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Emerson TCL User's Manual

1. 19 MODEL TCL SECTION 6 START UP SECTION 6 DISPLAY AND OPERATION 6 1 DISPLAY The analyzer has a six line display See Figure 6 1 The display can be customized to meet user require ments Refer to section 6 6 When the analyzer is being programmed or calibrated the display changes to a screen similar to the one shown in Figure 6 2 The live readings appear in small font at the top of the screen The rest of the dis play shows programming and calibration information Programming items appear in lists The screen can show only four items at a time and the arrow bar at the right of the screen indicates whether there are addi tional items in the list See Figure 6 3 for an explana tion of the arrow bar 20 1 00 25 0 T1 25 0 C O1 12 00 mA T2 25 0 C O2 12 00 mA FIGURE 6 1 Main Display Live 1 00 ppm 25 0C measurement 7 00 pH 25 0C Output 1 Configure Fassign Ef Measurement Range 4 20 mA Scale Linear Dampening 0 sec i Item list FIGURE 6 2 Programming Screen Showing Item List The position of the cursor is shown in reverse video See Section 4 2 and 4 3 for more information You are at the top of the list There are more items for viewing Scroll down You are at the bottom of the list There are more items for viewing Scroll up You are in the middie of the list There are more items for viewing Scroll up or down FIGURE 6 3 Arrow Bar The arrow bar shows whether a
2. MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7 7 CONFIGURING SECURITY SETTINGS 7 7 1 Purpose This section describes how to set security codes There are three levels of security a Auser can view the default display and diagnostic screens only b Auser has access to the calibration and hold menus only c Auser has access to all menus The security code is a three digit number The table shows what happens when different security codes XXX and YYY are assigned to Calibration Hold and All 000 means no security Calibration Hold om User enters XXX and has access to Calibration and Hold XXX YYY menus only User enters YYY and has access to all menus ow w What happens User enters XXX and has access to all menus User needs no security code to have access to all menus User needs no security code to have access to all menus 7 7 2 Procedure Configuring Security Settings 1 Press MENU The main menu screen appears Move the cursor to Program and press ENTER Program 2 Scroll to the bottom of the screen and continue scrolling unit Security is Alarms highlighted Press ENTER Measurement Temperature Security 3 The screen shows the existing security codes To make a change move the cursor to the desired line and press ENTER A screen will appear in Calibration Hold 000 which the present setting can be edited Press ENTER to store the All 000 change The security code takes effect two minutes af
3. Section Title Page 1 0 DESCRIPTION AND SPECIFICATIONS eene nnns 1 1 1 Features and Applications rna 2 1 2 Specifications Sample Conditioning System sse 3 1 3 Specifications Model 1056 Analyzer een 3 1 4 Specifications Model 499ACL 02 Sensor na 4 1 5 Performance Specifications Complete System sss 4 1 6 Ordering Information and Accessories ss nnnnnnnnnnnnnnzananannnnznnnnnnnnnnnaa 5 2 0 PRINCIPLES OF OPERATION ivccsstsccecccssecccesecsseecececcsciecescsatiesceseantinseceasseeeeesessceees 7 3 0 INSTALLATION RP 8 3 1 Unpacking and Inspection sss 8 3 2 nir Ae 8 4 0 WIRING mL 13 4 1 Prepare Analyzer Conduit Openings s sisien ena edet 13 4 2 Provide Power to the Sample Conditioning System 2 e eenennnnnnennnn 13 4 3 Make Power Alarm Output and Sensor Connections in the Analyzer 14 4 4 SENSOF WIRING eera A 15 5 0 START UP m 19 5 1 Prepare the Reagent g et 19 5 2 Zero E 19 5 3 Start Sample FOW e a a G 19 5 4 Begin Operation and Calibrate the Sensor nee nnnnnn nn an nanna 19 6 0 DISPLAY AND OPERATION i iii ie erri neutre scunupetessnsteteceenaszedeteadeccetes 20 6 1 BIS 20 6 2 Ajo m 21 6 3 Programming the Analyzer Tutorial 22 6
4. analyzer automatically detects the AC voltage 4 3 2 Analog output wiring HINGED END Two analog current outputs are located on the main circuit board which is attached to the inside of the enclosure door Figure 4 3 shows the location of the terminals The connectors can be detached for wiring TB 1 is output 1 TB 2 is output 2 Polarity is marked on the circuit board For best EMI RFI protection use shielded output signal cable enclosed in earth grounded metal conduit Keep output signal wiring separate from power wiring Do not run signal and power or relay wiring in the same conduit or close together in a cable tray FIGURE 4 2 Analog output connections The analog outputs are on the main board near the hinged end of the enclosure door 14 MODEL TCL SECTION 4 WIRING 4 3 3 Alarm wiring A WARNING Exposure to some chemicals may degrade the sealing properties used in the following devices Zettler Relays K1 K4 PN AZ8 1CH12DSEA The alarm relay terminal strip is located just below the NOI power connector on the power supply board See COMI Figure 4 3 NCI NO2 Keep alarm relay wiring separate from signal wiring COM2 Do not run signal and power or relay wiring in the NC2 same conduit or close together in a cable tray NO3 COM3 NC3 NO4 COM4 NC4 FIGURE 4 3 Alarm relay connections 4 4 SENSOR WIRING 1 Shut off power to the analyzer 2 Locate
5. 24165 00 Acetic acid 2 x 2 5 gal 9 5 L bottles case with 25 g potassium iodide 45 Ib 20 5 kg 48 Ib 22 0 kg 0 5 ppm total chlorine 24165 01 Acetic acid 2 x 2 5 gal 9 5 L bottles case with 50 g potassium iodide 45 Ib 20 5 kg 48 Ib 22 0 kg 0 10 ppm total chlorine 24164 00 Potassium iodide 25 g sufficient for 5 gallons 19 L of vinegar 1 Ib 0 5 kg 1 Ib 0 5 kg 0 5 ppm total chlorine 24164 01 Potassium iodide 50 g sufficient for 5 gallons 19 L of vinegar 1 Ib 0 5 kg 1 Ib 0 5 kg 0 10 ppm total chlorine Weights are rounded up to the nearest whole pound or 0 5 kg ACCESSORIES 1055 24 Analyzer DESCRIPTION WEIGHT SHIP WEIGHT 9240048 00 Tag stainless steel specify marking 1 Ib 0 5 kg 1 Ib 0 5 kg 23820 00 Pipe mounting kit 2 Ib 1 0kg 3 Ib 1 5 kg ACCESSORIES 54eA Analyzer 23545 00 Panel mounting kit 2 Ib 1 0 kg 23554 00 1 Ib 0 5 kg 9240048 00 Stainless steel tag specify marking 1 Ib 0 5 kg 1 Ib 0 5 kg ACCESSORIES Sensor DESCRIPTION WEIGHT SHIP WEIGHT 23501 02 Total Chlorine Membrane includes one membrane assembly and 1 Ib 0 5 kg 1 Ib 0 5 kg one O ring 23502 02 Total Chlorine Membrane Kit includes 3 membrane assemblies and 1 Ib 0 5 kg 1 Ib 0 5 kg three O rings 9210438 Total Chlorine Sensor Fill Solution 4 oz 120 mL 1 Ib 0 5 kg 2 Ib 1 0 kg Weights are rounded up to the nearest whole pound or 0 5 kg
6. 4 SO CUTE i is eco On cu E ERE ROO RED a tel cci de 23 6 5 IIa 24 6 6 Configuring the Main Display 25 7 0 PROGRAMMING THE ANALYZER eene nn nnne nennen 26 7 1 eu 2 2 pe M 26 7 2 Braces e M 26 7 3 Configuring Ranging and Simulating Outpute see 29 7 4 Configuring Alarms and Assigning Setpoints eseeeeeeeeeeene eere reeeeerrnrerrrsssrrenenne 32 7 5 Configuring the Measurement 12 rtt certet vet eissai kt Ld secs 36 7 6 Configuring Temperature Related Settings neesesseeeeeeesrreseerresnrirnnsnrenrrnnenn nnne 38 7 7 Configuring Security Gettngs snanar nanna nn 39 7 8 Resetting the AnalyZer rede ettet yy et ette ger a a 40 MODEL TCL TABLE OF CONTENTS TABLE OF CONTENTS CONT D 8 0 DIGITAL COMMUNICATIONS eene n nnn innen tnnt 41 9 0 CALIBRATION 42 9 1 IMTOO UCU OM E 42 9 2 Calibrating Temperatura cce te ee ere a i dines ve at 42 9 3 Calibrating Total Chlorime seen 44 9 4 Calibrating Analog Output 1 2 rect ecce tete res beo eu eig ese eva eoa vau bee 47 10 0 MAINTENANCE E 49 10 1 ANALY ZO ik aa E A O 50 10 2 Total Chlorine Gensors eee eee reece eee eeeae eme ener en nnne nnns 50 10 3 Sample Conditioning System erron n nrn A A 52 10 4 Simulatirg Inputs o reto E e O 54 11 0 TROUBLESHOOTING iecur itecto rt oinnes te nu uaa se c
7. 7 3 2 Definitions ANALOG CURRENT OUTPUT The analyzer provides either a continuous 4 20 mA or 0 20 mA output signal proportional to chlorine or temperature ASSIGNING AN OUTPUT Outputs can be assigned to either the measurement total chlorine or temperature If a dual input analyzer is being used the outputs are freely assignable to either sensor LINEAR OUTPUT Linear output means the current is directly proportional to the value of the variable assigned to the output chlorine or temperature LOGARITHMIC OUTPUT Logarithmic output means the current is directly proportional to the common logarithm of the variable assigned to the output chlorine or temperature DAMPENING Output dampening smoothes out noisy readings It also increases response time The time selected for output dampening is the time to reach 63 of the final reading following a step change Output dampening does not affect the response time of the display FAULT The analyzer continuously monitors itself and the sensor s for faults If the analyzer detects a fault a fault message appears in the main display At the same time the output current goes to the value programmed in this section There are two output fault modes fixed and live Fixed means the selected output goes the previously programmed value between 0 00 and 22 00 mA when a fault occurs Live means the selected output is unaffected when a fault occurs RANGING AN OUTPUT The outputs are fully rangeable
8. Chodes NO Once in hold the sensor remains in hold until hold is turned off However if power is lost then restored hold will automaticallv be turned off 24 MODEL TCL SECTION 6 START UP 6 6 CONFIGURING THE MAIN DISPLAY The main display can be configured to meet user requirements Main Format Language English Warning Enable Contrast 1 00 om 25 0 T1 25 0 C O1 12 00 mA T2 25 0 C O2 12 00 mA 1 Press MENU The main menu screen appears Move the cursor to Display and press ENTER The screen shows the present configuration There are four items Main Format Language Warning and Contrast To make a change move the cursor to the desired line and press ENTER A screen appears in which the present setting can be edited Press ENTER to store the setting Main Format lets you configure the second line in the main display as well as the four smaller items at the bottom of the display Move the cur sor to the desired place in the screen and press ENTER Scroll through the list of items and select the parameter you wish displayed Once you are done making changes press EXIT twice to return to the display menu Press MENU then EXIT to return to the main display The following abbreviations are used in the quadrant display ro ema temperature live temperature manual measurement sensor current CI If you have a dual input 1056 analyzer other abbreviations might appear Consul
9. FOR FIRST TIME VARIOPOL INSTALLATIONS Interconnecting cable VP 6 30 ft 9 1 m MODEL TCL SECTION 2 PRINCIPLES OF OPERATION SECTION 2 PRINCIPLES OF OPERATION Total chlorine by definition is the iodine pro duced in a sample when it is treated with reagent pump sample pump potassium iodide at a pH between 3 5 and 4 5 Typically acetic acid or vinegar is used to adjust the pH sensor The total chlorine analyzer consists of asam air pump ple conditioning system which injects the reagent into the sample and a sensor and analyzer which measure the amount of iodine produced Figure 2 1 shows the sample condi tioning system The sample enters the sample overflow conditioning enclosure and flows to an over sampler flow sampler from which the sample pump takes suction Excess sample drains to waste sample drain At the same time the reagent pump draws reagent a solution of potassium iodide in vinegar from the reagent carboy and injects it reagent into the suction side of the sample pump The bottle sample and reagent mix as they pass through the pump and total chlorine in the sample is FIGURE 2 1 Schematic of Sample Conditioning converted to the chemically equivalent amount System and Analyzer of iodine The flow rates are 11 mL min for the sample and 0 2 mL min for the reagent The treated sample next enters the flow cell Bubbles injected into the flow cell produce turbulence which improves the stability
10. If dechlorinated water is being measured provide a way for occasionally substituting a chlorinated water sample for the dechlorinated sample Chlorinated water is needed to calibrate the sensor and to check its response If a grab sample tap is not already available install one in the process piping Choose a point as close as pos sible to the sample line supplying the TCL Be sure that opening the sample valve does not appreciably alter the flow of sample to the instrument Connect the drain to a length of inch ID flexible plastic tubing The sample must drain to open atmosphere Find the reagent tubing and fitting in the plastic bag taped to the inside of the enclosure door Screw the reagent fitting onto the bulkhead fitting at the bottom left of the enclosure Pass the reagent tubing through the hole in the carboy cap Be sure the plastic weight will be inside the carboy when the cap is in place Attach the reagent tubing to the barbed connector See Figure 3 5 Place the blue plastic carboy beneath the enclosure Screw the cap and tubing assembly on to the carboy To prepare reagent see Section 5 2 3 2 4 Install the Sensor 1 From inside the sample conditioning enclosure thread the sensor cable or VP cable through the gland on the upper left side Leave about one foot of cable inside the enclosure Wire the cable to the analyzer Refer to Section 4 4 Remove the nut and adapter from the flow cell Slip the nut over the end o
11. Potassium iodide 50 g sufficient for 5 gallons 19 L of vinegar for 0 10 ppm total chlorine MODEL TCL SECTION 11 TROUBLESHOOTING SECTION 11 TROUBLESHOOTING 11 1 OVERVIEW The analyzer continuously monitors itself and the sensor s for problems When the analyzer identifies a problem the word warning or fault appears intermittently in the lower line of the main display When the fault or warning message appears press the DIAG diagnostic key for more information See Section 11 2 A warning means the instrument or sensor is usable but steps should be taken as soon as possible to correct the condition causing the warning A fault means the measurement is seriously in error and is not to be trusted A fault condition might also mean that the analyzer has failed Fault conditions must be corrected immediately When a fault occurs the analog output goes to 22 00 mA or to the value programmed in Section 7 3 2 The analyzer also displays warning messages if a calibration is seriously in error For more information see Section 11 3 11 2 USING THE DIAGNOSTIC FEATURE Diagnostic 1 To read diagnostic messages press DIAG The screen at left appears To display fault messages select Fault To display Warning messages select warning To read measurement information about the sensor s including raw sensor signal and calibration data choose the desired sen Sensor 1 sor and press ENTER Sensor 2 Warnings 2 f you choose Fa
12. Schematic peccet p een 56 10 16 Remove the Air Inlet Fitting inrer eee eere etae ese 57 10 17 Slide Pump Assembly Out of the Airp Pump Boch 57 MODEL TCL SECTION 1 DESCRIPTION AND SPECIFICATIONS SECTION 1 DESCRIPTION AND SPECIFICATIONS Model TCL Sample Conditioning System e NO METAL WETTED PARTS Ideal for seawater LOW SAMPLE FLOW about 15 mL minute means little waste e REAGENT BASED SYSTEM measures true total chlorine e FIVE GALLONS OF REAGENT lasts two months Model 1056 Chlorine Analyzer LARGE PROGRAMMABLE BACK LIT DISPLAY with easy to use interface e TWO INDEPENDENT ANALOG OUTPUTS e FOUR FULLY PROGRAMMABLE RELAYS optional DIGITAL COMMUNICATIONS HART OR PROFIBUS DP optional Model 499A CL 02 Sensor e MEMBRANE COVERED AMPEROMETRIC SENSOR NO TOOLS REQUIRED to change membrane MAINTENANCE TAKES ONLY A FEW MINUTES a month VARIOPOL CONNECTOR OPTION allows the sensor to be replaced without removing and rewiring cable 1 1 FEATURES MODEL TCL SAMPLE CONDITIONING SYSTEM The sample conditioning system permits a single sen sor to measure total chlorine in water The sample con ditioning system continuously injects a solution of acetic acid vinegar and potassium iodide into the sample The acid lowers the pH to between 3 5 and 4 5 and allows total chlorine in the sample to quantitatively react with the potassium iodide to produce iodine The sensor measures the iodine concentr
13. access panel Pull out the pump and panel 4 Disconnect the air inlet and outlet tubing from the air pump See Figure 10 14 5 Remove the five screws surrounded by squares in Figure 10 13 holding the air pump to the access panel 6 Remove the four screws holding the wiring access panel 7 Disconnect the air pump power wires from the terminal strip See Figure 10 15 Discard the old air pump 8 Remove the five screws holding the rubber base of the replace ment air pump to the body 9 Using the five screws removed in step 6 attach the replacement air pump to the access panel 10 Connect the air pump power wires to the terminal strip 11 Replace the wiring access panel 12 Connect the air inlet and outlet tubing to the air pump See Figure 10 14 The conical end of the check valve points in the direction of the air flow 13 Replace the air pump access panel 14 Connect the sample pump tubing to the pump Connect the reagent and air injection tubing Connect the air inlet tubing to the barbed fitting at the bottom of the enclosure Model option 11 115 Vac only Model option 12 230 Vac only air outlet TERMINAL BLOCK GROUND e 115 230 VAC air inlet Sb F2 NEUTRAL 81 FIGURE 10 14 REAGENT PUMP CONNECTOR SAMPLE PUMP ATR PUMP FIGURE 10 15 MODEL TCL SECTION 10 MAINTENANCE 10 3 5 Replacing the
14. alarm relays analog outputs 1056 03 24 38 HT analyzer with alarm relays HART 1056 03 24 38 DP analyzer with alarm relays Profibus DP SENSOR optional selection 499ACL 02 54 sensor with standard cable 499ACL 02 54 60 sensor with optimum EMI RFI cable 499ACL 02 54 VP sensor with Variopol 6 0 fitting interconnecting cable must be ordered separately ACCESSORIES SAMPLE CONDITIONING SYSTEM Ship Weight Weight l 24134 00 Air pump 115 Vac 50 60 Hz 1 Ib 0 5 kg 24134 01 Air pump 230 Vac 50 60 Hz 1 Ib 0 5 kg 9160578 Air pump repair kit 1 Ib 0 5 kg 9322052 Check valve for air injection line 1 Ib 0 5 kg 24153 00 Carboy for reagent 5 gal 19 L includes cap 5 Ib 2 0 kg 9100204 Fuse 0 25 A 250 V 3AG slow blow for option 11 115 Vac 1 Ib 0 5 kg 9100132 Fuse 0 125 A 250 V 3AG slow blow for option 12 230 Vac 1 Ib 0 5 kg 9380094 Reagent pump 115 Vac 50 60 Hz 2 Ib 1 kg 9380095 Reagent pump 230 Vac 50 60 Hz 2 Ib 1 kg 9380091 Reagent pump replacement tubing 2 Ib 1 kg 24151 00 Reagent tubing replacement kit 2 Ib 1 kg 24135 00 Reagent uptake tubing 6 ft 1 8 m includes weight 2 Ib 1 kg 9380090 Sample pump 115 Vac 50 60 Hz 1 Ib 0 5 kg 2 Ib 1 kg 9380093 Sample pump 230 Vac 50 60 Hz 1 Ib 0 5 kg 2 Ib 1 kg 9380092 Sample pump replacement tubing 1 Ib 0 5 kg 2 Ib 1 kg 24152 00 Sample tubing replacement kit 1 Ib 0 5 kg 2 Ib 1 kg Description S Weigh ShipWejght
15. already connected to the output disconnect the load Do not put the milliameter in parallel with the load Calibrate Sensor 1 Sensor 2 Output 1 Output 2 4 mA Output 1 Cal Meter 20 mA Output 1 Cal Meter 2 Press MENU The main menu screen appears The cursor will be on Calibrate Press ENTER Choose the output you wish to calibrate The analyzer will simulate the low output current Change the value in the display to match the reading from the milliammeter The analyzer will simulate the 20 mA output current Change the value in the display to match the reading from the milliammeter 47 MODEL TCL Output 1 Trim Complete 48 SECTION 9 CALIBRATION If the calibration was successful the screen at left will appear If the user entered value is more that 1 mA different from the nominal value a possible error screen will appear To force the analyzer to accept the calibration choose Yes To return to the main display press MENU then EXIT MODEL TCL SECTION 10 MAINTENANCE SECTION 10 MAINTENANCE 10 1 ANALYZER The Model 1056 analyzer used with the TCL needs little routine maintenance Clean the analyzer case and front panel by wiping with a clean soft cloth dampened with water ONLY Do not use solvents like alcohol that might cause a buildup of static charge The chlorine sensor circuit board PN 24203 01 is replaceable If you have a dual input Model 1056 analyzer con sult the Model 1
16. and press ENTER Choose Alarms Choose Configure Setpoint Choose Alarm 1 Alarm 2 Alarm 3 or Alarm 4 The screen summarizes the present configuration and setpoints There are nine items Setpoint Assign S1 is sensor 1 and 82 is sensor 2 Logic Deadband Interval time On time Recover time and Hold while active The last four items describe the operation of the timer Only four items are shown at a time To view the remaining items scroll to the bottom of the screen and continue scrolling To make a change move the cursor to the desired line and press ENTER A screen will appear in which the present setting can be edited Press ENTER to store the setting For an explanation of terms see sections 7 4 1 and 7 4 2 To return to the main display press MENU then EXIT MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7 4 4 Procedure Simulating Alarms 1 Press MENU The main menu screen appears Move the cursor to Program and press ENTER Program 2 Choose Alarms Outputs Alarms Measurement Temperature Alarms 3 Choose Simulate Configure Setpoint Synch Timers Yes Simulate 4 Choose Alarm 1 Alarm 2 Alarm 3 or Alarm 4 Alarm 2 Alarm 3 Alarm 4 Simulate Alarm 1 5 Choose Don t simulate De energize or Energize Press MENU or Don t Simulate EXIT to end simulation De energize Energize 35 MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7 4 5 Procedure Synchronizing Timers 1 Synch Ti
17. bubbles in the flow cell The bubbles help mix the sample and keep carbon dioxide bubbles off the membrane Carbon dioxide forms when bicarbonate alka linity in the sample reacts with acetic acid The bubbles accumulate on the membrane and eventually break away causing the total chlorine reading to wander Is the membrane damaged or loose Replace the membrane if necessary Is the space between the membrane and cathode filled with electrolyte solution and is the flow path between the electrolyte reservoir and membrane clear Refer to Section 11 5 2 step 3 for more information 11 5 5 Readings drift 1 Is the sample temperature changing Membrane permeability is a function of temperature The time constant for the 499ACL 01 sensor is about five minutes Therefore the reading may drift for a while after a sudden tem perature change Is the membrane clean For the sensor to work properly iodine must diffuse freely through the membrane A coating on the membrane will interfere with the passage of iodine resulting in a gradual downward drift in read ings The coating will also slow the response on the sensor to step changes Clean the membrane by rinsing is with a stream of water from a wash bottle Wipe the membrane with a soft tissue Is the sensor new or has it recently been serviced New or rebuilt sensors may require several hours to sta bilize Is the flow of sample past the sensor about 11 mL min See Section 11 5 3 step 9 for more i
18. calibration choose Yes To repeat the calibration choose No For troubleshooting assistance see Section 11 5 7 To return to the main display press MENU then EXIT 43 MODEL TCL SECTION 9 CALIBRATION 9 3 CALIBRATING TOTAL CHLORINE 9 3 1 Purpose The continuous determination of total chlorine requires two steps See Figure 9 1 First the sample flows into a conditioning system the Model TCL where it is treated with acetic acid vinegar and potassium iodide The acid lowers the pH which allows total chlorine in the sample to quantitatively oxidize the iodide to iodine The treated sample then flows to the sensor The sensor is a membrane covered amperometric sensor whose output is pro portional to the concentration of iodine Because the concentration of iodine is also proportional to the concentra tion of total chlorine the analyzer can be calibrated to read total chlorine Figure 9 2 shows a typical calibration curve for a total chlorine sensor Because the sensor really measures iodine calibrating the sensor requires exposing it to a solution containing no iodine zero standard and to a solution con taining a known amount of iodine full scale standard The zero standard is necessary because the sensor even when no iodine is present generates a small current called the residual or zero current The analyzer compensates for the residual current by subtracting it from the measured current before converting the result to a tota
19. chlorine in the sample the sensor current is ultimately proportional to the total chlorine concentration The permeability of the membrane to iodine is a function of temperature A Pt100 RTD in the sensor measures the tem perature and the analyzer uses the temperature to compen sate the total chlorine reading for changes in membrane permeability Sensor maintenance is fast and easy Replacing the mem brane requires no special tools or fixtures Simply place the membrane assembly on the cathode and screw the retainer in place Installing a new membrane and replenishing the electrolyte takes only a few minutes MODEL TCL SECTION 1 DESCRIPTION AND SPECIFICATIONS 1 2 SPECIFICATIONS SAMPLE CONDITIONING SYSTEM GENERAL Enclosure Fiberglass reinforced polyester NEMA 3 IP53 suitable for marine environments Dimensions 14 5 x 13 0 x 8 6 in 369 x 329 x 218 mm Mounting Wall Ambient Temperature 32 122 F 0 50 C Ambient Humidity 0 90 non condensing Power 115 Vac 6 9 W 50 60 Hz 230 Vac 7 0 W 50 60 Hz Hazardous Location The TCL sample conditioning sys tem has no hazardous location approvals Pumps EN 809 1998 C Weight Shipping Weight 14 Ib 16 Ib 6 5 kg 7 5 kg SAMPLE REQUIREMENTS Inlet Connection compression fitting accepts 1 4 in OD tubing Drain Connection 3 4 in barbed fitting must drain to open atmosphere Inlet Pressure lt 100 psig 791 kPa abs Flow at least 0 25
20. en nnnnn mnn rna nn enne eene 15 4 4 Wiring Sensor with Optimum EMI RFI or Variopol Cable to Model 1056 Analvzer 16 4 5 Wiring Sensor with Standard Cable to Model 1056 Analvzer sen 16 6 1 Main Dis play sities iii iii 20 6 2 Programming Screen Showing Item List 20 6 3 ATOW BAAN iii ne e e e i e ee 20 6 4 Analyzer Keypad tret rtr caer n Erg te udi ett d ikaw 21 6 5 Navigation KEVs M 21 7 1 High Tue e 33 7 2 Low lat Loge ii a a 33 T 3 Operation of the interval timer rna 33 9 1 Determination of Total Chlorine emn 44 9 2 Sensor Current as a Function of Total Chlorine Concentration 44 10 1 Sensor Board Contnections seiretan nen a at 49 10 2 Sensor Parts nanna nnnnnn nn nn nnn nnns 51 10 3 Replacing Reagent Tubumg nn nnnnr eene eene nnns 52 10 4 Replacing Sample Tubing i e oar ete e rox aee petet ce 53 10 5 Peristaltic Pump Tubing emere nenne 54 10 6 Pump COVOE c coii ee eet ee e eoe e n er e Vere E a cand spas Fed ERE xv e FEE onda 54 10 7 Removing the Cover 54 10 6 Inserting New TUDE unio e o Et ERR g l u 54 10 9 Replace the Covers t e re hee Rue e ne ua an estas Reina e tee RR etd 55 10 10 Bottom of the Cover 55 10 11 Traks IET 55 10 12 Disconnection nn nn E E 56 10 13 Removal Of SCIeWS tree str tes a E RP in 56 10 14 Connect the Air Inlet and Outlet Tubing to the Air Pump eeeeenennnnzznni 56 10 15
21. gph 15 mL min Temperature 32 122 F 0 50 C Total Alkalinity 300 mg L as CaCO3 For samples con taining lt 50 mg L alkalinity consult the factory SAMPLE CONDITIONING SYSTEM Reagent Potassium iodide in vinegar Reagent Usage 5 gallons lasts approximately 60 days Reagent Pump Fixed speed peristaltic pump about 0 2 mL min Sample Pump Fixed speed peristaltic pump about 11 mL min 1 3 SPECIFICATIONS MODEL 1056 ANALYZER Case Polycarbonate NEMA 4X CSA 4 IP65 Dimensions 6 10 x 6 10 x 5 15 in 155 x 155 x 131 mm Conduit openings Accepts PG13 5 or 1 2 in conduit fittings Display Monochromatic back lit LCD Main character height 0 6 in 15mm Display is user programable Languages English German Italian Spanish French Portuguese Ambient temperature and humidity 32 to 131 F 55 C RH 5 to 95 con condensing Storage temperature 4 to 140 F 20 C and 60 C Power Code 01 115 230 VAC 15 50 60 Hz 10 W Code 03 85 to 265 VAC 47 5 to 65 0 Hz 15 W includes four relays Equipment protected by double insulation 0 to Hazardous Location Approvals Applies to analyzer only GR LR 34186 C US Class I Division 2 Groups A B C amp D Class Il Division 2 Groups E F amp D Class Il T4 Tamb 50 C Evaluated to the ANSI UL Standards The C and US indi cators adjacent to the CSA Mark signity that the product has been evaluated to t
22. more relays are being used as interval timers choosing synchro nize timers will cause each timer to start one minute later than the preceding timer chlorine ppm alarm activates high alarm setpoint 0 3 ppm alarm deactivates time FIGURE 7 1 High alarm logic The alarm activates when the chlorine concentration exceeds the high set point The alarm remains activated until the reading drops below the value determined bv the deadband chlorine alarm ppm deactivates 1 5 deadband low alarm 421 sotpoint alarm activates FIGURE 7 2 Low alarm logic The alarm activates when the chlorine concentration drops below the low set point The alarm remains activated until the reading increases above the value determined by the deadband on time duration on 0 999 sec relay activated timer interval 0 999 9 hr FIGURE 7 3 Operation of the interval timer The num bers in parentheses are the allowed values for each timer parameter deadband 33 MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7 4 3 Procedure Configuring Alarms and Assigning Setpoints Program Outputs Alarms Measurement Temperature Configure Setpoint Simulate Synch Timers Yes Configure Setpoint Alarm 1 Alarm 2 Alarm 3 Alarm 4 Alarm 1 Settings Setpoint Assign S1 Measure Logic Low Deadband 0 000 ppm 34 Press MENU The main menu screen appears Move the cursor to Program
23. the sensor properly wired to the analyzer See Section 4 3 Verify that all connections are tight 2 Readings can be erratic when a new sensor is first placed in service Readings usually stabilize over about an hour 3 Is the space between the membrane and cathode filled with electrolyte solution and is the flow path between the electrolyte reservoir and membrane clear Often the flow of electrolyte can be started by simply holding the sensor with the membrane end pointing down and sharply shaking the sensor a few times as though shak ing down a clinical thermometer If shaking does not work try clearing the holes around the cathode stem Hold the sensor with the membrane end pointing up Unscrew the membrane retainer and remove the membrane assembly Use the end of a straightened paper clip to clear the holes at the base of the cathode stem Verify the sensor is filled with electrolyte solution Refer to Section 10 2 63 MODEL TCL SECTION 11 TROUBLESHOOTING 11 5 3 Sensitivity is low or readings are low 1 10 64 Does the reagent carboy contain reagent Is the reagent uptake tubing below the level of the reagent Has potassium iodide been added to the acetic acid vinegar reagent Is there adequate flow to the overflow sampler Excess sample should be flowing down the inside tube of the overflow sampler Does the reagent contain the correct amount of potassium iodide See the table Expected range Amount of KI neede
24. zraneni nebo smrt Odpojte napajeni pred udrzbou spowodowac uszkodzenie ciala lub smierc Odlacz zasilanie przed przystapieniem do prac FARLIG SPENNING Kan fere til alvorlige skader eller dodsulvkker Spenningstilfersel m frakobles for service utf res VOLTAJE PELIGROSO Puede causar severas lesiones o muerte Desconecte la alimentaci n antes del mantenimiento GEFAEHRLICHE SPANNUNG Am Geraet liegt eine gefaehrliche Spannung an Schalten Sie immer vor dem Oeffnen des Geraetes alle Zuleitungen spannungsfrei LIVSFARLIG SPANNING Kan medf ra allvarlig skada eller d dsfall Bryt sp nning innan service utf res A ADVARSEL FARLIG LN Kan for rsage alvorlige kveestelser eller dad Afbryd spaending fer servicering Waarschuwing GEVAARLIJKE BRANNING Kan ernstig of dodelijk letsel veroorzaken Schakel de voeding uit voordat u onderhoudswer kzaamheden uitvoert TENSAO res Pode causar les es graves ou a morte Desligar a energia antes de proceder a trabalhos de manuten o AX DANGER 4A CAUTION HAZARDOUS AREA INSTALLATION SENSOR PROCESS APPLICATION COMPATIBILITV Wetted materials mav not be compatible with process composition and operating conditions Application compatibilitv is entirelv the responsibilitv of the user Installations near flammable liquids or in haz ardous area locations must be carefully eval uated by qua
25. 056 instruction manual for the part number of the other board To replace the board 1 Turn off power to the analyzer 2 Loosen the four screws holding the front panel in place and let the front panel drop down 3 Loosen the gland fitting and carefully push the sensor cable up through the fitting as you pull out the circuit board 4 Once you have access to the terminal strip disconnect the sensor 5 Unplug the sensor board from the main board See Figure 10 1 6 Slide the replacement board partially into the board slot Plug the sensor board into the main board and reattach the sensor wires Carefully pull the sensor cable through the gland fitting as you push the sensor board back into the enclosure 8 Close the front panel 9 Turn on power SENSOR BOARD CABLE CONNECTION FIGURE 10 1 Sensor board connections 49 MODEL TCL SECTION 10 MAINTENANCE 10 2 TOTAL CHLORINE SENSOR 10 2 1 General When used in clean water the total chlorine sensor requires little maintenance Generally the sensor needs main tenance when the response becomes sluggish or noisy or when readings drift follow calibration Maintenance frequency is best determined by experience If the sensor is used in potable water expect to clean the mem brane every month and replace the membrane and electrolyte solution every three months Sensors used in dirty water require more frequent maintenance and calibration However if experience shows the senso
26. 2 Hold the sensor over a container with the cathode pointing down Remove the fill plug and allow the electrolyte solution to drain out Wrap the plug with two turns of pipe tape and set aside Remove old tape first Prepare a new membrane Hold the membrane assembly with the cup formed by the membrane and mem brane holder pointing up Fill the cup with electrolyte solution Set aside 6 Hold the sensor at about a 45 degree angle with the cathode end pointing up Add electrolyte solution PN 9210438 through the fill hole until the liquid overflows Tap the sensor near the threads to release trapped air bubbles Add more electrolyte solution if necessary 7 Place the fill plug in the electrolyte port and begin screwing it in After several threads have engaged rotate the sensor so that the cathode is pointing up and continue tightening the fill plug Do not overtighten 8 Place a new O ring in the groove around the cathode post Cover the holes at the base of the cathode stem with several drops of electrolyte solution 9 Insert a small blunt probe like a toothpick with the end cut off through the pressure equalizing port See Figure 10 2 ak wn gt 50 MODEL TCL SECTION 10 MAINTENANCE NOTE Do not use a sharp probe It will puncture the bladder and destroy the sensor Gently press the probe against the bladder several times to force liquid through the holes at the base of the cathode stem Keep pressing the bladder until no a
27. Alarm 1 2 3 or 4 Setpoint Assign sensor and measurement High or low logic Deadband Interval time On time Recovery time Simulate Synchronize timers Measurement L Total chlorine sensor 1 Measurement selection Units Filter Resolution Temperature Units Temperature compensation auto or manual Set manual temperature if selected Security Calibrate Hold only All Reset Analyzer 18 MODEL TCL SECTION 5 START UP SECTION 5 START UP NOTE Complete Section 4 before starting this section 5 1 PREPARE THE REAGENT AA WARNING The reagent contains potassium iodide dissolved in distilled vinegar or 570 acetic acid Avoid contact with skin and eves Wash thoroughiv after using 1 DONOT PREPARE THE SOLUTION UNTIL READY TO USE 2 Position the blue plastic carbov under the sample conditioning cabinet Unscrew the cap and reagent tube assembiv 3 Add the potassium iodide reagent to the carbov See the table Expected range Amount of KI needed Part number ppm as CID per 5 gal 19 L of vinegar 24164 00 24164 01 2 x 50 grams 24164 01 4 Add five gallons 19 L of distilled white vinegar one gallon 4 L at a time Swirl the carboy after each addition 5 Screw the cap on the carboy Be sure the reagent uptake tube extends to the bottom of the carboy 6 If it hasn t already been connected connect the reagent tube to the small fitting on the bottom left hand side of the enclosure NOTE The shelf life o
28. INGS ITEM CHOICES DEFAULT 3 Oor4 mA setting 4 20 mA setting 1 a 1 22 00 mA a a AL1 and AL2 chlorine temp fault chlorine interval timer b AL3 and AL4 SERIES Temm ES temperature interval timer 0 Ed i SA b b 5 Fault current fixed 0 00 to 22 00 mA C i 27 MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER TABLE 7 1 DEFAULT SETTINGS continued ITEM CHOICES DEFAULT 2 Temperature compensation automatic or manual automatic Security Code 1 Calibrate Hold 000 to 999 o OE 2 Program Display 000 to 999 fF pp Calibration Analog Outputs 1 4mA 0 000 to 22 000 mA 4 000 mA 2 20mA 0 000 to 22 000 mA 20 000 mA 28 MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7 3 CONFIGURING RANGING AND SIMULATING OUTPUTS 7 3 1 Purpose This section describes how to configure range and simulate the two analog current outputs CONFIGURE THE OUTPUTS FIRST 1 Configuring an output means a Assigning a sensor and measurement chlorine or temperature to an output b Selecting a 4 20 mA or 0 20 mA output c Choosing a linear or logarithmic output d Turning output current dampening on or off e Selecting the value the output current goes to if the analyzer detects a fault Ranging the outputs means assigning values to the low 0 or 4 mA and high 20 mA outputs Simulating an output means making the analyzer generate an output current equal to the value entered by the user
29. Instruction Manual PN 51 TCL 1056 rev D May 2011 Model TCL Total Chlorine Analyzer ROSEMOUNT Analytical OOOO EMERSON Process Management ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING Rosemount Analytical designs manufactures and tests its products to meet many national and international stan dards Because these instruments are sophisticated techni cal products you must properly install use and maintain them to ensure they continue to operate within their normal specifications The following instructions must be adhered to and integrated into your safety program when installing using and maintaining Rosemount Analytical products Failure to follow the proper instructions may cause any one of the following situations to occur Loss of life personal injury property damage damage to this instrument and warranty invalidation Read all instructions prior to installing operating and servicing the product If this Instruction Manual is not the correct manual telephone 1 800 654 7768 and the requested manual will be provided Save this Instruction Manual for future reference If you do not understand any of the instructions contact your Rosemount representative for clarification Follow all warnings cautions and instructions marked on and supplied with the product Inform and educate your personnel in the proper installa tion operation and maintenance of the product Ins
30. N OUR WEB SITE http www raihome com Specifications subject to change without notice ENT poem S s gt Ei 8 Ey QUNM 3 GC Credit Cards for U S Purchases Only xo EE i A HEN Ae VISA Weezer mmm UO g A ki EMERSON Process Management
31. R PUMP FIGURE 4 1 Power Wiring 13 MODEL TCL SECTION 4 WIRING 4 3 MAKE POWER ALARM OUTPUT AND SENSOR CONNECTIONS IN THE ANALYZER A WARNING RISK OF ELECTRICAL SHOCK Electrical installation must be in accordance with the National Electrical Code ANSI NFPA 70 and or any other applicable national or local code 4 3 1 Power Wire AC mains power to the power supply board which is mounted vertically on the left hand side of the analyzer enclosure The power connector is at the top of the board Unplug the connector from the board and wire the power cable to it Lead connections are marked on the connector L is live or hot N is neutral the ground connection has the standard symbol AC power wiring should be 14 gauge or greater Run the power wiring through the conduit opening nearest the power terminal Provide a switch or breaker to disconnect the analyzer from the main power supply Install the switch or breaker near the analyzer and label it as the disconnecting device for the analyzer If your 1056 analyzer does not have alarm relays options 270 271 or 272 you must set the black and red AC power switch located below the power terminal to the correct AC voltage The analyzer is shipped with the switch in the 230 VAC position For operation at 110 120 VAC slide the switch upward so that 115 VAC is showing If your 1056 analyzer has alarm relays options 273 274 or 275 there is no switch setting to make The
32. SECTION 12 RETURN OF MATERIAL SECTION 12 RETURN OF MATERIAL 12 1 GENERAL To expedite the repair and return of instruments proper communication between the customer and the factory is important Before returning a product for repair call 1 949 757 8500 for a Return Materials Authorization RMA number 12 2 WARRANTY REPAIR The following is the procedure for returning instruments still under warranty 1 Call Rosemount Analytical for authorization 2 To verify warranty supply the factory sales order number or the original purchase order number In the case of individual parts or sub assemblies the serial number on the unit must be supplied 3 Carefully package the materials and enclose your Letter of Transmittal see Warranty If possible pack the materials in the same manner as they were received 4 Send the package prepaid to Emerson Process Management Liquid Division Liquid Division 2400 Barranca Parkway Irvine CA 92606 Attn Factory Repair RMA No Mark the package Returned for Repair Model No 12 3 NON WARRANTY REPAIR The following is the procedure for returning for repair instruments that are no longer under warranty 1 Call Rosemount Analytical for authorization 2 Supply the purchase order number and make sure to provide the name and telephone number of the individ ual to be contacted should additional information be needed 3 Do Steps 3 and 4 of Section 11 2 NOTE Consult the factor
33. SHOOTING 11 5 TROUBLESHOOTING WHEN NO ERROR MESSAGE IS SHOWING Problem See Section Zero current was accepted but the current is outside the range 10 to 50 nA Error or warning message appears while zeroing the sensor zero current is too high Zero current is unstable Sensor can be calibrated but current is low Process readings are erratic or wander Readings drift Readings are too high Readings are too low Calibration temperature more than 3 C different from standard thermometer Current output is too low Alarm relays do not operate when setpoint is exceeded or do not release when reading is below setpoint 15 5 1 Zero current is too high 1 Is the sensor properly wired to the analyzer See Section 4 3 2 Is the zero solution chlorine free Take a sample of the zero solution and test it for total chlorine The con centration should be less than 0 05 ppm Avoid using tap water for zeroing the sensor Even though the tap water contains no iodine chlorine oxidants present in the tap water may produce a sensor current as high as 100 nA 3 Has adequate time been allowed for the sensor to reach a minimum stable zero current It may take several hours sometimes as long as overnight for a new sensor to stabilize Is the sensor fill solution fresh An old discolored fill solution may produce a high zero current 5 Is the membrane damaged Inspect the membrane and replace it if necessary 11 5 2 Zero current is unstable 1 Is
34. ademark of General Electric 2 Viton is a registered trademark of DuPont Performance Elastomers 1 5 PERFORMANCE SPECIFICATIONS COMPLETE SYSTEM Linear Range 0 to 20 ppm mg L as Cl for higher ranges consult factory Linearity per ISO 15839 0 10 ppm 2 0 20 ppm 3 SECTION 1 DESCRIPTION AND SPECIFICATIONS Response Time Following a step change in concentration the reading reaches 90 of final value within 7 minutes at 25 C Drift At about 1 5 ppm in clean water and constant temperature drift is typically less 0 05 ppm over two weeks Detection Limit per ISO 15839 0 02 ppm mg L in clean water at room temperature MODEL TCL SECTION 1 DESCRIPTION AND SPECIFICATIONS 1 6 ORDERING INFORMATION AND ACCESSORIES Model TCL Reagent Based Chlorine System The TCL is used for the continuous determination of total chlorine in water The TCL consists of a sample conditioning system a reagent carboy a sensor and an analyzer Reagents must be ordered separately Regent kits for 0 5 ppm and 0 10 ppm chlorine are available For higher ranges consult the factory See ACCESSORIES Sample Conditioning System REAGENT BASED CHLORINE SYSTEM POWER required selection 115 V 50 60 Hz 230 V 50 60 Hz ANALVZER optional selection 1056 01 24 38 AN analyzer no alarm relays analog outputs 1056 01 24 38 HT analyzer no alarm relays HART 1056 01 24 38 DP analyzer no alarm relays Profibus DP 1056 03 24 38 AN analyzer with
35. air pump diaphragm AWARNING and check valves HAZARDOUS Disconnect power to the analyzer n VOLTAGE 2 Refer to Figure 10 12 Disconnect the IET e CAN CAUSE reagent and air injection tubes Disconnect SEVERE INJURY the suction and discharge tubing by turning 9 PFATH DISCONNECT the Luer fitting in the direction shown in the POWER BEFORE figure Disconnect the air pump inlet tubing SERVICING from the barbed fitting in the bottom of the enclosure 9241136 B 3 Remove the four screws circled in Figure 10 13 holding the air l FIGURE 10 16 pump access panel Pull out the pump and panel 4 Disconnect the air inlet and outlet tubing from the air pump See Figure 10 14 5 Remove the five screws surrounded by squares in Figure 10 13 holding the air pump to the access panel Pull the rubber base off the pump Using needle nose pliers remove the air inlet fitting from the side of the air pump See Figure 10 16 8 Slide the pump assembly out of the air pump body See Figure 10 17 9 Following instructions on the package PN 9160518 replace the diaphragm and check valves FIGURE 10 17 10 Slide the pump assembly back into the pump body and replace the barbed inlet fitting 11 Replace the rubber base and screw the pump access panel back onto the air pump 12 Connect the air inlet and outlet tubing to the air pump See Figure 10 14 The conical end of the check valve points in the direction of th
36. ation and the analyzer displays the total oxidant concentration in ppm as Cl MODEL 1056 CHLORINE ANALYZER The Model 1056 24 chlorine analyzer is designed for the continuous determination of chlorine in water It is used with the Model 499ACL 02 sensor and TCL sam ple conditioning system The Model 1056 analyzer is housed in a weatherproof corrosion resistant NEMA 4X enclosure It is suitable for wall panel or pipe mounting Operation of the ana lyzer is through a membrane keypad A back lit six line display shows the total chlorine reading and tem perature in 0 6 inch 15 mm high characters The dis play can be customized to show other information for example output signal and diagnostics Menu screens for calibrating and programming are simple an intuitive Plain language prompts in six lan guages guide the user through procedures Information and diagnostic screens as well as basic trouble shooting guidelines are available at the touch of a button The Model 1056 has two isolated continuously vari able 4 20 mA outputs Outputs can be assigned to total chlorine concentration or to temperature Digital communications HART or Profibus DP are available as options Four fully programmable alarm relays are available as an option Relays can be assigned to total chlorine concentration or temperature A relay can also be MODEL TCL used to signal a fault condition A fault alarm activates when an analyzer or senso
37. be about 110 Q If there is an open or short circuit or if the resistance is more than about 5 different from 110 Q the sensor has failed and should be replaced 3 If there is no open or short check the analyzer See Section 11 7 2 61 MODEL TCL SECTION 11 TROUBLESHOOTING 11 4 TROUBLESHOOTING WHEN A WARNING MESSAGE IS SHOWING Sensor Need Factory Cal The sensor board was not calibrated at the factory 11 4 1 Sensor Negative Reading The chlorine reading is less than 0 5 ppm 11 4 2 Sensor RTD Sense Open RTD sensor line is broken or not connected 11 4 3 Sensor Temperature High Temperature is greater than 155 C 311 F 11 4 4 Sensor Temperature Low Temperature is less than 20 C 4 F 11 4 5 11 4 1 Sensor Need Factory Cal The sensor board was improperly calibrated at the factory Call the factory for assistance 11 4 2 Sensor Negative Reading The analyzer converts the raw current from the sensor to ppm chlorine by subtracting the zero current from the raw current and multiplying the result by a conversion factor If the zero current is larger than the raw current the result will be negative 1 Check the zero current It should be less than about 50 nA If it is greater than 50 nA repeat the zero step 2 Ifthe zero current is in the correct range the negative reading might be the result of the raw current or the sensitivity being too low A properly operating sensor should generate about 1000 nA for every 1 ppm of to
38. bility correction The membrane permeability changes about 3 C at 25 C so a 1 C error in temperature produces about a 3 error in the reading Without calibration the accuracy of the temperature measurement is about 0 4 C Calibrate the sensor analyzer unit if 1 0 4 C accuracy is not acceptable 2 the temperature measurement is suspected of being in error Calibrate temperature by making the analyzer reading match the temperature measured with a standard thermometer 42 MODEL TCL 9 2 2 Procedure SECTION 9 CALIBRATION 1 Remove the sensor from the flow cell Place it in an insulated container of water along with a calibrated thermometer Submerge at least the bottom two inches of the sensor 2 Allow the sensor to reach thermal equilibrium The time constant for the chlorine sensor is about 5 min so it may take as long as 30 min for equilibration Calibrate Sensor 1 Sensor 2 Output 1 Output 2 S1 Calibration Total Chlorine Temperature S1 Calibration 3 Press MENU The main menu screen appears The cursor will be on Calibrate Press ENTER Choose the sensor you wish to calibrate Sensor 2 appears only if you are using a dual input analyzer Choose Temperature Change the display to match the temperature read from the calibrated thermometer Press ENTER If the present temperature is more than 5 C different from the value entered an error message appears To force the analyzer to accept the
39. ction 4 3 2 Disconnect the sensor from the analyzer and measure the resistance between the RTD in and return wires See Figure 4 4 or 4 5 If there is an open circuit replace the sensor 3 If there is no open check the analyzer See Section 11 5 11 3 7 Sensor 1 Not Detected The ribbon cable from sensor 1 chlorine board must be plugged into sensor 1 plug See Figure 10 1 for the location of the sensor board connectors 1 Confirm that the ribbon cable connecting sensor 1 chlorine board to the main board is plugged into Sensor 1 connector on the main board 2 Confirm that the ribbon cable is seated at both ends 11 3 8 Sensor Factory Data Sensor Board User Data and Sensor EEPROM Write Error These messages mean factory eeprom data or user eeprom data on the sensor board is corrupted or the CPU on the sensor board is bad 1 Cycle power off then on 2 Replace the sensor board 11 3 9 Sensor ADC Error There is a bad component on the sensor board The sensor board must be replaced 11 3 10 Sensor RTD Out of Range 499ACL 02 chlorine sensor contains a Pt 100 RTD resistance temperature device for measuring temperature If the measured resistance is outside the expected range the analyzer will display the out of range error message 1 Check wiring connections 2 Disconnect the sensor from the analyzer and use an ohmmeter to check the resistance across the RTD in and return leads See Figure 4 4 or 4 5 The resistance should
40. d ppm as CID per 5 gallons of vinegar 24164 00 Part number 24164 01 2 x 50 grams 24164 01 Was the comparison or calibration sample tested as soon as it was taken Chlorine solutions can be unsta ble Test the sample immediately after collecting it Avoid exposing the sample to sunlight Is the membrane fouled or coated A dirty membrane inhibits diffusion of iodine through the membrane reduc ing sensor current Clean the membrane by rinsing it with a stream of water from a wash bottle Wipe gently with a soft tissue Are the reagent and sample pumps running If a pump is not running check the fuse and replace it if neces sary See Table 10 2 for part numbers If the fuse is okay replace the pump Are all tube fittings tight Pay particular attention to the luer fittings that connect the tubing to the pumps Does the pump tubing element need replacing Remove the tubing from the pump and inspect it If the tubing appears permanently pinched or deformed replace the tubing Refer to Section 10 3 3 for instructions on how to remove and replace the tubing elements The expected life of a tubing element is about one year Is the sample flow to the sensor about 11 mL min If the sample flow is too low the total chlorine reading will be low If the flow is too high the ratio between the sample flow and reagent flow will be too high and there might be insufficient reagent to properly react with the total chlorine in the sample To chec
41. dditional items in a list are available MODEL TCL SECTION 6 START UP 6 2 KEYPAD Local communication with the analyzer is through the membrane keypad Figures 6 4 and 6 5 explain the operation of the keys Press MENU The main menu screen appears Press DIAG The main diagnostic screen appears Navigation keys move k 73 the cursor in the Press EXIT to leave a screen direction indicated in ENTER without storing changes The Figure 4 5 1 a display returns to the previous screen Press ENTER to store a change or select an item The display changes to the next screen FIGURE 6 4 Analyzer keypad Four navigation keys move the cursor around the screen The position of the cursor is shown in reverse video The navigation keys are also used to increase or decrease the value of a numeral Pressing ENTER selects an item and stores numbers and settings Pressing EXIT returns to the previous screen without storing changes Pressing MENU always causes the main menu to appear Moves cursor up or increases the value of the selected digit Moves cursor to Moves cursor the left to the right Moves cursor down or decreases the value of the selected digit FIGURE 6 5 Navigation keys The operation of the navigation keys is shown To move a decimal point highlight it then press the up or down key 21 MODEL TCL SECTION 6 START UP 6 3 PROGRAMMING THE ANALYZER TUTORIAL Setting up and calibrating the analyzer is ea
42. display to the initial Quick Start screen d A vertical black bar with a downward pointing arrow on the right side of the screen means there are more items to display Continue scrolling down to display all the items When you reach the bottom of the list the arrow will point up Language 3 Choose the desired language Scroll down to display more choices English Francais Espanol Deutsch S1 Measurement 4 Choose total chlorine for sensor 1 S1 Free Chlorine pH Independ Free Cl Total Chlorine Monochloramine Units 5 Choose the desired units for chlorine ppm mg L 16 MODEL TCL SECTION 4 WIRING Temp Units 6 Choose the desired temperature units 7 The main display appears The outputs and alarms if an alarm board is present are assigned to default values 8 To change outputs alarms and other settings go to the main menu and choose Program Follow the prompts A menu tree is on the following page To calibrate the sensor refer to section 9 17 MENU TREE Calibrate Sensor 1 Total chlorine Chlorine Zero In process Temperature Output 1 Output 2 Hold Sensor 1 Sensor 2 Display Main format configuration Language selection Warning enable or disable Screen contrast Program Outputs Range assign values to 4 and 20 mA Configure Output 1 or 2 Assign sensor and measurement Range Scale Dampening Fault mode fixed or live Fault value output current Simulate Alarms Configure Setpoint
43. e air flow 13 Replace the air pump access panel 14 Connect the sample pump tubing to the pump Connect the reagent and air injection tubing Connect the air inlet tubing to the barbed fitting at the bottom of the enclosure 57 MODEL TCL SECTION 10 MAINTENANCE TABLE 10 2 Replacement Parts and Reagent for Sample Conditioning System 58 24134 00 24134 01 9160578 9322052 24153 00 9100204 9100132 9380094 9380095 9380091 24151 00 24135 00 9380090 9380093 9380092 24152 00 24165 00 24165 01 24164 00 24164 01 Description Air pump 115 Vac 60 Hz Air pump 230 Vac 50 Hz Air pump repair kit Check valve for air injection line Carboy for reagent 5 gal 19 L includes cap Fuse 0 25 A 250 V 3AG slow blow for option 11 115 Vac Fuse 0 125 A 250 V 3AG slow blow for option 12 230 Vac Reagent pump 115 Vac 50 60 Hz Reagent pump 230 Vac 50 60 Hz Reagent pump replacement tubing Reagent tubing replacement kit see Section 9 3 2 Reagent uptake tubing 6 ft 1 8 m includes weight Sample pump 115 Vac 50 60 Hz Sample pump 230 Vac 50 60 Hz Sample pump replacement tubing Sample tubing replacement kit includes tees see Section 9 3 2 Description Acetic acid 2 x 2 5 gal 9 5 L bottles case with 25 g potassium iodide Acetic acid 2 x 2 5 gal 9 5 L bottles case with 50 g potassium iodide Potassium iodide 25 g sufficient for 5 gallons 19 L of vinegar for 0 5 ppm total chlorine
44. ection 2 MANUAL TEMPERATURE CORRECTION In manual temperature correction the analyzer uses the temper ature entered by the user for correction It does not use the actual process temperature Do NOT use manual temperature correction unless the measurement and calibration temperatures differ by no more than about 2 C Manual temperature correction is useful if the sensor temperature element has failed and a replacement sensor is not available 7 6 3 Procedure Configuring Temperature Related Settings 1 Press MENU The main menu screen appears Move the cursor to Program and press ENTER Program 2 Choose Temperature Outputs Alarms Measurement Temperature 3 The screen summarizes the present sensor configuration There will be Temperature between two and five items Units and S1 Temp Comp always appear If manual temperature compensation was selected the manual S1 Temp Comp Auto temperature value will also appear If you have a dual input analyzer temperature compensation items will appear for the other sensor Only four items are shown at a time To view the remaining items scroll to the bottom of the screen and continue scrolling To make a change move the cursor to the desired line and press ENTER A screen will appear in which the present setting can be edited To store a setting press ENTER For an explanation of terms see sections 7 6 1 and 7 6 2 4 To return to the main display press MENU then EXIT 38
45. ess MENU The main menu screen appears Move the cursor to Program and press ENTER The cursor will be on Outputs Press ENTER Choose Range Choose Output 1 or Output 2 The screen shows the present settings for the outputs O1 is output 1 O2 is output 2 S1 is sensor 1 and S2 is sensor 2 To make a change move the cursor to the desired line and press ENTER A screen will appear in which the present setting can be edited Press ENTER to store the setting For an explanation of terms see sections 7 3 1 and 7 3 2 To return to the main display press MENU then EXIT 31 MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7 3 4 Procedure Simulating Outputs 1 Press MENU The main menu screen appears Move the cursor to Program and press ENTER Program 2 The cursor will be on Outputs Press ENTER Outputs Alarms Measurement Temperature Outputs 3 Choose Simulate Configure Simulate Simulate 4 Choose Output 1 or Output 2 Output 1 Output 2 Output 1 Hold at 5 Enter the desired simulated output current To end the simulated current press MENU or EXIT 7 4 CONFIGURING ALARMS AND ASSIGNING SETPOINTS 7 4 1 Purpose The Model 1056 analyzer has an optional alarm relay board This section describes how to configure and assign setpoints to the alarm relays simulate alarm action and synchronize interval timers CONFIGURE THE ALARMS FIRST 1 Configuring an alarm means a Assigning a measureme
46. f the potassium iodide vinegar solution is at least two months if stored in the blue carboy Do not store the reagent in a container other than the blue carboy The reagent is sensi tive to sunlight which the blue carboy effectively blocks 5 2 ZERO THE SENSOR 1 Place the sensor in a beaker of deionized water or simply place the sensor in air 2 Let the sensor operate until the sensor current is stable then zero the sensor See Section 9 3 2 for detailed instructions 5 3 START SAMPLE FLOW Adjust the sample flow until a slow stream of liquid is running down the inside tube of the sampling cup 5 4 BEGIN OPERATION AND CALIBRATE THE SENSOR 1 Turn on the reagent and sample pump switches Observe that liquid begins to fill the flow cell The sample flow is about 11 mL min so the flow cell will fill rather slowly Also observe that the air pump is operating The pump will produce very vigorous bubbling in the flow cell 2 Once the flow of reagent starts it takes about two minutes for the reagent to reach the flow cell If the con centration of total chlorine in the sample is greater than about 0 5 ppm the treated sample in the flow cell will be pale yellow Sample containing more chlorine will be dark yellow 3 Monitor the sensor current Once the reading is stable calibrate the unit See Section 9 3 3 for detailed instruc tions It may take thirty minutes or longer for the reading to stabilize when the sensor is first put in service
47. f the sensor Thread the adapter onto the sensor Hand tighten only If you are using a VP cable connect the cable to the sensor The connec tor and receptacle are keyed to ensure proper mating Once the key has slid into place tighten the connec tion by turning the knurled ring clockwise Remove the protective cap from the end of the sensor Insert the sensor in the flow cell Hand tighten the nut sensor cable TCL sample inlet 1 4 enclosure inch OD tubing sample tap drain 3 4 inch ID barbed fitting o a a o o o o o an a reagent bottle FIGURE 3 3 Installing the Sample Conditioning Enclosure 11 MODEL TCL SECTION 3 INSTALLATION SENSOR 045 RADIUS 3 8 e B ji aa REAGENT INLET lt INCH gt MILLIMETER FIGURE 3 4 TCL Case Dimensions Reagent tubing a Tubing should extend about 14 in 360 mm below cap Reagent niet fing FIGURE 3 5 Reagent tubing assembly 12 MODEL TCL SECTION 4 WIRING SECTION 4 WIRING 4 1 PREPARE ANALYZER CONDUIT OPENINGS The analyzer enclosure has six conduit openings Four conduit openings are fitted with conduit plugs Conduit openings accept 1 2 inch conduit fittings or PG 13 5 cable glands To keep the case watertight block unused openings with NEMA 4X or IP65 conduit plugs NOTE Use watertight fittings and hubs that comply with the requiremen
48. ge is necessary to ensure that the sensor current has the correct sign 1 Disconnect the anode and cathode leads from terminals 8 and 10 on TB1 and connect a decade box and 1 5V battery as shown in Figure 11 2 It is not necessary to disconnect the RTD leads Set the decade box to 1 4 MQ Note the sensor current It should be about 960 nA The actual value depends on the voltage of the battery To view the sensor 7 ANOD SHLD current go to the main display and press DIAG Choose sensor 1 The input current is the second line in the display Change the D ANOD decade box resistance and verify that the correct current is shown Calculate current from the equation IR E CATH SHLD current nA Vbattery 250 voltages in mV DI CATH The voltage of a fresh 1 5 volt battery is about 1 6 volt 1600 mv FIGURE 11 2 Simulating Chlorine resistance MQ 66 MODEL TCL 11 6 SIMULATING TEMPERATURE 11 6 1 General The Model 1056 accepts a Pt100 RTD The Pt100 RTD is in a three wire configuration See Figure 11 3 11 6 2 Simulating temperature To simulate the temperature input wire a decade box to the analyzer or junction box as shown in Figure 11 4 To check the accuracy of the temperature measure ment set the resistor simulating the RTD to the values indicated in the table and note the temperature read ings The measured temperature might not agree with the value in the table During sensor calibration an offset m
49. he applicable CSA and ANSI UL Standards for use in Canada and the U S respectively RFI EMI EN 61326 LVD EN 61010 1 C Outputs Two 4 20 mA or 0 20 mA isolated outputs Continuously adjustable Linear or logarithmic Maximum load 550 ohms Output dampening with time constant of 5 sec is user selectable Alarms relays analyzer option 03 only Four alarm relays for process measurement s or temperature Any relay can be configured as a fault alarm instead of a process alarm Each relay can be configured inde pendently and each can be programmed with interval timer settings Relays Form C SPDT epoxy sealed Relay Contact ratings jy 5 A at 28 VDC or 300 VAC resistive AN 1 8 HP at 120 240 VAC Terminal Connections Rating Power connector 3 leads 18 12 AWG wire size Current output con nectors 2 leads 24 16 AWG wire size Alarm relay terminal blocks 18 16 AWG wire size Weight Shipping Weight rounded up to nearest Ib or nearest 0 5 kg 1 5 kg 3 Ib 2 0 kg 4 Ib MODEL TCL 1 4 SPECIFICATIONS MODEL 499ACL 02 SENSOR Wetted Parts Gold Noryl PPO Viton 2 EPDM Silicone Dimensions 1 0 x 5 6 in 25 4 x 143 mm Cable 25 ft 7 6m standard Pressure Rating 0 to 65 psig 101 to 549 kPa Temperature Rating 32 to 122 F 0 to 50 C Electrolyte Capacity Approximately 25 mL Electrolyte Life Approximately 4 months Weight Shipping Weight 1 b 3 Ib 0 5 kg 1 5 kg 1 Noryl is a registered tr
50. id to Emerson Process Management Liquid Division 2400 Barranca Parkway Irvine CA 92606 The shipping container should be marked Return for Repair Model The returned material should be accompanied by a letter of transmittal which should include the following information make a copy of the Return of Materials Request found on the last page of the Manual and provide the following thereon Location type of service and length of time of service of the device Description of the faulty operation of the device and the circumstances of the failure Name and telephone number of the person to contact if there are questions about the returned material Statement as to whether warranty or non warranty service is requested Complete shipping instructions for return of the material Adherence to these procedures will expedite handling of the returned material and will prevent unnecessary additional charges for inspection and testing to determine the problem with the device If the material is returned for out of warranty repairs a purchase order for repairs should be enclosed The right people the right answers right now a wee ROSEMOUNT ANALYTICAL CUSTOMER SUPPORT CENTER 1 800 854 8257 mcm m Emerson Process Management 2400 Barranca Parkway Irvine CA 92606 USA Tel 949 757 8500 Fax 949 474 7250 http www raihome com Rosemount Analytical Inc 2010 ON LINE ORDERING NOW AVAILABLE O
51. ight have been applied to make the measured tem perature agree with a standard thermometer The offset is also applied to the simulated resistance The analyzer is measuring temperature correctly if the difference between measured temperatures equals the difference between the values in the table to within 0 1 C For example start with a simulated resistance of 103 9 Q which corresponds to 10 0 C Assume the offset from the sensor calibration was 0 3 0 Because of the offset the analyzer calculates temperature using 103 6 O The result is 9 2 C Now change the resistance to 107 8 Q which corresponds to 20 0 C The analyzer uses 107 5 0 to calculate the temperature so the display reads 19 2 C Because the difference between the displayed temperatures 10 0 C is the same as the difference between the simulated temperatures the analyzer is working correctly SECTION 11 TROUBLESHOOTING RTD SENSE RTD RETURN FIGURE 11 3 Three Wire RTD Configuration Although only two wires are required to connect the RTD to the analyzer using a third and some times fourth wire allows the analyzer to correct for the resistance of the lead wires and for changes in the lead wire resistance caused by temperature changes FIGURE 11 4 Simulating RTD Inputs Temp C Pt 100 Q 0 100 0 10 103 9 20 107 8 25 109 7 30 111 7 40 115 5 50 119 4 60 123 2 70 127 1 80 130 9 85 132 8 90 134 7 138 5 67 MODEL SOLU COMP II
52. including negative numbers If the output is logarithmic assigned values must be positive 29 MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7 3 3 Procedure Configure Outputs Program Outputs Alarms Measurement Temperature Configure Simulate Output 1 Configure Output 1 Output 2 Output 1 Configure S1 Meas Range 4 20 mA Scale Linear Dampening 0 sec 30 1 Press MENU The main menu screen appears Move the cursor to Program and press ENTER The cursor will be on Outputs Press ENTER Choose Configure Choose Output 1 or Output 2 The screen shows the present configuration There are six items Assign S1 is sensor 1 S2 is sensor 2 Range Scale Dampening Fault Mode and Fault Value To displav the fifth and sixth items scroll to the bottom of the screen and continue scrolling To make a change move the cursor to the desired line and press ENTER A screen will appear in which the present setting can be edited Press ENTER to store the setting For an explanation of terms see sections 7 3 1 and 7 3 2 To return to the main display press MENU then EXIT MODEL TCL 7 3 3 Procedure Ranging Outputs 1 Program 2 Outputs Alarms Measurement Temperature Outputs 3 Configure Simulate Output Configure 4 Output 1 Output 2 Output Range 5 0k E4 yN 0 000 ppm O1 S1 20mA 10 00 ppm O2 S1 4mA 0 0C O2 S1 20mA 100 0C SECTION 7 PROGRAMMING THE ANALYZER Pr
53. ion to reset 4 To return to the main display press MENU then EXIT 40 MODEL TCL SECTION 8 DIGITAL COMMUNICATIONS SECTION 8 DIGITAL COMMUNICATIONS For information about digital communications refer to the following manuals HART 51 1056HT Model 56 HART Addendum Profibus DP 51 1056DP Model 56 Profibus DP Addendum 41 MODEL TCL SECTION 9 CALIBRATION SECTION 9 CALIBRATION 9 1 INTRODUCTION The calibrate menu allows the user to do the following 1 Calibrate the temperature sensing element in the total chlorine sensor 2 Calibrate the chlorine sensor 3 Calibrate the analog outputs 9 2 CALIBRATING TEMPERATURE 9 2 1 Purpose The total chlorine sensor is a membrane covered amperometric sensor As the sensor operates iodine produced by the reaction between total chlorine and the vinegar potassium iodide reagent diffuses through the membrane and is consumed at an electrode immediately behind the membrane The reaction produces a current that depends on the rate at which iodine diffuses through the membrane The diffusion rate in turn depends on the concentra tion of the iodine and how easily it passes through the membrane the membrane permeability Because membrane permeability is a function of temperature the sensor current will change if either the concentration or temperature changes To account for changes in sensor current caused by temperature alone the analyzer automatically applies a membrane permea
54. ir bubbles can be seen leaving the holes Be sure the holes remain covered with electrolyte solution 10 Place a drop of electrolyte solution on the cathode then place the membrane assembly over the cathode Screw the membrane retainer in place 11 The sensor may require several hours operating at the polarizing voltage to equilibrate after the electrolyte solution has been replenished PRESSURE EQUALIZING PORT ml E O RING ELECTROLYTE FILL PLUG MEMBRANE ASSEMBLY WRAP WITH PIPE TAPE SENSOR CABLE CATHODE MEMBRANE RETAINER FIGURE 10 2 Sensor Parts TABLE 10 1 Spare Parts 33523 00 Electrolyte Fill Plu 9550094 O Ring Viton 2 014 33521 00 Membrane Retainer 23501 02 Total Chlorine Membrane Assembly includes one membrane assembly and one O rin 23502 02 Total Chlorine Membrane Kit includes 3 membrane assemblies and 3 O rings 9210438 Total Chlorine Sensor Fill Solution 4 oz 120 mL 51 MODEL TCL SECTION 10 MAINTENANCE 10 3 SAMPLE CONDITIONING SYSTEM 10 3 1 Reagent The sample conditioning reagent lasts about 2 months Before putting fresh reagent in the carboy discard any small amount of remaining reagent To prepare the reagent refer to the procedure in Section 5 1 See Table 10 2 for ordering information 10 3 2 Sample and reagent tubing Periodically inspect sample and reagent tubing for cracks and leaks Replace tubing if it is damaged After a period of time the samp
55. k sample flow a Turn off the reagent and sample pumps b Disconnect the luer fitting on the discharge of the sample pump See A in Figure 11 1 c Hold a small beaker under the discharge port d Start the sample pump and collect sample for two minutes e Measure the volume of sample collected in the beaker After two minutes the volume should be about 22 mL Is the reagent flow about 0 2 mL min If the reagent flow is too low there might be insufficient acetic acid to lower the sample pH and insufficient potassium iodide to react with total chlorine in the sample To check reagent flow a Turn off the reagent and sample pumps b Disconnect the reagent tubing at the injection tee See B in Figure 11 1 c Place the end of the tubing in a 5 mL graduated cylinder d Start the reagent pump and collect reagent for ten minutes e Note the volume of reagent collected in the graduated cylinder After ten minutes the volume should be about 2 mL MODEL TCL SECTION 11 TROUBLESHOOTING l i FIGURE 11 1 Disconnecting sample A and reagent B tubing prior to checking flow 11 5 4 Process readings are erratic or wander 1 2 Is the sensor properly wired to the analyzer See Section 4 3 Verify that all connections are tight Readings can be erratic when a new sensor is first placed in service Readings usually stabilize after about an hour Is the air pump working There should be a vigorous stream of
56. l chlorine value New sensors require zeroing before being placed in service and sensors should be zeroed whenever the electrolyte solution is replaced Deionized water is a good zero standard Do not zero the sensor by leaving it in the TCL flow cell and turning off reagent injec sensor tion Even though no iodine is present the measures iodine acetic acid and potassium iodide current measured under these conditions is not the zero current Instead it is the slight response of the sensor to total chlorine in the sample Always use deionized water for zeroing the sensor The purpose of the full scale standard is to establish the slope of the calibration curve total Because stable total chlorine standards do not chlorine exist the sensor must be calibrated against a sample test run on a grab sample of the process liquid Several manufacturers offer portable test kits FIGURE 9 1 Determination of Total Chlorine for this purpose Observe the following pre cautions when taking and testing the grab sample Take the grab sample from a point as close ifull scale as possible to the inlet of the TCL sample conditioning system Total chlorine solutions are unstable Run the test immediately after taking the sam ple Try to calibrate the sensor when the chlorine concentration is at the upper end of the normal operating range sensor current slope sensor current ppm total chlorine full scale standard total chl
57. le tubing may become plugged with suspended matter The tubing is flexible and difficult to clean mechanically Plugged sample tubing is best replaced Replacement tubing kits are available See Table 10 2 for part numbers To replace reagent tubing 1 Reagent tubing is shown in Figure 10 2 2 Turn off sample and reagent pumps 3 Luer fittings connect the reagent tubing to the pump Disconnect the tubing by turning the fitting in the direc tion of the arrows shown in Figure 10 5 4 Disconnect the other end of the suction tubing from the barb on the reagent inlet fitting in the bottom of the enclosure Disconnect the other end of discharge tubing from the reagent injection tee 5 Install the replacement tubing Note that the discharge tubing is longer than the suction tubing REAGENT SUCTION 64 mm INLET BULKHEAD FITTING DISCHARGE REAGENT 76 mm INJECTION TEE FIGURE 10 3 Replacing Reagent Tubing 52 MODEL TCL SECTION 10 MAINTENANCE To replace sample tubing 1 Sample tubing is shown in Figure 10 4 2 Turn off the sample and reagent pumps 3 Luer fittings connect the sample tubing to the pump Disconnect the tubing by turning the fitting in the direction of the arrows shown in Figure 10 5 4 Disconnect the other end of the sample pump suction tubing from the overflow sampler Pull the reagent injection tube off the reagent injection tee 5 Disconnect the other end of the sample pump discharge tubing from
58. lified on site safety personnel This device is not Intrinsically Safe or Explosion Proof To secure and maintain an intrinsically safe installation the certified safety barrier trans mitter and sensor combination must be used The installation system must comply with the governing approval agency FM CSA or BASEEFA CENELEC hazardous area classification requirements Consult your analyzer transmitter instruction manual for details Proper installation operation and servicing of this device in a Hazardous Area Instal lation is entirely the responsibility of the user About This Document This manual contains instructions for installation and operation of the Model TCL1056 Total Chlorine Analyzer The following list provides notes concerning all revisions of this document Rev Level Date Notes A 7 07 This is the initial release of the product manual The manual has been reformatted to reflect the Emerson documentation style and updated to reflect any changes in the product offering B 11 07 Page 3 additions to 1 3 Specifications page 5 changes to the Analyzer option selection table page 14 updated the caution box and page 15 updated section 4 3 3 C 7 10 Updated DNV logo D 5 11 Revised Sec 1 specs 1 3 replaced fig 3 3 revised sec 4 3 3 wiring replaced fig 4 4 add to digital communication sec 8 0 revise sec 11 6 MODEL TCL TABLE OF CONTENTS MODEL TCL TOTAL CHLORINE ANALYZER TABLE OF CONTENTS
59. mers is available only if two or more alarm relays have been configured as interval timers 2 Press MENU The main menu screen appears Move the cursor to Program and press ENTER Program 3 Choose Alarms Outputs Measurement Temperature Alarms 4 The summary display shows the current Synch Timers setting Yes or Configure Setpoint No Simulate Synch Timers To make a change choose Synch Timers and press ENTER A screen will appear in which the present setting can be edited Press ENTER to store the setting For an explanation of terms see sections 7 4 1 and 7 4 2 5 To return to the main display press MENU then EXIT 7 5 CONFIGURING THE MEASUREMENT 7 5 1 Purpose This section describes how to do the following 1 Program the analyzer to measure total chlorine This step is necessary because the analyzer can be used with other sensors to measure other chlorine oxidants 2 Setthe level of electronic filtering of the sensor current 3 Setthe display resolution 7 5 2 Definitions 1 CHLORINE OXIDANTS Although the TCL is used to measure total chlorine only the 1056 analyzer used with the TCL can be used to measure other chlorine oxidants for example monochloramine and free chlorine 2 FILTER The analyzer applies a filter to the raw sensor current The filter reduces noise but increases the response time The available filter s depend on the time setting If the filter is between 0 and 10 seconds the analyze
60. nal Electrical Code ANSI NFPA 70 and or any other applicable national or local codes Unused cable conduit entries must be securely sealed by non flammable closures to provide enclosure integrity in compliance with personal safety and environmental pro tection requirements The unused conduit openings need to be sealed with NEMA 4X or IP65 conduit plugs to maintain the ingress protection rating IP65 For safety and proper performance this instrument must be connected to a properly grounded three wire power source Proper relay use and configuration is the responsibility of the user No external connection to the instrument of more than 69VDC or 43V peak allowed with the exception of power and relay terminals Any violation will impair the safety protection provided Do not operate this instrument without front cover secured Refer installation operation and servicing to qualified personnel This product is not intended for use in the light indus trial residential or commercial environment per the instrument s certification to EN50081 2 EMERSON Process Management HAZARDOUS VOLTAGE Can cause severe injury or death Disconnect power before servicing TENSION Peut provoquer des blessures graves ou la mort D connecter l alimentation avant manipulation ALTA TENSIONE Pu causare grave lesione o morte Disattivare le tensioni prima di effettuare la manutenzione Muze zpusobit vazne
61. nclosure must be mount ed on a wall Provide adequate room beneath the enclosure for the 5 gallon reagent carboy 5 Be sure that the distance between the analyzer and sample conditioning cabinet does not exceed the length of the sensor cable 3 2 2 Install the Analyzer 1 Refer to the appropriate figure for installation details Type of Mounting Figure Wall or Pipe 2 See section 4 1 for more information about the conduit openings 3 See Section 4 2 for wiring instructions MODEL TCL SECTION 3 INSTALLATION lt INCH MILLIMETER 4X MOUNTING BRACKETS SCREWS i AN E PROVIDED WITH INSTRUMENT PANEL SUPPLIED BY OTHERS e Side View MAXIMUM THICKNE 375 IN 9 52 mm PANEL CULOUT Bottom View 152 73 6 0 FIGURE 3 1 PANEL MOUNTING DIMENSIONS L INCH gt MILLIMETER Wall Surface Mount Front View Pipe Mount Bottom View PANEL amp PIPE MOUNT ENCLOSURE 6x o 315 CONDUT OPENINGS 2 INCH PIPE BRACKET Side View 2X SET U BOLTS FOR 2 INCH Pif IN KIT PN 23820 00 SOTIOM VIEW FIGURE 3 2 PIPE AND WALL MOUNTING DIMENSIONS Mounting bracket PN 23820 00 MODEL TCL SECTION 3 INSTALLATION 3 2 3 Install the Sample Conditioning Enclosure 1 2 Refer to Figures 3 3 3 4 and 3 5 for installation details Connect the sample line to the sample conditioning system Use 74 inch OD hard plastic or stainless steel tubing
62. nformation Is the reagent flow about 0 2 mL min See Section 11 5 3 step 10 for more information 65 MODEL TCL SECTION 11 TROUBLESHOOTING 11 5 6 Readings are too high 1 Is the sample conditioning reagent clear and colorless If the reagent is pale yellow results will be high The pale yellow color is caused by iodine which comes from the reaction between atmospheric oxygen and potas sium iodide The reaction is catalyzed by sunlight The purpose of the blue carboy is to protect the reagent from sunlight 2 Is the sensor fill solution fresh An old discolored fill solution may produce a high reading 11 5 7 Temperature measured by standard thermometer was more than 3 C different from analyzer 1 Is the standard thermometer RTD or thermistor accurate General purpose liquid in glass thermometers par ticularly ones that have been mistreated can have surprisingly large errors 2 Is the temperature element in the sensor completely submerged in the liquid 3 Is the standard temperature sensor submerged to the correct level 11 5 8 Current Output Too Low Load resistance is too high Maximum load is 550 Q 11 5 9 Alarm Relays Do Not Work 1 Verify the relays are properly wired 2 Verify that deadband is correctly set See Section 7 4 11 6 SIMULATING INPUTS To check the performance of the analyzer use a decade box and 1 5V battery to simulate the current from the sensor The battery which opposes the polarizing volta
63. nly b Auser has access to the calibration and hold menus only c Auser has access to all menus 1 If a security code has been programmed pressing MENU causes the Security Code security screen to appear 2 Enter the three digit security code 3 Ifthe entry is correct the main MENU screen appears The user has access to the sub menus the code entitles him to 4 Ifthe entry is wrong the invalid code screen appears 6 4 2 Assigning Security Codes See Section 7 7 6 4 3 Bypassing Security Codes Call the factory 23 MODEL TCL SECTION 6 START UP 6 5 USING HOLD 6 5 1 Purpose To prevent unwanted alarms and improper operation of control systems or dosing pumps place the alarms and outputs assigned to the sensor in hold before removing it for maintenance During hold outputs assigned to the sensor remain at the last value and alarms assigned to the sensor remain in their present state Once in hold the sensor remains in hold until hold is turned off However if power is lost then restored hold will automatically be turned off 6 5 2 Using the Hold Function 1 Press MENU The main menu screen appears Move the cursor to Program Menu 2 Choose HOLD Calibrate Program Display 3 The screen shows the current hold status for each sensor Select the sensor to be put in hold Press ENTER S2 Hold S1 Hold outputs 4 To put the sensor in hold choose Yes To take the sensor out of hold and alarms
64. nt chlorine or temperature to an alarm If a dual input analyzer is being used the alarms are freely assignable to either sensor An alarm relay can also be used as a timer b Selecting high or low logic c Choosing a deadband d Setting the interval timer parameters 2 Simulating an alarm means making the analyzer energize or de energize an alarm relay 32 MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7 4 2 Definitions 1 ASSIGNING ALARMS There are four alarms relays The relays are freely assignable to any sensor and to either the measurement chlorine or temperature Alarm relays can also be assigned to operate as interval timers or as fault alarms A fault alarm activates when the analyzer detects a fault in either itself or the sensor FAULT ALARM A fault condition exits when the analyzer detects a problem with a sensor or with the analyzer itself that is likely to cause seriously erroneous readings If an alarm was programmed as a fault alarm the relay will activate At the same time a fault message will appear in the main display ALARM LOGIC SETPOINTS AND DEAD BANDS See Figures 7 1 and 7 2 INTERVAL TIMER Any alarm relay can be used as an interval timer Figure 7 3 shows how the timer operates While the interval timer is operat ing the main display analog output and alarms for the sensor s can be put on hold During hold the main display remains at the last value SYNCHRONIZE TIMER If two or
65. o calibration was successful the screen at left appears If the zero current is moderately larger than expected an error message appears To force the analyzer to accept the zero current choose Yes To repeat the calibration choose No For troubleshooting assistance see Section 11 5 45 MODEL TCL SECTION 9 CALIBRATION S1 Zero Cal If the zero current is much larger than expected the zero calibration Sensor zero failed failure screen appears The analyzer will not update the zero current For troubleshooting assistance see Section 11 5 Press Exit 8 To return to the main display press MENU then EXIT 9 3 3 Procedure Calibrating the sensor 1 If the sensor was just zeroed place the sensor back in the flow cell Confirm that excess sample is flowing down the inside tube of the overflow sampler Also verify that reagent is being delivered to the sample and that the air pump is working 2 Adjust the chlorine concentration until it is near the upper end of the control range Wait until the analyzer reading is stable before starting the calibration When the TCL is first started up or when a new sensor is put in service allow at least 30 minutes for the reading to stabilize 3 Press MENU The main menu screen appears The cursor will be on Calibrate Press ENTER Calibrate 4 Choose the sensor you wish to calibrate Sensor 2 appears only if you have a dual input 1056 analyzer Sensor 1 Sensor 2 Output 1 Outp
66. oard and main board are no longer communicating 1 Verify that the ribbon cable connecting the main board on the inside of the front panel and the sensor board are properly seated Inspect the connecting cable for obvious tears or breaks 2 Ifthe ribbon cable is properly seated and appears undamaged the sensor board should be replaced 60 MODEL TCL SECTION 11 TROUBLESHOOTING 11 3 4 Sensor Incompatible This error message means that the sensor board software is not supported by the main board software Either the sensor board or the main board software is too old Replace the main board with one compatible with the sensor board Call the factory for assistance You will be asked for the main and sensor board software revision numbers To read the main board software revision press the DIAG key and scroll down until Instr SW Ver is showing To view the sensor board software revision press the DIAG key choose the appropriate sensor and scroll down until Board SW Ver is showing The main board can be replaced only at the factory 11 3 5 Sensor CPU Error This message means the sensor board software is corrupted 1 Cycle the power off then on 2 If cycling the power does not help call the factory The sensor board must be replaced 11 3 6 Sensor RTD Open There is an open circuit in the sensor RTD resistance temperature device or wiring 1 It the sensor is being installed for the first time check the wiring connections See Se
67. of the reading A membrane covered amperometric sensor in the flow cell measures the concentration of iodine The analyzer receives the raw signal from the sensor and displays the concentration of total chlorine Display units are ppm mg L chlorine as Cl5 The treated sample leaves the flow cell and drains to waste along with the excess sample MODEL TCL SECTION 3 INSTALLATION SECTION 3 INSTALLATION 3 1 UNPACKING AND INSPECTION Inspect the shipping containers If there is damage contact the shipper immediately for instructions Save the boxes If there is no apparent damage unpack the containers Be sure all items shown on the packing list are pres ent If items are missing notify Rosemount Analytical immediately 3 2 INSTALLATION 3 2 1 General Information 1 Although the analyzer and sample conditioning system are suitable for outdoor use do not install them in direct sunlight or in areas of extreme temperature A CAUTION The TCL Total Chlorine sample conditioning system is NOT suitable for use in hazardous areas 2 Install the analyzer and sample conditioning system in an area where vibration and electromagnetic and radio frequency interference are minimized or absent 3 Keep the analyzer and sensor wiring at least one foot from high voltage conductors Be sure there is easy access to the analyzer and sample conditioning system 4 The analyzer is suitable for panel pipe or wall mounting The sample conditioning e
68. orine ppm FIGURE 9 2 Sensor Current as a Function of Total Chlorine Concentration 44 MODEL TCL SECTION 9 CALIBRATION 9 3 2 Procedure Zeroing the Sensor 1 Place the sensor in a beaker of deionized water Be sure no air bubbles are trapped against the membrane 2 Observe the sensor current The current will drop rapidly at first and then gradually reach a stable zero value To monitor the sensor current press the DIAG key Move the cursor to the chlorine sensor and press ENTER The input current is the first line in the display Note the units nA is nanoamps uA is microamps Typical zero current for a 499ACL 02 sensor is 10 to 50 nA A new sensor or a sensor in which the electrolyte solution has been replaced may require several hours occasionally as long as overnight to reach a minimum zero current DO NOT START THE ZERO ROUTINE UNTIL THE SENSOR HAS BEEN IN THE ZERO SOLUTION FOR AT LEAST TWO HOURS 3 Press MENU The main menu screen appears The cursor will be on Calibrate Press ENTER Calibrate Sensor 1 Sensor 2 Output 1 Output 2 S1 Calibration Total Chlorine Temperature S1 Calibration Zero Cal In Process Cal S1 Zero Cal Sensor zero done S1 Possible Error Proceed 4 Choose the sensor you wish to calibrate Sensor 2 appears only if you have a dual input 1056 analyzer 5 Choose Total Chlorine 6 Choose Zero Cal The analyzer will automatically start the zero calibration 7 Ifthe zer
69. por tion of the Goods Services All replacements or repairs necessitated by inadequate maintenance normal wear and usage unsuitable power sources unsuit able environmental conditions accident misuse improper installation modification repair storage or handling or any other cause not the fault of Seller are not covered by this limited warranty and shall be at Buyer s expense Seller shall not be obli gated to pay any costs or charges incurred by Buyer or any other party except as may be agreed upon in writing in advance by an authorized Seller representative All costs of dismantling reinstallation and freight and the time and expenses of Seller s per sonnel for site travel and diagnosis under this warranty clause shall be borne by Buyer unless accepted in writing by Seller Goods repaired and parts replaced during the warranty period shall be in warranty for the remainder of the original warranty peri od or ninety 90 days whichever is longer This limited warranty is the only warranty made by Seller and can be amended only in a writing signed by an authorized representative of Seller Except as otherwise expressly provided in the Agreement THERE ARE NO REPRESENTATIONS OR WARRANTIES OF ANY KIND EXPRESS OR IMPLIED AS TO MERCHANTABILITY FIT NESS FOR PARTICULAR PURPOSE OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES RETURN OF MATERIAL Material returned for repair whether in or out of warranty should be shipped prepa
70. present configuration for the chlorine sensor There are four items Measure Units Filter and Resolution To make a change move the cursor to the desired line and press ENTER A screen will appear in which the present setting can be edited To store the setting press ENTER a For Measurement choose Total Chlorine b Leave Filter at the default value unless readings are noisy For an explanation of terms see sections 7 5 2 6 To return to the main display press MENU then EXIT 37 MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7 6 CONFIGURING TEMPERATURE RELATED SETTINGS 7 6 1 Purpose This section describes how to do the following 1 Choose temperature units 2 Choose automatic or manual temperature correction for membrane permeability chlorine sensor 3 Enter a temperature for manual temperature compensation 7 6 2 Definitions Chlorine 1 AUTOMATIC TEMPERATURE CORRECTION The total chlorine sensor is a membrane covered amperometric sensor The permeability of the membrane is a function of temperature As temperature increases membrane permeability increases Thus an increase in temperature will cause the sensor current and the analyzer reading to increase even though the chlorine level remained constant A correction equation in the analyzer software automatically corrects for changes in membrane permeability In automatic temperature correction the analyzer uses the temperature measured by the sensor for the corr
71. r applies a window filter A window filter averages the measured value within the filter time For exam ple if the filter is 5 seconds and a step increase is applied to the input the displayed value increases linearly reaching the final value after 5 seconds If the filter is set to greater than 10 seconds the analyzer applies either an adaptive filter or a continuous filter An adaptive filter discriminates between noise and real process change It filters changes below a fixed threshold value but does not filter changes that exceed the threshold It is best used in situations where the noise is relatively low A continuous filter dampens all changes The fil ter time setting is approximately equal to the time constant the amount of time required for the reading to reach 63 of the final value following a step change 3 RESOLUTION If the chlorine concentration is less than 1 00 ppm mg L the display resolution can be set to O XX or O XXX 36 MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7 5 3 Procedure Configuring the Measurement Program Outputs Alarms Measurement Temperature Configure Sensor 2 S1 Configure Measure Total Cl Units ppm Filter 5 sec Resolution 0 001 ppm 1 Press MENU The main menu screen appears Move the cursor to Program and press ENTER Choose Measurement The screen at left appears only if you have a dual input 1056 Choose the Chlorine sensor The screen summarizes the
72. r fault occurs When used for the determination of total chlorine the Model 1056 analyzer is a single input instrument The ana lyzer is also available in a dual input version where the second input can be pH conductivity dissolved oxygen chlorine or turbidity For more information about the dual input option refer to product data sheet PDS 71 1056 MODEL 499A CL 02 SENSOR The Model 499ACL 02 total chlorine sensor is used in the TCL sample conditioning system Although the sensor is called a chlorine sensor it really measures iodine The iodine comes from the reaction between oxidants in the sample and the acetic acid potassium iodide reagent added by the sample conditioning system The sensor consists of a gold cathode and a silver anode in an electrolyte solution A silicone membrane permeable to iodine is stretched over the cathode The analyzer applies a voltage to the cathode sufficiently negative to reduce all the iodine reaching it Because the concentra SECTION 1 DESCRIPTION AND SPECIFICATIONS tion of iodine in the sensor is always zero a concentration gradient continuously forces iodine from the sample through the membrane into the sensor The reduction of iodine in the sensor generates a current directly proportional to the diffusion rate of iodine through the membrane which is directly proportional to the concen tration of iodine in the sample Because the iodine concen tration depends on the amount of total
73. r is holding calibration and not drifting appreciably between calibration intervals the maintenance interval can be extended 10 2 2 Cleaning the membrane Keep the membrane clean Clean the membrane with water sprayed from a wash bottle Use a soft tissue to gently wipe the membrane 10 2 3 Replacing the membrane 1 Hold the sensor with the membrane facing up 2 Unscrew membrane retainer Remove the membrane assembly and O ring See Figure 10 2 3 Inspect the cathode If it is tarnished clean it by gently rubbing in the direction of the existing scratches do not use a circular motion with 400 600 grit silicon carbide finishing paper Rinse the cathode thoroughly with water 4 Prepare a new membrane Hold the membrane assembly with the cup formed by the membrane and mem brane holder pointing up Fill the cup with electrolyte solution Set aside Put a new O ring in the groove Place a drop of electrolyte solution on the cathode Invert the membrane assembly and place it over the cathode stem Screw the membrane retainer back in place Hold the sensor with the membrane pointing down Shake the sensor a few times as though shaking down a Clinical thermometer o Jo 10 2 4 Replacing the membrane and electrolyte solution AA CAUTION Fill solution may cause irritation Avoid contact with skin and eyes May be harmful if swallowed Unscrew the membrane retainer and remove the membrane assembly and O ring See Figure 10
74. sert the new tubing one end at a time Tongues on the sides of the gray fittings at the ends of the tube fit into receiving grooves in the pump casing See Figure 10 8 Push the fitting into place until it clicks Gently stretch the tubing over the rollers and insert the other fitting into the receiving socket on the other side of the pump Lem FIGURE 10 8 MODEL TCL SECTION 10 MAINTENANCE 7 Replace the pump cover a Place the cover on the pump casing See Figure 10 9 b Be sure the pins at the bottom of the cover Figure 10 10 ride on the tracks in the pump casing FIGURE 10 10 c The position of the track is outlined in Figure 10 11 The pins on the pump cover must ride in these tracks as the cover is pushed into place Gently squeeze the ends of the cover to guide the pins FIGURE 10 11 d Push down until the cover snaps into place 8 Reconnect the tubing 55 MODEL TCL SECTION 10 MAINTENANCE 10 3 4 Replacing the air pump A WARNING 1 Disconnect power to the analvzer EI HAZARDOUS 2 Refer to Figure 10 12 Disconnect the reagent VOLTAGE and air injection tubes Disconnect the suction and discharge tubing by turning the Luer fitting SAV CRUSE py in the direction shown in the figure Disconnect OR DEATH the air pump inlet tubing from the barbed fitting pisconnect in the bottom of the enclosure SERVICING T 3 Remove the four screws circled in Figure 10 13 mE holding the air pump
75. sy The following tutorial describes how to move around in the programming menus For practice the tutorial also describes how to assign ppm chlorine values to the 4 and 20 mA analog outputs Calibrate Hold Program Display Program Outputs Alarms Measurement Temperature Configure Stimulate Output Range ORA 0 000 ppm O1 S1 20mA 10 00 ppm O2 S1 4mA 0 0C O2 S1 20mA 100 0C O1 S1 20 mA 22 Press MENU The main menu screen appears There are four items in the main menu Calibrate is in reverse video meaning that the cursor is on Calibrate To assign values to the analog outputs the Program sub menu must be open Use the down navigation key to move the cursor to Program Press ENTER The Program menu appears There are between five and seven items in the Program menu Alarms appears only if the analyzer contains the optional alarm relay board The screen displays four items at a time The downward pointing arrow on the right of the screen shows there are more items available in the menu To view the other items use the down key to scroll to the last item shown and continue scrolling down When you have reached the bottom the arrow will point up Move the cursor back to Outputs and press ENTER The screen at left appears The cursor is on Range Output Range is used to assign values to the low and high current outputs Press ENTER The screen at left appears The screen shows the present values assigned to outp
76. t the 1056 instruction manual for more details Choose Language to change the language used in the display Choose Warning to disable or enable warning messages Choose Contrast to change the display contrast To change the contrast choose either lighter or darker and press ENTER Every time you press ENTER the display will become lighter or darker 25 MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER SECTION 7 PROGRAMMING THE ANALYZER 7 1 GENERAL This section describes how to make the following program settings using the local keypad a Configure and assign values to the analog current outputs b Configure and assign values to the alarm relays if the alarm board is installed c Choose the type of chlorine measurement being made This step is necessary because the analyzer used with the TCL can measure forms of chlorine other than total chlorine d Choose temperature units and automatic or manual temperature correction e Set two levels of security codes f Resetthe analyzer to factory default settings 7 2 DEFAULT SETTINGS The analyzer leaves the factory with the default settings for total chlorine shown in Table 7 1 The setting can be changed by the user to any value shown in the column labeled CHOICES If you have a dual input 1056 analyzer refer to the 1056 instruction manual for information about the default settings for second input 26 MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER TABLE 7 1 DEFAULT SETT
77. tal chlorine Recalibrate the sensor If necessary clean or replace the membrane and check the fill solution 3 Replace the sensor 11 4 3 Sensor RTD Sense Open The analyzer measures temperature using a three wire RTD See Figure 11 3 The in and return leads are used to measure the resistance of the RTD The third lead called the sense line is connected to the return lead at the sensor The sense line allows the analyzer to correct for the resistance of the in and return leads and to compen sate for changes in wire resistance caused by changes in ambient temperature 1 Check wiring See Figure 4 4 or 4 5 2 Disconnect the sense and return wires and check the resistance between them It should be less than 19 See Figure 4 4 or 4 5 3 Even though the sense line is open the sensor is still usable Use a wire jumper to connect the sense and return terminals on the sensor terminal strip The temperature reading will no longer be corrected for the lead resistance nor will the analyzer be able to compensate for changes in ambient temperature The error could be several C or more 4 Replace the sensor 11 4 4 Sensor Temperature High or Low The sensor RTD is most likely miswired 1 Check wiring connections 2 Disconnect the RTD in and return leads and check the resistance between them See Figure 4 4 or 4 5 The resistance should be close to the values given in Section 11 5 3 Replace sensor 62 MODEL TCL SECTION 11 TROUBLE
78. tall your equipment as specified in the Installation Instructions of the appropriate Instruction Manual and per applicable local and national codes Connect all products to the proper electrical and pressure sources To ensure proper performance use qualified personnel to install operate update program and maintain the product When replacement parts are required ensure that quali fied people use replacement parts specified by Rosemount Unauthorized parts and procedures can affect the product s performance and place the safe oper ation of your process at risk Look alike substitutions may result in fire electrical hazards or improper operation Ensure that all equipment doors are closed and protec tive covers are in place except when maintenance is being performed by qualified persons to prevent electri cal shock and personal injury Emerson Process Management 2400 Barranca Parkway Irvine CA 92606 USA Tel 949 757 8500 Fax 949 474 7250 http www raihome com Rosemount Analytical Inc 2011 WARNING ELECTRICAL SHOCK HAZARD Making cable connections to and servicing this instrument require access to shock haz ard level voltages which can cause death or serious injury Be sure to disconnect all hazardous voltage before opening the enclosure Relay contacts made to separate power sources must be disconnected before servic ing Electrical installation must be in accordance with the Natio
79. ter pressing ENTER 4 To return to the main display press MENU then EXIT 39 MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7 8 RESETTING THE ANALYZER 7 8 1 Purpose This section describes how to clear user entered values and restore default settings There are three resets 1 Resetting to factory default values clears ALL user entered settings including sensor and analog output calibration and returns ALL settings and calibration values to the factory defaults 2 Resetting a sensor calibration to the default values clears user entered calibration data for the selected sensor but leaves all other user entered data unaffected 3 Resetting the analog output calibration clears only the user entered analog output calibration It leaves all other user entered settings unchanged 7 8 2 Procedure Resetting the Analyzer 1 Press MENU The main menu screen appears Move the cursor to Program and press ENTER Program 2 Scroll to the bottom of the screen and continue scrolling until Reset Analyzer is highlighted Press ENTER Temperature Security Diagnostics Reset Analyzer Reset Analyzer 3 Choose whether to reset all user entered values Factory Defaults Fact Def T sensor calibration Sensor Cal Only or output calibration Output Cal actory Derauits Only If you choose Sensor Cal Only or Output Cal Only a second Sensor Cal Only screen appears in which you can select which sensor or output Output Cal Only calibrat
80. the chlorine signal board Slot 1 left Slot 2 center Slot 3 right input 1 chlorine input 2 optional Insert the sensor cable through the conduit opening nearest the chlorine board Slide the board forward to gain access to the wires and terminal screws Connect the sensor cable to the chlorine board Refer to Figure 4 4 or 4 5 D mF o Once the cable has been connected slide the board fully into the enclosure while taking up the excess cable through the conduit opening If you are using a cable gland tighten the gland nut to secure the cable and ensure a sealed enclosure 15 MODEL TCL SECTION 4 WIRING FIGURE 4 4 Wiring Sensor with Optimum EMI RFI FIGURE 4 5 Wiring Sensor with Standard Cable or Variopol Cable to Model 1056 Analyzer to Model 1056 Analyzer 4 5 APPLY POWER TO THE ANALYZER AND COMPLETE QUICK START 1 Once all wiring connections are secured and verified apply power to the analyzer 2 When the analyzer is powered up for the first time Quick Start screens appear Using Quick Start is easy a A backlit field shows the position of the cursor b To move the cursor left or right use the keys to the left or right of the ENTER key To scroll up or down or to increase or decrease the value of a digit use the keys above and below the ENTER key Use the left and right keys to move the decimal point c Press ENTER to store a setting Press EXIT to leave without storing changes Pressing EXIT also returns the
81. the flow cell Pull the air injection tube off the air injection tee Disconnect the sample inlet and drain tubing Install the replacement sample pump suction and discharge tubing assemblies The assemblies look similar To tell the difference note the air injection tee in the discharge tubing assembly has a larger diameter barb than the reagent injection tee in the suction tubing assembly 8 Install replacement sample inlet and drain tubing The sample inlet tubing is longer than the drain tubing SAMPLE PUMP DISCHARGE SUCTION REAGENT PUMP SAMPLE INJECTION INLET INJECTION TEE TEE small barb large barb REAGENT FIGURE 10 4 Replacing Sample Tubing 53 MODEL TCL SECTION 10 10 3 3 Peristaltic pump tubing The expected life of the peristaltic pump tubing is one year To replace pump tubing 1 2 54 MAINTENANCE Turn off the sample and reagent pumps The reagent and sample tubing is connected to the pump tubing with luer fittings See Figure 10 5 Disconnect the fittings from the pump by turning the fitting in the direction of the arrow Using your thumb and forefinger gently pinch the sides of the pump cover Slide the cover upwards to remove it See Figure 10 6 FIGURE 10 6 Using your thumb as shown in Figure 10 7 push the tubing fit ting straight outward until the fitting slides out of the socket Repeat the process for the other fitting Remove and discard the pump tubing In
82. ts of UL514B Connect the conduit hub to the conduit before attaching the fitting to the analyzer UL508 26 16 4 2 PROVIDE POWER TO THE SAMPLE CONDITIONING SYSTEM A WARNING RISK OF ELECTRICAL SHOCK Electrical installation must be in accordance with the National Electrical Code ANSI NFPA 70 and or any other applicable national or local code NOTE Provide a switch or breaker to disconnect the sample conditioning cabinet from the main power supply Install the switch or breaker near the unit and identify if as the disconnecting device for the sample conditioning system 1 Be sure the pump switches on the wiring access panel are in the off position 2 Remove the four screws securing the wiring access panel Pull the panel out of the way to reveal the power terminal strip 3 Insert the power cable through the strain relief connection labeled power see Figure 3 4 Wire the power cable to the terminal strip as shown in Figure 4 1 Do not apply 230 Vac power to a 115 Vac TCL Model option 11 Doing so will damage the instrument 4 Leave the pump power switches off until ready to start up the unit See Section 5 Model option 11 115 Vac only Model option 12 230 Vac only TERMINAL BLOCK GROUND 1157230 vac 5 J NEUTRAL REAGENT PUMP CONNECTOR SAMPLE PUMP AI
83. ult or Warning a screen like the one shown at left S1 RTD Open appears S1 means sensor 1 S2 means sensor 2 For additional trou bleshooting information select the desired message and press ENTER S2 RTD Open For more information see Section 11 3 3 To return to the main display press MENU then EXIT 59 MODEL TCL SECTION 11 TROUBLESHOOTING 11 3 TROUBLESHOOTING WHEN A FAULT MESSAGE IS SHOWING Fauitmessage Explanation Se Sensor Incompatible Sensor board software is not supported by main board 11 34 software 11 3 1 Main Board CPU Main Board Factory Data and Main Board User Data Errors These error messages mean the main board software is corrupted or the eeprom data on the main board is corrupted 1 Cycle the power off then on 2 If cycling the power does not help call the factory The main board must be replaced To do this the analyzer must be returned to the factory 3 If cycling the power does not help and the fault message was Main Board User Data reset the analyzer to factory default See section 7 8 Re enter user settings and repeat calibration 11 3 2 Hardware Error Hardware error means there is a missing or bad hardware component on the sensor board The board must be replaced 11 3 3 Sensor Board Unknown Sensor Board HW Hardware or SW Software Mismatch or Sensor Board Not Communicating These error messages mean the main board either does not recognize the sensor board or the sensor b
84. urn ausi nnnc mauus secs 59 11 1 Eeer eebe ee 59 11 2 Using the Diagnostic Feature eececeeeceeeeeten nenne trennt nnn tnn nins 59 11 3 Troubleshooting When a Fault Message is ShOWINQ L ne nnnenennenennnnnnnna 60 11 4 Troubleshooting When a Warning Message is Showing eeeeeeeecceeeeeereeeeerrsseen 62 11 5 Troubleshooting When no Error Message is Showing eeeese 63 11 0 Simulating Temperature seine ika at u e e Lee tente at 67 12 0 RETURN OF MATERIAL reete ecu uet itn nti te ttum aE iiec R rv Rai cece 68 V2 General RM sen T E 68 12 2 Warrantv Etgen 68 123 Non Warrantv Repalf eesriie an e E e E aE eateries 68 LIST OF TABLES Number Title Page 7 1 Detault Settin s iii A 27 28 10 1 ert ea a an a ba qr p i dk fk 51 10 2 Replacement Parts and Reagent for Sample Conditioning System 58 MODEL TCL TABLE OF CONTENTS LIST OF FIGURES Number Title Page 2 1 Schematic of Sample Conditioning System and Analyzer eeen 7 3 1 Panel Mount Dimensions 2 2 2 2 Iit iere enemies pe pare sena eee ue Eee mde R Eva gen ERl ida 9 3 2 Pipe and Wall Mounting Dimensions emm 10 3 3 Installing the Sample Conditioning Enclosure nn 11 3 4 TCL Case Re Ee 12 3 5 Reagent Tubing Assembly sssssssssssseeem enm eee 12 4 1 Power WANG e 13 4 2 Location of power connector on power supply board Lee 14 4 3 Analog output Conpechons
85. ut 1 O1 and output 2 O2 The screen also shows which sensors the outputs are assigned to S1 is sensor 1 and S2 is sensor 2 S2 appears only if you have a dual input 1056 analyzer The assignments shown are the defaults for a single channel chlorine analyzer Outputs are freely assignable under the configure menu For practice change the 20 mA setting for output 1 to 8 5 ppm a Move the cursor to the O1 S1 20 mA 10 00 line and press ENTER b The screen at left appears c Usethe navigation keys to change 10 00 to 8 5 ppm Use the left and right keys to move from digit to digit Use the up and down keys to increase or decrease the numeral d To move the decimal point press the left or right navigation key until the decimal point is highlighted Press the up key to move the decimal point to the right Press the down key to move to the left e Press ENTER to store the setting MODEL TCL SECTION 6 START UP Output Range 7 The display returns to the summary screen at left Note that the 20 mA O1 S14mA 0 000 ppm setting for output1 has changed to 8 5 ppm XE 08 50 ppm O2 S1 4mA O2 S1 20mA 8 To return to the main menu press MENU To return to the main display press MENU then EXIT 6 4 SECURITY 6 4 1 How the Security Code Works Security codes prevent accidental or unwanted changes to program settings or calibrations There are three levels of security a Auser can view the default display and diagnostic screens o
86. ut 2 ST Calibration 5 Choose Total Chlorine Total Chlorine Temperature ST Calibration 6 Choose In Process Cal Zero Cal In Process Cal 46 MODEL TCL S1 Enter Value 0 00 ppm S1 InProcess Cal Calibration Error Press Exit 9 4 1 Purpose SECTION 9 CALIBRATION Follow the screen prompts Once the reading is stable press ENTER Take the sample and press ENTER At this point the analvzer will store the present sensor current and temperature and use those values in the calibration Determine the total chlorine concentration in the sample and enter the value in the screen shown at left See Section 9 3 1 for sampling and testing precautions If the calibration is successful the live reading will change to the value entered in step 7 and the displav will return to the screen in step 6 If the sensitivitv is too far outside the range of expected values the calibration error screen shown at left will appear The analvzer will not update the calibration For troubleshooting assistance see Section 11 5 9 Toreturn to the main displav press MENU then EXIT 9 4 CALIBRATING ANALOG OUTPUTS Although the analvzer analog outputs are calibrated at the factorv thev can be trimmed in the field to match the reading from a standard milliammeter Both the low 0 or 4 mA and high 20 mA outputs can be trimmed 9 4 2 Procedure 1 Connect a calibrated milliammeter across the output you wish to calibrate If a load is
87. y for additional information regarding service or repair 68 WARRANTY Seller warrants that the firmware will execute the programming instructions provided by Seller and that the Goods manufactured or Services provided by Seller will be free from defects in materials or workmanship under normal use and care until the expira tion of the applicable warranty period Goods are warranted for twelve 12 months from the date of initial installation or eighteen 18 months from the date of shipment by Seller whichever period expires first Consumables such as glass electrodes membranes liquid junctions electrolyte o rings catalytic beads etc and Services are warranted for a period of 90 days from the date of shipment or provision Products purchased by Seller from a third party for resale to Buyer Resale Products shall carry only the warranty extended by the original manufacturer Buyer agrees that Seller has no liability for Resale Products beyond making a reasonable commercial effort to arrange for procurement and shipping of the Resale Products If Buyer discovers any warranty defects and notifies Seller thereof in writing during the applicable warranty period Seller shall at its option promptly correct any errors that are found by Seller in the firmware or Services or repair or replace F O B point of man ufacture that portion of the Goods or firmware found by Seller to be defective or refund the purchase price of the defective

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