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Emerson Rosemount TCL User Manual

Total chlorine system with rosemount 56 transmitter
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LIQ-MAN-TCL-56, Rev B
July 2017
™
Rosemount
TCL
Total Chlorine System with Rosemount 56 Transmitter

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Summary of Contents for Emerson Rosemount TCL

  • Page 1 Manual LIQ-MAN-TCL-56, Rev B July 2017 ™ Rosemount Total Chlorine System with Rosemount 56 Transmitter...
  • Page 2 Essential instructions Read this page before proceeding! Rosemount 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.
  • Page 3 Notes 5/11 This is the initial release of the product manual. This manual has been refor- matted to reflect the Emerson documentation style and updated to reflect any change in the product offering. 7/17 All instances of analyzer have been replaced with transmitter. The manual has...

  • Page 5: Table Of Contents

    Contents Contents Chapter 1 Description and Specifications ..................1 Features ............................1 Specifications ..........................2 Ordering information and accessories ..................5 Chapter 2 Principles of operation ....................9 Chapter 3 Installation ........................11 Unpacking and inspection ......................11 Installation ..........................11 3.2.1 General information ....................11 3.2.2 Install the sample conditioning enclosure ..............11 3.2.3 Install the sensor ......................
  • Page 6 Replacing the air pump ....................63 12.3.6 Replacing the air pump diaphragm and check valves ...........65 Chapter 13 Troubleshooting ......................69 13.1 Overview ........................... 69 13.2 Reading and troubleshooting Fault and Warning messages ............69 13.3 Sensor diagnostics ........................70 Rosemount TCL...
  • Page 7 Contents 13.4 Troubleshooting calibration problems ..................70 13.5 Other troubleshooting ....................... 71 13.5.1 Readings are low......................71 13.5.2 Process readings are erratic or wander................ 73 13.5.3 Readings drift......................74 13.5.4 Readings are too high ....................74 13.6 Other troubleshooting - general ....................74 13.6.1 Current is output too low.
  • Page 8 Contents Rosemount TCL...

  • Page 9: Description And Specifications

    Description and Specifications Description and Specifications Features Rosemount TCL Sample Conditioning System The sample conditioning system permits a single sensor to measure total chlorine in water. The sample conditioning system continuously injects a solution of acetic acid (vinegar) and potassium iodide into the sample. The acid lowers the pH to between 3.5 and 4.5 and allows total chlorine in the sample to quantitatively react with the potassium iodide to produce iodine.

  • Page 10: Specifications

    Weight/shipping weight 14 lb/16 lb (6.5 kg/7.5 kg) Sample requirements Inlet connection Compression fitting, accepts 1/4 in. OD tubing Drain connection 3/4 in. barbed fitting (must drain to open at- mosphere) Inlet pressure <100 psig (791 kPa abs) Rosemount TCL...
  • Page 11 Description and Specifications Table 1-1: Sample Conditioning System (continued) Physical characteristics Specifications Flow At least 0.25 gph (15 mL/min) Temperature 0 to 50 °C (32 to122 °F) Total alkalinity <300 mg/L as CaCO . For samples containing <50 mg/L alkalinity, consult the factory. Sample conditioning system Reagent Potassium iodide in vinegar...
  • Page 12 0 to 50 °C (32 to 122 °F) 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. (2) Viton is a registered trademark of DuPont Performance Elastomers. Rosemount TCL...

  • Page 13: Ordering Information And Accessories

    Reagent kits must be ordered separately. Reagent kits for 0-5 ppm and 0-10 ppm chlorine are available. For higher ranges, consult the factory. Table 1-5. Table 1-5: Rosemount TCL Total Chlorine System Ordering Information Model Sensor type Total Chlorine System Power input...
  • Page 14 Description and Specifications Table 1-5: Rosemount TCL Total Chlorine System Ordering Information (continued) Rosemount 499ACL-02-54-60 Total Chlorine Sensor with optimum EMI/RFI ca- Rosemount 499ACL-02-54-VP Total Chlorine Sensor with VP cable connector Typical model number: TCL-11-280-32 (1) Interconnecting VP cable sold separately.
  • Page 15 Description and Specifications Table 1-7: Rosemount 1056 and 56 Transmitters Accessories Part number Description 23554-00 Cable glands (qty 5 of PG 13.5) 23820-00 Wall and 2 in. pipe mounting kti 240048-00 Stainless steel tag (specify marking) Table 1-8: Sensor Accessories Part number Description 23501-02...
  • Page 16 Description and Specifications Rosemount TCL...

  • Page 17: Principles Of Operation

    Principles of operation 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 system consists of a sample conditioning system, which injects the reagent into the sample, and a sensor and transmitter, which measure the amount of iodine produced.
  • Page 18 Principles of operation Rosemount TCL...

  • Page 19: Chapter 3 Installation

    Installation Installation Unpacking and inspection Complete the following steps when you unpack your instrument. Inspect the shipping containers. If there is damage, contact the shipper immediately for instructions. Save the box. If there is no apparent damage, unpack the containers. Ensure that all items shown on the packing list are present.
  • Page 20 Installation Figure 3-1: Installing the Sample Conditioning Enclosure Rosemount TCL...
  • Page 21 Installation Figure 3-2: TCL Case Dimensions Figure 3-3: Reagent Tubing Assembly Manual...

  • Page 22: Install The Sensor

    Slip the nut over the end of the sensor. Thread the adapter onto the sensor. Hand-tighten only. If you are using a VP cable, connect the cable to the sensor. The connector and receptacle are keyed to ensure proper mating. Rosemount TCL...
  • Page 23 Installation Once the key has slid into place, tighten the connection by turning the knurled ring clockwise. Remove the protective cap from the end of the sensor. Insert the sensor in the flow cell. Hand tighten the nut. Manual...
  • Page 24 Installation Rosemount TCL...

  • Page 25: Chapter 4 Wiring

    Wiring Wiring Prepare transmitter conduit openings The transmitter enclosure has six conduit openings. Four conduit openings are fitted with conduit plugs. Conduit openings accept 1/2 in. 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.

  • Page 26: Make Power, Alarm, Output, And Sensor Connections In The Transmitter

    Wire AC mains power supply to the power supply board, which is mounted vertically on the left hand side of the transmitter enclosure beneath the gray plastic cover. To remove the cover, grab it by the upper edges and pull straight out. Rosemount TCL...

  • Page 27: Analog Output Wiring

    Wiring The power connector is at the bottom of the board. See Figure 4-3. Bring the power cable through the conduit opening just below the connector. Unplug the connector from the board and wire the power cable to it. Lead connections are marked on the connector. (L is live or hot; N is neutral; the ground connection has the standard symbol.) Replace the cover.

  • Page 28: Alarm Wiring

    4.3.3 Alarm wiring The alarm relay terminal strip is located on the power supply board, which is mounted on the left hand side of the enclosure beneath the gray plastic cover. Figure 4-3. Rosemount TCL...

  • Page 29: Sensor Wiring

    Wiring Figure 4-3: Alarm relay connections To remove the cover, grab it by the upper edges and pull straight out. The relay terminal strip is at the top of the board. Bring the relay wires through the rear conduit opening on the left hand side of the enclosure and make connections to the terminals strip.

  • Page 30: Apply Power To The Transmitter And Complete Quick Start

    If you are using a cable gland, tighten the gland nut to secure the cable and ensure a sealed enclosure. Apply power to the transmitter and complete Quick Start For Rosemount Total Chlorine System with Rosemount 56 Transmitter Rosemount TCL...
  • Page 31 Wiring Once all wiring connections are secured and verified, apply power to the transmitter. When the transmitter is powered up for the first time, Quick Start screens appear. The first quick start screen has two control boxes, one for language and the other for temperature units.
  • Page 32 Wiring Rosemount TCL...

  • Page 33: Chapter 5 Startup

    Startup Startup Complete Chapter 4 before starting this section. Prepare the reagent Complete the following steps to prepare the potassium iodide reagent. WARNING! HAZARDOUS SUBSTANCE The reagent contains potassium iodide dissolved in distilled vinegar or 5% acetic acid. Avoid contact with skin and eyes. Wash thoroughly after using. Important Do not prepare the solution until ready to use.

  • Page 34: Zero The Sensor

    Adjust the sample flow until a slow stream of liquid is running down the inside tube of the sampling cup. Begin operation and calibrate the sensor Complete the following steps to start operating the Rosemount TCL and calibrate the 499ACL-02 Sensor. Turn on the reagent and sample pump switches.

  • Page 35: Display And Operation

    Display and operation Display and operation Main display The transmitter has a four line display. Figure 6-1. The display can be customized to meet your requirements. See Section 6.5. Fault or warning messages, if appropriate, appear at the bottom of the screen. See Section 13.1.

  • Page 36: Keypad

    Pressing the ENTER/MENU key will bring up the main Menu only if the main display is showing. Note that the current reading and temperature for sensor 1 (S1) and sensor 2 (S2), if applicable, always appear at the top of the screen. The cursor (dark blue backlit field) is on Calibrate. Rosemount TCL...
  • Page 37 Display and operation Press Down to move the cursor to Program. Press ENTER/MENU. The cursor is on Outputs, and the first screen in the Outputs submenu is showing. To select a different program submenu, use Right to move the cursor to the desired tab and press ENTER/MENU.
  • Page 38 The information screen for Dampening is shown below. To close the information screen, press any key. A NEXT and BACK button are at the bottom of the screen. NEXT means that additional control boxes are available on at least one or more screen. Rosemount TCL...

  • Page 39: Hold

    Display and operation To view the next screen, use the navigation keys (either Down or Right) to move the cursor to NEXT and press ENTER/MENU. The next screen in the Outputs submenu appears. The cursor is on the Outputs tab. To enter the screen, press Down.
  • Page 40 The screen describes how to take the transmitter out of hold. Important Be sure to press APPLY once the box has been unchecked. A message stating which sensors are in hold appears in the fault/warning banner at the bottom of the display. Rosemount TCL...

  • Page 41: Main Display

    Display and operation Main display 6.5.1 Configuring the main display The main display can be configured to meet your specific requirements. With the main display showing, press ENTER/MENU. The main menu appears. Choose Display Setup. The screen below appears. Move the cursor to Display setup and press ENTER/MENU. The screen below appears.

  • Page 42: Setting Brightness

    Enter the three digit security code. If the entry is correct, the requested submenu appears, and you have access to all the submenus the code entitles you to. If the entry is wrong, the Invalid code screen appears. Rosemount TCL...

  • Page 43: Assigning Security Codes

    Display and operation 6.6.2 Assigning security codes Section 7.6 6.6.3 Bypassing security codes Call the factory. Manual...
  • Page 44 Display and operation Rosemount TCL...

  • Page 45: Programming The Transmitter

    Programming the transmitter Programming the transmitter Entering the Program menus Complete the following steps to access the Program menus on your 56 Transmitter. With the main display showing, press ENTER/MENU to display the main menu. Move the cursor to Program and press ENTER/MENU. Move the cursor to the tab showing the desired submenu and press ENTER/MENU.

  • Page 46: Outputs

    Move the cursor to the appropriate control box and press the desired setting. For more information about the control box the cursor is on, press INFO. To close the information screen, press any key. Relays 7.3.1 Menu tree Figure 7-2 is the Relays menu tree. Rosemount TCL...

  • Page 47: Settings

    Programming the transmitter Figure 7-2: Menu tree for the Relays submenu 7.3.2 Settings A large number of relay actions are available in the Model 56. For more information about a relay action, move the cursor to the Explanation of relay actions button and press ENTER/MENU.

  • Page 48: Measurement

    Move the cursor to the appropriate control box and make the desired setting. For more information about the control the cursor is on, press INFO. To close the information screen, press any key. Measurement 7.4.1 Menu tree Figure 7-3 is the Measurement menu tree. Rosemount TCL...

  • Page 49: Settings

    Programming the transmitter Figure 7-3: Menu tree for the Measurement submenu 7.4.2 Settings Complete the following steps to change the measurement settings on your 56 Transmitter. Move the cursor to the appropriate control box and make the desired setting. For more information about the control the cursor is on, press INFO. To close the information screen, press any key.

  • Page 50: Security

    Move the cursor to the appropriate control box and make the desired setting. For more information about the control the cursor is on, press INFO. To close the information screen, press any key. 7.6.3 Restoring default settings Section 8.6. Rosemount TCL...

  • Page 51: Chapter 8 Calibration

    Calibration Calibration Introduction The Calibrate menu allows you to do the following: Calibrate the RTD (temperature sensing element) in the chlorine and pH sensors. Calibrate the chlorine sensor. Calibrate the analog outputs. Entering the Calibration menus Complete the following steps to enter the Calibration submenus on your 56 Transmitter. With the main display showing, press ENTER/MENU to display the main menu.

  • Page 52: Calibrating Temperature

    You are asked to accept the zero current. Press INFO for an information screen to aid with troubleshooting if the results are not acceptable. If the zero current is badly in error, the transmitter displays the Zero failed screen. Press INFO for troubleshooting. Rosemount TCL...

  • Page 53: Calibrating The Analog Outputs

    Calibration To calibrate the sensor response in chlorinated water, select Grab and follow the prompts. Be sure the sensor is installed in the flow cell in the TCL and the sample is flowing down the inside tube of the overflow sampler. Also verify that reagent is being delivered to the sample and that the air pump is working.

  • Page 54: Procedure

    8.6.2 Procedure Complete the following steps to reset your 56 Transmitter. With the main display showing, press ENTER/MENU to display the main menu. Move the cursor to Reset and press ENTER/MENU. Check the desired boxes and press APPLY. Rosemount TCL...

  • Page 55: Data And Event Logging And Retrieval

    Data and event logging and retrieval Data and event logging and retrieval Overview Data and event logging is a standard feature in the Rosemount 56 Transmitter. However, the feature must be enabled. When data and event logging is enabled, the Rosemount 56 Transmitter will automatically store the following events with date and time stamp: faults warnings, calibration data, calibration results (pass or fail), power on/off cycles, hold on/off, and new sensor board detected.

  • Page 56: Downloading Data And Events

    To reset the date and time from the main Menu, press the Time and Date button. Note Setting the date and time to an earlier value than the one showing will cause data to be lost from the data/event logger. See Section 9.3. Rosemount TCL...

  • Page 57: Chapter 10 Graphical Display

    Graphical display Graphical display 10.1 Overview The Rosemount 56 Transmitter has a dual graphical display. Each graph can be configured to meet your requirements, although the time axis on both graphs must be the same. The time scale can be set to one hour, one day, seven days, or thirty days. 10.2 Configuration Complete the following steps to configure the graphical display on your 56 Transmitter.
  • Page 58 The time axis can be expanded or shrunk. To expand the time scale, use Left or Right to move the pair of dotted green lines to the area of interest. Press Up to expand the graph. To shrink the time axis, press Down. Rosemount TCL...

  • Page 59: Chapter 11 Digital Communications

    Digital communications Digital communications The Rosemount 56 Transmitter has HART communications as a standard feature and Profibus DP as an option. For more information, refer to the Rosemount 56 HART or Profibus DP Addendum manuals. Manual...
  • Page 60 Digital communications Rosemount TCL...

  • Page 61: Chapter 12 Maintenance

    Maintenance Maintenance 12.1 Transmitter The Rosemount 56 Transmitter used with the TCL requires little routine maintenance. Clean the transmitter 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.

  • Page 62: Total Chlorine Sensor

    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 following calibration. Maintenance frequency is best determined by experience. For a sensor used in potable water, expect to clean the membrane every Rosemount TCL...

  • Page 63: Cleaning The Membrane

    Maintenance month and replace the membrane and electrolyte solution every three months. Sensors used in dirty water require more frequent maintenance and calibration. However, if experience shows the sensor is holding calibration and not drifting appreciably between calibration intervals, the maintenance interval can be extended. 12.2.2 Cleaning the membrane Keep the membrane clean.
  • Page 64 Place a new O-ring in the groove around the cathode post. Cover the holes at the base of the cathode stem with several drops of electrolyte solution. Insert a small blunt probe, like a toothpick with the end cut off, through the pressure equalizing port. Figure 12-2. Rosemount TCL...

  • Page 65: Sample Conditioning System

    Maintenance CAUTION! EQUIPMENT DAMAGE 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.

  • Page 66: Replacing Sample Tubing

    Disconnect the other end of the discharge tubing from the reagent injection tee. Install the replacement tubing. Note that the discharge tubing is longer than the suction tubing. 12.3.3 Replacing sample tubing To replace sample tubing: Sample tubing and tees are shown in Figure. Rosemount TCL...
  • Page 67 Maintenance Figure 12-4: Replacing sample tubing Procedure Turn off the sample and reagent pumps. 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 12-5. Disconnect the other end of the sample pump suction tubing from the overflow sampler.

  • Page 68: Peristaltic Pump Tubing

    Using your thumb and forefinger, gently pinch the sides of the pump cover. Slide the cover upwards to remove it. Figure 12-6. Figure 12-6: Pump Cover Using your thumb as shown in Figure 12-7, push the tubing fitting straight outward until the fitting slides out of the socket. Rosemount TCL...
  • Page 69 Maintenance Figure 12-7: Pushing the Tubing Fitting Out Remove and discard the pump tubing. Insert the new tubing one end at a time. Tongues on the sides of the gray fittings at the end of the tube fit into receiving grooves in the pump casing. Push the fitting in place until it clicks.
  • Page 70 Gently squeeze the ends of the cover to guide the pins. Figure 12-11: Track d. Push down until the cover snaps into place. Reconnect the tubing. Rosemount TCL...

  • Page 71: Replacing The Air Pump

    Maintenance 12.3.5 Replacing the air pump Complete the following steps to replace the air pump on your total chlorine system. WARNING! HAZARDOUS VOLTAGE Can cause severe injury or death. Disconnect power before servicing. Procedure Disconnect power to the transmitter. Refer to Figure 12-12.
  • Page 72 Using the five screws removed in step 6, attach the replacement air pump to the access panel. Connect the air pump power wires to the terminal strip. Replace the wiring access panel. Connect the air inlet and outlet tubing to the air pump. Rosemount TCL...

  • Page 73: Replacing The Air Pump Diaphragm And Check Valves

    Maintenance Figure 12-14. The conical end of the check valve points in the direction of the air flow. Replace the air pump access panel. Connect the sample pump tubing to the pump. Connect the reagent and air injection tubing. Connect the air inlet tubing to the barbed fitting at the bottom of the enclosure.
  • Page 74 Fuse, 0.125 A, 250 V, 3 AG, slow blow for option -12 (230 Vac) 9380094 Reagent pump, 115 Vac, 50/60 Hz 9380095 Reagent pump, 230 Vac, 50/60 Hz 9380091 Reagent pump replacement tubing 24151-00 Reagent tubing replacement kit (see Section 12.3.2) 24135-00 Reagent uptake tubing, 65 ft (1.8 m), includes weight Rosemount TCL...
  • Page 75 Maintenance Table 12-2: Replacement Parts and Reagent for Sample Conditioning System (continued) Description 9380090 Sample pump, 115 Vac, 50/60 Hz 9380093 Sample pump, 230 Vac, 50/60 Hz 9380092 Sample pump replacement tubing 24152-00 Sample tubing replacement kit (includes tees, see Section 12.3.2) 24165-00...
  • Page 76 Maintenance Rosemount TCL...

  • Page 77: Chapter 13 Troubleshooting

    Troubleshooting Troubleshooting 13.1 Overview The transmitter continuously monitors itself and the sensor for problems. When the transmitter identifies a problem, the word warning or fault appears intermittently at the bottom of the display. To read a fault or warning message and troubleshooting information, press INFO.

  • Page 78: Sensor Diagnostics

    For more information about a specific diagnostic measurement, move the cursor to the diagnostic of interest and press INFO. 13.4 Troubleshooting calibration problems If a calibration attempt results in an error or a likely error, the transmitter displays the appropriate warning screen. For troubleshooting suggestions, press INFO. Rosemount TCL...

  • Page 79: Other Troubleshooting

    Troubleshooting 13.5 Other troubleshooting Problem See Section Readings are too low. Section 13.5.1 Process readings are erratic or wander. Section 13.5.2 Readings drift. Section 13.5.3 Readings are too high. Section 13.5.4 13.5.1 Readings are low. 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? Is there adequate flow to the overflow sampler? Excess sample should be flowing...
  • Page 80 Place the end of the tubing in a 5 mL graduated cylinder. d. Start the reagent pump and collect reagent for ten minutes. e. Note the volume of reagent collected in the graduated cylinder. After ten minutes, the volume should be about 2 mL. Rosemount TCL...

  • Page 81: Process Readings Are Erratic Or Wander

    Troubleshooting Figure 13-1: Disconnecting Sample (A) and Reagent (B) Tubing Prior to Checking Flow 13.5.2 Process readings are erratic or wander. Is the sensor properly wired to the transmitter? See Section 4.3. Verify that all connections are tight. Readings can be erratic when a new sensor is first placed in service. Readings usually stabilize after about an hour.

  • Page 82: Readings Drift

    Alarm relays do not operate properly. Section 13.6.2 13.6.1 Current is output too low. Load resistance is too high. Maximum load is 600 Ω. 13.6.2 Alarm relays do not operate properly. Verify the relays are properly wired. Verify the relays are properly configured. Rosemount TCL...

  • Page 83: Simulating Inputs - Chlorine

    Troubleshooting 13.7 Simulating inputs - chlorine To check the performance of the transmitter, use a decade box and 1.5 V battery to simulate the current from the sensor. The battery, which opposes the polarizing voltage, is necessary to ensure that the sensor current has the correct sign. Disconnect the anode and cathode leads from terminals 8 and 10 on TB1 and connect a decade box and 1.5 V battery as shown in Figure...

  • Page 84: Simulating Temperature

    The offset is also applied to the simulated resistance. The transmitter is measuring temperature correctly if the difference between measured temperatures equals the difference between the values in the table to within ±0.1 °C. Rosemount TCL...
  • Page 85 Troubleshooting For example, start with a simulated resistance of 103.9 Ω, which corresponds to 10.0 °C. Assume the offset from the sensor calibration was -0.3 Ω. Because of the offset, the transmitter calculates temperature using 103.6 Ω. The result is 9.2 °C. Now change the resistance to 107.8 Ω, which corresponds to 20.0 °C.
  • Page 86 Troubleshooting Rosemount TCL...

  • Page 87: Return Of Material

    Return of material Return of material For any repair, warranty, and return of instrument requests, please contact the factory. Manual...
  • Page 88 Emerson Automation Solutions The Emerson logo is a trademark and service mark of Emerson 1 Pandan Crescent Electric Co. Rosemount is a mark of one of the Emerson family of Singapore 128461 companies. All other marks are the property of their respective Singapore owners.

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