Model 450
Free Residual Chlorine Sensor Assembly
Instruction Manual
PN 51-450/rev.B
March 2006
CAUTION
SENSOR/PROCESS
APPLICATION COMPATIBILITY
The wetted sensor materials may not
be compatible with process composition and operating conditions.
Application compatibility is entirely the
responsibility of the user.
DANGER
HAZARDOUS
AREA INSTALLATION
Installations near flammable liquids or in hazardous area locations must be carefully evaluated by qualified on site safety personnel.
This sensor is not
Intrinsically Safe or
Explosion Proof.
To secure and maintain an intrinsically safe
installation, the certified safety barrier,
transmitter, and sensor combination must
be used. The installation system must comply with the governing approval agency (FM,
CSA or BASEEFA/CENELEC) hazardous
area classification requirements. Consult
your analyzer/transmitter instruction manual
for details.
Proper installation, operation and servicing
of this sensor in a Hazardous Area Installation is entirely the responsibility of the user.
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PRO-
CEEDING!
Rosemount Analytical designs, manufactures, and tests its
products to meet many national and international standards. Because these instruments are sophisticated technical products, you must properly install, use, and maintain
them to ensure they continue to operate within their normal
specifications. The following instructions must be adhered
to and integrated into your safety program when installing,
using, and maintaining Rosemount Analytical products.
Failure to follow the proper instructions may cause any one
of the following situations to occur: Loss of life; personal
injury; property damage; damage to this instrument; and
warranty invalidation.
• Read all instructions prior to installing, operating, and
servicing the product. If this Instruction Manual is not the
correct manual, telephone 1-800-654-7768 and the
requested manual will be provided. Save this Instruction
Manual for future reference.
• If you do not understand any of the instructions, contact
your Rosemount representative for clarification.
• Follow all warnings, cautions, and instructions marked
on and supplied with the product.
• Inform and educate your personnel in the proper installation, operation, and maintenance of the product.
• Install your equipment as specified in the Installation
Instructions of the appropriate Instruction Manual and
per applicable local and national codes. Connect all
products to the proper electrical and pressure sources.
• To ensure proper performance, use qualified personnel
to install, operate, update, program, and maintain the
product.
• When replacement parts are required, ensure that qualified people use replacement parts specified by
Rosemount. Unauthorized parts and procedures can
affect the product’s performance and place the safe
operation of your process at risk. Look alike substitutions may result in fire, electrical hazards, or improper
operation.
• Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is
being performed by qualified persons, to prevent electrical shock and personal injury.
Emerson Process Management
Liquid Division
2400 Barranca Parkway
Irvine, CA 92606 USA
Tel: (949) 757-8500
Fax: (949) 474-7250
http://www.RAuniloc.com
© Rosemount Analytical Inc. 2006
MODEL 450 TABLE OF CONTENTS
MODEL 450
FREE RESIDUAL CHLORINE SENSOR
TABLE OF CONTENTS
Section Title Page
1.0 DESCRIPTION AND SPECIFICATIONS ................................................................ 1
1.1 Features and Applications....................................................................................... 1
1.2 Specifications........................................................................................................... 1
1.3 Ordering Information................................................................................................ 2
2.0 INSTALLATION....................................................................................................... 3
2.1 General.................................................................................................................... 3
2.2 Inspection and Unpacking ....................................................................................... 3
2.3 Application Requirements........................................................................................ 3
2.4 Preparation for Installation and Startup ................................................................... 3
2.5 Installation................................................................................................................ 4
3.0 TROUBLESHOOTING ............................................................................................ 6
3.1 General.................................................................................................................... 6
3.2 Troubleshooting the Model 450 Sensor .................................................................. 6
4.0 MAINTENANCE ...................................................................................................... 9
4.1 General.................................................................................................................... 9
4.2 Scheduled Preventative Maintenance..................................................................... 9
4.3 Sensor Disassembly, Rebuild and Assembly Procedure ........................................ 9
5.0 PARTS LISTS ......................................................................................................... 11
6.0 RETURN OF MATERIAL ........................................................................................ 15
i
MODEL 450 TABLE OF CONTENTS
MODEL 450
FREE RESIDUAL CHLORINE SENSOR
LIST OF FIGURES
Figure Title Page
1-1 Model 450 Dimensional Data 2
2-1 Model 450-01 and 450-02 Sensor Installation Diagrams 4
2-2 Handrail Mounting Installation for Model 450-03 and 450-04 Sensor Assemblies 5
5-1 Models 450-01 and 450-02 Free Residual Chlorine Flow Through Sensors 11
5-2 Model 450-03 Free Residual Chlorine Submersion Sensor 12
5-3 Model 450-04 Free Residual Chlorine Submersion Sensor/Agitator 13
5-4 Model 450 Free Residual Chlorine Sensor Assembly 14
LIST OF TABLES
Table Title Page
3-1 Temperature Resistance Chart 7
3-2 Model 1054A TFC Quick Troubleshooting Chart 8
1
MODEL 450 SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
1.1 FEATURES AND APPLICATIONS
The Rosemount Analytical Model 450 Free Residual
Chlorine Sensor, used with the Model 1054A Total
Free Chlorine Analyzer and the Models 1181 or 853
free residual chlorine analyzer/transmitter, measures
the free residual chlorine level in a wide variety of
applications, such as: Potable water treatment,
sewage plant effluent, cooling tower chlorination control, swimming pools, and industrial waste treatment
plant effluent.
The Model 450 sensor is constructed of PVC with
polymer membrane, hardwood liquid junction*, and
stainless steel hardware. The sensor is designed for
flow (Codes 01 and 02), submersion in a flowing sample (Code 03), and submersion in a stagnant pond
(Code 04). All sensors are furnished with an integral
20-foot cable. The Code Option 04 incorporates an
agitator and impeller, with a 20-foot power cord, for
agitation of a stagnant solution so a fresh sample is
always present at the sensor membrane in submersion applications.
The membrane retainer** is designed for ease of
installation, and provides adequate tension on the
membrane to insure an accurate measurement. In
addition, the electrolyte chamber incorporates a pressure compensator to maintain equal pressure on both
sides of the membrane, despite sample pressure
changes. A thermistor or an RTD for automatic temperature compensation is incorporated in the tip of the
sensor to adjust for temperature change effects on the
diffusion rate of free residual chlorine across the
membrane.
The sensor requires very little maintenance and
requires no special tools or fixtures.
1.2 SPECIFICATIONS
Temperature: 0 to 50°C (32 to 122°F)
Pressure: 0 to 345 kPa abs (0 to 50 psig)
Material: Housing: PVC
Hardware: Stainless steel
Liquid Junction: Hardwood
O-Rings: Buna-N
Membrane: Polymer
Cathode: Gold
Anode: Silver
Minimum Sample Flow Rate:
Code 01 & 02: 0.13 liter/sec (2 GPM)
Code 03: 0.3 meter/sec (1 ft/sec)
Code 04: None
Agitator Power Requirement:
(Model Code 04 only): 115 VAC ±10% 60Hz (0.2
amp)
Weight/Shipping Weight:
Code 01, 02 & 03: 0.9 kg/1.8 kg (2lbs/4 lbs)
Code 04: 2.3 kg/3.2 kg (5 lbs/7lbs)
• ELIMINATES THE NEED FOR WET CHEMICAL ANALYSIS.
• LOW MAINTENANCE with up to 12 months between rechargings.
• THREE CONFIGURATIONS AVAILABLE to meet most applications.
• COMPACT DESIGN provides for ease of installation and service.
*U.S. Patent No. 4,187,162
**U.S. Patent No. 3,887,194
Canadian Patent No. 1,025,496
2
MODEL 450 SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
1.3 ORDERING INFORMATION
Model 450 Free Residual Chlorine Sensor Includes PVC sensor housing with integral chlorine permeable
membrane and temperature compensator.
MODEL
450 FREE RESIDUAL CHLORINE SENSOR (3 lbs./1.5 kg)
CODE MOUNTING HARDWARE
01 1-1/2 inch PVC cell, 90° flow
02 1-1/2 inch PVC cell, 180° flow
03 PVC union with 3/4 inch FNPT for submersion service
04 PVC union with 1 inch FNPT, and agitator with 20-ft. cable for submersions. Agitator motor requires 115 VAC power only.
450 01 17 EXAMPLE
CODE OPTIONS
11 Stainless steel tags (specify marking)
14 Handrail mounting bracket (P/N 1000857) for use with J-box (see Code 17 below)
15 Handrail mounting bracket (P/N 1000856) for use with Model 803
17 Weatherproof NEMA 4X junction box (P/N 22719-02)
54 For use with Models 1054A TFC
NOTE: Recommended cable from sensor to transmitter is Belden 8434 or equivalent, available from Rosemount Analytical (P/N 9200074).
Specify length.
FIGURE 1-1. MODEL 450 DIMENSIONAL DATA
*CODE 02 SAME AS CODE 01 EXCEPT SENSOR MOUNTED IN TOP OF TEE, WITH FLOW IN EITHER DIRECTION
3
MODEL 450 SECTION 2.0
INSTALLATION
SECTION 2.0
INSTALLATION
2.1 GENERAL. This section provides installation
instructions for the Model 450 Sensor Assembly.
2.2 INSPECTION AND UNPACKING. Inspect the shipping container for any evidence of damage. If damage
is evident, notify the carrier immediately. If no damage
is evident, open the container and inspect the sensor.
Save the container for shipment to the factory for service.
2.3 APPLICATION REQUIREMENTS. The Model 450
is designed for typical clean water application. It is
NOT designed for the following:
1.
Processes containing ammonia (municipal waste water).
2. Processes containing sea water or bromine chem-
ical additions.
3. Low conductivity processes, less than 50 micro-
siemens (reverse osmosis).
4. Post-dechlorination processes (example: after
adding sodium bisulfite).
2.4 SENSOR PREPARATION FOR INSTALLATION
AND START-UP. The plumbing fittings provided on the
Model 450 Sensor differ slightly, depending on the piping
requirements. However, the main body, or chlorine sensing portion of each of the different codes, is identical. Each
sensor is shipped from the factory dry and without a
membrane installed. The recharge kit which accompa-
nies the sensor contains one bottle of dry electrolyte and
five membranes. The sensor should be charged utilizing
the following procedure:
CAUTION
Clean rubber gloves should be worn during
sensor preparation and maintenance to
avoid skin contact and contaminating the
membrane and cathode.
1. Prepare sensor electrolyte by filling the bottle of
crystals supplied with the recharge kit (Ag Cl/KCI)
to the neck with distilled or deionized water. Stir or
shake to wet crystals thoroughly. Some crystals
should remain undissolved.
NOTE
Please see Figure 5-4 for Model 450 Free
Residual Sensor assembly exploded view.
2. Remove sensor “cover” and membrane “Retainer”
(remove 6 screws at sensor tip).
3. Sand the gold cathode with the 400 grit sandpa-
per, in one direction only
until it is shiny. Rinse
cathode with clean water.
4. Remove the fill-plug.
5. Fill the syringe (included in the recharge kit) with
the AgCl/KCl electrolyte solution. Fill the sensor
body with the electrolyte, shaking the sensor to
remove air. Ensure that about 1 cc (or 1 ml) of
crystals get inside the sensor body.
6. Install the fill plug (wrapped with one or two turns
of TEFLON
®1
tape in the side of the sensor. As the
plug is screwed into place, electrolyte will be
forced through the wood junction. This is important, since the electrical continuity will not be
established unless the wood junction is thoroughly wetted.
Continue to screw the fill plug into place until it is flush
with the sensor body. Do not remove excess electrolyte
from the end of the sensor because it will wet the membrane and help hold it in place during installation.
7. Place the O-ring in the groove and press it into position around the wood junction. If there is no solution
remaining over the gold cathode after installing the Oring, add a few drops of electrolyte (no crystals).
IMPORTANT: No crystals underneath the membrane or damage will occur.
8. Place the white-opaque “membrane” on top of the
cathode. Place the white-translucent “protector”
over the membrane. DO NOT use the blue-paper
protective separators found in the membrane kit!
9. Lay the membrane “retainer” over the membrane
and protector. Screw down the (6) screws applying
even pressure. The membrane should be taut, not
spongy, when the retainer is secure.
10. Keep the sensor tip in water if installation is delayed
over an hour. Membrane may adhere to the cathode if allowed to dry out.
11. Sensor requires approximately (2) hours to polarize and (12-24) hours to obtain a stable zero in
chlorine-free water.
NOTE
Water should be agitated for zeroing and
spanning (magnetic stirrer is recommended)
CAUTION
Insufficient zeroing time may cause difficulties in calibration and readings that
drift.
1
Reg. U.S. Pat. Office for DuPont's fluorocarbon resins
4
MODEL 450 SECTION 2.0
INSTALLATION
12. Chlorine concentrations of 1 PPM or above are recommended for the most accurate chlorine calibration.
IMPORTANT: Process flow requirement is 1 ft./sec.
or if in a “Tee” 2.0-5.0 gal./min. If unable to adjust
process chlorine concentration to this level, perform
calibration in a beaker with a magnetic stirrer for agitation. Adding a drop or two of chlorine bleach to
deionized water (buffered to 7 pH) will create a chlorine residual.
13. Calibrate the chlorine reading to the titrated value
of the process or the chlorine residual sample.
14. The sensor is now ready to be installed.
2.5 INSTALLATION.
2.5.1 Mechanical Installation.
1. Model 450-01 and 450-02 Sensor Assemblies.
These sensors are available in two configurations:
Angle flow (Code 01) and straight flow (Code 02).
The PVC tee is for plumbing into 1-1/2 inch PVC
(SCH 80) tubing. Direction of flow should be as
shown in Figure 2-1.
2. Models 450-03 and 450-04 Sensor Assemblies.
These sensors are for submersion applications. If a
handrail mounting bracket (Code 14) is to be used,
refer to Figure 2-2 for installation details. The Model
450-03 Sensor Assembly should be installed in a
stream having a minimum flow of 1.5 ft./sec. to
obtain rated response time. Attach the union adapter
to a 3/4 inch FPT PVC (SCH 80) tube or metal pipe.
If PVC to metal connection is made, use RTV silicone rubber adhesive/sealant (Rosemount
Analytical P/N 9220106 or 9220018). Check the connection frequently for looseness, until no more looseness is observed. The sensor may be submerged to
a depth of up to 6.1 meters (20 feet).
CAUTION
Use extreme care when attaching PVC tubing or
components to metal pipe. Over-tightening can
cause damage to the PVC or components, so
tighten only until pressure is felt.
3. Model 450-04 Sensor Assembly. The Model 450-04
Sensor Assembly is for installation in processes
where insufficient flow or agitation exists. Attach the
union adapter to a 1 inch FPT PVC (SCH 80) tube
or metal pipe. If PVC to metal connection is made,
refer to Paragraph 2 and the CAUTION which follows. The sensor may be submerged to a depth of
up to 6.1 meters (20 feet). The agitator cable is
water tight and should be fastened to the standpipe
with tiewraps every five feet.
2.5.2 Electrical Installation. All sensors are wired the
same. Connect the sensor wiring as follows:
NOTE
The sensor is supplied with 20 feet of cable. If
more is needed, use Belden 8434 cable or
equivalent, available from Rosemount
Analytical as P/N 9200074 (specify length).
Junction box (P/N 22719-02) may be used for
connection if extended length of cable is used.
FIGURE 2-1. Model 450-01 and 450-02 Sensor Installation Diagrams
Transmitter
1054RCI/
Sensor Lead 1054ARCI/
1054ATFC 1181RCI 853RCI
Shield (Guard) to TB2-6 TB2-2 TB1-15
White (TC) to TB2-5 TB2-1 TB1-18
Green (TC) to TB2-7 TB2-3 TB1-17
Red (Anode) to TB2-1 TB2-4 TB1-16
Black (Cathode) to TB2-3 TB2-3 TB1-14
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