Instruction/ maintenance manual of the product TCL Emerson
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Model TCL T otal Chlorine Analyzer Instruction Manual PN 51-TCL-1056/rev .D May 201 1 1.00 ppm 25.0 ° c.
W ARNING ELECTRICAL SHOCK HAZARD Making cable connections to and servicing this instrument require access to shock haz- ard level voltages which can cause death or serious injury . Be sure to disconnect all hazardous voltage before opening the enclosure.
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CAUTION SENSOR/PROCESS APPLICA TION COMP A TIBILITY Wetted materials may not be comp atible with process com position and operating conditions. Application comp at ibility is entirely the responsibility of the user .
MODEL TCL T ABLE OF CONTENTS MODEL TCL T OT AL CHLORINE ANAL YZER T ABLE OF CONTENTS Section Title Page 1.0 DESCRIPTION AND SPECIFICA TIONS ................................................................. 1 1.1 Features and Applications .............
ii MODEL TCL T ABLE OF CONTENTS T ABLE OF CONTENTS CONT'D. 8.0 DIGIT AL COMMUNICA TIONS ................................................................................ 41 9.0 CALIBRA TION .........................................................
MODEL TCL T ABLE OF CONTENTS LIST OF FIGURES Number Title Page 2-1 Schematic of Sample Conditioning System and Analyzer .................................... 7 3-1 Panel Mount Dimensions .................................................................
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MODEL TCL SECTION 1 DESCRIPTION AND SPECIFICA TIONS 1 SECTION 1. DESCRIPTION AND SPECIFICA TIONS • MEMBRANE-COVERED AMPEROMETRIC SENSOR . • NO TOOLS REQUIRED to change membrane. • MAINTENANCE T AKES ONL Y A FEW MINUTES a month. • V ARIOPOL CONNECTOR OPTION allows the sensor to be replaced without removing and rewiring cable.
2 MODEL TCL SECTION 1 DESCRIPTION AND SPECIFICA TIONS 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.
3 Case: Polycarbonate NEMA 4X/CSA 4 (IP65). Dimensions: 6.10 x 6.10 x 5.15 in. (155 x 155 x 131 mm) Conduit openings: Accepts PG13.5 or 1/2 in. conduit fittings Display: Monochromatic back-lit LCD.
4 MODEL TCL SECTION 1 DESCRIPTION AND SPECIFICA TIONS 1.4 SPECIFICA TIONS — MODEL 499ACL-02 SENSOR 1.5 PERFORMANCE SPECIFICA TIONS — COMPLETE SYSTEM Wetted Part s: Gold, Noryl ® 1 (PPO), V iton ® 2 , EPDM, Silicone Dimensions: 1.0 x 5.6 in. (25.
MODEL TCL SECTION 1 DESCRIPTION AND SPECIFICA TIONS 1.6 ORDERING INFORMA TION 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 .
6 ACCESSORIES — Sensor PN DESCRIPTION WEIGHT* SHIP WEIGHT* 23501-02 T otal Chlorine Membrane, includes one membrane assembly and 1 lb (0.5 kg) 1 lb (0.5 kg) one O-ring 23502-02 T otal Chlorine Membrane Kit, includes 3 membrane assemblies and 1 lb (0.
T otal chlorine by definition is the iodine pro- duced in a sample when it is treated with potassium iodide at a pH between 3.5 and 4.5. T ypically , acetic acid (or vinegar) is used to adjust the pH.
3.1 UNP ACKING AND INSPECTION Inspect the shipping containers. If there is damage, cont act the shipper immediately for instructions. Save the boxes. If there is no apparent damage, unp ack the containers. Be sure all items shown on the p acking list are pres- ent.
MODEL TCL SECTION 3 INST ALLA TION Bottom View Front View Side View FIGURE 3-1 P ANEL MOUNTING DIMENSIONS INCH MILLIMETER 154.9 6.1 154.9 6.1 126.4 5.0 17.
Bottom View Front View Side View Side View W all / Surface Mount Pipe Mount 154.9 6.1 102 4.0 187 7.4 154.9 6.1 232 9.1 33.5 1.3 130 5.1 165 6.5 232 9.
MODEL TCL SECTION 3 INST ALLA TION 3.2.3 Inst all the Sample Conditioning Enclosure 1. Refer to Figures 3-3, 3-4, and 3-5 for installation det ails. 2. Connect the sample line to the sample conditioning system. Use ¼ -inch OD hard plastic or stainless steel tubing.
MODEL TCL SECTION 3 INST ALLA TION FIGURE 3-4. TCL Case Dimensions INCH MILLIMETER FIGURE 3-5. Reagent tubing assembly 12.
13 MODEL TCL SECTION 4 WIRING SECTION 4. WIRING 4.1 PREP ARE ANAL YZER 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.
14 MODEL TCL SECTION 4 WIRING 4.3 MAKE POWER, ALARM, OUTPUT , AND SENSOR CONNECTIONS IN THE ANAL YZER 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 SECTION 4 WIRING 15 4.4 SENSOR WIRING 1. Shut off power to the analyzer . 2. Locate the chlorine signal board. 3. Insert the sensor cable through the conduit opening nearest the chlorine board. 4. Slide the board forward to gain access to the wires and terminal screws.
16 MODEL TCL SECTION 4 WIRING 4.5 APPL Y POWER T O THE ANAL YZER AND COMPLETE QUICK ST ART 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 St art screens appear .
17 MODEL TCL SECTION 4 WIRING 6. Choose the desired temperature units. 7. The main display appears. The outputs and alarms (if an alarm board is present) are assigned to default values. 8. T o change outputs, alarms, and other settings go to the main menu and choose Program .
MENU TREE Calibrate Sensor 1 (T ot al chlorine) Chlorine Zero In process T emperature Output 1 Output 2 Hold Sensor 1 Sensor 2 Display Main format configuration Language selection W arning (enable or .
MODEL TCL SECTION 5 ST ART -UP SECTION 5. ST ART -UP 5.1 PREP ARE THE REAGENT 1. DO NOT PREP ARE THE SOLUTION UNTIL READY T O USE. 2. Position the blue plastic carboy under the sample conditioning cabinet. Unscrew the cap and reagent tube assembly . 3.
20 MODEL TCL SECTION 6 ST ART -UP SECTION 6. DISPLA Y AND OPERA TION 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.
MODEL TCL SECTION 6 ST ART -UP 21 6.2 KEYP AD 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 keyp ad. Four navigation keys move the cursor around the screen.
22 MODEL TCL SECTION 6 ST ART -UP 6.3 PROGRAMMING THE ANAL YZER—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 .
23 MODEL TCL SECTION 6 ST ART -UP 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 . a. A user can view the default display and diagnostic screens only .
24 MODEL TCL SECTION 6 ST ART -UP 6.5 USING HOLD 6.5.1 Purpose T o 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.
25 MODEL TCL SECTION 6 ST ART -UP 1. Press MENU. The main menu screen appears. Move the cursor to Display and press ENTER. 2. The screen shows the present configuration. There are four items: Main Format, Language, W arning, and Contrast. T o make a change, move the cursor to the desired line and press ENTER.
26 MODEL TCL SECTION 7 PROGRAMMING THE ANAL YZER SECTION 7. PROGRAMMING THE ANAL YZER 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.
27 MODEL TCL SECTION 7 PROGRAMMING THE ANAL YZER T ABLE 7-1. DEF AUL T SETTINGS ITEM CHOICES DEF AUL T Output s 1. Assignments a. output 1 chlorine, temp chlorine b. output 2 chlorine, temp temp 2. Range 0-20 or 4-20 mA 4 – 20 mA 3. 0 or 4 mA setting a.
28 MODEL TCL SECTION 7 PROGRAMMING THE ANAL YZER T ABLE 7-1. DEF AUL T SETTINGS (continued) ITEM CHOICES DEF AUL T T emperature related settings 1. Units ºC or ºF ºC 2. T emperature compensation automatic or manual automatic Security Code 1. Calibrate/Hold 000 to 999 000 2.
29 MODEL TCL SECTION 7 PROGRAMMING THE ANAL YZER 7.3 CONFIGURING , RANGING , AND SIMULA TING 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.
30 MODEL TCL SECTION 7 PROGRAMMING THE ANAL YZER 7.3.3. Procedure – Configure Output s. 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. 2. The cursor will be on Output s. Press ENTER. 3. Choose Configure. 4. Choose Output 1 or Output 2 .
31 MODEL TCL SECTION 7 PROGRAMMING THE ANAL YZER 7.3.3. Procedure – Ranging Output s. 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. 2. The cursor will be on Output s . Press ENTER. 3. Choose Range . 4. Choose Output 1 or Output 2 .
MODEL TCL SECTION 7 PROGRAMMING THE ANAL YZER 32 7.3.4 Procedure – Simulating Output s 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. 2. The cursor will be on Output s . Press ENTER. 3. Choose Simulate . 4. Choose Output 1 or Output 2 .
33 MODEL TCL SECTION 7 PROGRAMMING THE ANAL YZER 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.
34 MODEL TCL SECTION 7 PROGRAMMING THE ANAL YZER 7.4.3 Procedure – Configuring Alarms and Assigning Setpoint s 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. 2. Choose Alarms. 3. Choose Configure/Setpoint. 4.
35 MODEL TCL SECTION 7 PROGRAMMING THE ANAL YZER 7.4.4 Procedure – Simulating Alarms 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. 2. Choose Alarms. 3. Choose Simulate. 4. Choose Alarm 1, Alarm 2, Alarm 3, or Alarm 4.
36 MODEL TCL SECTION 7 PROGRAMMING THE ANAL YZER 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.
37 MODEL TCL SECTION 7 PROGRAMMING THE ANAL YZER 7.5.3 Procedure – Configuring the Measurement 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. 2. Choose Measurement. 3. The screen at left appears only if you have a dual input 1056.
38 MODEL TCL SECTION 7 PROGRAMMING THE ANAL YZER 7.6 CONFIGURING TEMPERA TURE RELA TED 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).
39 MODEL TCL SECTION 7 PROGRAMMING THE ANAL YZER 7.7 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 .
40 MODEL TCL SECTION 7 PROGRAMMING THE ANAL YZER 7.8 RESETTING THE ANAL YZER 7.8.1 Purpose This section describes how to clear user-entered values and restore default settings.
41 MODEL TCL SECTION 8 DIGIT AL COMMUNICA TIONS SECTION 8. DIGIT AL COMMUNICA TIONS For information about digit al communications, refer to the following manuals: HART 51-1056HT Model 56 HAR T Addendu.
42 MODEL TCL SECTION 9 CALIBRA TION SECTION 9. CALIBRA TION 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.
43 MODEL TCL SECTION 9 CALIBRA TION 3. Press MENU. The main menu screen appears. The cursor will be on Calibrate. Press ENTER. 4. Choose the sensor you wish to calibrate. Sensor 2 appears only if you are using a dual input analyzer . 5. Choose T emperature .
44 MODEL TCL SECTION 9 CALIBRA TION 9.3 CALIBRA TING TOT AL CHLORINE 9.3.1 Purpose The continuous determination of total chlorine requires two step s. See Figure 9-1. First, the sample flows into a conditioning system (the Model TCL) where it is treated with acetic acid (vinegar) and pot assium iodide.
45 MODEL TCL SECTION 9 CALIBRA TION 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.
46 MODEL TCL SECTION 9 CALIBRA TION 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 1 1.5. 8. T o return to the main display , press MENU then EXIT .
47 MODEL TCL SECTION 9 CALIBRA TION 7. Follow the screen prompts: Once the reading is stable, press ENTER. T ake 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.
48 MODEL TCL SECTION 9 CALIBRA TION 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 . T o force the analyzer to accept the calibration, choose Ye s .
49 MODEL TCL SECTION 10 MAINTENANCE SECTION 10. MAINTENANCE 10.1 ANAL YZER The Model 1056 analyzer used with the TCL needs little routine maintenance. Clean the analyzer case and front panel by wiping with a clean sof t cloth dampened with water ONL Y .
10.2.4 Replacing the membrane and electrolyte solution. 1. Unscrew the membrane retainer and remove the membrane assembly and O-ring. See Figure 10-2. 2. Hold the sensor over a container with the cathode pointing down. 3. Remove the fill plug and allow the electrolyte solution to drain out.
51 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.
52 MODEL TCL SECTION 10 MAINTENANCE FIGURE 10-3. Replacing Reagent T ubing 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.
53 MODEL TCL SECTION 10 MAINTENANCE FIGURE 10-4. Replacing Sample T ubing T o replace sample tubing: 1. Sample tubing is shown in Figure 10-4. 2. Turn of f 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.
54 MODEL TCL SECTION 10 MAINTENANCE FIGURE 10-8. FIGURE 10-7. FIGURE 10-6. FIGURE 10-5. 10.3.3 Perist altic pump tubing. The expected life of the peristaltic pump tubing is one year . T o replace pump tubing: 1. Turn of f the sample and reagent pumps.
55 MODEL TCL SECTION 10 MAINTENANCE FIGURE 10-1 1. FIGURE 10-9. FIGURE 10-10. 7. Replace the pump cover . a. Place the cover on the pump casing. See 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.
56 MODEL TCL SECTION 10 MAINTENANCE 10.3.4 Replacing the air pump 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.
57 MODEL TCL SECTION 10 MAINTENANCE FIGURE 10-16. FIGURE 10-17. 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.
58 MODEL TCL SECTION 10 MAINTENANCE PN Description 24134-00 Air pump, 1 15 V ac, 60 Hz 24134-01 Air pump, 230 V ac, 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.
59 MODEL TCL SECTION 1 1 TROUBLESHOOTING SECTION 1 1. TROUBLESHOOTING 1 1.1 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 .
60 MODEL TCL SECTION 1 1 TROUBLESHOOTING Fault message Explanation Section Main Board CPU Error Main board software is corrupted 1 1.3.1 Main Board Factory Data Main board factory eeprom data is corrupted 1 1.3.1 Main Board User Data Main board user eeprom data is corrupted 1 1.
61 MODEL TCL SECTION 1 1 TROUBLESHOOTING 1 1.3.4 Sensor Incompatible This error message means that the sensor board software is not supported by the main board sof tware. Either the sensor board or the main board software is too old. Replace the main board with one compatible with the sensor board.
62 MODEL TCL SECTION 1 1 TROUBLESHOOTING W arning message Explanation Section Sensor Need Factory Cal The sensor board was not calibrated at the factory . 1 1.4.1 Sensor Negative Reading The chlorine reading is less than -0.5 ppm. 1 1.4.2 Sensor RTD Sense Open RTD sensor line is broken or not connected 1 1.
63 MODEL TCL SECTION 1 1 TROUBLESHOOTING 1 1.5 TROUBLESHOOTING WHEN NO ERROR MESSAGE IS SHOWING 15.5.1 Zero current is too high 1. Is the sensor properly wired to the analyzer? See Section 4.3. 2. Is the zero solution chlorine free? T ake a sample of the zero solution and test it for total chlorine.
64 MODEL TCL SECTION 1 1 TROUBLESHOOTING 1 1.5.3 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.
MODEL TCL SECTION 1 1 TROUBLESHOOTING 1 1.5.4 Process readings are erratic or wander 1. Is the sensor properly wired to the analyzer? See Section 4.3. V erify that all connections are tight. 2. Readings can be erratic when a new sensor is first placed in service.
MODEL TCL SECTION 1 1 TROUBLESHOOTING 1 1.5.6 Readings are too high 1. Is the sample conditioning reagent clear and colorless? If the reagent is pale yellow , result s will be high. The pale yellow color is caused by iodine, which comes from the reaction between atmospheric oxygen and pot as- sium iodide.
67 MODEL TCL SECTION 1 1 TROUBLESHOOTING T emp. (°C) Pt 100 ( Ω ) 0 100.0 10 103.9 20 107.8 25 109.7 30 1 1 1.7 40 1 15.5 50 1 19.4 60 123.2 70 127.1 80 130.9 85 132.8 90 134.7 100 138.5 1 1.6 SIMULA TING TEMPERA TURE 1 1.6.1 General. The Model 1056 accepts a Pt100 R TD.
68 MODEL SOLU COMP II SECTION 12 RETURN OF MA TERIAL SECTION 12. RETURN OF MA TERIAL 12.1 GENERAL. T o expedite the repair and return of instruments, proper communication between the customer and the factory is important. Before returning a product for rep air , call 1-949-757-8500 for a Return Materials Authorization (RMA) number .
W ARRANTY 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 expira- tion of the applicable warranty period.
Credit Cards for U.S. Purchases Only . The right people, the right answers, right now . ON-LINE ORDERING NOW A V AILABLE ON OUR WEB SITE http://www .raihome.com Specifications subject to change without notice. 8 Emerson Process Management 2400 Barranca Parkway Irvine, CA 92606 USA T el: (949) 757-8500 Fax: (949) 474-7250 http://www .
An important point after buying a device Emerson TCL (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Emerson TCL yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Emerson TCL - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Emerson TCL you will learn all the available features of the product, as well as information on its operation. The information that you get Emerson TCL will certainly help you make a decision on the purchase.
If you already are a holder of Emerson TCL, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Emerson TCL.
However, one of the most important roles played by the user manual is to help in solving problems with Emerson TCL. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Emerson TCL along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
