Rosemount FCL Free Chlorine System with 54eA Analyzer Manuals & Guides

FCL with 54eA Analyzer

Instruction Manual

PN 51-FCL-54eA rev.B
March 2012

This product generates, uses, and can radiate radio frequency

energy and thus can cause radio communication interference.

Improper installation, or operation, may increase such interfer-

ence. 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.

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.

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.

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

Emerson Process Management

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

http://www.rosemountanalytical.com

© Rosemount Analytical Inc. 2012

WARNING

RISK OF ELECTRICAL SHOCK

WARNING

CAUTION

About This Document

This manual contains instructions for installation and operation of the Model FCL-54eA

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

Rev. Level

Date Notes

A 5/09 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 3/12 Update addresses - mail and web and DNV certificate logo.

i

MODEL FCL-54eA TABLE OF CONTENTS

FCL-54eA

TABLE OF CONTENTS

Section Title Page

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

1.1 Applications and Features ..................................................................................... 1

1.2 Specifications-General............................................................................................. 2

1.3 Ordering Information ................................................................................................ 3

2.0 INSTALLATION ....................................................................................................... 5

2.1 Unpacking and Inspection........................................................................................ 5

2.2 Installation................................................................................................................ 5

3.0 WIRING.................................................................................................................... 9

3.1 General .................................................................................................................... 9

3.2 Power, Alarm, and Output Wiring............................................................................. 9

4.0 DISPLAY AND OPERATION ................................................................................... 13

4.1 General Description ................................................................................................. 13

4.2 Display ..................................................................................................................... 13

4.3 Key Functions and Controls..................................................................................... 13

4.4 Alarm Status............................................................................................................. 13

5.0 PROGRAMMING THE ANALYZER ........................................................................ 15

5.1 Changing Alarm Setpoints ....................................................................................... 21

5.2 Ranging the Outputs ................................................................................................ 22

5.3 Test Outputs and Alarms.......................................................................................... 23

5.4 Chosing Display Options.......................................................................................... 24-25

5.5 Changing Output Parameters .................................................................................. 26-27

5.6 Changing Alarm Parameters .................................................................................... 28-31

5.7 Configuring the pH Measurement ............................................................................ 32

5.8 Temperature Compensation and Temperature Units ............................................... 33

5.9 Noise Reduction....................................................................................................... 34

5.10 Main Sensor Calibration Parameters ....................................................................... 35

5.11 Security ....................................................................................................................36

5.12 Analyzer Mode Priority............................................................................................. 37

6.0 CALIBRATION - TEMPERATURE .......................................................................... 39

6.1 Introduction .............................................................................................................. 39

6.2 Temperature Calibration........................................................................................... 40

Section Title Page

7.0 CALIBRATION CHLORINE .................................................................................... 41

7.1 Introduction .............................................................................................................. 41

7.2 Zeroing the Sensor .................................................................................................. 42

7.3 Full Scale Calibration ............................................................................................... 43

7.4 Dual Slope Calibration ............................................................................................. 44

8.0 CALIBRATION - CURRENT OUTPUTS ................................................................. 47

8.1 Introduction .............................................................................................................. 47

8.2 Trimming the Outputs............................................................................................... 47

9.0 MAINTENANCE ..................................................................................................... 49

9.1 Analyzer ................................................................................................................... 49

9.2 Chlorine Sensor ....................................................................................................... 50

9.3 Constant Head Flow Controller................................................................................ 52

10.0 TROUBLESHOOTING ........................................................................................... 55

10.1 Overview .................................................................................................................. 55

10.2 Troubleshooting When a Fault Message is Showing............................................... 55

10.3 Troubleshooting When No Fault Message is Showing - Temperature..................... 56

10.4 Troubleshooting When No Error Message is Showing - Chlorine............................ 56

10.5 Troubleshooting When No Error Message is Showing - General ............................ 59

10.6 Simulating Inputs - Chlorine..................................................................................... 59

10.7 Simulating Inputs - Temperature............................................................................... 60

LIST OF TABLES

Number Title Page

5.1 Program Settings List ............................................................................................... 15-17

5.2 Controller Mode Priority Chart.................................................................................. 37

10.2 Troubleshooting When a Fault Message is Showing ............................................... 55

10.4 Troubleshooting When No Error Message is Showing - Chlorine ............................ 56

10.5 Troubleshooting When No Error Message is Showing - General............................. 59

MODEL FCL-54eA TABLE OF CONTENTS

TABLE OF CONTENTS CONT’D

ii

LIST OF FIGURES

Number Title Page

2-1 Chlorine Sensor Parts .............................................................................................. 7

2-2 Model FCLi-01-230................................................................................................... 8

3-1 Power Input and Relay Output Wiring for Model 54eA ............................................ 10

3-2 Wiring Label .................................................................................................... 11

3-3 Wiring Sensor to Model 54eA Analyzer ...................................................................... 11

4-1 Main Display Screen ................................................................................................ 13

5-1 Menu Tree for the 54eA Controller .......................................................................... 18-20

5-2 Low Alarm ................................................................................................................ 30

5-3 High Alarm................................................................................................................ 30

5-4 Interval Timer............................................................................................................ 31

7-1 Sensor Current as a Function of Free Chlorine Concentration ................................ 41

7-2 Dual Slope Calibration.............................................................................................. 44

9-1 Chlorine Sensor Parts ............................................................................................. 51

9-2 Replacement Parts for the Flow Controller Assembly.............................................. 53

10-3 Three-Wire RTD Configuration................................................................................. 60

10-4 Simulating RTD Inputs.............................................................................................. 60

iii

Model FCL-54eA SECTION 1.0

DESCRIPTION AND SPECIFICATIONS

SECTION 1.0.

DESCRIPTION AND SPECIFICATIONS

1

• COMPLETE SYSTEM INCLUDES sensors, connecting cables, 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.

1

In 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 destroys any chlorine
that diffuses through the membrane, keeping 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.

There is a difficulty, however. Amperometric free
chlorine sensors measure only hypochlorous acid.
Because free chlorine is a pH-dependent mixture of
hypochlorous acid and hypochlorite ion, a change in
pH will cause the sensor response to change even
though the free chlorine level remained constant.
Most manufacturers solve the problem by treating the
sample with acid, which lowers the pH and converts
hypochlorite ion into hypochlorous acid. The

FCL

avoids the expense and inconvenience of

sample

conditioning by measuring the pH and applying a cor-

rection to the raw chlorine sensor signal. The correc­tion is valid between pH 6.0 and 9.5. Below pH 6.0,
no correction is needed. For samples having pH
between 9.5 and 10.0, consult the factory.

The 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 54eA

analyz-

er. The analyzer features two fully programmable

4-20
mA analog outputs and three alarm relays.
Programming and calibration are simple and intuitive.
The large backlit display allows the user to read
chlorine at a single 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 the sensors. 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.

2

MODEL FCL-54eA SECTION 1.0

DESCRIPTION AND SPECIFICATIONS

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 a
barbed fitting for use with soft tubing).

Drain connection: 3/4-in barbed fitting. Sample must

drain to open atmosphere.

Wetted parts:

Overflow sampler and flow cell: acrylic, polycar-

bonate, Kynar®1, nylon, silicone

Chlorine sensor: Noryl®2, Viton®3, wood, silicone,

polyethersulfone, polyester, and platinum

pH sensor: Tefzel®4, Viton, glass, ceramic

Response time to step change in chlorine concen-

tration: <80 sec to 95% of final reading for inlet

sample flow of 3 gph (11 L/hr).

Weight/shipping weight:

Model FCL-01-230: 10 lb/13 lb (4.5 kg/6.0 kg)

Model FCL-02-230: 11 lb/14 lb (5.0 kg/6.5 kg)

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

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.
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.

Electrolyte volume: 25 mL (approx.)

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

replace electrolyte monthly.

SPECIFICATIONS — MODEL 54eA
ANALYZER

Case: Epoxy-painted cast aluminum, NEMA4X (IP65).
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 con-

duit 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 user­selectable. 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

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 user-selectable. Maximum load
at 115/230 Vac is 600Ω. Maximum load at
100/200 Vac is 550Ω.

Alarms: Three alarm relays for process measurement,

temperature or interval timer. The fourth alarm
relay is a sensor/analyzer fault alarm.

Relay Contacts: Relays 1-3: Form A, SPST, NO,

epoxy sealed. Relay 4: Form C, SPDT, epoxy
sealed

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

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

Resistive Inductive

28 Vdc 5.0 3.0

115 Vac 5.0 3.0

230 Vac 5.0 1.5

SECTION 2.0.

INSTALLATION

MODEL FCL-54eA SECTION 2.0

INSTALLATION

3

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-01-230 (free chlorine without continuous pH correction)

Model FCL-01-230 consists of the following items mounted on a back plate.

1. Model 54eA-01 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), shipped with three membrane assemblies and a bottle of
electrolyte solution, are in a separate package.

2.1.2 FCL-02-230 (free chlorine with continuous pH correction)

Model FCL-02-230 consists of the following items mounted on a back plate.

1. Model 54eA-01 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 399VP-09 pH sensor are in separate packages.

4

MODEL FCL-54eA 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.

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 Model 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.

Remove the foam packing insert between the outer tube and the inner overflow tube. 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 Model FCL is provided with sensor cables pre-wired to the analyzer. Connect the chlorine sensor (Model
499ACL-01-54-VP) to the cable labeled CHLORINE. Connect the pH sensor (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.

Model FCL-54eA SECTION 2.0

INSTALLATION

FIGURE 2-1. Model FCL-01

FIGURE 2-2. Model FCL-02

INCH

MILLIMETER

INCH

MILLIMETER

5

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6

MODEL FCL-54eA SECTION 2.0

INSTALLATION

SECTION 3.0.

WIRING

MODEL FCL-54eA SECTION 3.0

WIRING

7

3.1 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 (already installed)
and the right front opening is for analog output wiring. Seal unused openings with conduit plugs.

3.2 POWER, ALARM, AND OUTPUT WIRING

Refer to Figure 3-1. 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.

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 3-1).
Keep sensor and output signal wiring separate from power wiring. Do not 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.

NOTE

The Model 54eA analyzer leaves the factory configured to measure dissolved oxygen, not free
chlorine. Before connecting the sensor to the cable, configure the analyzer to measure free chlo­rine. See section 5.4

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

DANGER

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.

WARNING

MODEL FCL-54eA SECTION 3.0

WIRING

8

FIGURE 3-1. Power Input and Relay Output Wiring for Model 54eA

DWG. NO. REV.

454EPH02 D

9

MODEL FCL-54eA SECTION 3.0

WIRING

FIGURE 3-2. Wiring Label

3.3 SENSOR WIRING

3.3.1 General

The wiring label 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. The Model FCLi is
provided with sensor cable pre-wired to the
analyzer. If it is necessary to replace the
cable, refer to Figures 3-2 (wiring label) and
3-3 and 3-4 (wiring diagrams).

DWG. NO. REV.

40054e03 A

FIGURE 3-3. Wiring Chlorine Sensor to

Model 54eA Analyzer

FIGURE 3-4. Wiring Chlorine and pH Sensor to 54eA Analyzer.

DWG. NO. REV.

4054eA02 B

DWG. NO. REV.

40499A24 A

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10

MODEL FCL-54eA SECTION 3.0

WIRING

11

MODEL FCL-54eA SECTION 4.0

DISPLAY AND OPERATION

SECTION 4.0

DISPLAY AND OPERATION

4.1 GENERAL DESCRIPTION

The 54eA analyzer is a single input, dual output instru­ment. It does, however, accept a second input for pH
when the main measurement is free chlorine.

4.2 DISPLAY

Figure 4-2 shows the main display.

4.3 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 é and ê 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 ê 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 é and ê keys
to increase or decrease a digit or to toggle the +
and - signs. Use the ç and è keys to move the
cursor left and right.

5. If an entire number or a word is highlighted, use the
é and ê 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).

4.4 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
programed in Sections 5.5 and 5.6.

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 5.6.

FIGURE 4-1. Main Display Screen

Chlorine 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 pH readings and the raw
sensor current in nA.

1.00 ppm

26.2°C. 12.00 mA
pH: 8.00 I: 340 nA

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12

MODEL FCL-54eA SECTION 4.0

DISPLAY AND OPERATION

13

SECTION 5.0

PROGRAMMING THE ANALYZER

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

The Model 54eA analyzer can be used to measure dissolved oxygen, ozone, total chlorine, and monochloramine
in addition to free chlorine. It is configured at the factory to measure dissolved oxygen. Before connecting the
sensor to the cable, the analyzer must be configured to measure free chlorine. See section 5.4.

Figure 5-1 is an outline of the analyzer menu structure. Settings that do not apply to the measurement of free chlorine
are grayed out. Settings that apply to PID and TPC control and HART digital communications, features not
available in the analyzer option provided with the FCL, are also grayed out.

Table 5-1 list the default settings and the choices available for each setting. Only the choices available for free
chlorine are shown.

TABLE 5-1. Program Settings List

Continued on the following page

ITEMS CHOICES FACTORY SETTINGS

A. Alarms setpoints (Section 5.1)

1. Alarm 1 (low action)
a. if chlorine -9999 to 9999 ppm 0 ppm
b. if temperature -5 to 130°C 0.1°C

2. Alarm 2 (high action)
a. if chlorine -9999 to 9999 ppm 20 ppm
b. if temperature -5 to 130°C 130°C

3. Alarm 3 See alarm 2 See alarm 2

B. Output ranging (Section 5.2)

1. Output 1 or 2: 4 mA setting
a. if chlorine -9999 to 9999 ppm 0 ppm
b. if temperature -5 to 130°C 0.1°C

2. Output 1 or 2: 20 mA setting
a. if chlorine -9999 to 9999 ppm 20 ppm
b. if temperature -5 to 130°C 130°C

C. Display options (Section 5.4)

1. Measurement Oxygen, ozone, free chlorine, total chlorine, monochloramine Oxygen

2. Temperature units °C or °F °C

3. Output 1 mA or % of full scale mA

4. Output 2 mA or % of full scale mA

5. Language English, Français, Español, Deutsch, Italiano English

6. Main display left See section 5.4 Sensor current

7. Main display right See section 5.4 Output 1 current

8. Display contrast 00-99 (darkest) 50

9. Test timeout On or off On

10. Timeout value 1 to 60 min 10 min

D Output parameters (Section 5.5)

1. Output 1 Control
a. Measurement Oxygen, chlorine, ozone, pH, or temperature Oxygen
b. Control Normal Normal

14

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

ITEMS CHOICES FACTORY SETTINGS

D. Outputs (Section 5.5) (continued)

2. Output 1 Setup (normal)
a. Current 4-20 mA or 0-20 mA* 4-20 mA
b. Dampening 0-299 sec 0 sec
c. Hold mode Hold last value or go to fixed value Hold last value
d. Fixed hold value 0-22 mA 21 mA
e. Fault value 0-22 mA 22 mA

3. Output 2 See output 1 See output 1

4. Hold feature Enable, disable, or 20 min timeout Disable

E. Alarms parameters (Section 5.6)

1. Alarm 1 Control
a. Activation method Oxygen, chlorine, ozone, temperature, pH Oxygen
b. Control mode Normal Normal

2. Alarm 1 setup (normal)
a. Configuration Low, high, or off High
b. Hysteresis

if chlorine -9999 to 9999 ppm 0 ppm

if temperature 0 to 10°C 0.1°C
c. Delay time 0-99 sec 0 sec
d. Relay fault none, open, closed None

3. Alarm 2 Control
a. Activation method Oxygen, chlorine, monochloramine, ozone, temperature, pH Oxygen
b. Control mode Normal Normal

4. Alarm 2 setup (normal)
a. Configuration Low, high, or off Low
Rest of alarm 2 setup is the same as alarm 1

5. Alarm 3 control and setup is the same as alarm 1

6. Alarm 4 control

Alarm Fault or off Fault

7. Feed limit timer
a. Feed limit Disable, alarm 1, alarm 2, or alarm 3 Disable
b. Timeout value 0 to 10,800 sec 600 sec

8. Interval timer
a. Select alarm Disable, alarm 1, alarm 2, or alarm 3 Disable
b. Interval time 0 to 999.9 hr 24.0 hr
c. Repeats 1 to 60 1
d. On time 0 to 2999 sec 120 sec
e. Off time 0 to 2999 sec 1 sec
f. Recovery time 0 to 999 sec 600 sec

F. Temperature compensation (Section 5.8)

1. Temperature compensation Auto or manual Auto

2. Manual temperature -15 to 130°C 25°C

TABLE 5-1. Program Settings List (continued)

Continued on the following page

15

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

TABLE 5-1. Program Settings List (continued)

ITEMS CHOICES FACTORY SETTINGS

G. Noise Reduction (section 5.9)

Noise rejection 50 or 60 Hz 60 Hz

H. Main sensor calibration (Section 5.10)

1. Stabilize reading (Chlorine) 0 to 999 ppm 0.05 ppm

2. Stabilize time 0 - 30 sec 10 sec

3. Sensor zero stabilization value

4. Dual range calibration Enable or disable disable

I. Security (Section 5.11)

1. Lock all 000-999 (000 disables) 000

2. Lock program 000-999 (000 disables) 000

3. Lock configuration 000-999 (000 disables) 000

16

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

FIGURE 5-1. Menu Tree for the 54eA Controller

Calibrate

Program (see page 17)

Diagnostic Variables

Main

Menu

Calibrate main sensor

Zero main sensor

Adjust temperature

Calibrate pH

Slope

Buffer calibration

Standardize

Main measurement
Main sensor current
Sensitivity (µA/ppm)
Zero current
pH reading
pH mV reading
pH slope (mV/pH)
pH offset
Glass impedance
Noise rejection
Software version

Output trim

17

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

Program

Calibrate (see page 16)

Diagnostic Variable (see page 16)

Main

Menu

Alarms 1, 2, and 3 setpoints

4 mA or 0 mA
20 mA
Present output current

Alarm Setpoints

Output setpoints

Test output 1 or 2
Test alarm 1, 2, 3, or 4

Simulated tests

Configure

Display

Main

Sensor

Oxygen

Free Chlorine

Total Chlorine

Monochloramine

Ozone

Outputs

Output 1 and 2

control

Measurement: main snr, pH, temp.

Control mode: normal, PID

Output 1 and 2

setup

Range (0-20 or 4-20 mA)
Dampen*
Hold - keep last value
Hold - go to specified value
Fault

Setpoint, proportional, integral
Derivative**

Hold feature setup

*Normal only

**PID only

Alarms

Alarm 1, 2, & 3

control

Measurement: main snr, pH, temp.

Control mode: normal, TPC

Alarm 1, 2, & 3

setup

Alarm: High, low, or off*
Setpoint
Hysteresis*
Delay*

Time period, URV, LRV**

Relay default

Interval timer

Timer: Alarm 1, 2, or 3 or disable
Interval
Repeats
On time
Off time
Recovery time

Alarm 4 setup

Feed limit timer

Feed limit: Alarm 1, 2, or 3 or disable
Timeout

*Normal only **TPC only

Continued on page 20

FIGURE 5-1. Menu Tree for the 54eA Controller

(continued)

Sensor type and manufac.
Units: ppm, ppb, % sat

°C or °F
Output 1 (mA or %FS)
Output 2 (mA or %FS)
Language
Line 3 display
Display contrast
Timeout (on or off)
Timeout - limit

Polling address

18

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

FIGURE 5-1. Menu Tree for the 54eA Controller (continued)

Display (see page 17)

Outputs (see page 17)

Alarms (see page 17)

Program

Calibrate (see page 16)

Diagnostic Variable (see page 16)

Main

Menu

Alarm Setpoints (see page 17)

Output setpoints

(see page 17)

Simulated tests

(see page 17)

Configure

pH

(available with free

chlorine only)

Disable

Enable

pH

diagnostics

Diagnostics: on or off
Glass impedance high
Glass impedance low
Zero offset
Impedance temp comp: on or off

Temperature

Temperature comp: auto or manual
Units: °C or °F

Noise

Rejection

Noise rejection: 50 or 60 Hz

Barometric

Pressure

Measurement: Auto or manual
Units: mm Hg, kPa, atm, barg, in Hg

Main sensor cal

Stabilize conc’n
Stabilize time

Salinity (oxygen only)

Security

pH

calibration

Autocal: standard, manual, Merck,
Ingold, DIN 19267
Stabilize pH
Stabilize time

Temperature

coefficient

Temperature coeff
Operating isopotential
Sensor isopotential

Lock all
Lock program
Lock configure

(oxygen only)

19

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

5.1 CHANGING ALARM SETPOINTS

2. Press any key to enter the main menu. Move the cursor to "Program"
and press Enter (F4).

3. Press Enter (F4).

4. Move the cursor to the desired alarm and press Enter (F4).

5. A screen like the one shown will appear. The alarm is a low alarm
and the setpoint is 0.00 ppm. Press Edit (F4). Use the arrow keys to
change the setpoint. Press Save (F4) to store the new value. Press
Exit (F1) to return to the screen in step 4. Choose a new alarm.

Alarm setpoints

Output setpoints
Simulate tests

Exit Enter

Alarm 1 setpoint

Alarm 2 setpoint

Alarm 3 setpoint

Exit Enter

Alarm Low : 0.000 ppm

Exit Edit

1. Before changing alarm setpoints, be sure that alarms are properly configured. See Section 5.6.

20

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

5.2 RANGING THE OUTPUTS

2. Press any key to enter the main menu. Move the cursor to "Program"
and press Enter (F4).

3. Move the cursor to "Output setpoints" and press Enter (F4).

4. Move the cursor to the desired output and press Enter (F4).

5. This screen confirms that changes to output 1 are going to be made.
Use caution. Changes may degrade process control. Press Cont
(F3) to continue. Otherwise, press Abort (F1).

6. This screen shows the present settings for Output 1. If the output
was configured to be 0-20 mA, the first line will show "0mA" instead
of "4mA". The live current output is shown on the third line.

Move the cursor to the desired line and press Edit (F4). Use the
arrow keys to change the setpoint. Press Save (F4) to store the new
value.

Press Exit (F1) to return to the screen in step 4. Choose the other
output and continue.

Output 1 setpoints

Output 2 setpoints

Exit Enter

Alarm setpoints

Output setpoints

Simulated test

Exit Enter

CAUTION: Current
Output 1 will be
affected.

Abort Cont

1. Ranging the outputs means assigning values to the low (0 or 4 mA) and high (20 mA) outputs. Before rang-

ing the outputs, be sure the outputs are properly configured. See Section 5.5.

4 mA : 0.00 ppm

20 mA: 20.00 ppm
Output 1: 12.00 mA

Exit Edit

21

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

5.3 TESTING OUTPUTS AND ALARMS

2. Press any key to enter the main menu. Move the cursor to "Program"
and press Enter (F4).

3. Move the cursor to "Simulated tests" and press Enter (F4).

4. Move the cursor to the desired output or alarm. Both outputs and all
four alarms can be tested. Press Enter (F4).

A screen will appear warning that the output or alarm will change.
Press Cont (F3) to continue. Press Abort (F1) to cancel the simulation.

5. This screen appears when an output is being simulated. To change
the simulation current, press Edit (F4). Use the arrow keys to change
the current to the desired value. Press Test (F4), then Esc (F3).

The simulated current will be generated for 10 minutes, then the out­put returns to normal operation. To change the timeout to a different
value see Section 5.4.

To end the simulation at any time, press Exit (F1).

6. This screen appears when an alarm is being simulated. To change
the state of the relay, press Edit (F4). Use the é or ê keys to change
from open to closed. Press Test (F4), then Esc (F3).

The alarm will be simulated for 10 minutes, then the alarm returns to
normal operation. To change the timeout to a different value, see
Section 5.4.

To end the simulation at any time, press Exit (F1).

Output setpoints

Simulated tests

Configure

Exit Enter

Test output 1

Test output 2
Test alarm 1

Exit Enter

Test output 1: 10.00 mA

Simulating output1

Exit Edit

Test alarm 1: Open

Simulating alarm1

Exit Edit

1. For testing purposes, the analyzer can be programmed to generate simulated outputs and to activate and
deactivate alarms.

22

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

Output setpoints
Simulated tests

Configure

Exit Enter

5.4 CHOOSING DISPLAY OPTIONS

3. Press any key to enter the main menu. Move the cursor to "Program"
and press Enter (F4).

4. Move the cursor to "Configure" and press Enter (F4).

5. With the cursor on "Display", press Enter (F4).

6. A screen showing the present main measurement will appear. To
change the measurement from oxygen to free chlorine, press Edit
(F4), then use the é key to scroll through the choices until free
chlorine is showing. Press Save (F4) to store the setting.

A screen will appear warning that if the measurement is changed, the
analyzer will return to factory default settings. Press Cont (F3) to
continue. Press Abort (F1) to cancel the change.

7. Set the remainder of the display parameters. Use the é and ê keys
to choose the desired parameter. Then press Edit (F4). Use the é
key to move the cursor to the desired selection. Press Save (F4)
to store.

Display

Outputs
Alarms

Exit Enter

Measure : Oxygen

Sensor: RMT Standard
Meas units: ppm

Exit Edit

1. The Model 54eA analyzer is a versatile instrument that, in addition to free chlorine, can be used to measure
oxygen, ozone, and other forms of chlorine. The default measurement is oxygen. Before connecting the
sensor to the cable, the analyzer must be configured to measure free chlorine.

2. The display menu also lets the user customize the third line in the display, change timeout values, choose a
language other than English, and change the display contrast.

Temp units: °C
Output 1: mA
Output 2: mA

Exit Edit

23

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

SECURITY CAUTION

The analyzer uses the timeout value to activate security. Once
the analyzer is unlocked by entering a security code, security will
not re-activate until a display timeout occurs. If timeout has been
turned off, security will never reactivate.

Language: English
Display left: I
Display right: Out 2

Exit Edit

Display contrast: 40
Timeout: On
Timeout value: 10 min

Exit Edit

5.4 CHOOSING DISPLAY OPTIONS (CONTINUED)

Temp units °C or °F

Output 1 mA or % of full scale
Output 2 mA or % of full scale

Language English, Français, Español, Deutsch, Italiano

Display left

sensor current (I), alarm 1 setpoint (no units),
alarm 3 setpoint (no units), or blank

Display right

sensor current (I), alarm 2 setpoint (no units), alarm
3 setpoint (no units), output 2, or blank

Display Contrast

00 (lightest)-99 (darkest); the display contrast
changes as the number changes

Timeout

Timeout returns the display from any other screen

to the main display if no key is pressed before the
timeout value is exceeded.

Timeout value

24

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

5.5 CHANGING OUTPUT PARAMETERS

2. Press any key to enter the main menu. Move the cursor to "Program"
and press Enter (F4).

3. Move the cursor to "Configure" and press Enter (F4).

4. Move the cursor to "Outputs" and press Enter (F4).

5. Five menu headers relate to outputs. Each output has a control header
and a setup header. The fifth header allows the output hold feature to
be configured.

Always configure the control parameters BEFORE making
changes in the output setup.

To access a header, move the cursor to the desired header and press
Enter (F4).

6. Output Control Settings:

a. The cursor is on "Output Measurement" press Enter (F4).

b. Press Edit (F4).

c. Use the é key to scroll through the choices: "Process" or

"Temperature". "Process" means free chlorine. Press Save (F4)
to store the selection.

Output 1 control

Output 1 setup
Output 2 control

Exit Enter

Output Measurement

Control Mode

Exit Enter

Output : Process

Exit Edit

Display

Outputs

Alarms

Exit Enter

1. This section describes how to configure the analyzer outputs. Outputs can be configured to represent chlorine
or temperature.

Output setpoints
Simulated tests

Configure

Exit Enter

NOTE

There are no settings to make under “Control Mode.”
The 54eA analyzer supplied with the FCLi does not
have control features.

25

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

5.5 CHANGING OUTPUT PARAMETERS (continued)

d. The display returns to the “Output: Process” screen. Press Exit

(F1) twice. The display returns to the “Control/Setup” screen
shown at left.

7. Output setup for normal outputs:

a. Move the cursor to the desired output setup and press Enter (F4).

b. Use the é and ê arrow keys to move the cursor to the desired

parameter. Press Edit (F4). Use the arrow keys to change the set­ting to the desired value and press Save(F4) to store the value.

Range: Choose 4-20 mA or 0-20 mA.

Dampen: Dampening averages the output current, thus smoothing

out a noisy reading. Higher values provide more smoothing but
increase the response time of the output.

Hold and Fixed Hold: If the analyzer is placed in hold, the
outputs will either remain at the last value or go to a fixed value
selected by the user. The fixed value must be between 0 and

22.00 mA.

Fault: If the analyzer detects a fault, the output will signal the fault
by going to a user-selected current between 0 and 22.00 mA.

For allowed values, see Table 5-1.

8. Hold setup.

a. Move the cursor to "Hold feature setup" and press Enter (F4).
b. Press Edit (F4). Use the é to scroll through the choices: "Disable

feature", "Enable feature", and "20 min timeout". If "20 min time­out" is selected, hold mode will automatically disengage after
being on for 20 minutes.

NOTE

Selecting "Enable hold" or "20-min timeout" does not put
the analyzer in hold. It only allows the user to put the
analyzer in hold when the analyzer is in calibrate mode.

9. Using hold.

If hold was enabled in step 8 above, the hold screen will appear
as soon as the user enters the Calibrate menu. To activate Hold,
press Edit (F4). Use the é key to change Off to On and press
Save (F4). "Hold Mode Activated" will be displayed. Outputs and
relays will go to the values programmed in step 7b.

Range : 4-20 mA

Dampen: 0 sec
Hold: Last Value

Exit Edit

Output 1 Control

Output 1 Setup

Output 2 Control

Exit Enter

Output 1 control

Output 1 setup
Output 2 control

Exit Enter

Output 2 control
Output 2 setup

Hold feature setup

Exit Enter

26

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

"Hold Mode Activated" will continue to flash in the main display even
after the user has left the Calibrate menu. To deactivate hold, enter
the Calibrate menu and press Edit (F4). Use the é key to change On
to Off and press Save (F4). Press Exit (F1) twice to return to the main
display.

5.5 CHANGING OUTPUT PARAMETERS (continued)

5.6 CHANGING ALARM PARAMETERS

2. Press any key to enter the main menu. Move the cursor to "Program"
and press Enter (F4).

3. Move the cursor to "Configure" and press Enter (F4).

4. Move the cursor to "Alarms" and press Enter (F4).

5. Nine menu headers relate to alarms. Alarms 1, 2 and 3, each have a
control header and a setup header. Alarm 4 has only a setup header.
The eighth menu header is for configuring the feed limit timer, and the
ninth menu header is for configuring the interval timer.

Always configure the control parameters BEFORE making
changes in the alarm setup.

To access a header, move the cursor to the desired header and press
Enter (F4).

Alarm 1 control

Alarm 1 setup
Alarm 2 control

Exit Enter

Outputs

Alarms

pH

Exit Enter

Output setpoints
Simulated tests

Configure

Exit Enter

1. This section describes how to configure the analyzer alarms relays. Alarms 1, 2, and 3 can be assigned to
chlorine or temperature. In addition, alarm 1, 2, or 3 can be configured as a feed limit timer or as an interval
timer (see steps 9 and 10). Alarm 4 is always a fault alarm.

27

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

Activation method

Control mode

Exit Enter

5.6 CHANGING ALARM PARAMETERS (continued)

6. Alarm Control Settings:

a. With the cursor on "Activation method" press Enter (F4).

b. To change the activation method, press Edit (F4). Use the é key

to scroll through the choices: "Process" or "Temperature".
"Process" means free chlorine. Press Save (F4) to store the
selection.

c. The display returns to the "Activate: Process" screen. Press Exit

(F1) twice. The display returns to the Control/Setup screen
shown at left.

7. Alarm setup for normal alarms:

a. Move the cursor to the desired alarm setup and press Enter (F4).

b. Use the é and ê keys to move the cursor to the desired param-

eter. Press Edit (F4). Use the arrow keys to change the setting to
the desired value and press Save (F4) to store the value. See the
Figures 5-2 and 5-3 for an explanation of terms: low alarm, high
alarm, hysteresis, and delay. See Table 5-1 for allowed values
and limits.

Relay default determines how the relay will operate if there is a
fault or the controller is in hold. Alarms can be forced on (Close),
off (Open), or remain unchanged (None).

Activate : Process

Exit Edit

Alarm : Low

Setpoint: 0.000 ppm
Hysteresis: 0.000 ppm

Exit Edit

Alarm 1 control

Alarm 1 setup

Alarm 2 control

Exit Enter

Alarm 1 control

Alarm 1 setup
Alarm 2 control

Exit Enter

NOTE

There are no settings to make under “Control Mode.”
The 54eA analyzer supplied with the FCLi does not
have control features.

28

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

5.6 CHANGING ALARM PARAMETERS (continued)

FIGURE 5-2. Low Alarm FIGURE 5-3. High Alarm

8. Alarm 4 setup:

Alarm 4 is a dedicated fault alarm. When a fault condition exists, the
red LED on the front display will light.

a. From the menu header screen (step 6) move the cursor to "Alarm

4 setup."

b. To disable the alarm, press Edit (F4) and use the é key to

change the "Fault" to "Off"

9. Feed limit timer setup:

Alarm 1, 2, or 3 can be configured as a feed limit timer. The feed limit
timer prevents overfeeding of treatment chemicals by automatically
turning off the relay after a timeout period.

a. From the menu header screen (step 6) move the cursor to "Feed

limit timer." Press Enter (F4).

b. With the cursor on "Feed limit" press Edit. Use the é key to scroll

through the choices: disable, AL 1, AL 2, and AL 3. Press Save
(F4) to store the selection.

c. Move the cursor to "Timeout". Press Edit (F4) and use the arrow

keys to change the timeout to the desired value. Press Save (F4)
to store the setting.

Operation of the feed limit timer. When a feed limit alarm has
timed out, "Feed limit alarm 1" (if alarm 1 was chosen) appears in
the display. At the same time the red FAIL LED will light and alarm
4 will close (if not turned off), and the selected feed limit relay (alarm

1) will open (de-energize). All other alarms and current outputs will
remain unchanged. The relays remain in the state described until
the Ack (F2) key is pressed, at which time the controller returns to
normal operation and the feed limit clock starts again.

NOTE

Pressing Ack (F2) acknowledges all conditions that turn
on the red LED. If another event occurs after F2 is
pressed, F2 must be pressed again to acknowledge the
new event.

Feed limit : Disable

Timeout: 3600 sec

Exit Edit

1.000 ppm

26.2°C 12.0mA

Feed limit alarm 1

Alarm : Fault

Exit Edit

29

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

5.6 CHANGING ALARM PARAMETERS (continued)

10. Interval timer setup:

Alarm 1, 2, or 3 can be used as an interval timer. The selected relay will
open and close at time intervals programmed by the user. The interval
timer is useful for automatic cleaning of sensors.

NOTE

The alarm relay used for the interval timer cannot be
used for other purposes. When a timer sequence is
occurring, both current outputs are placed in hold (even
if hold was not enabled) and the other two alarms will be
placed in their default states.

a. From the menu header screen (step 6c) move the cursor to

"Interval timer."

b. With the cursor on "Interval timer", press Enter (F4). Use the ê

key to scroll through the selections. Use the arrow keys to
change settings. Press Save (F4) to store.

Refer to the diagram for definition of terms: interval, repeats, on
time, off time, and recovery.

Timer : Disable

Timer: Time activated
Interval: 24.0 hr

Exit Edit

Alarm 4 setup
Feed limit timer

Interval timer

Exit Enter

FIGURE 5-4. Interval Timer

30

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

5.7 CONFIGURING THE pH MEASUREMENT

1. Press any key to enter the main menu. Move the cursor to "Program"
and press Enter (F4).

2. Move the cursor to "Configure" and press Enter (F4).

3. Move the cursor to “pH” and press Enter (F4).

4. The default settings are “pH sensor: Enable” and “pH comp: Auto.”
Keeping these settings permits the analyzer to continuously correct
raw chlorine readings for pH changes. Go to step 6.

If continuous pH correction is not required, the analyzer must be
configured for manual pH correction. Go to step 5.

5. For manual pH correction, press Edit (F4).
a. Use the é key to change "Enable" to "Disable" and press Save

(F4).

b.

The screen at left appears. Use the ê key to move the cursor
to “pH value.” Press Edit (F4). Use the arrow keys to change the
pH value to the desired number. The analyzer will use the value
entered in ALL pH correction calculations no matter what the true
pH is.

6. This screen appears if automatic pH correction for chlorine readings
is being used. To enable diagnostic fault alarms and warning
messages and to change pH diagnostic warning limits…

a. Move the cursor to "pH diagnostics" and press Enter (F4).
b. Move the cursor to "Diagnostics". Press Edit (F4) and use the é

key to change "Off" to "On". Press Save (F4).

NOTE

Choosing "On" means the controller will display pH diagnostic
warning messages and fault alarms. Choosing "Off" means
the messages and fault alarms will not be displayed.
Diagnostic variables will still be measured and can be viewed
under the Diagnostics menu.

pH sensor : Enable

pH comp: Auto
pH diagnostics

Exit Edit

pH sensor : Disable

pH comp: Manual
pH value: 7.00 pH

Exit Edit

Alarms

pH

Temperature

Exit Enter

pH comp: Auto

pH diagnostics

pH calibration

Exit Enter

31

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

5.7 CONFIGURING THE pH MEASUREMENT (continued)

c. Use the é and ê keys to move through the list of diagnostic

measurements. To change a warning limit, press Edit (F4). Use
the arrow keys to change the setting and press Save (F4) to store
the change. For allowed ranges, see Table 5-1. Setting the limit
to 0 disables the warning limit.

Glass imp hi: High glass impedance implies that the sensor may
be nearing the end of its useful life. Set the warning limit about
two times higher than the impedance of a new electrode. A typi­cal glass electrode has an impedance of about 100 MΩ at 25°C.

Glass imp lo: Low glass impedance warns of a broken electrode.
A good setting is 20 MΩ.

Zero offset: pH measuring cells are designed to have a potential
of 0 mV in pH 7 buffer. Zero offset is a measure of how far the
true value is from 0.0 mV. Zero offset is calculated every time the
sensor is calibrated. A good limit is 60 mV.

Imped comp: The impedance of a glass electrode is a strong
function of temperature. For accurate comparison of impedances,
readings must be temperature corrected. For best results, leave
"Imped comp" on.

d. Press Exit (F4) to return to the screen in step 6a.

7. To change calibration parameters…

a. Move the cursor to pH calibration and press Enter (F4).

b. Use the é and ê keys to move through the list of items. To make

a change press Edit (F4). Use the arrow keys to the setting to the
desired value and press Save (F4). For allowed ranges see Table
5-1.

Autocal: To disable automatic calibration, choose "Manual". The
other choices in the list ("Standard", "Merck", "Ingold", and "DIN
19267") refer to standard and technical buffers. Standard buffers
are the NIST primary and secondary buffers: pH 1.68, 3.56, 3.78,

4.01, 4.64, 6.86, 7.41, 9.18, 10.01, and 12.45 as well as pH 7.00.
Merck buffers are pH 2.00, 7.00, 9.00 and 12.00. Ingold buffers
are pH 2.00, 4.01, 7.00, and 9.21. DIN 19267 buffers are pH 1.09,

3.06, 4.65, 6.79, 9.23, and 12.75.

Stabilize pH and Stabilize time: For the controller to accept
calibration data, the pH must remain within a specified range for a
specified period of time. The default values are 0.01 pH for 10 sec­onds. Using a small pH value and a large time provides the best
protection against calibration while the reading is still changing.

Diagnostics : Off

Glass imp hi: 1000 MΩ
Glass imp lo: 20 MΩ

Exit Edit

Autocal : Standard

Stabilize pH: 0.01 pH
Stabilize time: 10 sec

Exit Edit

pH diagnostics

pH calibration

Temperature coeff

Exit Enter

32

5.7 CONFIGURING THE pH MEASUREMENT (continued)

Temp coeff : 0.000

Operate iso: 7.00 pH
Sensor iso: 7.00 pH

Exit Enter

pH diagnostics
pH calibration

Temperature coeff

Exit Enter

8. In certain industries pH is used and reported at a reference tempera­ture of 25°C. Correcting a pH reading to 25°C is often referred to as
a solution temperature correction.

NOTE

IN THE MODEL FCL, pH IS MEASURED FOR THE SOLE
PURPOSE OF CORRECTING THE FREE CHLORINE MEAS­UREMENT. FREE CHLORINE READINGS MUST BE COR­RECTED USING THE pH AT THE ACTUAL SAMPLE TEM­PERATURE. DO NOT USE SOLUTION TEMPERATURE

CORRECTION AND KEEP THE OPERATING AND SENSOR
ISOPOTENTIAL pH VALUES AT 7.00

a. With the cursor on “Temperature coeff”, press Enter (F4).

b. Make the following settings:

Temp coeff 0.000
Operate iso 7.00

Sensor iso 7.00

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

33

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

Temp comp : Auto

Temp units: °C

Exit Edit

Temp comp: Manual
Temp units: °C

Temperature : 25.0°C

Exit Edit

5.8 TEMPERATURE COMPENSATION AND TEMPERATURE UNITS

1. Refer to Section 6.1 for a discussion of the ways in which temperature affects the chlorine measurement.

pH

Temperature

Noise rejection

Exit Enter

2. Press any key to enter the main menu. Move the cursor to "Program"
and press Enter (F4).

3. Move the cursor to "Configure" and press Enter (F4).

4. Move the cursor to "Temperature" and press Enter (F4).

5. Use the é and ê keys to move through the list of items. To make a
change press Edit (F4). Use the arrow keys to change settings to the
desired value. Press Save (F4) to store changes.

Auto: In automatic temperature compensation, the analyzer meas­ures the temperature using an RTD (resistance temperature device)
in the sensor. The analyzer then uses the measured temperature to
calculate the membrane permeability correction.

Manual: In manual temperature compensation, the analyzer uses the
temperature entered by the user to calculate membrane permeability
correction. It does NOT use the actual process temperature. Do NOT
use manual temperature compensation unless the difference
between the calibration and measurement temperatures is less than
2°C.

Manual temperature compensation is useful if the sensor RTD
has failed and a replacement sensor is not available.

If Manual temperature compensation is selected, be sure to enter the
desired temperature.

34

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

Noise rejection : 60 Hz

Exit Edit

5.9 NOISE REDUCTION

1. For maximum noise reduction the frequency of the ac power must be entered into the analyzer.

Temperature

Noise rejection

Main sensor cal

Exit Enter

2. Press any key to enter the main menu. Move the cursor to "Program"
and press Enter (F4).

3. Move the cursor to "Configure" and press Enter (F4).

4. Move the cursor to "Noise rejection" and press Enter (F4).

5. To change the frequency setting, press Edit (F4). Use the é key to
toggle between 50 and 60 Hz. Press Save (F4) to store the change.

35

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

Stabilize : 0.050 ppm

Stabilize time: 10 sec

Exit Edit

Stabilize: 0.050 ppm
Stabilize time: 10 sec

Dual range cal : Disable

Exit Edit

5.10 MAIN SENSOR CALIBRATION PARAMETERS

1. Main sensor refers to the chlorine sensor.

Noise rejection

Main sensor cal

Security

Exit Enter

2. Press any key to enter the main menu. Move the cursor to "Program"
and press Enter (F4).

3. Move the cursor to "Configure" and press Enter (F4).

4. Move the cursor to "Main sensor cal" and press Enter (F4).

5. Use the é and ê keys to move through the list of items. To make a
change press Edit (F4). Use the arrow keys to change settings to the
desired value and press Save (F4). For allowed ranges, see Table 5-1.

The choices depend on the measurement being made.

Stabilize and Stabilize time: For the analyzer to accept calibration
data, the concentration must remain within a specified range for a
specified period of time. The default values are 0.05 ppm and 10
seconds. Using a small stabilize value and a long stabilize time is the
best protection against calibration while a reading is still changing.

Dual range cal: The response of the free chlorine sensor used
with the FCL becomes slightly non-linear at high concentrations of
chlorine. Dual range calibration allows the analyzer to correct for the
non-linearity of the sensor. For more information see Section 7.4.

.

36

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

5.11 SECURITY

1. The analyzer can be programmed to require a password for access to menus. There are three levels:
Level 1: A level 1 user can

1. Zero and calibrate the chlorine sensor

2. Change temperature compensation from automatic to manual and enter a manual compensation tem­perature

3. View diagnostic variables.

Level 2: A level 2 user can

1. Do everything a level 1 user can do

2. Change alarm setpoints

3. Rerange the 4-20 mA outputs

4. Manually test both outputs and all four alarm relays.

Level 3: A level 3 user has access to every menu item. Only a level 3 user can change passwords.
A person with no password can only view the main display.

2. Press any key to enter the main menu. Move the cursor to "Program"
and press Enter (F4).

3. Move the cursor to "Configure" and press Enter (F4).

4. Move the cursor to "Security" and press Enter (F4).

5. Use the é and ê keys to move through the list of items. To enter a
password, press Edit (F4). Use the arrow keys to enter a three-digit
password. Press Save (F4) to store the value.

Lock all: Until the user enters the "lock all" password, all he can do
is view the main display. Entering the "lock all" password allows the
user access to all Level 1 functions.

Lock program: Entering the "lock program" password allows the
user access to all Level 2 functions.

Lock config: Entering the "lock config" password allows the user
access to all Level 3 functions.

The controller will accept a higher level security code at a lower level
security gate. For example, the controller will accept a level 2 pass­word at a level 1 gate.

NOTES:

a. A code of 000 disables security for that level.
b. The security feature will not activate until after the timeout period

has passed with no key presses.
c. A hold condition will indefinitely prolong the timeout period.
d. Security will activate immediately if power is removed and then

restored.
e. To recall a forgotten code, press and hold F4 for five seconds

when the security screen appears. The code for that level will

appear.

Lock all : 0

Lock program: 0
Lock config: 0

Exit Edit

Noise rejection
Main sensor cal

Security

Exit Enter

37

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

5.12 ANALYZER MODE PRIORITY

The Model 54eA analyzer can function in different modes
depending on both how it is configured, what process
conditions exist, and what actions an operator may have
made. To reconcile these possible modes, there is a set
priority that determines exactly what will happen to the
two (2) current outputs and the four (4) alarm relays in the
event of multiple modes occurring at the same time. See
Table 5-2 below.

Priority is in the following order (from lowest to highest):
normal, fault, timer, hold, feed limit, test. Each output or
relay acts as if it is only in the state of highest priority.

NOTE

Some of these features may not be in use in the analyzer.

TABLE 5-2. Controller Mode Priority Chart

1

Indicates the state IF that item has been configured or selected (i.e. if it is an interval timer or a feed limit
timer or it is the one being tested). Unconfigured or unselected items are not affected by that mode.

Condition Definitions:

1. Normal refers to conditions when no other mode is present.

2. Fault means the instrument has diagnosed a fault condition. A fault message is displayed and the red LED
is on.

3. Interval Timer means the timer sequence is occurring.

4. Hold Mode occurs when hold is activated by the operator (i.e. during calibration).

5. Feed Limit occurs when a feed limit timer has reached its limit and is turned off after being on for too long.

6. Simulate tests are described in Section 5.3.

Action Definitions:

1. Normal is determined by process conditions or how the item has been configured (Section 5.6)

2. Open is a deenergized alarm relay (alarm off).

3. Default is the setting configured for each item if there is a fault. (Section 5.6)

4. Closed is an energized alarm relay (alarm on).

5. Hold is the setting for the current output configured in Section 5.5 (fixed mA value or the last normal value).

6. Prior is the state the alarm had before that mode occurred.

7. Test is the value input by the operator (mA for current, on or off for a relay).

Condition Priority Current Current Alarm Alarm Alarm Alarm

Output 1 Output 2 Relay 1 Relay 2 Relay 3 Relay 4

Normal 1 Normal Normal Normal Normal Normal Open

Fault 2 Default Default Default Default Default Closed

Interval Timer 3 Hold Hold Default/ Default/ Default/ Prior

Normal

1

Normal

1

Normal

1

Hold Mode 4 Hold Hold

Default Default Default Prior

Feed Limit 5 Normal Normal Open

1

Open

1

Open

1

Closed

Simulate tests 6 Test

1

Test

1

Test

1

Test

1

Test

1

Test

1

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38

MODEL FCL-54eA SECTION 5.0

PROGRAMMING THE ANALYZER

MODEL FCL-54eA SECTION 6.0

CALIBRATION

SECTION 6.0

CALIBRATION - TEMPERATURE

39

6.1 INTRODUCTION

The free chlorine sensor used in the FCL is a mambrane-covered amperometric sensor. As the sensor
operates free chlorine diffuses through the membrane and is consumed at an electrode immediately behind the
membrane. The reaction produces a current that depends on the rate at which chlorine diffuses through the
membrane. The diffusion rate, in turn, depends on the concentration of chlorine and how easily it passes through
the membrane (the membrane permeability). Because the membrane permeability is a function of temperature, the
sensor current will change if the temperature changes. To correct for changes in sensor current caused by temper­ature, the analyzer automatically applies a membrane permeability correction. The correction is about 3%/°C at
25°C, so a 1°C error in temperature produces about a 3% error in the reading.

Without calibration the accuracy of the temperature measurement is about ±0.4°C. Calibrate the analyzer if

1. ±0.4°C accuracy is not acceptable

2. the temperature measurement is suspected of being in error. Calibrate temperature by making the analyzer
reading match the temperature measured with a standard thermometer.

40

MODEL FCL-54eA SECTION 6.0

CALIBRATION

6.2 TEMPERATURE CALIBRATION

2. From the main display, press any key. With the cursor on “Calibrate,”
press Enter (F4).

NOTE

If Hold was enabled in Section 5.5, the hold screen will appear.
To activate hold, refer to Section 5.5, step 9.

3. Press the ê key twice to move the cursor to “Adjust temperature,”
then press Enter (F4).

4. Press Edit (F4) to adjust the temperature. The screen below will then
appear. Using the arrow keys, enter the correct temperature and
press Save (F4). The controller will enter the value in memory. To
abort the change, press Esc (F3). Press Exit (F1) three times for the
main display.

NOTE

If Hold was activated during calibration, “Hold Mode Activated”
will continue to flash in the main display. Return the sensor to
normal and deactivate Hold. Refer to Section 5.5, step 9.

25.1 °C

Adjust temp : + 025.1 °C

Esc Save

Zero main sensor

Adjust temperature

Output trim

Exit Enter

Place the sensor and a standard thermometer in a beaker of water. Allow the system to reach thermal equilibrium.

1. Check the temperature reading (main display) to make sure the sensor has stabilized. Compare the analyzer
temperature reading with the standard thermometer. The readings should differ by at most 1°C. If the readings
differ by a greater amount, refer to Section 11.8. Go to the next step if the reading requires adjustment.

25.1 °C

Adjust temp : 25.1 °C

Exit Edit

41

MODEL FCL-54eA SECTION 7 .0

CALIBRATION

SECTION 7.0

CALIBRATION - CHLORINE

7.1 INTRODUCTION

As Figure 7-1 shows, a free chlorine sensor generates a current directly proportional to the concentration of free
chlorine in the sample. Calibrating the sensor requires exposing it to a solution containing no chlorine (zero stan­dard) and to a solution containing a known amount of chlorine (full-scale standard).

The zero standard is necessary because chlorine sensors, even when no chlorine is in the sample, generate
a small current called the residual current. The analyzer compensates for the residual current by subtracting it
from the measured current before converting the result to a chlorine value. New sensors require zeroing before
being placed in service, and sensors should be zeroed whenever the electrolyte solution is replaced. Either of
the following makes a good zero standard:

• Deionized water containing a few crystals of salt for every three ounces (90 mL) of water.

• Tap water known to contain no chlorine. Expose tap water to bright sunlight for at least 24 hours.

The purpose of the full-scale standard is to establish the slope of the calibration curve. Because stable chlorine
standards do not exist, the sensor must be calibrated against a test run on a grab sample of the process
liquid. Several manufacturers offer portable test kits for this purpose. Observe the following precautions when tak­ing and testing the grab sample.

• Take the grab sample from a point as close to the sensor as possible. Be sure that taking the sample does
not alter the flow of the sample to the sensor. It is best to install the sample tap just downstream from the
tap for the FCL.

• Chlorine solutions are unstable. Run the test immediately after taking the sample. Try to calibrate the
sensor when the chlorine concentration is at the upper end of the normal operating range.

The Model 499ACL-01 free chlorine sensor loses sensitivity at high concentrations of chlorine. The 54eA analyzer
has a dual slope feature that allows the user to compensate for the non-linearity of the sensor. However, for the
vast majority of applications, dual slope calibration is unnecessary.

FIGURE 7-1. Sensor Current as a Function of Free Chlorine Concentration

MODEL FCL-54eA SECTION 7.0

CALIBRATION

1. Remove the sensor from the flow cell and place it in the zero standard. See Section 7.1 for suggested zero
standards. Be sure no air bubbles are trapped against the membrane. The sensor current will drop rapidly at
first and then gradually reach a stable zero value. To monitor the sensor current go to the main display and
press any key to obtain the main menu. Press the ê key once to highlight “Diagnostic variables.’ Press Enter
(F4). The sensor current is the second item in the display. Note the units: nA is nanoamps, uA is microamps.
To return to the main display, press exit (F1) twice. Typical zero current for the 499ACL-01 sensor is between

-10 and +10 nA. A new sensor or a sensor in which the electrolyte solution has been replaced may require sev­eral hours (occasionally as long as overnight) to reach a minimum zero current. DO NOT START THE ZERO
ROUTINE UNTIL THE SENSOR HAS BEEN IN ZERO SOLUTION FOR AT LEAST TWO HOURS.

7.2 ZEROING THE SENSOR

Calibrate main sensor

Zero main sensor

Adjust temperature

Exit Enter

0.0 ppm

Sensor must be in zero
solution

Abort Cont

2. From the main display, press any key to obtain the main menu.
With the cursor on “Calibrate,” press Enter (F4).

NOTE

If Hold was enabled in Section 5.5, the hold screen will appear.
To activate hold, refer to Section 5.5, step 9.

Press the ê key once to move the cursor to “Zero main sensor.”
Press Enter (F4).

3. The screen at left appears. Press Cont (F3). “Wait” flashes until the
sensor is stabilized. Once the zero step is complete, the message
“Sensor zero done” appears.

4. Press Exit (F1) three times to return to the main display.

NOTE

If Hold was activated during calibration, “Hold Mode Activated”
will continue to flash in the main display. Return the sensor to
normal and deactivate Hold. Refer to Section 5.5, step 9.

42

NOTE

During calibration, ERROR and WARNING messages may appear. If an ERROR message appears, press
Exit (F1) to leave and return to the previous screen. If a WARNING message appears, press Cont (F3) to
continue the calibration or press Abort (F1) to leave. Continuing the calibration after a warning message
appears may cause substantial errors in the subsequent measurement. Refer to Section 11.0 for assistance.

43

MODEL FCL-54eA SECTION 7.0

CALIBRATION

1. Place the sensor in the flow cell. If automatic pH correction is being used, calibrate the pH sensor (section 8.0)
and place it in the flow cell. If manual pH correction is being used, measure the pH of the sample and enter
the value (section 5.7). Adjust the sample flow until water overflows the inside tube in the constant head flow
controller.

2. Adjust the chlorine concentration until it is near the upper end of the control range. Wait until the analyzer
reading is stable before starting the calibration.

7.3 FULL SCALE CALIBRATION

1.100 ppm

Stabilizing . . . Wait

Abort Cont

1.100 ppm

Calibrate : 1.100 ppm

Exit Edit

Calibrate main sensor

Zero main sensor
Adjust temperature

Exit Enter

3. From the main display, press any key to obtain the main menu.
With the cursor on “Calibrate,” press Enter (F4).

NOTE

If Hold was enabled in Section 5.5, the hold screen will appear.
To activate hold, refer to Section 5.5, step 9.

Press Enter (F4).

4. Press Cont (F3). “Wait” flashes until the sensor is stabilized.

If the analyzer appears locked, the reading is not stable enough.
Wait until the process readings are stable before starting the
calibration.

Alternatively, increase the stability concentration or reduce the
stability time. See Section 5.9. Calibrating while readings are
unstable may substantially reduce accuracy.

5. Once the reading is stable, the screen at left appears. Sample the
process liquid. Make a note of the reading before taking the sample.
Immediately determine free chlorine. Note the analyzer reading
again. If the present reading (X) differs from the reading when the
sample was taken (Y), calculate the value to enter (C) from the
following formula:

C = (X/Y) (A)

where A is the concentration of chlorine measured in the grab sample.

Press Edit (F4). Use the arrow keys to change the concentration in the
second line of the display to the desired value. Press Save (F4) to
store the value.

6. Press Exit (F1) four times to return to the main display.

NOTE

If Hold was activated during calibration, “Hold Mode Activated”
will continue to flash in the main display. Return the sensor to
normal and deactivate Hold. Refer to Section 5.5, step 9.

7. During the calibration, the analyzer stores the measured current
and calculates the sensitivity. Sensitivity is the sensor current in nA
divided by the measured concentration. The sensitivity of the
499ACL-01 (free chlorine) sensor is 250-400 nA/ppm.

To view the sensitivity from the main display, press any key to enter
the main menu. Press the ê key once. Then press Enter (F4) to
display the diagnostic variables. The sensitivity is the third line on
the screen. Note the units: nA is nanoamps, μA is microamps.

44

MODEL FCL-54eA SECTION 7.0

CALIBRATION

Figure 7-2 shows the principle of dual slope calibra­tion. Between zero and concentration C1, the
sensor response is linear. When the concentration
of chlorine becomes greater than C1, the response
is non-linear. In spite of the non-linearity, the
response can be approximated by a straight line
between point 1 and point 2.

Dual slope calibration might be needed if the
chlorine concentration is greater than about 6 ppm.

1. Be sure the analyzer has been configured for
dual slope calibration. See Section 5.10.

2. Zero the sensor. See Section 7.2.

3. Place the sensor in the flow cell. If automatic
pH calibration is being used, calibrate the pH
sensor (section 8.0) and place it in the flow cell.
If manual pH correction is being used, measure
the pH of the sample and enter the value (section 5.7). Adjust the sample flow until water overflows the
inside tube in the constant head flow controller.

7.4 DUAL SLOPE CALIBRATION

FIGURE 7-2. Dual Slope Calibration

Adjust temperature

Dual range cal

Output trim

Exit Enter

4. From the main display, press any key to obtain the main menu.
With the cursor on “Calibrate,” press Enter (F4).

NOTE

If Hold was enabled in Section 5.5, the hold screen will appear.
To activate hold, refer to Section 5.5, step 9.

Press the ê key three times to move the cursor to “Dual range cal.”
Press Enter (F4).

5. Adjust the concentration of chlorine in the process until it is near the
upper end of the linear response range of the sensor, i.e., concen­tration near C1 as shown in Figure 7-2.

6. Press Cont (F3). “Wait” flashes until the sensor is stabilized.

If the controller appears locked, the reading is not stable enough.
Wait until the process readings are stable before starting the
calibration.

2.000 ppm

Calibrate low point

Abort Cont

2.000 ppm

Stabilizing . . . Wait

Abort Cont

NOTE

During calibration, ERROR and WARNING messages may appear. If an ERROR message appears, press
Exit (F1) to leave and return to the previous screen. If a WARNING message appears, press Cont (F3) to
continue the calibration or press Abort (F1) to leave. Continuing the calibration after a warning message
appears may cause substantial errors in the subsequent measurement. Refer to Section 10.4 for assistance.

45

MODEL FCL-54eA SECTION 7.0

CALIBRATION

7. Once the reading is stable, the screen at left appears.

Sample the process liquid. Make a note of the reading before taking
the sample. Immediately determine free chlorine. Note the controller
reading again. If the present reading (X) differs from the reading
when the sample was taken (Y), calculate the value to enter (C) from
the following formula:

C = (X/Y) (A)

where A is the concentration of chlorine measured in the grab sample.

Press Edit (F4). Use the arrow keys to change the concentration in
the second line of the display to the desired value. Press Save (F4)
to store the value.

8. Press High (F3). Adjust the concentration of chlorine in the process
until it is near the top end of the range, i.e., concentration near C2
as shown in Figure 7-2.

9. Press Cont (F3). “Wait” flashes until the sensor is stabilized.

10. Once the reading is stable, the screen at left appears. Following the
procedure in step 7, determine chlorine in a sample of the process
liquid.

Press Edit (F4). Use the arrow keys to change the concentration in
the second line of the display to the desired value. Press Save (F4)
to store the value.

11. Press Exit (F1) three times to return to the main display.

NOTE

If Hold was activated during calibration, “Hold Mode Activated”
will continue to flash in the main display. Return the sensor to
normal and deactivate Hold. Refer to Section 5.5, step 9.

6.000 ppm

Stabilizing . . . Wait

Abort Cont

2.000 ppm

Low point : 2.000 ppm

Exit High Edit

2.000 ppm

Calibrate high point

Abort Cont

6.000 ppm

High point : 6.000 ppm

Exit High Edit

NOTE

During calibration, ERROR and WARNING messages may appear. If an ERROR message appears, press
Exit (F1) to leave and return to the previous screen. If a WARNING message appears, press Cont (F3) to
continue the calibration or press Abort (F1) to leave. Continuing the calibration after a warning message
appears may cause substantial errors in the subsequent measurement. Refer to Section 10.4 for assistance.

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46

MODEL FCL-54eA SECTION 7.0

CALIBRATION

47

Model FCL-54eA SECTION 8.0

CALIBRATION - pH

SECTION 8.0

CALIBRATION - pH

8.1 INTRODUCTION

A new pH sensor must be calibrated before use. Regular recalibration is also necessary.

A pH measurement cell (pH sensor and the solution to be measured) can be pictured as a battery with an extreme­ly high internal resistance. The voltage of the battery depends on the pH of the solution. The pH meter, which is
basically a voltmeter with a very high input impedance, measures the cell voltage and calculates pH using a con­version factor. The actual value of the voltage-to-pH conversion factor depends on the sensitivity of the pH sens­ing element (and the temperature). The sensing element is a thin, glass membrane at the end of the sensor. As
the glass membrane ages, the sensitivity drops. Regular recalibration corrects for the loss of sensitivity. pH cali­bration standards, also called buffers, are readily available.

Two-point calibration is standard. Both automatic calibration and manual calibration are available. Auto calibration
avoids common pitfalls and reduces errors. Its use is recommended.

In automatic calibration the controller recognizes the buffer and uses temperature-corrected pH values in the cal­ibration. The table below lists the standard buffers the controller recognizes. The controller also recognizes sever­al technical buffers: Merck, Ingold, and DIN 19267. Temperature-pH data stored in the controller are valid between
at least 0 and 60°C.

FIGURE 8-1. Calibration Slope and Offset

Note 1: NIST is National Institute of Standards

DIN is Deutsche Institute für Normung, JSI is
Japan Standards Institute, and BSI is British
Standards Institute.

Note 2: pH 7 buffer is not a standard buffer. It is
a popular commercial buffer in the United
States.

During automatic calibration, the analyzer also measures
noise and drift and does not accept calibration data until
readings are stable. Calibration data will be accepted as soon
as the pH reading is constant to within the factory-set limits of

0.02 pH units for 10 seconds. The stability settings can be
changed. See Section 5.10.

In manual calibration, the analyzer still monitors readings for
stability; however, the buffer pH lookup feature is missing.
The user has to enter the correct pH at the temperature the
buffer is being used.

Once the analyzer completes the calibration, it calculates the
calibration slope and offset. The slope is reported as the
slope at 25°C. Figure 8-1 defines the terms.

The analyzer can also be standardized. Standardization is
the process of forcing the analyzer reading to match the
reading from a second pH instrument. Standardization is
sometimes called a one-point calibration.

pH of common buffers at 25°C (see note 1)

Standard (NIST) DIN 19267 Merck Ingold

1.68

1.09 2.00 2.00

3.56

3.06 4.00 4.01

3.78

4.65 7.00 7.00

4.01

6.79 9.00 9.21

6.86

9.23 12.00

7.00 (see note 2)

12.75

7.41

9.18

10.01

12.45

48

Model FCL-54eA SECTION 8.0

CALIBRATION - pH

4.02 pH

Buf1done: 4.00 @25°C

Abort Cont

4.02 pH

Autocal buffer 1

Abort Cont

Adjust temperature

Calibrate pH

Output trim

Exit Enter

Buffer calibration

Standardize pH
pH slope

Exit Enter

1. Be sure the pH feature has been enabled. See Section 5.7.

2. Obtain two buffer solutions. Ideally the buffer pH values should bracket the range of pH values to be meas­ured.

3. Remove the sensor from the process liquid. If the process and buffer temperatures are appreciably different,
place the sensor in a container of tap water at the buffer temperature. Do not start the calibration until the sen­sor has reached the buffer temperature. Thirty minutes is usually adequate.

8.2 AUTOMATIC TWO-POINT CALIBRATION

4. From the main display, press any key to obtain the main menu.
With the cursor on "Calibrate" press Enter (F4).

NOTE

If Hold was enabled in Section 5.5, the hold screen will appear.
To activate hold, refer to Section 5.5, step 9.

5. Press the ê key three times to move the cursor to "Calibrate pH".
Press Enter (F4).

6. Press Enter (F4).

7. Rinse the sensor with water and place it in buffer 1. Be sure the
glass bulb and reference junction are completely submerged. Swirl
the sensor. Press Cont (F3). "Wait" flashes until the reading
stabilizes.

If the analyzer appears locked, the reading is not stable enough.
Investigate and correct the cause of the noise or drift (see Section

11.5). Alternatively, change the stability limits (see Section 5.7) and
repeat the calibration.

8. The screen at left appears once the reading is stable. Use the é or
ê key to change the reading to the nominal pH of the buffer. The
nominal pH is the pH of the buffer at 25°C. Press Cont (F3).

49

Model FCL-54eA SECTION 8.0

CALIBRATION - pH

9. Remove the sensor from buffer 1, rinse it with water, and place it in
buffer 2. Swirl the sensor. Press Cont (F3). "Wait" flashes until the
reading is stable.

10. The screen at left appears once the reading is stable. Use the é or
ê key to change the reading to the nominal pH of the buffer. The
nominal pH is the pH of the buffer at 25°C. Press Cont (F3).

11. Press Exit (F1) four times to return to the main display.

NOTE

If Hold was activated during calibration, “Hold Mode Activated”
will continue to flash in the main display. Return the sensor to
normal and deactivate Hold. Refer to Section 5.5, step 9.

12. To view the slope and offset press any key to enter the main menu.
Press the ê key once to move the cursor to "Diagnostic variables".
Press Enter (F4). Press the ê key six times to scroll through the list
of diagnostic variables. Note that the pH slope is at 25°C.

10.02 pH

Buf2 done: 10.01 @25°C

Abort Cont

10.02 pH

Autocal buffer 2

Abort Cont

NOTE

During calibration, ERROR and WARNING messages may appear. If an ERROR message appears, press
Exit (F1) to leave and return to the previous screen. If a WARNING message appears, press Cont (F3) to
continue the calibration or press Abort (F1) to leave. Continuing the calibration after a warning message
appears may cause substantial errors in the subsequent measurement. Refer to Section 11.5 for
assistance.

50

Model FCL-54eA SECTION 8.0

CALIBRATION - pH

1. Be sure the pH feature has been enabled. See Section 5.7.

2. The controller comes from the factory set for automatic pH calibration. To do a manual calibration, the factory
default setting must be changed. Refer to Section 5.7.

3. Obtain two buffer solutions. Ideally the buffer pH values should bracket the range of pH values to be meas­ured. Also obtain a thermometer. The pH of most buffer solutions is a function of temperature. To calibrate the
sensor properly, the pH of the buffer at the measurement temperature must be entered in the analyzer.

4. Remove the sensor from the process liquid. If the process and buffer temperatures are appreciably different,
place the sensor in a container of tap water at the buffer temperature. Do not start the calibration until the
sensor has reached the buffer temperature. Thirty minutes is usually adequate.

8.3 MANUAL TWO-POINT CALIBRATION

5. From the main display, press any key to obtain the main menu. With
the cursor on "Calibrate" press Enter (F4).

NOTE

If Hold was enabled in Section 5.5, the hold screen will appear.
To activate hold, refer to Section 5.5, step 9.

6. Press the ê arrow key three times to move the cursor to "Calibrate
pH". Press Enter (F4).

7. With the cursor on "2-pt calibration" press Enter (F4).

8. Rinse the sensor and thermometer with water and place them in
buffer 1. Be sure the glass bulb and junction are completely sub­merged. Swirl the sensor. Press Cont (F3). "Wait" flashes until the
reading stabilizes. The large number on the first line is the measured
pH based on the previous calibration.

If the analyzer appears locked, the reading is not stable enough.
Investigate and correct the cause of the noise or drift (see Section

11.5). Alternatively, change the stability limits (see Section 5.7) and
repeat the calibration.

9. The screen at left appears once the reading is stable. Press Edit (F4)
and use the arrow keys to change the reading to the pH of the buffer
at the measured temperature. Most commercial buffers have a table
of pH values as a function of temperature on the label. Press Save
(F4) to store the value. If the pH value on the first line is correct, press
Pt 2 (F3) and go to step 11.

Adjust temperature

Calibrate pH

Output trim

Exit Enter

2-pt calibration

Standardize pH
pH slope

Exit Enter

4.01 pH

Pt. 1 : 04.00pH 25°C

Exit Pt 2 Edit

4.01 pH

Calibrate point 1

Abort Cont

51

Model FCL-54eA SECTION 8.0

CALIBRATION - pH

10. The screen at left appears if the pH reading in step 9 was changed.
Press Pt 2 (F3). Go to step 11.

11. Rinse the sensor and thermometer with water and place them in
buffer 2. Be sure the glass bulb and junction are completely
submerged. Swirl the sensor. Press Cont (F3). "Wait" flashes until the
reading stabilizes.

12. The screen at left appears once the reading is stable. Press Edit (F4)
and use the arrow keys to change the reading to the pH of the buffer
at the measured temperature. Press Save (F4) to store the value.

Press Exit (F1) four times to return to the main display.

NOTE

If Hold was activated during calibration, “Hold Mode Activated”
will continue to flash in the main display. Return the sensor to
normal and deactivate Hold. Refer to Section 5.5, step 9.

13. To view the slope and offset press any key to enter the main menu.
Press the ê key once to move the cursor to "Diagnostic variables".
Press Enter (F4). Press the ê key six times to scroll through the list
of diagnostic variables. Note that the pH slope is at 25°C.

4.00 pH

Pt. 1 : 4.00pH 25.0°C

Exit Pt 2 Edit

10.01 pH

Pt. 2 : 10.01pH 25.0°C

Exit Edit

NOTE

During calibration, ERROR and WARNING messages may appear. If an ERROR message appears, press
Exit (F1) to leave and return to the previous screen. If a WARNING message appears, press Cont (F3) to
continue the calibration or press Abort (F1) to leave. Continuing the calibration after a warning message
appears may cause substantial errors in the subsequent measurement. Refer to Section 11.5 for
assistance.

10.01 pH

Calibrate point 2

Abort Cont

52

Model FCL-54eA SECTION 8.0

CALIBRATION - pH

1. The pH measured by the analyzer can be changed to match the reading from a second or referee instrument.
The process of making the two reading agree is called standardization, or one-point calibration.

2. During standardization, the difference between the two pH values is converted to the equivalent voltage. The
voltage, called the reference offset, is added to all subsequent measured cell voltages before they are
converted to pH. If a sensor that has been calibrated with buffers is then standardized and placed back in a
buffer, the measured pH will differ from the buffer pH by an amount equivalent to the standardization offset.

3. Install the sensor in the process liquid. Once readings are stable, measure the pH of the liquid using a referee
instrument. Normally, it is acceptable to test a grab sample. Because the pH of the process liquid may change
if the temperature changes, measure the pH immediately after taking the grab sample. For poorly buffered
samples, it is best to determine the pH of a continuously flowing sample from a point as close as possible to
the process sensor.

8.4 STANDARDIZATION (ONE-POINT CALIBRATION)

Adjust temperature

Calibrate pH

Output trim

Exit Enter

4. From the main display, press any key to obtain the main menu. With
the cursor on "Calibrate" press Enter (F4).

NOTE

If Hold was enabled in Section 5.5, the hold screen will appear.
To activate hold, refer to Section 5.5, step 9.

5. Press the ê key three times to move the cursor to "Calibrate pH".
Press Enter (F4).

6. Press the ê key once to move the cursor to "Standardize pH". Press
Enter (F4).

7. The pH reading in large numbers is the current process reading.
Press Edit (F4). Use the arrow keys to change the reading in the
second line to match the referee instrument. Press Save (F4).

8. Press Exit (F1) four times to return to the main display.

NOTE

If Hold was activated during calibration, “Hold Mode Activated”
will continue to flash in the main display. Return the sensor to
normal and deactivate Hold. Refer to Section 5.5, step 9.

2-pt calibration

Standardize pH

pH slope

Exit Enter

NOTE

During calibration, ERROR and WARNING messages may appear. If an ERROR message appears,
press Exit (F1) to leave and return to the previous screen. If a WARNING message appears, press
Cont (F3) to continue the calibration or press Abort (F1) to leave. Continuing the calibration after a
warning message appears may cause substantial errors in the subsequent measurement. Refer to
Section 11.5 for assistance.

7.00 pH

Standardize : 7.00 pH

Exit Edit

53

Model FCL-54eA SECTION 8.0

CALIBRATION - pH

1. If the electrode slope is known from other measurements, it can be entered directly into the analyzer. The slope
must be entered as the slope at 25°C. To calculate the slope at 25°C from the slope at temperature t°C, use
the equation:

slope at 25°C = (slope at t°C)

Changing the slope overrides the slope determined from the previous buffer calibration.

8.5 pH SLOPE ADJUSTMENT

Adjust temperature

Calibrate pH

Output trim

Exit Enter

Buffer calibration
Standardize pH

pH slope

Exit Enter

2. From the main display, press any key to obtain the main menu. With
the cursor on "Calibrate" press Enter (F4).

NOTE

If Hold was enabled in Section 5.5, the hold screen will appear.
To activate hold, refer to Section 5.5, step 9.

3. Press the ê key three times to move the cursor to "Calibrate pH".
Press Enter (F4).

4. Press the ê key twice to move the cursor to “pH slope.” Press Enter
(F4).

5. Press Edit (F4). Use the arrow keys to change the slope to the
desired value. The slope msut be between 45 and 60 mV/pH. Press
Save (F4).

6. Press Exit (F1) four times to return to the main display.

NOTE

If Hold was activated during calibration, “Hold Mode Activated”
will continue to flash in the main display. Return the sensor to
normal and deactivate Hold. Refer to Section 5.5, step 9.

pH slope: 60.00 mV/pH

Exit Edit

298

t°C + 273

NOTE

During calibration, ERROR and WARNING messages may appear. If an ERROR message appears, press
Exit (F1) to leave and return to the previous screen. If a WARNING message appears, press Cont (F3) to
continue the calibration or press Abort (F1) to leave. Continuing the calibration after a warning message
appears may cause substantial errors in the subsequent measurement. Refer to Section 11.5 for
assistance.

THIS PAGE LEFT BLANK INTENTIONALLY

54

Model FCL-54eA SECTION 8.0

CALIBRATION - pH

55

2. Move the cursor to "Output trim” and press Enter (F4).

3. The warning screen reminds the user that the output currents will be
affected. Pres Cont (F3) to continue.

4. Use the é or ê keys to move the cursor to the desired output and
press Enter (F4).

5. Select “Cal point 1” (0 or 4 mA) or “Cal point 2” (20 mA).

6. Move the cursor to “Meter” and press Enter (F4). Measure the output
current with a calibrated milliammeter. Use the é or ê keys to change
the display to match the milliammeter reading and press Save (F4).

7. Move the cursor to the other “Cal point” and select it. Repeat step 6.

MODEL FCL-54eA SECTION 9.0

CALIBRATION-CURRENT OUTPUTS

SECTION 9.0

CALIBRATION - CURRENT OUTPUTS

9.1 INTRODUCTION

Although the analog outputs are calibrated at the factory, they can be trimmed in the field to match the reading
from a standard milliameter. Both the low output (0 or 4 mA) and the high output (20 mA) can be trimmed.

9.2 TRIMMING THE OUTPUTS

1. From the main display, press any key to obtain the main menu. With the cursor on "Calibrate" press Enter (F4).

NOTE

If Hold was enabled in Section 5.5, the hold screen will appear. To activate hold, refer to Section 5.5, step 9.

Adjust temperature
Calibrate pH

Output trim

Exit Enter

CAUTION:
Current outputs
may be affected

Abort Cont

Trim output 1

Trim output 2

Exit Enter

Cal point : 1

Meter: 4.00 mA
Expected: 4.00 mA

Simulating output1

Exit Edit

56

MODEL FCL-54eA SECTION 9.0

CALIBRATION-CURRENT OUTPUTS

NOTE

If Hold was activated during calibration, “Hold Mode Activated” will continue to flash in the main display.
Return the sensor to normal and deactivate Hold. Refer to Section 5.5, step 9.

57

PART NUMBER DESCRIPTION

23540-05 Enclosure, Front with Keyboard

23848-00 Power Supply Circuit Board Shield

23849-00 Half Shield, Power Supply

23969-02 PCB, CPU and power supply, calibrated, 115/230 Vac

23969-06 PCB, CPU and power supply, calibrated, 24 Vdc

33281-00 Hinge Pin

33286-00 Gasket, Front Panel

33293-00 Enclosure, Rear

9010377 Back-lit Display, LCD Dot Matrix

9510048 Enclosure Conduit Plug, 1/2 inch

MODEL FCL-54eA SECTION 10.0

MAINTENANCE

SECTION 10.0

MAINTENANCE

10.1 ANALYZER

The analyzer used with the FCL needs little routine maintenance.

Clean the analyzer case and front panel by wiping with a clean soft cloth dampened with water ONLY. Do not
use solvents, like alcohol, that might cause a buildup of static charge.

TABLE 10-1. Replacement parts

NOTE: Individual printed circuit boards cannot be ordered for Model 54e. Replacement boards for Model 54e

are assembled and calibrated as an integrated board stack.

MODEL FCL-54eA SECTION 10.0

MAINTENANCE

10.2.1 General.

When used in clean water, the chlorine sensor requires little maintenance. Generally, the sensor needs mainte­nance when the response becomes sluggish or noisy or when readings drift following calibration. For a sensor
used in potable water, expect to clean the membrane every month and replace the membrane and electrolyte solu­tion every two to three months. In water containing large amounts of suspended solids, for example open recir­culating cooling water, membrane cleaning or replacement will be more frequent.

10.2.2 Cleaning the membrane.

Clean the membrane with water sprayed from a wash bottle. Do not use tissues to clean the membrane.

10.2.3 Replacing the electrolyte solution and membrane.

1. Unscrew the membrane retainer and remove the membrane assembly and O-ring. See Figure 10-2.

2. Hold the sensor over a container with the cathode pointing down.

3. Remove the fill plug and allow the electrolyte solution to drain out.

4. Inspect the cathode. If it is tarnished, clean it using a cotton-tipped swab dipped in baking soda or alumina.
Use type A dry powder alumina intended for metallographic polishing of medium and soft metals. Rinse thor­oughly with water.

5. Prepare a new membrane. Hold the membrane assembly with the cup formed by the membrane and mem­brane holder pointing up. Fill the cup with electrolyte solution and allow the wooden ring to soak up the solu­tion (usually takes several minutes).

6. Hold the sensor at about a 45-degree angle with the cathode end pointing up. Add electrolyte solution through
the fill hole until the liquid overflows. Tap the sensor near the threads to release trapped air bubbles. Add more
electrolyte solution if necessary.

7. Place the fill plug in the electrolyte port and begin screwing it in. After several threads have engaged, rotate
the sensor so that the cathode is pointing up and continue tightening the fill plug. Do not overtighten.

8. Place a new O-ring in the groove around the cathode post. Cover the holes at the base of the cathode stem
with several drops of electrolyte solution.

9. Insert a small blunt probe, like a toothpick with the end cut off, through the pressure equalizing port. See
Figure 10-2.

NOTE

Do not use a sharp probe. It will puncture the bladder and destroy the sensor.

Gently press the probe against the bladder several times to force liquid through the holes at the base of the
cathode stem. Keep pressing the bladder until no air bubbles can be seen leaving the holes. Be sure the holes
remain covered with electrolyte solution.

10. Place a drop of electrolyte solution on the cathode, then place the membrane assembly over the cathode.
Screw the membrane retainer in place.

11. The sensor may require several hours operating at the polarizing voltage to equilibrate after the electrolyte
solution has been replenished.

10.2 CHLORINE SENSOR

58

CAUTION

Fill solution may cause irritation. May be harmful if
swallowed. Read and follow manual.

WARNING

PRESSURIZED SPRAY INJURY Before removing
the sensor from the process stream for maintenance,
be sure the process pressure is reduced to 0 psig
and the process temperature is at a safe level!

CAUTION

59

MODEL FCL-54eA SECTION 10.0

MAINTENANCE

10.3 pH SENSOR

10.3.1 General.

When used in clean water, the pH sensor requires little maintenance. Generally, the sensor needs maintenance
when the response becomes sluggish or noisy. In clean water the typical cleaning frequency is once a month. In
water containing large amounts of suspended solids, for example open recirculating cooling water, cleaning fre­quency will be substantially greater.

10.3.2 Cleaning the Sensor

Remove soft deposits by rinsing with a stream of water from a wash bottle. If the sensor becomes coated with
rust, dissolve the rust by soaking the sensor in dilute hydrochloric acid (mix 5 mL of concentrated hydrochloric
acid with 100 mL of water) for no longer than 5 minutes at room temperature. Rinse the sensor thoroughly with
water and soak in pH 4 buffer for several hours. Recalibrate the sensor in buffers before returning it to service.

10.3.3 Other Maintenance

The 399VP-09 pH sensor supplied with the Model FCL-02 is disposable. It has no replaceable parts.

33523-00 Electrolyte Fill Plug

9550094 O-Ring, Viton 2-014
33521-00 Membrane Retainer
23501-08 Free Chlorine Membrane Assembly: includes one membrane assembly and one O-ring
23502-08 Free Chlorine Membrane Kit: includes 3 membrane assemblies and 3 O-rings

9210356 #4 Free Chlorine Sensor Fill Solution, 4 oz (120 mL)

TABLE 10-2. Spare Parts

FIGURE 10-2. Chlorine Sensor Parts

60

MODEL FCL-54eA SECTION 10.0

MAINTENANCE

10.4 CONSTANT HEAD FLOW CONTROLLER

10.4.1 General

After a period of time, deposits may accumulate in the
constant head overflow chamber and in the tubing
leading to the flow cell(s). Deposits increase the resist­ance to flow and cause the flow to gradually decrease.
Loss of flow may ultimately have an impact on the
chlorine sensor performance. The flow controller is
designed to provide about 2 gal/hr flow. Loss of flow to
about 1 gal/hr causes a 10-15% drop in chlorine
sensor output. Loss of flow has almost no effect on pH
sensor performance other than to increase the overall
response time of the sensor.

10.4.2 Cleaning the flow controller

The low flow controller can be taken apart completely
for cleaning. Use a strong flow of water to flush out the
tubing. A pipe cleaner or a small bottlebrush can
remove more adherent deposits. To prevent leaks,
apply a thin layer of silicone grease (or equivalent) to
the two O-rings at the base of overflow chamber and to
the O-ring sealing the central overflow tube to the base.

10.4.3 Other Maintenance

Tables 10-3 and 10-4 and Figures 10-3 and 10-4 show
the replacement parts for the flow controller assembly
used in Models FCL-01and FCL-02.

61

MODEL FCL-54eA SECTION 10.0

MAINTENANCE

FIGURE 10-3. Replacement Parts for the Flow Controller Assembly used in Model FCL-01.

Location in Shipping
Figure 10-3 PN Description Weight

1 24091-01 Flow cell for chlorine sensor with bubble shedding nozzle 1 lb/0.5 kg

2 24040-00 O-ring kit, two 2-222 and one 2-024 silicone O-rings, 1 lb/0.5 kg

with lubricant

3 33812-00 Dust cap for constant head flow controller 1 lb/0.5 kg

4 9322032 Elbow, ¼ in FNPT x ¼ in OD tubing 1 lb/0.5 kg

5 9350029 Check valve, ¼ in FNPT 1 lb/0.5 kg

TABLE 10-3. Replacement parts for constant head flow controller assembly (Model FCL-01)

62

MODEL FCL-54eA SECTION 10.0

MAINTENANCE

FIGURE 10-4. Replacement Parts for the Flow Controller Assembly used in Model FCL-02.

Table 10-4 and Figure 10-4 show the replacement parts for the flow controller assembly used in Model FCL-02.

Location in Shipping
Figure 10-4 PN Description Weight

1 24091-01 Flow cell for chlorine sensor with bubble shedding nozzle 1 lb/0.5 kg

2 24091-00 Flow cell for pH sensor 1 lb/0.5 kg

3 24040-00 O-ring kit, two 2-222 and one 2-024 silicone O-rings, 1 lb/0.5 kg

with lubricant

4 33812-00 Dust cap for constant head flow controller 1 lb/0.5 kg

5 9322032 Elbow, ¼ in FNPT x ¼ in OD tubing 1 lb/0.5 kg

6 9350029 Check valve, ¼ in FNPT 1 lb/0.5 kg

TABLE 10-4. Replacement parts for constant head flow controller assembly (Model FCL-02)

63

MODEL FCL-54eA SECTION 11.0

TROUBLESHOOTING

SECTION 11.0

TROUBLESHOOTING

11.1 OVERVIEW

The analyzer used with the FCL continuously monitors itself and the sensor for faults. When the controller detects
a fault in the amperometric or pH sensor or in the instrument itself it displays a fault message. If alarm 4 was
enabled, the red FAIL LED will also light and relay 4 will activate. The outputs will go to 22.00 mA or to the value
programmed in Section 5.5.

Special rules apply to pH sensor diagnostics (high and low glass impedance). Alarm 4, the FAIL LED, and the
output current failure mode will operate only if pH sensor diagnostics have been enabled. See Section 5.7.

See Section 11.2 for an explanation of fault messages and suggested corrective actions.

The controller also displays error and warning messages if a calibration is seriously in error. Refer to the section

11.3 -11.5 for assistance. Each section also contains hints for correcting other measurement and calibration problems.

For troubleshooting not related to measurement problems, see Section 11.7.

To view diagnostic variables, go to the main display and press any key. Move the cursor to “Diagnostic variables”
and press Enter (F4). Use the é or ê key to move up or down the list.

11.2 TROUBLESHOOTING WHEN A FAULT MESSAGE IS SHOWING

Fault message Explanation See Section

High input current input current exceeds 210 uA 11.2.1

Check sensor zero sensor current was too high when sensor was zeroed 11.2.2

pH low input voltage input voltage is less than -1400 mV 11.2.3

pH high input voltage input voltage exceeds 1400 mV 11.2.3

pH low reference voltage input voltage is less than -1600 mV 11.2.4

pH high reference voltage input voltage exceeds 1600 mV 11.2.4

Old glass warning glass impedance exceeds high limit 11.2.5

Cracked glass failure glass impedance is less than low limit 11.2.6

Temp error low temperature less than -15°C 11.2.7

Temp error high temperature greater than 130°C 11.2.7

Sense line open RTD sense line is open 11.2.8

Failure factory instrument needs factory calibration 11.2.9
Failure eeprom write verify error has occurred 11.2.9

64

MODEL FCL-54eA SECTION 11.0

TROUBLESHOOTING

11.2.1 High input current

Excessive sensor current implies that the chlorine sensor is miswired or the sensor has failed. Verify that wiring is
correct. See Section 3.3. If wiring is correct, try replacing the sensor.

11.2.2 Check sensor zero

The sensor current was extremely high when the sensor was zeroed. The zero current should be less than about
10 nA. Zeroing the sensor before the zero current has reached a stable minimum value will lead to low results.
Allow adequate time, usually two or three hours but possibly as long as overnight, for the sensor to stabilize before
starting the zero routine. Also see section 11.4 for more information.

11.2.3 pH low or high input voltage

The input voltage fault message usually means there is an open connection somewhere in the wiring between the
pH sensor and analyzer. Check wiring connections. See Section 3.3. If wiring is correct, try replacing the sensor.

11.2.4 pH low or high reference voltage

The reference voltage fault message can mean several things: the pH sensor is no longer submerged in the sample,
the sensor is coated or fouled, or there is an open connection between the sensor and analyzer. First, verify all
electrical connections. Verify that the pH sensor is completely submerged in the process. Also, verify that the sen­sor is not coated with solids or oil. If the sensor looks dirty, clean it. Refer to section 10.3 for details. If cleaning the
sensor fails to solve the problem, replace the sensor.

11.2.5 Old glass warning (pH sensor only)

Old glass warning means the pH sensor is no longer submerged in the process or the sensor is possibly nearing
the end of its useful life. First, verify that the sensor is clean and submerged in the process liquid. Also verify that
the sensor can still be calibrated in buffers. Make a note of the sensor slope. If the slope is between 54 and 60
mV/ unit pH, the sensor is good. If the slope is between 48 and 50 mV/unit pH, the sensor is near the end of its
life. To make the warning message disappear, increase the warning limit (see Section 5.7).

11.2.6 Cracked glass failure (pH sensor only)

This fault message almost always means the pH sensor has failed and must be replaced. Before discarding the
sensor, try calibrating it in buffers. If the buffer calibration is successful, the sensor is okay, but the diagnostic limit
is set too high. To make the fault message disappear, lower the glass failure limit (see Section 5.7). Do not lower
the impedance below 10 MΩ.

11.2.7 Temperature error low or high

There is an open or short in the sensor RTD or wiring.
A. If the sensor cable has just been replaced, check the wiring connections. See Section 3.3.
B. Disconnect the sensor from the lead wire. Connect an ohmmeter across the RTD IN and RTD RETURN pins

on the Variopol plug at the top of the sensor. Refer to Figure 11-1 or 11-2. The resistance should be about 110 Ω.
If there is an open or short circuit, the sensor has failed and should be replaced. If the resistance is accept­able, attach the sensor the Variopol cable and disconnect the RTD IN and RTD RETURN leads at the ana­lyzer. Refer to Figure 3.3 or Figure 3.4. Connect an ohmmeter across the leads and measure the resistance.
If the circuit is open or shorted, the failure is in the cable, and the cable must be replaced.

C. If there is no open or short, check the analyzer. See Section 11.11.

65

MODEL FCL-54eA SECTION 11.0

TROUBLESHOOTING

FIGURE 11-1. Pin Out Diagram for

Model 499ACL-01-VP Sensor

(top view of connector end of sensor)

FIGURE 11-2. Pin Out Diagram for

Model 399VP-09 Sensor

(top view of connector end of sensor)

11.2.8 Sense line open.

The analyzer measures temperature using a three-wire RTD. See Figure 11-4. The in and return leads connect the
RTD to the measuring circuit in the analyzer. A third wire, called the sense line, is connected to the return line. The
sense line allows the analyzer to correct for the resistance of the in and return leads and to correct for changes in
lead wire resistance caused by changes in the ambient temperature.

A. Verify that all wiring connections are secure.

B. The system can be operated with the sense line open. The measurement will be less accurate because the

analyzer can no longer correct for lead wire resistance and for changes in lead wire resistance with ambient
temperature. However, if the sensor is to be used at approximately constant temperature, the lead wire resist­ance error can be eliminated by calibrating the sensor at the measurement temperature. Errors caused by
changes in lead wire resistance with changes in ambient temperature cannot be eliminated.To make the error
message disappear, connect the RTD sense and return terminals with a jumper.

11.2.9 Failure factory and Failure ecprom.

Turn the power off, wait about 30 sec, then turn the power back on. If the error message does not clear, call the
factory.

11.3 TROUBLESHOOTING WHEN NO FAULT MESSAGE IS SHOWING - TEMPERATURE

11.3.1 Temperature measured by standard was more than 1°C different from analyzer.

A. Is the standard thermometer, RTD, or thermistor accurate? General purpose liquid-in-glass thermometers,

particularly ones that have been mistreated, can have surprisingly large errors.

B. Is the temperature element in the sensor completely submerged in the liquid?

C. Is the standard temperature sensor submerged to the correct level?

66

MODEL FCL-54eA SECTION 11.0

TROUBLESHOOTING

11.4 TROUBLESHOOTING WHEN NO FAULT MESSAGE IS SHOWING - FREE CHLORINE

11.4.1 Zero current is too high

A. Is the sensor properly wired to the analyzer. See Section 3.3.

B. Is the zero solution chlorine-free? Take a sample of the solution and test it for free chlorine level. The

concentration should be less than 0.02 ppm.

C. Has adequate time been allowed for the sensor to reach a minimum stable residual current? It may take

several hours, sometimes as long as overnight, for a new sensor to stabilize.

D. Check the membrane for damage and replace it if necessary.

11.4.2 Zero current is unstable

A. Is the sensor properly wired to the analyzer? See Section 3.3. Verify that all wiring connections are tight.

B. Readings are often erratic when a new or rebuilt sensor is first placed in service. Readings usually stabilize

after about an hour.

C. Is the conductivity of the zero solution greater than about 50uS/cm. Use deionized water containing a small

amount of sodium chloride approximately 0.5 grams per liter. DO NOT USED DEIONIZED WATER ALONE.

D. Is the space between the membrane and cathode filled with electrolyte solution and is the flow path between

the electrolyte reservoir and membrane clear? Often the flow of electrolyte and be started by simply holding
the sensor with the membrane end pointing down and sharply shaking the sensor a few times as though
shaking down a clinical thermometer.

If shaking does not work, try clearing the holes around the cathode stem. Hold the sensor with the membrane
end pointing up. Unscrew the membrane retainer and remove the membrane assembly. Be sure the wood ring
remains with the membrane assembly. Use the end of a straightened paper clip to clear the holes at the base
of the cathode stem. Replace the membrane.

Verify that the sensor is filled with electrolyte solution. See section 10.2.

Problem See Section

Zero current was accepted, but the current is out of range 11.4.1
Error or warning message appears while zeroing the sensor (zero current is too high) 11.4.1
Zero current is unstable 11.4.2
Sensor can be calibrated, but sensitivity is out of range 11.4.3
Process readings are erratic 11.4.4
Readings drift 11.4.5
Sensor does not respond to changes in chlorine level 11.4.6

Chlorine reading spikes following rapid change in pH 11.4.7

67

MODEL FCL-54eA SECTION 11.0

TROUBLESHOOTING

11.4.3 Sensor can be calibrated, but the current is too low

A. Is the temperature low or is the pH high? Sensor current is a strong function of pH and temperature. The

sensor current decreases about 3% for every °C drop in temperature. Sensor current also decreases as pH
increases. Above pH 7, a 0.1 unit increase in pH lowers the current about 5%.

B. Sensor current depends on the rate of sample flow past the sensor tip. If the flow is too low, chlorine readings

will be low. Verify that the chlorine sensor is installed in the correct flow cell. See Figure 2-1. Be sure the
liquid level in the constant head sampler is level with the central overflow tube and that excess sample is
flowing down the tube. If necessary, disassemble and clean the overflow sampler. See Section 10.4.

C. Low current can be caused by lack of electrolyte flow to the cathode and membrane. See step D in Section

11.4.2

D. Is the membrane fouled or coated? A dirty membrane inhibits diffusion of free chlorine through the membrane,

reducing the sensor current. Clean the membrane by rinsing it with a stream of water from a wash bottle. DO
NOT use a tissue to wipe the membrane.

E. If cleaning the membrane does not improve the sensor response, replace the membrane and electrolyte

solution. If necessary, polish the cathode. See Section 10.4 for details.

11.4.4 Process readings are erratic

A. Readings are often erratic when a new sensor or a rebuilt sensor is first placed in service. The current usually

stabilizes after a few hours.

B. Are the holes between the membrane and the electrolyte reservoir open? Refer to Section 11.4.2.

C. Verify that wiring is correct. Pay particular attention to shield and ground connections.

D. If automatic pH correction is being used, check the pH reading. If the pH reading is noisy, the chlorine read-

ing will also be noisy. If the pH sensor is the cause of the noise, use manual pH correction until the problem
with the pH sensor can be corrected. Also, refer to Section 11.5.7 for troubleshooting noisy pH readings.

E. Is the membrane in good condition and is the sensor filled with electrolyte solution? Replace the fill solution

and electrolyte. Refer to Section 10.2 for details.

11.4.5 Readings drift

A. Is the sample temperature changing? Membrane permeability is a function of temperature. The time constant

for the 499ACL-01 sensor is about five minutes. Therefore, the reading may drift for a while after a sudden
temperature change.

B. Is the membrane clean? For the sensor to work properly, chlorine must diffuse freely through the membrane.

A coating on the membrane will interfere with the passage of chlorine, resulting in slow response. Clean the
membrane by rinsing it with a stream of water from a wash bottle. DO NOT use a membrane or tissue to wipe
the membrane.

C. Is the sample flow within the recommended range? Gradual loss of sample flow will cause a downward drift.

Be sure the liquid level in the constant head sampler is level with the central overflow tube and that excess
sample is flowing down the tube. If necessary, disassemble and clean the overflow sampler. See Section 10.4.

D. Is the sensor new or has it been recently serviced? New or rebuilt sensors may require several hours to

stabilize.

E. Is the pH of the process changing? If manual pH correction is being used, a gradual change in pH will cause

a gradual change in the chlorine reading. As pH increases, chlorine readings will decrease, even though the
free chlorine level (as determined by a grab sample test) remained constant. If the pH change is no more than
about 0.2, the change in the chlorine reading will be no more than about 10% of reading. If the pH changes
are more than 0.2, use automatic pH correction.

68

MODEL FCL-54eA SECTION 11.0

TROUBLESHOOTING

11.4.6 Sensor does not respond to changes in chlorine level.

A. Is the grab sample test accurate? Is the grab sample representative of the sample flowing to the sensor?

B. Is sample flowing past the sensor? Be sure the liquid level in the constant head sampler is level with the central

overflow tube and that excess sample is flowing down the tube. If necessary, disassemble and clean the over­flow sampler. See Section 10.4.

C. Is the pH compensation correct? If the analyzer is using manual pH correction, verify that the pH value in the

analyzer equals the actual pH to within ±0.1 pH. If the analyzer is using automatic pH correction, check the
calibration of the pH sensor.

D. Is the membrane clean? Clean the membrane and replace it if necessary. Check that the holes at the base of

the cathode stem are open. Use a straightened paper clip to clear blockages. Replace the electrolyte solution.

E. Replace the sensor.

11.4.7 Chlorine readings spike following sudden changes in pH.

Changes in pH alter the relative amounts of hypochlorous acid (HOCl) and hypochlorite ion (OCl-) in the sample.
Because the sensor responds only to HOCl, an increase in pH causes the sensor current (and the apparent
chlorine level) to drop even though the actual free chlorine concentration remained constant. To correct for the
pH effect, the controller automatically applies a correction. Generally, the pH sensor responds faster than the
chlorine sensor. After a sudden pH change, the controller will temporarily over-compensate and gradually
return to the correct value. The time constant for return to normal is about 5 minutes.

11.4.8 Chlorine readings are too low.

A. Was the sample tested as soon as it was taken? Chlorine solutions are unstable. Test the sample immediately

after collecting it. Avoid exposing the sample to sunlight.

B. Low readings can be caused by zeroing the sensor before the residual current has reached a stable minimum

value. Residual current is the current the sensor generates even when no chlorine is in the sample. Because
the residual current is subtracted from subsequent measured currents, zeroing before the current is a mini­mum can lead to low results.

Example: The true residual current for a free chlorine sensor is 4 nA, and the sensitivity is 350 nA/ppm.
Assume the measured current is 200 nA. The true concentration is (200-4)/350 or 0.56 ppm. If the sensor was
zeroed prematurely when the current was 10 nA, the measured concentration will be (200-10)/350 or 0.54
ppm. The error is 3.6%. Suppose the measured current is 400 nA. The true concentration is 1.13 ppm, and
the measured concentration is 1.11 ppm. The error is now 1.8%. The absolute difference between the reading
remains the same, 0.02 ppm.

C. Sensor response depends on flow. If the flow is too low, readings will be low and flow sensitive. Verify that the

chlorine sensor is installed in the correct flow cell. See Figure 2-1. Verify that the liquid level in the constant
head sampler is level with the central overflow tube and that excess sample is flowing down the tube. If
necessary, disassemble and clean the overflow sampler. See Section 10.4.

69

MODEL FCL-54eA SECTION 11.0

TROUBLESHOOTING

11.5 TROUBLESHOOTING WHEN NO FAULT MESSAGE IS SHOWING - pH

11.5.1 Warning or error message during two-point calibration.

Once the two-point (manual or automatic) calibration is complete, the analyzer automatically calculates the sen­sor slope (at 25°C). If the slope is less than 45 mV/pH, the analyzer displays a "Slope error low" message. If the
slope is greater than 60 mV/pH, the analyzer displays a "Slope error high" message. The analyzer will not update
the calibration. Check the following:

A. Are the buffers accurate? Inspect the buffers for obvious signs of deterioration, such as turbidity or mold

growth. Neutral and slightly acidic buffers are highly susceptible to molds. Alkaline buffers (pH 9 and greater),
if they have been exposed to air for long periods, may also be inaccurate. Alkaline buffers absorb carbon diox­ide from the atmosphere, which lowers the pH. If a high pH buffer was used in the failed calibration, repeat the
calibration using a fresh buffer. If fresh buffer is not available, use a lower pH buffer. For example, use pH 4
and pH 7 buffer instead of pH 7 and pH 10 buffer.

B. Was adequate time allowed for temperature equilibration? If the sensor was in a process liquid substantially

hotter or colder than the buffer, place it in a container of water at ambient temperature for at least 20 minutes
before starting the calibration.

C. Were correct pH values entered during manual calibration? Using auto calibration eliminates error caused by

improperly entered values.

D. Is the sensor properly wired to the analyzer? Check sensor wiring including any connections in a junction box.

See Section 3.3.

E. Is the sensor dirty or coated? See the sensor instruction sheet for cleaning instructions.

F. Is the sensor faulty? Check the glass impedance. From the main display, press any key to enter the main

menu. Move the cursor to "Diagnostic variables". Press Enter (F4). Press the ê key until "Glass imped" is
showing. Refer to the table for an interpretation of the glass impedance value.

G. Is the analyzer faulty? The best way to check for a faulty analyzer is to simulate pH inputs. See Section 11.10.

Problem See Section

Warning or error message during two-point calibration 11.5.1
Warning or error message during standardization 11.5.2
Analyzer will not accept manual slope 11.5.3
Sensor does not respond to known pH changes 11.5.4
Calibration was successful, but process pH is slightly different from expected value 11.5.5
Calibration was successful, but process pH is grossly wrong and/or noisy 11.5.6
Process reading is noisy 11.5.7

less than 10 MΩ Glass bulb is cracked or broken. Sensor has failed.
between 100 MΩ and 1000 MΩ Normal reading
greater than 1000 MΩ pH sensor may be nearing the end of its service life.

70

MODEL FCL-54eA SECTION 11.0

TROUBLESHOOTING

11.5.2 Warning or error message during standardization.

During standardization, the millivolt signal from the pH cell is increased or decreased until it agrees with the pH
reading from a reference instrument. A unit change in pH requires an offset of about 59 mV. The controller limits
the offset to ±1400 mV. If the standardization causes an offset greater than ±1400 mV, the analyzer will display the
Calibration Error screen. The standardization will not be updated. Check the following:

A. Is the referee pH meter working and properly calibrated? Check the response of the referee sensor in buffers.

B. Is the process sensor working properly? Check the process sensor in buffers.

C. Is the sensor fully immersed in the process liquid? If the sensor is not completely submerged, it may be meas-

uring the pH of the liquid film covering the glass bulb and reference element. The pH of this film may be
dif-ferent from the pH of the bulk liquid.

D. Is the sensor fouled? The sensor measures the pH of the liquid adjacent to the glass bulb. If the sensor is

heavily fouled, the pH of liquid trapped against the bulb may be different from the bulk liquid.

E. Has the sensor been exposed to poisoning agents (sulfides or cyanides) or has it been exposed to extreme

temperature? Poisoning agents and high temperature can shift the reference voltage many hundred millivolts.
To check the reference voltage, see Section 11.12.

11.5.3 Controller will not accept manual slope.

If the sensor slope is known from other sources, it can be entered directly into the controller. The controller will not
accept a slope (at 25°) outside the range 45 to 60 mV/pH. If the user attempts to enter a slope less than 45 mV/pH,
the controller will automatically change the entry to 45. If the user attempts to enter a slope greater than 60 mV/pH,
the controller will change the entry to 60 mV/pH. See Section 11.5.1 for troubleshooting sensor slope problems.

11.5.4 Sensor does not respond to known pH changes.

A. Did the expected pH change really occur? If the process pH reading was not what was expected, check the

performance of the sensor in buffers. Also, use a second pH meter to verify the change.

B. Is the sensor properly wired to the analyzer?

C. Is the glass bulb cracked or broken? Check the glass electrode impedance under diagnostic variables. See

Section 11.1

D. Is the analyzer working properly. Check the analyzer by simulating the pH input. See Section 11.10

11.5.5 Calibration was successful, but process pH is slightly different from expected value.

Differences between pH readings made with an on-line instrument and a laboratory or portable instrument are
normal. The on-line instrument is subject to process variables, for example ground potentials, stray voltages, and
orientation effects that may not affect the laboratory or portable instrument. To make the process reading agree
with a referee instrument, standardize the sensor using the procedure in Section 8.4.

71

MODEL FCL-54eA SECTION 11.0

TROUBLESHOOTING

11.5.6 Calibration was successful, but process pH is grossly wrong and/or noisy.

Grossly wrong or noisy readings suggest a ground loop (measurement system connected to earth ground at more
than one point), a floating system (no earth ground), or noise being brought into the analyzer by the sensor cable.
The problem arises from the process or installation. It is not a fault of the analyzer. The problem should disappear
once the sensor is taken out of the system. Check the following:

A. Is a ground loop present?

1. Verify that the system works properly in buffers. Be sure there is no direct electrical connection between
the buffer containers and the process liquid or piping.

2. Strip back the ends of a heavy gauge wire. Connect one end of the wire to the process piping or place it
in the process liquid. Place the other end of the wire in the container of buffer with the sensor. The wire
makes an electrical connection between the process and sensor.

3. If offsets and noise appear after making the connection, a ground loop exists.

B. Is the process grounded?

1. The measurement system needs one path to ground: through the process liquid and piping. Plastic pip­ing, fiberglass tanks, and ungrounded or poorly grounded vessels do not provide a path. A floating system
can pick up stray voltages from other electrical equipment.

2. Ground the piping or tank to a local earth ground.

3. If noise still persists, simple grounding is not the problem. Noise is probably being carried into the instru­ment through the sensor wiring.

C. Simplify the sensor wiring.

1. First, verify that pH sensor wiring is correct. Note that it is not necessary to jumper the solution ground and
reference terminals.

2. Disconnect all sensor wires at the analyzer except pH/mV IN, REFERENCE IN, RTD IN and RTD
RETURN. See the wiring diagrams in Section 3.3. If the sensor is wired to the analyzer through a remote
junction box containing a preamplifier, disconnect the wires at the sensor side of the junction box.

3. Tape back the ends of the disconnected wires to keep them from making accidental connections with other
wires or terminals.

4. Connect a jumper wire between the RTD RETURN and RTD SENSE terminals (see wiring diagrams in
Section 3.3).

5. If noise and/or offsets disappear, the interference was coming into the analyzer through one of the sensor
wires. The system can be operated permanently with the simplified wiring.

D. Check for extra ground connections or induced noise.

1. If the sensor cable is run inside conduit, there may be a short between the cable and the conduit. Re-run
the cable outside the conduit. If symptoms disappear, there is a short between the cable and the conduit.
Likely a shield is exposed and touching the conduit. Repair the cable and reinstall it in the conduit.

2. To avoid induced noise in the sensor cable, run it as far away as possible from power cables, relays, and
electric motors. Keep sensor wiring out of crowded panels and cable trays.

3. If ground loops persist, consult the factory. A visit from a technician may be required to solve the problem.

11.5.7 Process pH readings are noisy.

A. Is the sensor dirty or fouled? Suspended solids in the sample can coat the reference junction and interfere

with the electrical connection between the sensor and the process liquid. The result is often a noisy reading.
B. Is the sensor properly wired to the analyzer? See Section 3.3.
C. Is a ground loop present? Refer to Section 11.5.6.

72

MODEL FCL-54eA SECTION 11.0

TROUBLESHOOTING

11.7 TROUBLESHOOTING NOT RELATED TO MEASUREMENT PROBLEMS

Problem Action

Display segments missing Replace display board
Alarm relays are chattering 1. Check alarm setpoints.

2. Increase hysteresis time delay settings (see Section 5.6)

Incorrect current output 1. Verify that output load is less than 600 Ω.

2. For minor errors, trim outputs (see Section 8.0)

3. Replace power supply board
Display too light or too dark Change contrast (see Section 5.4)
“Level 1, 2 or 3 security: Lock” shown in display Analyzer has password protection (see Section 5.11)
“Hold mode activated” showing in display Analyzer is in hold (see Section 5.5, steps 8 and 9)
“Simulating output 1 or 2” showing in display Analyzer is simulating outputs (see Section 5.3)
“Simulating alarm 1, 2, 3 or 4” showing in display Analyzer is simulating alarms (see Section 5.3)

11.8 TROUBLESHOOTING WHEN NO ERROR MESSAGE IS SHOWING–TEMPERATURE

11.8.1 Difference Between Analyzer and Standard Thermometer is Greater Than 3°C.

A. Is the standard thermometer, RTD, or thermistor accurate? General purpose liquid-in-glass thermometers,

particularly ones that have been mistreated, can have surprisingly large errors.

B. Is the temperature element in the pH sensor completely submerged in the test liquid?

C. Is the standard temperature sensor submerged to the correct level?

D. Review Section 6.2.

11.9 SIMULATING INPUTS - FREE CHLORINE

To check the performance of the analyzer use a decade box and a battery to simulate the current from the
sensor. The battery, which opposes the polarizing voltage, is necessary to ensure that the sensor current has the
correct sign.

A. Disconnect the anode and cathode leads from terminals 1 and 2 on TB3 and connect a decade box and

battery as shown in Figure 11-2. It is not necessary to disconnect the RTD leads.

B. Set the decade box to the 2.8 MΩ.

C. Note the sensor current. It should about 500 nA. The

actual value depends of the voltage of the battery. To
view the sensor current from the main display, press
any key to enter the main menu. Move the cursor to
"Diagnostics" and press Enter (F4). The sensor current
is the second line in the display. Note the units: μA is
microamps, nA is nanoamps.

D. Change the decade box resistance and verify that the

correct current is shown. Calculate expected current
from the equation:

current (nA) =

The voltage of a fresh 1.5 volt battery is about 1.6 volt
(1600 mV).The polarizing voltage is 0.2 volt (200 mV)

V

battery

- V

polarizing

(mV)

resistance (MΩ)

FIGURE 11-2. Simulate Chlorine and Ozone

73

MODEL FCL-54eA SECTION 11.0

TROUBLESHOOTING

11.10 SIMULATING INPUTS - pH

11.10.1 General

This section describes how to simulate a pH input into the analyzer. To simulate a pH measurement, connect a
standard millivolt source to the analyzer. If the analyzer is working properly, it will accurately measure the input
voltage and convert it to pH.

11.10.2 Simulating pH input.

1. Turn off automatic temperature correction (Section 5.8) and set the manual temperature to 25°C.

2. Disconnect the sensor, including the jumper between the ANODE and REFERENCE IN terminals, and
connect a jumper wire between the pH IN and the REFERENCE IN terminals.

3. From the Diagnostics menu scroll down until the "pH input" line is showing. The pH input is the raw voltage
signal in mV. The measured voltage should be 0 mV and the pH should be 7.00. Because calibration data
stored in the analyzer may be offsetting the input voltage, the displayed pH may not be exactly 7.00.

4. If a standard millivolt source is available, disconnect
the jumper wire between the pH IN and the REFER­ENCE IN terminals and connect the voltage source as
shown if Figure 11-3.

5. Calibrate the analyzer using the procedure in Section

8.2. Use 0.0 mV for Buffer 1 (pH 7.00) and -177.4 mV
for Buffer 2 (pH 10.00). If the analyzer is working prop­erly, it should accept the calibration. The slope should
be 59.16 mV/pH and the offset should be zero.

6. To check linearity, set the voltage source to the values
shown in the table and verify that the pH and millivolt
readings match the values in the table.

Voltage (mV) pH (at 25°C)

295.8 2.00

177.5 4.00

59.2 6.00

-59.2 8.00

-177.5 10.00

-295.8 12.00

FIGURE 11-3. Simulate pH

74

MODEL FCL-54eA SECTION 11.0

TROUBLESHOOTING

11.11 SIMULATING TEMPERATURE

11.11.1 General.

The free chlorine sensor used in the FCL uses a Pt100
RTD in a three-wire configuration. See Figure 11-4.

11.11.2 Simulating temperature

To simulate the temperature input, wire a decade box to
the analyzer or junction box as shown in Figure 11-5.

To check the accuracy of the temperature measurement,
set the resistor simulating the RTD to the values indicated
in the table and note the temperature readings. The meas­ured temperature might not agree with the value in the
table. During sensor calibration an offset might have been
applied to make the measured temperature agree with a
standard thermometer. The offset is also applied to the
simulated resistance. The controller is measuring temper­ature correctly if the difference between measured temperatures equals the
difference between the values in the table to within ±0.1°C.

For example, start with a simulated resistance of 103.9 Ω, which corresponds
to 10.0°C. Assume the offset from the sensor calibration was -0.3 Ω. Because
of the offset, the analyzer calculates temperature using 103.6 Ω. The result is

9.2°C. Now change the resistance to 107.8 Ω, which corresponds to 20.0°C.
The analyzer uses 107.5 Ω to calculate the temperature, so the display reads

19.2°C. Because the difference between the displayed temperatures (10.0°C)
is the same as the difference between the simulated temperatures, the
analyzer is working correctly.

FIGURE 11-4. Three-Wire RTD Configuration.

Although only two wires are required to connect the RTD
to the analyzer, using a third (and sometimes fourth) wire
allows the analyzer to correct for the resistance of the
lead wires and for changes in the lead wire resistance
caused by changes in ambient temperature.

Temp. (°C) Pt 100 (Ω)

0 100.0

10 103.9

20 107.8

25 109.7
30 111.7
40 115.5
50 119.4

60 123.2
70 127.1

FIGURE 16-5. Simulating RTD Inputs.

11.12 MEASURING REFERENCE VOLTAGE

Some processes contain substances that poison or shift the
potential of the reference electrode. Sulfide is a good exam­ple. Prolonged exposure to sulfide converts the reference
electrode from a silver/silver chloride electrode to a silver/sil­ver sulfide electrode. The change in reference voltage is sev­eral hundred millivolts. A good way to check for poisoning
is to compare the voltage of the reference electrode with a
silver/silver chloride electrode known to be good. The refer­ence electrode from a new sensor is best. See Figure 11-6. If
the reference electrode is good, the voltage difference should
be no more than about 20 mV. A poisoned reference electrode
usually requires replacement.

75

MODEL FCL-54eA SECTION 11.0

TROUBLESHOOTING

FIGURE 11-6. Checking for a Poisoned

Reference Electrode.

Refer to the sensor wiring diagram to identify the
reference leads. A laboratory silver/silver chloride
electrode can be used in place of the second sensor.

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