Xylem CL500 User Manual
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
REV 2.0
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
REV 2.0
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
REV 2.0
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
REV 2.0
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
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