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YOKOGAWA FC500G User Manual Download Page 2

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IM 12F5A2-01E

 Introduction

This user’s manual describes the specifications, installation, operation, maintenance, and 

troubleshooting for Model FC500G Free Available Chlorine Analyzer. Read this manual 

thoroughly to understand the contents before operating the equipment.

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  Notes on Hardware

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  Appearance and Accessories

Check the following when you receive the product:

• Appearance
•  Standard accessories

Contact our sales representative or your local distributor if the product’s coating has come off, it 

has been damaged, or there is shortage of required accessories.

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  Model and Suffix Codes

The name plate on the product contains the model and suffix codes. Compare them with those in 

the general specification to make sure the product is the correct one. If you have any questions, 

contact our sales representative or your local distributor.

Media No. IM 12F5A2-01E 

5th Edition : July 2018 (YK)

All Rights Reserved Copyright © 2007, Yokogawa Electric Corporation

Summary of Contents for FC500G

Page 1: ...User s Manual TM Model FC500G Free Available Chlorine Analyzer Non Reagent Type IM 12F5A2 01E IM 12F5A2 01E 5th Edition ...

Page 2: ...ance Standard accessories Contact our sales representative or your local distributor if the product s coating has come off it has been damaged or there is shortage of required accessories l Model and Suffix Codes The name plate on the product contains the model and suffix codes Compare them with those in the general specification to make sure the product is the correct one If you have any question...

Page 3: ...for convenient reference Please read the information thoroughly before using the product The purpose of these user s manuals is not to warrant that the product is well suited to any particular purpose but rather to describe the functional details of the product No part of the user s manuals may be transferred or reproduced without prior written consent from YOKOGAWA YOKOGAWA reserves the right to ...

Page 4: ...ch are out of scope of warranty stated in instruction manual Failure caused by usage of software hardware or auxiliary equipment which Yokogawa Electric did not supply Failure due to improper or insufficient maintenance by user Failure due to modification misuse or outside of specifications operation which Yokogawa does not authorize Failure due to power supply voltage frequency being outside spec...

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Page 6: ...le Water Piping 3 2 3 2 2 Air Purge Piping 3 2 3 3 Wiring 3 3 3 3 1 Wiring for Power Supply and Grounding 3 3 3 3 2 Analog Output Wiring 3 3 4 OPERATION 4 1 4 1 Preparation for Operation 4 1 4 1 1 Inspection of Piping and Wiring Status 4 1 4 1 2 Fill with Glass Beads for Electrode Polishing 4 1 4 1 3 Measuring Range Setting 4 2 4 1 4 Setting of Applied Voltage Compensation Applied Voltage Fixation...

Page 7: ...Glass Beads and Measuring Tank Cleaning 6 2 6 1 3 Brush and Slip Ring Checking 6 3 6 2 Electrical System 6 5 6 2 1 Span Calibration 6 5 6 2 2 Converter Checking 6 5 6 2 3 Fuse Replacement 6 5 7 TROUBLESHOOTING 7 1 8 AUXILIARIES AND CONSUMABLES 8 1 8 1 Auxiliaries and Consumables List 8 1 8 2 Auxiliaries and Consumables 8 1 8 2 1 Polisher Part number K9088PE 8 1 8 2 2 Glass Beads Part number K9332Z...

Page 8: ...ement of free available chlorine in tap water distribution This analyzer consists of a detector and a converter as shown in Figure 1 1 This chapter describes the FC500G free available chlorine analyzer specifications and its measuring principle Detector Converter Figure 1 1 Appearance of Model FC500G Free Available Chlorine Analyzer ...

Page 9: ...Suspended Solid 10 mg L or less Air Purging for only 0 to 5 0 to 10 mg L Range Supply Air Pressure About 50 to 140 kPa Air Consumption About 5 L min Electrode Indicator Electrode Rotating gold electrode Counter Electrode Silver electrode with Pt 1000 installed Electrode Cleaning Glass beads used for cleaning Wetted Part Materials Measuring Tank Acrylic resin molding Piping Flexible PVC and PE Colo...

Page 10: ...ompensation Error 3 of full scale 5 to 35 C 3 4 5 6 7 8 9 10 pH pH6 5 pH7 5 Operating range 0 5 0 1 0 Indicated value mg l Figure 1 2 Sensitivity characteristics of diffusion current by pH value Figure 1 3 Sensitivity characteristics of diffusion current by conductivity Note If conductivity exceeds 300 μS cm default value of applied voltage should be changed n Accessories Fuse 1 A 4 pcs Glass Bead...

Page 11: ... 20 mA DC Power 3 4 5 6 100 V 10 50 60 Hz 110 V 10 50 60 Hz 200 V 10 50 60 Hz 220 V 10 50 60 Hz Inlet valve 0 1 Without Valve With Valve Language E English n Spare Parts Name Parts No Note Indicator Electrode K9332MB Rotating Electrore Counter Electrode K9332MK Reference Electrode Glass Beads K9332ZJ Washing Indicator Electrode 2 bags Polishing Powder K9088PE Polishing Indicator Electrode Brush K9...

Page 12: ...T for only FC500G 5 E Outlet Ø12 Nipple Drain cock Insert Tub 4 Ø8 5 holes for mounting U bolt on bracket Driving Box 35 33 4 17 3 2 Without Inlet Valve FC500G 0 E 0 50 mg l Unit mm Approx 150 260 146 5 5 5 108 Approx 160 Maintenance space Maintenance space 2 8 49 2 Approx 50 154 Drain cock Inlet 13 7 76 Cap Outlet 22 22 22 22 Cable gland 30 22 100 128 5 Wiring inlet 3 Ø23 holes Approx 250 Mainten...

Page 13: ... available chlorine concentration the applied voltage is compensated so that measurement can always be performed in the plateau region Also since the diffusion current is affected by the sample water temperature temperature is compensated using a temperature sensor Pt1000Ω incorporated in the counter electrode Figure 1 5 shows the block diagram for the FC500G free available chlorine analyzer non r...

Page 14: ...easuring tank Measuring tank Counter electrode Pt1000Ω sensor incorporated F2 1 ai Polishes the totating indicator electrode to hold indicator electrode in a clean state Drain cock If loosened this cock drains the liquid in the measuring tank Cell motor Air purge piping connection port for FC500G 5 A motor for rotaing the indicator electrode at a constant speed Sample inlet Figure 2 1 Component Na...

Page 15: ... Applied voltage compemsation fixation selection jumper Power switch Fuse External wiring connection terminals Power supply voltage selection jumper Operated when zero is to be calibrated To be operated with the terminal cover removed For converter checking select CHECK position Sets a measuring range The terminal cover should be attached or detached with this fastener grip pulled out Operated whe...

Page 16: ... a location which meets the following conditions Free from rain water such as an indoor location or in a cabinet Low vibration No exposure to direct sunshine Little dust Absence of corrosive gas Easy maintenance Figure 3 1 shows maintenance spaces 0 50 mg l Unit mm Approx 150 265 Approx 160 Maintenance space Maintenance space Approx 50 154 Approx 250 Maintenance space 310 Approx 150 Maintenance sp...

Page 17: ... the pressure at the valve inlet to 10 to 150 kPa Connect a hose of 12 mm lD to the sample outlet Make piping so that no drain stagnates in the hose 3 2 2 Air Purge Piping Make the air purge piping only when the FC500G 5 free available chlorine analyzer is used The air purge piping connecting port 1 8 NPT female is located at the electrode assembly Exercise care in piping because the electrode ass...

Page 18: ...2 ME RE T1 T2 SG G C1 C2 F3 3 ai Note Make grounding to earth grounding resistance 100 Ω or less Figure 3 3 Symbols on the Converter Terminals and the Types of Wiring to be Connected 3 3 1 Wiring for Power Supply and Grounding Use a three conductor cable of 9 to 12 mm OD each conductor having a cross section of 1 mm2 or more Make grounding to earth grounding resistance 100 Ω or less 3 3 2 Analog O...

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Page 20: ...ndicator rotating electrode and the counter electrode are not struck by the measuring tank Also do not touch the surface of the indicator electrode with the fingers Fixing screws 2 pcs Electrode assembly Measuring tank Holding stud F4 1 ai In maintenance position Figure 4 1 Removal of Electrode Assembly 2 Remove the beads case from the measuring tank The new glass beads are normally filled up to t...

Page 21: ...own in Table 4 1 Operate the setting switch using a small flat blade screwdriver Table 4 1 Switch Setting Corresponding to Measuring Range Model Measuring range DIP switch position 1 2 3 4 FC500G 1 0 to 1 mg l 0 to 2 mg l 0 to 3 mg l ON OFF OFF OFF OFF OFF OFF ON OFF OFF OFF ON FC500G 5 0 to 5 mg l 0 to 10 mg l OFF OFF ON OFF OFF OFF OFF ON ON OFF S3 1 2 3 4 J5 jumper see Figure 4 5 Figure 4 4 Mea...

Page 22: ...an be fixed to a definite value without applied voltage compensation When the applied voltage compensation applied voltage fixation transfer jumper shown in Figure 4 5 is set to the side B lower the applied voltage is fixed to the starting voltage value Applied voltage compensation Side A J5 Applied voltage fixation Side B J5 J5 F4 5 ai Figure 4 5 Applied Voltage Compensation Applied Voltage Fixat...

Page 23: ... 10 to 150 kPa After supplying sample water open the sample inlet valve so that the sample water flow rate is 0 1 to 2 5 l min 4 2 2 Confirmation of Power Supply Voltage and Measuring Range Selection Jumpers Setting Status If power supply specification for the free available chlorine analyzer non reagent type used is the 100 V system confirm that the power supply voltage selection jumper is set as...

Page 24: ...er supply whose voltage and frequency confirm to the specifications Confirm that the fuse holder cap in the converter is tight and then turn ON the power switch 4 2 4 Operation Check Confirm that a measured value is displayed in the display Also visually confirm that there is no irregularity or significant deflection when the indicator electrode revolves 4 2 5 Calibration Implement zero and span c...

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Page 26: ...cessary to stop the sample water 2 After display of the free available chlorine concentration has stabilized perform zero calibra tion First remove the terminal cover Next slowly turn the zero calibrator potentiometer using the attached flat blade screwdriv er to adjust display to zero 3 Mount the terminal cover Return the electrode assembly to the measuring tank and tightly fix the assembly using...

Page 27: ...edure Using Standard Solution Method 1 Prepare diluting solution which is obtained by adding 10 ml l of pH 7 buffer solution and 50 mg l of NaCl to purified water sample water can also be used instead of purified water 2 Prepare 2 to 3 liter of the standard solution conditioned to a free available chlorine concen tration of approximately 80 of the measuring range To obtain this solution dilute com...

Page 28: ... elapse Thus periodically polish the electrode surface using a polisher alumina Polish the electrode surface using the following procedure 1 Remove the converter cover and turn OFF the converter power switch 2 Remove the electrode assembly from the measuring tank and fix it to the holding stud It is not necessary to stop the sample water 3 Remove the electrode assembly cover 4 Insert an Allen wren...

Page 29: ...the measuring tank with the rubber packing attached In this case exercise care so as not to drop glass beads into the measuring tank 4 Clean the inside of the measuring tank using a brush with detergent on it Use dilute hydrochloric acid if manganese or iron adheres Do not use organic solvent After cleaning completely wash out the detergent or acid using clean water or sample water 5 Move the glas...

Page 30: ...ator soaked with alcohol with the indicator electrode rotated After cleaning re measure the resistance and confirm that the resistance is 500 Ω or less If the resistance does not decrease below 500 Ω or if abnormalities such as slip ring wear or brush wear and bending are detected the slip ring and or the brush must be replaced The following is the replacement procedure However in principle replac...

Page 31: ...llowing procedure Loosen the two securing screws of the brush mounting bracket Loosen the lock screw to the right of the contact pressure adjusting screw Move the brush mounting bracket toward you to once separate the brush contactor from the slip ring Screw in the contact pressure adjusting screw and then further screw in by three and a half turns from the position where the brush contactor just ...

Page 32: ...the MEAS CHECK selector switch in the CHECK position transfers the converter input current input and temperature input from connection to the detector to connection to the simulated input When the converter is normal the free available chlorine concentration display indicates 0 90 to 1 10 mg l regardless of the measuring range In this case the analog output is sent out in the range shown in Table ...

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Page 34: ...he slip ring a Adjust the brush contact pressure and remove wear debris from the slip ring see subsection 8 2 6 b Replace the brush and slip ring see sub section 6 1 3 4 Disconnect leadwires to the counter elec trode terminals T1 and T2 and check that the resistance across terminals T1 and T2 is approx 1 kΩ at room temperature and the resistance across the terminals RE and T1 or T2 is 1 MΩ or more...

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Page 36: ... indicator electrode surface 8 2 2 Glass Beads Part number K9332ZJ The cleaning capability of glass beads in prolonged use deteriorates owing to abrasion Normally replace the beads once or twice a year 8 2 3 Indicator Electrode Part number K9332MB The electrode is gradually abraded by cleaning using glass beads Generally the electrode can be used for around three or four years However it is recomm...

Page 37: ...ace of the slip ring to prevent the generation of wear debris and the ingress of wear debris generated into a space between the slip ring and the brush and furthermore increase the contact pressure of the brush to the slip ring surface 1 Polishing and cleaning the surface of the slip ring With the FC500G being powered press sandpaper 2000 on the rotating slip ring Then press a cotton swab soaked i...

Page 38: ...ly 5 Y9620NU 2 M6320 Bolt 6 A1109EF 1 Fuse 1A 7 1 Protector Assembly 8 1 Plate 9 1 Bracket Assembly 10 1 Main Board Assembly 11 K9332ZJ 1 Beads 12 K9332KZ 1 Packing 13 K9332KX 1 Beads Case 14 K9332MB 1 Indicator Electrode 15 K9044FX 1 Conductive Grease 16 K9332MK 1 Counter Electrode 17 Y9416LU 4 M4316 Bolt 18 1 Cover 19 K9332LK 1 Gasket 20 2 Post 21 K9332KL 1 Measuring Cell 22 Y9114XB 1 O Ring 23 ...

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Page 40: ...ection 3 3 3 Contact Output Wiring this function doesn t exist p 4 2 Deletion of subsection 4 1 3 Setting of Display Free Available Chlorine or Conductivity Selection Jumper p 4 6 Deletion of subsection 4 3 1 Out of Sample Detection Contact Signal Output p 7 1 Deletion of conductivity display shows abnormality and Abnomal out of sample detection in chapter 7 TROUBLESHOOTING table p 8 1 Some revisi...

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