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Foxcroft FX-1000p Instruction Manual

Amperometric chlorine residual analyzer
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Foxcroft Equipment & Service, Co. Inc.
Model FX-1000p
Amperometric Chlorine Residual Analyzer
Instruction Manual
Warning!
Please Read Carefully and Save.
The FX-1000p Amperometric Chlorine Analyzer includes an instruction manual that contains important
information about its operation. Purchasers who install this analyzer for use by others must leave this
instruction manual or a copy with the user.
Copyright © 2012 FOXCROFT
Every effort has been made to ensure the accuracy of this document at the time of printing. In accordance with the
company's policy of continuous product improvement, Foxcroft reserves the right to make product changes without notice.
No liability is accepted for any consequential losses, injury or damage resulting from the use of this document or from any
omissions or errors herein.

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  • Page 1 Every effort has been made to ensure the accuracy of this document at the time of printing. In accordance with the company’s policy of continuous product improvement, Foxcroft reserves the right to make product changes without notice. No liability is accepted for any consequential losses, injury or damage resulting from the use of this document or from any...

  • Page 2: Table Of Contents

    Table of Contents Important Safety Information Introduction Specifications INSTALLATION 1.1 Unpacking 1.2 Mechanical Requirements 1.3 Sample Point Selection Guidelines 1.4 Sample Line 1.5 Sample Flow 1.6 PLUMBING 1.7 ELECTRICAL STARTUP 2.1 Buffer Feed Pump Tube Selection 2.2 Preparing Buffer Solution 2.2 Preparing Copper Electrode 2.3 Preparing System for Calibration CALIBRATION...
  • Page 3 Table of Contents MAINTENANCE 5.1 Preserving Measurement Accuracy 5.2 Maintenance Schedule 5.3 Cleaning the Copper Electrode 5.4 Peristaltic Pump Motor Replacement 5.5 Mixer Gap Adjustment 5.6 PREVENTIVE MAINTENANCE KIT 6. AUXILIARY KI PUMP 6.1 Total Chlorine 6.2 Installation of Auxiliary KI Pump 7 PARTS LISTING 7.1 Electronics 7.2 Amperometric Cell...

  • Page 4: Important Safety Information

    IMPORTANT SAFETY INFORMATION Please read and observe the following: Opening the analyzer door exposes you to line voltage, if present, at power terminals TB-1D at the bottom of the enclosure. This may be hazardous. Always remove power source before entering this area of the enclosure.

  • Page 5: Introduction

    General Information Instrument Description and Capability The FX-1000p Amperometric Chlorine Residual Analyzer amperometrically measures the free or total residual chlorine in treated drinking water, process water, or wastewater using integral gold and copper bare electrodes that are not covered by a membrane.
  • Page 6 FX-1000p Introduction Electronics Enclosure Buffer Pump Measurement Cell Figure 1 Figure 2...

  • Page 7: Specifications

    Specifications Operational Type of Measurement Amperometric (free or total chlorine) Measurement Range 0-5.00 ppm (mg/l) factory-set range; other field-configurable measuring ranges are: 0-0.50; 0-1.00; 0-2.00; 0-3.00; 0-10.0; 0-20.0; 0-0.50; and 0-60.0 ppm (mg/l) Display Three-digit LED; 0.56 in. (14 mm) high Ambient Conditions 32-120°F (0-49°C);...

  • Page 8: Installation

    Instruction Manual Serial Number The FX-1000p Amperometric Chlorine Analyzer measurement system has two serial number labels found on the bottom right side of the enclosure, and on the top of the base plate inside the enclosure. The label on the outside of the enclosure indicates the chlorine residual range. Should technical assistance be required, refer to the serial number to identify your system.
  • Page 9 FX-1000p Installation The FX-1000p should be level from side to side and front to back to ensure that its integral weir operates properly. Attach the vinegar bottle bracket on the wall. The bottom of the bracket should be about 3” above the bottom surface of the electronics enclosure, and slightly below the height of the peristaltic pump mechanism.

  • Page 10: Sample Point Selection Guidelines

    It is preferred to install a pressure regulator and flow control valve to ensure a consistent flow. The part number FX-1000p-RM is available to control the sample flow and pressure into the analyzer.

  • Page 11: Plumbing

    Installation (Plumbing) Plumbing Connection To The Analyzer Connect the supplied 1/4” id x 3/8” od x 3’ length, clear flexible PVC sample line to the flow control valve and secure. Cut if necessary to keep the sample line as short as possible. Route the tubing down to the analyzer, through the sample line guide hole and into the flow cell.
  • Page 12 FX-1000p Installation (Plumbing) Clean Water Application Dirty Water Application Figure 11 Figure 10 Reservoir Application Figure 12...
  • Page 13 FX-1000p Installation (Plumbing) Non-Continuous Flow Application Carbon Filter Installation Figure 13 Figure 14...

  • Page 14: Electrical

    Installation (Electrical) Conduit Holes Run all wiring in 1/2-inch, grounded metal conduit. If using only shielded cable, appropriate strain reliefs or cable grips are required. Seal unused cable entry holes with appropriate plugs. NOTE: Use NEMA 4-rated fittings and plugs to maintain the watertight integrity of the NEMA 4X enclosure.
  • Page 15 FX-1000p Installation (Electrical) AC Power TB-1D AC power input terminal is shown below. Use maximum 14 gauge stranded wire only. Do not use solid wire. Always connect to an earth ground. Figure 16 110/220 VAC INPUT Analog Output 4-20mA The isolated 4-20mA output signal is provided at terminals on TB-1E. This output can drive a load of up to 600 ohms.
  • Page 16 FX-1000p High and Low Alarm Relay Outputs: The FX-1000p is equipped with two electromechanical relays. Two sets of SPDT relay outputs, one for high alarm and one for low alarm. They energize upon alarm conditions and are located on the bottom circuit board.
  • Page 17 FX-1000p Installation (Electrical) Connecting External Devices Connecting a Chart Recorder: 4-20 mA Signal Figure 20 Recorder must be configured for 4-20mA input signal. See Model FX-4300 instruction manual. Electrical Schematic Figure 21...
  • Page 18 Installation (Electrical) FX-1000p Connecting a Telephone Dialer: High Alarm Status Signal Low Alarm Status Signal See Model FX-1104 or Model FX-1108 Figure 22 instruction manuals. Electrical Schematic Figure 23...
  • Page 19 FX-1000p Installation (Electrical) Connecting a Metering Pump: + 4-20 mA signal - - 4-20 mA signal + - 4-20 mA signal + Metering Pump FX-8500 Single Loop Controller 4-20 mA Out Figure 24 Electrical Schematic Figure 25...
  • Page 20 FX-1000p Installation (Electrical) Connecting a Compound Loop Control System: + 4-20 mA signal - FX-8500 Compound Loop Chlorine Control Valve - 4-20 mA signal + - 4-20 mA signal + Flow Meter 4-20 mA Signal Figure 26 Electrical Schematic Figure 27...

  • Page 21: Startup

    Startup Buffer Feed Pump Tube Selection A buffer feed pump is supplied with #14 tubing factory installed. Smaller diameter #13 tubing is also supplied but should only be used when specific application conditions exist. Refer to the table below to determine which tubing size best suits your application. #13 Tubing #14 Tubing (supplied)

  • Page 22: Preparing Buffer Solution

    White Reduction Connector Preparing the Buffer Solution The FX-1000p Amperometric Chlorine Analyzer is designed to use only 5% food grade distilled white vinegar as a buffering agent to lower the pH in the measuring cell. The recommended white distilled vinegar should be available for purchase in any local food store.
  • Page 23 FX-1000p Startup Once opened, vinegar can become contaminated with biological organisms. To minimize the chances of contamination: • Do not add new vinegar to the existing bottle when the vinegar runs out. Always discard the old bottle and replace it with a new bottle.

  • Page 24: Preparing Copper Electrode

    FX-1000p Startup Preparing the Copper Electrode It is recommended to polish the inside of the copper ring as it is 99% pure copper and will probably be somewhat tarnished due to normal atmospheric oxidation. The inner surface of the copper electrode ring must be de-oxidized (i.e. polished to a bright metal shine) to obtain a strong measuring signal and accurate readings.

  • Page 25: Preparing System For Calibration

    FX-1000p Startup Preparing System for Calibration Check to make sure that the buffer feed tubing is in the fresh vinegar bottle and at the bottom. See Figure 31 (below) to be sure sample tubing is placed in the weir properly.

  • Page 26: Calibration

    See Figure 37 (page 29) to locate the Std. control (VR-2), and adjust it until the FX-1000p display reads the known, ppm value. If the Std. control is out of adjustment refer to “Coarse Adjustment”...

  • Page 27: Coarse Adjustment

    FX-1000p Calibration Coarse Adjustment The coarse adjustment is only necessary if one of the two following cases is found during Std. Control adjustment. Both the Std. Control trimmer (VR-2), and the Coarse Span trimmer (VR-3), are at maximum (both fully clockwise), and the analyzer cannot be calibrated high enough to match the chlorine residual test.
  • Page 28 FX-1000p Calibration To Calibrate Using The Low Range Sensitivity Amplifier Board Turn Standard Adjustment (trimmer VR2) and Input Range Adjustment (trimmer VR4) to their mid points. Do this by turning the trimmers fully counterclockwise until they “click” at their endpoints, 30 turns. Then turn clockwise 15 turns.

  • Page 29: Special Configurations

    Special Configurations Trimmer Locations Coarse Adjustment VR-3 Alarm Control VR-10 Range Control VR-7 VR-2 VR-1 Figure 37 Input Range Adjustment VR-4 TP-1 TP-2...

  • Page 30: Setting Alarm Relays

    Run switch “off” (right) position Adjust the low set control VR-9 until the FX-1000p display indicates the desired low alarm point value. Locate the block of four DIP switches (S-1; see Figure 38, page 31), and set the switches to these settings.

  • Page 31: Changing Measuring Range

    High Set Control VR-8 Low Set Control VR-9 Figure 38 Changing Measuring Range The measuring range of the FX-1000p is factory set to 0-5.00 ppm. It can be changed in the field to one of these other ranges: • 0-0.50 ppm (mg/l) •...
  • Page 32 FX-1000p Special Configurations Shifting the Decimal Point If the new measuring range only requires a decimal point shift (e.g., from 50.0 to 5.00 ppm) simply move the jumper on the back of the display circuit board. Refer to Figure 39 (below) and move the yellow jumper to the appropriate pin position. Please note the orientation of the display in the photo below.
  • Page 33 FX-1000p analog output signal. The milliamp method ensures an accurate output calibration to the new analyzer range. Adjust the range trimmer (VR-7) until the FX-1000p display reads the high endpoint of the new range (e.g., 1.00 ppm).

  • Page 34: 4-20Ma Output Adjustment

    FX-1000p Special Configurations 4-20mA Output Adjustment The display has a dampening circuit that slows the response of the display. The output signal will not show the same dampening effect. Allow time for the display to match the output signal when calibrating.

  • Page 35: Maintenance

    Maintenance Preserving measurement accuracy The FX-1000p Amperometric Chlorine Analyzer is designed to operate continuously, 24 hours a day, 365 days a year. The system requires little routine maintenance other than changing the vinegar bottle as the vinegar buffering agent becomes depleted, and mandated calibration checks.

  • Page 36: Cleaning The Copper Electrode

    This condition can be reduced or eliminated by installing a “flushing wye strainer” in the sample line just before it reaches the FX-1000p. The strainer is particularly well suited for high suspended solids applications. It has a built-in flushing port that can be plumbed to a drain, or back to the process.
  • Page 37 FX-1000p Maintenance Carefully pull the bottom block, together with the copper electrode ring, down from the top block. This should help prevent losing any of the 150 small PVC mixing balls contained within the copper ring electrode. NOTE: During removal, be careful not to lose the O-ring that seals the top edge of the copper electrode ring to the top block of the flow cell.

  • Page 38: Peristaltic Pump Motor Replacement

    Turn off the AC power to the FX-1000p. Remove the inner cover plate to access the motor and PC boards.
  • Page 39 FX-1000p Maintenance Peristaltic Pump Motor With Coupling 1/16” Gap Required Figure 45 Brass Nuts Figure 47 Figure 46 Pump Motor TB-1B Pump Wiring...

  • Page 40: Mixer Gap Adjustment

    FX-1000p Maintenance Mixer Gap Adjustment Maintaining the proper clearance between the bottom tips of the mixer and the floor of the sample cell is critical to prevent premature mixing motor failure. If the gap is too high the mixing balls become jammed under the tips of the mixer, and/or come out of the top of the cell through the sample water exit gap.

  • Page 41: Preventive Maintenance Kit

    Preventive Maintenance Kit Preventive Maintenance Kit Installation The Preventive Maintenance Kit includes: Item Number Qty Description Part Number #13 Buffer Pump Tubing, 9” long 130-0488-1300-2 #14 Buffer Pump Tubing, 9” long 130-0488-1400-2 O-ring #31 129-0031-0121-1 PVC Mixing Balls (150 ct) 119-0371-0001-1 O-ring #14 129-0014-0001-1...
  • Page 42 FX-1000p Preventive Maintenance Kit The way to perform preventive maintenance on the analyzer is to remove it from the wall and place it upside down on a table. Even with the disconnections needed to remove the analyzer you will be able to work more quickly and accurately by avoiding potential problems such as dropped parts and mixing balls jamming under the mixer.
  • Page 43 FX-1000p Preventive Maintenance Kit 10. Rotate the mixer by hand until the set screw is visible, remove the screw with a 3/32” Allen wrench. 11. Pull out the mixer. If it’s not damaged keep it for a spare. 12. Clean the upper block of any deposits. Do not use chlorinated cleansers.
  • Page 44 FX-1000p Preventive Maintenance Kit Parts Replacement Replace all of the O-rings removed. A light coating of silicone grease may be applied to the O-rings. Figure 55 Figure 56 Figure 57 To replace the item #3 O-rings: in the lower block for the negative cell, stretch it slightly before putting it into the block.
  • Page 45 Place the other end of the tubing with new blue bottle cap and new sinker into the vinegar bottle and secure the cap. 22. Recalibrate the analyzer before returning it to service. Refer to the calibration section of this product manual on pages 26-28 for instructions on how to calibrate the FX-1000p.

  • Page 46: Auxiliary Ki Pump

    Auxiliary KI Pump Total Chlorine: The secondary peristaltic pump option is available for analyzers monitoring total chlorine residual applications. Potassium Iodide (KI) is added to the measuring cell to convert any free and combined chlorine residuals into free iodine, which then provides a total chlorine reading. Typically a specific amount of KI (depending on residual range) is mixed with the vinegar pH buffer just before use.
  • Page 47 FX-1000p Auxiliary KI Pump Position the buffer tube holder with the drilled hole below the pins, and fasten with (1) 1/4”-20 x 2” round head machine screw. Tighten the #4-40 x 7/8” pump mounting screws from step 3. Place the pump motor onto the threaded studs in the pump motor mounting block, with the pump drive pin aligned with the coupling slot.

  • Page 48: Parts Listing

    Parts Listing Electronics Item Number Description Part Number Power Supply 110V 356-1001-0122-2 Power Supply 220V 356-1220-0122-2 Display Board 356-0352-0122-2 Ribbon Interconnect Cable 356-1004-0001-2 Amplifier Board 356-1000-0122-2 Switches (2 required) 257-0115-0121-1 Item 2 Item 3 Item 5 Item 4 Item 1 Figure 61...

  • Page 49: Amperometric Cell

    Mixing motor 115VAC, 60Hz, 120rpm 142-1000-0002-3 Mixing motor 110VAC, 50Hz 257-0220-0121-1 Positive electrode with block 162-1441-0121-1 Not Shown Preventive Maintenance Kit FX-1000p PM Kit Item 1 Item 16 Item 2 Item 3 Item 15 Item 4 Item 5 Item 14...

  • Page 50: Cell And Pump Parts

    FX-1000p Preventive Maintenance Kit Pump Parts Item Number Description Part Number Buffer Pump Motor 110VAC 257-0730-0121-2 Buffer Pump Motor 220VAC 257-0731-0121-2 Buffer Pump 257-1000-0003-2 Buffer Pump Motor Mounting Block 158-0730-0121-1 Coupling with Setscrew for Peristaltic Pump 258-0700-0121-2 Buffer Tube Holder...

  • Page 51: Accessories

    Accessories Figure 65 Figure 64 Figure 66 FX-1200 Chlorine Test Kits FX-4300 Recorders FX-1200 Chlorine Test Kits Figure 67 Figure 68 Figure 69 FX-8500 Chlorine Control Systems FX Datalogger Second KI Pump Figure 70 Dilution Panel...

  • Page 52: Troubleshooting

    Troubleshooting Initial Startup On initial startup, the inside surface of the copper electrode should be cleaned BEFORE any calibration is done, due to the rapid oxidation that takes place on pure copper. Trimmer Adjustment All the trimmers used on the analyzer are of the 30-turn variety, so it may take several turns before you get the desired residual setting or voltage.
  • Page 53 FX-1000p Troubleshooting Vinegar Buffer Check on vinegar itself. Sometimes an older bottle of vinegar just doesn’t have enough acidity to cut the pH in the cell properly. The vinegar my also contain mother of vinegar, a slimy, sometimes wispy appearing cellulose substance produced by Acetobacter, the bacteria used to make vinegar. The substance can cause blockages and can also create a false chlorine demand in the measuring cell.
  • Page 54 FX-1000p Troubleshooting Positive Electrode While the sample cell is dismantled, check the positive probe (gold). The probe is 24 karat gold, and as such, it is inert. So normally, it will not require any cleaning, other than wiping with a cloth. The gold probe should never need replacement, unless it has been physically damaged.
  • Page 55 FX-1000p Troubleshooting Std. Control The Std. trimmer (VR-2) is wired in parallel with the coarse span timmer (VR- 3). If either one is already at its minimum value, it will negatively affect the usable range of the other. If you are unsure of how low a trimmer is set, turn it in one direction until you feel a click (or 30 turns, if it does not click), and then turn back 15 full turns.

  • Page 56: Service

    A Return Material Authorization Number (RMA) is required before shipping any products for service. Call telephone number above to receive a RMA number. NOTE: Returns will only be held at Foxcroft for 90 days. If a decision is not made regarding the repair, the product will be returned.

  • Page 57: Product Warranty

    Warrantor (Foxcroft Equipment and Service) will repair the unit, without charges for parts, labor and return freight. Foxcroft Equipment & Service is not responsible for damage to its products through improper installation, maintenance, act of God, use or attempts to operate such products beyond their functional capacity, intentionally or otherwise, or for any unauthorized repair.
  • Page 58 Serial Number Label of FX-1000p Amperometric Chlorine Residual Analyzer: Foxcroft Equipment and Service, Co. Inc. 2101 Creek Road, P.O. Box 39 Glenmoore, PA 19343 Tel: (800) 874-0590 (610) 942-2888 Fax: (610) 942-2769 Email: service@foxcroft.com www.foxcroft.com...

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