fact
probable especially when considering the measurement quality toolbar that we might have a situation arise
where the indicator is happily reporting 100% (no problems) then suddenly reports 0% (impending significant
concern!). It is also possible as the instrument ages to have one thing fixed and still be in the yellow or even
the red because another item is leading the next required service.
6.2 Diagnostic Menu Navigation and Usage
More useful functions for troubleshooting,

analyzer observation, and final checkout…
Menu selections are as follows:
Diagnostics – shows active warnings and errors.

For many errors, the Diagnostics / Help menu will be sufficient to isolate a problem.
Note an analyzer restart is needed if a Hardware Error occurs – this is not a bug, but by design. The
intent is to turn off power, fix the problem, turn on power again. There is no other way to reset a
Hardware Error.
- If a Hardware Error occurs you must go to [Menu] / View Data / Log Data / View Event Log, in
order to view the specific Event Code corresponding to the error. The Event Code is available
only in the Event Log, whether viewed in the Log or downloaded to SD card. Refer to Event Log
Codes.xls and Hardware Codes Event 24.xls for details. The analyzer goes into shutdown mode
when a Hardware Error occurs, so the error event will probably be very near the top of the
Event Log list.
Prognosys – view the factors that determine the Prognosys graphs on the Home screen.
Current status – similar to Output Status on S5000, but no printout. All sample measurement info is always
saved in curves log.
57
Analyzer help – lists of warnings, alarms, and reminders. Select an item, then press [Enter] for user help tips.
Many errors will jump directly to the help tips when Help is selected (or sometimes Enter pressed) from the
error list.
Perform test - see Intermediate Diagnostics section of this manual for submenu listing
Outputs – allows testing the recorder and alarm relay outputs

- 4-20mA – select output 1-4, edit the value – update is in real time as value is edited.
With a DMM connected to the output terminals, this is a very simple way to test.
- Relay – select 1-4, select Energize/De-energize – update is in real time by selection.
Again, a very simple test with DMM connected to the output terminals.
- Hold outputs – elaborate version of Hold Outputs function in other analyzers. As with all ‘hold
outputs’ you might not trust it (or yourself) to hold while servicing the analyzer. You may believe you’ll
unexpectedly leave this menu or perform other actions that will accidentally release the hold.
However, until power is cycled or the hold times out – even though a Reset Defaults – the outputs will
remain held. The numeric concentration display will flash on-off while outputs are held (this is not
mentioned in the user manual). See SC200 manual for additional info. Hold outputs turns off only if it
times out, power is cycled or it is turned off in the Hold Outputs menu.
- Output Status – displays the current from Rec Out 1-4. (Yes, “current current” – the output current
that is currently being output.) Relay status is not displayed.
- Simulate Measure – Maintenance Manual says this shows only when a sensor or module is
connected.
View LED – select how many seconds – Turns on cell viewing LED, then turns it off when the time elapses. The
analyzer continues sample measurements, and the viewing LED may cause interference with sample readings
when turned on. “Unstable Sample” is a likely error.
Modbus stats – (if available).
Service - To reset a maintenance item go to [Diag] / Service / Service Part / Select Part / [Enter]. Select “Yes” /
[Enter]. This sequence removes the item from the Diagnostic list and resets its maintenance timer.
System Data – displays ambient temp, power voltage & freq, DC power supplies. However, ambient
temperature is read in the A/D converter, so it is possible a bad ambient temperature reading might indicate an
A/D problem.
Overfeed reset – resets the overfeed timer.
6.3 Intermediate Diagnostics - Troubleshooting and Corrective Actions

If [Diag] / Diagnostics does not clearly indicate the cause and solution to a fault condition, then further troubleshooting
may be needed. If you have not already done so, begin by referring to Simplest Path to Important Internal Data.doc for
basic troubleshooting information.
Go to [Diag] / Perform Test / [Enter] to view the following:
58
1. Select Perform Test, then press 2. Select Yes, then press [Enter]. 3. The Perform Test menu is ready
[Enter]. The analyzer may display a ‘wait’ for use.
message as the sample cell is
flushed.
After 30 minutes with no keyboard activity the analyzer will return to the Home Screen but remain stopped. If
additional tests need to be performed, select Restart Analyzer and then return to the Perform Test menu to
continue.
Italic text under Expected Result in table below is either the analyzer specification, or it is a condition of normal
operating mode only. Please note that errors or warnings mentioned below will not occur during these
diagnostic tests.
Menu function: What it tests, and test details: Expected result: Corrective action(s):
Reagent Tests reagent valves, Reag1 140ul = 10 drops; Reag 2 Verify tubing maintenance
Delivery capillaries, interconnecting 80ul = 10 drops; Reag 3 140ul = is current, reagent pressure
tubing and fittings from air 10 drops. A count of 9-11 drops is good (5 psi). Replace cell
manifold to bottle to indicates dispensing accuracy of cap assembly, then retest.
colorimeter, and valve control about +/- 10%, close enough to Replace reagent valve, then
circuit. reasonably assume retest.
dispensation is good.
Select Reagent 1, 2, or 3;
dispense time or volume. A Flow must stop immediately
simple and reasonably when valve closes.
accurate test is ‘counting
drops’ as reagent is dispensed. Spec is +/- 10% of volume
Since the reagents have
different viscosities and
surface tensions, drop count
will be slightly different for
each reagent even when
volumes are the same. Hold
the cell cap over the sample
cell and count the drops for
volumes in the next column.
Sample delivery Tests sample valve, pressure The analyzer should dispense at Verify tubing maintenance
sensors, valve control circuit, least 100 ml/minute with is current, sample pressure
interconnecting tubing and Pressure 1 at 4 psi, though is good (4 psi), sample
fittings from sample inlet to dispensing rate may be lower if strainer is clean. Replace
sample heater to sample valve sample source pressure is sample pinch valve.
to colorimeter. lower. The dispensed rate
displayed should reasonably
59
Select a sample stream, then agree with the grad cylinder.
dispense time. Remove cell
cap and insert sample straw Flow must stop immediately
into top of a 100 ml graduated when valve closes.
cylinder. Set time for 30
seconds, then start test. No spec, but warning will occur
Observe screen; test will show if <54 ml/min or total flush <99
a calculated dispensing rate. ml.
At the end of the test, note
sample volume captured in the
cylinder and multiply by 2 for
per minute rate.
Cal Sol Delivery Tests standard solution valve, The analyzer should dispense Verify tubing maintenance
interconnecting tubing and standard solution at is current, reagent pressure
fittings from air manifold to approximately 80-100 is good (5 psi), standard
valve to colorimeter, and valve ml/minute. Standard bottle fill bottle is not empty.
control circuit. level is decremented when this Replace standard valve.
test is performed.
Select delivery time in
seconds. Remove cell cap and Flow must stop immediately
insert standard solution straw when valve closes.
into the top of a graduated
cylinder. Display will show No spec, flow is not measured
time remaining, but not flow by analyzer
rate.
Mixer Tests the stir motor, stir Stirrer should appear to spin Verify stirrer wiring, inspect
magnet, wiring and connection smoothly, though stepper motor armature bushings
between controller board and motor “cogging” will be visible. for corrosion, lube with
the motor, and motor control thin oil and manually ‘help’
circuit. No spec, but Hardware Error motor to start. Replace stir
24-21 will occur if motor current motor assembly or entire
Allows forward, backward, <50mA or >300mA colorimeter.
rpm’s 10-500, run time in
seconds. Visually observe stir
bar during test. This test
should be unnecessary for
troubleshooting, as the stirrer
obviously spins during the
sample cycle.
Colorimeter Tests the colorimeter heater, In Ames Service test, temp fell If temperature reading is
Heater interconnecting wiring and from 50 to 42’ in about 800 incorrect or if temperature
connection to the controller seconds; temp increased from does not change, replace
board, heater control circuit, 42-50’ in about 100 seconds. colorimeter.
and infers proper temp sensor (Note this can be affected by
response. ambient conditions.)
Allows setting 20-50’. Set No spec, but Hardware Error

temp to 20’ and wait several 24-19 will occur if current
minutes while observing, then <500mA or > 2880mA.
set temp at 50’ and wait
several minutes while
observing.
Sample Heater Tests the sample heater, Perform this test in same If temperature reading is
interconnecting wiring and manner as colorimeter heater incorrect or if temperature
connection to the interconnect test. The sample heater core does not change, replace
60
board, heater control circuit, may require substantial time to sample heater.
and infers proper temp sensor cool (depending on sample
response. bypass temperature and flow).
It will heat more quickly than
Allows setting 20-50’. Sample colorimeter due to higher
heater has a high thermal wattage element.
mass. Since sample is already
heated to 50’ C, any change in No spec, but Hardware Error
setting will not be seen 24-20 may occur – see Event
quickly. Log Codes.xlsx for details.
Colorimeter Tests colorimeter LED, Detector typically saturates at Clean sample cell, then
photodetector, interference ~30% or less. retest. Replace sample cell,
filter, LED control circuit, A/D then retest. Replace
circuit, and whether you No spec. LED Low error if <5M interference filter, then
remembered to visually insect counts at 100% DC, or LED High retest. Replace
the sample cell for cleanliness. error if saturated with LED colorimeter.
turned off.
Tests colorimeter throughput
from zero light to detector
saturation. Displays detector
output counts as LED
increments duty cycle by 5%
every 5 seconds. Test ends
when saturation (8388608
counts) is reached and last
DC% is shown.
A2D Tests same components as Observe the displayed reading Verify Colorimeter test
Colorimeter test above. for a few minutes. Leading above is good. If not, and
Requires clean water in the three digits of the reading A2D is unstable, check for
sample cell. should be absolutely stable. colorimeter
The reading may show some fogging/condensation.
Tests detector output counts noise depending on contents of Replace colorimeter
at arbitrary LED DC%. Select a cell, stray lighting, or thermal assembly.
DC% that displays effects, or bubbles.
approximately 4M to 8M
counts. No spec.
Status LED Tests the front panel status Visually verify the LED is Verify LED wiring. Test LED
LED, LED wiring and working. LED failure by itself with multimeter, replace if
connection to controller does not otherwise affect bad.
board. analyzer operation.
Cycles through off, red, green, No spec.

yellow – about 2 seconds per
color.
Air Pump Tests the compressor, Tests the air compressor ability Verify door pinch tube is
compressor filter (clogged?), to deliver and maintain reagent good, bottle caps properly
bottle cap seals, tubing and bottle pressure. The pressure tightened, tubing
fittings from compressor to will overshoot slightly when maintenance is current, no
manifold to bottles, manifold bottles repressurize, then air leaks at manifold, no leaks
and fittings, compressor wiring bleed valve will lower pressure at pressure sensor.
and connection to to correct value. Allow about Replace pump if all else is
interconnect board, and 30 seconds to stabilize. Final good.
compressor control circuit. pressure should be between
3.95 and 4.10 psi.
The compressor will pressurize
61
reagent bottles to the selected
pressure setting. Open the
reagent compartment door to
observe pressure drop, then
close door to observe pressure
increase to setpoint. There is
no need to adjust deadband,
low or high values.
Fan Tests the fan, fan filter for Listen for fan running, displayed Replace filter if fan runs,
clogging, air inlet ports for speed ~7000 - 10000 rpm. but is faster than 9400
obstruction, fan wiring and rpm. Replace fan if it does
connection to controller No spec. Fan Failure error will not run..
board, fan control circuit. occur if rpm is zero.
Tests cabinet fan. Select Duty

Cycle, then press [Enter]. No
need to adjust Duty Cycle from
0%; press [Enter] again. The
fan will begin running. (Duty
cycle here has no effect for the
fan we are using. Anything
you put in will just turn the fan
on until you exit out of menu.)
Fan Speed and Fan Filter menu
entries require service
password. Speed is set for
9400, Filter 180 days by
default. Adjusting these values
in the Perform Test menu
globally changes them. At the
moment these values should
not be changed. The way it
works is: after 180 days the
instrument will check to see if
the RPM’s are over 9400. If so,
a warning will be indicated to
replace the fan filter.
Analyzer Type Change analyzer parameter Not for troubleshooting
and Open/Closed chemistry. purposes.
For factory setup only, if
controller must be replaced, or
if performing modification.
Requires service password.
Access expires when Perform
Test menu is exited.
Select Script Requires service password. Not for troubleshooting
There are currently no scripts purposes.
for this function; this may find
use at a later date. Access
expires when Perform Test
menu is exited.
Set Channels Selects whether the analyzer is Not for troubleshooting
1, 2, 4, or 6 sample streams. purposes.
For factory setup only, if
controller must be replaced, or
62
if performing modification.
Requires service password.
Access expires when Perform
Test menu is exited.
63
7 Troubleshooting charts
7.1 Reagent air leak
64
7.2 Calibration failure
65
7.3 Suspected low reading
66
7.4 Unstable reading warning
67
8 Electronics- Connection diagrams
8.1 Mother board
68
8.2 ADIOB – Analogue Digital Input Output Board
O-rings for pressure Air Pump updated in

tubings added in December 2016
December 2016, part
number 8628400
69
8.3 Electronic module options
70
9 Assembly drawings & parts
9.1 Assembly case
9.2 Enclosure dimensions
71
9.3 Colorimeter assembly drawing
Quality update May 2016
Note:
1. The part numbers have not changed with this update, but the adaptor is now a round disk and uses a shorter
magnet.
2. The two parts needed are PNs 6769300, 6767900
Colorimeter - Current Stir Magnet Colorimeter - New Stir Magnet/

implemented May 2016
72
9.4 4 channels sequencer assembly drawing
73
9.5 Mechanical parts
Quality update for reagent tray see below
74
75
9.6 PCB Assembly
76
9.7 Fluidics panel assembly
77
9.8 Valve plate assembly
Qualtity update on the Chemistry/Hinge Valve Plate implemented

in December 2016, new order code is 8627800
78
9.9 Analyzer plate assembly
79
9.10 Mechanical parts multichannel version
80
Quality update for reagent tray see below
81
82
9.11 Interconect PCB assembly multichannel version
83
9.12 Fluidics panel assembly multichannel version
Air Manifold updated in December 2016
84
9.13 Valve plate assembly multichannel version
85
86
9.14 Analyzer plate assembly multi channel version
87
9.15 Parts for field tech only
Item Description Item Description
6773900 CABLE ASSY, DETECTOR 6782100 CABLE ASSY, AC POWER, PROCESS ANALYZER
6779200 si CABLE ASSY, LEAK DETECTOR 6782200 CABLE ASSY, 12V POWER, PROCESS ANALYZER
6776500 CABLE ASSY, LOWER DOOR, PROCESS ANALYZER 6782300 si CABLE ASSY, ANALYZER POWER
6779100 si CABLE ASSY, THERMISTOR, REAGENT 6782500 si CABLE ASSY, BACKLIGHT, PROCESS ANALYZER
6774100 CABLE ASSY, MOTOR/HEATER 6783200 si CABLE ASSY, CHASSIS GROUND, PROCESS ANALYZER
6778600 CKT BD ASSY, OPEN DOOR DETECTOR 6773300 CLIP, SPRING MOUNTING, SST FOR 1" VALVES
6778400 si CKT BD ASSY, LEAK DETECTOR 6787800 SCREW, M3 X 0.5 X 10MM TORX SS W/ STAR WASHER
6768100 PANEL, SAMPLE PREP, PROCESS ANALYZER 6787900 NUT, M5 X 4MM SS HEX
6769400 FTG, BARB, 1/4-28 THREAD, 3/32" ID TUBING, POLYPROPYLENE 6770800 DIFFUSER, STATUS LED, PROCESS ANALYZER
6772100 CORE, SAMPLE HEATER, PROCESS ANALYZER 6787500 FTG, TEE, 1/2" FEMALE, QUICK CONNECT
6772400 COIL, SAMPLE HEATER 6784000 FTG, REDUCING BARB, 1/8" TO 3/32" ID TBG, POLYPRO
6772800 FTG, 1/2" ELBOW, QUICK CONNECT, POLYPROPYLENE 3101600 vv CLAMP TWIST-LOK WIRE DIA .40-.50
6773000 MANIFOLD, AIR, PROCESS ANALYZER / design changed in Dec 5743700 VALVE, SHUT-OFF, 2-WAY F/ 1/4" TBG
2016, see page 84
4271700 TBG C-FLEX .193OD .063ID +/-.002 6760305 ASSY, REAGENT BOTTLE CAP, YELLOW
6764500 ASSY, ENCLOSURE, PROCESS ANALYZER 6788200 si CKT BD ASSY, SD CARD BOARD PROCESS ANALYZER
6764800 SEAL, BULKHEAD, ENCLOSURE, PROCESS ANALYZER 6783500 KIT, INSTALLATION, PROCESS ANALYZER
6764900 FOOT, ENCLOSURE, PROCESS ANALYZER 2264472 FUNNEL, POWDER PP 150MM
6766400 PLATE, CONDUIT, PROCESS ANALYZER 6782900 PRESSURE REGULATOR, PRESET 4PSI
6766300 LATCH PLATE, ANALYTICS PANEL, PROCESS ANALYZER 6784800 ASSY, Y-STRAINER, PROCESS ANALYZER
6768500 TRAY STOP, ENCLOSURE, PROCESS ANALYZER 2300200 FTG, REDUCE BUSHING, PVC HEX
6768300 BRACKET, LOCK, PROCESS ANALYZER 4661600 STRAINER, SEDIMENT PVC 30 MESH
5441800 vv SCREW 8- X .50 TORX STL TPG 4566700 FTG, TUBE 1/4 OD MALE POLYPROP
6766103 INPUT PANEL, ELECTRICAL, PROCESS ANALYZER 1085145 TEFLON THREAD TAPE, 1/2 IN
6766200 SCREW M5 X 8MM TORX 316 SST PANHEAD 4366500 LABEL,BLANK WHITE, POLY 2.00"X1.00"
6767200 ASSY, LATCH SET, ENCLOSURE, PROCESS ANALYZER 6788800 TORX DRIVER, T20
5441800 vv SCREW 8- X .50 TORX STL TPG 6772600 STIR BAR, STAR HEAD, 17.2 MM DIA X 10.5 HIGH
6765400 CATCH PLATE, LATCH, ENCLOSURE, PROCESS ANALYZER 6785600 TUBING, TYGON 11/16 OD x 1/8 W
6768200 PANEL, BULKHEAD, ENCLOSURE, PROCESS ANALYZER 6767600 BRACKET, WALL MOUNT, PROCESS ANALZYER
6764701 DOOR, UPPER, ENCLOSURE, PROCESS ANALYZER 5441800 vv SCREW 8- X .50 TORX STL TPG
6764702 DOOR, LOWER, ENCLOSURE, PROCESS ANALYZER 6770500 CONN, STRAIN RELIEF, SKINTOP, PG-09
6765000 HINGE, ENCLOSURE, PROCESS ANALYZER 6788900 TORX DRIVER, T25
6766200 SCREW M5 X 8MM TORX 316 SST PANHEAD 6790100 ASSY, SAMPLE VALVE, PROCESS ANALYZER
6771200 BRACKET, PRESSURE DUMP VALVE 6784900 VALVE, 2-WAY, 1/4 COMPRESSION X 1/4 JACO
6765900 REAGENT TRAY, PROCESS ANALYZER 4566700 FTG, TUBE 1/4 OD MALE POLYPROP
6765800 ANALYTICS PANEL, PROCESS ANALYZER 1085145 TEFLON THREAD TAPE, 1/2 IN
6766500 COVER, INTERCONNECT PCB, HIGH-VOLTAGE 4379400 BUSHING, STRAIN RELIEF
6766600 COVER, INTERCONNECT PCB, LOW-VOLTAGE 6772500 TUBING, POLYETHYLENE, 6MM OD X 1MM W
6766800 COVER, ANALYTICS PCB, PROCESS ANALYZER 5902201371 vv LOCKNUT, NYLON, SKINTOP, NPT-1/2"
6766900 COVER, COLORIMETER, PROCESS ANALYZER 6786800 ASSY, COLORIMETER, SILICA
6786801 ASSY, COLORIMETER, PHOSPHATE LR 6786802 ASSY, COLORIMETER, PHOSPHATE HR
6767100 FUNNEL, GRAB SAMPLE, PROCESS ANALYZER 6763800 CKT BD ASSY, COLORIMETER, SILICA, PROCESS ANALYZER
88
6771300 CLAMP, POLYPROPYLENE LOOP FOR 5/8" OD 6773800 CABLE ASSY, MOTOR, PROCESS ANALYZER
5441800 vv SCREW 8- X .50 TORX STL TPG 6767700 ADAPTOR, FILTER/DETECTOR
6771001 LABEL, INSTRUMENT, S5500, SILICA, HACH 6767800 CELL CAP, PROCESS ANALYZER
6770900 LABEL, HACH BADGE, EXTRA LARGE 6767900 ADAPTOR, MOTOR MAGNET
6761400 CKT BD ASSY, ANALYTICS, PROCESS ANALYZER 6768000 CELL, COLORIMETER, PROCESS ANALYZER
6763600 si CKT BD ASSY, INTERCONNECT, AC/DC, PROCESS ANALYZER 6769100 CELL BLOCK, COLORIMETER, PROCESS ANALYZER
6763000 POWER SUPPLY, 120-240V, 12VDC, 65W 6769300 MAGNET, BAR, 3/16"D X 3/4"H
4329300 TBG C-FLEX .250OD .125ID 6773100 SHROUD, COLORIMETER, PROCESS ANALYZER
6777600 VALVE, PRESSURE RELIEF, 1/8 NPT, 10PSI 55480 FILTER, 480 nm 1/2"
6778000 FTG, TEE, 4-WAY 1/8" TBG POLYPRO 55880 FILTER, 880 nm 1/2"
6778200 FTG, TUBE TO HOSE ADAPTER, ½”, POLYPRO 55810 FILTER, 810 NM 1/2"
6778800 FTG, TEE, BARBED 1/8" TBG POLYPRO 6785900 STDF, M3 X 0.5 X 20MM SS
6779000 FTG, UNION, BARBED MALE/MALE 5/32" ID TBG POLYPRO 6787800 SCREW, M3 X 0.5 X 10MM TORX SS W/ STAR WASHER
6779900 CHECK VALVE, MINIATURE BARBED 1/8" TBG 6789800 si ASSY, BLOWER, PROCESS ANALYZER
6760100 COVER, REAGENT TUBING COMPARTMENT, PROCESS ANALYZER 5117300 SPRING, .300IN OD, WIRE DIA .032
6777500 COMPARTMENT, REAGENT TUBING, PROCESS ANALYZER, 6777402 PINCH BOSS, PRESSURE DUMP VALVE
Obsolete in December 2016, see page 78
6760900 COVER, FLUIDICS, BOTTOM PANEL, PROCESS ANALYZER 6777401 HOUSING, PUSHROD, PRESSURE DUMP VALVE
6761800 NEEDLE VALVE, MINIATURE, BARBED 8782200 PLUG 5.08MM SPRING CLAMP 3 POST
6782400 CABLE ASSY, ANALYZER DATA, PROCESS ANALYZER 8785600 PLUG 5.08MM SPRING CLAMP 4 POST
6773700 LCD MOUNT, PROCESS ANALYZER 6783900 FTG, BARBED MALE/MALE 3/32" ID TBG, POLYPRO
6773500 COVER, FUNNEL, PROCESS ANALYZER 6793500 TEST CERTIFICATE, PROCESS ANALYZER
6765600 KEYPAD, MEMBRANE, S5500 6788500 ADAPTER PLATE, THERMAL FUSE, PROCESS ANALYZER
6760800 CLAMP, ANALYZER PCB, PROCESS ANALYZER 6766121 ASSY, INPUT PANEL, FLUIDICS, 6-PORT
6782600 CABLE ASSY, THERMISTOR, SAMPLE HEATER 6776700 HINGE BRACKET, ANALYTICS PANEL, PROCESS ANALYZER,
obsolete in December 2016, see page 78
6780600 DISPLAY, LCD 5.7" COLOR 6790200 BRACKET, GRAB SAMPLE, PROCESS ANALYZER
6772900 FTG, BARB, 1/8-27 THREAD, 1/8 TBG, POLYPRO 6790300 BRACKET, BYPASS VALVE, PROCESS ANALYZER
3157100 vv FTG, PLUG THREAD 1/8-27 POLYPROP 5057 CLIP,TUBE HOLDER
6773400 GUARD, PRESSURE TRANSDUCER, PROCESS ANALYZER 6774000 CABLE ASSY, OPTIC LED
6782700 ASSY, HEATER CARTRIDGE, PROCESS ANALYZER 4734200 FTG, TEE .125ID TBG, .062ID TBG
6783700 CABLE ASSY, REAGENT VALVE, PROCESS ANALYZER 6788400 FTG, REDUCING TEE, 3/8 X 3/8 X 5/32 POLYPROPYLENE
6784500 CABLE ASSY, AIR COMPRESSOR, PROCESS ANALYZER/ Type 4707200 vv SCREW 4-20 X .375 PAN SST TPG
changed in Dec 2016 to a brushless motor, see page 69
6760200 SHIPPING CARTON, PROCESS ANALYZER 6790500 FAN MOUNT BOTTOM, PROCESS ANALYZER
6784700 CABLE, FLEX, FFC CARD FOR LCD 6790400 FAN MOUNT, TOP, PROCESS ANALYZER
6760301 ASSY, REAGENT BOTTLE CAP, BLUE 2300200 FTG, REDUCE BUSHING, PVC HEX
6760302 ASSY, REAGENT BOTTLE CAP, GREEN 6793900 FTG, 1/8 BARB TO 1/4-18 FNPT
6760303 ASSY, REAGENT BOTTLE CAP, RED 6794300 VALVE, TOGGLE, 1/8 FNPT TO 1/8 FNPT
6784100 SEAL, 15.5MM HOLE 7E1065 JUNCTION,KYNAR,A44,SD73
6784200 SEAL LOCK, 15.5MM HOLE 6791500 FTG, 1/4-28 UNF TO 1/8 BARB POLYPRO
6784300 SEAL, 21.4 MM HOLE 6793200 FTG, ELBOW 3/32" BARB POLYPROPYLENE
6784400 SEAL LOCK, 21.4 MM HOLE 6793000 FTG, TEE 3/32" BARB POLYPROPYLENE
6784600 NUT M4 HEX KEPS 18-8 SST SE 817 CABLE TIE,NYLON,4 IN.
6787200 PLUG, FOR 6MM TUBING 8785800 PLUG 5.08MM SPRING CLAMP 8 POST
89
6785600 TUBING, TYGON 11/16 OD x 1/8 W 8522700 PLUG, 2.5MM, 8 CKT
6785200 FTG, FEMALE 1/2" NPT TO 1/2" BARB POLYPRO 6790600 ASSY, FAN FILTER, PROCESS ANALYZER
6785700 STANDOFF, PREHEATER, PROCESS ANALYZER 789812 WASHER #10 INT LOCK TYPE A ZN
6785900 STDF, M3 X 0.5 X 20MM SS 6794400 si WIRE, JUMPER
6786000 SCREW M5 X 0.8 X 20MM PANHEAD TORX SS 6794100 si ASSY, SEQUENCER VALVE
6786100 SCREW M5 X 0.8 X 35MM PANHEAD TORX SS 6786400 CABLE ASSY, PINCH VALVE, 2 WAY, PROCESS ANALYZER
6786200 STDF, M5 X 0.8 X 52MM SS 6766000 HINGE ASSY, ENCLOSURE, PROCESS ANALYZER
6786300 CABLE ASSY, PINCH VALVE, 2 WAY, NC, PROCESS ANALYZER 6786500 si CABLE ASSY, PINCH VALVE, 3 WAY, PROCESS ANALYZER
8628400 O-RING, -015, EPDM, 70 DURO, pressure sensor, see page 69 8627800 HINGE BRACKET, ANALYTICS PANEL, PROCESS ANALYZER
90
Sample Heater update May 2016
Part numbers new sample heater:
91
10 Service Procedures
10.1 Filter replacement
92
10.2 SD Card Reader Ckt Bd replacement
Note: Advise using a ground strap if you have one.
1‐ Turn off the Instrument power.
2‐ Remove the Analyzer Board Cover behind the Display. There are three screws that hold that cover.
3‐ In the view below remove screws, items 1, 2 & 3
4‐ Remove brace item 4
5‐ Lift the Analyzer board at point 5 just enough to disconnect the SC Card Reader Item 6 and replace with new SD Card
Reader.
6‐ Reassemble in reverse order.
93
10.3 Checking or Changing Factory Settings
The following steps are for checking or changing Factory Settings and must be kept for internal use only.
Use CAUTION in making changes because without appropriate hardware, the Instrument will display
Hardware Errors and not operate.
IMPORTANT! Never change a 5500sc to 9610sc/9611sc and vice versa.
94
Examples of checks
95
10.4 Circuit Boards Replacement
Precautions:
‐Be sure to follow standard static protection guide lines, use a rist‐strap
‐Remove power when removing cables and circuit boards
‐Turn off all sample supplies
Main Analyzer Board Removal

1‐Remove cover over Main Analyzer Circuit Board, qty 3 T‐20 screws.
2‐Remove all cable connections be sure to label the Valve connection for reconnecting.
3‐Remove the qty 6 T‐20 screws that hold the Main Analyzer Board. Use caution: there is one ribbon cable that
connects to LCD display on the back of the board and a flat ribbon cable that connects the KeyPad at the bottom of the
board.
4‐Refer to Figure 1 and the Connection Diagram when reconnecting new board.
Figure 1, Main analyzer Board
96
Interconnect Board Removal
97
1‐Remove the Low Voltage Cover over the Interconnect Board. Requires removal of the Drain Vent Tube and qty 4 T‐20
screws
2‐Remove Connectors 1 thru 9
3‐Remove Cable Assembly 1, Screws 1,2 & 3 to remove the High Voltage Cover shown in Figure 2
Figure 2, Interconnect Board High Voltage Cover
Refer to Figure 3 for the remaining steps
98
4‐Remove the remaining cables, the Pre‐Heater Cable can be detached and carefully slide under the Power Supply.
5‐ Remove all tubing connections, there are adaptors boots that are on two of the Pressure Sensors that will easily slide
off and keep all the tubes attached. Take note of tubing strain relief in circuit board for re‐assembly.
6‐Remove the remaining 9 screws and remove the circuit board
7‐NOTE: There should not be any screw under the Power Supply
Figure 3, Interconnect Board Removal
99
10.5 Calibration offset entry
To program a PPB offset, do the following:
1) Press “cal”
2) Go to “OVERRIDE CALIBRATION” and press “enter”
3) Select “YES” at the bottom of the screen and press “enter”
4) Select “ZERO” and press “enter”
5) Enter your desired ppb value
10.6 Change the serial number

(1) Connect one end of the Hach/Hach-Lange Service Cable (HACH-LANGE #LZX887) to the analyzer service port and
the other end to a PC RS232 port.
(2) Open the ProcessLink.
(3) Auto Scan to connect the analyzer by clicking the little wizard icon. Make sure the baud rate is 115200 and select
the right Com port.
100
(4) Press the poll button (the magnifying glass)to read the reserved registers of the analyzer.
101
(5) Write 31281 to the Program Sequence Code register.
(6) Update the Serial Number 1, 2 and 3.
Please note the serial number in the analyzer is hex-coded and the Processlink uses decimal numbers. For example, if the
serial number is 012345678900, the serial number 1 is 0x0123(291 decimal), the serial number 2 is 0x4567(17767 decimal)
and the serial number 3 is 0x8900(35072 decimal). Write those corresponding decimal numbers to the Processlink serial
number registers.
102
Go to the folder “Information” and press the poll button. The new serial number should appear.
(7) Write 0 to the Program Sequence Code register in order to disable write access.
11 Others
11.1 Training outline
Overview
A. Replaces Series 5000 and Polymetron 9210
1. Polymetron 9210 is 55% of sales worldwide, not for sale in US
2. Series 5000 is 45% of sales, mostly in US
B. Platform for future analyzers
1. List benefits of new analyzer, reasons to update
a. Aging design of S5000 – will require redesign soon anyway due to coming obsolescence of
key components.
b. One common design for sale worldwide.
c. Designed for manufacturability
- Cabinet is two identical halves, only one mold needed
- Simple and quick to assemble – less fabrication labor
- Common parts for many parameters
- Compatibility with existing SC200 and SC1000 parts
d. Open or Closed versions (for appropriate markets)
- Closed will require Hach-manufactured reagents
- Open allows users to use alternte or home-brew reagents
c. It’s a replacement for the APA! Yahoo!
- Ammonia/monochloramine will be next release
103
- Will also be released later as hardness
- Other parameters are not committed yet
d. High visibility color display
e. Simple to operate and maintain
f. Prognosys
- Early indications of elapsed component lifespans
- Alerts user to potentially developing problems
- Maximizes uptime
- However….
- This is our first attempt at this feature
- Implementation is not fully explained.
- May cause undue customer concerns.
- Persistent on Home screen, cannot be hidden
- More discussion about this later in session
C. Design specifics
1. Pressurized reagents
a. 2 liter bottles, not 3 liter
b. 4 psi, not 12 psi
c. Self-contained feed straws, no flinging Molybdate, no holey jeans!
d. Internal compressor to pressurize bottles, no external air needed
e. Bleed valve on reagent pressure manifold. Compressor is not accurate enough to maintain
very stable pressure. Also allows relief of excess pressure if ambient temperature increases.
2. Sample conditioning
a. Similar to S5000, but simplified
b. Internal bypass flow and adjustment
c. Integral sample heater
d. Optional internal sample sequencer, no Sentry needed!
f. Sample pressure regulated to be fixed
g. Will work with sample pressure low as 2 psi, maybe even lower
3. Analytics
a. Modular colorimeter – no disassembly required (or possible)
- Sample cell is replaceable as maint item, easy to swap
- Interference filter will be replaceable
b. Colorimeter has integral heater for temp control and to prevent fogging
c. LED infrared light source, no lamps to replace
d. Colorimeter has viewing LED for inspection
e. No capillary tubing module
- Capillaries and cell cap are one integrated unit
4. Controller
a. Controller is essentially a modified SC200
b. Can be interfaced with external SC200 or SC1000
c. Accepts SC1000 input/output and networking modules
d. Extensive self-diagnostic functions to simplify troubleshooting and isolate faults
e. Qty 4 4-20mA outputs, qty 4 relay outputs (on interface board)
f. Full color LCD dot matrix display with graphics
5. Other features
a. Can be operated on 120/240 VAC, auto-sensing
b. 24 VDC operation optional
c.
Installation & setup

A. Location and mounting
1. Wall mount
- mounting plates are included
104
2. Panel mount
- Optional retrofit plate available to replace Series 5000 or 9210
3. Bench
B. Connections
1. Sample & drains
a. Sample fitting is 6mm, not ¼”
b. Can be replaced with 5119200
c. Correct name for quick-disconnects is ‘John Guest fitting’
d. Diameter difference between 6mm and ¼” is only .010” – but ¼” quick-disconnects may not
grip 6mm tubing sufficiently to not leak or pop off
2. Electrical
a. Power
- 120/240 VAC auto-sensing, or 24 VDC
- 24 VDC current requirement?
- What visually/obviously differentiates AC-DC versions?
b. Auxilliary power output connections
- Fused – what rating for AC vs DC?
- Not switched, always on
- Still powered if main fuse blows?
- OK to use for powering the alarm relays?
c. Alarm relays
d. 4-20mA outputs
e. Optional I/O boards
3. Miscellaneous
a. Air purge
b. Catastrophic case drain
- Use trap and air break if connected
- Fan purges case, but only runs during FAA dispense
Startup
A. Preparation
1. Reagent installation
a. Bottle handling
- Don’t squeeze bottles!
- Demonstrate ‘fountain’ when squeezed with standard solution; problem only when
bottle is full
- Reinstall straw/stopper assy before shaking FAA – cap alone leaks
b. Other?
2. Stir bar installation
a. In sample cell, not behind overflow weir
b. Be careful to not damage capillaries when replacing cell cover
B. Initial power-up
1. Standard (per manual) startup
a. Perform this when customer is in training/participating
b. Takes a while – how long?
c. Have trainees do this as hands-on exercise
2. Quick startup
a. See Quick startup guide
b. Note how this save time, but may not be appropriate if user training is needed
C. What the analyzer is doing
1. POST (Power On Self Test)
a. Processor boots up and initializes
105
b. Test of solenoid valves, compressor, temp sensors, colorimeter (to see if it is correct one,
and functional test. You hear clicking noises during this period.
c. Check for sample pressure, begin flushing cell
d. Pressurize reagents
e. Measure colorimeter Dark, turn on LED and look for light’
f. Above may not be exact order, but close enough
2. Halt or continue?
a. If fatal malfunction is found, halt and wait for operator intervention
b. If no error or only minor error found, go to Main Loop
3. Main Loop
a. Check sample pressure
a. If OK, continue
b. If no pressure, log event, wait 10 minutes and test again
c. If sequencing, log event and go to next stream, restart loop.
b. Perform sample cycle
c. Check status (system warnings or alarms)
- System alarm – log event and halt
- System warning – log event and continue
d. Display reading
e. Update outputs (4-20mA and relays)
f. If sequencing, go to next stream
g. Restart loop
h. Above may not be exact order, but close enough
Operation
A. The display
1. General layout
a. Progress bar
b. Prognosis
c. Sample status area
d. Cal and reagents status
2. Prognosis – detailed explanation
a. Persistent on Home screen (single sample view), cannot be removed or hidden
b. What it means
c. How to avoid unnecessary service visits
2. Top status bar – details
- Icons and what they mean
3. Selecting different screens
a. Home
a. Graph
b. Multiple samples (if sequencing)
B. Overall menu structure
1. Main menu
2. Diag menu
a. if display background is yellow or red, press [Enter] as shortcut from Home
3. Cal menu
C. Optional operations
1. Sample sequencing
a. Setting up a sequence
2. Optional modules & connection to SC200/SC1000
3. 24 VDC power
4. Backing up/restoring analyzer setup with a SD card.
- also, making a basic setup for transferring to other analyzers
106
Maintenance
A. Maintenance kits & their contents
B. Maintenance tasks & intervals
C. Maintenance exercise
- include maint. counter/timer resets
Customer training
- Most discussion above is suitable for customer training
- Most discussion below is not appropriate to share with customers
Troubleshooting
A. Troubleshooting tree
- if can be prepared in time, otherwise…
1. Basic - Go to Diag menu and look for errors, then address as instructed
2. Intermediate - Run additional tests, make repairs as faults indicate
3. Advanced – Depends on fault symptoms and analyzer knowledge level, so proceed at your own risk.
B. Accessing fault info

1. Menu navigation
- what is the error and when did it happen?
- no time-date stamp in Diag listings
- are there other errors?
- Event log can be very cumbersome unless error was very recent
- Try cycling power and see if fault recurs
- If fault recurs, then look at last hour of Event Log menu
- if fault does not immediately recur, it might be intermittent; in this case use SD card
to download Event Log and read it in Excel.
2. Use of SD card
- Especially useful for 24 Hardware Error
- Good also for capturing intermittent problems
- analyzer error?
- upset in customer’s system?
- Capacity of card required – 1 GB?
- How long, how many entries does Event Log hold?
- How long, how many entries does Data log hold?
C. Observed faults
1. need list from Lvld
2. Leaky pressure sensors
3. Can’t clear errors or restart analyzer, requires power cycled
4.
D. Diagnostics and test functions
- Perform Test menu
- Induce some errors and troubleshoot
- Compressor error – already has loose wire in new analyzer #1
- Swap colorimeter heater and thermistor cables
- Pinch tube to reagent bottles
-
E. Advanced troubleshooting
- This comes later; no real-world experience yet
- Will answer questions as best possible
- Field input is needed as situations are encountered.
- See Service Manual for additional info
107
Servicing
A. Tools required and other handy items
1. Torx drivers
- qty 2 are included with analyzer
2. Sharp knife or diagonal cutters – for cutting tubing
- knife is also useful if clearance is too tight on quick-disconnects (esp. on bottom of sample cell)
3. Zip ties – in case wire bundles need tied
4. Flashlight
5. Optional – puck light in cabinet
Tubing clamps
6. Pressure tester, tees for connecting to tubing
7. Short T torx wrench – same as used on CL17
- for left hand screws of interface board
A. Parts identification
1. Exploded views
2. Locations of important parts
3. Terminology
a. Proper parts descriptions
- e.g. APA – it ain’t a ‘stator module’.
- Especially – NEVER say “em gee slash ell”. Ever.
- Glossary of terms needed?
B. Parts replacements
1. Special care considerations
a. Controller replacement
- Delicate, fiddly display and keyboard cables
- Controller must be removed to replace keyboard, otherwise keyboard itself is not
difficult
b. Interface board
- how hard to get to screws?
- power disconnect is necessary and critical for safety
- both AC power in and relays
c. Possible future software compatibility issues between interface board and controller
- both have software, though minimal on interface board
- not an issue at release
2. Available parts list
B. Updates & upgrades

1. Software updates
- performed with SD card
1. Serial number if controller is replaced
2. Sequencing
a. Concerns
i. Upgrade is not difficult, but is a hidden service setting.
ii. Customer cannot always foresee future needs.
iii. This policy practically assures loss of customer good will.
- What if customer is replacing a Series 5000 and already has a Sentry sequencer?
Already has substantial $$$ invested.
- No End of Measurement signal.
b. Practical considerations and parts needed
3. Conversion between Closed and Open chemistry
a. US market will be Closed only
- Requires Hach-provided reagents and standards
b. International market
108
- Some customers may find Hach quality control is superior and decide to convert to
Closed chemistry
- Open chemistry success depends on customer’s ability and willingness to prepare his
own reagents (and use low-silica water and chemicals)
- Some customers may find preparing their own reagents is more cost-effective, or
alternate chemistry meets local regulatory needs or customary procedures.
109

5500sc 961Xsc Service Manual v3.3 Official Version October 2019

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5500sc 961Xsc Service Manual v3.3 Official Version October 2019

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5500sc & Polymetron 961Xsc

Service manual – Edition 3.3

1 Theory – Measuring principle

1.1 Measurement cycle principle

a ci di c s ol uti on. Thi s rea gent cons i s ts of mol ybda te a nd s ul furi c

Add Reagent 2 110 Mea s a ges : 1-R2 2-MIX 3-STABILIZE

cel l for bubbl e remova l a nd 2) the orga ni c a ci d i nhi bi ts rea cti on of

LED Adjustment Mea s a ges : 1-REFERENCE

Opti ca l LED a djus tment to keep the reference counts to ~7,600,000

Add Reagent 3 85 Mea s a ges : 1-R3 2-MIX 3-COLOR

The a ddi ti on of certa i n reduci ng a gents (s uch a s ANSA, As corbi c

form. The a ddi ti on of the reducta nt ca us es a more i ntens e col or

Sample Measurement Mea s a ges : 1-SAMPLE

End Flush with 30 Mea s a ges : 1-FLUSH

Thi s ri nce i s to fl us h the cel l of rea cted ma teri a l tha t produces

Wait State ? Mea s a ges : 1-WAIT

a ci di c s ol uti on. Thi s rea gent cons i s ts of mol ybda te a nd s ul furi c

Add Reagent 2 110 Mea s a ges : 1-R2 2-MIX 3-STABILIZE

cel l for bubbl e remova l a nd 2) the orga ni c a ci d i nhi bi ts rea cti on of

LED Adjustment Mea s a ges : 1-REFERENCE

Opti ca l LED a djus tment to keep the reference counts up to 7,600,000

Reference Measurement 10 Mea s a ges : 1-REFERENCE

Add Reagent 3 85 Mea s a ges : 1-R3 2-MIX 3-COLOR

The a ddi ti on of certa i n reduci ng a gents (s uch a s ANSA, As corbi c

form. The a ddi ti on of the reducta nt ca us es a more i ntens e col or

Sample Measurement Mea s a ges : 1-SAMPLE

End Flush with 30 Mea s a ges : 1-FLUSH

Thi s ri nce i s to fl us h the cel l of rea cted ma teri a l tha t produces

Total Seconds = 557

~12sec Mea s a ges : 1-R1 2-REACT

a ci di c s ol uti on. Thi s rea gent cons i s ts of mol ybda te a nd s ul furi c

Add Reagent 2 110 Mea s a ges : 1-R2 2-MIX 3-STABILIZE

cel l for bubbl e remova l a nd 2) the orga ni c a ci d i nhi bi ts rea cti on of

LED Adjustment Mea s a ges : 1-REFERENCE

Opti ca l LED a djus tment to keep the reference counts up to 7,600,000

Reference Measurement 10 Mea s a ges : 1-REFERENCE

Add Reagent 3 85 Mea s a ges : 1-R3 2-MIX 3-COLOR

The a ddi ti on of certa i n reduci ng a gents (s uch a s ANSA, As corbi c

form. The a ddi ti on of the reducta nt ca us es a more i ntens e col or

Sample Measurement Mea s a ges : 1-SAMPLE

End Flush with 30 Mea s a ges : 1-FLUSH

Thi s ri nce i s to fl us h the cel l of rea cted ma teri a l tha t produces

Ins trument goes ba ck to previ ous s ta te of opera ti on

open chemistry they are added nearly at the same time.

Add Reagent 2 110 Measages: 1-R2 2-MIX 3-STABILIZE

LED Adjustment Measages: 1-REFERENCE

Optical LED adjustment to keep the reference counts up to 7,600,000 counts

Reference Measurement 10 Measages: 1-REFERENCE

Add Reagent 3 85 Measages: 1-R3 2-MIX 3-COLOR

The addition of certain reducing agents (such as ANSA, Ascorbic

to form. The addition of the reductant causes a more intense color

Sample Measurement Measages: 1-SAMPLE

End Flush with 30 Measages: 1-FLUSH

Wait State ? Measages: 1-WAIT

open chemistry they are added nearly at the same time.

Add Reagent 2 110 Measages: 1-R2 2-MIX 3-STABILIZE

LED Adjustment Measages: 1-REFERENCE

Optical LED adjustment to keep the reference counts up to 7,600,000 counts

Reference Measurement 10 Measages: 1-REFERENCE

Add Reagent 3 85 Measages: 1-R3 2-MIX 3-COLOR