Emerson FCL with 1056 Analyzer User Manual

4 (1)

Instruction Manual

PN 51-FCL-1056 rev.E

March 2012

FCL with 1056 Analyzer

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Your purchase from Rosemount Analytical, Inc. has resulted in one of the finest instruments available for your particular application. These instruments have been designed, and tested to meet many national and international standards. Experience indicates that its performance is directly related to the quality of the installation and knowledge of the user in operating and maintaining the instrument. To ensure their continued operation to the design specifications, personnel should read this manual thoroughly before proceeding with installation, commissioning, operation, and maintenance of this instrument. If this equipment is used in a manner not specified by the manufacturer, the protection provided by it against hazards may be impaired.

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.

Ensure that you have received the correct model and options from your purchase order. Verify that this manual covers your model and options. If not, call 1-800-854-8257 or 949-757-8500 to request correct manual.

For clarification of instructions, contact your Rosemount representative.

Follow all warnings, cautions, and instructions marked on and supplied with the product.

Use only qualified personnel to install, operate, update, program and maintain the product.

Educate your personnel in the proper installation, operation, and maintenance of the product.

Install equipment as specified in the Installation section of this manual. Follow appropriate local and national codes. Only connect the product to electrical and pressure sources specified in this manual.

Use only factory documented components for repair. Tampering or unauthorized substitution of parts and procedures can affect the performance and cause unsafe operation of your process.

All equipment doors must be closed and protective covers must be in place unless qualified personnel are performing maintenance.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by it against hazards may be impaired.

Emerson Process Management

2400 Barranca Parkway

Irvine, CA 92606 USA

Tel: (949) 757-8500

Fax: (949) 474-7250

http://www.rosemountanalytical.com

WARNING

RISK OF ELECTRICAL SHOCK

Equipment protected throughout by double insulation.

Installation of cable connections and servicing of this product require access to shock hazard voltage levels.

Main power and relay contacts wired to separate power source must be disconnected before servicing.

Do not operate or energize instrument with case open!

Signal wiring connected in this box must be rated at least 240 V.

Non-metallic cable strain reliefs do not provide grounding between conduit connections! Use grounding type bushings and jumper wires.

Unused cable conduit entries must be securely sealed by non-flammable closures to provide enclosure integrity in compliance with personal safety and environmental protection requirements. Unused conduit openings must be sealed with NEMA 4X or IP65 conduit plugs to maintain the ingress protection rating (NEMA 4X).

Electrical installation must be in accordance with the National Electrical Code (ANSI/NFPA-70) and/or any other applicable national or local codes.

Operate only with front and rear panels fastened and in place over terminal area.

Safety and performance require that this instrument be connected and properly grounded through a three-wire power source.

Proper relay use and configuration is the responsibility of the user.

CAUTION

This product generates, uses, and can radiate radio frequency energy and thus can cause radio communication interference. Improper installation, or operation, may increase such interference. As temporarily permitted by regulation, this unit has not been tested for compliance within the limits of Class A computing devices, pursuant to Subpart J of Part 15, of FCC Rules, which are designed to provide reasonable protection against such interference. Operation of this equipment in a residential area may cause interference, in which case the user at his own expense, will be required to take whatever measures may be required to correct the interference.

WARNING

This product is not intended for use in the light industrial, residential or commercial environments per the instrument’s certification to EN50081-2.

© Rosemount Analytical Inc. 2012

QUICK START GUIDE

FOR FCL ANALYZER

1.Refer to Section 2.0 for installation instructions and Section 3.0 for wiring instructions.

2.Once connections are secured and verified, apply power to the analyzer.

3.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 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

4. Choose the desired language. Scroll down to display more choices.

 

 

 

 

English

 

 

 

 

Francais

 

 

 

Espanol

 

 

 

Deutsch

 

 

 

 

 

 

 

 

 

 

 

 

 

S1 Measurement

Free Chlorine

pH Independ. Free Cl

Total Chlorine

Monochloramine

5. Choose free chlorine for sensor 1 (S1).

Units

ppm mg/L

S2 Measurement

pH ORP Redox

Ammonia

6. Choose the desired units for chlorine.

7.The screens shown in steps 7 through 9 appear only if you have an FCL-02. If you have an FCL-01, go to step 10. Otherwise, choose pH for sensor 2 (S2).

S2 Preamp

AnalyzerAnalyzer

Sensor/J Box

8. Choose Analyzer.

S1 Free Cl

pH Correction

Manual

Live/Continous

S1 Manual pH

0 7.00

Temp Units

oC

oF

9. Choose Live/Continuous. Go to step 11.

10.The screen shown at left appears only if you have an FCL-01. Enter the pH of the process liquid.

11. Choose the desired temperature units.

12.The main display appears. The outputs and alarms (if an alarm board is present) are assigned to default values.

13.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 two pages. To calibrate the sensor(s) refer to section 6.0.

MENU TREE

Calibrate

Sensor 1 (Free chlorine)

Chlorine Zero

In process Temperature

Sensor 2 (pH)

pH

Buffer Cal

Auto

Select buffer (NIST, DIN19267, Ingold, Merck, or Fisher) Select stability criteria

Manual Standardize

Enter slope or offset Temperature

Output 1 Output 2

Hold

Sensor 1

Sensor 2

Display

Main format configuration

Language selection

Warning (enable or disable)

Screen contrast

See next page for rest of menu tree

MENU TREE (continued)

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

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

Free chlorine (sensor 1)

Measurement selection

Units

Filter

Resolution

pH (sensor 2)

Measurement selection

Preamplifier location

Solution temperature correction

Resolution

Filter

Reference impedance (high or low)

Temperature

Units

Temperature compensation (auto or manual)

Set manual temperature (if selected)

Security

Calibrate/Hold only

All

Diagnostic Setup

Reference Offset

Diagnostics (on or off)

Glass impedance temperature correction

Glass fault high

Reference fault high

Reset Analyzer

About This Document

This manual contains instructions for installation and operation of the Model FCL-1056

The following list provides notes concerning all revisions of this document.

Rev. Level

Date

Notes

A

9/08

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

11/09

Minor changes to manual.

C

10/10

Updated DNV logo and copyright date.

D

4/11

Updated cover photo, added Model 3900 pH sensor wiring diagrams (blue

 

 

and gray cables), corrected flow cell part numbers, added removing trapped

 

 

bubbles information to troubleshooting section.

E

03/12

Update addresses - mail and web.

MODEL FCL-1056

TABLE OF CONTENTS

 

FCL-1056

 

 

TABLE OF CONTENTS

 

Section

Title

Page

1.0

DESCRIPTION AND SPECIFICATIONS ................................................................

1

1.1

Applications .............................................................................................................

1

1.2

Features...................................................................................................................

1

1.3

Specifications - General...........................................................................................

2

1.4

Specifications - Sensor ............................................................................................

2

1.5

Specifications - Analyzer..........................................................................................

2

1.6

Ordering Information................................................................................................

3

2.0

INSTALLATION .......................................................................................................

5

2.1

Unpacking and Inspection........................................................................................

5

2.2

Installation................................................................................................................

6

3.0

WIRING....................................................................................................................

9

3.1

Power, Alarm, and Output Wiring.............................................................................

9

3.2

Sensor Wiring .........................................................................................................

10

4.0

DISPLAY AND OPERATION...................................................................................

13

4.1

Display .....................................................................................................................

13

4.2

Keypad.....................................................................................................................

14

4.3

Programming the Analyzer - Tutorial........................................................................

15

4.4

Security....................................................................................................................

16

4.5

Using Hold ...............................................................................................................

17

4.6

Configuring the Main Display...................................................................................

18

5.0

PROGRAMMING THE ANALYZER ........................................................................

19

5.1

General ....................................................................................................................

19

5.2

Default Settings........................................................................................................

19

5.3

Configuring, Ranging and Simulating Outputs.........................................................

22

5.4

Configuring Alarms and Assigning Setpoints ...........................................................

25

5.5

Configuring the Measurement..................................................................................

30

5.6

Configuring Temperature Related Settings ..............................................................

32

5.7

Configuring Security Settings...................................................................................

33

5.8

Setting up Diagnostics .............................................................................................

34

5.9

Resetting the Analyzer.............................................................................................

36

6.0

CALIBRATION ........................................................................................................

37

6.1

Introduction ..............................................................................................................

37

6.2

Calibrating Temperature...........................................................................................

37

6.3

Calibration - Free Chlorine ......................................................................................

39

6.4

Calibration - pH .......................................................................................................

42

6.5

Calibration - Analog Outputs ....................................................................................

49

i

MODEL FCL-1056

TABLE OF CONTENTS

TABLE OF CONTENTS CONT’D

Section

Title

Page

7.0

DIGITAL COMMUNICATIONS ...............................................................................

51

8.0

MAINTENANCE ......................................................................................................

53

8.1

Analyzer...................................................................................................................

53

8.2

Chlorine Sensor .......................................................................................................

54

8.3

pH Sensor................................................................................................................

55

8.4

Constant Head Flow Controller................................................................................

56

9.0

TROUBLESHOOTING ...........................................................................................

59

9.1

Overview..................................................................................................................

59

9.2

Using the Diagnostic Feature...................................................................................

59

9.3

Troubleshooting When a Fault Message is Showing..............................................

60

9.4

Troubleshooting When a Warning Message is Showing..........................................

63

9.5

Troubleshooting When No Error Message is showing - Chlorine ............................

64

9.6

Troubleshooting When No Error Message is showing - pH .....................................

67

9.7

Troubleshooting When No Error Message is showing - General.............................

70

9.8

Simulating Inputs - Chlorine.....................................................................................

70

9.9

Simulating Inputs - pH..............................................................................................

71

9.10

Simulating Inputs Temperature ................................................................................

72

 

LIST OF TABLES

 

Number

Title

Page

1.6

Ordering Information ...............................................................................................

3

1.6

Component Parts .....................................................................................................

3

1.6

Accessories ..............................................................................................................

3

3.2

Sensor Wiring...........................................................................................................

10

4.6

Display Abbreviations ...............................................................................................

18

5.1

Default Settings ........................................................................................................

20

5.1

Default Settings cont ................................................................................................

21

5.7

Configuring Security Settings ...................................................................................

33

5.8.2

Procedure - Setting Up Diagnostics .........................................................................

35

6.4.2

Calibration - pH ........................................................................................................

42

8.1

Analyzer ...................................................................................................................

53

8.2.1

Spare Parts ..............................................................................................................

55

8-3

Replacement Parts for Constant Head Flow Controller Assembly (Model FCL-01).

 

 

................................................................................................................................

57

8-3

Replacement Parts for Constant Head Flow Controller Assembly (Model FCL-02).

 

 

................................................................................................................................

58

9.3

Troubleshooting When a Fault Message is Showing ...............................................

60

9.4

Troubleshooting When a Warning Message is Showing ..........................................

63

9.5

Troubleshooting When No Error Message is Showing - Chlorine ............................

64

9.6

Troubleshooting When No Error Message is Showing - pH.....................................

67

ii

MODEL FCL-1056

TABLE OF CONTENTS

LIST OF TABLES CONT’D

9.6.1

Calibration Error During Two-Point Calibration ........................................................

67

9.7

Troubleshooting When No Error Message is Showing - General.............................

70

9.9.2

Simulating pH Input ..................................................................................................

71

9.10

Simulating Inputs Temperature.................................................................................

72

 

LIST OF FIGURES

 

Number

Title

Page

2-1

Model FCL-01 ....................................................................................................

7

2-2

Model FCL-02 ....................................................................................................

7

3-1

Analog Output Connections ....................................................................................

9

3-2

Alarm Relay Connections.........................................................................................

10

3-3

Wiring Diagram for Free Chlorine Sensor ................................................................

11

3-4

Wiring Diagram for 399VP-09 pH Sensor ...............................................................

11

3-5

Wiring Diagram for 3900VP-10 pH Sensor (gray cable) .........................................

11

3-6

Wiring Diagram for 3900VP-10 pH Sensor (blue cable) ..........................................

11

4-1

Main Display.............................................................................................................

13

4-2

Programming Screen Showing Item List ..................................................................

13

4-3

Arrow Bar .................................................................................................................

13

4-4

Analyzer Keypad ......................................................................................................

14

4-5

Navigation Keys .......................................................................................................

14

5-1

High Alarm Logic .....................................................................................................

26

5-2

Low Alarm Logic ......................................................................................................

26

5-3

Operation of the Interval Timer.................................................................................

26

6-1

Sensor Current as a Function of Free Chlorine Concentration ................................

39

6-2

Calibration Slope and Offset ....................................................................................

42

8-1

Chlorine Sensor Parts ..............................................................................................

55

8-2

Replacement Parts for the Flow Controller Assembly used in Model FCL-01..........

57

8-3

Replacement Parts for the Flow Controller Assembly used in Model FCL-02..........

58

9-1

Pin Out Diagram for Model 499ACL-01-VP Sensor ................................................

61

9-2

Pin Out Diagram for Model 3900VP Sensor.............................................................

61

9-3

Simulating Chlorine ..................................................................................................

70

9-4

Simulating pH Inputs ................................................................................................

71

9-5

Three-Wire RTD Configuration.................................................................................

72

9-6

Simulating RTD Inputs..............................................................................................

72

iii

Model FCL-1056

SECTION 1.0

 

DESCRIPTION AND SPECIFICATIONS

SECTION 1.0.

DESCRIPTION AND SPECIFICATIONS

COMPLETE SYSTEM INCLUDES sensor, connecting cable, analyzer, and flow controller

CONTINUOUS pH CORRECTION eliminates expensive and messy reagents and troublesome sample conditioning systems

MEASURES FREE CHLORINE IN SAMPLES having pH as high as 9.5 1

VARIOPOL QUICK-DISCONNECT FITTINGS make replacing sensors easy

FEATURE-PACKED ANALYZER: dual outputs, four fully-programmable alarm relays, and large four line display

1In some cases, the sensor can be used in samples having pH as great as 10.0. Consult the factory.

1.1 APPLICATIONS

The FCL free chlorine system is intended for the determination of free chlorine in fresh water. Unlike free chlorine analyzers from other manufacturers, the FCL does not use expensive sample conditioning systems or messy reagents to control pH. Instead, the analyzer automatically compensates for changes in the pH of the sample. The FCL is not intended for the determination of total chlorine or combined chlorine (like monochloramine). Nor, can the FCL be used for the determination of chlorine in seawater.

1.2 FEATURES

The FCL uses a membrane-covered amperometric sensor. A polarizing voltage applied to a platinum cathode behind the membrane reduces the chlorine diffusing through the membrane and keeps the concentration of chlorine in the sensor equal to zero. The current generated by the cathode reaction is proportional to the rate of diffusion of chlorine through the membrane. Because the concentration of chlorine in the sensor is zero, the diffusion rate and the current are proportional to the concentration of chlorine in the sample.

All amperometric free chlorine sensors respond to changes in pH. Although free chlorine is a mixture of hypochlorous acid and hypochlorite ion, hypochlorous acid alone is responsible for the sensor current. Because the relative amounts of hypochlorous acid and hypochlorite ion depend on pH, a pH change will cause the current and the apparent free chlorine concentration to change, even though the true concentration remained constant. Most manufacturers solve the pH-dependence problem by treating the sample with

acid, which lowers the pH and converts hypochlorite ion into hypochlorous acid. The Model FCL avoids the expense and inconvenience of sample conditioning by measuring the pH and applying a correction to the raw chlorine sensor signal. The correction is valid between pH 6.0 and 9.5. For samples having pH between 9.5 and 10.0, consult the factory.

The Model FCL is available in two options: Model FCL-01 with manual pH correction and Model FCL-02 with continuous pH correction. Choose the FCL-01 if the pH varies less than 0.2 or if pH changes are predictable or seasonal. Choose the FCL-02 if the pH varies more than 0.2. To provide the continuous pH correction, the Model FCL-02 requires a separate pH sensor.

Maintenance is fast and easy. Replacing a membrane requires no special tools or fixtures. A screw cap holds the pre-tensioned membrane in place. Replacing the electrolyte solution takes only minutes.

The FCL includes the easy-to-use Model 1056 analyzer. The analyzer features two fully programmable 4-20 mA outputs and four fully programmable relays. The back-lit, four line display allows the user to read sample pH and chlorine concentration at a glance.

Valves, rotameters, and pressure regulators to control sample flow are things of the past with the Model FCL. A constant head overflow sampler ensures the correct sample flow to each sensor. To eliminate wiring hassles, quick-disconnect Variopol cable is standard.

Stable free chlorine standards do not exist. The chlorine sensor must be calibrated using the results of a laboratory test run on a grab sample.

1

MODEL FCL-1056

1.3 SPECIFICATIONS — GENERAL

Sample requirements:

Pressure: 3 to 65 psig (122 to 549 kPa abs)

A check valve in the inlet prevents the sensor flow cells from going dry if sample flow is lost. The check valve opens at 3 psig (122 kPa abs). If the check valve is removed, minimum pressure is 1 psig (108 kpa abs).

Temperature: 32 to 122°F (0 to 50°)

Minimum Flow: 3 gal/hr (11 L/hr)

Maximum flow: 80 gal/hr (303 L/hr); high flow causes the overflow tube to back up

Sample Conductivity: >50 µS/cm at 25°C

Process connection: 1/4-in OD tubing compression fitting (can be removed and replaced with barbed fitting for soft tubing)

Drain connection: 3/4-in barbed fitting. Sample must drain to open atmosphere

Wetted parts:

Overflow sampler and flow cell: acrylic, polycarbonate, Kynar®1, nylon, silicone

Chlorine sensor: Noryl®2, Viton®3, wood, silicone, polyethersulfone, polyester, and platinum

pH sensor (3900VP) : Stainless steel, glass, Teflon®4, polyphenylene sulfide, EPDM, and silicone

Response time to step change in chlorine concentration: <80 sec to 95% of final reading for inlet sample flow of 3 gph (11 L/hr)

Weight/shipping weight:

Model FCL-01: 10 lb/13 lb (4.5 kg/6.0 kg)

Model FCL-02: 11 lb/14 lb (5.0 kg/6.5 kg)

[rounded to the nearest 1 lb. (0.5 kg)]

1.4 SPECIFICATIONS — SENSOR

Free chlorine range: 0 to 10 ppm as Cl2. For higher ranges, consult the factory.

pH correction range: 6.0 to 9.5. For samples having pH between 9.5 and 10.0, consult the factory. If pH < 6.0, correction is not necessary. For manual pH correction, choose option -01. For continuous pH correction choose option -02.

Accuracy: Accuracy depends on the accuracy of the chemical test used to calibrate the sensor.

SECTION 1.0

DESCRIPTION AND SPECIFICATIONS

Interferences: Monochloramine, permangante, peroxides.

Electrolyte volume: 25 mL (approx.)

Electrolyte life: 3 months (approx.); for best results replace electrolyte monthly.

1.5 SPECIFICATIONS — ANALYZER

Case: Polycarbonate, NEMA 4X/CSA4 (IP65)

Display: Monochromatic back-lit LCD. Main character height 0.6 in (15 mm). Display is user-programable.

Languages: English, German, Italian, Spanish,

French, Portuguese

Ambient temperature and humidity: 32 to 131°F (0 to 55°C); RH 5 to 95% (con-condensing)

Storage temperature: -4 to 140°F (-20°C and 60°C)

Power: 84 to 265 Vac, 47.5-65.0 Hz, 15 W. Equipment protected by double insulation.

RFI/EMI: EN-61326

LVD: EN-61010-1

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: Four alarm relays. Any relay can be configured as a fault alarm instead of a process alarm. Each relay can be configured independently and each can be programmed with interval timer settings.

Relays: Form C, SPDT, epoxy sealed

Relay Contact ratings:

5 A at 28 VDC or 300 VAC (resistive) 1/8 HP at 120/240 VAC.

Terminal Connections Rating: Power connector (3-leads): 18-12 AWG wire size. Current output connectors (2-leads): 24-16 AWG wire size. Alarm relay terminal blocks: 18-16 AWG wire size

1

Kynar is a registered trademark of Elf Atochem North America.

2

Noryl is a registered trademark of General Electric.

3

Viton is a registered trademark of E.I. duPont de Nemours & Co.

4

Teflon is a registered trademark of E.I. duPont de Nemours & Co.

2

MODEL FCL-1056

SECTION 1.0

 

DESCRIPTION AND SPECIFICATIONS

1.6 ORDERING INFORMATION

FCL Free Chlorine Measuring System. The FCL is a complete system for the determination of free chlorine in aqueous samples. It consists of the sensor(s), analyzer, and constant head overflow device to control sample flow. All components are mounted on a backplate. Model option -02 includes a pH sensor for continuous, automatic pH correction. Three replacement membranes and a 4-oz. bottle of electrolyte solution are shipped with the chlorine sensor.

FCL FREE CHLORINE MEASURING SYSTEM

CODE

pH CORRECTION (required selection)

01

Without pH sensor

02

With pH sensor

 

 

 

 

CODE

pH CORRECTION (required selection)

2201056-03-24-38-AN, 115/230 Vac 50/60 Hz, alarm relays, analog outputs, chlorine only (option -01 only)

2211056-03-24-32-AN, 115/230 Vac 50/60 Hz, alarm relays, analog outputs, chlorine and pH (option -02 only)

FCL-02 -221 EXAMPLE

COMPONENT PARTS

 

 

ANALYZER MODEL

DESCRIPTION

 

 

1056-03-24-38-AN

1056-03-24-38-AN, 115/230 Vac 50/60 Hz, alarm relays, analog outputs, chlorine only

 

 

1056-03-24-32-AN

1056-03-24-32-AN, 115/230 Vac 50/60 Hz, alarm relays, analog outputs, chlorine and pH

 

 

 

 

 

 

 

 

 

 

SENSOR MODEL

DESCRIPTION

 

 

499ACL-01-54-VP

Free chlorine sensor with Variopol connector

 

 

3900VP-02-10

pH sensor with Variopol connector

 

 

 

 

 

 

 

 

 

 

SENSOR CABLE

DESCRIPTION

 

23747-04

Interconnecting cable, Variopol for 499ACL sensor, 4 ft

 

23645-08

Interconnecting cable, Variopol for 3900VP sensor, 4 ft

 

 

 

 

ACCESSORIES

PART # DESCRIPTION

9240048-00 Tag, stainless steel (specify marking)

3

MODEL FCL-1056

SECTION 1.0

 

DESCRIPTION AND SPECIFICATIONS

This page left blank intentionally

4

MODEL FCL-1056

SECTION 2.0

 

INSTALLATION

SECTION 2.0.

INSTALLATION

2.1 UNPACKING AND INSPECTION

Inspect the shipping container. If it is damaged, contact the shipper immediately for instructions. Save the box. If there is no apparent damage, unpack the container. Be sure all items shown on the packing list are present. If items are missing, notify Rosemount Analytical immediately.

2.1.1 FCL-01 (free chlorine without continuous pH correction)

Model FCL-01 consists of the following items mounted on a back plate.

1.Model 1056-03-24-38-AN analyzer with sensor cable attached.

2.Constant head overflow sampler with flow cell for chlorine sensor.

The free chlorine sensor (Model 499ACL-01-54-VP), three membrane assemblies, and a bottle of electrolyte solution are in a separate package.

2.1.2 FCL-02 (free chlorine with continuous pH correction)

Model FCL-02 consists of the following items mounted on a back plate.

1.Model 1056-03-24-32-AN analyzer with sensor cables attached.

2.Constant head overflow sampler with flow cells for pH and chlorine sensors.

3.Stand to hold pH buffer solution during calibration.

The free chlorine sensor (Model 499ACL-01-54-VP), shipped with three membrane assemblies and a bottle of electrolyte solution, and the Model 3900VP-02-10 pH sensor, which replaces the older Model 399VP-09 sensor, are in separate packages.

5

MODEL FCL-1056

SECTION 2.0

 

INSTALLATION

2.2 INSTALLATION

2.2.1 General Information

1.Although the system is suitable for outdoor use, do not install it in direct sunlight or in areas of extreme temperature.

CAUTION

The FCL free chlorine system is NOT suitable for use in hazardous areas.

2.To keep the analyzer enclosure watertight, install plugs (provided) in the unused cable openings.

3.Install the system in an area where vibrations and electromagnetic and radio frequency interference are minimized or absent.

4.Be sure there is easy access to the analyzer and sensors.

2.2.2 Sample Requirements

Be sure the sample meets the following requirements:

1.Temperature: 32 to 122ºF (0 to 50ºC)

2.Pressure: 3 to 65 psig (122 to 549 kPa abs)

3.Minimum flow: 3 gal/hr (11 L/hr)

2.2.3 Mounting, Inlet, and Drain Connections

The FCL is intended for wall mounting only. Refer to Figure 2-1 or 2-2 for details. The sensor(s) screw into the flow cell adapters as shown in the figures. For Model FCL-02 (free chlorine with continuous pH adjustment), the pH sensor must be installed as shown in Figure 2-2.

A 1/4-inch OD tubing compression fitting is provided for the sample inlet. If desired, the compression fitting can be removed and replaced with a barbed fitting. The fitting screws into a 1/4-inch FNPT check valve. The check valve prevents the sensor flow cells from going dry if sample flow is lost.

The sample drains through a 3/4-inch barbed fitting. Attach a piece of soft tubing to the fitting and allow the waste to drain open atmosphere. Do not restrict the drain line.

Adjust the sample flow until the water level is even with the central overflow tube and excess water is flowing down the tube.

2.2.4 Electrical Connections

Refer to Section 3.1 for details.

2.2.5 Installing the Sensor(s)

The FCL is provided with sensor cables pre-wired to the analyzer. Connect the chlorine sensor (Model 499ACL- 01-54-VP) to the cable labeled CL. Connect the pH sensor (Model 3900VP-02-10 or older Model 399VP-09) to the cable labeled pH. The terminal end of the sensor is keyed to ensure proper mating with the cable receptacle. Once the key has slid into the mating slot, tighten the connection by turning the knurled ring clockwise.

The sensor(s) screw into the plastic fitting(s), which are held in the flow cell(s) by the union nut. Do not remove the protective cap on the sensor(s) until ready to put the sensor(s) in service.

6

Emerson FCL with 1056 Analyzer User Manual

MODEL FCL-1056

SECTION 2.0

 

INSTALLATION

INCH

MILLIMETER

FIGURE 2-1. Model FCL-01

INCH

MILLIMETER

FIGURE 2-2. Model FCL-02

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MODEL FCL-1056

SECTION 2.0

 

INSTALLATION

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8

MODEL FCL-1056

SECTION 3.0

 

WIRING

SECTION 3.0.

WIRING

3.1 POWER, ALARM, AND OUTPUT WIRING

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.

3.1.1Power

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.

3.1.2Analog output wiring

Two analog current outputs are located on the main circuit board, which is attached to the inside of the enclosure door. Figure 3-1 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 3-1. Analog output connections. The analog outputs are on the main board near the hinged end of the enclosure door.

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MODEL FCL-1056

3.1.3

Alarm wiring.

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 power connector on the power supply board. See Figure 3-2.

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.

SECTION 3.0

WIRING

FIGURE 3-2. Alarm relay connections.

3.2 SENSOR WIRING

The Model FCL is provided with sensor cables pre-wired to the analyzer. If it is necessary to replace the sensor cable, refer to the instructions below.

1.

Shut off power to the analyzer.

 

 

 

2.

Loosen the four screws holding the front panel in place and let it drop down.

3.

Locate the appropriate signal board.

 

 

 

 

 

 

 

 

 

 

 

 

Slot 1 (left)

 

Slot 2 (center)

Slot 3 (right)

 

 

 

 

 

 

 

 

 

 

communication

 

input 1 (chlorine)

input 2 (pH)

 

 

 

 

 

 

 

4.

Loosen the gland fitting and carefully push the sensor cable up through the fitting as you pull the board

 

forward to gain access to the wires and terminal screws. Disconnect the wires and remove the cable.

5.

Insert the new cable through the gland and pull the cable through the cable slot.

6.

Wire the sensor to the signal board. Refer to the wiring diagrams in Figures 3-3 and 3-4.

7.

Once the cable has been connected to the board, slide the board fully into the enclosure while taking up the

 

excess cable through the cable gland. Tighten the gland nut to secure the cable and ensure a sealed enclosure.

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MODEL FCL-1056

Figure 3-3. Wiring Diagram

for Free Chlorine Sensor

Figure 3-5. Wiring Diagram

for 3900VP-10 pH sensor (gray cable)

SECTION 3.0

WIRING

WHITE

RED

Figure 3-4. Wiring Diagram

for 399VP-09 pH Sensor

Figure 3-6. Wiring Diagram

for 3900VP-10 pH sensor (blue cable)

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MODEL FCL-1056

SECTION 3.0

 

WIRING

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12

MODEL FCL-1056

SECTION 4.0

 

DISPLAY AND OPERATION

SECTION 4.0

DISPLAY AND OPERATION

4.1. DISPLAY

The analyzer has a four line display. See Figure 4-1. The display can be customized to meet user requirements. Refer to section 4.6.

 

1.

ppm

 

7.

pH

T1:

25.0qC

O1: 12.00 mA

T2:

25.0 qC

O2: 12.00 mA

 

 

Warnini g

FIGURE 4-1. Main Display

When the analyzer is being programmed or calibrated, the display changes to a screen similar to the one shown in Figure 4-2. The live readings appear 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 show only 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 4.3 for an explanation of the arrow bar.

Live

1.00 ppm

25.0C

measurement

7.00 pH

25.0C

 

Output 1 Configure

Assign: S1 Measurement

Range:

4-20 mA

 

Arrow

Item list

 

 

Scale:

Linear

 

bar

 

Warning

 

 

Dampening:

0 sec

 

 

FIGURE 4-2. 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 middle of the list. There are more items for viewing. Scroll up or down.

FIGURE 4-3. Arrow Bar. The arrow bar shows whether additional items in a list are available.

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MODEL FCL-1056

SECTION 4.0

 

DISPLAY AND OPERATION

4.2 KEYPAD

Local communication with the analyzer is through the membrane keypad. Figures 4-4 and 4-5 explain the operation of the keys.

FIGURE 4-4. 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 to the left.

Moves cursor up or increases the value of the selected digit.

Moves cursor to the right.

Moves cursor down or decreases the value of the selected digit.

FIGURE 4-5. Navigation keys. The operation of the navigation keys is shown. To move a decimal point, highlight it, then press the up or down key.

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MODEL FCL-1056

SECTION 4.0

 

DISPLAY AND OPERATION

4.3 PROGRAMMING THE ANALYZER—TUTORIAL

Setting up and calibrating the analyzer is easy. 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.

Menu

Calibrate

Hold

Program

Display

1.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.

2.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.

Program

Outputs

Alarms

Measurement

Temperature

Outputs

Range

Configure

Stimulate

Output Range

O1 S1 4mA 0.000 ppm

O1 S1 20mA: 10.00 ppm

O2

S1 4mA:

0.0C

O2

S1 20mA:

100.0C

O1 S1 20 mA

1 0.00 ppm

3.The Program menu appears. There are between five and seven items in the Program menu. Diagnostic Setup appears only if you have the FCL02 with pH sensor. 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.

4.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.

5.The screen at left appears. The screen shows the present values assigned to output 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. The assignments shown are the defaults for the FCL-01. For the FCL-02, Output 2 is assigned to sensor 2 (pH). Outputs are freely assignable under the configure menu.

6.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.Use the 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.

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MODEL FCL-1056

SECTION 4.0

 

DISPLAY AND OPERATION

Output Range

O1 S1 4mA: 0.000 ppm

O1 S1 20mA: 08.50 ppm

O2 S1 4mA: 0.0C

O2 S1 20mA: 100.0C

4.4 SECURITY

7.The display returns to the summary screen at left. Note that the 20 mA setting for output1 has changed to 8.5 ppm.

8.To return to the main menu, press MENU. To return to the main display, press MENU then EXIT.

4.4.1 How the Security Code Works

Security codes prevent accidental or unwanted changes to program settings or calibrations. There are three levels of security.

a.A user can view the default display and diagnostic screens only.

b.A user has access to the calibration and hold menus only.

c.A user has access to all menus.

Security Code

000

4.4.2Assigning Security Codes.

See Section 5.7.

4.4.3Bypassing Security Codes

Call the factory.

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.

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