In addition to this instruction sheet, the following are included in this kit (some additional parts are included for future maintenance):

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1 Instruction Sheet Overview The components in this kit directly replace components in the existing analyzer. Some of these components have safety and/or electrostatic discharge considerations associated with them. Only qualified personnel should install the components supplied in this kit. Disconnect the power to the analyzer by pulling the plug on the power cord or switching the breaker to the off position before performing the procedures described in this instruction sheet. Wear appropriate safety equipment including eye protection and gloves. This kit includes the new APA 6000 Installation and Maintenance Manual and a parameter-specific manual. The Installation and Maintenance Manual provides information regarding sample conditioning, changes to the instrument, and changes to the software. The parameter-specific manual contains information concerning parameter-specific instrument components and functions. In addition to this instruction sheet, the following are included in this kit (some additional parts are included for future maintenance): Item or Kit Quantity Catalog Number Alignment tool, pump, for use in replacing valve seals 1 each Card, warranty 1 each Colorimeter, HTR Block assembly* 1 each Varies (parameter-dependent) Colorimeter cover assembly* 1 each Cover, valve module assembly circuit board* 1 each Grease, High Temperature, non-flammable 1 tube Flat washers, replacement on colorimeter plumbing* 2 each Ferrules, replacement on colorimeter plumbing* 4 each and Kit, IC Program* 1 each Kit, sample conditioning. Includes: 2 ferrule fittings, 2 types of tubing, IC program kit, Installation and Maintenance manual, parameter-specific manual, filter assembly, 1 each Varies (parameter-dependent) ceramic filter, the Grab sample kit, and an instruction sheet. Label, maintenance record 1 each Label, plumbing diagram 1 each Varies (parameter-dependent) Nut, hex 4 each Nut, flangeless, 0.62 OD tubing 4 each O-rings 3 each Pencil, grease 1 each Pump module assembly 1 each Screws, 6/32 x pan head, for installing the cover plate on the valve module 2 each Seal, flanged 6 each * If this kit was obtained to upgrade an Ammonium, Nitrate, or Ammonium/Nitrate Analyzer, some of the items listed in the table above are not included in your kit. The parts not included in your kit are denoted by an asterisk (*). In addition, please disregard the following sections of this Instruction Sheet: Removing the Valve Heater Block, Replacing the Valve Module Software Chip, Installing the Detector Block, and Increasing the Back Pressure Regulator Setting. Page 1

2 Required customer-supplied equipment: Hex wrench, 9 /64 in. Grounded wrist strap Phillips-head screwdriver Flat-blade screwdriver Software chip extraction tool Installing the New Main PCB Software Chip Important Note: The APA 6000 Analyzer circuit board components are extremely susceptible to static electricity damage. Do not touch the circuit board without wearing a properly grounded wrist strap. Follow these instructions carefully to avoid personal injury and damage to the instrument. Only qualified personnel should install the software chip. 1. Place the analyzer in standby mode: From the main menu, select the SENSOR MENU, select the APA being upgraded, select SENSOR STATUS, then select STANDBY. When the instrument is in standby mode, the display will show Operation Halted and the pump will be in its most forward position. This may take 1 3 minutes. 2. Turn the analyzer off and disconnect ac line power. 3. Shut off sample flow to the analyzer. 4. Make sure all modules are secured in the module panel, then remove the two #10 phillips-head screws from the upper right and left corners of the module panel. Carefully lower the panel until it is supported by the cable inside. 5. Remove the access cover at the inside back of the APA 6000 by removing the single #6 phillips-head screw near the center. 6. Refer to Figure 1 to locate socket U3 (the second chip down on the left side of the circuit board). Use an appropriate tool such as the PLCC extraction tool (Cat. No ) to remove the flash memory chip. Remove the memory chip from the socket by placing the metal teeth of the extraction tool in the slotted corners of the socket. Gently squeeze the extraction tool to close around the chip and pull the chip from the socket. 7. Carefully install the new flash memory chip (Cat. No for LR Ammonia and Monochloramine/LR Ammonia; Cat. No for HR Copper, LR Copper, LR Hardness, and Alkalinity) in socket U3 with the angled corner of the chip aligned with the angled corner of the socket. Press the memory chip firmly in place until it is seated in the socket. 8. Replace the cover and secure the module panel. 9. Proceed with installing the Vortex sample conditioning kit. Page 2

3 Figure 1 Main PCB Software Chip Location Installing the Vortex Sample Conditioning Kit on the APA 6000 Analyzer 1. Make sure the analyzer is in standby mode and that the power is disconnected. 2. Shut off sample flow to the analyzer. 3. Remove the sample bypass block from the outer left side of the analyzer by removing the two #6 phillips-head screws (see Figure 2). 4. Disconnect the ¼-in. tubing from the sample bypass block, as well as the smaller line feeding sample to the analyzer. 5. Install the vortex sample conditioning block in place of the sample bypass block using two 1½ in. x #6 phillips-head screws from the Cat. No kit. Orient the block with the knurled filter holder on the bottom and the ¼-in. connections facing the rear of the analyzer, see Figure 3. Tighten the screws until snug. Do not overtighten. Page 3

4 Figure 2 Removing the Sample Bypass Block Remove these two screws to take off the Sample Bypass Block. Save these screws. To Drain Shut off the sample flow to the analyzer and disconnect the tubing from the Sample Bypass Block. Sample Bypass Block 6. Connect the ¼-28 fitting (filtered sample to the instrument) to the bottom port of the sample conditioning block as shown in Figure 3. Ensure the ¼-28 fitting and the filter holder are finger tight. Do not overtighten. 7. Install a ¼-in. unfiltered sample line to the bottom connector facing the rear of the vortex sample conditioning block.two distinct stops will be felt when the tubing is properly seated. The sample should be valved and preset at less than 30 psi. Figure 3 The Vortex Sample Conditioning Block Page 4

5 Removing the Valve Heater Block 8. Install a ¼-in. sample outlet to the unfiltered sample out (top) connector. Route this outlet so it flows to a vent above or near the same height as the sample conditioning block. 9. Establish flow to the vortex sample conditioning block. Maximize flow (100 ml/min to 2000 ml/min) to provide a rapid vortex around the ceramic 0.5 µm filter. This helps the filter element to self-clean. 1. Make sure the analyzer is in standby mode and that the power is disconnected. 2. Remove the center port tubing and fitting and the pump body tubing and fitting. 3. Remove the three screws holding the valve heater block to the module, see Figure 4. Figure 4 Removing the Screws Holding the Valve Heater Block 4. Pull the block forward to allow access to the valve head screw, see Figure Using the short end of a 9 /64 in. hex wrench, loosen the valve head screw. 6. Pull the valve out through the face of the block. 7. Unplug the wire assemblies connecting the block to the valve module and remove the block. Discard the block. Important Note: The APA 6000 Analyzer circuit board components are extremely susceptible to static electricity damage. Do not touch any circuit board without wearing a properly grounded wrist strap. Follow these instructions carefully to avoid personal injury and damage to the instrument. Only qualified personnel should install the software chip. 8. Loosen the two captive screws securing the valve module to the analyzer. Page 5

6 Figure 5 Loosening the Screw Holding the Valve Head in Place 9. Remove the valve module from the instrument. 10. Remove the three screws from the plastic cover on the back of the module (see Figure 6) and remove the plastic cover. 11. Slide the circuit board out of the module (see Figure 6) and unplug the wires as necessary. 12. Squeeze the chip removal tool around the chip and remove it. 13. Align the pins and insert the new valve module chip, Cat. No , (see Figure 6). Press it firmly into place. Figure 6 Removing the Valve Module Circuit Board and Positioning the Valve Module Software Chip Page 6

7 14. Reassemble the module and reinstall it back into the analyzer by performing steps 8 11 above in reverse order. 15. Replace the valve body back onto the module with valve port 1 at the top. Tighten the valve head screw. 16. Install the cover over the exposed connectors on the Valve Module using the provided screws and washers, see Figure 7. Figure 7 Installing the Cover Plate on the Valve Module Installing the New Detector Block 1. Remove the tubing from the front of the detector module by unscrewing the fittings. 2. Take the colorimeter out of the detector block by removing the two screws directly above and below the tubing. (Do not remove the two that are to the left and right of the tubing.) Retain the screws. 3. Pull the mounting plate straight out. 4. Remove the detector block from the detector module by removing the three mounting screws (see Figure 8). Retain the screws for reassembly. 5. Install the new Detector Block onto the Detector Module using the three recessed mounting screws removed in step Remove the mounting plate from the colorimeter by removing the four mounting screws. 7. Using the screws from the plate removed in step 6, replace with the new plate included in the kit. 8. Orient the colorimeter with the black side to the left and slide it into the detector block. Install and tighten the two screws above and below the tubing ports. 9. Use the enclosed fittings and ferrules and refer to the new plumbing diagram and tubing lengths table in the parameter-specific operations manual to make the connection to the valve. Page 7

8 Figure 8 Assembling the Detector Block Installing the New Pump Module 1. Disconnect the tubing from the existing pump module. Retain the shorter tube and its associated connector. 2. Remove the two screws holding the pump module in place and pull the module out of the analyzer. 3. Slide the new pump module into the analyzer and replace the screws. 4. Install the tube retained in Step 1 above, between the bottom of the valve and the top of the solenoid. 5. Ensure the remaining plumbing connections match the new plumbing diagram. Installing New Labels The upgrade kit includes two new labels: a plumbing diagram and a maintenance record label. To install the new plumbing diagram, remove the backing, align it with the existing plumbing diagram label and press to firmly attach it. To install the maintenance record label, remove the backing from the adhesive strip on the back bottom and sides. Starting in the center, press and smooth the label out toward the edges (see Figure 9 for placement location). Use the area behind the label to store a grease pencil for entering information on the label. Page 8

9 Figure 9 Label Placement Restarting the Analyzer 1. Replace reagents if appropriate. 2. Supply power to the instrument. 3. Allow the instrument to initialize. 4. Prime the instrument. 5. Recalibrate the instrument. Increasing the Back Pressure Regulator Setting Note: This procedure must be performed during normal analyzer operation. 1. Locate the drain block and remove the label on the back. 2. While watching the pressure gauge for its highest pressure cycle (approximately 15 psig), use a flat-blade screwdriver and slowly turn the screw clockwise to increase the pressure. The correct pressure setting is 20 psig. Page 9

10 FOR TECHNICAL ASSISTANCE, PRICE INFORMATION AND ORDERING: In the U.S.A. Call toll-free Outside the U.S.A. Contact the HACH office or distributor serving you. On the Worldwide Web HACH COMPANY WORLD HEADQUARTERS Telephone: (970) FAX: (970) Hach Company, All rights reserved. Printed in the U.S.A. dd/dp 03/02 1ed

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