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Teledyne Analytical Instruments FCA380 Instruction Manual
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Teledyne Analytical Instruments FCA380 Instruction Manual

Free chlorine analyzer
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Use and Disclosure of Data
Information contained herein is classified as EAR99 under the U.S.
Export Administration Regulations. Export, reexport or diversion
contrary to U.S. law is prohibited.
I
M
NSTRUCTION
ANUAL
MODEL FCA380
FREE CHLORINE ANALYZER
Teledyne Confidential; Commercially Sensitive Business Data

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Summary of Contents for Teledyne Analytical Instruments FCA380

  • Page 1 Use and Disclosure of Data Information contained herein is classified as EAR99 under the U.S. Export Administration Regulations. Export, reexport or diversion contrary to U.S. law is prohibited. NSTRUCTION ANUAL MODEL FCA380 FREE CHLORINE ANALYZER Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 3 Sensor 1 or 2 Ramp #1 ON/OFF #2 ON/OFF Relays (Simulate) #3 ON/OFF 4-20 mA Ch 1 Enter Value 4-20 mA 4-20 mA Ch 2 Enter Value Page i Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 4 PREFACE Purchasing products from TELEDYNE ANALYTICAL INSTRUMENTS. provides you with the finest liquid analytical instrumentation available. If this is your first purchase from TAI, please read the entire manual before installing and commissioning your new equipment. If there are any questions concerning this equipment, please contact your local TAI representative, or the...
  • Page 5 TAI. Making copies of any part of this manual for any purpose other than personal use is a violation of United States copyright laws. Document printed in the United States of America. Page iii Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 6 1.0 General Description .............................. 3 1.1 Features ................................4 1.2 Specifications ..............................4 1.2.1 Sensors and Flow Train ..........................4 1.2.2 FCA380 Analyzer ............................4 1.3 Model Codes ..............................5 2.0 Installation ................................6 2.0.1 ATEX/IECEx Installations ..........................6 2.0.2 FM Installations ............................6 2.1 Mounting ................................
  • Page 7 4.1.1 AUTO Cal using pH 4.01, 7.00, 10.00 buffers ................... 24 4.1.2 AUTO Cal using other pH buffers ......................24 4.1.3 Standardize .............................. 25 4.2 Free Chlorine Calibration Procedures ......................25 4.4.2 Standardize .............................. 26 4.4.3 Manual Cal ............................... 26 Page 1 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 8 5.3 Constant Head Flow Controller (CHFC) ......................30 6.0 Troubleshooting ..............................31 7.0 Parts and Accessories ............................33 7.1 FCA380 Replacement parts ..........................33 7.1 380 Replacement Parts ........................... 33 Appendix ................................... 34 A. Auto Cal Buffer Tables ............................34 B.
  • Page 9 Transmitter. Simply supply power to the LXT380 Transmitter and plumb the sample line in and the drain line out and the FCA380 is ready to use. The CHFC maintains a constant sample flow to the pH and Chlorine flow cells. Activateure regulators and rotameters are not needed to maintain a constant flow rate, the CHFC provides trouble free sample conditioning between 10 and 80 gal/hr.
  • Page 10 Response Time: T90 in 2 minutes Electrolyte Life: Up to 12 months 1.2.2 FCA380 A NALYZER Measurements: Chlorine: 0.00 ppb to 20.00 ppm (color inverted screen above 20.00 ppm to the limit of the sensor) pH: 0.00 to 14.00 pH...
  • Page 11 Transient over voltages: CAT II Pollution Degree: 2 1.3 M ODEL ODES Model FCA380- 0 0.05 to 20 ppm Free Chlorine (Standard) Sensor type 1 0.01 to 5.00 ppm Free Chlorine and Range 2 0.05 to 20 ppm Free Chlorine (Seawater) 3 0.005 to 2.00 ppm Free Chlorine (Seawater)
  • Page 12 2.0 INSTALLATION Mount the FCA380 in a location where there is easy access to the analyzer and sensors. Install the system in an area where vibrations, electromagnetic and radio frequency interference are minimized or absent. Do not mount in direct sunlight or areas of extreme heat. The FCA380 is suitable for outdoor use if mounted with a protective cover or sunshield.
  • Page 13 2.1 M OUNTING The FCA380 panel is drilled with 4 x 0.265” holes, one at each corner, and is designed to use ¼” -20 hardware or 6mm metric hardware. Page 7 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 14 (NFPA33, NEC 500 and 516, IEC 60079-14). Electrical wiring should only be conducted by qualified personnel. See the LXT380 wiring diagram in Figure 2.2.1 Figure 2.2.2 4-Wire Transmitter, 24VDC, MODBUS, Relays Page 8 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 15 IRING ENSOR The Free Chlorine Sensor and the SP3X pH Sensor were connected to the FCA380 analyzer at the factory, no additional connections are necessary. Color coded connections for these sensors are shown in the wiring diagrams in Section 8.3 or on the inside cover of the LXT380 transmitter.
  • Page 16 NSTALLING THE ENSORS The FCA380 is supplied with the sensor cables pre-wired to the analyzer. The FCA380 instrument and sensors were calibrated at the factory and should be ready for use when assembled. However, changes may have occurred during shipping and storage requiring recalibration. (See Calibration section below) The pH sensor mounts in the Flow Cell using an o-ring sealed flange/union mount with threaded locking cap.
  • Page 17 8 since there is little actual HOCl to measure and a large compensation to perform. The FCA380 uses the dissociation constant (7.49) for hypochlorous acid, HOCl, to compensate the free chlorine measurement. The mV signal from the free chlorine sensor is divided by the slope of the sensor to yield a ppm value.
  • Page 18 The FCA380 automatically compensates for the changes. The temperature sensor is located inside the free chlorine sensor and it has a response time of several minutes. Rapid changes of temperature will introduce an error until the sensor has equilibrated to the new temperature.
  • Page 19 HOME Menu screen activate any of the Selection/Adjustment keys twice within one second. The various Menu choices and adjustment tools are displayed above the buttons once inside the MENU. Page 13 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 20 Laboratory generated calibration data for an electrode can be input to a remote analyzer where calibration is difficult or impractical. ❖ TEMP allows the displayed temperature to be trimmed to agree with actual process temperature. Page 14 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 21 Timed, Enter Period, Duration times and Hold On/Off o Fault, No input required, relay condition changes from energize to de-energize. o Disable, Inactivates relay and removes the relay button from the HOME Screen display. Page 15 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 22 ❖ Sensor Screen, details the Name, Part #, Serial # and three sets of Calibration data. ❖ COMP, displays the pKa, the sensor affected and the dissociation Factor Page 16 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 23 2) CHECK AUX EQUIP Relay 2 Expired ON EXPIRED A) PUMPS B) TANKS 1) CHECK SENSOR OP RELAY 3 TIME 2) CHECK AUX EQUIP Relay 3 Expired ON EXPIRED A) PUMPS B) TANKS Page 17 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 24 SET POINT OFF: The Value of the process variable that deactivates the relay. ▪ SET POINT OFF > Set Point → Low Set Point ▪ SET POINT OFF < Set Point → Hi Set Point Page 18 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 25 ½ hour before verifying the reading against a grab sample. If calibration is required follow the instruction in Section 4.0 below. Page 19 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 26 NEXT to advance the cursor to the next digit. Activating and holding the ▲ or ▼ keys will initiate two speed auto scrolling. Activate BACK to exit the screen. Location: CONFIG → XMTR → LCD → LABELS → TAG Page 20 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 27 ON/OFF _ _ _ _ Locks SIM and CONFIG In the case of a Lost or Forgotten password enter MSTR to access the screen. Location: CONFIG → XMTR → PSSWD Page 21 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 28 (3) a slope for the electrode. This allows laboratory generated calibration data for an electrode to be entered in a remote analyzer where calibration is difficult or impractical. Page 22 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 29 6.8 mV, activate OK, Accept Offset?, activate YES, enter slope -58.2 mV/pH, activate OK, Accept Slope?, Activate YES 6. The Calibration is complete, the Offset and Slope values are displayed, activate OK to exit. Page 23 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 30 OFFSET: 6.86 pH 8.2 mV, SLOPE: -59.16 mV/pH (data written to Log) Activate OK Calibration complete Activate HOME Hold is ON Activate HOLD Turn off Hold Activate EXIT Main Display Page 24 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 31 Cal 2. Cal 2 sets the slope of the sensor. It is accomplished by setting the ppm value of the instrument to agree with a DPD tested value of the water flowing through the FCA380 Analyzer. The analyzer will suggest a corrected value of 0.00 ppm, 5.00 ppm or 10.00 ppm, which will not be correct unless that happens to be the actual value...
  • Page 32 Slope 15.00 mV/ppm, (60.00 mV/ppm for Low Range) Accept this Value? Activate YES Back to Cal Menu Activate HOME Hold is ON (Activate HOLD to turn off Hold) Activate HOLD Turn off Hold Activate EXIT Main Display Page 26 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 33 Page 27 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 34 Make sure the sponge inside the cap is wetted. For longer terms rinse out the electrolyte with distilled water and allow the sensor to dry. Loosely reassemble the dry sensor so as not to tension the membrane during storage. Page 28 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 35 ORP electrodes. If possible, the electrode should be cleaned without removing it from the sensor body. However, if the electrode must be removed, the o-rings must be inspected and re-lubricated. Page 29 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 36 The CHFC and tubing can be easily disassembled and cleaned with soap and water. Some dirty applications like blowdown from Cooling Towers may require periodic cleaning due to sediments. Page 30 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 37 6.0 TROUBLESHOOTING The FCA380 was evaluated and calibrated at the factory before shipment. Upon initial start up the system should require minimal to no adjustments. Verify the system has adequate flow, greater than 10 gals /hr. This is accomplished by setting the flow to the CHFC so that the water fills the outer chamber and slightly overflows into the center tube.
  • Page 38 Air bubbles on the membrane Loosen FCS fitting and lift sensor slightly to purge air trapped in the flow cell. Changing temperature, the Wait for equilibrium lag of the temperature sensor looks like drift Page 32 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 39 7.0 PARTS AND ACCESSORIES 7.1 FCA380 R EPLACEMENT PARTS Part # Description S02052 Free Chlorine Sensor, Standard Range, 0.5 – 20.0 ppm HOCl/OCl S02164 Free Chlorine Sensor, Low Range, 0.01 – 5.00 ppm HOCl/OCl K00277 Membrane Replacement Kit (2 Cap, 50 ml bottle of electrolyte )
  • Page 40 1 to 247 (0x01 to 0xF7) Function code 1 Byte 0x03 Byte Count 1 Byte 2 X N* Register Value(s) *N X 2 Bytes 2 Bytes calculated *N = Quantity of Registers Page 34 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 41 16 bit BusCommunicationsError total CRC error count Integer 16 bit SlaveExceptionError total count of exceptions detected Integer total messages addressed to the slave (remote 16 bit SlaveMessage device) Integer Page 35 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 42 - None, 2 - 5min., 3 - 10min., 4 - 15min., 6 - 30min.) Read/Write Timed Relay Period (0 - 15min., 1 - 16 bit Relay Period 30min., 2 - 1hr., 3 - 2hr., 4 - 4hr., 5 - 8hr., 6 - Integer Page 36 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 43 Unit operating mode (0- Integer SP3X Serial Number (hi Unit Serial Number (32 bit integer hi word) word) Long Integer SP3X Serial Number (lo Unit Serial Number (32 bit integer lo word) Page 37 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 44 Sensor Full Name ASCII bytes 2 and 3 Integer 16 bit Sensor Full Name ASCII bytes 4 and 5 Integer 16 bit Sensor Full Name ASCII bytes 6 and 7 Integer Page 38 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 45 (bytes 1 and 0) word) SP3X Cal Log offset (bytes 3 and 2) 32 bit Voltage Floating (hi word) Point SP3X Cal Log offset (bytes 1 and 0) Voltage (lo word) Page 39 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...
  • Page 46 Data Meaning Measurement Decimal Hexadecimal Chemical Sensor Type Units 0010 none FCA (max range) mg/L 0023 0024 FCA (min range) mg/L 0025 FCA HR mg/L 0039 FCL (max range) mg/L Page 40 Model FCA380 Teledyne Confidential; Commercially Sensitive Business Data...