Instruction Manual PN 51-TCL-1056/rev.D May 2011 Model TCL Total Chlorine Analyzer 1.00ppm 25.
ESSENTIAL INSTRUCTIONS WARNING READ THIS PAGE BEFORE PROCEEDING! ELECTRICAL SHOCK HAZARD Rosemount Analytical designs, manufactures, and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you must properly install, use, and maintain them to ensure they continue to operate within their normal specifications.
DANGER CAUTION HAZARDOUS AREA INSTALLATION SENSOR/PROCESS APPLICATION COMPATIBILITY 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. Wetted materials may not be compatible with process composition and operating conditions. Application compatibility is entirely the responsibility of the user.
MODEL TCL TABLE OF CONTENTS MODEL TCL TOTAL CHLORINE ANALYZER TABLE OF CONTENTS Section 1.0 1.1 1.2 1.3 1.4 1.5 1.6 Title DESCRIPTION AND SPECIFICATIONS................................................................. Features and Applications ...................................................................................... Specifications — Sample Conditioning System ...................................................... Specifications — Model 1056 Analyzer ..........................................
MODEL TCL TABLE OF CONTENTS TABLE OF CONTENTS CONT'D. 8.0 DIGITAL COMMUNICATIONS ................................................................................ 41 9.0 9.1 9.2 9.3 9.4 CALIBRATION ....................................................................................................... Introduction .............................................................................................................. Calibrating Temperature .........................................................
MODEL TCL TABLE OF CONTENTS LIST OF FIGURES Number 2-1 3-1 3-2 3-3 3-4 3-5 4-1 4-2 4-3 4-4 4-5 6-1 6-2 6-3 6-4 6-5 7-1 7-2 7-3 9-1 9-2 10-1 10-2 10-3 10-4 10-5 10-6 10-7 10-8 10-9 10-10 10-11 10-12 10-13 10-14 10-15 10-16 10-17 Title Schematic of Sample Conditioning System and Analyzer .................................... Panel Mount Dimensions ....................................................................................... Pipe and Wall Mounting Dimensions ........................................
MODEL TCL SECTION 1 DESCRIPTION AND SPECIFICATIONS SECTION 1. DESCRIPTION AND SPECIFICATIONS Model TCL Sample Conditioning System • • • • NO METAL WETTED PARTS. Ideal for seawater. LOW SAMPLE FLOW (about 15 mL/minute) means little waste. REAGENT-BASED SYSTEM measures true total chlorine. FIVE GALLONS OF REAGENT lasts two months. Model 1056 Chlorine Analyzer • • • • LARGE, PROGRAMMABLE, BACK-LIT DISPLAY with easy to use interface. TWO INDEPENDENT ANALOG OUTPUTS. FOUR FULLY PROGRAMMABLE RELAYS optional.
MODEL TCL used to signal a fault condition. A fault alarm activates when an analyzer or sensor fault occurs. When used for the determination of total chlorine, the Model 1056 analyzer is a single input instrument. The analyzer is also available in a dual input version, where the second input can be pH, conductivity, dissolved oxygen, chlorine, or turbidity. For more information about the dual input option, refer to product data sheet PDS 71-1056.
MODEL TCL SECTION 1 DESCRIPTION AND SPECIFICATIONS 1.2 SPECIFICATIONS — SAMPLE CONDITIONING SYSTEM GENERAL SAMPLE REQUIREMENTS Enclosure: Fiberglass reinforced polyester, NEMA 3 (IP53) suitable for marine environments Dimensions: 14.5 x 13.0 x 8.6 in. (369 x 329 x 218 mm) Mounting: Wall Ambient Temperature: 32° - 122°F (0 - 50°C) Ambient Humidity: 0 - 90% (non-condensing) Power: 115 Vac, 6.9 W, 50/60 Hz; 230 Vac, 7.
MODEL TCL SECTION 1 DESCRIPTION AND SPECIFICATIONS 1.4 SPECIFICATIONS — MODEL 499ACL-02 SENSOR Wetted Parts: Gold, Noryl®1 (PPO), Viton®2, EPDM, Silicone Dimensions: 1.0 x 5.6 in. (25.4 x 143 mm) Cable: 25 ft. (7.6m) standard Pressure Rating: 0 to 65 psig (101 to 549 kPa) Temperature Rating: 32 to 122°F (0 to 50°C) Electrolyte Capacity: Approximately 25 mL Electrolyte Life: Approximately 4 months Weight/Shipping Weight: 1 lb/3 lb (0.5 kg/1.5 kg) 1 Noryl is a registered trademark of General Electric.
MODEL TCL SECTION 1 DESCRIPTION AND SPECIFICATIONS 1.6 ORDERING INFORMATION AND ACCESSORIES Model TCL Reagent-Based Chlorine System. The TCL is used for the continuous determination of total chlorine in water. The TCL consists of a sample conditioning system, a reagent carboy, a sensor, and an analyzer. Reagents must be ordered separately. Regent kits for 0-5 ppm and 0-10 ppm chlorine are available. For higher ranges, consult the factory. See ACCESSORIES - Sample Conditioning System.
ACCESSORIES — 1055-24 Analyzer PN 9240048-00 23820-00 DESCRIPTION WEIGHT* SHIP WEIGHT* Tag, stainless steel, specify marking 1 lb (0.5 kg) 1 lb (0.5 kg) Pipe mounting kit 2 lb (1.0 kg) 3 lb (1.5 kg) WEIGHT* SHIP WEIGHT* ACCESSORIES — 54eA Analyzer PN DESCRIPTION 2002577 Wall and two inch pipe mounting kit 2 lb (1.0 kg) 3 lb (1.5 kg) 23545-00 Panel mounting kit 23554-00 Cable glands, kit (Qty 5 of PG 13.5) 2 lb (1.0 kg) 1 lb (0.5 kg) 3 lb (1.5 kg) 1 lb (0.
MODEL TCL SECTION 2 PRINCIPLES OF OPERATION SECTION 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 analyzer consists of a sample conditioning system, which injects the reagent into the sample, and a sensor and analyzer, which measure the amount of iodine produced. Figure 2-1 shows the sample conditioning system.
MODEL TCL SECTION 3 INSTALLATION SECTION 3. INSTALLATION 3.1 UNPACKING AND INSPECTION Inspect the shipping containers. If there is damage, contact the shipper immediately for instructions. Save the boxes. If there is no apparent damage, unpack the containers. Be sure all items shown on the packing list are present. If items are missing, notify Rosemount Analytical immediately. 3.2 INSTALLATION. 3.2.1 General Information 1.
MODEL TCL SECTION 3 INSTALLATION INCH MILLIMETER 17.13 1.1 126.4 5.0 154.9 6.1 154.9 6.1 Front View Side View ( 126.4 5.0 ) 76.2 3.0 41.4 1.6 Bottom View 152.73 6.
INCH MILLIMETER 154.9 6.1 Wall / Surface Mount 102 4.0 232 9.1 33.5 1.3 130 5.1 187 7.4 154.9 6.1 165 6.5 Side View Front View Pipe Mount 232 9.1 Bottom View 33.5 1.3 130 5.1 80.01 3.2 45.21 1.8 165 6.5 108.9 4.3 Side View 71.37 2.
MODEL TCL SECTION 3 INSTALLATION 3.2.3 Install the Sample Conditioning Enclosure 1. Refer to Figures 3-3, 3-4, and 3-5 for installation details. 2. Connect the sample line to the sample conditioning system. Use ¼-inch OD hard plastic or stainless steel tubing. If dechlorinated water is being measured, provide a way for occasionally substituting a chlorinated water sample for the dechlorinated sample. Chlorinated water is needed to calibrate the sensor and to check its response. 3.
MODEL TCL SECTION 3 INSTALLATION INCH MILLIMETER FIGURE 3-4. TCL Case Dimensions FIGURE 3-5.
MODEL TCL SECTION 4 WIRING SECTION 4. WIRING 4.1 PREPARE ANALYZER CONDUIT OPENINGS The analyzer enclosure has six conduit openings. Four conduit openings are fitted with conduit plugs. Conduit openings accept 1/2-inch 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.
MODEL TCL SECTION 4 WIRING 4.3 MAKE POWER, ALARM, OUTPUT, AND SENSOR CONNECTIONS IN THE ANALYZER 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 code. 4.3.1 Power Wire AC mains power to the power supply board, which is mounted vertically on the left hand side of the analyzer enclosure. The power connector is at the top of the board.
MODEL TCL 4.3.3 SECTION 4 WIRING Alarm wiring. WARNING Exposure to some chemicals may degrade the sealing properties used in the following devices: Zettler Relays (K1-K4) PN AZ8-1CH12DSEA The alarm relay terminal strip is located just below the power connector on the power supply board. See Figure 4-3. Keep alarm relay wiring separate from signal wiring. Do not run signal and power or relay wiring in the same conduit or close together in a cable tray. FIGURE 4-3. Alarm relay connections. 4.
MODEL TCL SECTION 4 WIRING FIGURE 4.4. Wiring Sensor with Optimum EMI/RFI or Variopol Cable to Model 1056 Analyzer FIGURE 4.5 Wiring Sensor with Standard Cable to Model 1056 Analyzer 4.5 APPLY POWER TO THE ANALYZER AND COMPLETE QUICK START 1. Once all wiring connections are secured and verified, apply power to the analyzer. 2. When the analyzer is powered up for the first time, Quick Start screens appear. Using Quick Start is easy. a. A backlit field shows the position of the cursor. b.
MODEL TCL Temp Units SECTION 4 WIRING 6. Choose the desired temperature units. o C F o 7. The main display appears. The outputs and alarms (if an alarm board is present) are assigned to default values. 8. To change outputs, alarms, and other settings go to the main menu and choose Program. Follow the prompts. A menu tree is on the following page. To calibrate the sensor refer to section 9.
MENU TREE Calibrate Sensor 1 (Total chlorine) Chlorine Zero In process Temperature Output 1 Output 2 Hold Sensor 1 Sensor 2 Display Main format configuration Language selection Warning (enable or disable) Screen contrast Program Outputs Range (assign values to 4 and 20 mA) Configure Output 1 or 2 Assign sensor and measurement Range Scale Dampening Fault mode (fixed or live) Fault value (output current) Simulate Alarms Configure/Setpoint Alarm 1, 2, 3, or 4 Setpoint Assign sensor and measurement High or low
MODEL TCL SECTION 5 START-UP SECTION 5. START-UP NOTE Complete Section 4 before starting this section. 5.1 PREPARE THE REAGENT WARNING The reagent contains potassium iodide dissolved in distilled vinegar or 5% acetic acid. Avoid contact with skin and eyes. Wash thoroughly after using. 1. DO NOT PREPARE THE SOLUTION UNTIL READY TO USE. 2. Position the blue plastic carboy under the sample conditioning cabinet. Unscrew the cap and reagent tube assembly. 3. Add the potassium iodide reagent to the carboy.
MODEL TCL SECTION 6 START-UP SECTION 6. DISPLAY AND OPERATION 6.1. DISPLAY The analyzer has a six line display. See Figure 6-1. The display can be customized to meet user requirements. Refer to section 6.6. FIGURE 6-1. Main Display When the analyzer is being programmed or calibrated, the display changes to a screen similar to the one shown in Figure 6-2. The live readings appear in small font at the top of the screen. The rest of the display shows programming and calibration information.
MODEL TCL SECTION 6 START-UP 6.2 KEYPAD Local communication with the analyzer is through the membrane keypad. Figures 6-4 and 6-5 explain the operation of the keys. FIGURE 6-4. Analyzer keypad. Four navigation keys move the cursor around the screen. The position of the cursor is shown in reverse video. The navigation keys are also used to increase or decrease the value of a numeral. Pressing ENTER selects an item and stores numbers and settings.
MODEL TCL SECTION 6 START-UP 6.3 PROGRAMMING THE ANALYZER—TUTORIAL Setting up and calibrating the analyzer is easy. The following tutorial describes how to move around in the programming menus. For practice, the tutorial also describes how to assign ppm chlorine values to the 4 and 20 mA analog outputs. Menu Calibrate Hold Program Display 1. Press MENU. The main menu screen appears. There are four items in the main menu. Calibrate is in reverse video, meaning that the cursor is on Calibrate. 2.
MODEL TCL Output Range O1 S1 4mA: 0.000 ppm O1 S1 20mA: 08.50 ppm O2 S1 4mA: 0.0C O2 S1 20mA: 100.0C SECTION 6 START-UP 7. The display returns to the summary screen at left. Note that the 20 mA setting for output1 has changed to 8.5 ppm. 8. To return to the main menu, press MENU. To return to the main display, press MENU then EXIT. 6.4 SECURITY 6.4.1 How the Security Code Works Security codes prevent accidental or unwanted changes to program settings or calibrations. There are three levels of security.
MODEL TCL SECTION 6 START-UP 6.5 USING HOLD 6.5.1 Purpose To prevent unwanted alarms and improper operation of control systems or dosing pumps, place the alarms and outputs assigned to the sensor in hold before removing it for maintenance. During hold, outputs assigned to the sensor remain at the last value, and alarms assigned to the sensor remain in their present state. Once in hold, the sensor remains in hold until hold is turned off.
MODEL TCL SECTION 6 START-UP 6.6 CONFIGURING THE MAIN DISPLAY The main display can be configured to meet user requirements. 1. Press MENU. The main menu screen appears. Move the cursor to Display and press ENTER. Display Main Format Language: English Warning: Enable Contrast 2. The screen shows the present configuration. There are four items: Main Format, Language, Warning, and Contrast. To make a change, move the cursor to the desired line and press ENTER.
MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER SECTION 7. PROGRAMMING THE ANALYZER 7.1 GENERAL This section describes how to make the following program settings using the local keypad. a. Configure and assign values to the analog current outputs. b. Configure and assign values to the alarm relays (if the alarm board is installed). c. Choose the type of chlorine measurement being made. This step is necessary because the analyzer used with the TCL can measure forms of chlorine other than total chlorine. d.
MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER TABLE 7-1. DEFAULT SETTINGS ITEM CHOICES DEFAULT a. output 1 chlorine, temp chlorine b. output 2 chlorine, temp temp 0-20 or 4-20 mA 4 – 20 mA a. chlorine -9999 to +9999 0 b. temperature -999.9 to +999.9 0 a. chlorine -9999 to +9999 10 b. temperature -999.9 to +999.9 0 5. Fault current (fixed) 0.00 to 22.00 mA 22.00 mA 0 to 999 sec 0 sec 0.00 to 22.00 mA 12.00 mA high or low AL1 low, AL2,3,4 high a.
MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER TABLE 7-1. DEFAULT SETTINGS (continued) ITEM CHOICES DEFAULT ºC or ºF ºC automatic or manual automatic 1. Calibrate/Hold 000 to 999 000 2. Program/Display 000 to 999 000 1. 4 mA 0.000 to 22.000 mA 4.000 mA 2. 20 mA 0.000 to 22.000 mA 20.000 mA Temperature related settings 1. Units 2.
MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7.3 CONFIGURING, RANGING, AND SIMULATING OUTPUTS. 7.3.1 Purpose This section describes how to configure, range, and simulate the two analog current outputs. CONFIGURE THE OUTPUTS FIRST. 1. Configuring an output means… a. Assigning a sensor and measurement (chlorine or temperature) to an output. b. Selecting a 4-20 mA or 0-20 mA output. c. Choosing a linear or logarithmic output. d. Turning output current dampening on or off. e.
MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7.3.3. Procedure – Configure Outputs. 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. Program Outputs Alarms Measurement Temperature Outputs 2. The cursor will be on Outputs. Press ENTER. 3. Choose Configure. Range Configure Simulate Output 1 Configure Program Output 1 Output 2 Output 1 Configure S1 Meas Assign: Range: 4-20 mA Scale: Linear Dampening 0 sec 4. Choose Output 1 or Output 2. 5.
MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7.3.3. Procedure – Ranging Outputs. 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. Program Outputs Alarms Measurement Temperature Outputs 2. The cursor will be on Outputs. Press ENTER. 3. Choose Range. Range Configure Simulate Output Configure Program Output 1 Output 2 Output Range O1 S1 4mA 0.000 ppm O1 S1 20mA: 10.00 ppm O2 S1 4mA: 0.0C O2 S1 20mA: 100.0C 4. Choose Output 1 or Output 2. 5.
MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7.3.4 Procedure – Simulating Outputs 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. Program Outputs Alarms Measurement Temperature 2. The cursor will be on Outputs. Press ENTER. Outputs Range Simulate Configure Simulate 3. Choose Simulate. Simulate Program Output 1 Output 2 4. Choose Output 1 or Output 2. Output 1 Hold at 1 2.00 mA 5. Enter the desired simulated output current.
MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7.4.2 Definitions 1. ASSIGNING ALARMS. There are four alarms relays. The relays are freely assignable to any sensor and to either the measurement (chlorine) or temperature. Alarm relays can also be assigned to operate as interval timers or as fault alarms. A fault alarm activates when the analyzer detects a fault in either itself or the sensor. 2. FAULT ALARM.
MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7.4.3 Procedure – Configuring Alarms and Assigning Setpoints 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. Program Outputs Alarms Measurement Temperature 2. Choose Alarms. Alarms Configure/Setpoint Simulate Synch Timers: Yes 3. Choose Configure/Setpoint. Configure/Setpoint Alarm 1 Alarm 2 Alarm 3 Alarm 4 4. Choose Alarm 1, Alarm 2, Alarm 3, or Alarm 4. Alarm 1 Settings Setpoint: 0.
MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7.4.4 Procedure – Simulating Alarms 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. Program Outputs Alarms Measurement Temperature 2. Choose Alarms. Alarms Configure/Setpoint Simulate Synch Timers: Yes 3. Choose Simulate. Simulate Alarm 1 Alarm 2 Alarm 3 Alarm 4 4. Choose Alarm 1, Alarm 2, Alarm 3, or Alarm 4. Simulate Alarm 1 Don’t Simulate De-energize Energize 5. Choose Don’t simulate, De-energize, or Energize.
MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7.4.5 Procedure – Synchronizing Timers 1. Synch Timers is available only if two or more alarm relays have been configured as interval timers. 2. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. Program Outputs Alarms Measurement Temperature 3. Choose Alarms. Alarms Configure/Setpoint Simulate Synch Timers: Yes 4.
MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7.5.3 Procedure – Configuring the Measurement 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. Program Outputs Alarms Measurement Temperature 2. Choose Measurement. Configure? Sensor1 Sensor 1 Sensor 2 3. The screen at left appears only if you have a dual input 1056. Choose the Chlorine sensor. S1 Configure Measure Total Cl Measure: Units: ppm Filter: 5 sec Resolution: 0.001 ppm 4.
MODEL TCL SECTION 7 PROGRAMMING THE ANALYZER 7.6 CONFIGURING TEMPERATURE RELATED SETTINGS 7.6.1 Purpose This section describes how to do the following: 1. Choose temperature units. 2. Choose automatic or manual temperature correction for membrane permeability (chlorine sensor). 3. Enter a temperature for manual temperature compensation. 7.6.2 Definitions - Chlorine 1. AUTOMATIC TEMPERATURE CORRECTION. The total chlorine sensor is a membrane-covered amperometric sensor.
MODEL TCL 7.7 SECTION 7 PROGRAMMING THE ANALYZER CONFIGURING SECURITY SETTINGS 7.7.1 Purpose This section describes how to set security codes. There are three levels of security. a. A user can view the default display and diagnostic screens only. b. A user has access to the calibration and hold menus only. c. A user has access to all menus. The security code is a three digit number. The table shows what happens when different security codes (XXX and YYY) are assigned to Calibration/Hold and All.
MODEL TCL 7.8 SECTION 7 PROGRAMMING THE ANALYZER RESETTING THE ANALYZER 7.8.1 Purpose This section describes how to clear user-entered values and restore default settings. There are three resets: 1. Resetting to factory default values clears ALL user entered settings, including sensor and analog output calibration, and returns ALL settings and calibration values to the factory defaults. 2.
MODEL TCL SECTION 8 DIGITAL COMMUNICATIONS SECTION 8.
MODEL TCL SECTION 9 CALIBRATION SECTION 9. CALIBRATION 9.1 INTRODUCTION The calibrate menu allows the user to do the following: 1. Calibrate the temperature sensing element in the total chlorine sensor. 2. Calibrate the chlorine sensor. 3. Calibrate the analog outputs. 9.2 CALIBRATING TEMPERATURE 9.2.1 Purpose The total chlorine sensor is a membrane-covered amperometric sensor.
MODEL TCL SECTION 9 CALIBRATION 9.2.2 Procedure 1. Remove the sensor from the flow cell. Place it in an insulated container of water along with a calibrated thermometer. Submerge at least the bottom two inches of the sensor. 2. Allow the sensor to reach thermal equilibrium. The time constant for the chlorine sensor is about 5 min., so it may take as long as 30 min for equilibration. 3. Press MENU. The main menu screen appears. The cursor will be on Calibrate. Press ENTER.
MODEL TCL SECTION 9 CALIBRATION 9.3 CALIBRATING TOTAL CHLORINE 9.3.1 Purpose The continuous determination of total chlorine requires two steps. See Figure 9-1. First, the sample flows into a conditioning system (the Model TCL) where it is treated with acetic acid (vinegar) and potassium iodide. The acid lowers the pH, which allows total chlorine in the sample to quantitatively oxidize the iodide to iodine. The treated sample then flows to the sensor.
MODEL TCL SECTION 9 CALIBRATION 9.3.2 Procedure — Zeroing the Sensor 1. Place the sensor in a beaker of deionized water. Be sure no air bubbles are trapped against the membrane. 2. Observe the sensor current. The current will drop rapidly at first and then gradually reach a stable zero value. To monitor the sensor current, press the DIAG key. Move the cursor to the chlorine sensor and press ENTER. The input current is the first line in the display. Note the units: nA is nanoamps, uA is microamps.
MODEL TCL S1 Zero Cal Sensor zero failed SECTION 9 CALIBRATION If the zero current is much larger than expected, the zero calibration failure screen appears. The analyzer will not update the zero current. For troubleshooting assistance, see Section 11.5. Press Exit 8. To return to the main display, press MENU then EXIT. 9.3.3 Procedure — Calibrating the sensor 1. If the sensor was just zeroed, place the sensor back in the flow cell.
MODEL TCL SECTION 9 CALIBRATION 7. Follow the screen prompts: Once the reading is stable, press ENTER. Take the sample and press ENTER. At this point, the analyzer will store the present sensor current and temperature and use those values in the calibration. S1 Enter Value 1 0.00 ppm Determine the total chlorine concentration in the sample and enter the value in the screen shown at left. See Section 9.3.1 for sampling and testing precautions. 8.
MODEL TCL Output 1 Trim Complete SECTION 9 CALIBRATION 6. If the calibration was successful, the screen at left will appear. 7. If the user entered value is more that ±1 mA different from the nominal value, a possible error screen will appear. To force the analyzer to accept the calibration, choose Yes. 8. To return to the main display, press MENU then EXIT.
MODEL TCL SECTION 10 MAINTENANCE SECTION 10. MAINTENANCE 10.1 ANALYZER The Model 1056 analyzer used with the TCL needs little routine maintenance. Clean the analyzer case and front panel by wiping with a clean soft cloth dampened with water ONLY. Do not use solvents, like alcohol, that might cause a buildup of static charge. The chlorine sensor circuit board (PN 24203-01) is replaceable.
MODEL TCL SECTION 10 MAINTENANCE 10.2 TOTAL CHLORINE SENSOR 10.2.1 General When used in clean water, the total chlorine sensor requires little maintenance. Generally, the sensor needs maintenance when the response becomes sluggish or noisy or when readings drift follow calibration. Maintenance frequency is best determined by experience. If the sensor is used in potable water, expect to clean the membrane every month and replace the membrane and electrolyte solution every three months.
MODEL TCL SECTION 10 MAINTENANCE NOTE Do not use a sharp probe. It will puncture the bladder and destroy the sensor. Gently press the probe against the bladder several times to force liquid through the holes at the base of the cathode stem. Keep pressing the bladder until no air bubbles can be seen leaving the holes. Be sure the holes remain covered with electrolyte solution. 10. Place a drop of electrolyte solution on the cathode, then place the membrane assembly over the cathode.
MODEL TCL SECTION 10 MAINTENANCE 10.3 SAMPLE CONDITIONING SYSTEM 10.3.1 Reagent The sample conditioning reagent lasts about 2 months. Before putting fresh reagent in the carboy, discard any small amount of remaining reagent. To prepare the reagent refer to the procedure in Section 5.1. See Table 10-2 for ordering information. 10.3.2 Sample and reagent tubing. Periodically inspect sample and reagent tubing for cracks and leaks. Replace tubing if it is damaged.
MODEL TCL SECTION 10 MAINTENANCE To replace sample tubing: 1. Sample tubing is shown in Figure 10-4. 2. Turn off the sample and reagent pumps. 3. Luer fittings connect the sample tubing to the pump. Disconnect the tubing by turning the fitting in the direction of the arrows shown in Figure 10-5. 4. Disconnect the other end of the sample pump suction tubing from the overflow sampler. Pull the reagent injection tube off the reagent injection tee. 5.
MODEL TCL SECTION 10 MAINTENANCE 10.3.3 Peristaltic pump tubing. The expected life of the peristaltic pump tubing is one year. To replace pump tubing: 1. Turn off the sample and reagent pumps. 2. The reagent and sample tubing is connected to the pump tubing with luer fittings. See Figure 10-5. Disconnect the fittings from the pump by turning the fitting in the direction of the arrow. FIGURE 10-5. 3. Using your thumb and forefinger gently pinch the sides of the pump cover.
MODEL TCL SECTION 10 MAINTENANCE 7. Replace the pump cover. a. Place the cover on the pump casing. See Figure 10-9. FIGURE 10-9. b. Be sure the pins at the bottom of the cover (Figure 10-10) ride on the tracks in the pump casing. FIGURE 10-10. c. The position of the track is outlined in Figure 10-11. The pins on the pump cover must ride in these tracks as the cover is pushed into place. Gently squeeze the ends of the cover to guide the pins. FIGURE 10-11. d.
MODEL TCL SECTION 10 MAINTENANCE 10.3.4 Replacing the air pump WARNING 1. Disconnect power to the analyzer. 2. Refer to Figure 10-12. Disconnect the reagent and air injection tubes. Disconnect the suction and discharge tubing by turning the Luer fitting in the direction shown in the figure. Disconnect the air pump inlet tubing from the barbed fitting in the bottom of the enclosure. HAZARDOUS VOLTAGE CAN CAUSE SEVERE INJURY OR DEATH. DISCONNECT POWER BEFORE SERVICING. 9241136/B 3.
MODEL TCL 10.3.5 Replacing the air pump diaphragm and check valves. 1. Disconnect power to the analyzer. 2. Refer to Figure 10-12. Disconnect the reagent and air injection tubes. Disconnect the suction and discharge tubing by turning the Luer fitting in the direction shown in the figure. Disconnect the air pump inlet tubing from the barbed fitting in the bottom of the enclosure. SECTION 10 MAINTENANCE WARNING HAZARDOUS VOLTAGE CAN CAUSE SEVERE INJURY OR DEATH. DISCONNECT POWER BEFORE SERVICING.
MODEL TCL SECTION 10 MAINTENANCE TABLE 10-2. Replacement Parts and Reagent for Sample Conditioning System PN 24134-00 Air pump, 115 Vac, 60 Hz 24134-01 Air pump, 230 Vac, 50 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, 3AG, slow blow for option -11 (115 Vac) 9100132 Fuse, 0.
MODEL TCL SECTION 11 TROUBLESHOOTING SECTION 11. TROUBLESHOOTING 11.1 OVERVIEW The analyzer continuously monitors itself and the sensor(s) for problems. When the analyzer identifies a problem, the word warning or fault appears intermittently in the lower line of the main display. When the fault or warning message appears, press the DIAG (diagnostic) key for more information. See Section 11.2.
MODEL TCL SECTION 11 TROUBLESHOOTING 11.3 TROUBLESHOOTING WHEN A FAULT MESSAGE IS SHOWING Fault message Explanation Section Main Board CPU Error Main board software is corrupted 11.3.1 Main Board Factory Data Main board factory eeprom data is corrupted 11.3.1 Main Board User Data Main board user eeprom data is corrupted 11.3.1 Sensor Hardware Error Missing or bad hardware component 11.3.2 Sensor Board Unknown Analyzer does not recognize sensor board 11.3.
MODEL TCL SECTION 11 TROUBLESHOOTING 11.3.4 Sensor Incompatible This error message means that the sensor board software is not supported by the main board software. Either the sensor board or the main board software is too old. Replace the main board with one compatible with the sensor board. Call the factory for assistance. You will be asked for the main and sensor board software revision numbers. To read the main board software revision, press the DIAG key and scroll down until Instr SW Ver is showing.
MODEL TCL SECTION 11 TROUBLESHOOTING 11.4 TROUBLESHOOTING WHEN A WARNING MESSAGE IS SHOWING Warning message Explanation Section Sensor Need Factory Cal The sensor board was not calibrated at the factory. 11.4.1 Sensor Negative Reading The chlorine reading is less than -0.5 ppm. 11.4.2 Sensor RTD Sense Open RTD sensor line is broken or not connected 11.4.3 Sensor Temperature High Temperature is greater than 155ºC (311ºF) 11.4.
MODEL TCL SECTION 11 TROUBLESHOOTING 11.5 TROUBLESHOOTING WHEN NO ERROR MESSAGE IS SHOWING Problem See Section Zero current was accepted, but the current is outside the range -10 to 50 nA 11.5.1 Error or warning message appears while zeroing the sensor (zero current is too high) 11.5.1 Zero current is unstable 11.5.2 Sensor can be calibrated, but current is low 11.5.3 Process readings are erratic or wander 11.5.4 Readings drift 11.5.5 Readings are too high 11.5.6 Readings are too low 11.
MODEL TCL SECTION 11 TROUBLESHOOTING 11.5.3 Sensitivity is low or readings are low 1. Does the reagent carboy contain reagent? Is the reagent uptake tubing below the level of the reagent? Has potassium iodide been added to the acetic acid (vinegar) reagent? 2. Is there adequate flow to the overflow sampler? Excess sample should be flowing down the inside tube of the overflow sampler. 3. Does the reagent contain the correct amount of potassium iodide? See the table.
MODEL TCL SECTION 11 TROUBLESHOOTING FIGURE 11-1. Disconnecting sample (A) and reagent (B) tubing prior to checking flow. 11.5.4 Process readings are erratic or wander 1. Is the sensor properly wired to the analyzer? See Section 4.3. Verify that all connections are tight. 2. Readings can be erratic when a new sensor is first placed in service. Readings usually stabilize after about an hour. 3. Is the air pump working? There should be a vigorous stream of bubbles in the flow cell.
MODEL TCL SECTION 11 TROUBLESHOOTING 11.5.6 Readings are too high 1. Is the sample conditioning reagent clear and colorless? If the reagent is pale yellow, results will be high. The pale yellow color is caused by iodine, which comes from the reaction between atmospheric oxygen and potassium iodide. The reaction is catalyzed by sunlight. The purpose of the blue carboy is to protect the reagent from sunlight. 2. Is the sensor fill solution fresh? An old, discolored fill solution may produce a high reading.
MODEL TCL SECTION 11 TROUBLESHOOTING 11.6 SIMULATING TEMPERATURE 11.6.1 General. The Model 1056 accepts a Pt100 RTD. The Pt100 RTD is in a three-wire configuration. See Figure 11-3. 11.6.2 Simulating temperature To simulate the temperature input, wire a decade box to the analyzer or junction box as shown in Figure 11-4. To check the accuracy of the temperature measurement, set the resistor simulating the RTD to the values indicated in the table and note the temperature readings.
MODEL SOLU COMP II RETURN OF MATERIAL SECTION 12 SECTION 12. RETURN OF MATERIAL 12.1 GENERAL. To expedite the repair and return of instruments, proper communication between the customer and the factory is important. Before returning a product for repair, call 1-949-757-8500 for a Return Materials Authorization (RMA) number. 12.2 WARRANTY REPAIR. The following is the procedure for returning instruments still under warranty: 1. Call Rosemount Analytical for authorization. 2.
WARRANTY Seller warrants that the firmware will execute the programming instructions provided by Seller, and that the Goods manufactured or Services provided by Seller will be free from defects in materials or workmanship under normal use and care until the expiration of the applicable warranty period. Goods are warranted for twelve (12) months from the date of initial installation or eighteen (18) months from the date of shipment by Seller, whichever period expires first.
The right people, the right answers, right now. ON-LINE ORDERING NOW AVAILABLE ON OUR WEB SITE http://www.raihome.com Specifications subject to change without notice. 8 Credit Cards for U.S. Purchases Only. Emerson Process Management 2400 Barranca Parkway Irvine, CA 92606 USA Tel: (949) 757-8500 Fax: (949) 474-7250 http://www.raihome.com © Rosemount Analytical Inc.
