1 DESCRIPTION

2 Dissolved Oxygen Analyzer at the WWTP MOS OGT used to monitoring, measuring and regulating the oxygen content in products water.
This dissolved oxygen analyzer will run for a long time, so that it requires regular maintenance so that its performance is maintained and
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reliable. This document contains procedures for performing maintenance according to the dissolved oxygen analyzer manufacturer's
4 manual.
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6 EQUIPMENT LIST AND SPESIFICATION
7 Measuring
No. Name Tag Number Tag Service Manufactur Model Electricity P&ID Number
8 Range (mg/l)

9 100 - 230
monitoring, OXYMAX EP0013A-58-
1 Dissolved Oxygen 3-22-AT-O021 E&H 0.01 to 100 VAC and 24
measuring and W COS51D PE-03-PD-004
10 VAC
regulating the
11 oxygen content in
2 products water
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1 Any Deviation Against This Procedure Must Have Written Approval from Concerned Head (S)
2 1 HSEGP-008-2001 (Guide Preparation & Operation of Work Permit System)
3 2 HSEGP-011-2001 (Procedure for selection, maintenance & use of PPE)
4 DOCUMENT REF. : 3 Manual Book
5 4 Work Plan & HSE Plan
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7 1 Safety briefing & job planning discussion (toolbox meeting)
8 2 Qualified & trained person
9 REQUIREMENT : 3 Personal gas detector
10 4 Proper PPE (Coverall, Safety Shoes, Safety Helmet, Gloves )
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12 1 Toxic / flammable gas
SOURCE / POTENTIAL
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HAZARD
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15 1 Conduct toolbox meeting before starting the job
16 PREPARATION 2 Appoint supervisor as watcher
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18 ACTIVITY 1 Maintenance
19 2 Calibration
20 3 Trouble shooting
21 4 Spare parts
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24 MAINTENANCE
25 Maintenance work must carried out at regular intervals.
26 The maintanance cycle primarily depends on :
27 a. the system
28 b. the installation conditions and
29 c. the medium in which measurement is taking place
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31 The following activities must be carried out :
32 a. Cleaning the sensor
33 (in particular when the membrane is soiled)
34 b. If necessary, replacing wear and tear materials:
35 MAINTENANCE - sealing ring
36 - electrolyte
37 - membrane cap
38 c. Check the measuring function:
39 - remove the sensor from the medium
40 - clean and dry the membrane
41 - after about 10 mintes, measure the oxygen index in air (without recalibration)
42 - the measured value should be near to102% SAT
43 d. Recalibration
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2 1 Cleaning
3 The measurement can be corrupted by sensor fouling or malfunction, e.g :
4 a) Coatings on the sensor membrane
5 cause longer response times and a reduced slope under certain circumstances
6 b) Soiling or polsoining of the electrolyte
7 cause longer response times and false measurement
8 c) Coatings on the electrodes
9 cause longer response times and false measurement
10 To ensure reliable measurement, the sensore must be cleaned at regular intervals.
11 The frequency and intensity of the cleaning operation depend on the measuring medium
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13 1,1 External cleaning
14 Clean the outside of the sensor:
15 - before every calibration
16 - at regular intervals during peration at necessary
17 - before returning it for repairs
18 Depending on the type of soilling, proceed as follows :
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20 Type of soilling Cleaning
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Immerse the sensor in drinking water or in 1-5% hydrochloric acid for a few minutes.
Salt deposits
22 Afterwards, rinse it with copious amounts of water.

23 Dirt particles on the

Clean the sensor body mechanically with water and a suitable brush.
24 sensor body
25 Dirt particles on the
26 membrane cap or the Clean with water and a soft sponge.
27 membrane

28 MAINTENANCE After cleaning, rinse the sensor with copious amounts of clean water
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30 1,2 Cleaning the cathode
31 The cathode only needs to be cleaned when it is visibly soiled or there is a coating of silver
32 on it. To clean it, proceed as follows:
33 a) Unscrew the membrane capfrom the membrane body
34 b) Carefully clean the cathode surfacein two stages with th3 abrasive sheet (contained in
35 scope of supply) untill the (silver) coating is fully removed. Use the green sheet and then
36 the yellow sheet.
37 c) Clean the open sensor head with drinking or distilled water
38 d) Fill the membrane cap with fresg electrolyte COY3-F and screw it back onto the
39 membrane body (up to the stop).
40 NOTICE
41 Removed silver bromide layer (normally brownish coating)
42 Sensor is unusable (anode and/or reference electrode is/are silver) and must be sent in for recoating
43 ► Do not clean anode and/or reference electrode under any circumstances!
44 ► If the coating is removed as a result of operation: Contact your sales office.
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46 2 Replacing wear and tear materials
47 Parts of the sensor will suffer wear and tear during operation.
48 Suitable action can restore normal operating functionality. This action includes:
49 Action Cause
50 Replacing the sealing ring Visual damage to a sealing ring
51 Replacing the electrolyte Unstable or implausible measuring signal or electrolyte soiling
52 Replacing the membrane cap Uncleanable membrane, damaged membrane (hole or overstrecth)
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1 2,1 Replacing the sealing ring
2 The sealing ring must be replaced if visibly damaged. For replacement, use only original sealing
3 rings.
4 2,2 Replacing the electrolyte
5 Replacing the electrolyte :
6 a) Remove the membrane cap
7 b) Replace the electrolyte and, if necessary the membrane cap
8 c) Place the membrane cap back on the membrane body and screw the cap to the stop
9 CAUTION
10 The electrolyte is strongly alkaline
11 Risk of acid burns
12 ► You must follow the appropriate occupational safety regulations.
13 ► Always wear protective gloves and goggles with handling electrolytes.
14 2,3 Replacing the membrane cap
15 Use the right membrane cap (COY31-WP : black for normal response time, COY31S-WP :
16 white for fast response time)
17 ROUTINE Removing the old membrane cap :
18 MAINTENANCE a) Remove the sensor from the medium
19 b) Unscrew the protection guard
20 c) Clean the outside of the sensor
21 d) Unscrew the membrane cap
22 e) If necessary, clean the cathode or replace the sealing if it is damaged
23 f) Rinse the electrode holder with drinkingwater
24 Installing the new membrane cap
25 g) Make sure that there are no dirt particles on the sealing surface
26 h) Fill the complete contents of a plastic ampoule (containing electrolyte COY3-F) into the
27 membrane cap.
28 i) Remove all the air bubbles in the electrolyte by tapping the side of the membrane cap
29 (e.g. with pencil)
30 j) Hold the sensor body at an angle and carefully screw the membrane cap onto it down to the stop
31 k) Screw the protection guard back on
32 l) Reset the calibration counter (Liquiline calibration menu, "Cap replacement")
33 After replacing the membrane cap, polarize and recalibrate the sensor. Then insert the sensor into
34 the medium and check that no alarm is displayed on the transmitter.
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1 1 Function check
2 Before first commissioning, check if:
3 - the sensor is correctly installed
4 - the electrical connection is correct.
5 If using an assembly with automatic cleaning, check the correct connection of the cleaning agent
6 (e.g. water or air).
7 WARNING
8 Escaping process medium
9 Risk of injury from high pressure, high temperatures or chemical hazards
10 ► Before applying compressed air to an assembly with cleaning facility, make sure the connections
11 are correctly fitted.
12 ► Do not install the assembly in the process if you cannot make the correct connection reliably.
13 2 Polarization
14 NOTICE
15 Measurement errors due to environmental conditions
16 ► Urgently protect the sensor from strong sunlight.
17 ► Make sure you comply with the instructions for commissioning and calibration in the Operating
18 Instructions of the transmitter.
19 To prepare for Calibration, proceed as follows :
20 a) Remove the sensor protective cap
21 b) Place the externally dry sensor in atmospheric air. The air should be saturated with
22 CALIBRATION water vapour. Therefore, install the sensor as close to the water surface as possible.
23 When calibrating the sensor membrane, make sure the membrane remains dry. Therefore,
24 avoid any direct contact with the water surface.
25 c) Connect the sensor to the transmitter and switch on the transmitter
26 d) Siwtch-on the transmitter
27 If you connect the sensor to the transmitter, polarization is automatically perfomed after
28 switching on the transmitter.
29 e) Wait for the polarization time to end
30 3 Calibration
31 Calibrate the sensor (calibration type "Air") immediately after it’s polarization.
32 3,1 Calibration in air
33 a) Remove the sensor from the medium
34 b) Clean the outside of the sensor with a damp cloth. Then dry the sensor membrane e.g.
35 by using a tissue
36 c) Then wait while the sensor adjust to the ambient air. This takes about 20 minutes.
37 Check that the sensor is not in direct sunlight during this time.
38 d) If the measured value display on the transmitter is stable, carry out the calibration in
39 accordance with the operating instructions of the transmitter
40 e) Place the sensor in the medium again
41 Make sure you comply with the instructions for calibration in the operating instructions of the
42 transmitter.
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1 Troubles Check Action
2 Mains voltage to the transmitter? Connect mains voltage
3 Sensor connected correctly? Set up correct connection
4 No display, no sensor Medium flow available? Create flow
5 reaction Coating on the membrane? Clean the sensor
6 Fill with electrolyte or replace
Electrolyte in the measuring chamber?
7 electrolyte
8 Humidity or dirt in plug? (Fixed cable Cleaning by using cleaning
9 version only) alcohol
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Polarization complete? Wait untill polarization time ends
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Last calibration with different sensor? Recalibrate
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DISSOLVED OXYGEN ANALYZER

14 Check sensor, if necessary send

Temperature display clearly too low?
15 sensor in for repair
Displayed value too high
16 Membrane visibly stretched? Replace membrane cap
17 Electrolyte soiled? Replace electrolyte
18 Check electrical connection. If
TROUBLE SHOOTING Open sensor. Dry electrodes
19 the problem still occurs, send
transmitter display now at 0?
20 the sensor in

21 Anode coating dissolved, is the anode

Send in the sensor for recoating
22 silver instead of brown?
23 Cathode silver-plated? Clean the cathode
24 Humidity or dirt in plug? (Fixed cable Cleaning by using cleaning
25 version only) alcohol
26 Sensor calibrated? Recalibrate
27 Medium flow available? Create flow
28 Displayed value too low Displayed temperature clearly too Check sensor, if necessary send
29 high? sensor in for repair
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Coating on the membrane? Clean membrane or replace cap
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32 Electrolyte soiled? Replace electrolyte
33 Membrane visibly stretched? Replace membrane cap
34 Strong deviations in Check electrical connection. If
displayed value Open sensor. Dry electrodes
35 the problem still occurs, send
transmitter display now at 0?
36 the sensor in
1 Position Spare parts kit Order no.

2 acc. To product
1 Sensor
3 structure
4 Sealing ring COY32-OR
5 2 - Material : Viton 51506985
6 - 3 plieces
7 Membrane cap 51506976
8 - Replacement cartridge COY31-WP
9 for normal response time
10 - 2 preterminated replacement
11 cartridge with pretensioned
12 membrane
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13 Membrane cap 51506977
14 - Replacement cartridge COY31S-WP
15 for fast response time
16 - 2 preterminated replacement
17 cartridge with pretensioned
18 membrane
19 Zero solution 50001041
SPARE PARTS
20 - 3 units to produce 3x1 litre oxygen
21 free solution
22 without Electrolyte COY3-F 50053349
23 fig. - 10 plastic ampoules, transparent
24 Polishing sheets COY3-PF 51506973
25 - for cathode cleaning
26 - 10 pieces
27 Accessoris kit COY31-Z, one of each : 51506784
28 - Electrolyte COY3F
29 - Replacement cartridge COY31-WP
30 for normal response time
31 - Sealing ring COY31-OR
32 - Polishing sheet COY3-PF
2-4
33 Accessoris kit COY31-S-Z, one of each: 51506785
34 - Electrolyte COY3F
35 - Replacement cartridge COY31S-WP
36 for fast response time
37 - Sealing ring COY31-OR
38 - Polishing sheet COY3-PF
1 POST- CONNECTION CHECK
2 Instrument status and spesifications YES NO Remarks
3 Are the sensor, assembly, junction box or cable
Visual inspection
4 damaged?
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6 Instrument status and spesifications YES NO Remarks
7 Does the supply voltage of the transmitter match
8 the spesifications on the nameplate?
9 Are the installed cables strain-relieved and not
10 twisted?
11 Is the cable type route completely isolated? Power cable/weak current cable
12 Are the power supply and signal cable correctly
Use the connection diagram of the transmitter
13 connected to the transmitter?
14 Long enough length of cable core stripped and
Check seating (pull slightly)
15 correct in terminal?
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Are all the screws terminals properly tightened? Tighten
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18 Are all the cable entries installed, tightened and
19 sealed? For cable entries lateral: cable loops downwards for
20 Are all the cable entries installed downwards or water to be able to drip off.
21 lateral?
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