Real Clean System I Manual v2.1 (Controller) - Real Tech
Real Clean System I Manual v2.1 (Controller) - Real Tech
1 Contents
2 Overview _____________________________________________________________________________ 4
3 Safety and Warranty Registration __________________________________________________________ 5
3.1 Safety Instructions _________________________________________________________________ 5
3.2 Warranty Registration _______________________________________________________________ 5
4 Technical Specifications _________________________________________________________________ 6
5 Installation ____________________________________________________________________________ 6
5.1 Unpacking and Inspection ___________________________________________________________ 6
5.2 Assembly ________________________________________________________________________ 7
5.3 Mounting _________________________________________________________________________ 7
5.4 Plumbing _________________________________________________________________________ 8
5.4.1 Connecting a PL/GL UV-VIS Sensor _______________________________________________9
5.5 Electrical and Communication _______________________________________________________ 10
5.5.1 Connection to Real Controller____________________________________________________10
5.5.2 Connection to Real Controller Pro ________________________________________________10
6 Operation ___________________________________________________________________________ 11
7 Cleaning ____________________________________________________________________________ 12
8 Cleaning Configuration _________________________________________________________________ 13
8.1 Configuration with the Real Controller Pro ______________________________________________ 14
8.1.1 Add / Enable Real Clean with ML Sensor __________________________________________14
8.1.2 Add / Enable Real Clean with GL/PL Sensor ________________________________________16
8.1.3 Cleaning Controls _____________________________________________________________18
8.2 Configuration with the Real Controller _________________________________________________ 19
9 Maintenance _________________________________________________________________________ 24
10 Parts and Accessories _________________________________________________________________ 24
11 Cabinet Dimensions and Clearance _______________________________________________________ 25
12 Warranty ____________________________________________________________________________ 26
List of Tables
List of Illustrations
2 Overview
Thank you for purchasing from Real Tech Inc.
The Real Clean System I is an automatic chemical cleaning system for use
with any Real Tech Inc. ML2000, ML3000, or GL/PL series sensors. The
purpose of the system is to reduce fouling of the flow cell within the sensor.
Control of the cleaning system is made through the Operator Interface of the
Real Controller or Real Controller Pro.
The Real Clean and the Sensor are plumbed so that process water goes through the Real Clean to the Sensor.
When a cleaning cycle starts, the Real Clean system halts input of process water and pumps cleaning solution
from its wash bottle to the flow cell of the sensor on a timed schedule, or when needed, immediately through
manual intervention.
Cleaning fluid to
flow cell for a
10-minute hold
time.
On schedule,
cleaning fluid drawn
from bottle by
pump.
A portion of cleaning fluid is recaptured and directed back into the wash bottle after a cleaning cycle is
completed. Sensor measurement resumes after the tubing is cleared of residual cleaning fluid by influx of
process water.
Cleaning of the flow cell is best achieved when cleaning frequency and cleaning fluid work in unison to prevent
the accumulation of fouling agents inside the flow cell.
Serial Number*
Please read and follow all safety instructions outlined in this owner’s manual prior to
installation and/ or operation.
1. Visually inspect the device prior to operation. If it seems broken or damaged in any way, do not use.
Contact Real Tech Inc. for a replacement.
2. Ensure that all responsible personnel carefully read this manual before installing or servicing the device.
3. Failure to properly install and maintain this device may impact its effectiveness and warranty.
To activate your standard two-year warranty for your product, the end user of the product is responsible for
filling out the warranty registration information for their company. Failure to do so could void the warranty. See
the warranty section for full details on Real Tech’s two-year warranty program.
4 Technical Specifications
5 Installation
5.1 Unpacking and Inspection
To begin, remove the Real Clean system from the packaging and carefully inspect the product to ensure that no
visible damage has occurred during shipping. The following items will be packed inside the box:
ITEM QUANTITY
1L Wash Bottle 1
Owner’s Manual 1
Please ensure all items are unpacked and accounted for before moving on to assembly.
5.2 Assembly
The wash bottle holder must be mounted onto the Real Clean I
system from the underside of the enclosure as shown in Figure 5.1.
Fittings are supplied with the holder.
After mounting the enclosure, fill the 1L wash bottle supplied with
cleaning fluid. Recommended fluids are outlined in Section 6 –
Cleaning. Connect the tubing from the system to the spout on the
1L bottle supplied.
5.3 Mounting
5.4 Plumbing
Process water from a pressurized source flows through the Real Clean system and into the connected
instrument for measurement.
Piping is required to be ¼” OD flex tubing of whatever pressure rating is needed for the particular site. Figure
5.4 displays the two push-to-connect inlet and outlet ports on the side of the Real Clean system.
From Process
To Sensor
The Real Clean system is connected in series with the instrument to be cleaned. It is preferred to keep the
tubing between the Real Clean and instrument less than 2 feet. Configurations for the PL/GL series instruments
are outlined in Figure 5.6.
Note: If installing with a Dual Feed system, the Real Clean will be installed prior to the Dual feed on the Stream
1 port (See Figure 5.5). Refer to the Dual Feed manual for further instructions.
To Sensor
From Process
To Stream 1
Water Out
Water In
Figure 5.6: PL/GL UV-VIS sensor and Real Clean System I plumbing connections
6 Operation
The system consists of a 3-way stainless solenoid valve, a peristaltic chemical pump, and a 1L chemical cleaner
storage container. The cleaning process is initiated automatically on a preselected time interval or can be
manually triggered.
To start the cleaning cycle, or make any modifications to it, refer to Sections 8.1 and 8.2.
1. Solenoid shuts off the process water flow to the sensor flow cell (LED turns on).
2. Solenoid opens flow from peristaltic pump to the sensor flow cell.
3. Peristaltic pump turns on and pumps cleaning solution into the sensor flow cell.
4. The pump turns off and the system waits to allow the chemical cleaning solution to remove fouling and
staining present on the walls of the quartz flow cell.
5. The pump turns on in the opposite direction to re-capture the cleaning chemical.
6. Solenoid valve opens the water flow from the process to purge out the cleaning solution (LED turns off).
During the cleaning cycle, all sensor measurements shown on the Real Controller or Real Controller Pro are
held to the last valid value measured before the cycle started and are released after the purge time is complete.
7 Cleaning
The Real Clean system comes with a 1L chemical storage bottle. After
a cleaning cycle, approximately 85% of the cleaning fluid is pumped
back into the bottle reducing the need to replenish the fluid on a
regular basis.
Two important factors that affect the sensor performance are the
cleaning fluid used to clean the flow cell, and how often the flow cell
is cleaned (cleaning frequency).
Cleaning Frequency
The optimum frequency of cleaning is quite variable depending on
the amount and type of fouling agents in the water. This will be
dependent on the application and installation point.
Figure 7.1: Effective cleaning
Once in operation, observe the flow cell for signs of fouling prior to
the first cleaning cycle. If fouling is present, increase the cleaning
frequency accordingly. The measured data can also be observed for
signs of a saw tooth effect as shown in Figure 7.1. If the saw tooth
shows an upward trend, as shown in Figure 7.2, the sensor is
drifting, and cleaning frequency must be increased.
Cleaning Fluid
Selecting an effective cleaning solution is essential for optimal
performance. The following commercial cleaning solutions and acids
are readily available to remove common fouling agents.
Lactic Acid <20% solution (CLR®) Removes lime, calcium, rust, magnesium, and other dissolved minerals
Sulfamic Acid <10% solution (Lime Away®) Removes lime, calcium, rust, magnesium, and other dissolved minerals
Phosphoric Acid <30% solution (Rust Off, Hagasen Blue) Removes lime, calcium, rust and color staining
Sodium Hypochlorite <6% solution (Not bleach) Removes oil, grease and biofilm
8 Cleaning Configuration
The Real Clean system is controlled and configured through the Real Controller or Real Controller Pro. Below is
a general summary of the functions and configurations for a Real Clean I system.
FUNCTION DESCRIPTION
Enable Clean Cleaning must be enabled for the Real Clean system to operate.
At any time, the user can trigger a cleaning cycle by selecting force clean. This will not change the
Force Clean
scheduling of the cleaning cycle.
Factory recommended settings for injection of cleaning fluid into the flow cell and amount of time for
Cleaning Controls
cleaning fluid to clean the flow cell are displayed as defaults but can be changed by the user.
Cleaning Fluid allows for configuration of the cleaning bottle size and cleaning fluid warning alarm.
Cleaning Fluid When the cleaning fluid is changed or refilled, the user must do a Reset to ensure the enabled
alarms and Remaining Cycle are properly displayed.
Popup 1
Popup 2
Popup 3
Popup 1
Popup 2
BOX DESCRIPTION
The Cleaning Cycle box allows for the frequency of cleaning to be configured. The user can update the
Cleaning
frequency by applying new values to the Days or Hours fields and pressing Apply. At any time, the user
Cycle
can trigger a cleaning cycle by pressing the Force Clean button.
Factory recommended settings will be displayed here. Fields for use are:
• Chemical Injection Time
Cleaning
• Total Washing Time
Controls
• Chemical Recapture Time
Depending on your local conditions, the default settings may have to be adjusted.
1. Press the Menu button to display +System settings at the top of the screen. The arrow cursor is
situated beside +System settings. Press Enter to expand the System settings menu. Scroll down using
the down arrow button to +Devices, and press Enter to expand the Devices menu.
2. Scroll down to Cleaning sys. Press Enter to place a checkmark against the device. This enables the
cleaning system.
The Cleaning System menu is reproduced below. Note that the menu for all Real Tech cleaning systems is
common. Therefore, you will see features described in the menu that fall outside the scope of the Real Clean
System I, for example Air Purge, which applies to the Real Air Purge Pump Clean system.
MENU ITEM
MENU ITEM DESCRIPTION
TYPE
-Cleaning System
Stop radio button Stop all pumps. Reset cleaning if it was ongoing.
Triggers cleaning.
MENU ITEM
MENU ITEM DESCRIPTION
TYPE
-State: [text] text Shows one of the following ongoing processes in the system:
Cleaning fluid is held within sensor and not agitated. This is only
ChemHold text
displayed if Agitation is disabled under the -Config menu.
MENU ITEM
MENU ITEM DESCRIPTION
TYPE
Start on
Units:
day
Length of time used to inject cleaning fluid into lines and flow cell
Injection: number
(1 to 999 seconds).
MENU ITEM
MENU ITEM DESCRIPTION
TYPE
Agit Total: number Length of time used to run an agitation cycle (1 to 999 seconds).
Length of time to rinse lines and sensor with process water before
CleanPurge: number
reverting to measurement of process flow (1 to 999 seconds).
Checking this box will enable the settings entered against each of
Scheduled: checkbox the AirPurge parameters (not including Str1 only, which is enabled
separately).
MENU ITEM
MENU ITEM DESCRIPTION
TYPE
Heater On/Off text Indicates heater status i.e. heater switched on or off.
Heater turns off at this setting (typically set for 50 degrees Celsius)
Overheat t: number and will remain off until temperature lowers to the value entered for
Heating t.
9 Maintenance
FREQUENCY TASK
Site Specific • Automatic cleaning cycle configuration to ensure proper sensor cleaning
Cleaning Fluid Bottle 1 Litre wash bottle for chemical fluid storage S-166011
Chemical Pump Tubing Replacement internal pump tubing for chemical pump UVT-139013
The front, side, and back views of the cabinet are shown below to the nearest 1/8 inch. The back view gives the
dimensions relevant for spacing of screws to mount the cabinet. Allow a clearance of 6 inches around the
cabinet for unit connection.
12 Warranty
Real Tech Inc. (Real Tech) warrants to the original Real Tech assumes no liability for indirect or
purchaser of this instrument that it will be free of consequential damage, losses, injury or costs of
defects in material and workmanship, in normal use any kind, and the original purchaser, by placement
and service, for a period of two years from date of of any order for the instrument, or parts thereof,
delivery to the original purchaser. Real Tech's shall be deemed liable for any and all damages
obligation under this warranty is limited to replacing incurred by the use or misuse of the instruments, or
or repairing the instrument, at Real Tech’s option, at
parts thereof, by the purchaser, its employees, or
Real Tech's factory. Excluded from this limited
others, following receipt thereof.
warranty are accessories and supplies.
The original purchaser is responsible for return of Carefully inspect this product for shipping damage, if
the instruments, or parts thereof, to Real Tech's damaged, immediately notify the shipping company
and arrange an on-site inspection. Real Tech cannot
factory. This includes all freight and insurance
be responsible for damage in shipment and cannot
charges incurred in shipping to and from Real
assist with claims without an on-site inspection of the
Tech's factory. damage.
Real Tech is not responsible for any personal injury This warranty is given in lieu of and excludes all other
or damage to the instrument, or parts thereof, warranties, conditions and guarantees, expressed or
resulting from any accident, improper use of the implied, statutory or otherwise including those of
instrument, negligence or willful neglect on the part merchantability and fitness for use. No agent or
of the user of the instrument. Real Tech is not representative is authorized to assume any liability
responsible for any personal injury or defects to the for Real Tech.
instrument resulting from repairs or alterations
made by any person not authorized by Real Tech.