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Instruction Manual – MicroChem®2 Chlorine Probes Series CL4000

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These instructions describe the installation, operation and maintenance of the subject equipment. Failure to strictly follow these instructions can lead to an equipment rupture that may cause significant property damage, severe personal injury and even death. If you do not understand these instructions, please call De Nora Water Technologies for clarification before commencing any work at 215-997-4000 and ask for a Field Service Manager. De Nora Water Technologies, Inc. reserves the rights to make engineering refinements that may not be described herein. It is the responsibility of the installer to contact De Nora Water Technologies, Inc. for information that cannot be answered specifically by these instructions.

Any customer request to alter or reduce the design safeguards incorporated into De Nora Water Technologies equipment is conditioned on the customer absolving De Nora Water Technologies from any consequences of such a decision.

De Nora Water Technologies has developed the recommended installation, operating and maintenance procedures with careful attention to safety. In addition to instruction/operating manuals, all instructions given on labels or attached tags should be followed. Regardless of these efforts, it is not possible to eliminate all hazards from the equipment or foresee every possible hazard that may occur. It is the responsibility of the installer to ensure that the recommended installation instructions are followed. It is the responsibility of the user to ensure that the recommended operating and maintenance instructions are followed. De Nora Water Technologies, Inc. cannot be responsible for deviations from the recommended instructions that may result in a hazardous or unsafe condition.

De Nora Water Technologies, Inc. cannot be responsible for the overall system design of which our equipment may be an integral part of or any unauthorized modifications to the equipment made by any party other that De Nora Water Technologies, Inc.

De Nora Water Technologies, Inc. takes all reasonable precautions in packaging the equipment to prevent shipping damage. Carefully inspect each item and report damages immediately to the shipping agent involved for equipment shipped “F.O.B. Colmar” or to De Nora Water Technologies for equipment shipped “F.O.B Jobsite”. Do not install damaged equipment.

De Nora Water Technologies, COLMAR OPERATIONS COLMAR, PENNSYLVANIA, USA ISO 9001: 2008 CERTIFIED

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TABLE OF CONTENTS 2

1 INTRODUCTION.................................................................................................................4 1.1 General Description.................................................................................................4 1.2 Safety .....................................................................................................................4 1.3 Chlorine Probes, Cables Accessories and Consumables .......................................5 1.4 Technical Data / Specifications ...................................................................................5 1.5 Principle of Operation..................................................................................................7

2 INSTALLATION..................................................................................................................8

2.1 General....................................................................................................................8 2.2 Mounting Dimensions..............................................................................................8

2.3 Chlorine Probes.......................................................................................................9 2.4 Flow Cell................................................................................................................12

2.5 Flow Regulation Components ...............................................................................12 2.6 Electrical................................................................................................................14

3 STARTUP ....................................................................................................... 15 4 MAINTENANCE................................................................................................................15

4.1 Periodic functional Check......................................................................................15 4.2 Electrode Maintenance..........................................................................................15

4.2.1 Electrode Membrane .................................................................................15 4.2.2 Cleaning the electrode surfaces ................................................................15

5 TROUBLE SHOOTING PROCEDURE.............................................................................16 FIGURES 1 Chlorine Probe ..................................................................................................................... 4 2 Mounting Dimension ............................................................................................................ 8 3 Chlorine Probe Components.............................................................................................. 11 4 Arrangement, Piping, CL4000 Sensor ............................................................................... 13 5 Probe Cable Connections ................................................................................................. 14

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1 INTRODUCTION

1.1 General Description

This manual describes the general description, installation, operation and maintenance of the CL4000 Chlorine probes and accessories.

Chlorine is the most common chemical used in disinfection of municipal drinking water, cooling towers and many industrial applications. Once added to water the chlorine will react with chemicals already in the water forming combined chlorine or stay available as free chlorine.

A chlorine measuring system incorporating the CL4000 chlorine probes, connected to the MicroChem®2 transmitter, provides automatic measurement/control of chlorine dosage in such systems. The CL4000 chlorine probe measures free chlorine.

The transmitter is part of the MicroChem®2 series, which is capable of supporting up to three of the following measurements in all possible combinations: Dissolved Oxygen, Chlorine Dioxide, Residual Chlorine, Bromine, Ozone, ORP, Temperature, pH, Iodine and Conductivity. For a description and instructions regarding the transmitter see the MicroChem®2 transmitter instruction manual.

The chlorine probes are 3 electrode amperometric cells covered with a permeable membrane. The probe exterior is manufactured from a durable PVC and stainless steel and has a diameter of 25mm (1 inch). The probes are engineered to fit a specially designed flow cell.

De Nora Water Technologies chlorine probes can be used without the need for pH compensation.

All the CL4000 probes are designed to run without the need for reagents. The probes have no moving parts and are designed to require minimal maintenance.

Figure 1 - Chlorine Probe

1.2 Safety The recommended operating procedures have been designed with careful attention to safety. De Nora Water Technologies has made formal safety reviews of the initial design and any subsequent changes. This procedure is followed for all new products and covers areas in addition to those included in applicable safety standards.

Observe the following safety precautions: a. Observe all safety warnings marked on the equipment. These warnings identify areas of

immediate hazard, which could result in personal injury, or loss of life.b. Do not use this equipment for any purpose other than described in this manual.c. Disconnect power prior to making any terminal connections within the enclosure.d. Use the recommended connection procedures described in Section 2 of this manual.

This equipment should only be installed by suitably qualified personnel.

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1.3 Chlorine Probes, Cables, Accessories and Consumables

Chlorine Probe 0-2 ppm, pH tolerable 4.0 - 9.5 (Note 1,2) 23183 Chlorine Probe 0-5 ppm, pH tolerable 4.0 - 9.5 (Note 1,2) 23184 Chlorine Probe 0-10 ppm, pH tolerable 4.0 - 9.5 (Note 1,2) 23185

4 Foot Cable (Note 3) 78-4001 12 Foot Cable (Note 3) 78-4002 40 Cable (Note 3) 78-4003 Sample/Drain Tubing, CLEAR, 3/16” ID X 5/16” OD R-376 Flow Through Cell with integral shut off valve (Note 4) 23411 Flow Through Cell and Flow Control Kit (Note 4, 6) 23449 Sample Flow Control Kit (Note 7) 23318 Flow Control Panel Kit (Note 6) 23451 Y Strainer 80 mesh, Max Inlet 75 PSIG 22901 Pressure Reducing Valve Kit, 0-25 PSIG, Max Inlet 300 PSIG w/15 PSIG Gauge & Bracket 23425 Flow Meter Assembly w/Rate Valve, 0-10 GPH 23426 Flow Switch (Note 7) 22896 Carbon Dechlorinating Filter (Note 9) 23450 Annual Maintenance Kit for: 01-4030 and 01-4031 Probes Includes: PN 77-4005 and PN 94-2135 10-4001 23183, 23184, 23185, 01-4032 and 01-4033 Probes Includes: PN 77-4004 and PN 94-2136 10-4002 01-4034 and 01-4035 Probes Includes: PN 77-4004 and PN 94-2137 10-4003

M48 Membrane Cap to fit 23183, 23184, 23185, 01-4032, 01-4033, 01-4034 and 01-4035 Probes 77-4004 M20 Membrane Cap to fit 01-4030 and 01-4031 Probes 77-4005 G-Holder for 23183, 23184, 23185, 01-4032 and 01-4033 Probes 77-4017 Electrolyte Solution (100ml) for 01-4030 and 01-4031 Probes 94-2135 Electrolyte Solution (100ml) for 23183, 23184, 23185, 01-4032 and 01-4033 Probes 94-2136 Electrolyte Solution (100ml) for 01-4034 and 01-4035 Probes 94-2137

Notes: 1. The MicroChem2 Transmitter/Controller must be fitted with the expanded function board (P/N 1T686B129U12, U13 or U14)

in order to provide power to the probe and the software must be Version 2.8 or above. Consult factory on upgrading earlier versions of microchem2 transmitter/controllers to the latest revision.

2. 23183, 23184, and 23185, probes with 3-electrode sensor for the measurement of free available chlorine. Temperature compensated (0 to 40°C). pH tolerable within the operating range 4 to 9.5.

3. Cable 78-4001, 78-4002 or 78-4003 must be used for probe to function properly. 4. Flow cell 23411 includes a low pressure fitting (installed) and is also provided with a back pressure fitting to prevent the formation of air bubbles in the probe chamber at sample pressures of 6-8 PSIG (0.4-0.5 bar). 5. Flow Control Kit (P/N 23318) improves flow and pressure control of CL4000 probes. It includes a PRV Kit (P/N 23425), Flow Meter Assembly (P/N 23426), 10 ft of tubing and connectors. 6. The Flow Control Panel Kit (P/N 23451) (26" H X 28” W X 0.5" thick) is predrilled and tapped for mounting the Microchem2 and 2

acrylic flow cells for chlorine or for use with pH, conductivity, or ORP 12mm probes and is supplied with mounting hardware. 7. Flow Switch: dry contact opens on loss of sample flow. 8. Dechlorinating Filter provides a chlorine free sample stream, used for calibrating the MicroChem2.

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1.4 Technical Data / Specifications Quality Management System:

Range:

Type of measurement:

Temperature Compensation:

Speed of Response:

Ambient/sample Temp:

Limit of Detection:

Reproducibility:

Accuracy:

Sample Inlet Pressure:

Sample Temperature:

The design & manufacturing process of De Nora Water Technologies are certified to ISO9001.

0 - 2 mg/l, 0 -5 mg/l or 0 - 10 mg/l (probe dependant)

Free chlorine

Internal

Ninety (90)% step change < 2 minutes.

°32 F - 104 °F (0 °C - 40 °C) Probe, chlorine, 0-2 ppm : 0.01 ppm Probe, chlorine, 0-5 ppm : 0.03 ppm Probe, chlorine, 0-10 ppm : 0.05 ppm

0.05 mg/l

± 5% of range

0 to 8 psi (0 to .5 bar)

°32 F - 104 °F (0 °C - 40 °C)

Sample Flow: 8 gph (30 liters per hour)

Electrodes: Working Electrode - gold

Counter Electrode - stainless steel

Reference Electrode: Silver/Silver-Chloride

pH: Chlorine:independent of pH (pH 4 to pH 9.5) Signal loss is 5% per pH unit (pH greater than 7)

Dimensions: In flow cell: 14.6” (h) x 2.25” (dia) 370mm x 55 mm

Probe alone 1” (dia) x 9” (l), 25mm (dia) x 230mm (l)

Weight: probe and flow cell 1lb (450g)

Connectors: 2 x compression fitting for flexible tubing ID 3/16”, OD 5/16”

Cable: Various lengths available

Sample Limitations: Samples containing particles 100 microns (0.004 inches) in diameter and larger may require pre-filtration. There should be no surfactants in the water.

Ammonia Interference: CL4000 probes in the presence of ammonia will measure free and/or combined chlorine.

Permanganate Interference: 1 ppm permanganate = 0.5 ppm chlorine

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1.5 Principle of Operation The chlorine probes are amperometric cells covered with a permeable membrane. The probes are engineered to fit a specially designed flow cell. A sample of liquid is delivered to the input (bottom) of the flow cell at an approximate rate of 500 ml/min. The sample passes the membrane on the tip of the membrane cap. Chlorine diffuses through the membrane and into the internal filling solution where a small DC current is generated between the stainless steel counter electrode and gold working electrode in direct linear proportion to the amount of residual present in the sample. A third reference electrode establishes a constant potential on the gold working electrode to provide an accurate and stable residual signal. The signal is amplified and transmitted to the MicroChem®2 transmitter/controller via the sensor cable. The probe needs to be loop powered. This power is generated within the MicroChem®2 and supplied to the probe in the same cable which transmits the residual signal. All the CL4000 chlorine probes are designed to run without the need for reagents. The probes have no moving parts and are designed to require minimal maintenance.

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2 INSTALLATION 2.1 General

Remove the instrument from its box and carefully inspect each item and report damages immediately. The box will include the chlorine probe (electrode shaft, top cap and membrane cap), electrolyte bottle and a sheet of blue abrasive paper. The chlorine probes are designed for general duty indoor installation. Outdoor installation is possible if the instrument is shielded from dripping water and not mounted in direct sunlight. Ensure that the process and environmental conditions are within specified limits (see specification). Excessive heat and vibration will affect the sensors.

2.2 Mounting Dimensions

Figure 2 - Mounting Dimensions

Sample connectors are compression fitting, requiring flexible tubing 3/16” ID x 5/16” OD

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Vent holeVent Seal

2.3 Chlorine Probes

WARNING Do not touch the electrode finger (see Figure 3)

Do not touch the bottom of the membrane cap (see Figure 3)

To assemble the probes for use:

Fill the membrane cap to the top with electrode filling solution (note each electrode has a specially formulated filling solution which is unique to that sensor – see parts list for details). Tap the side of the membrane cap to remove any air bubbles that may have formed in the solution. Reposition the vent seal, making sure that the vent hole is completely covered.

Fill up the G-holder with filling solution. Be careful that there are no bubbles.

Hold the electrode shaft upright and push the electrode finger carefully into the filled G-holder.

While holding the electrode shaft vertically with the G-holder in place, screw the filled membrane cap back on to the electrode shaft. Make sure not to press on the vent ring seal or cover the area of the vent hole with a finger when installing the membrane cap. Excess filling solution will escape from top or the vent in the membrane cap. Rinse off any filling solution that may have escaped during the installation with clean water.

When removing the membrane cap, move the vent seal away from the vent hole to allow air into the membrane cap. Not doing so may cause a vacuum to form and damage the membrane.

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Note: The G-holder is supplied and required for use with the chlorine probes and with the annual maintenance kits containing the M48 membrane cap. See parts list for details.

Note: When unscrewing the filled membrane cap from the electrode shaft, first remove the vent seal and ensure that the vent is not covered by a finger (air needs to be allowed through the vent hole to equalize the pressure). Note: Make sure the membrane cap is tightly fastened to the electrode shaft ensuring that no gap remains between the electrode shaft and the membrane cap. Note: It is best to wait 1 - 4 hours before the first calibration is performed. After one day repeat the calibration. See the MicroChem®2 electronics manual for calibration instructions. Note: Calibration must be made with a continuous flow of liquid at 500 mL/min across the cell membrane.

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Figure 3 - Chlorine Probe Components.

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2.4 Flow Cell The probe is inserted through a fitting which includes a slide ring and o-ring. Loosen or disassemble the fitting to allow the probe to slide through the o-ring. The fitting may include a cap through which the probe cable must be fed. Position the probe so it is about 1 inch (25 mm) from the bottom of the cell. Tighten the fitting into the housing to compress the o-ring around the probe, providing a seal.

The inlet valve may be used to provide control the flow to the probe. It should be full open if the sample stream is controlled by other components.

The adapter to be used on the outlet from the cell and is dependent on the sample supply. The sample flow as noted in the section 1.4 is required. Excessive air in the sample may adversely affect the readings. The small orifice adapter may be used to provide back pressure to keep the air from outgasing from the sample stream.

2.5 Flow Regulation Components (See Figure 4) To provide a sample to be measured for chlorine content with reduced potential for erratic readings and calibration problems, it is highly recommended that some or all of the components in Figure 4 are incorporated in the sample line. The Y-strainer is for particulate removal. The flow switch provides alarm when flow is not present. The remaining components through the back pressure assembly will ensure that you are providing the proper flow and pressure to allow optimum analysis. The back pressure assembly is used in applications where air bubbles effervesce from the sample.

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Figure 4 – Arrangement, Piping, CL4000 Sensor

Key Part Number Description 1 22901 Y-strainer - (optional) for particulate removal 2 22832 (See Note 1) Pressure Reducing Valve, 0-25 PSIG 3 23101 (See Note 1) Pressure Gauge, 0-15 PSIG, ¼” NPT SS 4 22834 (See Note 1) Flowmeter with Rate Valve, 0-10 GPH 5 22896 (See Note 2) Flow Switch 6 23411 CL4000 Flow Cell 9 23102 Fitting, ¼ MNPT x 5/16 Tube 10 23104 Fitting, 1/8 MNPT x 5/16 Tube 90 Deg Notes: 1. Included in Flow Control Kit P/N 23068 2. Used to indicate if sample flow is present. For connection to external device or alarm contact.

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(+)

(-)

(6)

(5)

2.6 Electrical

The chlorine probes are connected to the transmitter analog board at pin 5 and 6 AND to the 24v power supply terminals (see Figure 5). For more details on the analog board see the transmitter manual.

WARNING The transmitter power MUST be switched OFF before the probe is attached.

Figure 5 - Probe Cable Connections

WARNING For proper operation of the chlorine probe, one of the above listed cable

Assemblies must be used.

Terminals 9-12 are +24v Terminals 13-16 are 0V

- +probe

S4000 Cable Assembly 4 feet 78-4001 12 feet 78-4002 40 feet 78-4003

(G)

1 2 3 4

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3 STARTUP

1. Check that the entire installation is connected properly. Check the electrode is properly connected via the supplied cable. 2. Configure the transmitter channel that the probe is connected to for CL (Chlorine). Select CL probe (mA) as the probe type. Set the probe range (0-2, 0-5 or 0-10 ppm) as indicated on the chlorine probe label. Refer to the MicroChem®2 Transmitter instruction manual for additional start-up information. 3. A calibration must be performed. Please find the instructions related to the procedure in the MicroChem®2 instruction bulletin. 4. Output from CL4000 probes is never below 3.8 mA. At start-up, the probes may have an

output as low as 2 to 2.5 mA, but will rise to about 4 mA after half an hour. If output is less, the electrolyte will need to be changed and the gold probe cleaned. Momentary power losses will also result in low output, but will increase in about 30 minutes.

4 MAINTENANCE 4.1 Periodic Functional Check

The MicroChem®2 analyzer, like other analyzers, should be checked once per week to assure the best measurement accuracy.

4.2 Electrode Maintenance

There is very little maintenance required on a chlorine electrode. Periodically the electrode should be removed, and rinsed with de-ionised water.

CAUTION Do not touch the tip of the electrode.

4.2.1 Electrode Membrane

The membrane cap needs to be replaced periodically (typically annually). The internal filling solution needs to be replaced at the same time (section 2.3) Note: pay particular attention to the notes on removing the membrane cap. If the membrane gets coated it is possible to clean it. Very carefully swirl the membrane in a 1% hydrochloric acid solution.

4.2.2 Cleaning the electrode surfaces

If the electrode has been stored for a long period of time the (gold) working electrode surface may become tarnished and require polishing. Empty out the internal filling solution – (section 2.3). Dry the electrode finger carefully using a clean dry cloth .Holding the blue abrasive paper flat on a clean dry surface and holding the electrode body vertically move the tip of the electrode across the paper two or three times. Refill and reattach the membrane cap. (see section 2.3)

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5 TROUBLE SHOOTING PROCEDURE

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION No indication No power supply to the transmitter Power the transmitter up or check the

power supply fuse. Check power supply jumper setting.

Faulty transmitter Verify transmitter (especially analogue board)

The sensor is not continuously in contact with the sample

Modify sensor installation

The connection between the sensor and the transmitter is not correct.

Make correct connections

Membrane is split or coated; internal filling solution contaminated or depleted

Replace membrane and filling solution

The working electrode may be tarnished

Clean the electrode surface

The chlorine cell has been selected rather than the chlorine probe. (RT Fault will be displayed with this error)

Reprogram the transmitter software

Reading on Display is not in agreement with the chlorine level present in the sample

The wrong chlorine range has been set up

Reprogram the transmitter software

Not properly calibrated Recalibrate P2

Chlorine level is fluctuating Check the process Sample flow rate is too low or variable

Resolve flow problems. Add Pressure Regulator and Flow meter for sample control.

The sensor is not continuously in contact with the sample

Modify sensor installation

Reading on Display is fluctuating or erratic

Air bubbles in the sample Eliminate the air bubbles or modify the installation

“RTD” Fault displayed Incorrect chlorine channel definition – Wrong chlorine input selected

Refer to transmitter instruction manual. Select chlorine probe channel definition.

Design improvements may be made without notice.

Represented By:

SEP 2015

De Nora Water Technologies Arley Drive Birch Coppice Business Park Dordon, Tamworth B78 1SA Tel +44 (0) 182 726 6000 Fax +44 (0) 182 726 6099

De Nora Water Technologies

3000 Advance Lane Colmar, PA 18915

ph +1 215 997 4000 • fax +1 215 997 4062

web: www.denora.com

mail: info.dnwt@denora.com

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