FCLi with 56 Analyzer
Instruction Manual
PN 51-FCLi-56 rev.C
June 2013
This product generates, uses, and can radiate radio frequency
energy and thus can cause radio communication interference.
Improper installation, or operation, may increase such interference. As temporarily permitted by regulation, this unit has not
been tested for compliance within the limits of Class A computing devices, pursuant to Subpart J of Part 15, of FCC Rules,
which are designed to provide reasonable protection against
such interference. Operation of this equipment in a residential
area may cause interference, in which case the user at his own
expense, will be required to take whatever measures may be
required to correct the interference.
CAUTION
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: (949) 757-8500
Fax: (949) 474-7250
http://www.rosemountanalytical.com
© Rosemount Analytical Inc. 2012
WARNING
RISK OF ELECTRICAL SHOCK
WARNING
QUICK START GUIDE
FOR FCLi ANALYZER
1. Refer to Section 2.0 for installation instructions and Section 3.0 for wiring instructions.
2. Once connections are secure and verified, apply power to the analyzer.
3. When the analyzer is powered up for the first time Quick Start screens appear.
4. The first quick start screen has two control boxes, one for language and the other for temperature units.
a. The cursor, shown by dark blue backlighting, will be on the language control box. To change the language,
press the ENTER/MENU key. A list of available languages, shown two at a time, will appear. Using the up
and down keys, scroll (see section 4.2) to display the choices. Press ENTER/MENU to select the desired
language. Press the down key to move to the cursor to the temperature control box. To change units,
press ENTER/MENU and scroll to either °F or °C. Press ENTER/MENU to store the selection.
b. To move to the next screen, use the navigation keys to move the cursor to NEXT and press
ENTER/MENU.
5. The next screen lists navigation rules. Press ENTER/MENU for the next screen.
6. The next step is to configure sensor 1. Sensor 1 is the free chlorine sensor. The screen has three control boxes.
a. For measurement choose pH-independent free chlorine.
b. Choose the desired units, mg/L or ppm
7. If you have an FCLi-02 (with pH sensor), the next step is to configure sensor 2 (the pH sensor). The screen has two
control boxes.
a. For measurement choose pH.
b. For pre-amplifier location choose analyzer.
c. Move the cursor to NEXT and press ENTER/MENU. The display will change to show some basic keypad
operation guidelines. Press ENTER/MENU to show the main display.
8. The outputs, alarms, display configuration, and data logging are all assigned to default values. The default value for
data logging is disabled. To change the settings refer to Sections 4.5, 5.0, and 8.0.
About This Document
This manual contains instructions for installation and operation of the FCLi-56
The following list provides notes concerning all revisions of this document.
Rev. Level
Date Notes
A 7/11 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 03/12 Update addresses - maill and web
C 06/13 Correct PN 33521-03, page 37
i
MODEL FCLI-56 TABLE OF CONTENTS
FCLi-56
TABLE OF CONTENTS
Section Title Page
1.0 DESCRIPTION AND SPECIFICATIONS ................................................................ 1
1.1 Applications and Features ..................................................................................... 1
1.2 Specifications........................................................................................................... 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 Preparing Conduit Openings.................................................................................... 9
3.2 Power, Alarm, Output, and Sensor Connections ..................................................... 10
4.0 DISPLAY AND OPERATION................................................................................... 13
4.1 Display ..................................................................................................................... 13
4.2 Keypad..................................................................................................................... 14
4.3 Programming the Analyzer - Tutorial........................................................................ 15
4.4 Security .................................................................................................................... 16
4.5 Using Hold ............................................................................................................... 17
4.6 Configuring the Main Display ................................................................................... 18
5.0 PROGRAMMING THE ANALYZER ........................................................................ 19
5.1 General .................................................................................................................... 19
5.2 Default Settings........................................................................................................ 19
5.3 Configuring, Ranging and Simulating Outputs......................................................... 22
5.4 Configuring Alarms and Assigning Setpoints ........................................................... 25
5.5 Configuring the Measurement.................................................................................. 30
5.6 Configuring Temperature Related Settings.............................................................. 32
5.7 Configuring Security Settings................................................................................... 33
5.8 Setting up Diagnostics ............................................................................................. 34
5.9 Resetting the Analyzer............................................................................................. 36
6.0 CALIBRATION ........................................................................................................ 37
6.1 Introduction .............................................................................................................. 37
6.2 Calibrating Temperature........................................................................................... 37
6.3 Calibration - Free Chlorine ...................................................................................... 39
6.4 Calibration - pH ....................................................................................................... 42
6.5 Calibration - Analog Outputs .................................................................................... 49
Section Title Page
7.0 DIGITAL COMMUNICATIONS ............................................................................... 51
8.0 MAINTENANCE ...................................................................................................... 53
8.1 Analyzer ................................................................................................................... 53
8.2 Chlorine Sensor ....................................................................................................... 54
8.3 pH Sensor ................................................................................................................ 56
8.4 Constant Head Flow Controller................................................................................ 56
9.0 TROUBLESHOOTING ........................................................................................... 59
9.1 Overview .................................................................................................................. 59
9.2 Using the Diagnostic Feature................................................................................... 59
9.3 Troubleshooting When a Fault Message is Showing.............................................. 60
9.4 Troubleshooting When a Warning Message is Showing.......................................... 63
9.5 Troubleshooting When No Error Message is showing - Chlorine ............................ 64
9.6 Troubleshooting When No Error Message is showing - pH ..................................... 67
9.7 Troubleshooting When No Error Message is showing - General............................. 70
9.8 Simulating Inputs - Chlorine..................................................................................... 70
9.9 Simulating Inputs - pH.............................................................................................. 70
9.10 Simulating Inputs Temperature ................................................................................ 71
LIST OF TABLES
Number Title Page
1.3 Ordering Information ............................................................................................... 3
1.3 Component Parts ..................................................................................................... 3
1.3 Accessories .............................................................................................................. 3
1.3 Spare Parts............................................................................................................... 3
3.2 Sensor Wiring........................................................................................................... 10
4.6 Configuring the Main Display ................................................................................... 18
5.1 Default Settings ........................................................................................................ 20
5.1 Default Settings cont ................................................................................................ 21
5.7 Configuring Security Settings ................................................................................... 33
5.8.2 Procedure - Setting Up Diagnostics ......................................................................... 35
6.4 Calibration - pH ........................................................................................................ 42
8.1 Analyzer ................................................................................................................... 53
8.2.3 Spare Parts .............................................................................................................. 55
8-2 Replacement Parts for Constant Head Flow Controller Assembly (Model FCLi-01)
................................................................................................................................57
8-3 Replacement Parts for Constant Head Flow Controller Assembly (Model FCLi-02)
................................................................................................................................58
9.3 Troubleshooting When a Fault Message is Showing ............................................... 60
9.4 Troubleshooting When a Warning Message is Showing .......................................... 63
9.5 Troubleshooting When No Error Message is Showing - Chlorine ............................ 64
9.6 Troubleshooting When No Error Message is Showing - pH..................................... 67
MODEL FCLi-56 TABLE OF CONTENTS
TABLE OF CONTENTS CONT’D
ii
LIST OF FIGURES
Number Title Page
2-1 Chlorine Sensor Parts .............................................................................................. 7
2-2 FCLi-01..................................................................................................................... 8
2-3 FCLi-02..................................................................................................................... 8
3-1 Analog Output Connections ..................................................................................... 9
3-2 Alarm Relay Connections......................................................................................... 10
3-3 Wiring Diagram for Free Chlorine Sensor ................................................................ 11
3-4 Wiring Diagram for 399VP-09 pH Sensor ............................................................... 11
3-5 Wiring Diagram for 3900VP-10 pH sensor (gray cable)........................................... 11
3-6 Wiring Diagram for 3900VP-10 pH sensor (blue cable) ........................................... 11
4-1 Main Display............................................................................................................. 13
4-2 Programming Screen Showing Item List .................................................................. 13
4-3 Arrow Bar ................................................................................................................. 13
4-4 Analyzer Keypad ...................................................................................................... 14
4.5 Navigation Keys ....................................................................................................... 14
5-1 High Alarm Logic ..................................................................................................... 26
5-2 Low Alarm Logic ...................................................................................................... 26
5-3 Operation of the Interval Timer................................................................................. 26
6-1 Sensor Current as a Function of Free Chlorine Concentration ................................ 39
6-2 Calibration Slope and Offset .................................................................................... 42
8-1 Chlorine Sensor Parts .............................................................................................. 55
8-2 Replacement Parts for the Flow Controller Assembly used in Model FCLi-01......... 57
8-3 Replacement Parts for the Flow Controller Assembly used in Model FCLi-02......... 58
9-1 Pin Out Diagram for Model 498CL-01-VP Sensor ................................................... 61
9-2 Pin Out Diagram for Model 399VP-09 Sensor ......................................................... 61
9-3 Simulating pH Inputs ................................................................................................ 70
9-4 Three-Wire RTD Configuration................................................................................. 71
9-5 Simulating TRD Inputs.............................................................................................. 71
MODEL FCLi-56 TABLE OF CONTENTS
LIST OF TABLES CONT’D
9.6.1 Calibration Error During Two-Point Calibration ........................................................ 67
9.7 Troubleshooting When No Error Message is Showing - General............................. 70
9.9.2 Simulating pH Input .................................................................................................. 70
9.10 Simulating Inputs Temperature................................................................................. 72
iii
THIS PAGE LEFT BLANK INTENTIONALLY
Model FCLi-56 SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
SECTION 1.0.
DESCRIPTION AND SPECIFICATIONS
1
• COMPLETE SYSTEM INCLUDES sensor, connecting cable, analyzer, and flow controller
• SENSOR RESPONSE IS PRACTICALLY INDEPENDENT of pH between pH 6 and 10
• NO REAGENTS
• NO AUXILIARY pH ELECTRODE
• VARIOPOL QUICK-DISCONNECT FITTINGS makes sensor replacement easy
1.1 APPLICATIONS AND FEATURES
The FCLi free chlorine system is intended for the
determination of free chlorine (hypochlorous acid plus
hypochlorite ion) in fresh water. Unlike other free chlorine analyzers, the FCLi does not use expensive sample conditioning systems or messy reagents to control
pH. Nor, does it require an auxiliary pH sensor for pH
correction. Instead, the pH adjustment takes place
inside the sensor, producing a signal that changes
less than 4% per unit change in pH between pH 6 and
10. Below pH 6.5 the change is less than 1%. The linear range of the sensor is 0 to 20 ppm (mg/L).
The FCLi is not intended for the determination of total
or combined chlorine (like monochloramine). Nor, can
the FCLi be used for the determination of chlorine in
seawater.
The FCLi uses a three electrode, membrane-covered
amperometric sensor. The sensor consists of a
hydrophilic membrane stretched over a gold mesh
cathode. A silver/silver chloride reference electrode
and an external copper auxiliary electrode complete
the circuit. The fill solution is saturated succinic acid
slurry. During operation, an electrochemical reaction,
driven by the polarizing voltage, consumes free chlorine at the cathode surface. The auxiliary electrode
provides the electrons for the cathode reaction, and
a current proportional to the reaction rate flows
between the electrodes. Because the concentration of
chlorine at the cathode is zero, free chlorine in the
sample continuously diffuses through the membrane
and is destroyed at the cathode. Thus, the cathode
current is proportional to the diffusion rate, which is
proportional to the concentration of free chlorine in the
sample.
The FCLi sensor requires neither sample pretreatment
nor pH correction. All amperometric free chlorine sensors generate a raw current that depends primarily on
the concentration of hypochlorous acid. Because the
fraction of free chlorine present as hypochlorous acid
is a function of pH, readings will be in error if the sample pH changes from the value it had during calibration. To correct for pH changes, some manufacturers
treat the sample with acid to convert hypochlorite to
hypochlorous acid. Others continuously measure the
pH and use the pH value to correct the chlorine sensor
reading. The Model FCLi is different. The sensor uses
a highly buffered acidic fill solution for internal pH
adjustment. The fill solution converts all the free chlorine entering the sensor as well as much of the free
chlorine at the outside surface of the membrane into
hypochlorous acid. Thus, the sensor response is practically independent of pH.
For customers who wish to measure pH, an option
that includes a pH sensor and flow cell is available.
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
membrane and fill slurry takes only a few minutes.
The FCLi includes the easy-to-use Model 56 analyzer.
The analyzer features four fully programmable 4-20
mA outputs and four fully programmable relays. The
large, full color display allows the user to read sample
pH and chlorine concentration at a glance. A data logger, graphical display, and HART digital communications are standard.
Valves, rotameters, and pressure regulators to control
sample flow are things of the past with the FCLi. A
constant head overflow sampler ensures the correct
flow to the sensor no matter how much the sample
flow or pressure changes. 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 on a grab sample.
1.2 SPECIFICATIONS — GENERAL
Sample requirements:
Pressure: 3 to 65 psig (122 to 549 kPa abs)
A check valve in the inlet 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: 2 gal/hr (7.6 L/hr)
Maximum flow: 80 gal/hr (303 L/hr); high flow
causes the overflow tube to back up.
Sample Conductivity: >10 µS/cm
Process connection: 1/4-in OD tubing compression
fitting (can be removed and replaced with barbed
fitting for soft tubing).
Drain connection: 3/4-in barbed fitting. Sample must
drain to open atmosphere.
Wetted parts:
Overflow sampler: acrylic, polycarbonate,
polyester, Kynar1, nylon, silicone
Chlorine sensor: PVC, Viton2, silicone, polyether-
sulfone, polyester, gold, and copper (or 316
stainless steel)
pH sensor (3900VP) : Stainless steel, glass,
Teflon®2, polyphenylene sulfide, EPDM, and
silicone
Response time to step change in chlorine concen-
tration: <120 sec to 90% of final reading for inlet
sample flow of 2 gph (7.6 L/hr).
Weight/shipping weight:
Model FCLi-01: 10 lb/13 lb (4.5 kg/6.0 kg)
Model FCLi-02: 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 20 ppm as Cl2. For higher
ranges, consult the factory.
Accuracy: Accuracy depends on the accuracy of the
chemical test used to calibrate the sensor
Linearity (0-20 ppm): 1% per IEC 60746
Linearity (0-2 ppm): ±0.05 ppm following calibration
at 2 ppm
Sensitivity to pH: Between pH 6.5 and 10, sensor
signal changes <4% per unit change in pH. Below
pH 6.5 the change is
<1% per unit change in pH.
Interferences: Monochloramine, dichloramine, and
permanganate, peroxides
Electrolyte life: 3 months (approx.)
SPECIFICATIONS — ANALYZER
Case: Polycarbonate
Display: Full color LCD, 3.75 x 2.20 in. (95 x 56 mm);
display can be customized by the user.
Languages: English, French, German, Italian, Spanish,
Portuguese, Chinese, Russian, and Polish.
Ambient Temperature and Humidity: 14 to 140°F
(-10 to 60°C); RH 5 to 95% (non-condensing).
Between 23 and 131°F (-5 to 55°C) there is no visible degradation in display response or performance.
Storage temperature: -4 to 140°F (-20 to 60°C)
Power: 85 to 265 VAC, 47.5 to 65.0 Hz, 20 W
RFI/EMI: EN-61326
LVD: EN-6101-01
Outputs: Four 4-20 or 0-20 mA isolated current outputs;
assignable to measurement or temperature; fully
scalable; maximum load 550 Ω. HART digital signal
is superimposed on output 1.
Alarms and Timers: Four relays, fully configurable as
a setpoint alarm, interval timer, TPC, bleed and
feed timer, delay timer, date and time timer, and
fault alarm.
Relays: Form C, SPDT, epoxy sealed.
Relay Contact ratings:
5 A at 28 VDC or 300 VAC (resistive)
1/8 HP at 120/240 VAC
Control features: PID control (analog output) and time
proportional control or TPC (relays) are standard.
Data logger: Data automatically stored every 30 seconds
for 30 days; older data removed to make room for
new data. The following data are automatically stored:
Chlorine: date and time, ppm, temperature, raw
sensor current
pH: date and time, pH, temperature, mV, glass
impedance, and reference impedance (if available)
Event logger: Stores up to 300 events with data and
time stamp: faults, warnings, calibration data, calibration results (pass or fail), power on/off cycles, and
hold on/off. Alarm relay activation and deactivation
can also be stored. Older events are automatically
removed to make room for new events.
Data and event downloading: through USB port on
front panel.
Graphical display: Dual graphical display shows
measurement data on the y-axis and time on the
x-axis. Y-axis is fully assignable and scalable. Xaxis can be set to one hour, one day, seven days,
or 30 days.
Digital communications: HART digital communica-
tions is standard.
2
MODEL FCLi-56 SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
1
Kynar is a registered trademark of Elf Atochem North America.
2
Viton and Teflon are registered trademarks of DuPont
Performance Eastomers.
3
1.3 ORDERING INFORMATION
Model FCLi Free Chlorine Measuring System. The FCLi is a complete system for the determination of free
chlorine in aqueous samples. It consists of the sensor(s), analyzer, and constant head flow controller. All components are mounted on a backplate. Model option -02 includes a pH sensor for customers who wish to measure
pH in addition to free chlorine. Three replacement membranes and enough electrolyte chemicals to fill the sensor
three times are shipped with each sensor.
ACCESSORIES
PART # DESCRIPTION
9240048-00 Tag, stainless steel (specify marking)
SENSOR CABLE DESCRIPTION
24150-00 Interconnecting cable, Variopol for 498ACL sensor, 4 ft
23645-08 Interconnecting cable, Variopol for 3900VP sensor, 4 ft
SPARE PARTS
PART # DESCRIPTION
33970-00 Fill plug
33968-00 Membrane retainer
9550094 O-ring, 2-014, Viton
®
23501-10 pH-independent free chlorine membrane assembly, includes one membrane assembly and O-ring
23502-10
pH-independent free chlorine membrane assembly, includes three membrane assemblies and three
O-rings
24146-00
pH-independent free chlorine sensor electrolyte kit, includes three bottles of saturated succinic acid and
three bottles of succinic acid crystals
MODEL FCLi-56 SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
COMPONENT PARTS
ANALYZER MODEL DESCRIPTION
56-03-24-38-HT 56-03-24-38-HT, 85–265 VAC, 47.5/65.0 Hz, chlorine only
56-03-24-32-HT 56-03-24-32-HT, 85–265 VAC, 47.5/65.0 Hz, chlorine and pH
CODE pH CORRECTION (required selection)
01 Without pH sensor
02 With pH sensor
CODE pH CORRECTION (required selection)
240
56-03-24-38-HT, 85–265 VAC, 47.5/65.0 Hz, chlorine only (option -01 only)
241
56-03-24-32-HT, 85–265 VAC, 47.5/65.0 Hz, chlorine and pH (option -02 only)
FCLi FREE CHLORINE MEASURING SYSTEM
FCLi-02 -241 EXAMPLE
SENSOR MODEL DESCRIPTION
498CL-01-VP pH Independent free chlorine sensor with Variopol connector
3900VP-02-10 pH sensor with Variopol connector
MODEL FCLi-56 SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
4
SECTION 2.0.
INSTALLATION
MODEL FCLi-56 SECTION 2.0
INSTALLATION
2.1 UNPACKING AND INSPECTION
Inspect the shipping container. If it is damaged, contact the shipper immediately for instructions. Save the box. If
there is no apparent damage, unpack the container. Be sure all items shown on the packing list are present. If
items are missing, notify Rosemount Analytical immediately.
2.1.1 FCLi-01-240 (free chlorine without pH sensor)
Model consists of the following items mounted on a back plate.
1. Model 56-03-24-38-HT analyzer with sensor cable attached.
2. Constant head overflow sampler with flow cell for chlorine sensor.
The free chlorine sensor (Model 498CL-01-VP), is in a separate package. The sensor is shipped with three
membrane assemblies and enough electrolyte chemicals to fill the sensor three times.
2.1.1 FCLi-02-241 (free chlorine with pH sensor)
Model consists of the following items mounted on a back plate.
1. The 56-03-24-32-HT analyzer with sensor cables attached.
2. Constant head overflow sampler with flow cells for chlorine and pH sensors.
3. Stand to hold buffer solution during calibration.
The free chlorine sensor (498CL-01-VP), and the Model 3900VP-02-10 pH sensor, which replaces the older
399VP-09 sensor, are in separate packages. The free chlorine sensor is shipped with three membrane assemblies
and enough electrolyte chemicals to fill the sensor three times.
5
6
MODEL FCLi-56 ... 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: 2 gal/hr (7.6 L/hr)
2.2.3 Mounting and Making Inlet and Drain Connections
The FCLi is intended for wall mounting only. Refer to Figure 2-2 or 2-3 for details.
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. Do not remove the check valve. The threads are 1/4-inch FNPT.
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 to 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. Confirm that
sample is flowing through the flow cells.
2.2.4 Electrical Connections
Refer to Section 3.1 for details.
2.2.5 Installing the Sensor(s)
1. The chlorine sensor leaves the factory with a shipping membrane in place. The shipping membrane
must be removed and replaced with the chlorine membrane before putting the sensor in service. The
chlorine membrane is in a plastic bag attached to the sensor. Do not remove the shipping membrane
until you are ready to put the sensor in service.
a. Remove the red protective cap from the end of the sensor.
b. Holding the membrane end pointing up (cable connector end pointing down), unscrew the retainer cap
and remove the shipping membrane. See Figure 2.1. It is not necessary to remove the O-ring. Save the
shipping membrane. It should be reinstalled on the sensor when the sensor is not in use.
c. Still holding the membrane end pointing up, install the chlorine membrane. The chlorine membrane is in
the plastic bag attached to the sensor. Screw the retainer back in place.
The FCLi free-chlorine system is NOT
suitable for use in hazardous areas.
CAUTION
FIGURE 2-1. Chlorine Sensor Parts
fill plug
o-ring
membrane
assembly
membrane
retainer cap
auxiliary
electrode
cable
end
7
MODEL FCLi-56 ... SECTION 2.0
INSTALLATION
2. If you are using a pH sensor, remove the protective cap on the sensor.
3. Install the sensors in the flow cells as shown in Figures 2.2 and 2.3. For Model FCLi-02-241, the pH sensor
must be installed as shown in Figure 2.3. The chlorine sensor sits in the flow cell and is held in place by the
union nut. The pH sensor screws into a plastic fitting, which the union nut holds in the flow cell. Be sure to
slip the union nut over the sensor before connecting the cable to the sensor.
4. The Model FCLi is provided with sensor cables pre-wired to the analyzer. Connect the chlorine sensor to the
cable labeled Chlorine Sensor. Connect the pH sensor to the cable labeled pH Sensor. 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.
NOTE
The chlorine sensor is available in two styles. One has a copper auxiliary electrode; the other has a stainless steel auxiliary electrode. The auxiliary electrode is the metal band visible at the bottom of the sensor. The copper electrode is gradually being phased out and replaced by a stainless steel electrode.
If the sensor has a copper electrode…Generally, it is best to keep the sensor in a continuously flowing
sample. The sensor can tolerate loss of sample flow for about four days as long as it remains immersed
in water in the flow cell. A check valve in the sample inlet prevents water from draining out of the flow
cell. If the sensor sits too long in a stagnant sample, copper ions from the air oxidation of the electrode
can diffuse into the sensor. Once inside the sensor, the copper undergoes an electrochemical reaction
that greatly increases the background current and can potentially damage the sensor.
If the sensor has a stainless steel electrode…The stainless steel electrode is not susceptible to air oxidation. Therefore, loss of sample flow does not normally present a problem.
Do not expose the chlorine sensor to air for any longer than an hour. Prolonged exposure to air will cause
the membrane to dry out. Once this happens, the membrane must be replaced.
CHECK VALVE
INLET
DRAIN
CHLORINE SENSOR
pH SENSOR
8
MODEL FCLi-1056 SECTION 2.0
INSTALLATION
FIGURE 2-2. Model FCLi-01-220
CHECK VALVE
CHLORINE SENSOR
INLET
DRAIN
INCH
MILLIMETER
FIGURE 2-3. Model FCLi-02-221
INCH
MILLIMETER
9
MODEL FCL–56 SECTION 3.0
WIRING
SECTION 3.0.
WIRING
3.1 POWER, ALARM, AND OUTPUT WIRING
3.1.1 Power
Wire AC mains power to the power supply board, which is mounted vertically on the left hand side of the analyzer
enclosure. The power connector is at the top of the board. Unplug the connector from the board and wire the power
cable to it. Lead connections are marked on the connector. (L is live or hot; N is neutral, the ground connection
has the standard symbol.)
AC power wiring should be 14 gauge or greater. Run the power wiring through the conduit opening nearest the
power terminal. Provide a switch or breaker to disconnect the analyzer from the main power supply. Install the
switch or breaker near the analyzer and label it as the disconnecting device for the analyzer.
3.1.2 Analog output wiring
Four analog current outputs are
located on the main circuit
board, which is attached to the
inside of the enclosure door.
Figure 3-1 shows the location of
the terminals, the outputs they
are assigned to, and the polarity.
For best EMI/RFI protection, use
shielded output signal cable
enclosed in earth-grounded
metal conduit.
Keep output signal wiring separate from power wiring. Do not
run signal and power or relay
wiring in the same conduit or
close together in a cable tray.
FIGURE 3-1. Analog output connections.
The analog outputs are on the main board near the
hinged end of the enclosure door.
Electrical installation must be in accordance with
the National Electrical Code (ANSI/NFPA-70)
and/or any other applicable national or local codes.
WARNING
RISK OF ELECTRICAL SHOCK
10
MODEL FCL–56 SECTION 3.0
WIRING
3.2 SENSOR WIRING
The Model FCLi is provided with sensor cables pre-wired to the analyzer. If it is necessary to replace the sensor
cable, refer to the instructions below.
1. Shut off power to the analyzer.
2. Loosen the four screws holding the front panel in place and let it drop down.
3. Locate the appropriate signal board.
4. Loosen the gland fitting and carefully push the sensor cable up through the fitting as you pull the board
forward to gain access to the wires and terminal screws. Disconnect the wires and remove the cable.
5. Insert the new cable through the gland and pull the cable through the cable slot.
6. Wire the sensor to the signal board. Refer to the wiring diagrams in Figures 3-3 through 3-6.
7. Once the cable has been connected to the board, slide the board fully into the enclosure while taking up the
excess cable through the cable gland. Tighten the gland nut to secure the cable and ensure a sealed enclosure.
Slot 1 (left) Slot 2 (center) Slot 3 (right)
communication input 1 (chlorine) input 2 (pH)
3.1.3 Alarm wiring.
The alarm relay terminal strip is located just above the
power connector on the power supply board. See
Figure 3-2.
Keep alarm relay wiring separate from signal wiring.
Do not run signal and power or relay wiring in the
same conduit or close together in a cable tray.
FIGURE 3-2. Alarm relay
connections.
WARNING
Exposure to some chemicals may degrade the sealing
properties used in the following devices: Zettler
Relays (K1-K4) PN AZ8-1CH12DSEA
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