Model TCL
Total Chlorine Analyzer
Instruction Manual
PN 51-TCL1055/rev.B
May 2007
WARNING
ELECTRICAL SHOCK HAZARD
Making cable connections to and servicing
this instrument require access to shock hazard level voltages which can cause death or
serious injury.
Be sure to disconnect all hazardous voltage
before opening the enclosure.
Relay contacts made to separate power
sources must be disconnected before servicing.
Electrical installation must be in accordance
with the National Electrical Code
(ANSI/NFPA-70) and/or any other applicable
national or local codes.
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.
The unused conduit openings need to be
sealed with NEMA 4X or IP65 conduit plugs
to maintain the ingress protection rating
(IP65).
For safety and proper performance this
instrument must be connected to a properly
grounded three-wire power source.
Proper relay use and configuration is the
responsibility of the user.
No external connection to the instrument of
more than 69VDC or 43V peak allowed with
the exception of power and relay terminals.
Any violation will impair the safety protection
provided
Do not operate this instrument without front
cover secured. Refer installation, operation
and servicing to qualified personnel.
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE
PROCEEDING!
Rosemount Analytical designs, manufactures, and tests its
products to meet many national and international standards. Because these instruments are sophisticated technical products, you must properly install, use, and maintain
them to ensure they continue to operate within their normal
specifications. The following instructions must be adhered
to and integrated into your safety program when installing,
using, and maintaining Rosemount Analytical products.
Failure to follow the proper instructions may cause any one
of the following situations to occur: Loss of life; personal
injury; property damage; damage to this instrument; and
warranty invalidation.
• Read all instructions prior to installing, operating, and
servicing the product. If this Instruction Manual is not the
correct manual, telephone 1-800-654-7768 and the
requested manual will be provided. Save this Instruction
Manual for future reference.
• If you do not understand any of the instructions, contact
your Rosemount representative for clarification.
• Follow all warnings, cautions, and instructions marked on
and supplied with the product.
• Inform and educate your personnel in the proper installation, operation, and maintenance of the product.
• Install your equipment as specified in the Installation
Instructions of the appropriate Instruction Manual and
per applicable local and national codes. Connect all
products to the proper electrical and pressure sources.
• To ensure proper performance, use qualified personnel to
install, operate, update, program, and maintain the product.
• When replacement parts are required, ensure that qualified people use replacement parts specified by
Rosemount. Unauthorized parts and procedures can
affect the product’s performance and place the safe operation of your process at risk. Look alike substitutions may
result in fire, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is
being performed by qualified persons, to prevent electrical shock and personal injury.
WARNING
This product is not intended for use in the light industrial, residential or commercial environment, 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. 2005
CAUTION
SENSOR/PROCESS
APPLICATION COMPATIBILITY
Wetted materials may not be compatible with process com position and
operating conditions. Application
compat ibility is entirely the responsibility of the user.
DANGER
HAZARDOUS AREA INSTALLATION
Installations near flammable liquids or in hazardous area locations must be carefully evaluated by qualified on site safety personnel.
This device is not
Intrinsically Safe or
Explosion Proof.
To secure and maintain an intrinsically safe
installation, the certified safety barrier,
transmitter, and sensor combi nation must
be used. The installation system must comply with the governing approval agency (FM,
CSA or BASEEFA/CENELEC) hazardous
area classification requirements. Consult
your analyzer/transmitter instruc tion manual
for details.
Proper installation, operation and servicing
of this device in a Hazardous Area Instal lation is entirely the responsibility of the user.
About This Document
This manual contains instructions for installation and operation of the Model TCL Total
Chlorine Analyzer.
The following list provides notes concerning all revisions of this document.
Rev. Level
Date Notes
A 7/05 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 2/06 Corrected typographical errors. Added statement to calibration
section concerning initial stabilization time.
MODEL TCL TABLE OF CONTENTS
MODEL TCL
TOTAL CHLORINE ANALYZER
TABLE OF CONTENTS
Section Title Page
1.0 DESCRIPTION AND SPECIFICATIONS................................................................. 1
1.1 Features and Applications ...................................................................................... 2
1.2 Specifications — Sample Conditioning System ...................................................... 3
1.3 Specifications — Model 1055-24 Analyzer .............................................................. 3
1.4 Specifications — Model 499ACL-02 Sensor............................................................ 4
1.5 Performance Specifications — Complete System ................................................. 4
1.6 Ordering Information and Accessories ................................................................... 5
2.0 PRINCIPLES OF OPERATION .............................................................................. 7
3.0 INSTALLATION ...................................................................................................... 8
3.1 Unpacking and Inspection ...................................................................................... 8
3.2 Installation................................................................................................................ 8
4.0 WIRING .................................................................................................................. 14
4.1 Prepare Analyzer Conduit Openings ....................................................................... 14
4.2 Provide Power to the Sample Conditioning System ................................................ 14
4.3 Make Power, Alarm, Output, and Sensor Connections in the Analyzer................... 15
4.4 Apply Power to the Analyzer and Complete Quick Start.......................................... 16
5.0 START-UP .............................................................................................................. 17
5.1 Start Sample Flow.................................................................................................... 17
5.2 Prepare the Reagent ............................................................................................... 17
5.3 Zero the Sensor....................................................................................................... 17
5.4 Begin Operation and Calibrate the Sensor.............................................................. 17
6.0 DISPLAY AND OPERATION .................................................................................. 18
6.1 Display..................................................................................................................... 18
6.2 Keypad..................................................................................................................... 18
6.3 Programming and Calibrating the Solu Comp II — Tutorial..................................... 19
6.4 Security.................................................................................................................... 20
6.5 Using Hold ............................................................................................................... 20
7.0 PROGRAMMING THE ANALYZER ....................................................................... 21
7.1 General.................................................................................................................... 21
7.2 Changing Start-up Setting........................................................................................ 21
7.3 Configuring and Ranging the Outputs ..................................................................... 22
7.4 Configuring Alarms and Assigning Setpoints ........................................................... 24
7.5 Selecting the Type of Measurement ........................................................................ 27
7.6 Choosing Temperature Units and Manual or Automatic Temperature Compensation 28
7.7 Setting a Security Code........................................................................................... 29
7.8 Noise Rejection........................................................................................................ 29
7.9 Resetting Factory Calibration and Factory Default Settings.................................... 30
7.10 Selecting a Default Screen, Language, and Screen Contrast ................................. 31
i
ii
MODEL TCL TABLE OF CONTENTS
TABLE OF CONTENTS CONT'D.
8.0 CALIBRATION ........................................................................................................ 32
8.1 Introduction.............................................................................................................. 32
8.2 Calibrating Temperature .......................................................................................... 32
8.3 Calibration................................................................................................................ 34
9.0 MAINTENANCE ..................................................................................................... 39
9.1 1055 Analyzer.......................................................................................................... 39
9.2 Total Chlorine Sensor .............................................................................................. 41
9.3 Sample Conditioning System................................................................................... 43
10.0 TROUBLESHOOTING ........................................................................................... 50
10.1 Overview.................................................................................................................. 50
10.2 Troubleshooting Using Fault Codes ........................................................................ 50
10.3 Troubleshooting When No Error Message is Showing............................................ 51
10.4 Simulating Inputs ..................................................................................................... 54
10.5 Simulating Temperature ........................................................................................... 55
11.0 RETURN OF MATERIAL ........................................................................................ 56
LIST OF TABLES
Number Title Page
7-1 Default Settings ...................................................................................................... 21
9-1 Replacement Parts for 1055 Analyzer (Panel Mount Version) ............................... 39
9-2 Replacement Parts for 1055 Analyzer (Wall Mount Version) ................................. 40
9-3 Spare Parts ............................................................................................................ 42
9-4 Replacement Parts and Reagent for Sample Conditioning System ...................... 49
MODEL TCL TABLE OF CONTENTS
LIST OF FIGURES
Number Title Page
2-1 Schematic of Sample Conditioning System and Analyzer .................................... 7
3-1 Panel Mount Installation ......................................................................................... 9
3-2 Pipe Mount Installation............................................................................................ 10
3-3 Surface Mount Installation ...................................................................................... 11
3-4 Installing the Sample Conditioning Enclosure......................................................... 12
3-5 TCL Case Dimensions ............................................................................................ 13
3-6 Reagent Tubing Assembly ...................................................................................... 13
4-1 Removing the Knockouts ....................................................................................... 14
4-2 Power Wiring ........................................................................................................... 14
4-3 Wiring Connections for Model 1055-01-10 (Panel Mount with 115/230 Vac Power) 15
4-4
Wiring Connections for Model 1055-01-11 (Pipe/Surface Mount with 115/230 Vac Power) .15
4-5 Chlorine sensor with Standard Cable...................................................................... 16
4-6 Chlorine sensor with Optimum EMI/RFI or Variopol Cable ..................................... 16
6-1 Displays During Normal Operation ........................................................................ 18
6-2 Solu Comp II Keypad .............................................................................................. 18
7-1 High Alarm Logic .................................................................................................... 24
7-2 Low Alarm Logic...................................................................................................... 24
8-1 Determination of Total Chlorine .............................................................................. 34
8-2 Sensor Current as a Function of Total Chlorine Concentration............................... 34
8-3 Dual Slope Calibration ............................................................................................ 37
9-1 Exploded View of 1055 Analyzer (Panel Mount Version) ....................................... 39
9-2 Exploded View of 1055 Analyzer (Wall Mount Version) ......................................... 40
9-3 Sensor Parts ........................................................................................................... 42
9-4 Replacing Reagent Tubing...................................................................................... 43
9-5 Replacing Sample Tubing ....................................................................................... 44
9-6 Replacing Peristaltic Pump Tubing — step 2.......................................................... 45
9-7 Replacing Peristaltic Pump Tubing — step 3.......................................................... 45
9-8 Replacing Peristaltic Pump Tubing — step 4.......................................................... 45
9-9 Replacing Peristaltic Pump Tubing — step 6.......................................................... 45
9-10 Replacing Peristaltic Pump Tubing — step 7a........................................................ 46
9-11 Replacing Peristaltic Pump Tubing — step 7b........................................................ 46
9-12 Replacing Peristaltic Pump Tubing — step 7c ........................................................ 46
9-13 Disconnecting Reagent and Air Injection Tubing .................................................... 47
9-14 Air Pump Access Panel........................................................................................... 47
9-15 Inlet and Discharge Tubing ..................................................................................... 47
9-16 Air Pump Wiring ...................................................................................................... 47
9-17 Removing the Inlet Fitting ....................................................................................... 48
9-18 Pump Assembly ...................................................................................................... 48
10-1 Disconnecting Sample and Reagent Tubing Prior to Checking Flow ..................... 53
10-2 Simulating Chlorine ................................................................................................. 54
10-3 Three-Wire RTD Configuration ............................................................................... 55
10-4 Simulating RTD Inputs ............................................................................................ 55
iii
1
MODEL TCL SECTION 1
DESCRIPTION AND SPECIFICATIONS
SECTION 1. DESCRIPTION AND SPECIFICATIONS
• MEMBRANE-COVERED AMPEROMETRIC SENSOR.
• NO TOOLS REQUIRED to change membrane.
• MAINTENANCE TAKES ONLY A FEW MINUTES a month.
• VARIOPOL CONNECTOR OPTION allows the sensor to be replaced without removing and
rewiring cable.
Model 1055-24 Chlorine Analyzer
Model TCL Sample Conditioning System
Model 499A CL-02 Sensor
The Model TCL is intended for the determination of total chlorine in water,
including the determination of chlorine in seawater. The system consists
of a sample conditioning unit, a sensor, and a 1055-24 chlorine analyzer.
• TWO LINE, BACK-LIT DISPLAY with easy to use interface.
• TWO INDEPENDENT OUTPUTS
• THREE FULLY PROGRAMMABLE ALARMS
• INPUT FILTER improves stability at low concentrations.
• NO METAL WETTED PARTS. Ideal for seawater.
• LOW SAMPLE FLOW (about 15 mL/minute) means little
waste.
• REAGENT-BASED SYSTEM measures true total chlorine.
• FIVE GALLONS OF REAGENT lasts two months.
2
MODEL TCL SECTION 1
DESCRIPTION AND SPECIFICATIONS
1.1 FEATURES AND APPLICATIONS
MODEL 1055-24 SOLU COMP II CHLORINE ANALYZER
The Model 1055-24 Solu Comp II chlorine analyzer is designed for the continuous determination of chlorine in
water
. It is used with the Model 499ACL-02 sensor and the TCL sample conditioning system.
The Solu Comp II analyzer is housed in a weatherproof, corrosion-resistant, NEMA 4X enclosure. It is suitable for
wall, panel, or pipe mounting. Operation of the analyzer is through a membrane keypad. A back lit, two-line display shows the total chlorine level as well as temperature. User-customized displays are available.
Menu screens for calibrating and programming are simple and intuitive. Plain language prompts in English,
German, Italian, Portuguese, French, or Spanish guide the user through procedures. There are no service codes
to enter. Information and diagnostic screens are available at the push of a button.
The Solu Comp II has two isolated, continuously variable 4-20 mA outputs. Outputs can be assigned to total chlorine concentration or to temperature. Output dampening and linear or logarithmic output are also available.
The Solu Comp II has three programmable alarm relays. Alarms can be assigned to total chlorine concentration
or temperature. The third alarm can be configured as a fault alarm. The fault alarm activates when an analyzer or
sensor fault occurs.
The analyzer fully compensates chlorine readings for changes in membrane permeability caused by temperature
changes.
Solu Comp II Model 1055-24 for the determination of total chlorine is a single input instrument. The Solu Comp II
is also available with dual input, for example, chlorine and pH. For additional information concerning the dual
input option see Product Data Sheet (PDS 71-1055).
MODEL 499A CL-02 SENSOR
The Model 499ACL-02 total chlorine sensor is used in the TCL sample conditioning system. Although the sensor
is called a chlorine sensor
, it really measures iodine. The iodine comes from the reaction between halogen
oxidants in the sample and the acetic acid/potassium iodide reagent added by the sample conditioning system.
The sensor consists of a gold cathode and a silver anode in an electrolyte solution. A silicone membrane,
permeable to iodine, is stretched over the cathode. The analyzer applies a voltage to the cathode sufficiently
negative to reduce all the iodine reaching it. Because the concentration of iodine in the sensor is always zero, a
concentration gradient continuously forces iodine from the sample through the membrane into the sensor.
The reduction of iodine in the sensor generates a current directly proportional to the diffusion rate of iodine
through the membrane, which is directly proportional to the concentration of iodine in the sample. Because the
iodine concentration depends on the amount of total chlorine in the sample, the sensor current is ultimately
proportional to the total chlorine concentration.
The permeability of the membrane to iodine is a function of temperature. A Pt100 RTD in the sensor measures
the temperature, and the analyzer uses the temperature to compensate the total chlorine reading for changes in
membrane permeability.
Sensor maintenance is fast and easy. Replacing the membrane requires no special tools or fixtures. Simply place
the membrane assembly on the cathode and screw the retainer in place. Installing a new membrane and
replenishing the electrolyte takes only a few minutes.
MODEL TCL SECTION 1
DESCRIPTION AND SPECIFICATIONS
1.3 SPECIFICATIONS — MODEL 1055-24 ANALYZER
1.2 SPECIFICATIONS — SAMPLE CONDITIONING SYSTEM
GENERAL
Enclosure: Fiberglass reinforced polyester, NEMA 3
(IP53) suitable for marine environments
Dimensions: 14.5 x 13.0 x 8.6 in. (369 x 329 x 218 mm)
Mounting: Wall
Ambient Temperature: 32° - 122°F (0 - 50°C)
Ambient Humidity: 0 - 90% (non-condensing)
Power: 115 Vac, 6.9 W, 50/60 Hz;
230 Vac, 7.0 W, 50/60 Hz
Hazardous Location: The TCL sample conditioning sys-
tem has no hazardous location approvals.
Pumps:
EN 809:1998
Weight/Shipping Weight: 14 lb/16 lb (6.5 kg/7.5 kg)
SAMPLE REQUIREMENTS
Inlet Connection: compression fitting, accepts 1/4 in. OD
tubing
Drain Connection: 3/4 in. barbed fitting (must drain to
open atmosphere)
Inlet Pressure: <100 psig (791 kPa abs)
Flow: at least 0.25 gph (15 mL/min)
Temperature: 32 - 122°F (0 - 50°C)
Total Alkalinity: <300 mg/L as CaCO
3
. For samples con-
taining <50 mg/L alkalinity, consult the factory.
SAMPLE CONDITIONING SYSTEM
Reagent: Potassium iodide in vinegar.
Reagent Usage: 5 gallons lasts approximately 60 days.
Reagent Pump: Fixed speed peristaltic pump, about
0.2 mL/min
Sample Pump: Fixed speed peristaltic pump, about 11 mL/min
Case: ABS. Pipe, surface, and panel mount versions
are NEMA 4X/CSA 4 (IP65).
Dimensions
Panel (code -10): 6.10 x 6.10 x 3.72 in. (155 x 155 x
94.5 mm)
Surface/Pipe (code -11): 6.23 x 6.23 x 3.23 in. (158
x 158 x 82 mm); see page 8 for dimensions of pipe
mounting bracket.
Conduit openings: Accepts PG13.5 or 1/2 in. conduit fit-
tings
Display: Two line, 16-character, back-lit display. Character
height: 4.8 mm. Display can be customized to meet
individual requirements.
Ambient temperature and humidity: 0 to 50°C,
(32 to 122°F) RH 5 to 95% (non-condensing)
Note: The analyzer is operable from -20 to 60°C
(-4 to 140°F) with some degradation in display performance.
Power:
115/230 Vac ±15%, 50/60 Hz ±6%, 8.0W
Installation Category II
Equipment protected throughout by double insulation.
Hazardous Location: Applies to analyzer only, not to system
Class I, Division 2,
Groups A, B, C, & D
POLLUTION DEGREE 4: Extended Environment
Outdoor use where conductive contamination
such as rain, snow, or dust may be present. (Hazardous
Location only)
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
Terminal Connections Rating: 26-14 AWG wire size
Weight/Shipping weight (rounded up to nearest lb or
nearest 0.5 kg): 3 lb (1.5 kg)/4 lb (2.0 kg)
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
3
4
MODEL TCL SECTION 1
DESCRIPTION AND SPECIFICATIONS
1.4 SPECIFICATIONS — MODEL 499ACL-02 SENSOR
1.5 PERFORMANCE SPECIFICATIONS — COMPLETE SYSTEM
Wetted Parts: Gold, Noryl
®
1
(PPO), Viton
®
2
, EPDM, Silicone
Dimensions: 1.0 x 5.6 in. (25.4 x 143 mm)
Cable: 25 ft. (7.6m) standard
Pressure Rating: 0 to 65 psig (101 to 549 kPa)
Temperature Rating: 32 to 122
°
F (0 to 50°C)
Electrolyte Capacity: Approximately 25 mL
Electrolyte Life: Approximately 4 months
Weight/Shipping Weight: 1 lb/3 lb (0.5 kg/1.5 kg)
1
Noryl is a registered trademark of General Electric.
2
Viton is a registered trademark of DuPont Performance Elastomers.
Linear Range: 0 to 20 ppm (mg/L) as Cl2(for higher ranges, consult factory)
Linearity (per ISO 15839): 0-10 ppm: 2%; 0-20 ppm: 3%
Response Time: Following a step change in concentration, the reading reaches 90% of final value within 7 minutes at
25°C.
Drift: At about 1.5 ppm in clean water and constant temperature, drift is typically less 0.05 ppm over two weeks.
Detection Limit (per ISO 15839): 0.02 ppm (mg/L) in clean water at room temperature
MODEL TCL SECTION 1
DESCRIPTION AND SPECIFICATIONS
1.6 ORDERING INFORMATION AND ACCESSORIES
Model TCL Reagent-Based Chlorine System. The TCL is used for the continuous determination of total chlorine in water.
The TCL consists of a sample conditioning system, a reagent carboy, a sensor, and an analyzer. Reagents must be
ordered separately. Regent kits for 0-5 ppm and 0-10 ppm chlorine are available. For higher ranges, consult the
factory. See ACCESSORIES - Sample Conditioning System.
CODE SENSOR (optional selection)
30 499ACL-02-54 sensor with standard cable
31 499ACL-02-54-60 sensor with optimum EMI/RFI cable
32 499ACL-02-54-VP sensor with Variopol 6.0 fitting (interconnecting cable must be ordered separately)
CODE POWER (required selection)
11 115 V 50/60 Hz
12 230 V 50/60 Hz
CODE ANALYZER (optional selection)
250 1055-01-10-24 analyzer, panel mount
251 1055-01-11-24 analyzer, pipe/wall mount
260 54eA-01 analyzer
261 54eA-01-09 analyzer with HART communications
262 54eA-01-20 controller with PID and TPC control
263 54eA-01-09-20 controller with PID and TPC control and HART communications
MODEL
TCL REAGENT-BASED CHLORINE SYSTEM
PN Description Weight* Ship Weight**
24134-00 Air pump, 115 Vac, 50/60 Hz 1 lb (0.5 kg) 1 lb (0.5 kg)
24134-01 Air pump, 230 Vac, 50/60 Hz 1 lb (0.5 kg) 1 lb (0.5 kg)
9160578 Air pump repair kit 1 lb (0.5 kg) 1 lb (0.5 kg)
9322052 Check valve for air injection line 1 lb (0.5 kg) 1 lb (0.5 kg)
24153-00 Carboy for reagent, 5 gal/19 L, includes cap 4 lb (1.5 kg) 5 lb (2.0 kg)
9100204 Fuse, 0.25 A, 250 V, 3AG, slow blow for option -11 (115 Vac) 1 lb (0.5 kg) 1 lb (0.5 kg)
9100132 Fuse, 0.125 A, 250 V, 3AG, slow blow for option -12 (230 Vac) 1 lb (0.5 kg) 1 lb (0.5 kg)
9380094 Reagent pump, 115 Vac, 50/60 Hz 1 lb (0.5 kg) 2 lb (1 kg)
9380095 Reagent pump, 230 Vac, 50/60 Hz 1 lb (0.5 kg) 2 lb (1 kg)
9380091 Reagent pump replacement tubing 1 lb (0.5 kg) 2 lb (1 kg)
24151-00 Reagent tubing replacement kit 1 lb (0.5 kg) 2 lb (1 kg)
24135-00 Reagent uptake tubing, 6 ft (1.8 m), includes weight 1 lb (0.5 kg) 2 lb (1 kg)
9380090 Sample pump, 115 Vac, 50/60 Hz 1 lb (0.5 kg) 2 lb (1 kg)
9380093 Sample pump, 230 Vac, 50/60 Hz 1 lb (0.5 kg) 2 lb (1 kg)
9380092 Sample pump replacement tubing 1 lb (0.5 kg) 2 lb (1 kg)
24152-00 Sample tubing replacement kit 1 lb (0.5 kg) 2 lb (1 kg)
ACCESSORIES — SAMPLE CONDITIONING SYSTEM
PN Description Weight* Ship Weight**
24165-00 Acetic acid, 2 x 2.5 gal (9.5 L) bottles/case, with 25 g potassium iodide 45 lb (20.5 kg) 48 lb (22.0 kg)
(0-5 ppm total chlorine)
24165-01 Acetic acid, 2 x 2.5 gal (9.5 L) bottles/case, with 50 g potassium iodide 45 lb (20.5 kg) 48 lb (22.0 kg)
(0-10 ppm total chlorine)
24164-00 Potassium iodide, 25 g, sufficient for 5 gallons (19 L) of vinegar 1 lb (0.5 kg) 1 lb (0.5 kg)
(0-5 ppm total chlorine)
24164-01 Potassium iodide, 50 g, sufficient for 5 gallons (19 L) of vinegar 1 lb (0.5 kg) 1 lb (0.5 kg)
(0-10 ppm total chlorine)
*Weights are rounded up to the nearest whole pound or 0.5 kg.
5
6
ACCESSORIES — Sensor
FOR FIRST TIME VARIOPOL INSTALLATIONS
PN DESCRIPTION WEIGHT* SHIP WEIGHT*
23501-02 Total Chlorine Membrane, includes one membrane assembly and 1 lb (0.5 kg) 1 lb (0.5 kg)
one O-ring
23502-02 Total Chlorine Membrane Kit, includes 3 membrane assemblies and 1 lb (0.5 kg) 1 lb (0.5 kg)
three O-rings
9210438 Total Chlorine Sensor Fill Solution, 4 oz (120 mL) 1 lb (0.5 kg) 2 lb (1.0 kg)
ACCESSORIES — 1055-24 Analyzer
PN DESCRIPTION WEIGHT* SHIP WEIGHT*
9240048-00 Tag, stainless steel, specify marking 1 lb (0.5 kg) 1 lb (0.5 kg)
23820-00 Pipe mounting kit
2 lb (1.0 kg) 3 lb (1.5 kg)
23554-00 Gland fitting PG 13.5, 5 per package 1 lb (0.5 kg) 1 lb (0.5 kg)
ACCESSORIES — 54eA Analyzer
PN DESCRIPTION WEIGHT* SHIP WEIGHT*
2002577 Wall and two inch pipe mounting kit
2 lb (1.0 kg) 3 lb (1.5 kg)
23545-00 Panel mounting kit
2 lb (1.0 kg) 3 lb (1.5 kg)
23554-00 Cable glands, kit (Qty 5 of PG 13.5) 1 lb (0.5 kg) 1 lb (0.5 kg)
9240048-00 Stainless steel tag (specify marking) 1 lb (0.5 kg) 1 lb (0.5 kg)
*Weights are rounded up to the nearest whole pound or 0.5 kg.
PN DESCRIPTION WEIGHT* SHIP WEIGHT*
23747-02 VP 6.0 interconnecting cable, 10 ft (3 m) 1 lb (0.5 kg) 2 lb (1.0 kg)
23747-03 VP 6.0 interconnecting cable, 50 ft (15 m) 5 lb (2.5 kg) 6 lb (3.0 kg)
23747-04 VP 6.0 interconnecting cable, 4 ft (1.2 m) 1 lb (0.5 kg) 1 lb (0.5 kg)
7
Total chlorine by definition is the iodine produced in a sample when it is treated with
potassium iodide at a pH between 3.5 and 4.5.
Typically, acetic acid (or vinegar) is used to
adjust the pH.
The total chlorine analyzer consists of a sample conditioning system, which injects the
reagent into the sample, and a sensor and
analyzer, which measure the amount of iodine
produced. Figure 2-1 shows the sample conditioning system. The sample enters the sample
conditioning enclosure and flows to an overflow sampler from which the sample pump
takes suction. Excess sample drains to waste.
At the same time, the reagent pump draws
reagent, a solution of potassium iodide in
vinegar, from the reagent carboy and injects it
into the suction side of the sample pump. The
sample and reagent mix as they pass through
the pump, and total chlorine in the sample is
converted to the chemically equivalent amount
of iodine. The flow rates are 11 mL/min for the
sample and 0.2 mL/min for the reagent.
The treated sample next enters the flow cell. Bubbles injected into the flow cell produce turbulence, which
improves the stability of the reading. A membrane-covered amperometric sensor in the flow cell measures the
concentration of iodine. The analyzer receives the raw signal from the sensor and displays the concentration of
total chlorine. Display units are ppm (mg/L) chlorine as Cl
2
. The treated sample leaves the flow cell and drains
to waste along with the excess sample.
SECTION 2. PRINCIPLES OF OPERATION
MODEL TCL SECTION 2
PRINCIPLES OF OPERATION
FIGURE 2-1. Schematic of Sample Conditioning
System and Analyzer.
8
3.1 UNPACKING AND INSPECTION
Inspect the shipping containers. If there is damage, contact the shipper immediately for instructions. Save the
boxes. If there is no apparent damage, unpack the containers. Be sure all items shown on the packing list are present. If items are missing, notify Rosemount Analytical immediately.
3.2 INSTALLATION.
3.2.1 General Information
1. Although the analyzer and sample conditioning system are suitable for outdoor use, do not install them in direct
sunlight or in areas of extreme temperature.
2. Install the analyzer and sample conditioning system in an area where vibration and electromagnetic and radio
frequency interference are minimized or absent.
3. Keep the analyzer and sensor wiring at least one foot from high voltage conductors. Be sure there is easy
access to the analyzer and sample conditioning system.
4. The analyzer is suitable for panel, pipe or wall mounting. The sample conditioning enclosure must be mounted on a wall. Provide adequate room beneath the enclosure for the 5-gallon reagent carboy.
5. Be sure that the distance between the analyzer and sample conditioning cabinet does not exceed the length
of the sensor cable.
3.2.2 Install the Analyzer
1. The analyzer enclosure has two conduit openings and three knockouts. Refer to Section 4.1 for removal of the
conduit knockouts.
2. Refer to the appropriate figure for installation details.
3. See Section 4.2 for wiring instructions.
SECTION 3. INSTALLATION
MODEL TCL SECTION 3
INSTALLATION
CAUTION
The TCL Total Chlorine analyzer is NOT
suitable for use in hazardous areas.
Type of Mounting Figure
Panel 3-1
Pipe 3-2
Wall or surface 3-3
MODEL TCL SECTION 3
INSTALLATION
FIGURE 3-1. Panel Mount Installation
Access to the wiring terminals is through the rear cover. Four screws hold the cover in place.
Panel Mounting.
MILLIMETER
INCH
9
10
MODEL TCL SECTION 3
INSTALLATION
FIGURE 3-2. Pipe Mount Installation
The front panel is hinged at the bottom. The panel swings down for access to the wiring terminals.
Pipe Mounting.
MILLIMETER
INCH
MODEL TCL SECTION 3
INSTALLATION
FIGURE 3-3. Surface Mount Installation
The front panel is hinged at the bottom. The panel swings down for access to the wiring terminals.
Surface Mounting.
MILLIMETER
INCH
11
12
MODEL TCL SECTION 3
INSTALLATION
3.2.3 Install the Sample Conditioning Enclosure
1. Refer to Figures 3-4, 3-5, and 3-6 for installation details.
2. Connect the sample line to the sample conditioning system. Use ¼-inch OD hard plastic or stainless steel tubing. If dechlorinated water is being measured, provide a way of substituting a chlorinated water sample for the
dechlorinated sample. Chlorinated water is needed to calibrate the sensor and to check its response.
3. If a grab sample tap is not already available, install one in the process piping. Choose a point as close as possible to the sample line supplying the TCL. Be sure that opening the sample valve does not appreciably alter
the flow of sample to the instrument.
4. Connect the drain to a length of ¾-inch ID flexible plastic tubing. The sample must drain to open atmosphere.
5. Find the reagent tubing and fitting in the plastic bag taped to the inside of the enclosure door. Screw the
reagent fitting onto the bulkhead fitting at the bottom left of the enclosure. Pass the reagent tubing through the
hole in the carboy cap. Be sure the plastic weight will be inside the carboy when the cap is in place. Attach the
reagent tubing to the barbed connector. See Figure 3-6.
6. Place the blue plastic carboy beneath the enclosure. Screw the cap and tubing on to the carboy. To prepare
reagent, see Section 5.2.
3.2.4 Install the Sensor
1. From inside the sample conditioning enclosure, thread the sensor cable through the gland on the upper left
side. Leave about one foot of cable inside the enclosure.
2. Wire the sensor to the analyzer. Refer to Section 4.2.3.
3. Remove the nut and adapter from the flow cell. Slip the nut over the end of the sensor. Thread the adapter
onto the sensor. Hand tighten only. Remove the protective cap from the end of the sensor.
4. Insert the sensor in the flow cell. Hand tighten the nut.
FIGURE 3-4. Installing the Sample Conditioning Enclosure
MODEL TCL SECTION 3
INSTALLATION
FIGURE 3-5. TCL Case Dimensions
INCH
MILLIMETER
FIGURE 3-6. Reagent tubing assembly
13
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