Rosemount Manual: MCL-220 Monochloramine System with Rosemount 1056 Transmitter Manuals & Guides
Reference Manual
00809-0100-3414, Rev AA
Rosemount™ MCL-220
Monochloramine System with Rosemount 1056 Transmitter
May 2019
Essential instructions
Read this page before proceeding!
Your instrument purchase from Emerson is one of the finest 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 quailty of the installation and knowledge of the user in operating and maintaining the instrument. To ensure
continued operation to the design specifications, 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 1-800-999-9307 to request the corrrect 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, program, and maintain 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.
Note
Risk of electrical shock
Installing cable connections and servicing this product may require access to shock and high voltage levels.
Equipment protected throughout by double insulation.
Disconnect main power wired to separate power source before servicing.
Do not operate or energize instrument with case open.
Signal wiring within 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 exposure 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 (IP65).
Electrical installation must be in accordance with the National Electrical Code (ANSI/NFPA-70) and/or any other 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.
This product is not intended for use in the light industrial, residential, or commercial environments per the instrument's
certification to EN50081-2.
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Note
Radio interference
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 operator, at his own
expense, will be required to take whatever measures may be required to correct the interference.
WARNING
Physical access
Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end users’ equipment. This
could be intentional or unintentional and needs to be protected against.
Physical security is an important part of any security program and fundamental to protecting your system. Restrict physical
access by unauthorized personnel to protect end users’ assets. This is true for all systems used within the facility.
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Reference Manual Contents
00809-0100-3414 May 2019
Contents
Chapter 1 Quick Start.....................................................................................................................7
Chapter 2 Description and specifications......................................................................................11
2.1 Specifications................................................................................................................................. 11
2.2 Ordering information..................................................................................................................... 12
Chapter 3 Install...........................................................................................................................13
3.1 Unpack and inspect........................................................................................................................ 13
3.2 Rosemount MCL-220......................................................................................................................13
3.3 General installation information..................................................................................................... 13
3.4 Sample requirements..................................................................................................................... 14
3.5 Mounting, inlet, and drain connections.......................................................................................... 14
3.6 Install the sensor............................................................................................................................ 15
Chapter 4 Wire............................................................................................................................ 17
4.1 Wire power.....................................................................................................................................17
4.2 Wire analog outputs.......................................................................................................................17
4.3 Alarm wiring...................................................................................................................................18
4.4 Wire sensor.................................................................................................................................... 20
Chapter 5 Display and operation.................................................................................................. 23
5.1 Display........................................................................................................................................... 23
5.2 Keypad........................................................................................................................................... 24
5.3 Program the transmitter.................................................................................................................26
5.4 Security.......................................................................................................................................... 28
5.5 Using hold...................................................................................................................................... 29
5.6 Configure the main display.............................................................................................................30
Chapter 6 Programming the transmitter......................................................................................33
6.1 Programming overview.................................................................................................................. 33
6.2 Default settings.............................................................................................................................. 33
6.3 Configuring, ranging, and simulating outputs................................................................................ 35
6.4 Configuring alarms and assigning setpoints....................................................................................39
6.5 Configuring the measurement....................................................................................................... 46
6.6 Configuring temperature related settings...................................................................................... 47
6.7 Configuring security settings..........................................................................................................49
6.8 Resetting the transmitter............................................................................................................... 51
Chapter 7 Calibrate...................................................................................................................... 53
7.1 Introduction................................................................................................................................... 53
7.2 Calibrating temperature.................................................................................................................53
7.3 Calibrating monochloramine..........................................................................................................55
7.4 Calibration - analog outputs........................................................................................................... 60
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Chapter 8 Maintenance................................................................................................................63
8.1 Replace sensor circuit board........................................................................................................... 63
8.2 Monochloramine sensor.................................................................................................................64
8.3 Constant head flow controller........................................................................................................ 66
Chapter 9 Troubleshoot............................................................................................................... 69
9.1 Overview........................................................................................................................................ 69
9.2 Use the diagnostic feature..............................................................................................................69
9.3 Troubleshooting when a Fault message is showing.........................................................................70
9.4 Troubleshooting when a Warning message is showing...................................................................74
9.5 Troubleshooting when no error message is showing...................................................................... 75
9.6 Troubleshooting when no error message is showing - general........................................................79
9.7 Simulate inputs.............................................................................................................................. 80
9.8 Simulating temperature................................................................................................................. 81
Appendix A EU Declaration of Conformity....................................................................................... 85
Appendix B China RoHS Table......................................................................................................... 87
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Reference Manual Quick Start
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1 Quick Start
Procedure
1. Once connections are secured and verified, apply power to the transmitter.
When the transmitter is powered up for the first time, Quick Start screens appear.
Using Quick Start is easy.
a. A backlit field shows the position of the cursor.
b. To move the cursor left or right, use the keys to the left or right of the ENTER
key. To scroll up or down or to increase or decrease the value of a digit, use
the keys above and below the ENTER key. Use the left and right keys to move
the decimal point.
c. Press ENTER to store a setting. Press EXIT to leave without storing changes.
Pressing EXIT also returns the display to the initial Quick Start screen.
d. A vertical black bar with a downward pointing arrow on the right side of the
screen means there are more items to display. Continue scrolling down to
display all the items. When you reach the bottom of the list, the arrow points
up.
2. Choose the desired language. Scroll down to display more choices.
3. Choose Monochloramine for sensor 1 (S1).
4. Choose the desired units for chlorine.
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5. Choose the desired temperature units.
The main display appears. The outputs and alarms (if an alarm board is present) are
assigned to default values.
6. To change outputs, alarms, and other settings, go to the Main Menu and choose
Program. Follow the prompts.
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Reference Manual Description and specifications
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2 Description and specifications
2.1 Specifications
Rosemount™ 1056 Transmitter
For Rosemount 1056 Transmitter specifications, see the Rosemount 1056 Transmitter
Reference Manual on Emerson.com/Rosemount: Manual: Rosemount 1056 Dual-Input
Transmitter.
Table 2-1: General Specifications
Characteristic Specification
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 °C)
• 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 >10 µS/cm at 77 °F (25 °C)
Process connection ¼-in. OD tubing compression fitting (can be
removed and replaced with barbed fitting for
soft tubing)
Drain connection ¾-in. barbed fitting. Sample must drain to open
atmosphere.
Wetted parts Overflow sampler: acrylic, nylon, polycarbonate,
polyester, and silicone
Monochloramine sensor: Noryl®, Viton®,
silicone, and Zitex®. PFTE gold mesh cathode
(not normally wetted).
Response time to step change in
monochloramine concentration
Weight/shipping weight (rounded to the
nearest 1 lb. or 0.5 kg)
<60 sec to 95% of final reading for inlet sample
flow of 17 gph (64 L/hr)
10 lb./13 lb. (4.5 kg/6.0 kg)
Table 2-2: Sensor Specifications
Characteristic Specification
Range 0 to 6 ppm as Cl2. For higher ranges, consult the
factory.
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Table 2-2: Sensor Specifications (continued)
Characteristic Specification
pH range Response is practically independent of pH
between pH 7.0 and 10.0. Sensor current at pH
10.0 is within 5% of sensor current at pH 7.0.
Accuracy Accuracy depends on the accuracy of the
chemical test used to calibrate the sensor.
Linearity 2% (typ.)
Electrolyte volume 25 mL (approx.)
Electrolyte life 2 months (approx.)
2.2 Ordering information
The Rosemount MCL-220 is a complete system for the determination of monochloramine
in water. It consists of a monochloramine sensor, Rosemount 1056 transmitter, Variopol
cable, and constant head overflow cup to control sample flow. All components are
mounted on a backplate, and the cable is pre-wired to the transmitter. Three replacement
membranes and a 4-oz bottle of electrolyte solution are shipped with the sensor.
Table 2-3: Component Parts
Transmitter model Description
1056-03-24-38-AN Rosemount 1056 transmitter, single input
(monochloramine), alarm relays, analog output,
115/230 Vac
Sensor model Description
499ACL-03-54-VP Monochloramine sensor with Variopol connector
Sensor cable Description
23747-04 Interconnecting cable, Variopol for Rosemount
499ACL sensor, 4 ft
Table 2-4: Accessories
Part number Description
9240048-00 Tag, stainless steel (specify marking)
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Install
3 Install
3.1 Unpack and inspect
Procedure
1. Inspect the shipping container(s). If there is damage, contact the shipper
immediately for instructions.
2. If there is no apparent damage, unpack the container(s).
3. Ensure that all items shown on the packing list are present.
If items are missing, notify Emerson immediately.
3.2 Rosemount MCL-220
The Rosemount MCL-220 consists of the following items mounted on a back plate.
1. The Rosemount 1056-03-24-38-AN with sensor cable attached.
2. Constant head overflow sampler with flow cell for monochloramine sensor.
3. The monochloramine sensor (Rosemount 499ACL-03-54-VP), three membrane
assemblies, and a bottle of electrolyte solution are in a separate package.
3.3 General installation information
1. Although the system is suitable for outdoor use, do not install it in direct sunlight or
in areas of extreme temperature.
CAUTION
Hazardous areas
The system is not suitable for use in hazardous areas.
2. To keep the transmitter enclosure watertight, install plugs (provided) in the unused
conduit openings.
3. Install the system in an area where vibrations and electromagnetic and radio
frequency interference are minimized or absent.
4. Keep the transmittter and sensor wiring at least one foot from high voltage
conductors. Be sure there is easy access to the transmitter and sample conditioning
system.
5. Be sure there is easy access to the transmitter and sensor(s).
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Reference Manual
3.4 Sample requirements
Be sure the sample meets the following requirements:
1. Temperature: 32 to 122 °F (0 to 50 °C )
2. Pressure: 3 to 65 psig (122 to 549 kPa abs)
3.
3.5 Mounting, inlet, and drain connections
The Rosemount™ MCL-220 is intended for wall mounting only.
Refer to Figure 3-1 for details. The sensor screws into the flow cell adapter.
Figure 3-1: Rosemount MCL-220 Monochloramine System
A. Chlorine sensor
B. Check valve
C. Inlet
D. Drain
If desired, you can remove the compression fitting and replace it with a barb fitting. The
inlet fitting screws into a ¼-in. FNPT check valve. The check valve prevents the sensor flow
cell from going dry if sample flow is lost.
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1. Attach a piece of soft tubing to the fitting and allow the waste to drain to open
atmosphere.
Important
Do not restrict the drain line.
2. Remove the foam packing insert between the outer tube and the inner overflow
tube.
3. Adjust the sample flow until the water level is even with the central overflow tube
and excess water is flowing down the tube.
3.6 Install the sensor
Emerson provides the Rosemount™ MCL with the sensor cable pre-wired to the
transmitter. The terminal end of the sensor is keyed to ensure proper mating with the
cable receptacle.
Procedure
1. Once the key has slid into the mating slot, tighten the connection by turning the
knurled ring clockwise.
2. Screw the sensor into a plastic fitting, which is held in the flow cell by a union nut.
Do not remove the protective cap on the sensor until ready to put the sensor in
service.
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4 Wire
4.1 Wire power
Wire AC mains power supply to the power supply board, which is mounted vertically on
the left hand side of the transmitter enclosure.
WARNING
Electrical shock
Electrical installation must be in accordance with the National Electrical Code (ANSI/
NFPA-70) and/or any other applicable national or local codes.
The power connector is at the top of the board.
Procedure
1. 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.)
2. Provide a switch or breaker to disconnect the transmitter from the main power
supply.
3. Install the switch or breaker near the transmitter and label it as the disconnecting
device for the transmitter.
4.2 Wire analog outputs
Two analog output currents are located on the main circuit board, which is attached to the
inside of the enclosure door.
Figure 4-1 shows the locations of the terminals. The connectors can be detached for
wiring. TB-1 is output 1. TB-2 is output 2. Polarity is marked on the circuit board.
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Figure 4-1: Analog output connections
Reference Manual
The analog outputs are on the main board near the hinged end of the enclosure door.
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.
4.3 Alarm wiring
The alarm relay terminal strip is located just below the power connector on the power
supply board.
See Figure 4-2.
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Figure 4-2: Alarm relay connections
A. Alarm relay 1
B. Alarm relay 2
C. Alarm relay 3
D. Alarm relay 4
1. To remove the cover, grab it by the upper edges and pull straight out. The relay
terminal strip is at the top of the board.
2. Bring the relay wires through the rear conduit opening on the left hand side of the
enclosure and make connections to the terminals strip.
3. Replace the cover. The two tabs on the back edge of the cover fit into slots at the
rear of the enclosure, and the three small slots in the front of the cover snap into the
three tabs next to the relay terminal strip. See Figure 4-2. Once the tabs are lined
up, push the cover to snap it in place.
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.
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4.4 Wire sensor
The Rosemount™ MCL is provided with sensor cables pre-wired to the transmitter. If it is
necessary to replace the sensor cable, refer to the instructions below.
Procedure
1. Shut off power to the transmitter.
2. Loosen the four screws holding the front panel in place and let it drop down.
3. Locate the appropriate signal board.
Slot 1 (left) Slot 2 (center)
communication input 1 (chlorine)
Slot 1 (left) Slot 2 (center) Slot 3 (right)
communication input 1 (chlorine) input 2 (optional)
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.
5. Disconnect the wires and remove the cable.
6. Insert the new cable through the gland and pull the cable through the cable slot.
7. Wire the sensor to the signal board.
See Figure 4-3.
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Figure 4-3: Rosemount 499ACL-03-54-60 Sensor Wiring to Rosemount 1056
Transmitter
A. White
B. Resistance temperature device return
C. White/red
D. Resistance temperature device sense
E. Red
F. Resistance temperature device in
G. Clear
H. Resistance temperature device shield
I. +5 V out
J. -4.5 V out
K. Anode shield
L. Orange
M. Anode
N. Cathode shield
O. Gray
P. Cathode
Connect green wire to metal conduit ground plate in bottom of enclosure.
8. 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.
9. Tighten the gland nut to secure the cable and ensure a sealed enclosure.
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Reference Manual Display and operation
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5 Display and operation
5.1 Display
See Figure 5-1. You can customize the display to meet your requirements. Refer to
Configure the main display.
Figure 5-1: Main Display
When the transmitter is being programmed or calibrated, the display changes to a screen
similar to the one shown in Figure 5-2. The live readings appear in small font at the top of
the screen. The rest of the display shows programming and calibration information.
Programming items appear in lists. The screen can only show four items at a time, and the
arrow bar at the right of the screen indicates whether there are additional items in the list.
See Figure 5-3 for an explanation of the arrow bar.
Figure 5-2: Programming Screen Showing Item List
A. Live measurement\
B. Item list
C. Arrow bar
The position of the cursor is shown in reverse video. See Keypad and Program the
transmitter for more information.
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Figure 5-3: Arrow Bar
A. You are at the top of the list. There are more items for viewing. Scroll down.
B. You are at the bottom of the list. There are more items for viewing. Scroll up.
C. You are in the middle of the list. There are more items for viewing. Scroll up or down.
The arrow bar shows whether additional items in a list are available.
5.2 Keypad
Local communication with the transmitter is through the membrane keypad.
Figure 5-4 and Figure 5-5 explain the operation of the keys.
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Figure 5-4: Transmitter Keypad
A. Press MENU. The Main Menu screen appears.
B. Press DIAG. The main diagnostic screen appears.
C. Navigation keys move the cursor in the direction indicated in Figure 5-5.
D. Press EXIT to leave a screen without storing changes. The display returns to the previous
screen.
E. Press ENTER to store a change or select an item. The display changes to the next screen.
Four navigation keys move the cursor around the screen. The position of the cursor is
shown in reverse video. The navigation keys are used to increase or decrease the value of a
numeral. Press ENTER to select an item and store numbers and settings. Press EXIT to
return to the previous screen without storing changes. Pressing MENU always causes the
main menu to appear.
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Figure 5-5: Navigation Keys
A. Moves cursor up or increases the value of the selected digit.
B. Moves cursor to the right.
C. Moves cursor down or decreases the value of the selected digit.
D. Moves cursor to the left.
The operation of the navigation keys is shown. To move a decimal point, highlight it and
then press Up or Down.
5.3 Program the transmitter
Setting up and calibrating the transmitter is easy. The following tutorial describes how to
move around in the programming menus. For practice, the tutorial also describes how to
assign ppm monochloramine values to the 4 and 20 mA analog outputs.
Procedure
1. Press MENU.
The main Menu screen appears. There are four items in the main menu. Calibrate is
in reverse video, meaning that the cursor is on Calibrate.
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2. To assign values to the analog outputs, you must open the Program sub-menu. Use
Down to move the cursor to Program. Press ENTER.
The Program menu appears. There are six items in the Program menu. Alarms
appears only if the transmitter contains the optional alarm relay board. The screen
displays four items at a time. The downward pointing arrow on the right of the
screen shows there are more items available in the menu.
3. To view the other items, use Down to scroll to the last item shown and continue
scrolling down. When you have reached the bottom, the arrow will point up. Move
the cursor back to Outputs and press ENTER.
The Outputs screen appears. The cursor is on Range. Output range is used to assign
values to the low and high current outputs.
4. Press ENTER.
The Output Range screen appears. The screen shows the present values assigned
to output 1 (O1) and output 2 (O2). The screen also shows which sensors the
outputs are assigned to. S1 is sensor 1.. The assignments shown are the defaults for
the Rosemount MCL-220. Outputs are freely assignable under the Configure menu.
5. For practice, change the 20 mA settings for output 1 to 8.5 ppm.
a) Move the cursor to the O1 S1 20 mA: 10.00 line and press ENTER.
The screen below appears.
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