Model MCL
Monochloramine Measuring System
Instruction Manual
PN 51-MCL/rev.C
November 2004
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.
WARNINGS
RISK OF ELECTRICAL SHOCK
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.
CAUTION
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.
WARNING
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
Rosemount Analytical Inc.
2400 Barranca Parkway
Irvine, CA 92606 USA
Tel: (949) 757-8500
Fax: (949) 474-7250
http://www.raihome.com
© Rosemount Analytical Inc. 2004
QUICK START GUIDE
FOR MODEL MCL ANALYZER
1. Refer to Section 2.0 for installation instructions, and Section 3.0 for wiring instructions.
2. Once connections are secured and verified, apply power to the analyzer.
3. When the analyzer is powered up for the first time, Quick Start screens appear. Using Quick Start is easy.
a. A blinking field shows the position of the cursor.
b. Use the or key to move the cursor left or right. Use the s or t key to move the cursor up or down or to
increase or decrease the value of a digit. Use the s or t key 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 previous screen.
4. Choose the desired language. Choose >> to show more choices.
5. Move the cursor to >> and press ENTER. Choose monochloramine.
6. Choose temperature units.
7. The main display appears. The outputs and alarms are assigned to default values.
8. To change outputs, alarms, and temperature-related settings, go to the main
menu and choose Program. Follow the prompts. For a guide to the Program
menu, see the menu tree on the following page.
9. To return the analyzer to the default settings, choose Reset Analyzer in the
Program menu.
Temperature in?
*
CC
*
F
S1 Chlorine Type
ffrreeee
total >>
EEnngglliisshh
Fran ais
Espa ol >>
QUICK REFERENCE GUIDE
MENU TREE FOR MONOCHLORAMINE MEASUREMENTS
i
MODEL MCL TABLE OF CONTENTS
MODEL MCL
SYSTEM FOR THE DETERMINATION OF MONOCHLORAMINE
TABLE OF CONTENTS
Section Title Page
1.0 DESCRIPTION AND SPECIFICATIONS ................................................................ 1
1.1 Features................................................................................................................... 1
1.2 Specifications........................................................................................................... 2
1.3 Ordering Information ................................................................................................ 3
2.0 INSTALLATION ....................................................................................................... 4
2.1 Unpacking and Inspection........................................................................................ 4
2.2 Installation................................................................................................................ 4
3.0 WIRING.................................................................................................................... 7
3.1 Power, Alarm, and Output Wiring............................................................................. 7
3.2 Sensor Wiring ......................................................................................................... 8
4.0 DISPLAY AND OPERATION ................................................................................... 9
4.1 Display ..................................................................................................................... 9
4.2 Keypad..................................................................................................................... 9
4.3 Programming and Calibrating the Analyzer - Tutorial .............................................. 10
4.4 Security .................................................................................................................... 11
4.5 Using Hold ............................................................................................................... 11
5.0 PROGRAMMING THE ANALYZER ........................................................................ 12
5.1 General .................................................................................................................... 12
5.2 Changing StartUp Settings....................................................................................... 12
5.3 Configuring and Ranging the Outputs...................................................................... 13
5.4 Configuring Alarms and Assigning Setpoints ........................................................... 15
5.5 Selecting Type of Chlorine Measurement ................................................................ 18
5.6 Choosing Temperature Units and Manual/Automatic Temperature Compensation . 19
5.7 Setting a Security Code ........................................................................................... 20
5.8 Noise Rejection........................................................................................................ 21
5.9 Resetting Factory Calibration and Factory Default Settings .................................... 22
5.10 Selecting a Default Screen, Language, and Screen Contrast ................................. 23
6.0 CALIBRATION ........................................................................................................ 24
6.1 Introduction .............................................................................................................. 24
6.2 Calibrating Temperature........................................................................................... 24
6.3 Calibrating Monochloramine .................................................................................... 26
Section Title Page
7.0 MAINTENANCE ..................................................................................................... 29
7.1 Analyzer ................................................................................................................... 29
7.2 Monochloramine Sensor .......................................................................................... 31
7.3 Constant Head Flow Controller................................................................................ 33
8.0 TROUBLESHOOTING ............................................................................................ 35
8.1 Overview .................................................................................................................. 35
8.2 Troubleshooting Using Fault Codes......................................................................... 35
8.3 Troubleshooting When No Error Message is Showing - Monochloramine............... 37
8.4 Troubleshooting When No Error Message is Showing - General ............................ 40
8.5 Simulating Inputs ..................................................................................................... 40
8.6 Simulating Temperature ........................................................................................... 41
9.0 RETURN OF MATERIAL ........................................................................................ 42
LIST OF TABLES
Number Title Page
5-1 Default Settings ........................................................................................................ 13
7-1 Replacement Parts for MCL (1055-01-11-24-68) ..................................................... 30
7-2 Spare Parts............................................................................................................... 32
7-3 Replacement Parts for Constant Head Flow Controller Assembly (Model MCL) ..... 33
MODEL MCL TABLE OF CONTENTS
TABLE OF CONTENTS CONT’D
ii
MODEL MCL TABLE OF CONTENTS
LIST OF FIGURES
Number Title Page
2-1 Model MCL ............................................................................................................... 6
3-1 Wiring Connections .................................................................................................. 7
3-2 Wiring Diagram for Monochloramine Sensor ........................................................... 8
4-1 Displays During Normal Operation........................................................................... 9
4-2 MCL Analyzer Keypad .............................................................................................. 9
5-1 High Alarm Logic ..................................................................................................... 15
5-2 Low Alarm Logic ....................................................................................................... 15
6-1 Sensor Current as a Function of Monochloramine Concentration ........................... 26
7-1 Exploded View of Model MCL Analyzer.................................................................... 30
7-2 Monochloramine Sensor Parts ................................................................................. 32
7-3 Replacement Parts for the Flow Controller Assembly used in Model MCL .............. 34
8-1 Pin Out Diagram for Model 499A CL-03-VP Sensor ................................................ 36
8-2 Simulating Monochloramine ..................................................................................... 40
8-3 Three-Wire RTD Configuration................................................................................. 41
8-4 Simulating RTD Inputs.............................................................................................. 41
iii
About This Document
This manual contains instructions for installation and operation of the Model MCL
Monochloramine Measuring System.
The following list provides notes concerning all revisions of this document.
Rev
. Level Date Notes
A 7/03 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 12/03 Added note on page 35.
C 11/04 Updated drawings on pages 6, 30, and 34.
Emerson Process Management
Liquid Division
2400 Barranca Parkway
Irvine, CA 92606 USA
Tel: (949) 757-8500
Fax: (949) 474-7250
http://www.raihome.com
© Rosemount Analytical Inc. 2003
MODEL MCL SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
SECTION 1.0.
DESCRIPTION AND SPECIFICATIONS
1.1 FEATURES
1.2 SPECIFICATIONS
1.3 ORDERING INFORMATION AND ACCESSORIES
1
• COMPLETE SYSTEM INCLUDES sensor, connecting cable, analyzer, and flow controller.
• VARIOPOL QUICK-DISCONNECT FITTINGS make replacing sensor easy.
• FEATURE-PACKED ANALYZER: dual outputs, three fully-programmable alarm relays, twoline display.
1.1 FEATURES
The Model MCL monochloramine system is intended
for the determination of monochloramine in fresh
water.
The Model MCL uses a membrane-covered amperometric sensor. A polarizing voltage applied to a gold
mesh cathode behind the membrane reduces the
monochloramine diffusing through the membrane and
keeps the concentration of monochloramine in the
sensor equal to zero. The current generated by the
cathode reaction is proportional to the rate of diffusion
of monochloramine through the membrane. Because
the concentration of monochloramine in the sensor is
zero, the diffusion rate and the current are proportional to the concentration of monochloramine in the sample.
Diffusion rate also depends on membrane permeability, which is a function of temperature. An RTD in the
sensor continuously measures the temperature of the
sample and the analyzer automatically corrects the
raw sensor current for temperature changes.
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 Model MCL includes the easy-to-use Model 1055
analyzer. The analyzer features two fully programmable 4-20 mA outputs and three fully programmable
relays. The back-lit, two line display allows the user to
read monochloramine concentration at a glance.
Valves, rotameters, and pressure regulators to control
sample flow are things of the past with the Model
MCL. A constant head overflow sampler ensures the
correct sample flow to each sensor. To eliminate wiring
hassles, quick-disconnect Variopol cable is standard.
Stable monochloramine standards do not exist. The
monochloramine sensor must be calibrated using the
results of a laboratory test run on a grab sample.
MODEL MCL SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
2
1.2 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: >10 μS/cm at 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, CPVC, Buna N,
316 stainless steel
Monochloramine sensor: Noryl
1
, Viton2, silicone,
and Zitex3PTFE (Gold mesh cathode — not
normally wetted)
Response time to step change in monochloramine
concentration: <60 sec to 95% of final reading
for inlet sample flow of 17 gph (64 L/hr).
Weight/shipping weight: 10 lb/13 lb (4.5 kg/6.0 kg)
[rounded to the nearest 1 lb. (0.5 kg)]
SPECIFICATIONS — SENSOR
Range: 0 to 6 ppm as Cl2. For higher ranges, consult
the factory.
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: 3 months (approx.)
1
Noryl is a registered trademark of General Electric.
2
Viton is a registered trademark of E.I. duPont de Nemours & Co.
3
Zitex is a registered trademark of Performance Plastic Corp.
SPECIFICATIONS — ANALYZER
Case: ABS, NEMA 4X
Display: Two-line, 16-character, back-lit. Character
height: 4.8 mm.
Languages: English, German, Italian, Spanish,
French, Portuguese
Ambient temperature and humidity: 0 to 50°C (32
to 122°F); RH 5 to 95% (con-condensing)
The analyzer can be operated between -20 and
60°C (-4 to 140°F) with some degradation in display performance.
Power: 115/230Vac ± 15%, 50/60 Hz ± 6%, 8.0 W.
Installation category II.
Equipment protected throughout by double insulation.
RFI/EMI: EN-61326
LVD: EN-61010-1
Outputs: Two 4-20 mA or 0-20 mA isolated outputs.
Continuously adjustable. Linear or logarithmic.
Maximum load 600 ohms. Output dampening with
time constant of 5 sec is user-selectable.
Alarms: Three alarm relays for process measure-
ment(s) or temperature. Alarm 3 can be
configured as a fault alarm, instead of a
process alarm. Each relay can be configured
independently. Alarm logic (high or low activation)
and deadband are user-programmable.
Relays: Form C, single pole double throw, epoxy sealed
Resistive Inductive
28 Vdc 5.0 A 3.0 A
115 Vac 5.0 A 3.0 A
230 Vac 5.0 A 1.5 A
Ordinary Location:
POLLUTION DEGREE 2: Normally only non-conductive pollution occurs. Occasionally, however, a
temporary conductivity caused by condensation
must be expected.
12RN
MODEL MCL SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
3
1.3 ORDERING INFORMATION
Model MCL Monochloramine Measuring System. The MCL is a complete system for the determination of
monochloramine in water. It consists of the sensor, analyzer, 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 analyzer.
Three replacement membranes and a 4-oz. bottle of electrolyte solution are shipped with the sensor.
ACCESSORIES
PART # DESCRIPTION
9240048-00 Tag, stainless steel (specify marking)
COMPONENT PARTS
ANALYZER MODEL DESCRIPTION
1055-01-11-24-68 1055 analyzer, single input (monochloramine), wall mount, 115/230 Vac
1055-01-11-24-32-68 1055 analyzer, dual input (monochloramine and pH), wall mount, 115/230 Vac
SENSOR MODEL DESCRIPTION
499ACL-03-54-VP monochloramine sensor with Variopol connector
SENSOR CABLE DESCRIPTION
23747-04 Interconnecting cable, Variopol for 499ACL sensor, 4 ft
MCL Monochloramine Measuring System
MODEL DESCRIPTION
MCL EXAMPLE
4
SECTION 2.0.
INSTALLATION
MODEL MCL SECTION 2.0
INSTALLATION
2.1 UNPACKING AND INSPECTION
2.2 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 MODEL MCL
Model MCL consists of the following items mounted on a back plate.
1. Model 1055-01-13-24 analyzer with sensor cable attached.
2. Constant head overflow sampler with flow cell for monochloramine sensor.
The monochloramine sensor (Model 499ACL-03-54-VP), three membrane assemblies, and a bottle of electrolyte
solution are in a separate package.
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)
MODEL MCL SECTION 2.0
INSTALLATION
2.2.3 Mounting, Inlet, and Drain Connections
The Model MCL is intended for wall mounting only. Refer to Figure 2-1 for details. The sensor screws into the flow
cell adapter as shown in the figure.
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 inlet 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
The Model MCL is provided with the sensor cable pre-wired to the analyzer. 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 screws 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.
5
6
MODEL MCL SECTION 2.0
INSTALLATION
FIGURE 2-1. Model MCL
Monochloramine Sensor
Inlet
Drain
INCH
MILLIMETER
SECTION 3.0.
WIRING
3.1 POWER, ALARM, AND OUTPUT WIRING
3.2 SENSOR WIRING
MODEL MCL SECTION 3.0
WIRING
3.1 POWER, ALARM, AND OUTPUT WIRING
See Figure 3-1 for identification of power, alarm, and output terminals. Note that the sensors are already wired to
the analyzer.
AC power wiring should be 14 gauge or greater. Run the power wiring through the conduit opening nearest the
power terminal (TB1). 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.
Keep output signal wiring separate from power wiring. Do run signal and power wiring in the same conduit or close
together in a cable tray.
For best EMI/RFI protection use shielded output signal cable enclosed in an earth-grounded metal conduit.
Connect the shield to earth ground at TB1-4.
Keep output wiring at least one foot from high voltage conductors.
To reduce stress on the wiring connections, do not remove the hinged front panel from the base while installing
wiring. Be sure the leads are sufficiently long to avoid stress on the conductors.
AC connections and grounding must be
in compliance with UL 508 or local electrical code. DO NOT apply power to the
analyzer until all electrical connections
are verified and secure.
WARNING:
RISK OF ELECTRICAL SHOCK
Figure 3-1. Wiring connections.
7
8
MODEL MCL SECTION 3.0
WIRING
3.2 SENSOR WIRING
The Model MCL is provided with the sensor cable pre-wired to the analyzer.
If it is necessary to replace the cable, refer to the wiring diagram below.
Figure 3-2. Wiring diagram for monochloramine sensor.
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