Rosemount Analytical TCL Operating Manual
Rosemount™ TCL
Total Chlorine System with Rosemount 56 Transmitter
Manual
LIQ-MAN-TCL-56, Rev B
July 2017
Essential instructions
Read this page before proceeding!
Rosemount 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 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, call 1 800 999 9307, and Rosemount will provide the requested manual. 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 this 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 product 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 people, to prevent electrical shock and personal injury.
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 combination must be
used. The installaiton system must comply with the governing approval agency (FM, CSA, or BASEEFA/CENELEC) hazardous area
classification requirements. Consult your transmitter instruction manual for details.
Proper installation, operation, and servicing of this device in a hazardous area installation is entirely your responsibility.
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 your responsibility.
No external to the instrument of more than 69 Vdc or 43 V peak allowed with the exception of power and relay terminals. Any
violation will impair the safety protection provided.
Do not operate this instrument without the front cover secured. Refer installation, operation, and servicing to qualified personnel.
WARNING!
This product is not intended for use in the light industrial, residential, or commercial environment, per the instrument's certification
to EN50081-2.
WARNING!
HAZARDOUS VOLTAGE
Can cause severe injury or death. Disconnect power before servicing.
CAUTION!
SENSOR/PROCESS APPLICATION COMPATIBILITY
Wetted materials may not be compatible with process composition and operating conditions. Application compatibility is entirely
your responsibility.
About this document
This manual contains instructions for installation and operation of the Model TCL56 Total
Chlorine Transmitter.
The following list provides notes concerning all revisions of this document.
Rev. level Date Notes
A 5/11 This is the initial release of the product manual. This manual has been refor-
matted to reflect the Emerson documentation style and updated to reflect
any change in the product offering.
B 7/17 All instances of analyzer have been replaced with transmitter. The manual has
been reformatted to reflect new Emerson branding guidelines.
Contents
Contents
Chapter 1 Description and Specifications ........................................................................................1
1.1 Features .......................................................................................................................................1
1.2 Specifications ...............................................................................................................................2
1.3 Ordering information and accessories ..........................................................................................5
Chapter 2 Principles of operation ................................................................................................... 9
Chapter 3 Installation ...................................................................................................................11
3.1 Unpacking and inspection ..........................................................................................................11
3.2 Installation .................................................................................................................................11
3.2.1 General information ....................................................................................................11
3.2.2 Install the sample conditioning enclosure ....................................................................11
3.2.3 Install the sensor ......................................................................................................... 14
Chapter 4 Wiring ..........................................................................................................................17
4.1 Prepare transmitter conduit openings ........................................................................................17
4.2 Provide power to the sample conditioning system .....................................................................17
4.3 Make power, alarm, output, and sensor connections in the transmitter ..................................... 18
4.3.1 Power ..........................................................................................................................18
4.3.2 Analog output wiring .................................................................................................. 19
4.3.3 Alarm wiring ................................................................................................................20
4.4 Sensor wiring ............................................................................................................................. 21
4.5 Apply power to the transmitter and complete Quick Start ......................................................... 22
Chapter 5 Startup .........................................................................................................................25
5.1 Prepare the reagent ................................................................................................................... 25
5.2 Zero the sensor .......................................................................................................................... 26
5.3 Start sample flow ....................................................................................................................... 26
5.4 Begin operation and calibrate the sensor ................................................................................... 26
Chapter 6 Display and operation .................................................................................................. 27
6.1 Main display ...............................................................................................................................27
6.2 Keypad .......................................................................................................................................28
6.3 Operation .................................................................................................................................. 28
6.4 Hold ...........................................................................................................................................31
6.4.1 Purpose .......................................................................................................................31
6.4.2 Using the Hold function ...............................................................................................31
6.5 Main display ...............................................................................................................................33
6.5.1 Configuring the main display .......................................................................................33
6.5.2 Setting brightness .......................................................................................................34
6.6 Security ......................................................................................................................................34
6.6.1 How the security code works .......................................................................................34
6.6.2 Assigning security codes ............................................................................................. 35
6.6.3 Bypassing security codes .............................................................................................35
Chapter 7 Programming the transmitter ...................................................................................... 37
7.1 Entering the Program menus ..................................................................................................... 37
7.2 Outputs ..................................................................................................................................... 38
7.2.1 Menu tree ....................................................................................................................38
7.2.2 Settings .......................................................................................................................38
Manual i
Contents
7.3 Relays ........................................................................................................................................ 38
7.3.1 Menu tree ....................................................................................................................38
7.3.2 Settings .......................................................................................................................39
7.4 Measurement ............................................................................................................................ 40
7.4.1 Menu tree ....................................................................................................................40
7.4.2 Settings .......................................................................................................................41
7.5 Temperature ..............................................................................................................................41
7.5.1 Menu tree ....................................................................................................................41
7.5.2 Settings .......................................................................................................................41
7.6 Security ......................................................................................................................................42
7.6.1 Menu tree ....................................................................................................................42
7.6.2 Settings .......................................................................................................................42
7.6.3 Restoring default settings ........................................................................................... 42
Chapter 8 Calibration ................................................................................................................... 43
8.1 Introduction ...............................................................................................................................43
8.2 Entering the Calibration menus ..................................................................................................43
8.3 Calibrating temperature ............................................................................................................ 44
8.4 Calibrating the free chlorine sensor ............................................................................................44
8.5 Calibrating the analog outputs ...................................................................................................45
8.6 Reset ..........................................................................................................................................45
8.6.1 Purpose .......................................................................................................................45
8.6.2 Procedure ....................................................................................................................46
Chapter 9 Data and event logging and retrieval ............................................................................47
9.1 Overview ................................................................................................................................... 47
9.2 Configuration ............................................................................................................................ 47
9.3 Downloading data and events ....................................................................................................48
9.4 Date and time ............................................................................................................................ 48
Chapter 10 Graphical display ..........................................................................................................49
10.1 Overview ................................................................................................................................... 49
10.2 Configuration ............................................................................................................................ 49
Chapter 11 Digital communications ............................................................................................... 51
Chapter 12 Maintenance ................................................................................................................ 53
12.1 Transmitter ................................................................................................................................53
12.2 Total chlorine sensor ..................................................................................................................54
12.2.1 General ....................................................................................................................... 54
12.2.2 Cleaning the membrane ..............................................................................................55
12.2.3 Replacing the membrane ............................................................................................ 55
12.2.4 Replacing the electrolyte solution and membrane .......................................................55
12.3 Sample conditioning system ......................................................................................................57
12.3.1 Reagent .......................................................................................................................57
12.3.2 Sample and reagent tubing ......................................................................................... 57
12.3.3 Replacing sample tubing .............................................................................................58
12.3.4 Peristaltic pump tubing ...............................................................................................60
12.3.5 Replacing the air pump ............................................................................................... 63
12.3.6 Replacing the air pump diaphragm and check valves ...................................................65
Chapter 13 Troubleshooting .......................................................................................................... 69
13.1 Overview ................................................................................................................................... 69
13.2 Reading and troubleshooting Fault and Warning messages ....................................................... 69
13.3 Sensor diagnostics ..................................................................................................................... 70
ii Rosemount TCL
Contents
13.4 Troubleshooting calibration problems ....................................................................................... 70
13.5 Other troubleshooting ...............................................................................................................71
13.5.1 Readings are low. ........................................................................................................ 71
13.5.2 Process readings are erratic or wander. ....................................................................... 73
13.5.3 Readings drift. ............................................................................................................. 74
13.5.4 Readings are too high ..................................................................................................74
13.6 Other troubleshooting - general ................................................................................................ 74
13.6.1 Current is output too low. ........................................................................................... 74
13.6.2 Alarm relays do not operate properly. ......................................................................... 74
13.7 Simulating inputs - chlorine ....................................................................................................... 75
13.8 Simulating inputs - temperature ................................................................................................ 75
13.8.1 General ....................................................................................................................... 75
13.8.2 Simulating temperature .............................................................................................. 76
Chapter 14 Return of material ........................................................................................................ 79
Manual iii
Contents
iv Rosemount TCL
Description and Specifications
1 Description and Specifications
1.1 Features
Rosemount TCL Sample Conditioning System
The sample conditioning system permits a single sensor to measure total chlorine in water.
The sample conditioning system continuously injects a solution of acetic acid (vinegar) and
potassium iodide into the sample. The acid lowers the pH to between 3.5 and 4.5 and
allows total chlorine in the sample to quantitatively react with the potassium iodide to
produce iodine. The sensor measures the iodine concentration, and the transmitter
displays the total oxidant concentration in ppm as Cl2.
Rosemount 56 Transmitter
The Rosemount 56 Transmitter measures total chlorine when used with the TCL and
499ACL-02 sensor.
The transmitter is housed in a corrosion resistant NEMA 4X enclosure. It is suitable for
panel, pipe, or wall mounting. The large, high resolution, full color display shows total
chlorine concentration and temperature in 0.5 in. (13 mm) high characters. Six other userselectable variables can be shown in smaller characters. Operation of the transmitter is
through the membrane keypad.
Menu screens for calibration and programming screens are simple and intuitive. Plain
language prompts in nine languages guide you. Information about program settings and
calibration, as well as troubleshooting guidance, is available on-screen at the press of a
button.
The transmitter has four fully programmable analog outputs, with HART digital
communication superimposed on output 1. Profibus DP digital communication is available
as an option. PID control is standard.
Four fully programmable relays are available. Relays can be configured as simple high/low
setpoint alarms or can be used to perform a number of timer functions as well as time
proportional control (TPC). For more information about relay actions, refer to the
Rosemount 56 Product Data Sheet.
A data and event logger are standard. The data logger stores up to 30 days of data, and the
event logger stores up to 300 events. Events can be viewed on screen, and data can be
shown in a full color dual graphics display. Data and events can also be downloaded
through a USB port on the front panel of the transmitter.
Rosemount 499ACL-02 Total Chlorine Sensor
The Rosemount 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 oxidants in the sample and the acetic acid/
potassium iodide reagent added by the sample conditioning system.
Manual 1
Description and Specifications
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 transmitter
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 transmitter 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.
1.2 Specifications
Sample Conditioning SystemTable 1-1:
Physical characteristics Specifications
General
Enclosure Fiberglass reinforced polyester, NEMA 3 (IP53)
Dimensions 14.5 x 13.0 x 8.6 in. (369 x 329 x 218 mm)
Mounting Wall
Ambient temperature 0 to 50 °C (32 to122 °F)
Ambient humidity 0 to 90% (non-condensing)
Power 115 Vac, 6.9 W, 50/60 Hz
Hazardous location The TCL Sample Conditioning System has no
Pumps
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 at-
Inlet pressure <100 psig (791 kPa abs)
suitable for marine environments
230 Vac, 7.0 W, 50/60 Hz
hazardous location approvals.
EN 809:1998
mosphere)
2 Rosemount TCL
Description and Specifications
Sample Conditioning System (continued)Table 1-1:
Physical characteristics Specifications
Flow At least 0.25 gph (15 mL/min)
Temperature 0 to 50 °C (32 to122 °F)
Total alkalinity <300 mg/L as CaCO3. For samples containing
<50 mg/L alkalinity, consult the factory.
Sample conditioning system
Reagent Potassium iodide in vinegar
Reagent usage 5 gallons last approximately 60 days.
Reagent pump Fixed speed peristaltic pump, about 0.2 mL/min
Sample pump Fixed speed peristaltic pump, about 11 mL/min
Rosemount 56 TransmitterTable 1-2:
Physical characteristics Specifications
Case Polycarbonate
Display Full color LCD, 3.75 x 2.20 in. (95 x 56 mm); you can cus-
tomaize the display.
Languages English, French, German, Italian, Spanish, Portuguese,
Chinese, Russian, and Polish
Ambient temperature and humidity -10 to 60 °C (14 to 140 °F); relative humidity 5 to 95%
(non-condensing). Between -5 and 55 °C (23 and 131 °F)
there is no visible degradation in display response or performance.
Storage temperature -20 to 60 °C (-4 to 140 °F)
Power 85 to 265 Vac, 47.5 to 65.0 Hz, 20 W
RFI/EMI
LVD
Outputs Four 4-20 or 0-20 mA isolated current outputs; assigna-
Alarms and timers Four relays, fully configurable as a setpoint alarm, inter-
Relays Form C, SPDT, epoxy sealed
Relay contact ratings
Control features PID control (analog output) and time proportional con-
EN-61326
EN-6101-01
ble to measurement or temperature; fully scalable; maximum load 550 Ω. HART digital signal is superimposed on
output 1.
val timer, TPC, bleed and feed timer, delay timer, date
and time timer, and fault alarm.
5 A at 28 Vdc or 300 Vac (resistive)
1/8 HP at 120/240 Vac
trol or TPC (relays) are standard.
Manual 3
Description and Specifications
Physical characteristics Specifications
Data logger Data automatically stored every 30 seconds for 20 days;
Event logger Stores up to 300 events with date and time stamps:
Data and event downloading Through USB port on front panel.
Graphical display Dual graphical display shows measurement data on the
Digital communications HART digital communications is standard. Profibus DP is
Weight/shipping weight (rounded up
to nearest 1 lb or 0.5 kg)
Rosemount 56 Transmitter (continued)Table 1-2:
older data removed to make room for new data. The following data are automatically stored: date and time,
ppm, temperature, and raw sensor current.
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.
Y-axis and time on the X-axis. The Y-axis is fully assignable and scalable. The X-axis can be set to 1 hour, 1 day, 7
days, or 30 days.
optional.
3 lb/4 lb (1.5 kg/2.0 kg)
Rosemount 499ACL-02 Total Chlorine SensorTable 1-3:
Physical characteristics Specifications
®
Wetted parts Gold, Noryl
cone
Dimensions 1.0 x 5. 6 in. (25.4 x 143 mm)
Cable 25 ft (7.6 m) standard
Pressure rating 0 to 65 psig (101 to 549 kPa)
Temperature rating 0 to 50 °C (32 to 122 °F)
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.
(1)
(PPO), Viton
®
(2)
, EPDM, and sili-
4 Rosemount TCL
Description and Specifications
Performance Specifications - Complete SystemTable 1-4:
Physical characteristics Specifications
Linear range 0 to 20 ppm (mg/L) as Cl2 (for higher ranges,
consult factory)
Linearity (per ISO 15839) 0 to 10 ppm: 2%; 0 to 20 ppm: 3%
Response time Following a step change in concentration, the
reading reaches 90% of final value within 7 minutes at 25 °C (77 °F)
Drift At about 1.5 ppm in clean water and constant
temperature, drift is typically less than 0.05
ppm over two weeks.
Detection limit (per ISO 15839) 0.02 ppm (mg/L) in clean water at room tem-
perature
1.3 Ordering information and accessories
Rosemount 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 a transmitter.
Important
Reagent kits must be ordered separately. Reagent kits for 0-5 ppm and 0-10 ppm chlorine are
available. For higher ranges, consult the factory.
See Table 1-5.
Rosemount TCL Total Chlorine System Ordering InformationTable 1-5:
Model Sensor type
TCL Total Chlorine System
Power input
11 115 Vac 50/60 Hz
12 230 Vac 50/60 Hz
Transmitter
- No selection - no transmitter
280 Rosemount 56-03-24-38-HT, relays, analog/HART
281 Rosemount 56-03-24-38-DP, relays, analog/Profibus DP
Sensor
- No selection - no sensor
30 Rosemount 499ACL-02-54 Total Chlorine Sensor with standard cable
Manual 5
Description and Specifications
31 Rosemount 499ACL-02-54-60 Total Chlorine Sensor with optimum EMI/RFI ca-
32 Rosemount 499ACL-02-54-VP Total Chlorine Sensor with VP cable connector
Typical model number: TCL-11-280-32
(1) Interconnecting VP cable sold separately.
Accessories
Part number Description
24134-00 Air pump, 115 Vac, 50/60 Hz
24134-01 Air pump, 230 Vac, 50/60 Hz
9160578 Air pump repair kit
9322052 Check valve for air injection line
24153-00 Carboy for reagent, 5 gal/19 L, includes cap
9100204 Fuse, 0.25 A, 250 V, 3 AG, slow blow for option-11
9100132 Fuse, 0.125 A, 250 V, 3 AG, slow blow for option -12
9380094 Reagent pump, 115 Vac, 50/60 Hz
9380095 Reagent pump, 230 Vac, 50/60 Hz
9380091 Reagent pump replacement tubing
24151-00 Reagent tubing replacement kit
24135-00 Reagent uptake tubing, 6 ft (1.8 m), includes weight
9380090 Sample pump, 115 Vac, 50/60 Hz
9380093 Sample pump, 230 Vac, 50/60 Hz
9380092 Sample pump replacement tubing
24152-00 Sample tubing replacement kit
24164-00 Potassium iodide, 25 g, sufficient for 5 gallons (19 L) of
24164-01 Potassium iodide, 50 g, sufficient for 5 gallons (19 L) of
24165-00 Acetic acid, 2 x 2.5 gal (9.5 L) bottles/case, with 25 g po-
24165-01 Acetic acid, 2 x 2.5 gal (9.5 L) bottles/case, with 50 g po-
Rosemount TCL Total Chlorine System Ordering Information (continued)Table 1-5:
ble
(1)
Sample Conditioning System AccessoriesTable 1-6:
(115 Vac)
(230 Vac)
vinegar (0-5 ppm total chlorine)
vinegar (0-10 ppm total chlorine)
tassium iodide (0-5 ppm total chlorine)
tassium iodide (0-10 ppm total chlorine)
6 Rosemount TCL
Description and Specifications
Rosemount 1056 and 56 Transmitters AccessoriesTable 1-7:
Part number Description
23554-00 Cable glands (qty 5 of PG 13.5)
23820-00 Wall and 2 in. pipe mounting kti
240048-00 Stainless steel tag (specify marking)
Sensor AccessoriesTable 1-8:
Part number Description
23501-02 Total chlorine membrane, includes 1 membrane assembly
and 1 O-ring
23502-02 Total chlorine membrane kit, includes 3 membrane as-
semblies and 3 O-rings
9210438 Total chlorine sensor fill solution, 4 oz (120 mL)
For First Time Variopol InstallationsTable 1-9:
Part number Description
23747-06 Interconnecting cable, VP 6, 2.5 ft (0.8 m)
23747-04 Interconnecting cable, VP 6, 4 ft (1.2 m)
23747-02 Interconnecting cable, VP 6, 10 ft (3.0 m)
23747-07 Interconnecting cable, VP 6, 15 ft (4.6 m)
23747-08 Interconnecting cable, VP 6, 20 ft (6.1 m)
23747-09 Interconnecting cable, VP 6, 25 ft (6.1 m)
23747-10 Interconnecting cable, VP 6, 30 ft (9.1 m)
23747-03 Interconnecting cable, VP 6, 50 ft (15.2 m)
23747-11 Interconnecting cable, VP 6, 100 ft (30.5 m)
Manual 7
Description and Specifications
8 Rosemount TCL
2 Principles of operation
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 system consists of a sample conditioning system, which injects the
reagent into the sample, and a sensor and transmitter, 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.
Schematic of Sample Conditioning System and TransmitterFigure 2-1:
Principles of operation
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
transmitter receives the raw signal from the sensor and displays the concentration of total
chlorine. Display units are ppm (mg/L) chlorine as Cl2. The treated sample leaves the flow
cell and drains to waste along with the excess sample.
Manual 9
Principles of operation
10 Rosemount TCL
3 Installation
3.1 Unpacking and inspection
Complete the following steps when you unpack your instrument.
1. Inspect the shipping containers. If there is damage, contact the shipper immediately
for instructions.
2. Save the box.
3. If there is no apparent damage, unpack the containers.
4. Ensure that all items shown on the packing list are present. If items are missing,
notify Rosemount immediately.
3.2 Installation
Installation
3.2.1 General information
1. Although the transmitter and sample conditioning system are suitable for outdoor
use, do not install them in direct sunlight or in areas of extreme temperature.
CAUTION!
HAZARDOUS AREAS
The TCL Total Chlorine Sample Conditioning System is not suitable for use in hazardous
areas.
2. Install the transmitter and sample conditioning system in an area where vibrations
and electromagnetic and radio frequency interference are minimized or absent.
3. The transmitter 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.
4. Be sure that the distance between the transmitter and sample conditioning cabinet
does not exceed the length of the sensor cable.
3.2.2 Install the sample conditioning enclosure
Follow the steps below to install the sample conditioning enclosure.
Refer to Figure 3-1, Figure 3-2, and Figure 3-3 for installation details.
Manual 11
Installation
Installing the Sample Conditioning EnclosureFigure 3-1:
12 Rosemount TCL
Installation
TCL Case DimensionsFigure 3-2:
Reagent Tubing AssemblyFigure 3-3:
Manual 13
Installation
Procedure
1. Connect the sample line to the sample conditioning system. Use 1/4 in. OD hard
plastic or stainless steel tubing. If dechlorinated water is being measured, provide a
way for occasionally substituting a chlorinated water sample for the dechlorinated
sample.
Chlorinated water is needed to calibrate the sensor and to check its response.
2. If a grab sample 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.
3. Connect the drain to a length of 3/4 in. ID flexible plastic tubing.
Important
The sample must drain to open atmosphere.
4. 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 3-3.
5. Place the blue plastic carboy beneath the enclosure. Screw the cap and tubing
assembly on the carboy.
To prepare reagent, see Section 5.1.
3.2.3 Install the sensor
Complete the following steps to install the Rosemount 499ACL-02 Sensor in the TCL
system.
1. From inside the sample conditioning enclosure, thread the sensor cable or VP cable
through the gland on the upper left side.
Leave about one foot of cable inside the enclosure.
2. Wire the cable to the transmitter.
Refer to Section 4.4.
3. Remove the nut and adapter from the flow cell.
4. Slip the nut over the end of the sensor.
5. Thread the adapter onto the sensor. Hand-tighten only.
6. If you are using a VP cable, connect the cable to the sensor.
The connector and receptacle are keyed to ensure proper mating.
14 Rosemount TCL
Installation
7. Once the key has slid into place, tighten the connection by turning the knurled ring
clockwise.
8. Remove the protective cap from the end of the sensor.
9. Insert the sensor in the flow cell. Hand tighten the nut.
Manual 15
Installation
16 Rosemount TCL
4 Wiring
4.1 Prepare transmitter conduit openings
The transmitter enclosure has six conduit openings. Four conduit openings are fitted with
conduit plugs.
Conduit openings accept 1/2 in. conduit fittings or PG 13.5 cable glands. To keep the case
watertight, block unused openings with NEMA 4X or IP65 conduit plugs.
Note
Use watertight fittings and hubs that comply with the requirements of UL514B. Connect the conduit
hub to the conduit before attaching the fitting to the transmitter (UL508-26 16).
4.2 Provide power to the sample conditioning
Wiring
system
Complete the following steps to power the sample conditioning system.
WARNING!
RISK OF ELECTRICAL SHOCK
Electrical installation must be in accordance with the National Electric Code (ANSI/NFPA-70)
and/or any other applicable national or local codes.
Note
Provide a switch or breaker to disconnect the sample conditioning cabinet from the main power
supply. Install the switch or breaker near the unit and identify it as the disconnecting device for the
sample conditioning system.
Procedure
1. Be sure the pump switches on the wiring access panel are in the Off position.
2. Remove the four screws securing the wiring access panel. Pull the panel out of the
way to reveal the power terminal strip.
3. Insert the power cable through the strain relief connection labeled Power.
See Figure 3-2.
4. Wire the power cable to the terminal strip as shown in Figure 4-1.
Manual 17
Wiring
CAUTION!
EQUIPMENT DAMAGE
Do not apply 230 Vac power to a 115 Vac TCL (Model option -11). Doing so will damage
the instrument.
Power wiringFigure 4-1:
Important
Leave the pump power switches off until ready to start up the unit.
See Chapter 5.
4.3 Make power, alarm, output, and sensor connections in the transmitter
WARNING!
RISK OF 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.
4.3.1 Power
Wire AC mains power supply to the power supply board, which is mounted vertically on
the left hand side of the transmitter enclosure beneath the gray plastic cover.
1.
To remove the cover, grab it by the upper edges and pull straight out.
18 Rosemount TCL
Wiring
The power connector is at the bottom of the board. See Figure 4-3.
2. Bring the power cable through the conduit opening just below the connector.
3. 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.)
4. Replace the cover.
The two tabs at 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 4-3.
5. Once the tabs are lined up, push the cover to snap it into place.
6. AC power wiring should be 14 gauge or greater. Run the power wiring through the
conduit opening nearest the power terminal.
7. Provide a switch or breaker to disconnect the transmitter from the main power
supply.
8. Install the switch or breaker near the transmitter and label it as the disconnecting
device for the transmitter.
4.3.2 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 4-2 shows the location of the terminals, the outputs they are assigned to, and the
polarity.
Manual 19
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