Global Water
OWNER’S MANUAL
CL500 OnLine Residual
Chlorine Monitor
Global Water Instrumentation
11390 Amalgam Way
Gold River CA 95670
Phone: 800-876-1172
Fax: 847-672-9988
EMail:Globalw@globalw.com
Website:
www.globalw.com
Catalog #24420GW (2/08)
REV. 2.0
Table of Contents
Section Page
Specifications....................................................................................................1
1.0 Overview...........................................................................................................2
1.1 Unpacking and Inspection of the Instrument and Accessories .............2
1.2 The Display ...........................................................................................3
1.3 The Touch Pad ......................................................................................3
2.0 Safety.................................................................................................................4
2.1 Symbols Used In CL500........................................................................4
3.0 Theory of Operation........................................................................................5
4.0 Installation and Commissioning ....................................................................6
4.1 Mounting & Site Selection.....................................................................6
4.2 Plumbing ..............................................................................................7
4.3 Electrical Connections ..........................................................................8
4.3.1 Power ........................................................................................9
4.3.2 RS-485 .....................................................................................9
4.3.3 Relays.......................................................................................10
4.3.4 4-20 mA ..................................................................................10
4.3.5 RS-485/4-20 mA cable Ferrite.................................................10
4.4 Installing Reagents ..............................................................................10
5.0 Operation .......................................................................................................11
5.1 Routine Measurement .........................................................................11
5.2 Security Access Feature.......................................................................12
6.0 Instrument Calibration ................................................................................13
6.1 Slope (gain) Calibration Procedure .....................................................13
6.2 Zero (offset) Calibration Procedure ....................................................14
6.3 Restore Factory Settings ......................................................................14
7.0 Instrument Configuration (CONFIG mode)...............................................15
7.1 Setting the 4-20 mA.............................................................................15
7.2 Configuring the Error Level.................................................................16
7.3 Configuring the RS-485 Port ..............................................................16
7.4 Configuring the Alarms .......................................................................17
7.4.1 Alarm 1 ....................................................................................17
7.4.2 Alarm 2 ...................................................................................18
7.5 Enabling the Security Access...............................................................18
7.6 Extended Settings.................................................................................18
Table of Contents (continued)
Section Page
7.7 Speed of Response...............................................................................19
7.8 LCD Backlight Brightness...................................................................19
7.9 RS- 485 Parameters..............................................................................20
7.10 Cycle Time ..........................................................................................20
7.11 Saving Configuration Settings.............................................................20
8.0 Additional Features and Options ................................................................21
8.1 Backlit LCD.........................................................................................21
8.2 RS-485 Output.....................................................................................21
8.2.1 Online SCADA........................................................................21
8.2.2 Simple Communication ...........................................................21
8.2.3 Modbus Communication..........................................................22
8.3 Remote Panel Meter.............................................................................22
8.4 Desiccant Cartridge..............................................................................22
9.0 Troubleshooting.............................................................................................23
9.1 CL500 Fault Detection.........................................................................23
9.2 Setting Flow Rate.................................................................................24
9.3 Clearing Faults.....................................................................................24
9.4 Diagnostic Chart .................................................................................25
9.5 Technical and Customer Assistance ...................................................25
10.0 Routine Maintenance.....................................................................................26
10.1 Maintenance Schedule ........................................................................26
10.2 Replacing or Installing the Reagents ...................................................28
10.3 Cuvette Change ...................................................................................29
10.4 Instrument Storage ..............................................................................29
10.5 Cleaning the CL500 ............................................................................30
11.0 Accessories and Replacement Parts List .....................................................31
12.0 Warranty .......................................................................................................32
Specifications
Measurement Range
Accuracy
Resolution
Cycle Time
Display
Alarms
Analog Output
Communications Port
Water Pressure
Flow Rate to Waste
Operating Temperature
Wetted Materials
0 – 10.00 mg/L (PPM)
±5% of reading or ±0.03 mg/L (PPM) whichever is greater for range of
0-6.0 mg/L(PPM)
±10% of reading from 6.01-10.00 mg/L (PPM)
0.01 mg/L (PPM)
Adjustable; 110 seconds to 10 minutes (600 seconds)
Note: the system defaults to 2.5 minutes
Multi-Line Liquid Crystal Backlit Display
Two Programmable, 120-240VAC 2A Form C Relay
Powered 4-20 mA, 600 Ω drive, isolated
Bi-directional RS-485 with Modbus
Integral pressure regulator 0.34 bar(5.0 PSI) to 10.3 bar (150 PSI.)
200 – 400 ml/min.
5°C – 40°C (41°F – 104°F)
PVC, Borosilicate Glass, Reslyn (FFKM), Viton® (FKM),
Polypropylene, Stainless Steel, Acetal, Nitrile, Noryl®, Nylon
Sample Temperature Range
Power Supply
Insulation Rating
Environmental Conditions
Enclosure Rating
Regulatory Compliance
And Certifications
Shipping Weight
Shipping Dimensions
Warranty
5°C – 40°C (41°F – 104°F)
100 – 240 VAC, 47 – 63 Hz, 150VA
Double Insulated, Pollution Degree 2, Overvoltage Category II
Not recommended for outdoor use.
Altitude up to 2000 meters
Up to 95 % RH (non-condensing)
Designed to meet IP 66 /NEMA 4X
CE Approved, ETL listed to UL 61010-1-2004 &
ETL Certified to CSA 22.2 No. 61010.1 2
nd
edition dated July 2004
2.5 kg (5.5 lbs.) Reagents Shipped Separately
406 mm X 406 mm X 229 mm (16”X 16” X 9”)
1 Year from date of shipment
CL500 (2/08) Page 1
REV 2.0
1.0 Overview
The CL500 Online Chlorine Analyzer allows for the reading of chlorine levels of process
water on-line. The CL500 has been designed to meet the design criteria specified by
Standard Methods for the Examination of Water and Wastewater (21th Edition) Method
4500-Cl G. DPD Colorimetric Method. The CL500 uses a 515nm LED as the
measurement light source.
Every effort has been made to ensure the accuracy of this manual. Due to the continuous
development and improvement of all instrumentation, there may be slight differences
between this manual and the instrument received. Therefore, no legal claims can be made
against any discrepancies herein. The latest version of the manual can be downloaded
www.globalw.com.
from
1.1 Unpacking and Inspection of the Instrument and Accessories
The table below indicates the items in the shipment.
Item Quantity
CL500 Analyzer 1
Instruction Manual 1
Mounting Kit 1
Tubing/Cuvette Kit: 8 black “B” tubes, 2 Cap Assemblies, 1 replacement cuvette 1
In-Line Strainer Kit 1
Ferrite 1
Remove the instrument from the packing carton. Carefully inspect all items to ensure that
no visible damage has occurred during shipment. If the items received do not match the
order, please immediately contact the local distributor or Global Water’s Customer
Service Department.
CL500 (2/08) Page 2
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1.2 The Display
Figure 1 illustrates all the items that can appear on the display. The upper row of the
display (1) is used for reporting the chlorine levels and to provide user guidance in the
customer setting routine. The lower row of the display (2) is used to communicate error
messages (message queue) and provide user guidance. The display has two icons (3) that
are used to indicate the use of access code and offset mode. In addition, mode arrows (4)
are used to indicate the current instrument operating mode; AUTO (normal operation),
CAL (calibration) and CONFIG (configuration).
Figure 1: Display used in the instrument.
1.3 The Touch Pad Figure 2 illustrates the touch pad. The touch pad has six buttons: PRIME, SERVICE, MODE/EXIT, , S and T
The MODE/EXIT button is used to cycle between the three operational modes of the
instrument: CAL, CONFIG, and AUTO (Measurement) mode. The button enters the
option or mode that is highlighted or chosen. The S and T buttons are used to change
settings.
The PRIME and SERVICE buttons are dedicated controls. The PRIME will start 75
reagent pump pulses to prime the tubing after a change or addition of reagent bottles. The
SERVICE button will drain the instrument and hold all operations until either the
SERVICE button is pushed again or the power is reset. This button should be used while
changing the tubing, the measurement cuvette or reagent bottles.
Figure 2: The CL500 touch pad.
CL500 (2/08) Page 3
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2.0 Safety
This manual contains basic instructions that must be followed during the commissioning,
operation, care and maintenance of the instrument. The safety protection provided by this
equipment may be impaired if it is commissioned and/or used in a manner not described in
this manual. Consequently, all responsible personnel must read this manual prior to
working with this instrument.
In certain instances “Notes”, or helpful hints, have been highlighted to give further
clarification to the instructions. Refer to the Table of Contents to easily find specific
topics and to learn about unfamiliar terms.
2.1 Symbols Used In CL500
Standard IEC symbols are used on the high voltage cover.
ISO 3864, No. B.3.6 Caution, risk of electric shock.
cover
This symbol indicates that hazardous voltages may be present under this
This symbol is reminding you to read the sections in the manual referring
to the electrical connections, and potential hazards.
ISO 3864, No.B3.1 Caution refer to accompanying documents.
CL500 (2/08) Page 4
REV 2.0
3.0 Theory of Operation
The CL500 has two solenoid valves, one for sample water (FLOW) and one for draining
of the cuvette (PURGE). A third solenoid, along with four check valves forms a reagent
pump. Sample water flow is controlled by the FLOW solenoid valve. The PURGE
solenoid valve is used to empty the measurement cuvette.
The measurement chamber consists of a sample inlet, a purge drain, and an overflow. The
reagent is added below the cuvette. A green LED provides the 515 nm source lamp, a red
LED is used for sample level and flow measurement. A single detector is located 180 º
from the green LED. A replaceable glass cuvette separates the sample water from the
optical devices and maintains the measurement path length. Sample water flows in the
inlet at the bottom, through the measurement cuvette and out through overflow drain. This
flow is used to both fill the cuvette and flush the system.
The reagents consist of two replaceable bottles. One bottle has a buffer to control the pH;
the second has an indicator that contains the DPD, which produces color when chlorine is
present in the sample. The degree of color is dependant on the amount of chlorine in the
sample water.
The measurement chamber is open to view operations in the cuvette. A white LED
illuminates the chamber for a clearer view. The white LED will flash to attract attention in
the case of a warning or failure. Most warnings and failures are displayed on the screen.
During normal operation the CL500 will run through a timed cycle. A simplified cycle
will consist of the following sequences:
• Flushing – continuous sample flow
• Zeroing – no flow with cuvette full
• Purging – PURGE valve opens
• Adding Reagents – one pulse of the reagent pump
• Mixing with sample – sample flow pulses in
• Reading resulting sample – no flow with cuvette full
• Purging – PURGE valve opens to remove reacted sample
The cycle above does not describe all the actions and testing that occurs. The CPU
continuously diagnoses the entire system for correct operation and sample water flow. If
an error occurs, a message is posted to the message queue.
The reagent is added from the front, below the cuvette, by a single pulse of the reagent
solenoid. When the reagents require replacement, the PRIME button is pushed to bring
new reagents into the system. The reagent solenoid is pulsed several times to draw fluid
from the two reagent bottles and fill the tubes with new reagent. A complete prime takes
less than a minute.
The SERVICE button empties the cuvette, stops the flow of sample water, and clears any
errors. This provides a convenient way to replace reagents and the measurement cuvette. If
more extensive servicing is performed, all power to the CL500 should be removed. If the
CL500 is to be turned off, it is recommended that the instrument be placed in SERVICE
mode before removing power. This ensures that the cuvette is emptied and the flow is off.
CL500 (2/08) Page 5
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4.0 Installation and Commissioning
Prior to use for the first time, one of the reagents (the indicator) will have to be mixed.
Refer to section 10.2 Replacing or Installing the Reagents.
4.1 Mounting & Site Selection
The instrument is designed for wall mounting. If wall mounting is not practical, the
instrument can be mounted on any suitable level surface Choose a location that is easily
accessible for operation and service and ensure that the front display rests at eye level.
Consideration must be made the plumbing connections. The overall mounting dimensions
of the instrument are shown in Figure 3.
219.08mm
(8.625")
298.45mm
(1
1.750")
219.08mm
(8.625")
298.45mm
(11.750")
REAR VIEW
OF THE
INSTRUMENT
IT MAY BE NECESSARY TO REMOVE
THIS BULKHEAD NUT TO ACCESS THE
BOTTOM LEFT MOUNTING HOLE WITH
THE BRACKET IN THIS POSITION.
Figure 3: Overall Mounting Dimensions of the Instrument
It is critical that the instrument be mounted as close as possible to the sampling point to
ensure a quick response time (within 2-3 meters (6-10 ft) of the sampling point).
The provided mounting feet will need to be installed with the provided screws. These can
be rotated as shown above. Suggested mounting screws are up to M6 (¼”).
CL500 (2/08) Page 6
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4.2 Plumbing
The recommended plumbing for the instrument is shown in Figure 4. The instrument is
designed to require very little head pressure to operate, but will need around 0.34 bar (5
PSI). The maximum pressure for proper operation should not exceed 10.3 bar (150 PSI).
The maximum allowable fluid temperature is 40°C (104°F).
ONLINE CHLORINE MONITOR
CABINET VENT
DRAIN CONNECTION
ACCEPTS 12,7 MM
(1/2") I. D. TUBING
INLINE T-STRAINER
PRESSURE
REGULATOR
WATER INLET
ACCEPTS 6,35 MM
(1/4") O. D. TUBING
1/4" OD PE TUBING
NOTE DIRECTION OF ARROW
IF NECESSARY, CHANGE
THE INLET FITTING HERE
Figure 4: Recommended Plumbing for the Instrument
The supplied T-strainer should always be used to prevent clogging of the instrument. ¼”
quick connect fittings are supplied on the T strainer. If a pipe fitting change is required,
this adaptation should be made at the T-strainer, not the instrument. Opaque tubing is
recommended be used if the tubing will be exposed to sunlight, to prevent algae growth.
Please note that the supplied connectors are compatible with ¼” O.D. semi-rigid or rigid
tubing.
The instrument is equipped with an internal cabinet drain (vent) to prevent damage in the
event of a tubing failure.
The drain tubing connects to a hose barb. The rated tubing size is ½” ID tubing. It is
recommended that opaque tubing be used to prevent algae growth. Keep this tubing as
short as possible. This drain must be kept open to the atmosphere.
CL500 (2/08) Page 7
REV 2.0
The fluid waste from drain connection of this instrument contains reagents
diluted with large quantities of sample water. Global Water Instrumentation
recommends that operators check with local authorities concerning proper
disposal of waste fluids.
A ½ “ ID tubing can be placed over the cabinet vent to redirect accidental
spills of reagent to a suitable container.
4.3 Electrical Connections
All of the electrical connections to the instrument are made at the termination area which
is located on the left side of the instrument. Remove the high voltage cover by loosening
the captive screw. Refer to figure 5. The connections are labeled and are self-descriptive
(see Figure 5). Please follow all local and government recommendations for installation
of electrical connections to and between the instrument and other peripheral devices.
Bulkhead
Communication
Bulkhead
Captive Screw
High Voltage Cover
Power Cable
Strain Relief
Anchor
Power
Bulkhead
Alarms
Power
Terminal
Block
Alarm #2
Terminal
Block
Alarm #1
Terminal
Block
RS-485
Terminal
Block
4-20mA
Terminal
Block
Figure 5: Electrical Connections for the Instrument
CL500 (2/08) Page 8
REV 2.0
Plugs are inserted into the RS-485 and 4-20mA cable bulkheads when shipped, to ensure a
watertight seal. These plugs should be removed and discarded when cabling to either of
these connections.
The power cable bulkhead will accept cable diameters from 5.8mm (.230 in.) up to 10 mm
(.395 in.). All terminals are designed to accept wires in the range of 14-28 AWG. All
wires should be stripped to a length of 6 mm (¼”). A strain relief strap is provided to
reduce tension on the power terminals.
It is the user’s responsibility to assure that a watertight seal is maintained after the CL500
has been wired for operation. If any of the bulkheads are not tightened properly around a
cable or plug, the ratings of the instrument will be jeopardized and there is a possibility of
creating a shock hazard.
Only qualified electricians should be allowed to perform the installation of the
instrument as it involves a line voltage that could endanger life.
4.3.1 Power
The instrument is equipped with 100-240 VAC, 47-63 Hz power supplies requiring
150VA; please verify that the line voltage falls within these specifications. It is
recommended that a circuit breaker be placed prior to the power connection to
allow for service. For safety it is recommended that the connection be less than 2
meters (six feet) from the instrument. While making connections, refer to Figure 5.
The CL500 is intended for cord connection with a three wire non-locking
grounded power cord; however ridged or flexible conduit connections can be used.
A power cord can be purchased separately from the factory (Catalog No. 00-302).
The CL500 is not supplied with a power cord. If the CL500 is to be used in the
U.S. or Canada the power cord must be UL Listed & CSA Certified. Please consult
all local electrical codes for proper connection.
The connection block is marked N for Neutral and L for line the third symbol
indicates a secure earth ground. The green removable terminal block is suitable for
wire gauges 18 to 12 AWG.
4.3.2 RS-485
The RS-485 half-duplex (2-wire) digital interface operates with differential levels
that are not susceptible to electrical interferences. This is why cable lengths up to
3000 ft can be implemented. The last device on each bus may require terminating
with a 120 ohm resistor to eliminate signal reflection on the line. Do not run RS485 cables in the same conduit as power. Set-up of the RS-485 is covered in 7.3
Configuring the RS–485 Port
To prevent damage to the instrument, ensure that power is disconnected prior to
making connections. For ease of connecting, remove the plug-in terminal block.
Connections are labeled beside this termination on the PC board.
The recommended cable is 22 AWG shielded twisted pair. The grey terminal block
is removable to assist in making connections.
CL500 (2/08) Page 9
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4.3.3 Relays
The Alarm 1 and Alarm 2 relays are mechanical relays rated at 240 VAC 2A.
Please note that the relays are labeled NO (Normally Open), NC (Normally
Closed) and C (Common). As these alarms are configured fail-safe, the normal
condition is with power applied to the CL500 and in a non-alarm condition.
Operation of these alarms is covered in section 7.4 Configuring the Alarms.
The lever operated terminal blocks are rated for wire gauges 28-14.
4.3.4 4-20 mA
The 4-20 mA output is driven by a 15 VDC power source and can drive recorder
loads up to 600 ohms. Transformer isolation is provided on the CL500. Do not run
4-20 mA cables in the same conduit as power. Operation of this output is covered
in section 7.1 Setting the 4-20 mA.
To prevent damage to the instrument, and for general safety ensure that power is
disconnected to the CL500 prior to making any connections. Polarities of the
connections are labeled beside this termination on the PC board.
The recommended cable is 22 AWG shielded twisted pair. To prevent ground
loops, connect the shield at either the CL500 or at its destination, but not both.
The grey terminal block is removable to assist in making connections.
4.3.5 RS-485/4-20 mA cable Ferrite
To meet IEC requirements for RF radiated immunity a clamp-on type ferrite is
supplied in the accessory kit. It should be placed on the RS-485 or 4-20 mA cable
outside, as close as possible to the CL500. If both outputs will be used, an
additional ferrite will be needed and can be ordered from Global Water
Instrumentation Catalog number 24560GW.
4.4 Installing Reagents
The CL500 will require that two reagents be installed prior to operation. These are a
buffer and an indicator. Be sure the correct, prepared reagents are on hand as different
reagents are required to read Free than Total chlorine residual. For reagent preparation
refer to section 10.2 Replacing and Installing the Reagents.
CL500 (2/08) Page 10
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5.0 Operation
The CL500 Online Chlorine Analyzer allows for the measurement of the chlorine of
process water on-line. The chlorine value of the process water is usually reported in
milligrams per Liter (mg/L), these units are equivalent to Parts Per Million (PPM).
Readings above 10.00 mg/L are outside the range of this instrument. Although the CL500
may display above 10.0 mg/L, these readings will not be within the stated accuracy. As
the reagents degrade due to aging, readings above 10.0 mg/L may decrease in value.
5.1 Routine Measurement
First, ensure that all plumbing and electrical connections are complete before continuing.
The following steps describe how to measure the value of chlorine of a sample using this
instrument:
1. Apply power to the instrument and allow the unit to warm up (typically 45 minutes to
one hour on initial commissioning).
2. When a continuous process stream is flowing through the instrument, the instrument
will display the measured chlorine level of the sample by displaying it on the LCD
screen. In addition, the equivalent signal is provided on the analog (4-20 mA) output,
or the digital (RS-485) output, depending on the options selected.
During normal operation, the instrument will have the arrow beside AUTO highlighted
with the current scale displayed on the lower row of the display and the measured reading
on the upper row of the display (see illustration below).
The screen depicted below indicates that the system has just been started or just entered
AUTO mode from Service mode and no readings have been taken yet.
Please note that calibrations will not be allowed until a reading is posted.
CL500 (2/08) Page 11
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5.2 Security Access Feature
The instrument is equipped with a security access code feature that can be activated in the
configuration mode. If the security feature is enabled, the screen shown in the illustration
below will appear when the MODE/EXIT button is pressed.
The security code (333) must be entered to gain access to CAL or CONFIG menus.
Notice that the first number in the code is flashing. The flashing indicates that this is the
number to be changed. Use the S or T arrows to select the first of the three numbers in
the code and then press the button to accept the first number of the code. Now enter the
second number in the code. Proceed as with the first number followed by . Then repeat
the process for the third number in the access code, and finish with the button.
If the valid access code has been selected, the instrument will be directed to the calibration
mode. If the wrong access code is selected, the instrument will return to the AUTO mode.
Refer to section 7.5 Enabling the Security Access for more information.
CL500 (2/08) Page 12
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6.0 Instrument Calibration
The instrument was tested prior to leaving the factory. Since it operates from a predetermined calibration curve, no calibration is required.
Calibration can easily be performed if required. The method is by comparison against
another instrument, such as a laboratory or hand held photometer.
There are two points of calibration. The slope or gain and the zero (offset). To perform the
zero the instrument must be plumbed to a sample of known chlorine free water such as deionized water for a zero adjustment.
6.1 Slope (gain) Calibration Procedure
It is important that the chlorine level be quite stable to use this method. The comparison
will be made against a trusted measurement such as a chlorine photometer,
spectrophotometer, or an amperometric titration.
1. Obtain a grab sample of the flow.
2. Measure the value of the sample with one of the methods shown above.
3. On the CL500, press the MODE/EXIT button once. The screen is shown below.
4. Press to enter the calibration adjustment.
5. The screen will show the current reading on the CL500. Using the S & T buttons
adjust the reading to agree with the laboratory method or portable photometer.
6. Press to accept the calibration adjustment and return to AUTO measurement
mode.
There is a limit to the size of the change that can be made to a current
reading. The upper limit is the current reading times 1.5. The lower limit is
the current reading divided by 1.5.
Ensure a reading is posted to the display before calibrating to avoid a nOnE
error.
CL500 (2/08) Page 13
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6.2 Zero (offset) Calibration Procedure
Generally this calibration is only required if readings are expected to be below 1 mg/L or
if it is required by a regulatory authority. To perform this calibration, the water supply to
the CL500 must be changed to chlorine free water such as de-ionized water. This chlorine
free water must be run through the instrument for at least 5 minutes prior to using the
following procedure.
1. On the CL500, press the MODE/EXIT button once. The screen is shown
below.
2. Press either the S or Tbuttons to get the following screen.
3. Press to enter the zero calibration screen.
4. The screen will show the current reading on the CL500. Since there is no
chlorine, the only reading may be a slight offset due to the absorbance of the
reagents. There should be no pink color developed.
5. Press to perform a Zero calibration. When the calibration has completed the
instrument will return to AUTO measurement mode automatically.
There is a limit of ±0.20 mg/L total adjustment available. A ZERO Cal.
greater than this will cause a CAL warning and no calibration will have
occurred. Enter SERVICE mode to clear this error.
6.3 Restore Factory Settings
If the CL500 displays a CAL error or the calibration was incorrectly performed, it may be
desired to restore the factory calibration. All factory defaults including factory
configurations can be reset by holding down the S button and then pressing and releasing
the button then releasing the S button.
CL500 (2/08) Page 14
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7.0 Instrument Configuration (CONFIG mode)
The instrument has been designed to provide the ability to customize the instrument
according to needs at any time during normal operation. This mode has been split into
sub-menus to facilitate instrument configuration. This section describes how to use each
of the sub-menus to configure the instrument. While in the configuration mode, the
instrument has a time-out feature that automatically returns the system operation to the
AUTO mode after a fifteen (15) minute period of no button pushes.
Enter the CONFIG mode of the instrument by pressing the MODE/EXIT button until the
arrow beside CONFIG is illuminated, then press the ↵ button.
To exit the CONFIG mode, press the MODE/EXIT button.
7.1 Setting the 4-20 mA Output
The first configuration selection is 4-20 for the 4-20 mA output. Select the either On or
OFF using the S and T buttons. Once the desired output has been set, press the button
to accept it. The next prompts will depend on the output selected.
If the 4-20 mA output was turned On, prompts to set the 4 mA (4MA) and 20 mA
(20MA) chlorine limits will be displayed. There will also be a menu to adjust the error
level (ERLV). The first prompt will be the chlorine limit assigned to the 4 mA output
level:
Select the chlorine level to assign to the 4MA using the S and T buttons.
Once the desired level has been set, press the button to accept it.
The 4MA can be set higher than 20MA level to invert the output current if
required. This may be required to control a dosing pump.
CL500 (2/08) Page 15
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The next prompt will be the chlorine level assigned to the 20MA. Select the chlorine level
using the S and T buttons. Once the desired level has been set, press the button to
accept it.
7.2 Configuring the Error Level
In case of an error in the CL500, the 4-20 mA reading can be used to indicate a problem
by sending the current to either 4.00 mA, 2.00 mA or 0 mA. The factory default setting is
OFF. Select the desired ERLV by using the S and T buttons then press the button to
accept the desired error response.
7.3 Configuring the RS–485 Port
The instrument is equipped with an RS 485 port which operates in Simple bus, a
proprietary communication) or Modbus. Prompts will appear for setting the baud rate, the
address and the Modbus transmission mode (RTU or ASCII).
Select the correct baud rate (1200, 2400, 4800, 9600, or 19200) for operation of the I/O
port by pressing the S or T buttons to change the displayed baud rate.
CL500 (2/08) Page 16
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Press the button to continue on and select the desired instrument address using the S or
T buttons. Once the selection is satisfactory, press the button.
To use the Modbus mode, select ASCII or RTU. Refer to the Modbus Manual available
from Global Water Instrumentation or online at
7.4 Configuring the Alarms
Two relays are provided that are designed to operate as two independent programmable
alarms or as a system problem alarm. Please note that changes to alarms will not be
recognized until the start of the next cycle. Two settings must be selected to fully program
each alarm:
1. The alarm function (HI, LO, OFF or Error)
2. The alarm set point (level at which the alarm activates)
These items are described below:
www.globalw.com.
Alarm Function: The alarms can either be turned OFF or selected to operate in one of
three different manners:
1. HI alarm: the relay changes state when the measured chlorine level is higher than the
programmed alarm level (set point).
2. LO alarm: the relay changes state when the measured chlorine level is lower than the
programmed alarm level (set point).
3. Error alarm: If there is a system fault or problem the alarm will change states.
Alarm Set Point: The level at which an alarm activates is called the alarm set point. On
the instrument, the alarm set point is designated as “S/P”. The set point is adjustable to
any valid chlorine level over the range of the instrument in steps of 0.01 mg/L. This
setting is not available if the Error function is chosen
7.4.1 Alarm 1 Alarm 1 Function: The ALM1 is displayed and the display indicates the current
function of alarm 1 (HI, LO, OFF, or Error). Use the S or T buttons to cycle
through and select the desired function. Press the button to accept the selection.
If the alarm was turned OFF, a prompt will appear to set up alarm 2 (go to section
7.4.2).
CL500 (2/08) Page 17
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Alarm 1 Set Point: This prompt is used to select the set point for this alarm; this
is indicated by “S/P” shown on the lower row of the display. Select the desired
alarm level by using the S and T buttons. Once the desired set point has been
set, press the button to accept it.
7.4.2 Alarm 2
Repeat the procedure listed in section 7.4.1 to set up the parameters for alarm 2. If
a selection was made to turn the alarm OFF, the next selection for the speed of
response RESP is shown.
Due to the cyclic nature of the CL500, relay chatter is not an issue. There is no
need for alarm delays or hysteresis.
7.5 Enabling the Security Access
The instrument is equipped with a security access. If this option is turned on, the user is
required to input the access code into the instrument to get to any mode other than AUTO.
The only code is 333. This code may not be changed. See section 5.2 for more
information on this security feature. The security key icon will be visible and flashing on
the display whenever the access option is selected using the S or T buttons. (On or
OFF).
7.6 Extended Settings
The last few settings are grouped together to prevent them from being adjusted by
accident. To gain access to the extended settings, select On using the S or T buttons and
press the button.
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7.7 Speed of Response
The speed of response for both displayed and output values of mg/L can be adjusted in
this menu. Although the default setting is 1, thirty-one (0-30) response speeds are
available. The higher the number selected, the slower the response will be. A high
number could be used to ignore minor process variations in a slow changing process. A
low number is used where a rapid response is desirable
Select the desired speed of response using the S and T buttons. Press the button to
accept it.
To avoid reading air and other anomalies, select the slowest speed (30). Select the fastest
response (0) where monitoring of rapid changes is needed.
7.8 LCD Backlight Brightness
The LCD backlight brightness may need to be adjusted. This is of particular interest if
multiple instruments are located in the same area and it is desired for the entire group to
have the same appearance. Ten levels are available. The default brightness is 8.
Change the brightness by pressing the S or T button. When the desired brightness has
been selected, press the button.
CL500 (2/08) Page 19
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7.9 RS-485 Parameters
These menus will only appear if the RS-485 is enabled (see 7.3). The default is 8 Bit, no
(nOnE) Parity, 1 Stop Bit. Make selections using the S and T buttons then press the
button to move to the next menu.
7.10 Cycle Time
The cycle time can be changed using this menu. Please note that changing this menu
will directly affect the volume of reagent that will be consumed. The default is set to
150 seconds (2 ½ minutes). Using this setting the reagents will last 30 days. Make
selections using the S and T buttons then press the ↵ button to move to exit to AUTO
mode. Allowable setting is from 110 to 600 seconds (10 minutes).
Reagents have a 30 day life after being mixed.
7.11 Saving Configuration Settings
If extended settings are set to OFF, pressing the button will save all settings and the
CL500 will automatically return to the normal AUTO mode of the instrument.
If extended settings are set to On, after the last menu of the extended settings, pressing the
button will save all settings and the CL500 will automatically return to the normal
AUTO mode of the instrument.
The CONFIG menu may be used at any time to reset or change any of the parameters.
The CONFIG menu may be exited at any point in the menu by using the MODE/EXIT
key. Any features that have been modified will be saved.
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8.0 Additional Features and Options
8.1 Backlit LCD
The backlit LCD allows for easier readability of the LCD display in low light or no light
conditions. The backlight is intended for continuous operation. The brightness is
adjustable from a menu in the CONFIG mode.
8.2 RS-485 Outputs
The CL500 has the capability to operate in three different RS-485 modes. Included is a
mode for interfacing into the online software package (section 8.2.1 below), a simple
communication mode and Modbus communications. All modes will automatically
configure and do not require any changes or selections
8.2.1 Online SCADA(Catalog # 19783GW)
The CL500 can operate as a small SCADA system with an optional PC software
package. This system allows for an interface with a combination of TB500’s or
CL500’s, totaling up to 255 units, for the purpose of data logging. This system will
interface directly with common database and spreadsheet software.
8.2.2 Simple Communication
The CL500 can provide basic communications over simple programs such as the
Hilgraeve HyperTerminal that is included with most Microsoft Windows
packages. The user could also use Visual Basic or other programs. The default
communication parameters are 8 bits, no parity and 1 stop bit. These can be
changed in the Extended CONFIG menus 7.9 RS-485 Parameters.
The master computer will send out:
• Byte #1 the attention character “:” in ASCII or 3A Hex
• Byte #2 the address of the CL500 being queried
• Byte #3 & 4 CR LF or 0D 0A in hex
The CL500 will respond with:
• The same attention character “:” in ASCII or 3A Hex
• The address of the CL500
• The Reading
• The Unit (mg/L)
A sample communication would look like this:
(Master computer requesting a report from address #1) :1 CRLF
(CL500 set to address #1 Response) :001 0.0249mg/L
CL500 (2/08) Page 21
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8.2.3 Modbus Communication
Modbus protocol communication manual is available Cat. #24569GW. This
manual is available free online at www.globalw.com.
8.3 Remote Panel Meter (Catalog # 19609GW)
The remote panel meter allows for remote indication of the mg/L reading using the 4-20
mA loop of the CL500. No external power is required, as the meter is run off of the 4-20
mA source of the CL500.
8.4 Desiccant Cartridge Option (Catalog #09944GW)
An optional desiccant cartridge kit can be purchased for use in applications where
condensation on the glass cuvette may compromise accuracy. The desiccant changes color
from blue to pink when expended. Instructions for replacement are included with the kit.
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9.0 Troubleshooting
9.1 CL500 Fault Detection
The CL500 performs continuous diagnostic monitoring. In the CL500, there are 4 severity
levels of fault detection. Level 4, 3 & 2 will allow normal operation, but warn of the
problem. Level 1 is an instrument failure and the instrument will not operate. Any faults
are displayed in a queue form in the bottom row of the LCD.
A level 4 fault is simply a screen indication that one of the alarm levels has been
activated. This fault level will not affect the 4-20 mA and will only affect the alarm
activated. The sample back light blinks at a rate of once every 4 seconds.
A level 3 fault indicates a failure or a problem that usually can be corrected by the
operator. Refer to the chart below. If any of these errors occur, the instrument will still
display readings and probably will operate correctly. These faults will self-clear when the
problem is corrected. If any of these faults occur, they will affect the 4-20mA and any
alarm set for fault detection (Error). The sample back light blinks at a rate of once every
2.5 seconds.
Message Description of Fault Corrective Action
MA 4-20 mA enabled & loop open Check 4-20 mA wiring or turn off 4-
CAL Calibration invalid –not accepted Recalibrate if needed
WATR No water flowing Check water flow
FAST Intake water flow too fast Set flow rate (see section 9.2)
SLOW Sample cuvette filling too slowly Set flow rate (see section 9.2)
PURG Sample cuvette has slow purge Check drain lines
NPRG Sample cuvette not purging Check drain lines
ISOL Problem with intake solenoid Check wiring, check for clogged solenoid
PSOL Problem with purge solenoid Check wiring, check for clogged solenoid
RGNT Problem with reagent Check reagent and lines
GLAS Dirty cuvette Replace or clean cuvette
WCAL Water Level Calibration Invalid Clear fault (see section 9.3)
REPL Reagents Expired Replace reagents and press PRIME
Level 3 (Self-Clearing) fault conditions
20mA if not used
A level 2 fault indicates a severe problem that will usually require technical assistance
from Global Water’s customer service (see section 9.5). The queued display will show
POST. If this fault occurs it will affect the 4-20mA and any alarm set for fault detection
(Error). The sample back light blinks at rate of once every 1 second.
CL500 (2/08) Page 23
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A level 1 fault is a system fault. This is NOT a problem that the operator can correct, and
the unit must be returned to the factory for service (see section 9.5). These failures consist
of failures in the CPU, A/D, EEPROM or other devices internal to the instrument. The
queued display will show FAIL, the upper display is a five digit code. If this fault occurs,
it will affect the 4-20mA and any alarm set for fault detection (Error). The instrument will
not operate with this fault. The sample back light blinks at rate of once every 0.4 seconds.
If any fault condition occurs, the message indicating the fault will be shown on the lower
row of the display.
9.2 Setting Flow Rate
The flow rate on the CL500 was factory adjusted and should not need adjustment.
Installation variances may affect the flow. The optimal flow rate through the CL500 may
be adjusted if needed. The flow is adjusted by removing regulator vinyl cap and turning
the adjustment screw on the pressure regulator. Refer to figure 4. To assist in this
adjustment follow the procedure shown below:
1. Press the SERVICE button.
2. Wait for the display to read HOLd, then press Mode/ Exit.
3. Display will show FLOW with the number 0. Press either the S or T button.
4. CL500 will drain, and then pulse in water while a count is displayed on the screen.
5. The display will show one of three messages HI, LO or Good.
The flow test determines if the flow rate is suitable for proper operation. Loosen the
locking nut then adjust the pressure regulator using a coin or a large flat blade
screwdriver. Press either the S or T button while in the FLOW routine to display a new
flow rate. Please note that only ¼ turn incremental adjustments should be made to the
regulator on each attempt.
If the message is LO, turn the regulator control clockwise. If the message is HI, turn the
regulator counterclockwise. If the message is Good, no adjustment is required. Tighten the
locking nut after adjustment and replace the regulator vinyl cap. To return to normal
operation, press the ↵ button.
9.3 Clearing Faults
Every time SERVICE mode is exited, all faults are cleared. If the original fault or a new
fault occurs, it will be posted.
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9.4 Diagnostic Chart
Symptom Cause Cure
Lower display shows MA 4-20 mA loop open Check wiring. See sections
4.3.4 and 7.2
Lower display shows FAIL Major system fault Refer to section 9.1
Readings are erratic (1) Bubbles in solution
(2) Debris in flow
(1) See above
(2) Install T strainer at inlet
Readings are lower than expected (1) Condensate or leaky
measurement cuvette
(2) Measurement cuvette
dirty
(3) Reagents bad or expired
(4) Buffer reagent not being
dispensed
Upper display flashes Sample Over-Range Check sample. Sample may be
Upper display shows nOnE while
attempting to calibrate
9.5 Technical and Customer Assistance
If for any reason assistance is needed regarding this instrument please do not hesitate to
contact Global Water’s Customer Service Department:
No current reading displayed Wait for CL500 to post a
Global Water Instrumentation
11390 Amalgam Way
Gold River CA 95670
Phone: (800) 876-1172
Fax: (847) 672-9988
Email:
www.globalw.com
globalw@globalw.com
(1) Install desiccant cartridge
kit
(2) Replace or clean cuvette
(3) Replace reagents
(4) Check buffer lines and
check valves.
too high to read.
reading
CL500 (2/08) Page 25
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10.0 Routine Maintenance
10.1 Maintenance Schedule
The recommended schedule is shown below. It is important to replace the reagents on a
monthly basis to get reliable accurate readings from the CL500.
The CL500 is shipped with one CL500 Tubing/Cuvette kit, Cat. #09950GW. The kit
consists of the following:
Qty Part
2 “A” Cap Assemblies
8 “B” Pump Tubes
1 Cuvette
Cap Assembly "A"
Figure 6: Reagent Tubing Set
The drawing above shows one complete reagent tubing set (check valves not included in
kit). Two complete sets are used in the CL500; one for the buffer and one for the indicator.
The supplied kit is intended to last for one year. Additional kits can be ordered from your
local Global Water Instrumentation distributor or representative. It is recommended to
keep one kit on hand at all times.
Generally, all “B” tubes should be replaced on a three month basis. If the CL500 is
operated in an ambient temperature above 27 ° C (81° F), the “B” tubes should be changed
every two months. The “A” Cap Assemblies and the cuvette should be replaced annually.
Every Month
1. The reagent required for operating this instrument must be changed on a monthly
basis (with a 2.5 minute cycle time).
2. The external strainer should be checked and cleaned if necessary
3. The glass cuvette should be inspected. Check for excessive debris on the inside
surface of the glass. It is suggested to keep a spare cuvette to replace when required.
The old cuvette may be cleaned, if possible, for future replacement.
Flushing the System
It is recommended that the tubings replacements be timed with reagent replacement. Press
the SERVICE button to stop the water flow. Remove old reagents and discard. Place the
inlet tubings in a small container of clean water. Press SERVICE to return to operation
mode, press PRIME and then to flush the system with water. Remove the inlet tubings
from the water Press PRIME and then to remove most of the water.
CL500 (2/08) Page 26
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Check Valve
Flow
Tube"B"
After a PRIME the CL500 will perform a water calibration (WCAL). It will
take a few minutes to complete this procedure.
3 Month Tubing Replacement
The “B” tubings need replacement more often due to the fact that they are subject to wear
from the reagent “Pump”. The check valves should not need to be replaced and should be
saved. Please note that the check valves are directional and that the “IN” side is smaller in
diameter (see drawing).
Steps:
1 Flush the system as described above to reduce personal contact with the reagents.
2 Press SERVICE to stop the flow of sample water and drain the cuvette.
3 Remove and retain the thumb screw on top of the pump; pull the pump hammer and
spring up and out of the way. There is no need to completely remove the hammer and
spring.
4 Working on one reagent side at a time. Replace the “B” (black) tubing between optics
inlet and the check valve OUTLET. Discard the old “B” tubing.
5 Ensure the check valve is placed into its seat.
6 Repeat steps 4 & 5 for the other reagent.
7 Replace the hammer and spring back into place and secure with the thumb screw.
8 Check the drawing on the following page to ensure correct installation.
9 Return to operation as described.
Annual Tubing Replacement
Once a year, complete the 3 Month Tubing Replacement as above, and then follow the
steps below:
1. Replace the two “A” Cap Assemblies.
2. Turn the knurled top on the optics system counterclockwise (as viewed for the top)
until the cuvette just “pops” out, but do not remove the top.
3. When the cuvette “pops” out, move the retaining o-ring & remove the cuvette. You
may need a stiff wire such as a bent paper clip to grasp the cuvette. Retain this cuvette
for future use if it can be cleaned.
4. Install the new cuvette by pushing it firmly in place and turning the knurled top
clockwise until the cuvette is held securely.
5. Check the drawing on the following page to ensure correct installation.
6. Return to operation as described.
Return to Normal Operation
Press the SERVICE button to return sample flow to the system. Check for leaks. If a leak
occurs press SERVICE again, repair leak and try again. Once the system is operating
correctly, return or replace reagents and press PRIME and then one time to restart
reagent flow. The system will automatically return to normal operation.
Tubes may darken due to contact with the reagent. This condition does not
affect the performance of these parts.
CL500 (2/08) Page 27
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CAP ASSEMBLY "A"
THUMB
SCREW
PUMP
HAMMER
AND SPRING
REAGENT
PUMP
ASSY
INLET
CHECK
VALVES
INLET
CHECK VALVE DETAIL
Figure 7: Reagent Tubing Installation
10.2 Replacing or Installing the Reagents
FLOW
KNURLED TOP
OPTICS SYSTEM
CAP ASSEMBLY "A"
CUVETTE
RETAINING
O-RING
`
OUTLET
Reagent kits are available from Global Water Instrumentation for Free Chlorine and for
Total Chlorine Refer to section 11.0 Replacement Parts and Accessories for the
appropriate Catalog numbers. There are two reagents required, and supplied in each kit;
the buffer
and the indicator.
The buffer and indicator reagents are provided as dry reagents and require the addition of
deionized water. You will need to have at least 1 liter of deionized water on hand prior to
preparing the solutions. Allow about ½ hour time to prepare the reagents.
Use caution while preparing. These reagents are caustic and can burn skin
and stain clothing. The use of protective gloves, clothing and eye protection is
highly recommended.
Buffer Reagent Preparation
Add about 400 ml of deionized water into the buffer bottle. Cap tightly and shake
vigorously until the powder is fully dissolved. When fully dissolved add enough deionized
water to bring the volume in the bottle up to the fill line.
CL500 (2/08) Page 28
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Indicator Reagent Preparation
Add about 400 ml of deionized water into the indicator bottle. Cap tightly and shake
vigorously until the powder is dissolved. Remove the cap and add the contents of the DPD
powder bottle (small brown bottle). Cap and shake to fully dissolve the powder. When
fully dissolved add enough deionized water to bring the volume in the bottle up to the fill
line.
Once mixed the reagents have a expected life of 30 days. Write the mixing
date on the reagent bottle labels in the area provided. Dispose of expired
reagents correctly.
To replace the reagents, press the SERVICE button; this will empty the cuvette and stop
any flow of water. Remove the cap on both bottles replace with the blue cap supplied with
the CL500. Be sure to replace the reagents in the correct location as labeled on the inside
of the CL500. The buffer is installed on the left and the indicator is installed on the right
side. The suction tube for both reagents will reach the bottom of the bottles.
To complete the replacement procedure, press the PRIME button. This will draw enough
of each reagent to completely prime the tubes and replace any old solution. The system
will automatically return to normal operation after it has primed.
Use caution when changing the reagents as they are caustic. These reagents
will stain clothing and anything they contact. After changing the reagents,
operators should wash their hands.
10.3 Cuvette Change
As recommended in section 10.1 Maintenance Schedule the cuvette should be inspected at
monthly intervals and replaced when needed.
To replace the cuvette, press the SERVICE key. When HOLD shows on the
screen, the system is ready.
The cuvette is spring loaded to allow for removal. Leave the cuvette retainer
(O-ring) in place while loosening top.
Loosen the knurled top until the cuvette pops out. Pull the cuvette retainer down to allow
for cuvette removal. Remove and replace or clean cuvette. Reverse the procedure to
replace. To avoid damage do not over tighten the knurled top. Press the SERVICE key to
return the system to normal sample flow and check for leaks.
10.4 Instrument Storage
If the CL500 is relocated or will be inactive for more than 48 hours, remove the reagents.
Flush the reagent system as describe in 10.1 Maintenance Schedule. Place the instrument
in Service mode to drain the system then remove power by disconnecting the mains power
plug. It is usually a good idea to disconnect or shut off the source water.
CL500 (2/08) Page 29
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10.5 Cleaning the CL500
Flush the system as mentioned in section 10.1 Maintenance Schedule. When the flushing
is finished, press the SEVICE button wait until the display reads HOLd.
As a mater of safety, always disconnect any power source to the CL500 prior to
attempting any cleaning. It is recommended that the source water is also shut off.
Isopropyl alcohol (rubbing alcohol) on a soft cotton cloth works very well in removing
reagent stains from plastic parts, the key pad and the display. Use care when cleaning
around electrical components. Do not use any harsh cleaning agents as these may cause
damage to the instrument components.
Ensure that the system is dry prior to applying power.
CL500 (2/08) Page 30
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11.0 Accessories and Replacement Parts List
The items shown below are recommended accessories and replacement parts.
Accessory Catalog Number
J.A.W. Reagent Kit – Free Chlorine 30 day supply 09951GW
J.A.W. Reagent Kit – Total Chlorine 30 day supply 09952GW
J.A.W. Reagent Kit – Free Chlorine 60 day supply 09953GW
J.A.W. Reagent Kit – Total Chlorine 60 day supply 09954GW
J.A.W. Reagent Kit – Free Chlorine 12 month supply 09955GW
J.A.W. Reagent Kit – Total Chlorine 12 month supply 09956GW
Operating Manual CL500 24420GW
Tubing/Cuvette Kit 09950GW
Replacement Cuvette 25018GW
Check Valve Set 25017GW
Ferrite for 4-20mA or RS-485 24560GW
To order any accessory or replacement part, please contact the Global Water’s Customer
Service Department. If for any reason technical assistance is needed regarding this
instrument, please do not hesitate to contact the Global Water’s Service Department.
Global Water Instrumentation
11390 Amalgam Way
Gold River CA 95670
Phone: (800) 876-1172
Fax: (847) 672-9988
Email: globalw@globalw.com
www.globalw.com
CL500 (2/08) Page 31
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12.0 Warranty
Global Water Instrumentation., as vendor, warrants to the original purchaser of this
instrument that it will be free of defects in material and workmanship, in normal use and
service, for a period of one year from date of delivery to the original purchaser. Global
Water Instrumentation’s, obligation under this warranty is limited to replacing, at its
factory, the instrument or any part thereof. Parts, which by their nature are normally
required to be replaced periodically, consistent with normal maintenance, specifically
reagent, desiccant, sensors, electrodes, tubing and fuses are excluded. Also excluded are
accessories and supply type items.
Original purchaser is responsible for return of the instruments, or parts thereof, to Global
Water Instrumentation’s factory. This includes all freight charges incurred in shipping to
and from Global Water Instrumentation’s factory.
Global Water Instrumentation is not responsible for damage to the instrument, or parts
thereof, resulting from misuse, environmental corrosion, negligence or accident, or defects
resulting from repairs, alterations or installation made by any person or company not
authorized by Global Water Instrumentation
Global Water Instrumentation assumes no liability for consequential damage of any kind,
and the original purchaser, by placement of any order for the instrument, or parts thereof,
shall be deemed liable for any and all damages incurred by the use or misuse of the
instruments, or parts thereof, by the purchaser, its employees, or others, following receipt
thereof.
Carefully inspect this product for shipping damage, if damaged, immediately notify the
shipping company and arrange an on-site inspection. Global Water Instrumentation
cannot be responsible for damage in shipment and cannot assist with claims without an
on-site inspection of the damage.
This warranty is given expressly and in lieu of all other warranties, expressed or implied.
Purchaser agrees that there is no warranty on merchantability and that there are no other
warranties, expressed or implied. No agent is authorized to assume for Global Water
Instrumentation any liability except as set forth above.
Global Water Instrumentation
11390 Amalgam Way
Gold River CA 95670
Phone: (800) 876-1172
Fax: (847) 672-9988
Email:
www.globalw.com
globalw@globalw.com
CL500 (2/08) Page 32
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