Omega FCLTX-100 User's Manual
Contents
1. M4679 0708 page 1 of 6 PRODUCT INSTRUCTION SHEET OE OMEGA SECTION 3 0 SENSOR PREPARATION 3 0 FREE CHLORINE SENSOR ASSEMBLY The Free Chlorine Sensor is shipped with the membrane cap pre installed and covered with a cap with water inside to keep the membrane wet Make sure to keep sensor cap anode and cathode inside the sensor body away oily or greasy materials Contact with oil or grease will result in inaccurate measurements NOTE IF SENSOR WILL BE STORED DRY OUT OF FLOW CELL SHAKE BODY DOWNWARD INTO A SINK TO REMOVE THE FILL SOLUTION TAKE THE MEMBRANE CAP AND IMMERSE IN A CUP OF TAP WATER UNTILL READY TO REUSE SEE SECTION 9 REPLACE CAP AND ELECTROLYTE BEFORE INSTALL ING INTO FLOW CELL see SECTION 10 for cap and electrolyte change See SECTION 5 for sensor installation into flow cell SECTION 4 0 FLOW CELL INSTALLATION 4 0 FLOW CELL To obtain accurate Free Chlorine reading the Sensor must be installed into the Flow Cell to prevent air bubbles formation on the membrane proper spacing between the sensor and the installation wall and laminar flow across the membrane 4 1 Using two 1 4 NPT Tube fittings connect the FC72 Flow poeowce Cell into your system noting the inlet bottom and outlet side orientation see FIGURE 2 4 2 Install clamp with rubber backing as shown in FIG 2A 4 3 Drill 3 8 diameter hole on the panel 4 4 Insert bolt as shown2. Cable short circuit or damage 5 pH value less than pH 5 5 b Sensor output LOWER than DPD test 1 Run in time too short 2 Deposits on Membrane cap 3 Flow rate too low 4 Air bubbles on membrane 5 Surfactants in water 6 pH value more than pH 8 0 7 No electrolyte in membrane cap c Sensor ouput is 4mA zero ppm 1 Run in time too short 2 Only bound chlorine present 3 Chlorine content below detection limit 4 Sensor not wired correctly See SECTION 6 0 of this manual 5 Defective sensor d Sensor output UNSTABLE 1 Air bubbles on membrane 2 Membrane damage 3 Non sensor problem Symptom The sensor cannot be calibrated ouput is HIGHER than DPD Test The sensor cannot be calibrated output is LOWER than DPD Test Sensor output is 4mA 0 ppm Unstable output from sensor OMEGA INJECT UNTIL SOLUTION LEAKS OUT OF FILL HOLE TROUBLESHOOTING CHART Possible Cause 1 Run in time too short 2 Membrane cap damaged 3 Interference from contaminants 4 DPD chemicals bad 5 pH value lt pH 5 5 6 Temperatue increased since cal 1 Run in time too short 2 Deposits on membrane cap 3 Flow rate too low 4 Air bubbles on membrane 5 Surfactants in water 6 pH gt pH 8 0 7 No electrolyte in cap 8 Temperature decreased since cal 9 Organic chlorination agents present in water 1 Only bound chlorine present NO FREE CHLORINE 2 Run in time too short 3 Chlorine c
3. is then conditioned to 4 20mA current by the sensor s onboard elec tronic circuitry SECTION 2 0 FACTORS INFLUENCING THE SENSOR 2 1 pH Free Chlorine FCL exists as hypochlorous acid and hy pochlorite anion FIG 1 The acid base dissociation of FCL has a pKa of approximately 7 5 The FCL sensor responds to hypochlorous acid and hypochlorite anion with different sensitivity In combina tion an increase in pH reduces the measured FCL and decrease in pH increases the measured FCL The need for automatic pH compensa tion depends on the pH value and the variation range of pH Table 1 If pH variation of your sample is more than that listed in the table automatic pH compensation is required pH compensation for the sensors current mA reading is sensor output in mA 4 0 0502pH 0 867pH 5 051pH 12 43 4 2 2 Chemical Interferences The sensors should not be used in water containing surfactants organic chlorine or stabilizers such as cyanuric acid 2 2 FLOW The membrance covered free chlorine sensors FCL series functions at any flow rate To acheive reproducible measurements these free chlorine sensors require a specified constant flow rate To avoid complications such as bubbles it is best to operate the sen sors at a flow rate of 0 2 0 6 gpm if using flow cell FC72 or FC70 old version Parts covered by this product instruction sheet include FCLTX 100 Series Percent of free chlorine in protonated form HCIO
4. PLC s connect clear shield to it Attach the red wire to the power supply positive terminal and the black wire to the PLC or DVM positive terminal Connect a wire customer supplied from the power suppy negative and the PLC or DVM See FIG 3 The Sensor will require several minutes to stabilize after power is supplied to it SECTION 7 0 SENSOR CONDITIONING 7 0 SENSOR CONDITIONING The sensor requires conditioning prior to generating stable values a For new Sensors allow the Sensor to run for at least 4 hours before calibration b If the Sensor will be un powered for 2 hours or more run for 3 hours prior to use c After membrane electrolyte replacement allow the Sensor to run for at least 4 hours OMEGA Power Supply sensor red wire sensor black wire PLC DVM Parts covered by this product instruction sheet include FCLTX 100 Series M4679 0708 page 3 of 6 PRODUCT INSTRUCTION SHEET OMEGA SECTION 8 0 CALIBRATION IMPORTANT NOTE SENSORS ARE SUPPLIED FACTORY CALIBRATED WITH A 4 20mA SIGNAL OUTPUT CORRESPONDING TO THEIR SPECIFIC RANGE 0 2 0 5 OR 0 10ppm SPAN CALIBRATION IS NECESSARY WHEN RECEIVING A NEW SENSOR SINCE YOUR CONDITIONS MAY VARY FROM THOSE USED AT THE FACTORY FOR SPAN CALIBRATION THE ZERO POINT CALIBRATION IS NOT NECESSARY SINCE THE ZERO SETTING IS VERY STABLE PERIODIC CALIBRATION ABOUT ONCE PER WEEK IS RECOMMENDED THIS IS USEFUL IN TRACKIN
5. G SENSOR FAILURES AS WELL 8 1 Removal of cord grip to access ZERO and SPAN potentiometers inside the sensor body a Remove top nut of cord grip as shown in FIGURE 4 b Remove remaining cord grip as shown in FIGURE 5 A wrench may be required 8 2 Slope Calibration a Determine the free chlorine content using a diethyl p phenylenediamine DPD colorimeter test kit see FIGURE 9 not included with ClO2 sensor and flow cell b Measure Free Chlorine content with sensor Make sure that calibration flow rate and pH matches flow rate when Left Right measuring sample since probe output is flow rate and pH potentiometer potentiometer dependent Make sure pH is within 5 5 8 0 range Zero adjust Span adjust c Adjust the span potentiometer to the desired mA see FIGURES 9 amp 9A c Repeat this slope calibration one day after sensor is initially installed d Repeat the slope calibration monthly SECTION 9 0 to Increase SENSOR STORAGE output 9 0 STORAGE Store sensor at 5 C 50 C ONLY and maximum humidity of 90 non condensing a Short Term Storage 1 week or less Store in Flow cell ta Decrease AL with water to prevent the probe from drying out O output b Intermediate Term 1 week to 1 month Store in cap bottle or beaker with water to keep membrane wet c Long Term 1 month or longer Remove Membrane Cap and store completely immersed in tap water Turn sensor upright and shake it to remove fill solution from ins
6. PRODUCT INSTRUCTION SHEET CE OMEGA FCLTX 100 Series SECTION 1 0 THEORY OF OPERATION 1 0 FREE CHLORINE DEFINED Free Chlorine or freely active chlorine is defined as the sum of molecular chlorine Cl2 hypochlorous acid HOCI and hypochlorite ions OCI Molecular chlorine occurs at pH values lt pH4 Hypochlorus acid and hypochlorite ions are in pH dependent equilibrium with one another as shown in FIG 1 The graph shows hypochlorous acid on the left of the curve Hypochlorous acid is a much stronger disinfecting agent oxidizer as compared to hypochlorite ions 1 2 SENSOR OPERATING PRINCIPLE Both hypochlorous acid HOCI and hypochlorite ion OCI diffuse through the membrane between the cathode and sample solution even though the diffusion coeffi cients for each are different At the applied potential only hyphochlo rous acid is electrochemically reduced HOCI is reduced to chloride ion at the gold cathode At the same time the silver anode is oxidized to form silver chloride AgCI When the concentration of HOCI at the cathode is dramatically decreased by electrochemical reduction hypochlorite ion will be transformed into hypochlorous acid to some extent by proton transfer The release of electrons at the cathode and acceptance at the anode creates a current flow which under constant conditions is proportional to the free chlorine concentration in the medium outside the sensor The resulting low current output
7. ck PVC Membrane Material polyethersulfone O ring material Viton Cathode Gold Anode Silver chloride AgCI Cable 2 conductor shielded 10ft 3mtr tinned wire leads FLOW CELL Dimensions 5 58 H x 2 25 DIA Material Acrylic Connections 1 4 NPT inlet and outlet OPERATING SPECIFICATIONS Operating temperature range 0 45 degC Maximum operating pressure 1 bar 14 7 psi latm Flow rate minimum 20 gpm Flow rate maximum 0 6 ppm PH range 5 5 9 0 Output signal 4 0 0 2mA in air zero 20mA 0 2mA at high range 2 5 or 10ppm Power Requirement 12 24 VDC 250 mA minimum Cross Sensitivity CIO2 ozone bromine Chemical Compatibility up to 50 ethanol water or up to 50 glycerol water MAINTENANCE REPLACEMENT PARTS FC72 Flow Cell 1 4 inch FNPT inlet and outlet includes 2 each 1 4 barbed tube fittings clamp threaded flow cell installation fitting FCL ES Free Chlorine sensor fill solution 30mL 1 each FCL RM FCL Replacement premembraned cap 1 each CE OMEGA FC72 FLOW CELL DIMENSIONS SENSOR AND FLOW CELL INSTALLATION DIMENSIONS Parts covered by this product instruction sheet include FCLTX 100 Series M4679 0708 page 6 of 6
8. ide the sensor d Electrolyte bottle shelf life 1 year from date of manufature see expiration date on bottle Note The DPD method for Free chlorine mea surement is not selective for free chlorine alone Other oxidants in the water can also be mea sured as free chlorine M4679 0708 page 4 of 6 Parts covered by this product instruction sheet include FCLTX 100 Series PRODUCT INSTRUCTION SHEET SECTION 10 0 SENSOR MAINTENANCE RECONDITIONING 10 1 GENERAL MAINTENANCE Service the sensor regularly weekly is suggested 10 2 MEMBRANE CAP REPLACEMENT If membrane replace ment is required a new cap with preinstalled membrane must be used Order FCLA 2016 replacement membrane cap and FCLA 2015 refill solution To change membrane cap do the following over a sink or washbasin a turn sensor upside down with cap facing upward b rotate cap counter clockwise to remove see FIG 10 c fill sensor body with electrolyte using needle and bottle of refill solution see FIG 11 d install a new membrane cap by threading cap onto sensor rotating cap clockwise opposite of FIG 10 10 3 MEMBRANE CAP SENSOR CLEANING Rinse cap with water only If cap does not clean replace with new one SECTION 11 0 SENSOR TROUBLESHOOTING 11 1 CALIBRATION PROBLEMS a Sensor output HIGHER than DPD test 1 Run in time too short 2 Membrane cap damaged 3 Interference from water contaminants see Specifications Cross Sensitivity 4
9. in FIG 2A 4 5 On back of panel attach lock washer and nut to secure clamp and flow cell to panel SECTION 5 0 SENSOR INSTALLATION 5 0 SENSOR INSTALLATION INTO FLOW CELL a First install threaded fitting onto sensor body remove fitting if pre installed in flow cell b Install snap ring into groove on sensor body c Next slide o ring onto body of sensor until it reaches bottom of threaded fitting d Thread sensor assembly into top of flow cell as shown in FIGURE 2 d Turn on flow and verify the flow through the Flow Cell is at least 0 2gpm 45 liters hour and no more than 0 6gpm 135 liters hour A lt SENSOR SNAP RING GROOVE eo FITTING G snap RING INSTALLS INTO PROBE GROOVE O RING BARBED TUBE FITTING FLOW CELL BARBED TUBE DA FITTING Parts covered by this product instruction sheet include FCLTX 100 Series M4679 0708 page 2 of 6 PRODUCT INSTRUCTION SHEET SECTION 6 0 ELECTRICAL INSTALLATION 6 0 ELECTRICAL INSTALLATION The sensor produces an ap proximate output of 4 mA in air and 20mA at the top range of free chlorine output 0 2ppm 0 5ppm 0 10ppm NOTE The supply voltage to the Sensor must be 12 24 V DC with minimum of 250 mA Maximum load is 1 Watt The sensor has 3 wires red black and clear shield Twist together or solder black and clear if instrument does not have separate ground If a separate ground is available such as for
10. ontent below limit 4 No electrolyte in cap 5 Sensor electrical connection wrong 1 Air bubbles on sensor membrane 2 Membrane damaged 3 Non sensor problem Solution Remedy 1 See Sec 5 0 CONDITIONING 2 Replace cap See Sec 8 0 3 See SPECIFICATIONS 4 Use new DPD kit 5 Increase pH 5 5 8 0 See SPECIFICATIONS 6 Match calibration temp 1 See Sec 7 0 CONDITIONING 2 Remove deposits or replace cap if cleaning ineffective 3 increase flow See SPECIFICATIONS 4 Remove and re install sen sor to remove bubbles 5 Remove surfactants and replace cap 6 Lower pH 5 5 8 0 See SPECIFICATIONS 7 Add new electrolyte run in sensor and re calibrate 8 Increase temp to match cal 9 Use chlorinating agents per DIN 19643 1 Check for Chloramine with appropriate DPD test Replace water Rechlorinate 2 See Sec 7 0 CONDITIONING 3 Add chlorine and repeat calibration 4 Refill electrolyte 5 See SECTION 6 0 1 Tap to remove bubbles 2 Replace membrane run in sensor and recalibrate 3 check PLC or I O device Parts covered by this product instruction sheet include FCLTX 100 Series M4679 0708 page 5 of 6 PRODUCT INSTRUCTION SHEET SECTION 12 0 SENSOR SPECIFICATION 12 1 OPERATING SPECIFICATIONS Follow all operating specifications especially for pH and flow rate as noted in the specification tables below TECHNICAL SPECIFICATIONS SENSOR Dimensions 8 2 Lx 1 dia Body Material Bla
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