Instruction Manual PN 51-FCL-1056 rev.
ESSENTIAL INSTRUCTIONS WARNING READ THIS PAGE BEFORE PROCEEDING! Your purchase from Rosemount Analytical, Inc. has resulted in one of the finest instruments available for your particular application. These instruments have been designed, and tested to meet many national and international standards. Experience indicates that its performance is directly related to the quality of the installation and knowledge of the user in operating and maintaining the instrument.
QUICK START GUIDE FOR FCL ANALYZER 1. Refer to Section 2.0 for installation instructions and Section 3.0 for wiring instructions. 2. Once connections are secured and verified, apply power to the analyzer. 3. 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. To move the cursor left or right, use the keys to the left or right of the ENTER key.
S1 Free Cl pH Correction Manual Live/Continous 9. Choose Live/Continuous. Go to step 11. S1 Manual pH 0 7.00 10. The screen shown at left appears only if you have an FCL-01. Enter the pH of the process liquid. Temp Units 11. Choose the desired temperature units. o C F o 12. The main display appears. The outputs and alarms (if an alarm board is present) are assigned to default values. 13. To change outputs, alarms, and other settings go to the main menu and choose Program. Follow the prompts.
MENU TREE Calibrate Sensor 1 (Free chlorine) Chlorine Zero In process Temperature Sensor 2 (pH) pH Buffer Cal Auto Select buffer (NIST, DIN19267, Ingold, Merck, or Fisher) Select stability criteria Manual Standardize Enter slope or offset Temperature Output 1 Output 2 Hold Sensor 1 Sensor 2 Display Main format configuration Language selection Warning (enable or disable) Screen contrast See next page for rest of menu tree
MENU TREE (continued) 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 logic Deadband Interval time On time Recovery time Simulate Synchronize timers Measurement Free chlorine (sensor 1) Measurement selection Units Filter Resolution pH (sensor 2) Measurement selection P
About This Document This manual contains instructions for installation and operation of the Model FCL-1056 The following list provides notes concerning all revisions of this document. Rev. Level Date Notes A 9/08 This is the initial release of the product manual. The manual has been reformatted to reflect the Emerson documentation style and updated to reflect any changes in the product offering. B 11/09 Minor changes to manual. C 10/10 Updated DNV logo and copyright date.
MODEL FCL-1056 TABLE OF CONTENTS FCL-1056 TABLE OF CONTENTS Section 1.0 1.1 1.2 1.3 1.4 1.5 1.6 Title DESCRIPTION AND SPECIFICATIONS ................................................................ Applications ............................................................................................................. Features................................................................................................................... Specifications - General .......................................
MODEL FCL-1056 TABLE OF CONTENTS TABLE OF CONTENTS CONT’D Section Title 7.0 DIGITAL COMMUNICATIONS ............................................................................... Page 51 8.0 8.1 8.2 8.3 8.4 MAINTENANCE ...................................................................................................... Analyzer ................................................................................................................... Chlorine Sensor ............................................
MODEL FCL-1056 TABLE OF CONTENTS LIST OF TABLES CONT’D 9.6.1 9.7 9.9.2 9.10 Calibration Error During Two-Point Calibration ........................................................ Troubleshooting When No Error Message is Showing - General............................. Simulating pH Input .................................................................................................. Simulating Inputs Temperature.................................................................................
Model FCL-1056 SECTION 1.0 DESCRIPTION AND SPECIFICATIONS SECTION 1.0. DESCRIPTION AND SPECIFICATIONS • COMPLETE SYSTEM INCLUDES sensor, connecting cable, analyzer, and flow controller • CONTINUOUS pH CORRECTION eliminates expensive and messy reagents and troublesome sample conditioning systems • MEASURES FREE CHLORINE IN SAMPLES having pH as high as 9.
MODEL FCL-1056 1.3 SPECIFICATIONS — GENERAL Sample requirements: Pressure: 3 to 65 psig (122 to 549 kPa abs) A check valve in the inlet prevents the sensor flow cells from going dry if sample flow is lost. The check valve opens at 3 psig (122 kPa abs). If the check valve is removed, minimum pressure is 1 psig (108 kpa abs). Temperature: 32 to 122°F (0 to 50°) SECTION 1.0 DESCRIPTION AND SPECIFICATIONS Interferences: Monochloramine, permangante, peroxides. Electrolyte volume: 25 mL (approx.
MODEL FCL-1056 SECTION 1.0 DESCRIPTION AND SPECIFICATIONS 1.6 ORDERING INFORMATION FCL Free Chlorine Measuring System. The FCL is a complete system for the determination of free chlorine in aqueous samples. It consists of the sensor(s), analyzer, and constant head overflow device to control sample flow. All components are mounted on a backplate. Model option -02 includes a pH sensor for continuous, automatic pH correction. Three replacement membranes and a 4-oz.
MODEL FCL-1056 4 SECTION 1.
MODEL FCL-1056 SECTION 2.0 INSTALLATION SECTION 2.0. INSTALLATION 2.1 UNPACKING AND INSPECTION Inspect the shipping container. If it is damaged, contact the shipper immediately for instructions. Save the box. If there is no apparent damage, unpack the container. Be sure all items shown on the packing list are present. If items are missing, notify Rosemount Analytical immediately. 2.1.
MODEL FCL-1056 SECTION 2.0 INSTALLATION 2.2 INSTALLATION 2.2.1 General Information 1. Although the system is suitable for outdoor use, do not install it in direct sunlight or in areas of extreme temperature. CAUTION The FCL free chlorine system is NOT suitable for use in hazardous areas. 2. To keep the analyzer enclosure watertight, install plugs (provided) in the unused cable openings. 3.
MODEL FCL-1056 SECTION 2.0 INSTALLATION INCH MILLIMETER FIGURE 2-1. Model FCL-01 INCH MILLIMETER FIGURE 2-2.
MODEL FCL-1056 8 SECTION 2.
MODEL FCL-1056 SECTION 3.0 WIRING SECTION 3.0. WIRING 3.1 POWER, ALARM, AND OUTPUT WIRING WARNING RISK OF ELECTRICAL SHOCK Electrical installation must be in accordance with the National Electrical Code (ANSI/NFPA-70) and/or any other applicable national or local codes. 3.1.1 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 FCL-1056 3.1.3 SECTION 3.0 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 3-2. 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 3-2. Alarm relay connections. 3.
MODEL FCL-1056 SECTION 3.0 WIRING WHITE RED Figure 3-3. Wiring Diagram for Free Chlorine Sensor Figure 3-4. Wiring Diagram for 399VP-09 pH Sensor Figure 3-5. Wiring Diagram for 3900VP-10 pH sensor (gray cable) Figure 3-6.
MODEL FCL-1056 12 SECTION 3.
MODEL FCL-1056 SECTION 4.0 DISPLAY AND OPERATION SECTION 4.0 DISPLAY AND OPERATION 1. 7. 4.1. DISPLAY The analyzer has a four line display. See Figure 4-1. The display can be customized to meet user requirements. Refer to section 4.6. ppm pH T1: 25.0qC O1: 12.00 mA T2: 25.0 qC O2: 12.00 mA Warning Warning FIGURE 4-1. Main Display When the analyzer is being programmed or calibrated, the display changes to a screen similar to the one shown in Figure 4-2.
MODEL FCL-1056 SECTION 4.0 DISPLAY AND OPERATION 4.2 KEYPAD Local communication with the analyzer is through the membrane keypad. Figures 4-4 and 4-5 explain the operation of the keys. FIGURE 4-4. 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 FCL-1056 SECTION 4.0 DISPLAY AND OPERATION 4.3 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.
MODEL FCL-1056 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 4.0 DISPLAY AND OPERATION 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. 4.4 SECURITY 4.4.1 How the Security Code Works Security codes prevent accidental or unwanted changes to program settings or calibrations.
MODEL FCL-1056 SECTION 4.0 DISPLAY AND OPERATION 4.5 USING HOLD 4.5.1 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. Hold is also useful if calibration, for example, buffering a pH sensor, will cause an out of limits condition. During hold, outputs assigned to the sensor remain at the last value, and alarms assigned to the sensor remain in their present state.
MODEL FCL-1056 SECTION 4.0 DISPLAY AND OPERATION 4.6 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 FCL-1056 SECTION 5.0 PROGRAMMING THE ANALYZER SECTION 5.0 PROGRAMMING THE ANALYZER 5.1 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. c. Choose the type of chlorine measurement being made. This step is necessary because the analyzer used with the FCL can measure forms of chlorine other than free chlorine. d.
MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANALYZER TABLE 5-1. DEFAULT SETTINGS ITEM Sensor assignment CHOICES DEFAULT 1. Sensor 1 chlorine chlorine 2. Sensor 2 pH pH a. output 1 chlorine, temp chlorine b. output 2 chlorine, temp temp a. output 1 chlorine, pH, temp chlorine b. output 2 chlorine, pH, temp pH 0-20 or 4-20 mA 4 – 20 mA a. chlorine and pH -9999 to +9999 0 b. temperature -999.9 to +999.9 0 a. chlorine -9999 to +9999 10 b. pH -9999 to +9999 14 c.
MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANALYZER TABLE 5-1. DEFAULT SETTINGS (continued) ITEM CHOICES Measurement DEFAULT 1. Chlorine (sensor 1) a. units ppm or mg/L ppm b. resolution 0.01 or 0.001 0.001 c. input filter 0 to 999 sec 5 sec analyzer or sensor/junction box analyzer on or off off c. resolution 0.01 or 0.1 0.01 d. input filter 0 to 999 sec 2 sec low or high low ºC or ºF ºC automatic or manual automatic 1. Calibrate/Hold 000 to 999 000 2.
MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANALYZER 5.3 CONFIGURING, RANGING, AND SIMULATING OUTPUTS. 5.3.1 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, pH, or temperature) to an output. b. Selecting a 4-20 mA or 0-20 mA output. c. Choosing a linear or logarithmic output. d. Adjusting the amount of dampening on the analog current output. e.
MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANALYZER 5.3.3. 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 FCL-1056 SECTION 5.0 PROGRAMMING THE ANALYZER 5.3.4. 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 FCL-1056 SECTION 5.0 PROGRAMMING THE ANALYZER 5.3.5 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 FCL-1056 SECTION 5.0 PROGRAMMING THE ANALYZER 5.4.2 Definitions 1. ASSIGNING ALARMS. There are four alarms relays. The relays are freely assignable to any sensor and to either the measurement (for example, 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 FCL-1056 SECTION 5.0 PROGRAMMING THE ANALYZER 5.4.3 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 FCL-1056 SECTION 5.0 PROGRAMMING THE ANALYZER 5.4.4 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.
MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANALYZER 5.4.4 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. The summary display shows the current Synch Timers setting (Yes or No).
MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANALYZER 5.5 CONFIGURING THE MEASUREMENT. 5.5.1 Purpose This section describes how to do the following: 1. Program the analyzer to measure free chlorine (and pH). This step is necessary because the Model FCL analyzer can be used with other sensors to measure other chlorine oxidants. It can also be used to measure ORP (oxidation reduction potential).
MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANALYZER 5. RESOLUTION. The pH display resolution is user selectable: XX.X or XX.XX. 6. FILTER. The analyzer applies a software filter to the raw voltage value coming from the pH sensor. The filter reduces noise, but increases the response time. See section 5.5.2 for more information. 7. REFERENCE IMPEDANCE. Usually the impedance of the reference electrode in a pH sensor is low.
MODEL FCL-1056 S2 Configure Measure: Measure: pH Preamp: Analyzer Soln Temp Corr: Off Resolution: 0.01 pH SECTION 5.0 PROGRAMMING THE ANALYZER 5. The screen summarizes the present configuration for sensor 2 (pH). There are six items: Measure, Preamp, Sol’n Temp Corr, Resolution, Filter, and Reference Z (reference impedance). Only four items are shown at a time. To view the remaining items, scroll to the bottom of the screen and continue scrolling.
MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANALYZER 5.6.4 Procedure – Configuring Temperature Related Settings 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. Program Outputs Alarms Measurement Temperature 2. Choose Temperature. Temperature Units: C Units: S1 Temp Comp: Auto S2 Temp Comp: Auto 3. The screen summarizes the present sensor configuration. There will be between three and five items. Units, S1 Temp Comp, and S2 Temp Comp always appear.
MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANALYZER 5.7.2 Procedure – Configuring Security Settings 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. 2. Scroll to the bottom of the screen and continue scrolling unit Security is highlighted. Press ENTER. Program Alarms Measurement Temperature Security Security Calibration/Hold Calibration/Hold All 000 000 3. The screen shows the existing security codes.
MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANALYZER 5.8.3 Procedure – Setting Up Diagnostics 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. Program Measurement Temperature Security Diagnostic Setup Diagnostic Setup Sensor Sensor22 S2 Diagnostic Setup Ref Offset: 60mV Diagnostic: On Z Temp Corret’n: On GI Fault High: 1500MΩ 2. Scroll to the bottom of the screen and continuing scrolling until Diagnostic Setup is highlighted. Press ENTER. 3.
MODEL FCL-1056 5.9 SECTION 5.0 PROGRAMMING THE ANALYZER RESETTING THE ANALYZER 5.9.1 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 FCL-1056 SECTION 6.0 CALIBRATION SECTION 6.0 CALIBRATION 6.1 INTRODUCTION The calibrate menu allows the user to do the following: 1. Calibrate the temperature sensing element in the chlorine and pH sensors. 2. Calibrate the chlorine sensor. 3. Calibrate the pH sensor. Four methods are available. a. Two-point calibration with automatic buffer recognition. b. Manual two-point calibration. c. Standardization. d. Manual entry of pH sensor slope and offset. 4. Calibrate the analog outputs. 6.
MODEL FCL-1056 SECTION 6.0 CALIBRATION 6.2.2 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 both the chlorine and pH 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 FCL-1056 SECTION 6.0 CALIBRATION 6.3 CALIBRATION — FREE CHLORINE 6.3.1 Purpose As Figure 6-1 shows, a free chlorine sensor generates a current directly proportional to the concentration of free chlorine in the sample. Calibrating the sensor requires exposing it to a solution containing no chlorine (zero standard) and to a solution containing a known amount of chlorine (full-scale standard).
MODEL FCL-1056 Calibrate Sensor11 Sensor Sensor 2 Output 1 Output 2 S1 Calibration Free Chlorine Temperature S1 Calibration Zero Cal Zero Cal In Process Cal S1 Zero Cal Sensor zero done S1 Possible Error, Proceed? No No Yes S1 Zero Cal Sensor zero failed SECTION 6.0 CALIBRATION 3. Choose the sensor you wish to calibrate. Sensor 1 is the chlorine sensor. Sensor 2 (if present) is the pH sensor. 4. Choose Free Chlorine. 5. Choose Zero Cal. The analyzer will automatically start the zero calibration 6.
MODEL FCL-1056 SECTION 6.0 CALIBRATION 6.3.3 Procedure-Calibrating the Sensor 1. Place the chlorine sensor in the chlorine flow cell. If continuous (live) pH correction is being used, calibrate the pH sensor (section 6.4) and place it in the pH flow cell. If manual pH correction is being used, measure the pH of the sample and enter the value. See section 5.5. Adjust the sample flow until water overflows the center tube of the constant head flow controller. 2.
MODEL FCL-1056 SECTION 6.0 CALIBRATION 6.4 CALIBRATION – pH 6.4.1 Purpose A pH sensor consists of a glass and reference electrode. Usually, the two electrodes are combined into a single body, called a combination pH sensor. When the sensor is placed in an aqueous solution, it produces a voltage proportional to pH. An ideal pH sensor has a potential of 0 mV in pH 7 solution and a slope of -59.16 mV/pH at 25ºC, that is, a unit increase in pH causes the potential to drop 59.16 mV.
MODEL FCL-1056 SECTION 6.0 CALIBRATION 5. USER ENTERED SLOPE AND OFFSET. If the slope and offset are known from other measurements, they can be directly entered in the analyzer. Enter the slope as a positive number corrected to 25ºC. To calculate the slope at 25ºC from the slope at temperature tºC, use the equation: slope at 25ºC = (slope at tºC) 298 tºC + 273 To calculate the offset use the following equation. The offset can be either positive or negative. offset = mVbuffer - (pHbuffer - 7.
MODEL FCL-1056 S2 pH Auto Cal StartAuto AutoCal Cal Start Setup SECTION 6.0 CALIBRATION 8. Choose Start Auto Cal. If you wish to change the stability criteria or the pH buffer list from the default values, choose Setup instead and go to step 14. The default stability is defined as a less than 0.02 pH change in 10 seconds. The default buffer list is Standard. See the table in section 6.4.2. S2 pH Auto Cal Place Sensor in Buffer 1 Press Enter 9.
MODEL FCL-1056 SECTION 6.0 CALIBRATION 6.4.4 Procedure-Manual Calibration 1. Obtain two buffer solutions. Ideally, the buffer pH values should bracket the range of pH values to be measured. 2. Remove the sensor from the flow cell. If the process and buffer temperatures are appreciably different, place the sensor in a container of tap water at the buffer temperature. Do not start the calibration until the sensor has reached the buffer temperature. 3. Press MENU. The main menu screen appears.
MODEL FCL-1056 Manual Buffer 1 0 7.00 pH S2 pH Manual Cal Buffer 1 Buffer 2 Manual Buffer 2 1 0 0.00 pH S2 pH Manual Cal Slope: 59.16 mV/pH Offset: 10 mV SECTION 6.0 CALIBRATION 10. Watch the pH reading for sensor 2 (S2) at the top of the screen. Once the reading is stable, enter the pH value of the buffer at the buffer temperature and press ENTER. 11. The display returns to the screen shown in step 8. Choose Buffer 2. Remove the sensor from the first buffer.
MODEL FCL-1056 SECTION 6.0 CALIBRATION 6.4.5 Procedure-Standardization 1. The pH value measured by the analyzer can be changed to match the reading from a second or referee instrument. The process of making the two readings agree is called standardization. 2. Place the sensor in the flow cell. Wait until pH readings are stable. 3. Press MENU. The main menu screen appears. The cursor will be on Calibrate. Press ENTER. Calibrate? Sensor 1 Sensor 2 Output 1 Output 2 S2 Calibration 4.
MODEL FCL-1056 SECTION 6.0 CALIBRATION 6.4.6 Procedure-Entering a Known Slope and Offset 1. Calibration data, i.e., slope and offset at pH 7, can be entered directly into the analyzer if the data for the sensor are already known. 2. Press MENU. The main menu screen appears. The cursor will be on Calibrate. Press ENTER. Calibrate? Sensor 1 Sensor 2 Output 1 Output 2 S2 Calibration 3. Choose the sensor you wish to calibrate. Sensor 1 is the chlorine sensor. Sensor 2 is the pH sensor. 4. Choose pH.
MODEL FCL-1056 SECTION 6.0 CALIBRATION 6.5 CALIBRATION – Analog Outputs 6.5.1 Purpose Although the analyzer analog outputs are calibrated at the factory, they can be trimmed in the field to match the reading from a standard milliammeter. Both the low (0 or 4 mA) and high (20 mA) outputs can be trimmed. 6.5.2 Procedure 1. Connect a calibrated milliammeter across the output you wish to calibrate. If a load is already connected to the output, disconnect the load.
MODEL FCL-1056 50 SECTION 6.
MODEL FCL-1056 SECTION 7.0 DIGITAL COMMUNICATIONS SECTION 7.0 DIGITAL COMMUNICATIONS THE ANALYZER SUPPLIED WITH THE FCL DOES NOT HAVE THE DIGITAL COMMUNICATIONS OPTION.
MODEL FCL-1056 52 SECTION 7.
MODEL FCL-1056 SECTION 8.0 MAINTENANCE SECTION 8.0 MAINTENANCE 8.1 ANALYZER The analyzer used with the FCL 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. Sensor circuit boards are replaceable.
MODEL FCL-1056 SECTION 8.0 MAINTENANCE 8.2 CHLORINE SENSOR 8.2.1 General. When used in clean water, the chlorine sensor requires little maintenance. Generally, the sensor needs maintenance when the response becomes sluggish or noisy or when readings drift following calibration. For a sensor used in potable water, expect to clean the membrane every month and replace the membrane and electrolyte solution every three months.
MODEL FCL-1056 SECTION 8.0 MAINTENANCE FIGURE 8-1. Chlorine Sensor Parts TABLE 8-1. Spare Parts 33523-00 9550094 33521-00 23501-08 23502-08 9210356 Electrolyte Fill Plug O-Ring, Viton 2-014 Membrane Retainer Free Chlorine Membrane Assembly: includes one membrane assembly and one O-ring Free Chlorine Membrane Kit: includes 3 membrane assemblies and 3 O-rings #4 Free Chlorine Sensor Fill Solution, 4 oz (120 mL) 8.3 pH SENSOR 8.3.1 General.
MODEL FCL-1056 SECTION 8.0 MAINTENANCE 8.4 CONSTANT HEAD FLOW CONTROLLER 8.4.1 General After a period of time, deposits may accumulate in the constant head overflow chamber and in the tubing leading to the flow cell(s). Deposits increase the resistance to flow and cause the flow to gradually decrease. Loss of flow may ultimately have an impact on the chlorine sensor performance. The flow controller is designed to provide about 2 gal/hr (120 mL/mm) flow.
MODEL FCL-1056 SECTION 8.0 MAINTENANCE TABLE 8-2. Replacement parts for constant head flow controller assembly (Model FCL-01) Location in Figure 8-2 PN Description Shipping Weight 1 24039-00 Flow cell for chlorine sensor with bubble shedding nozzle 1 lb/0.5 kg 2 24040-00 O-ring kit, two 2-222 and one 2-024 silicone O-rings, with lubricant 1 lb/0.5 kg 3 33812-00 Dust cap for constant head flow controller 1 lb/0.5 kg 4 9322032 Elbow, ¼ in FNPT x ¼ in OD tubing 1 lb/0.
MODEL FCL-1056 SECTION 8.0 MAINTENANCE TABLE 8-3. Replacement parts for constant head flow controller assembly (Model FCL-02) Location in Figure 8-3 PN Description Shipping Weight 1 24039-00 Flow cell for chlorine sensor with bubble shedding nozzle 1 lb/0.5 kg 2 24039-01 Flow cell for pH sensor 1 lb/0.5 kg 3 24040-00 O-ring kit, two 2-222 and one 2-024 silicone O-rings, with lubricant 1 lb/0.5 kg 4 33812-00 Dust cap for constant head flow controller 1 lb/0.
MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING SECTION 9.0 TROUBLESHOOTING 9.1 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 9.2.
MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.3 TROUBLESHOOTING WHEN A FAULT MESSAGE IS SHOWING Fault message Explanation Section Main Board CPU Error Main board software is corrupted 9.3.1 Main Board Factory Data Main board factory eeprom data is corrupted 9.3.1 Main Board User Data Main board user eeprom data is corrupted 9.3.1 Sensor Hardware Error Missing or bad hardware component 9.3.2 Sensor Board Unknown Analyzer does not recognize sensor board 9.3.
MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.3.4 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.
MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.3.10 Sensor RTD Out of Range Both the chlorine and pH sensor contain a Pt 100 RTD (resistance temperature device) for measuring temperature. If the measured resistance is outside the expected range, the analyzer will display the out of range error message. 1. Check wiring connections. 2. Disconnect the sensor from the cable and use an ohmmeter to check the resistance across the RTD. See Figures 9-1 and 9-2. The resistance should be about 110 Ω.
MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.4 TROUBLESHOOTING WHEN A WARNING MESSAGE IS SHOWING Warning message Explanation Section Sensor No Solution Gnd pH sensor may be miswired. 9.4.1 Sensor Need Factory Cal The sensor board was not calibrated at the factory. 9.4.2 Sensor Out of Range The pH measurement is invalid. 9.4.3 Sensor Negative Reading The chlorine reading is less than -0.5 ppm. 9.4.4 Sensor RTD Sense Open RTD sensor line is broken or not connected 9.4.
MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.4.6 Sensor Temperature High or Low The sensor RTD is most likely miswired. 1. Check wiring connections. 2. Check resistance between RTD in and return leads. The resistance should be close to the values given in Section 9.10.2. 3. Replace sensor. 9.4.7 Broken Glass Disabled The impedance of the pH glass electrode is a strong function of temperature. As temperature increases, the glass impedance decreases.
MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.5.3 Sensor can be calibrated, but the current is too low 1. Is the temperature low or is the pH high? Sensor current is a strong function of pH and temperature. The sensor current decreases about 3% for every °C drop in temperature. Sensor current also decreases as pH increases. Above pH 7, a 0.1 unit increase in pH lowers the current about 5%. 2. Sensor current depends on the rate of sample flow past the sensor tip.
MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.5.6 Sensor does not respond to changes in chlorine level. 1. Is the grab sample test accurate? Is the grab sample representative of the sample flowing to the sensor? 2. Is sample flowing past the sensor? Be sure the liquid level in the constant head sampler is level with the central overflow tube and that excess sample is flowing down the tube. If necessary, disassemble and clean the over flow sampler. See Section 8.4. 3.
MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.6 TROUBLESHOOTING WHEN NO ERROR MESSAGE IS SHOWING — pH. Problem See Section Calibration Error warning during two-point calibration 9.6.1 Offset Error warning during standardization 9.6.2 Sensor does not respond to known pH changes 9.6.3 Calibration was successful, but process pH is slightly different from expected value 9.6.4 Calibration was successful, but process pH is grossly wrong and/or noisy 9.6.
MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.6.2 Calibration Error during Standardization. During standardization, the millivolt signal from the pH cell is increased or decreased until the pH agrees with the pH reading from a referee instrument. A unit change in pH requires an offset of about 59 mV. The analyzer limits the offset to ±60 mV. If the standardization causes an offset greater than ±60 mV, the analyzer will display the Offset Error screen. The standardization will not be updated.
MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.6.5 Calibration Was Successful, but Process pH Is Grossly Wrong and/or Noisy. Grossly wrong or noisy readings suggest a ground loop (measurement system connected to earth ground at more than one point), a floating system (no earth ground), or noise being brought into the analyzer by the sensor cable. The problem arises from the process or installation. It is not a fault of the analyzer. The problem should disappear once the sensor is taken out of the system.
MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.7 TROUBLESHOOTING WHEN NO ERROR MESSAGE IS SHOWING — GENERAL See Section Problem New temperature during calibration more than 2-3C° different from live reading 9.7.1 Current output is too low 9.7.2 Alarm relays do not operate when setpoint is exceeded 9.7.3 9.7.1 Difference Between Analyzer and Standard Thermometer is Greater Than 3°C. 1.
MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.9 SIMULATING INPUTS — pH 9.9.1 General This section describes how to simulate a pH input into the analyzer. To simulate a pH measurement, connect a standard millivolt source to the analyzer. If the analyzer is working properly, it will accurately measure the input voltage and convert it to pH. 9.9.2 Simulating pH input. 1. Set automatic temperature correction to manual and set manual temperature to 25°C. Turn off solution temperature correction. See Section 5.
MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.10 SIMULATING INPUTS — TEMPERATURE 9.10.1 General. The analyzer accepts a Pt100 RTD (for pH and chlorine sensors). The Pt100 RTD is in a three-wire configuration. See Figure 9-5. 9.10.2 Simulating temperature To simulate the temperature input, wire a decade box to the analyzer as shown in Figure 9-6. To check the accuracy of the temperature measurement, set the resistor simulating the RTD to the values in the table and note the temperature readings.
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