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Manual

LIQ-MAN-TCL-1056, Rev E

July 2017

Rosemount

™

TCL

Total Chlorine System with Rosemount 1056 Transmitter

Summary of Contents for Rosemount TCL

Page 1: ...Manual LIQ MAN TCL 1056 Rev E July 2017 Rosemount TCL Total Chlorine System with Rosemount 1056 Transmitter ...

Page 2: ... protective covers are in place except when maintenance is being performed by qualified people to prevent electrical shock and personal injury DANGER HAZARDOUS AREA INSTALLATION Installations near flammable liquids or in hazardous area locations must be carefully evaluated by qualified on site safety personnel This device is not intrinsically safe or explosion proof To secure and maintain an intri...

Page 3: ...rine Transmitter The following list provides notes concerning all revisions of this document Rev level Date Notes A 07 07 This is the initial release of the product manual This manual has been reformatted to reflect the Emerson documentation style and updated to reflect any change in the prod uct offering B 11 07 Page 3 additions to Section 1 2 page 5 changes to the Analyzer option selection table...

Page 4: ......

Page 5: ...alog output wiring 21 4 3 3 Alarm wiring 22 4 4 Sensor wiring 22 4 5 Apply power to the transmitter and complete Quick Start 24 Chapter 5 Startup 27 5 1 Prepare the reagent 27 5 2 Zero the sensor 28 5 3 Start sample flow 28 5 4 Begin operation and calibrate the sensor 28 Chapter 6 Display and operation 29 6 1 Display 29 6 2 Keypad 30 6 3 Programming the transmitter tutorial 32 6 4 Security 34 6 4 ...

Page 6: ...ing the transmitter 56 7 8 1 Purpose 56 7 8 2 Procedure resetting the transmitter 57 Chapter 8 Digital communications 59 Chapter 9 Calibration 61 9 1 Introduction 61 9 2 Calibrating temperature 61 9 2 1 Purpose 61 9 2 2 Procedure 61 9 3 Calibrating total chlorine 63 9 3 1 Purpose 63 9 3 2 Procedure zeroing the sensor 65 9 3 3 Procedure calibrating the sensor 67 9 4 Calibrating analog outputs 69 9 ...

Page 7: ...Out of Range 88 11 4 Troubleshooting when a Warning message is showing 89 11 4 1 Sensor Need Factory Cal 89 11 4 2 Sensor Negative Reading 89 11 4 3 Sensor RTD Sense Open 89 11 4 4 Sensor Temperature High or Low 90 11 5 Troubleshooting when no error message is showing 90 11 5 1 Zero current is too high 91 11 5 2 Zero current is unstable 91 11 5 3 Sensitivity is low or readings are low 91 11 5 4 Pr...

Page 8: ...Contents iv Rosemount TCL ...

Page 9: ...cedures Information and diagnostic screens as well as basic troubleshooting guidelines are available at the touch of a button The Rosemount 1056 Transmitter has two isolated continuously variable 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 avail...

Page 10: ...new membrane and replenishing the electrolyte takes only a few minutes 1 2 Specifications Sample Conditioning System Table 1 1 Physical characteristics Specifications 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 0 to 50 C 32 to122 F Ambient humidity 0 to 90 non con...

Page 11: ...nt temperature and humidity 0 to 55 C 32 to 131 F relative humidity 5 to 95 non condensing Storage temperature 20 to 60 C 4 to 140 F 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 Hazardous location approvals Applies to transmitter only Class 1 Division 2 Groups A B C D Class II Division 2 Groups E...

Page 12: ...al blocks 18 16 AWG wire size Weight shipping weight rounded up to nearest 1 lb or 0 5 kg 3 lb 4 lb 1 5 kg 2 0 kg Rosemount 499ACL 02 Total Chlorine Sensor Table 1 3 Physical characteristics Specifications Wetted parts Gold Noryl 1 PPO Viton 2 EPDM and sili cone Dimensions 1 0 x 5 6 in 25 4 x 143 mm Cable 25 ft 7 6 m standard Pressure rating 0 to 65 psig 101 to 549 kPa Temperature rating 0 to 50 C...

Page 13: ...sed for the continuous determination of total chlorine in water The TCL consists of a sample conditioning system a reagent carboy a sensor and a transmitter Important Reagent kits must be ordered separately Reagent kits for 0 5 ppm and 0 10 ppm chlorine are available For higher ranges consult the factory See Table 1 5 Rosemount TCL Total Chlorine System Ordering Information Table 1 5 Model Sensor ...

Page 14: ...ine 24153 00 Carboy for reagent 5 gal 19 L includes cap 9100204 Fuse 0 25 A 250 V 3 AG slow blow for option 11 115 Vac 9100132 Fuse 0 125 A 250 V 3 AG slow blow for option 12 230 Vac 9380094 Reagent pump 115 Vac 50 60 Hz 9380095 Reagent pump 230 Vac 50 60 Hz 9380091 Reagent pump replacement tubing 24151 00 Reagent tubing replacement kit 24135 00 Reagent uptake tubing 6 ft 1 8 m includes weight 938...

Page 15: ...and 1 O ring 23502 02 Total chlorine membrane kit includes 3 membrane as semblies and 3 O rings 9210438 Total chlorine sensor fill solution 4 oz 120 mL For First Time Variopol Installations Table 1 9 Part number Description 23747 06 Interconnecting cable VP 6 2 5 ft 0 8 m 23747 04 Interconnecting cable VP 6 4 ft 1 2 m 23747 02 Interconnecting cable VP 6 10 ft 3 0 m 23747 07 Interconnecting cable V...

Page 16: ...Description and specifications 8 Rosemount TCL ...

Page 17: ...ar from the reagent carboy and injects it into the suction side of the sample pump The sample and reagent mix as they pass through the pump and total chlorine in the sample is converted to the chemically equivalent amount of iodine The flow rates are 11 mL min for the sample and 0 2 mL min for the reagent Schematic of Sample Conditioning System and Transmitter Figure 2 1 The treated sample next en...

Page 18: ...Principles of operation 10 Rosemount TCL ...

Page 19: ... suitable for use in hazardous areas 2 Install the transmitter and sample conditioning system in an area where vibrations and electromagnetic and radio frequency interference are minimized or absent 3 Keep the transmittter and sensor wiring at least one foot from high voltage conductors Be sure there is easy access to the transmitter and sample conditioning system 4 The transmitter is suitable for...

Page 20: ...Type of mounting Figure Wall or pipe Figure 3 2 Panel Mounting Dimensions Figure 3 1 Installation 12 Rosemount TCL ...

Page 21: ...23820 00 2 See Section 4 1 for more information about the conduit openings 3 See Section 4 2 for wiring instructions 3 2 3 Install the sample conditioning enclosure Follow the steps below to install the sample conditioning enclosure Installation Instruction Manual 13 ...

Page 22: ...Refer to Figure 3 3 Figure 3 4 and Figure 3 5 for installation details Installing the Sample Conditioning Enclosure Figure 3 3 Installation 14 Rosemount TCL ...

Page 23: ...TCL Case Dimensions Figure 3 4 Reagent Tubing Assembly Figure 3 5 Installation Instruction Manual 15 ...

Page 24: ...o 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 5 Place the blue plastic carboy beneath the enclosure Screw the cap and tubing assembly on the carboy To prepare reagent see Section 5 1 3 ...

Page 25: ...id into place tighten the connection by turning the knurled ring clockwise 8 Remove the protective cap from the end of the sensor 9 Insert the sensor in the flow cell Hand tighten the nut Installation Instruction Manual 17 ...

Page 26: ...Installation 18 Rosemount TCL ...

Page 27: ...stem WARNING RISK OF ELECTRICAL SHOCK Electrical installation must be in accordance with the National Electric Code ANSI NFPA 70 and or any other applicable national or local codes 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 it as the disconnecting device for the sample conditioni...

Page 28: ...er alarm output and sensor connections in the transmitter 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 codes 4 3 1 Power Wire AC mains power supply to the power supply board which is mounted vertically on the left hand side of the transmitter enclosure The power connector ...

Page 29: ...he main power supply 4 Install the switch or breaker near the transmitter and label it as the disconnecting device for the transmitter 4 3 2 Analog output wiring Two analog current outputs are located on the main circuit board which is attached to the inside of the enclosure door Figure 4 2 shows the location of the terminals The connectors can be detached for wiring TB 1 is output 1 TB 2 is outpu...

Page 30: ...m wiring The alarm relay terminal strip is located just below the power connector on the power supply board See Figure 4 3 Alarm relay connections Figure 4 3 Keep alarm relay wiring separate from signal wiring Do not run signal and power or relay wiring in the same conduit or close together in a cable tray 4 4 Sensor wiring If it is necessary to replace the sensor cable refer to the instructions b...

Page 31: ...r to the chlorine board Refer to Figure 4 4 or Figure 4 5 Wiring Sensor with Optimum EMI RFI or Variopol Cable to Rosemount 1056 Transmitter Figure 4 4 Wiring Power with Standard Cable to Rosemount 1056 Transmitter Figure 4 5 6 Once the cable has been connected slide the board fully into the enclosure while taking up the excess cable through the conduit opening 7 If you are using a cable gland tig...

Page 32: ... 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 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 li...

Page 33: ... alarms if an alarm board is present are assigned to default values 7 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 Chapter 9 Wiring Instruction Manual 25 ...

Page 34: ...Wiring 26 Rosemount TCL ...

Page 35: ...ange ppm as Cl2 Amount of KI needed per 5 gal 19 L of vinegar Part number 0 5 ppm 25 grams 24164 00 0 10 ppm 50 grams 24164 01 0 20 ppm 2 x 50 grams 24164 01 3 Add 5 gallons 19 L of distilled white vinegar one gallon 4 L at a time Swirl the carboy after each addition 4 Screw the cap on the carboy Be sure the reagent uptake tube extends to the bottom of the carboy 5 If it hasn t already been connec...

Page 36: ... 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 fills rather slowly Also observe that the air pump is operating The pump produces very vigorous bubbling in the flow cell Once the flow of reagent starts it takes about two minutes for the reagent to reach the flow cell If the concentration of total chlorine in the sample ...

Page 37: ...r in small font at the top of the screen The rest of the display shows programming and calibration information Programming items appear in lists The screen can only show four items at a time and the arrow bar at the right of the screen indicates whether there are additional items in the list See Figure 6 3 for an explanation of the arrow bar Programming Screen Showing Item List Figure 6 2 The posi...

Page 38: ...shows whether additional items in a list are available 6 2 Keypad Local communication with the transmitter is through the membrane keypad Figure 6 4 and Figure 6 5 explain the operation of the keys Display and operation 30 Rosemount TCL ...

Page 39: ...ease the value of a numeral Press ENTER to select an item and store numbers and settings Press EXIT to return to the previous screen without storing changes Pressing MENU always causes the main menu to appear Navigation Keys Figure 6 5 The operation of the navigation keys is shown To move a decimal point highlight it and then press Up or Down Display and operation Instruction Manual 31 ...

Page 40: ... 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 transmitter contains the optional alarm relay board The screen displays four items at a time The downward pointing arrow on the right of the sreen shows there are more items available in the menu 3 To view the other items use Down to scroll to th...

Page 41: ...hange the 20 mA settings for output 1 to 8 5 ppm a Move the cursor to the O1 S1 20 mA 10 00 line and press ENTER The screen below appears b Use the navigation keys to change 10 00 to 8 5 ppm Use Left and Right to move from digit to digit Use Up and Down to increase or decrease the numeral c To move the decimal point press Left or Right until the decimal point is highlighted Press Up to move the de...

Page 42: ...ly 2 A user has access to the calibration and hold menus only 3 A user has access to all menus 1 If a security code has been programmed pressing MENU causes the security screen to appear 2 Enter the three digit security code 3 If the entry is correct the main Menu screen appears The user has access to the sub menus the code entitles him to 4 If the entry is wrong the Invalid code screen appears 6 ...

Page 43: ...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 loss than restored hold is automatically turned off 6 5 2 Using the hold function To put the sensor in hold complete the following steps 1 Press MENU The main Menu screen appears 2 Choose Hold The screen shows the current hold status...

Page 44: ...R The screen shows the present configuration There are four items Main Format Language Warning and Contrast 3 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 4 Press ENTER to store the setting 5 Main Format lets you configure the second line in the main display as well as the four smaller items at the bottom of the di...

Page 45: ...al M measurement I Sensor current Cl If you have a dual input Rosemount 1056 Transmitter other abbreviations might appear Consult the Rosemount 1056 Transmitter manual for more details 9 Choose Language to change the language used in the display 10 Choose Warning to disable or enable warning messages 11 Choose Contrast to change the display contrast 12 To change the contrast choose either lighter ...

Page 46: ...Display and operation 38 Rosemount TCL ...

Page 47: ...ngs The transmitter leaves the factory with the default settings for total chlorine shown in Table 7 1 You can change the settings to any value shown in the column labeled Choices If you have a dual input Rosemount 1056 Transmitter refer to the Rosemount 1056 Transmitter Instruction Manual for information about the default settings for the second input Default Settings Table 7 1 Item Choices Defau...

Page 48: ... interval time 0 0 to 999 9 hr 24 0 hr b on time 0 to 999 sec 10 sec c recovery time 0 to 999 sec 60 sec Measurement chlorine a units ppm or mg L ppm b resolution 0 01 or 0 001 0 001 c input filter 0 to 999 sec 5 sec Temperature related settings 1 Units C or F C 2 Temperature compensation automatic or manual automatic Security code 1 Calibrate Hold 000 to 999 000 2 Program Display 000 to 999 000 C...

Page 49: ...nsmitter 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 O...

Page 50: ...positive 7 3 3 Procedure configure outputs Complete the following steps to configure the analog current outputs 1 Press MENU The main Menu screen appears 2 Move the cursor to Program and press ENTER The cursor is on Outputs 3 Press ENTER 4 Choose Configure 5 Choose Output 1 or Output 2 Programming the transmitter 42 Rosemount TCL ...

Page 51: ...screen appears in which the present setting can be edited 7 Press ENTER to store the setting For an explanation of terms see Section 7 3 1 and Section 7 3 2 8 To return to the main display press MENU and then EXIT 7 3 4 Procedure ranging outputs Complete the following steps to range the outputs by assigning values to the low and high outputs 1 Press MENU The main Menu screen appears 2 Move the cur...

Page 52: ...creen appears in which the present setting can be edited 7 Press ENTER to store the setting For an explanation of terms see Section 7 3 1 and Section 7 3 2 8 To return to the main display press MENU and then EXIT 7 3 5 Procedure simulating outputs Complete the following steps to simulate an output by making the transmitter generate an output current equal to the value you enter 1 Press MENU Progra...

Page 53: ...s 2 Move the cursor to Program and press ENTER The cursor is on Outputs 3 Press ENTER 4 Choose Simulate 5 Choose Output 1 or Output 2 6 Enter the desired simulated output current Programming the transmitter Instruction Manual 45 ...

Page 54: ...he interval timer parameters 2 Simulating an alarm means making the transmitter energize or de energize an alarm relay 7 4 2 Definitions Assigning alarms There are four alarm relays The relays are freely assignable 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 transmitter detects...

Page 55: ...centration drops below the low setpoint The alarm remains activated until the reading increases above the value determined by the deadband 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 operating the main display analog outputs and assigned alarms for the sensor can be put on hold During hold the main display rema...

Page 56: ...imers choosing synchronize timers will cause each timer to start one minute later than the preceding timer 7 4 3 Procedure configuring alarms and assigning setpoints Complete the following steps to configure the alarms and assign setpoints 1 Press MENU The main Menu screen appears 2 Move the cursor to Program and press ENTER 3 Choose Alarms Programming the transmitter 48 Rosemount TCL ...

Page 57: ...ms 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 6 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 7 Press ENTER to store the setting For an explanation of terms see Section 7 4 1 and Section 7 4 2 8 To retu...

Page 58: ...ake the transmitter energize or de energize an alarm relay 1 Press MENU The main Menu screen appears 2 Move the cursor to Program and press ENTER 3 Choose Alarms 4 Choose Simulate 5 Choose Alarm 1 Alarm 2 Alarm 3 or Alarm 4 Programming the transmitter 50 Rosemount TCL ...

Page 59: ...figured as interval timers 1 Press MENU The main Menu screen appears 2 Move the cursor to Program and press ENTER 3 Choose Alarms The summary display shows the current Synch Timers setting Yes or No 4 To make a change choose Synch Timers and press ENTER A screen appears in which the present setting can be edited 5 Press ENTER to store the setting Programming the transmitter Instruction Manual 51 ...

Page 60: ...w filter averages the measured value within the filter time For example 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 transmitter applies either an adaptive filter or a continuous filter An adaptive filter discriminates between noise and real ...

Page 61: ...sired line and press ENTER A screen appears in which the present setting can be edited 5 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 Section 7 5 2 6 To return to the main display press MENU and then EXIT 7 6 Configuring temperature related settings 7 6 1 Purpose This section d...

Page 62: ...perature correction the transmitter uses the temperature you enter 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 co...

Page 63: ...set security codes There are three levels of security 1 A user can view the default display and diagnostic screens only 2 A user has access to the calibration and hold menus only 3 A user 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 ...

Page 64: ...xisting security codes 4 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 5 Press ENTER to store a change The security code takes effect two minutes after pressing ENTER 6 To return to the main display press MENU and then EXIT 7 8 Resetting the transmitter 7 8 1 Purpose This section describes how to clear user entered ...

Page 65: ...tings unchanged 7 8 2 Procedure resetting the transmitter Complete the following steps to reset the transmitter 1 Press MENU The main Menu screen appears 2 Move to Program and press ENTER 3 Scroll to the bottom of the screen and continue scrolling until Reset Analyzer is highlighted Press ENTER 4 Choose whether to reset all user entered values Factory Defaults sensor calibration Sensor Cal Only or...

Page 66: ...Programming the transmitter 58 Rosemount TCL ...

Page 67: ...cations 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 Digital communications Instruction Manual 59 ...

Page 68: ...Digital communications 60 Rosemount TCL ...

Page 69: ...tion or the temperature changes To account for changes in sensor current caused by temperature alone the transmitter automatically applies a membrane permeability correction The membrane permeability changes about 3 C at 25 C 77 F 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...

Page 70: ...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 8 To force the transmitter to accept the calibration choose Yes To repeat the calibration choose No For troubleshooting assistance see Section 11 5 9 To return to the main display press MENU and then EXIT Calibra...

Page 71: ...metric sensor whose output is proportional to the concentration of iodine Because the concentration of iodine is also proportional to the concentration of total chlorine the transmitter can be calibrated to read total chlorine Determination of Total Chlorine Figure 9 1 Figure 9 2 shows a typical calibration curve for a total chlorine sensor Because the sensor really measures iodine calibrating the...

Page 72: ...t the zero current Instead it is the slight response of the sensor to total chlorine in the sample Important Always use deionized water for zeroing the sensor The purpose of the full scale standard is to establish the slope of the calibration curve Because stable total chlorine standards do not exist the sensor must be calibrated against a test run on a grab sample of the process liquid Several ma...

Page 73: ...nt 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 Important Do not start the zero routine until the sensor has been in the zero solution for...

Page 74: ...the zero current is moderately larger than expected an error message appears 9 To force the transmitter to accept the zero current choose Yes To repeat the calibration choose No For troubleshooting information see Section 11 5 If the zero current is much larger than expected the zero calibration failure screen appears Calibration 66 Rosemount TCL ...

Page 75: ... 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 operating range Wait until the transmitter reading is stable before starting 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 ME...

Page 76: ...nter the value in the screen below See Section 9 3 1 for sampling and testing precautions If the calibration was successful the live reading changes to the value entered in step 9 and the display returns to the screen in step 6 If the sensitivity is too far outside the range of expected values the following screen appears The transmitter doesn t update the calibration For troubleshooting assistanc...

Page 77: ...log outputs 1 Connect a calibrated milliameter across the output you wish to calibrate If a load is already connected to the output disconnect the load Do not put the milliameter in parallel with the load 2 Press MENU The main Menu screen appears The cursor is on Calibrate 3 Press ENTER 4 Choose the output you wish to calibrate The transmitter simulates the low output current 5 Change the value in...

Page 78: ...as successful the screen below appears If the user entered value is more than 1 mA different from the nominal value a possible error screen appears 7 To force the transmitter to accept the calibration choose Yes 8 To return to the main display press MENU and then EXIT Calibration 70 Rosemount TCL ...

Page 79: ...transmitter consult the Rosemount 1056 Instruction Manual for the part number of the other board To replace the board Procedure 1 Turn off power to the transmitter 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 t...

Page 80: ...tle Use a soft tissue to gently wipe the membrane 10 2 3 Replacing the membrane Complete the following steps to replace the membrane on the total chlorine sensor 1 Hold the sensor with the membrane facing up 2 Unscrew the 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 scr...

Page 81: ...e pointing down 4 Remove the fill plug 5 Allow the electrolyte solution to drain out 6 Remove the old pipe tape from the plug 7 Wrap the plug with two turns of pipe tape and set aside 8 Prepare a new membrane a Hold the membrane assembly with the cup formed by the membrane and membrane holder pointing up b Fill the cup with electrolyte solution c Set it aside 9 Hold the sensor at about a 45 angle ...

Page 82: ... equalizing port See Figure 10 2 CAUTION EQUIPMENT DAMAGE Do not use a sharp probe It will puncture the bladder and destroy the sensor 18 Place a drop of electrolyte solution on the cathode then place the membrane assembly over the cathode 19 Screw the membrane retainer in place Spare Parts Table 10 1 Part number Description 33523 00 Electrolyte fill plug 9550094 O ring Viton 2 014 33521 00 Membra...

Page 83: ...y Plugged sample tubing is best replaced Replacement tubing kits are available See Table 10 2 Reagent tubing is shown in Figure 10 3 Replacing Reagent Tubing Figure 10 3 To replace reagent tubing Procedure 1 Turn off sample and reagent pumps 2 Luer fittings connect the reagent tubing to the pump Disconnect the tubing by turning the fitting in the direction of the arrows shown in Figure 10 5 3 Disc...

Page 84: ...by turning the fitting in the direction of the arrows shown in Figure 10 5 3 Disconnect the other end of the sample pump suction tubing from the overflow sampler Pull the reagent injection tubing off the reagent injection tee 4 Disconnect the other end of the sample pump discharge tubing from the flow cell Pull the air injection tubing off the air injection tee 5 Disconnect the sample inlet and dr...

Page 85: ...ic pump tubing The expected life of the peristaltic pump tubing is one year To replace pump tubing Procedure 1 Turn off the sample and reagent pumps 2 The reagent and sample tubing is connected to the pump tubing with luer fittings Disconnect the fittings from the pump by turning the fitting in the direction of the arrow See Figure 10 5 Luer Fittings Figure 10 5 3 Using your thumb and forefinger g...

Page 86: ...ng 6 Insert the new tubing one end at a time Tongues on the sides of the gray fittings at the end of the tube fit into receiving grooves in the pump casing Push the fitting in 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 See Figure 10 8 Inserting New Tubing Figure 10 8 7 Replace the pump cover ...

Page 87: ...ride on the tracks in the pump casing Pins 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 Track Figure 10 11 d Push down until the cover snaps into place Maintenance Instruction Manual 79 ...

Page 88: ...smitter 2 Refer to Figure 10 12 Disconnect the reagent and air injection tubes Disconnect the suction and discharge tubing by turning the Luer fitting in the direction shown in the figure Disconnect the air pump inlet tubing from the barbed tubing in the bottom of the enclosure Replacing the Air Pump Figure 10 12 3 Remove the four screws circled in Figure 10 12 and Figure 10 13 holding the air pum...

Page 89: ...nd Outlet Tubing 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 Discard the old air pump See Figure 10 15 Maintenance Instruction Manual 81 ...

Page 90: ...he 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 10 3 6 Replacing the air pump diaphragm and check valves Complete the following steps to replace the air pump diaphragm and check valve...

Page 91: ... 14 5 Remove the five screws surrounded by squares in Figure 10 13 holding the air pump to the access panel 6 Pull the rubber base off the pump 7 Using needle nose pliers remove the air inlet fitting from the side of the air pump See Figure 10 16 Inlet Fitting Figure 10 16 8 Slide the pump assembly out of the air pump body See Figure 10 17 Pump Assembly Figure 10 17 9 Following instructions on the...

Page 92: ...on 11 115 Vac 9100132 Fuse 0 125 A 250 V 3 AG slow blow for option 12 230 Vac 9380094 Reagent pump 115 Vac 50 60 Hz 9380095 Reagent pump 230 Vac 50 60 Hz 9380091 Reagent pump replacement tubing 24151 00 Reagent tubing replacement kit see Section 10 3 2 24135 00 Reagent uptake tubing 65 ft 1 8 m includes weight 9380090 Sample pump 115 Vac 50 60 Hz 9380093 Sample pump 230 Vac 50 60 Hz 9380092 Sample...

Page 93: ... might also mean that the transmitter has failed Correct fault conditions immediately When a fault occurs the analog output goes to 22 00 mA or to the value programmed in Section 7 3 3 11 2 Using the diagnostic feature Complete the following steps to troubleshoot your transmitter with the diagnostic feature 1 To read diagnostic messages press DIAG The screen below appears 2 To display fault messag...

Page 94: ...rd software Section 11 3 3 Sensor Not Communicating Sensor board is not communicating with main board Section 11 3 3 Sensor CPU Error Sensor board software is corrupted Section 11 3 5 Sensor RTD Open Temperature measuring circuit is open Section 11 3 6 S1 Not Detected No sensor board is connected to sensor 1 termi nal Section 11 3 7 Sensor Factory Data Sensor board factory eeprom data is corrupted...

Page 95: ...ated 2 Inspect the connecting cable for obvious tears or breaks 3 If the ribbon cable is properly seated and appears undamaged replace the sensor board 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 ...

Page 96: ... the main board is plugged into the 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 errors 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 and then on 2 Replace the sensor board 11 ...

Page 97: ... 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 transmitter 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 nega...

Page 98: ...ance nor will the transmitter 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 Figure 4 5 The resistance should be close to the value...

Page 99: ...ero current is unstable 1 is the sensor properly wired to the transmitter See Figure 4 4 and Figure 4 5 Verify that all wiring connections are tight 2 Readings are often erratic when a new sensor is first placed in service Readings usually stabilize after about an hour 3 Is the space between the membrane and cathode mesh filled with electrolyte solution and is the flow path between the electrolyte...

Page 100: ...g from the pump and inspect it If the tubing appears permanently pinched or deformed replace the tubing Refer to Section 10 3 4 for instructions on how to remove and replace the tubing elements The expected life of a tubing element is about one year 9 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 ra...

Page 101: ...lize after about an hour 3 Is the air pump working There should be a vigorous stream of bubbles in the flow cell The bubbles help mix the sample and keep carbon dioxide bubbles off the membrane Carbon dioxide forms when bicarbonate alkalinity in the sample reacts with acetic acid The bubbles accumulate in the membrane and eventually break away causing the total chlorine reading to wander 4 Is the ...

Page 102: ...on 11 5 3 step 10 for more information 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 potassium iodide The reaction is catalyzed by sunlight The purpose of the blue carboy is to protect the reagent from sunl...

Page 103: ...ect the RTD leads 2 Set the decade box to 1 4 MΩ 3 Note the sensor current It should be about 960 nA The actual value depends on the voltage of the battery To view the sensor current go to the main display and press INFO Choose sensor 1 The input current is the second line in the display 4 Change the decade box resistance and verify that the correct current is shown Calculate current from the equa...

Page 104: ...ng RTD Inputs Figure 11 4 To check the accuracy of the temperature measurement set the resistor simulating the RTD to the values indicated in the table and note the temperature readings The measured temperature might not agree with the value in the table During sensor calibration an offset might have been applied to make the measured temperature agree with a standard thermometer The offset is also...

Page 105: ... to 107 8 Ω which corresponds to 20 0 C The transmitter uses 107 5 Ω 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 transmitter is working correctly Temp C Pt 100 Ω 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...

Page 106: ...Troubleshooting 98 Rosemount TCL ...

Page 107: ...12 Return of material For any repair warranty and return of instrument requests please contact the factory Return of material Instruction Manual 99 ...

Page 108: ...sis MIDDLE EAST AND AFRICA Emerson Automation Solutions Emerson FZE Jebel Ali Free Zone Dubai United Arab Emirates P O Box 17033 T 971 4 811 8100 F 971 4 886 5465 liquid csc emerson com www Emerson com RosemountLiquidAnalysis ASIA PACIFIC Emerson Automation Solutions 1 Pandan Crescent Singapore 128461 Singapore T 65 777 8211 F 65 777 0947 liquid csc emerson com www Emerson com RosemountLiquidAnaly...

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