Emerson Process Management TLC User Manual

Model TCL

Total Chlorine Analyzer

Instruction Manual

PN 51-TCL54e/rev.B
May 2007

WARNING

ELECTRICAL SHOCK HAZARD

Making cable connections to and servicing
this instrument require access to shock haz­ard level voltages which can cause death or
serious injury.

Be sure to disconnect all hazardous voltage
before opening the enclosure.

Relay contacts made to separate power
sources must be disconnected before servic­ing.

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

Unused cable conduit entries must be
securely sealed by non-flammable closures
to provide enclosure integrity in compliance
with personal safety and environmental pro­tection requirements.

The unused conduit openings need to be
sealed with NEMA 4X or IP65 conduit plugs
to maintain the ingress protection rating
(IP65).

For safety and proper performance this
instrument must be connected to a properly
grounded three-wire power source.

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

No external connection to the instrument of
more than 69VDC or 43V peak allowed with
the exception of power and relay terminals.
Any violation will impair the safety protection
provided

Do not operate this instrument without front
cover secured. Refer installation, operation
and servicing to qualified personnel.

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE

PROCEEDING!

Rosemount Analytical designs, manufactures, and tests its
products to meet many national and international stan­dards. Because these instruments are sophisticated techni­cal products, you must properly install, use, and maintain
them to ensure they continue to operate within their normal
specifications. The following instructions must be adhered
to and integrated into your safety program when installing,
using, and maintaining Rosemount Analytical products.
Failure to follow the proper instructions may cause any one
of the following situations to occur: Loss of life; personal
injury; property damage; damage to this instrument; and
warranty invalidation.

• Read all instructions prior to installing, operating, and
servicing the product. If this Instruction Manual is not the
correct manual, telephone [phone] and the
requested manual will be provided. Save this Instruction
Manual for future reference.

• If you do not understand any of the instructions, contact
your Rosemount representative for clarification.

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

• Inform and educate your personnel in the proper installa­tion, operation, and maintenance of the product.

• Install your equipment as specified in the Installation
Instructions of the appropriate Instruction Manual and
per applicable local and national codes. Connect all
products to the proper electrical and pressure sources.

• To ensure proper performance, use qualified personnel to
install, operate, update, program, and maintain the prod­uct.

• When replacement parts are required, ensure that quali­fied people use replacement parts specified by
Rosemount. Unauthorized parts and procedures can
affect the product’s performance and place the safe oper­ation of your process at risk. Look alike substitutions may
result in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protec­tive covers are in place, except when maintenance is
being performed by qualified persons, to prevent electri­cal shock and personal injury.

WARNING

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

Emerson Process Management

Rosemount Analytical Inc.

2400 Barranca Parkway
Irvine, CA 92606 USA
Tel: [phone]
Fax: [phone]

http://www.raihome.com

© Rosemount Analytical Inc. 2006

CAUTION

SENSOR/PROCESS

APPLICATION COMPATIBILITY

Wetted materials may not be compati­ble with process com position and
operating conditions. Application
compat ibility is entirely the responsi­bility of the user.

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 intrinsically safe
installation, the certified safety barrier,
transmitter, and sensor combi nation must
be used. The installation system must com­ply with the governing approval agency (FM,
CSA or BASEEFA/CENELEC) hazardous
area classification requirements. Consult
your analyzer/transmitter instruc tion manual
for details.

Proper installation, operation and servicing
of this device in a Hazardous Area Instal ­lation is entirely the responsibility of the user.

About This Document

This manual contains instructions for installation and operation of the Model TCL Total
Chlorine Analyzer.

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

Rev. Level

Date Notes

A 7/05 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 2/06 Corrected typographical errors. Added statement to calibration

section concerning initial stabilization time.

MODEL TCL TABLE OF CONTENTS

MODEL TCL

TOTAL CHLORINE ANALYZER

TABLE OF CONTENTS

Section Title Page

1.0 DESCRIPTION AND SPECIFICATIONS................................................................. 1

1.1 Features and Applications ...................................................................................... 2

1.2 Specifications — Sample Conditioning System ...................................................... 3

1.3 Specifications — Model 54e-24 Analyzer ................................................................ 3

1.4 Specifications — Model 499ACL-02 Sensor............................................................ 4

1.5 Performance Specifications — Complete System ................................................. 4

1.6 Ordering Information and Accessories ................................................................... 5

2.0 PRINCIPLES OF OPERATION .............................................................................. 7

3.0 INSTALLATION ...................................................................................................... 8

3.1 Unpacking and Inspection ...................................................................................... 8

3.2 Installation................................................................................................................ 8

4.0 WIRING .................................................................................................................. 14

4.1 Prepare Analyzer Conduit Openings ....................................................................... 14

4.2 Provide Power to the Sample Conditioning System ................................................ 14

4.3 Make Power, Alarm, Output, and Sensor Connections in the Analyzer................... 14

4.4 Apply Power to the Analyzer and Complete Quick Start.......................................... 16

5.0 START-UP .............................................................................................................. 17

5.1 Start Sample Flow.................................................................................................... 17

5.2 Prepare the Reagent ............................................................................................... 17

5.3 Zero the Sensor....................................................................................................... 17

5.4 Begin Operation and Calibrate the Sensor.............................................................. 17

6.0 DISPLAY AND OPERATION .................................................................................. 18

6.1 Display..................................................................................................................... 18

6.2 Keypad..................................................................................................................... 18

6.3 Programming and Calibrating the Solu Comp II — Tutorial..................................... 19

6.4 Security.................................................................................................................... 20

6.5 Using Hold ............................................................................................................... 20

7.0 PROGRAMMING THE ANALYZER ....................................................................... 21

7.1 General.................................................................................................................... 21

7.2 Changing Start-up Setting........................................................................................ 21

7.3 Configuring and Ranging the Outputs ..................................................................... 22

7.4 Configuring Alarms and Assigning Setpoints ........................................................... 24

7.5 Selecting the Type of Measurement ........................................................................ 27

7.6 Choosing Temperature Units and Manual or Automatic Temperature Compensation 28

7.7 Setting a Security Code........................................................................................... 29

7.8 Noise Rejection........................................................................................................ 29

7.9 Resetting Factory Calibration and Factory Default Settings.................................... 30

7.10 Selecting a Default Screen, Language, and Screen Contrast ................................. 31

i

ii

MODEL TCL TABLE OF CONTENTS

TABLE OF CONTENTS CONT'D.

8.0 CALIBRATION ........................................................................................................ 32

8.1 Introduction.............................................................................................................. 32

8.2 Calibrating Temperature .......................................................................................... 32

8.3 Calibration................................................................................................................ 34

9.0 MAINTENANCE ..................................................................................................... 39

9.1 54e Analyzer............................................................................................................ 39

9.2 Total Chlorine Sensor .............................................................................................. 41

9.3 Sample Conditioning System................................................................................... 43

10.0 TROUBLESHOOTING ........................................................................................... 48

10.1 Overview.................................................................................................................. 48

10.2 Troubleshooting Using Fault Codes ........................................................................ 48

10.3 Troubleshooting When No Error Message is Showing............................................ 49

10.4 Simulating Inputs ..................................................................................................... 52

11.0 RETURN OF MATERIAL ........................................................................................ 53

LIST OF TABLES

Number Title Page

7-1 Default Settings ...................................................................................................... 21

9-1 Replacement Parts for 54e Analyzer (Panel Mount Version) ................................. 39

9-1 Replacement Parts for 54e Analyzer (Wall Mount Version) ................................... 40

9-1 Spare Parts ............................................................................................................ 42

9-1 Replacement Parts and Reagent for Sample Conditioning System ...................... 47

MODEL TCL TABLE OF CONTENTS

TABLE OF CONTENTS CONT'D.

LIST OF FIGURES

Number Title Page

1-1 Dimensions of TCL Case ........................................................................................ 6

2-1 Schematic of Sample Conditioning System and Analyzer .................................... 7

3-1 Panel Mount Installation ......................................................................................... 9

3-2 Pipe Mount Installation............................................................................................ 10

3-3 Surface Mount Installation ...................................................................................... 11

3-4 Installing the Sample Conditioning Enclosure......................................................... 12

3-5 [something] ............................................................................................................. 13

4-1 Removing the Knockouts ....................................................................................... 14

4-2 Wiring Connections for Model 54e-01-10 (Panel Mount with 115/230 Vac Power) .. 15

4-3

Wiring Connections for Model 54e-01-11 (Pipe/Surface Mount with 115/230 Vac Power) ... 15

4-4 Chlorine sensor with Standard Cable...................................................................... 16

4-5 Chlorine sensor with Optimum EMI/RFI or Variopol Cable ..................................... 16

6-1 Displays During Normal Operation ........................................................................ 18

6-2 Solu Comp II Keypad .............................................................................................. 18

7-1 High Alarm Logic .................................................................................................... 24

7-2 Low Alarm Logic...................................................................................................... 24

8-1 Determination of Total Chlorine .............................................................................. 34

8-2 Sensor Current as a Function of Total Chlorine Concentration............................... 34

8-3 Dual Slope Calibration ............................................................................................ 37

9-1 Exploded View of 54e Analyzer (Panel Mount Version) ......................................... 39

9-2 Exploded View of 54e Analyzer (Wall Mount Version) ........................................... 40

9-3 Sensor Parts ........................................................................................................... 42

9-4 Replacing Reagent Tubing...................................................................................... 43

9-5 Replacing Sample Tubing ....................................................................................... 44

9-6 Replacing Peristaltic Pump Tubing — step 2.......................................................... 45

9-7 Replacing Peristaltic Pump Tubing — step 3.......................................................... 45

9-8 Replacing Peristaltic Pump Tubing — step 4.......................................................... 45

9-9 Replacing Peristaltic Pump Tubing — step 6.......................................................... 45

9-10 Replacing Peristaltic Pump Tubing — step 7a........................................................ 46

9-11 Replacing Peristaltic Pump Tubing — step 7b........................................................ 46

9-12 Replacing Peristaltic Pump Tubing — step 7c ........................................................ 46

10-1 Disconnecting Sample and Reagent Tubing Prior to Checking Flow ..................... 51

10-2 Simulating Chlorine ................................................................................................. 52

iii

1

MODEL TCL SECTION 1

DESCRIPTION AND SPECIFICATIONS

SECTION 1. DESCRIPTION AND SPECIFICATIONS

• RUGGED molded Noryl1(PPO) construction.

• NO TOOLS REQUIRED to change membrane.

• MAINTENANCE TAKES ONLY A FEW MINUTES a month.

1

Noryl is a registered trademark of General Electric.

Model TCL Sample Conditioning System

Model 499A CL-02 Sensor

The Model TCL is intended for the determination of total chlorine in water,
including the determination of chlorine in seawater. The system consists
of a sample conditioning unit, a sensor, and a 54eA chlorine analyzer.

Model 54eA Analyzer

• THREE LINE BACK-LIT DISPLAY with easy to use interface

• TWO INDEPENDENT OUTPUTS

• THREE FULLY PROGRAMMABLE ALARMS, plus one dedicated fault alarm

• OPTIONAL HART DIGITAL COMMUNICATIONS

• OPTIONAL PID AND TPC CONTROL

• CORROSION RESISTANT ALL PLASTIC CONSTRUCTION. Ideal for seawater.

• LOW SAMPLE FLOW (about 20 mL/hour) means little waste.

• REAGENT-BASED SYSTEM measures true total chlorine.

2

MODEL TCL SECTION 1

DESCRIPTION AND SPECIFICATIONS

1.1 FEATURES AND APPLICATIONS

MODEL 54eA ANALYZER

The Model 54eA analyzer can be used with the TCL sample conditioning system and 499ACL-02 sensor for the
continuous determination of chlorine in water.

The Model 54eA analyzer is housed in a rugged NEMA 4X weatherproof, corrosion resistant enclosure of epoxy­painted aluminum. It is suitable for panel, pipe, or wall mounting. Operation of the analyzer is through a front
panel membrane keypad. The large back-lit dot matrix display continuously indicates chlorine concentration in
large numerals along with temperature, current output, and two programmable process parameters, such as
alarms or diagnostic variables. Menu screens for calibrating and programming the analyzer are simple and intu­itive. Plain language prompts in English, Spanish, Italian, German, or French guide the user through instrument
configuration and sensor calibration

The Model 54eA is a member of the Rosemount SMART FAMILY®of instruments. It is designed to communicate
with the Model 375 HART®communicator or any host that supports the HART communication protocol.

Two independent isolated outputs provide either a 0-20 mA or 4-20 mA output and can be assigned to chlorine or
temperature. The controller option allows PID control acting on chlorine or temperature.

Three, fully programmable process alarms are standard. One relay can be configured as an interval timer. An
overfeed timer is available for any one process relay, and one relay can also be used as an interval timer. The
TPC option allows any alarm relay to be used for Time Proportional Control.

The analyzer fully compensates chlorine readings for changes in membrane permeability caused by temperature
changes.

For additional information, see Product Data Sheet 71-54e.

MODEL 499A CL-02 SENSOR

The Model 499ACL-02 total chlorine sensor is used in the TCL sample conditioning system. Although the sensor
is called a chlorine sensor, it really measures iodine. The iodine comes from the reaction between halogen
oxidants in the sample and the acetic acid/potassium iodide reagent added by the sample conditioning system.

The sensor consists of a gold cathode and a silver anode in an electrolyte solution. A silicone membrane,
permeable to iodine, is stretched over the cathode. The analyzer applies a voltage to the cathode sufficiently
negative to reduce all the iodine reaching it. Because the concentration of iodine in the sensor is always zero, a
concentration gradient continuously forces iodine from the sample through the membrane into the sensor.

The reduction of iodine in the sensor generates a current directly proportional to the diffusion rate of iodine
through the membrane, which is directly proportional to the concentration of iodine in the sample. Because the
iodine concentration depends on the amount of total chlorine in the sample, the sensor current is ultimately
proportional to the total chlorine concentration.

The permeability of the membrane to iodine is a function of temperature. A Pt100 RTD in the sensor measures
the temperature, and the analyzer uses the temperature to compensate the total chlorine reading for changes in
membrane permeability.

Sensor maintenance is fast and easy. Replacing the membrane requires no special tools or fixtures. Simply place
the membrane assembly on the cathode and screw the retainer in place. Installing a new membrane and
replenishing the electrolyte takes only a few minutes.

MODEL TCL SECTION 1

DESCRIPTION AND SPECIFICATIONS

1.3 SPECIFICATIONS — MODEL 54e-24 ANALYZER

1.2 SPECIFICATIONS — SAMPLE CONDITIONING SYSTEM

3

GENERAL

Enclosure: Fiberglass reinforced polyester, NEMA 3

(IP53) suitable for marine environments

Dimensions: 14.5 x 13.0 x 8.6 in. (369 x 329 x 218 mm)
Mounting: Wall
Ambient Temperature: 32° - 122°F (0 - 50°C)
Ambient Humidity: 0 - 90% (non-condensing)
Power: 115 Vac, 6.9 W, 50/60 Hz;

230 Vac, 7.0 W, 50/60 Hz

Hazardous Location: The TCL sample conditioning sys-

tem has no hazardous location approvals.

Pumps:

EN 809:1998

Weight/Shipping Weight: 14 lb/16 lb (6.5 kg/7.5 kg)

SAMPLE REQUIREMENTS

Inlet Connection: compression fitting, accepts 1/4 in. OD

tubing

Drain Connection: 3/4 in. barbed fitting (must drain to

open atmosphere)

Inlet Pressure: <100 psig (791 kPa abs)
Flow: at least 0.25 gph (15 mL/min)
Temperature: 32 - 122°F (0 - 50°C)
Total Alkalinity: <300 mg/L as CaCO3. For samples con-

taining <50 mg/L alkalinity, consult the factory.

SAMPLE CONDITIONING SYSTEM

Reagent: Potassium iodide in vinegar.
Reagent Usage: 5 gallons lasts approximately 60 days.
Reagent Pump: Fixed speed peristaltic pump, about

0.2 mL/min

Sample Pump: Fixed speed peristaltic pump, about 11 mL/min

Case: Epoxy-painted cast aluminum, NEMA4X (IP65).
Dimensions: 5.7 x 5.7 x 5.2 in. (144 x 144 x 132 mm),

DIN size panel cut-out.

Front Panel: Membrane keypad with tactile feedback.

Three green LEDs indicate alarm status. Red LED
indicates fault condition.

Conduit Openings: Accepts PG 13.5 or 1/2 inch conduit

fittings

Display: Three-line, back-lit, dot matrix LCD, 70 x 35 mm.

First line is measurement reading. Second line is tem­perature and current output. Third line is user-selec­table. Character heights: 1st line - 16 mm (0.6 in.),
2nd and 3rd lines - 7 mm (0.3 in.).

Ambient Temperature and Humidity: 0 to 50°C (32 to

122°F). 95% (maximum) non-condensing.

Analyzer can be operated between -20 and 60°C

(-4 to 140°F) with some degradation in display quality.

Power: 100-127 Vac ± 10%, 50/60 Hz ± 6%, 8 W

200-253 Vac ± 10%, 50/60 Hz ± 6%, 8 W

Hazardous Location: Applies to analyzer only, not to system
Class I, Division 2, Groups A, B, C, & D.
T5 Ta=50°C. Dust ignition proof: Class II,
Division 1, Groups E, F, & G; Class III.

FM: Max. relay contact rating: 28 Vdc
resistive

150 mA - Groups A & B;
400 mA - Group C;
540 mA - Group D

CSA:

Max. relay contact rating:
28 Vdc; 110 Vac; 230 Vac;
6 amps resistive. Enclosure Type 4.

RFI/EMI: EN-61326

LVD: EN-61010-1
Outputs: Two 4-20 mA or 0-20 mA isolated outputs.

Continuously adjustable. Outputs can be assigned to
chlorine or temperature. Output dampening is user­selectable. Maximum load at 115/230 Vac is 600Ω.
Maximum load at 100/200 Vac is 550Ω. Output 1 has
superimposed HART signal (options -261 and -263).
Outputs can be programmed for PID control (options

-262 and -263).

Alarms:

Relay 1 - Process, Interval, or Time Proportional
Control (TPC requires code -262 or -263)

Relay 2 - Process, Interval, or Time Proportional
Control (TPC requires code -262 or -263)

Relay 3 - Process, Interval, or Time Proportional
Control (TPC requires code -262 or -263)

Relay 4 - Sensor/analyzer and process fault alarm

Each relay has a dedicated LED on the front panel.

Relay Contacts: Relays 1-3: Epoxy sealed form A

contacts, SPST, normally open

Relay 4: Epoxy sealed form C, SPDT

Resistive

Inductive
28 Vdc 5.0 Amps 3.0 Amps
115 Vac 5.0 Amps 3.0 Amps
230 Vac 5.0 Amps 1.5 Amps

Weight/Shipping Weight: 5 lb/6 lb (2 kg/2.5 kg)

4

MODEL TCL SECTION 1

DESCRIPTION AND SPECIFICATIONS

1.4 SPECIFICATIONS — MODEL 499ACL-02 SENSOR

1.5 PERFORMANCE SPECIFICATIONS — COMPLETE SYSTEM

Wetted Parts: Gold, Noryl®1(PPO), Viton®2, EPDM, Silicone

Dimensions: 1.0 x 5.6 in. (25.4 x 143 mm)

Cable: 25 ft. (7.6m) standard

Pressure Rating: 0 to 65 psig (101 to 549 kPa)

Temperature Rating: 32 to 122°F (0 to 50°C)

Electrolyte Capacity: Approximately 25 mL

Electrolyte Life: Approximately 4 months

Weight/Shipping Weight: 1 lb/3 lb (0.5 kg/1.5 kg)

1

Noryl is a registered trademark of General Electric.

2

Viton is a registered trademark of DuPont Performance Elastomers.

Linear Range: 0 to 20 ppm (mg/L) as Cl2(for higher ranges, consult factory)

Linearity (per ISO 15839): 0-10 ppm: 2%; 0-20 ppm: 3%

Response Time: Following a step change in concentration, the reading reaches 90% of final value within 7 minutes at

25°C.

Drift: At about 1.5 ppm in clean water and constant temperature, drift is typically less 0.05 ppm over two weeks.

Detection Limit (per ISO 15839): 0.02 ppm (mg/L) in clean water at room temperature

MODEL TCL SECTION 1

DESCRIPTION AND SPECIFICATIONS

1.6 ORDERING INFORMATION AND ACCESSORIES

Model TCL Reagent-Based Chlorine System. The TCL is used for the continuous determination of total chlorine in
water. The TCL consists of a sample conditioning system, a reagent carboy, a sensor, and an analyzer. Reagents must
be ordered separately. Regent kits for 0-5 ppm and 0-10 ppm chlorine are available. For higher ranges, consult
the factory. See ACCESSORIES - Sample Conditioning System.

5

CODE SENSOR (optional selection)

30 499ACL-02-54 sensor with standard cable
31 499ACL-02-54-60 sensor with optimum EMI/RFI cable
32 499ACL-02-54-VP sensor with Variopol 6.0 fitting (interconnecting cable must be ordered separately)

CODE POWER (required selection)

11 115 V 50/60 Hz

12 230 V 50/60 Hz

CODE ANALYZER (optional selection)

250 1055-01-10-24 analyzer, panel mount
251 1055-01-11-24 analyzer, pipe/wall mount
260 54eA-01 analyzer
261 54eA-01-09 analyzer with HART communications
262 54eA-01-20 controller with PID and TPC control
263 54eA-01-09-20 controller with PID and TPC control and HART communications

MODEL

TCL REAGENT-BASED CHLORINE SYSTEM

PN Description Weight* Ship Weight**

24134-00 Air pump, 115 Vac, 50/60 Hz 1 lb (0.5 kg) 1 lb (0.5 kg)
24134-01 Air pump, 230 Vac, 50/60 Hz 1 lb (0.5 kg) 1 lb (0.5 kg)
9160578 Air pump repair kit 1 lb (0.5 kg) 1 lb (0.5 kg)
9322052 Check valve for air injection line 1 lb (0.5 kg) 1 lb (0.5 kg)

24153-00 Carboy for reagent, 5 gal/19 L, includes cap 4 lb (1.5 kg) 5 lb (2.0 kg)

9100204 Fuse, 0.25 A, 250 V, 3AG, slow blow for option -11 (115 Vac) 1 lb (0.5 kg) 1 lb (0.5 kg)
9100132 Fuse, 0.125 A, 250 V, 3AG, slow blow for option -12 (230 Vac) 1 lb (0.5 kg) 1 lb (0.5 kg)
9380094 Reagent pump, 115 Vac, 50/60 Hz 1 lb (0.5 kg) 2 lb (1 kg)
9380095 Reagent pump, 230 Vac, 50/60 Hz 1 lb (0.5 kg) 2 lb (1 kg)

9380091 Reagent pump replacement tubing 1 lb (0.5 kg) 2 lb (1 kg)
24151-00 Reagent tubing replacement kit 1 lb (0.5 kg) 2 lb (1 kg)
24135-00 Reagent uptake tubing, 6 ft (1.8 m), includes weight 1 lb (0.5 kg) 2 lb (1 kg)

9380090 Sample pump, 115 Vac, 50/60 Hz 1 lb (0.5 kg) 2 lb (1 kg)

9380093 Sample pump, 230 Vac, 50/60 Hz 1 lb (0.5 kg) 2 lb (1 kg)

9380092 Sample pump replacement tubing 1 lb (0.5 kg) 2 lb (1 kg)
24152-00 Sample tubing replacement kit 1 lb (0.5 kg) 2 lb (1 kg)

ACCESSORIES — SAMPLE CONDITIONING SYSTEM

PN Description Weight* Ship Weight**

24165-00 Acetic acid, 2 x 2.5 gal (9.5 L) bottles/case, with 25 g potassium iodide 45 lb (20.5 kg) 48 lb (22.0 kg)

(0-5 ppm total chlorine)

24165-01 Acetic acid, 2 x 2.5 gal (9.5 L) bottles/case, with 50 g potassium iodide 45 lb (20.5 kg) 48 lb (22.0 kg)

(0-10 ppm total chlorine)

24164-00 Potassium iodide, 25 g, sufficient for 5 gallons (19 L) of vinegar 1 lb (0.5 kg) 1 lb (0.5 kg)

(0-5 ppm total chlorine)

24164-01 Potassium iodide, 50 g, sufficient for 5 gallons (19 L) of vinegar 1 lb (0.5 kg) 1 lb (0.5 kg)

(0-10 ppm total chlorine)

6

MODEL TCL SECTION 1

DESCRIPTION AND SPECIFICATIONS

ACCESSORIES — Sensor

FOR FIRST TIME VARIOPOL INSTALLATIONS

PN DESCRIPTION WEIGHT* SHIP WEIGHT*

23501-02 Total Chlorine Membrane, includes one membrane assembly and 1 lb (0.5 kg) 1 lb (0.5 kg)

one O-ring

23502-02 Total Chlorine Membrane Kit, includes 3 membrane assemblies and 1 lb (0.5 kg) 1 lb (0.5 kg)

three O-rings

9210438 Total Chlorine Sensor Fill Solution, 4 oz (120 mL) 1 lb (0.5 kg) 2 lb (1.0 kg)

ACCESSORIES — 54eA Analyzer

PN DESCRIPTION WEIGHT* SHIP WEIGHT*

2002577 Wall and two inch pipe mounting kit

2 lb (1.0 kg) 3 lb (1.5 kg)

23545-00 Panel mounting kit

2 lb (1.0 kg) 3 lb (1.5 kg)

23554-00 Cable glands, kit (Qty 5 of PG 13.5) 1 lb (0.5 kg) 1 lb (0.5 kg)

9240048-00 Stainless steel tag (specify marking) 1 lb (0.5 kg) 1 lb (0.5 kg)

PN DESCRIPTION WEIGHT* SHIP WEIGHT*

23747-02 VP 6.0 interconnecting cable, 10 ft (3 m) 1 lb (0.5 kg) 2 lb (1.0 kg)

23747-03 VP 6.0 interconnecting cable, 50 ft (15 m) 5 lb (2.5 kg) 6 lb (3.0 kg)

23747-04 VP 6.0 interconnecting cable, 4 ft (1.2 m) 1 lb (0.5 kg) 1 lb (0.5 kg)

7

SECTION 2. PRINCIPLES OF OPERATION

MODEL TCL SECTION 2

PRINCIPLES OF OPERATION

Total chlorine by definition is the iodine pro­duced in a sample when it is treated with
potassium iodide at a pH between 3.5 and 4.5.
Typically, acetic acid (or vinegar) is used to
adjust the pH.

The total chlorine analyzer consists of a sam­ple conditioning system, which injects the
reagent into the sample, and a sensor and
analyzer, which measure the amount of iodine
produced. Figure 2-1 shows the sample condi­tioning system. The sample enters the sample
conditioning enclosure and flows to an over­flow sampler from which the sample pump
takes suction. Excess sample drains to waste.
At the same time, the reagent pump draws
reagent, a solution of potassium iodide in vine­gar, 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.

The treated sample next enters the flow cell. Bubbles injected into the flow cell produce turbulence, which
improves the stability of the reading. A membrane-covered amperometric sensor in the flow cell measures the
concentration of iodine. The analyzer receives the raw signal from the sensor and displays the concentration of
total chlorine. Display units are ppm (mg/L) chlorine as Cl2. The treated sample leaves the flow cell and drains to
waste along with the excess sample.

FIGURE 2-1. Schematic of Sample Conditioning

System and Analyzer.

8

3.1 UNPACKING AND INSPECTION

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

3.2 INSTALLATION.

3.2.1 General Information

1. Although the analyzer and sample conditioning system are suitable for outdoor use, do not install them in direct
sunlight or in areas of extreme temperature.

2. Install the analyzer and sample conditioning system in an area where vibration and electromagnetic and radio
frequency interference are minimized or absent.

3. Keep the analyzer and sensor wiring at least one foot from high voltage conductors. Be sure there is easy
access to the analyzer and sample conditioning system.

4. The analyzer is suitable for panel, pipe or wall mounting. The sample conditioning enclosure must be mount­ed on a wall. Provide adequate room beneath the enclosure for the 5-gallon reagent carboy.

5. Be sure that the distance between the analyzer and sample conditioning cabinet does not exceed the length
of the sensor cable.

3.2.2 Install the Analyzer

1. Refer to the appropriate figure for installation details.

2. See Section 4.3 for wiring instructions.

SECTION 3. INSTALLATION

MODEL TCL SECTION 3

INSTALLATION

CAUTION

The TCL Total Chlorine analyzer is NOT

suitable for use in hazardous areas.

Type of Mounting Figure(s)

Wall 3-1

Pipe 3-2 and 3-3

Panel 3-4 and 3-5

MODEL TCL SECTION 3

INSTALLATION

9

FIGURE 3-1. Wall Mounting

FIGURE 3-2. Pipe Mounting

9.52
.375

SIDE VIEW

FRONT VIEW

4 MOUNTING

HOLES

WHEN INCH AND METRIC DIMS

ARE GIVEN

MILLIMETER

INCH

PIPE MOUNTING PN 2002577 WALL MOUNTING

FIGURE 3-3. Pipe and Wall Mounting Dimensions

DWG. NO. REV.

40005402 E

MODEL TCL SECTION 3

INSTALLATION

10

FIGURE 3-4. Panel Mounting

WHEN INCH AND METRIC DIMS

ARE GIVEN

MILLIMETER

INCH

FIGURE 3-5. Panel Mounting Dimensions

11

MODEL TCL SECTION 3

INSTALLATION

3.2.3 Install the Sample Conditioning Enclosure

1. Refer to Figures 3-6 and 3-7 for installation details.

2. Connect the sample line to the sample conditioning system. Use ¼-inch OD hard plastic or stainless steel tub­ing. If dechlorinated water is being measured, provide a way of substituting a chlorinated water sample for the
dechlorinated sample. Chlorinated water is needed to calibrate the sensor and to check its response.

3. If a grab sample tap is not already available, install one in the process piping. Choose a point as close as pos­sible to the sample line supplying the TCL. Be sure that opening the sample valve does not appreciably alter
the flow of sample to the instrument.

4. Connect the drain to a length of ¾-inch ID flexible plastic tubing. The sample must drain to open atmosphere.

5. Find the reagent tubing and fitting in the plastic bag taped to the inside of the enclosure door. Screw the
reagent fitting onto the bulkhead fitting at the bottom left of the enclosure. Pass the reagent tubing through the
hole in the carboy cap. Be sure the plastic weight will be inside the carboy when the cap is placed on the car­boy. Attach the reagent tubing to the barbed connector. See Figure 3-8.

6. Place the blue plastic carboy beneath the enclosure. Place the weighted end of the reagent tubing inside the
carboy. To prepare reagent, see Section 5.2.

3.2.4 Install the Sensor

1. From inside the sample conditioning enclosure, thread the sensor cable through the gland on the upper left
side. Leave about one foot of cable inside the enclosure.

2. Wire the sensor to the analyzer. Refer to Section 4.3.

3. Remove the nut and adapter from the flow cell. Slip the nut over the end of the sensor. Thread the adapter
onto the sensor. Hand tighten only. Remove the protective cap from the end of the sensor.

4. Insert the sensor in the flow cell. Hand tighten the nut.

FIGURE 3-6. Installing the Sample Conditioning Enclosure

MODEL TCL SECTION 3

INSTALLATION

12

FIGURE 3-7. TCL Case Dimensions

INCH

MILLIMETER

FIGURE 3-8. Attaching reagent tubing

13

MODEL TCL SECTION 4

WIRING

SECTION 4. WIRING

4.1 GENERAL

WARNING

Electrical installation must conform to the National Electrical Code, all state and local codes, and all plant
codes and standards for electrical equipment. Electrical installation and wiring must be done by qualified
personnel.

The five holes in the bottom of the instrument case accept 1/2-in. strain relief connectors or conduit fittings. The
rear openings are for power and alarm relay wiring. The left front opening is for sensor wiring and the right front
opening is for analog output wiring. Seal unused openings with conduit plugs.

4.2 PROVIDE POWER TO THE SAMPLE CONDITIONING SYSTEM

NOTE

Provide a switch or breaker to disconnect the sample conditioning cabinet from
the main power supply. Install the switch or breaker near the unit and identify if as
the disconnecting device for the sample conditioning system.

1. Be sure the pump switches on the wiring access panel are in the off position.

2. Remove the four screws securing the wiring access panel. Pull the panel out of the way to reveal the power
terminal strip.

3. Insert the power cable through the
strain relief connection labeled
power (see Figure 3-7). Wire the
power cable to the terminal strip as
shown in Figure 4-1. Do not apply
230 Vac power to a 115 Vac TCL
(Model option -11). Doing so will
damage the instrument.

4. Leave the pump power switches

off until ready to start up the unit.

See Section 5.

NOTE

The Model 54eA analyzer leaves the factory configured for use with the Model 499ADO oxygen sensor.
Because a 499ADO sensor is NOT used in the TCL system, turn to Section 7.5 and configure the analyz­er to read total chlorine before wiring the sensor to the analyzer. Operating the analyzer and sensor for
longer than five minutes while the analyzer is improperly configured will greatly increase the stabilization
time for the sensor.

Be sure to turn off power to the analyzer before wiring the sensor.

FIGURE 4-1. Power Wiring

WARNING: RISK OF ELECTRICAL SHOCK

AC connections and grounding must be in compliance with
UL 508 or local electrical code. DO NOT apply power to the
analyzer until all electrical connections are verified and secure.

Model option -11 115 Vac only
Model option -12 230 Vac only

MODEL TCL SECTION 4

WIRING

4.3 MAKE POWER, ALARM, OUTPUT AND SENSOR CONNECTIONS IN THE ANALYZER

Refer to Figure 4-2. Make power and alarm connections on TB3. Make analog output wiring connections on TB2. For
access to power and alarm terminals, loosen the screw holding the protective cover in place and remove the cover.

DANGER

Live voltages may be present.
Will cause severe injury or death.

Alarm contacts are dry (i.e., not powered) and are normally open. Refer to Section 1.0 for relay specifications.
For best EMI/RFI protection, shield the output cable and enclose it in an earth-grounded, rigid, metal conduit.

Connect the outer shield of the output cable to the earth ground connection on TB2 (see Figure 4-2).
Keep sensor and output signal wiring separate from power wiring. Do no run sensor and power cables in the same

conduit or close together in a cable tray.
AC wiring must be 14 gauge or greater. Be sure to connect earth ground from the power cable to the nearby

ground lug. A good earth ground is necessary for proper operation of the controller. 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.

WARNING: RISK OF ELECTRICAL SHOCK

AC connections and grounding must comply with UL 508 or local electrical code. DO NOT apply
power to the analyzer until all electrical connections are verified and secure.

NOTE

The Model 54eA analyzer leaves the factory configured for use with the Model 499ADO oxygen
sensor. Because a 499ADO sensor is NOT used in the TCL system, turn to Section 7.5 and con­figure the analyzer to read total chlorine before wiring the sensor to the analyzer. Operating the
analyzer and sensor for longer than five minutes while the analyzer is improperly configured will
greatly increase the stabilization time for the sensor.

Be sure to turn off power to the analyzer before wiring the sensor.

The wiring label, which is shown in Figure 4-3, is a general purpose label. It has wiring information concerning
other sensors, for example, contacting and inductive conductivity sensors, that can be used with the 54e instru­ment platform. For total chlorine measurements, only TB3 is used.

Refer to Figures 4-4 and 4-5 for sensor wiring. Use the pigtail wire and wire nuts provided with the sensor when
more than one wire must be attached to a single terminal

14

15

MODEL TCL SECTION 4

WIRING

FIGURE 4-2. Power Input and Relay Output Wiring for Model 54eA

DWG. NO. REV.

454EPH02 D

MODEL TCL SECTION 4

WIRING

FIGURE 4-4. Total chlorine sensor

(499ACL-02) with standard cable.

FIGURE 4-5. Total chlorine sensor (499ACL-02)

with optimum EMI/RFI cable or Variopol cable.

FIGURE 4-3. Wiring Label

DWG. NO. REV.

40054e03 A

DWG. NO. REV.

40499A23 A

DWG. NO. REV.

40499A24 A

16

MODEL TCL SECTION 5

START-UP

SECTION 5. START-UP

5.1 PREPARE THE REAGENT

1. DO NOT PREPARE THE SOLUTION UNTIL READY TO USE.

2. Position the blue plastic carboy under the sample conditioning cabinet. Unscrew the cap and reagent tube
assembly.

3. Add the potassium iodide reagent to the carboy. See the table.

4. Add five gallons (19 L) of distilled white vinegar one gallon (4 L) at a time. Swirl the carboy after each addition

5. Screw the cap on the carboy. Be sure the reagent uptake tube extends to the bottom of the carboy.

6. Connect the reagent tube to the small fitting on the bottom left hand side of the enclosure.

NOTE

The shelf life of the potassium iodide vinegar solution is at least two months if stored in the blue
carboy. Do not store the reagent in a container other than the blue carboy. The reagent is sensi­tive to sunlight, which the blue carboy effectively blocks.

5.2 ZERO THE SENSOR

1. Place the sensor in a beaker of deionized water or simply place the sensor in air.

2. Let the sensor operate until the sensor current is stable, then zero the sensor. See Section 8.3.2 for detailed
instructions.

5.3 START SAMPLE FLOW

Adjust the sample flow until a slow stream of liquid is running down the inside tube of the sampling cup.

5.4 BEGIN OPERATION AND CALIBRATE THE SENSOR

1. Turn on the reagent and sample pump switches. Observe that liquid begins to fill the flow cell. The sample flow
is about 11 mL/min, so the flow cell will fill rather slowly. Also observe that the air pump is operating. The pump
will produce very vigorous bubbling in the flow cell.

2. Once the flow of reagent starts, it takes about two minutes for the reagent to reach the flow cell. If the con­centration of total chlorine in the sample is greater than about 0.5 ppm, the treated sample in the flow cell will
be pale yellow. Sample containing more chlorine will be dark yellow.

3. Monitor the sensor current. Once the reading is stable, calibrate the unit. See Section 9.3.3 for detailed instruc­tions. It may take thirty minutes or longer for the reading to stabilize when the sensor is first put in service.

WARNING

The reagent contains potassium iodide dissolved in distilled vinegar or 5%
acetic acid. Avoid contact with skin and eyes. Wash thoroughly after using.

NOTE

Complete Section 4 before starting this section.

Expected range, Amount of KI needed Part number

ppm as Cl2 per 5 gal (19 L) of vinegar

0 – 5 ppm 25 grams 24164-00

0 – 10 ppm 50 grams 24164-01

0 – 20 ppm 2 x 50 grams 24164-01

171818

MODEL TCL SECTION 6

DISPLAY AND OPERATION

SECTION 6. DISPLAY AND OPERATION

6.1 GENERAL DESCRIPTION

The 54eA analyzer/controller is a single input, dual out­put instrument. Figure 6-1 shows how the instrument
inputs and outputs can be configured for total chlorine.

In addition to PID control, the 54eA controller can be
used for time proportional control (TPC). TPC control
uses the alarm relays.

6.2 DISPLAY

Figure 6-2 shows the main display.

6.3 KEY FUNCTIONS AND CONTROLS

The keys labeled F1, F2, F3, and F4 are multi-function.
The function appears in the main display just above the
key. For example, F1 is usually labeled Exit and F4
may be labeled Edit, Save, or Enter.

1. To enter the main menu, press any key.

2. Use the  and  keys to move the cursor to the

desired sub-menu. The position of the cursor is
shown in reverse video.

NOTE

When the last item of a menu has been
reached, the cursor will be on the third line
of the display. If the cursor is on the second
line of the display more items remain.
Continue pressing the  key.

3. Press Enter (F4) to access a sub-menu or an item
in a sub-menu.

4. To change a number or a setting press Edit (F4).
The display will change to show the cursor on the
first digit or on a + or - sign. Use the  and  keys
to increase or decrease a digit or to toggle the +
and - signs. Use the  and  keys to move the
cursor left and right.

5. If an entire number or a word is highlighted, use the
 and  keys to scroll through the list of choices.

6. To store a number or setting in memory, press
Save (F4).

7. To leave without storing changes, press Esc (F3).

8. To leave and return to the previous screen, press
Exit (F1).

9. To end a calibration step and leave the previous
calibration in place, press Abort (F1).

10. Occasionally, information screens will appear. To
leave the information screen and move to the next
screen press Cont (F3).

6.4 ALARM STATUS

Green LEDs (labeled 1, 2, and 3) indicate when alarm
relays 1, 2, and 3 are energized. The fourth relay indi­cates a fault condition. When a fault occurs, the red
LED (labeled FAIL) lights up, a descriptive error mes­sage appears, and the outputs and alarm relays act as
described in Section 7.6 and Section 7.7 under fault
value.

The red LED also indicates when the interval timer rou­tine is activated and when the time limit has been
reached on a feed limit timer. For more information on
these subjects, see Section 7.7.

FIGURE 6-1. Configuration of Outputs

for Total Chlorine

Outputs can be assigned to total chlorine or to
temperature. The outputs can be configured as
either linear (4-20 mA) or PID outputs.

FIGURE 6-2. Main Display Screen

The total chlorine measurement is always displayed con­tinuously in large numerals. The temperature and output
current are always displayed on the second line of the main
display. The third line can be configured by the user. In the
example, the third line shows the alarm 1 setpoint and the
total chlorine sensor current in nA.

1.00 ppm

26.2°C. 12.00 mA
AL1: 0.50 I: 340 nA