ECD FCA-22 Manuel utilisateur

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FCA‐22InstructionManual

FreeChlorineAnalyzer/Controller

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The information and technical data disclosed in this document may be used and disseminated only for the purposes and to the

extent specifically authorized in writing by Electro-Chemical Devices. Electro-Chemical Devices reserves the right to change

published specifications and designs without prior notice. Part No. 33FCA-22 Revision A A/05-08

FCA‐22InstructionManual

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TableofContents

GeneralDescription

ProductDrawing3

Applications4

Components4

HowitWorks4

InfluencesontheMeasurement

pHValue5

Flowrate6

Temperature6

InstallationandStartUp

GeneralInformation7

Samplerequirements7

MountingandPlumbing7

PoweringtheC‐227

InstallingtheSensors7

StartUp8

Calibration

TemperatureSensor8

pHSensor9

ChlorineSensor10

CommissioningOutputs

4‐20mAoutput12

Assigning&SettingRelays14

Maintenance

FreeChlorineSensor(FCS)18

pHSensor19

ConstantHeadFlowController19

Troubleshooting

TroubleshootingGuide20

Specifications

ProductSpecifications22

SpareParts23

Warranty

Warrantyandservice23

FCA‐22InstructionManual

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Page3

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GeneralDescription

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FCA‐22Components(fromLefttoRight)

ConstantHeadFlowController

FreeChlorineSensorinFlowCell

pHSensorinFlowCell

C‐22Analyzer/Controller

Part#ModelandProductDescription

1290020‐1FreeChlorineAnalyzer,withautomaticpHcompensation,completeassembly,

panelmountedwithC‐22transmitter/controller

1290020‐2FreeChlorineAnalyzer,withmanualpHcompensation,completeassembly,panel

mountedwithC‐22transmitter/controller

FCA‐22InstructionManual

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Page4 

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GeneralDescription

Application

TheFCA‐22isdesignedforuseindrinkingwater,industrialcoolingandrinsewaterorothersamplesof

freshwaterthatusechlorineintherangeof0‐20ppmasadisinfectant.ChlorineexistsinwaterasapH

dependentmixtureofhypochlorousacidandhypochloriteion.Thesumofthesetwocomponentsis

referredtoasFreeChlorine,sometimesResidualFreeChlorine.

Organicchlorinecompoundsandchloramines,BoundChlorine,arenotdetectedbytheFCA‐22.Other

measurementtechniquesarerequiredforsamplescontainingtheseboundchlorinechemicals.Bound

ChlorineplusFreeChlorineequalsTotalChlorine.TheFCA‐22doesnotmeasureTotalChlorine.

Parts

TheFCA‐22isacompletesystemformeasuringFreeChlorine.Thepanelmountedsystemincludesa

ConstantHeadFlowController(CHFC),FreeChlorinesensor(FCS)andFlowCell,pHsensor(PHS10)and

FlowCellandtheC22Analyzer.SimplysupplypowertotheC22Analyzerandplumbthesamplelinein

andthedrainlineoutandtheFCA‐22isreadytouse.

Howitworks

TheFreeChlorineSensor(FCS)isanamperometricsensorwithaPTFEmembrane,goldcathodeanda

silver/silverchlorideanode.

TheC22analyzerappliesafixedvoltageacrosstheelectrodesandmeasuresthecurrentflow.

Hypochlorousacid(HOCl)diffusesthroughthePTFEmembraneandisreduced(gainselectrons)bythe

goldcathodetochlorideion.Silverontheanodeisoxidized(donateselectrons)tosilverchloride

completingthecurrentloop.Withstabletemperatureandsampleflow,thecurrentflowisproportional

tothefreechlorineconcentration.

Manycompetitivechlorinesensorsrequireserviceonamonthlyorbimonthlybasis.TheFCSusesalarge

surfaceareaanode,combinedwithalargevolumeofelectrolyteandasmallcathodetoprovide

operationalcyclesofuptoayearwithoutrefilling.ThereplaceablePTFEmembraneisalsodesignedfor

longtermstability.Aspecialsupportgridmaintainsaconstanttensionbetweenmembraneandthe

cathodeminimizingeffectscausedbyvaryingpressuresandflow.ReplacingthePTFEmembraneand

rechargingtheelectrolyteiseasilyaccomplishedwithouttheuseoftools.

TheCHFCmaintainsaconstantsampleflowtothepHandChlorineflowcells.Pressure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.

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FCA‐22InstructionManual

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InfluencesontheMeasurement

pHValue

TheFCSonlymeasurestheHOClcomponentofthetotalFreeChlorine.TheHOClproportionvariesfrom

100%atpH5.5to0%atpH10,seeFigure2.1.ThePHS10pHsensorprovidesautomaticcompensation

forthepHdependentratioofHOClandOCl‐presentinthewater.

ThePTFEmembranerejectschargedionsallowingonlyneutralmoleculestopassthrough.Saltsand

otherionicsubstancesareblockedbythemembraneeliminatinganyinfluenceonthemeasurementby

changesintheconductivityofthesample.TheHOClportionofthefreechlorinepassesthroughthe

membranetothecathodeandismeasuredwhilethenegativelychargedhypochloriteion,OCl‐,portion

isrejectedbythemembrane.TheC‐22analyzerusesthepHfromthePHS10sensortocalculatetheOCl‐

value.ThemeasuredvalueandthecalculatedvaluearecombinedanddisplayedasFreeChlorine.

TheDPDcalibrationmethodmeasurestheTotalChlorinebybufferingthesampletopH6.3,thereby

convertingtheentireamountofchlorinetoHOClandthenmeasuringthisHOClcomponent.ThepH

compensationalgorithmintheC‐22isdesignedtomatchthismethod.Thehighestaccuracyisattained

withcalibrationsperformedatneutralpHvaluesandhigherchlorineconcentrations.Theaccuracyof

thecompensationdecreaseswhenthepHisabovepH8sincethereislittlechlorinetomeasureanda

largecompensationtoperform.

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Figure2.1

Flow

TheFCSconsumeschlorinetoproducethesignal.Theareanearthesensingtipwillbecomedepletedof

chlorinewithoutadequateflowtoreplenishthesample.Thesensorrequiresaminimumvelocityof0.5

ft/secpastthemembrane.Belowthisvaluethesensorwillindicatealowerconcentrationthanthe

actualvalue.Higherflowrateshavelittletonoeffectonthemeasurement.SeeFigure2.2.

100

46810

pHEffects

%HOCl

%OCl

FCA‐22InstructionManual

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Page6

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Figure2.2

Temperature

TemperaturevariationinfluencestheFCSbychangingthepermeabilityofthePTFEmembraneandthe

Nernstianresponseofthesensor.Combinedthesechangesaccountforachangeof4%/C°.Thechange

followsthetemperature,asthetemperatureincreasestheoutputofthesensorincreases,asthe

temperaturedropstheoutputdrops.TheFCA‐22automaticallycompensatesforthechanges.The

temperaturesensorislocatedinthepH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.Calibrationshouldbedoneclosetotheprocesstemperatureforthehighestaccuracy.See

fig.2.3.

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Figure2.3

100

0 102030

%output

Flowrate,gal/hr

FCAFlowdependence

0204060

mV/ppm

Cl2

TemperatureC°

FCATemperature

Dependence,4%/C°

FCA‐22InstructionManual

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Page7

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InstallationandStartUp

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GeneralInformation

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MounttheFCA‐22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FCA‐22issuitableforoutdooruseif

mountedwithaprotectivecoverorsunshield.

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SampleRequirements

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Theconstantheadflowcontrollercanadapttochangingsampleflowsbetween10and80gal/hr

(40‐300L/hr).

Minimumflow:10gal/hr(38L/hr)

SamplePressure:1to30psig(0.1‐2bar)

Temperature:32°to122°F(0°to50°C)

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MountingandConnectingtheInletandDrainfittings

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TheFCA‐22isintendedforwallmountingonly.Thesensorsinsertintotheflowcellsasshowninthe

figures.A¼”barbedfittingisprovidedforthesampleinlet.Ifdesired,a¼”compressionfittingcanbe

used.Thesampleinletis¼”FNPT.Thesampledrainsthroughthe¾”FNPTholeatthebottomofthe

CHFD.Attacha¾”fittingtoalengthofsofttubingandallowthewastetodraintoopenatmosphere.Do

notrestrictthedrainline.Thesamplecanbeintroducedafterthesensorshavebeencalibratedand

installedintheflowcells.

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PoweringtheC‐22

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AttachpowerasdescribedintheC‐22manual.Tightenthecableglandsprovideagoodsealtothe

cable.

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InstallingtheSensors

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TheFCA‐22issuppliedwiththesensorcablespre‐wiredtotheanalyzer.TheFCA‐22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)

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ThepHsensormountsintheFlowCellusingthesupplied¾”compressionglandfitting.Removethe

protectivecapandsaveitforfutureuse,thecapcontainsapotassiumchloridesolutionusecarewhen

removingthecapfromthesensor.Loosenthecompressionfittingtoallowthesensortospinfreelyin

thefitting.Insertthesensorintotheflowcellandhandtightentheglandfitting.RetractthepHsensor

approximately½”fromthebottomoftheflowcellandhandtightenthecompressionnuttofixits

position.TheChlorinesensorisheldintheflowcellwithaunionnut.Removetheprotectivecapand

saveitforfutureuse.Slidethesensorintotheflowcellandhandtightentheknurlednut.

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FCA‐22InstructionManual

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Page8

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StartUp



Supplysampleflowtothesystem.Adjustthesampleflowuntilthewaterisoverflowingintothecentral

overflowtube.Athigherflowratestheexcesswaterwilloverflowdownthedrain.Aminimumflowof

10gal/minisrequiredtomaintaintheoverflowcondition.Verifythesampleflowispassingthrough

bothflowcellsandreturningtothedrain.TheChlorineSensorrequires1‐1½hoursofpolarizationby

theinstrumentbeforeaccuratemeasurementscanbemade.Allowthesystemtorunatleast1hour

beforeproceedingtotheChlorineSensorcalibrationbelow.



Calibration



TemperatureCalibration



TheTemperaturesensorinsidethePHS10sensorwascalibratedatthefactorybeforeshipping.Verify

thedisplayedtemperatureagreeswiththeactualtemperature.Ifthevaluedeviatesbymorethan2°C

thenadjusttheTemperatureTrimintheConfiguration&TrimMenutothecorrectvalue.Foradetailed

descriptionseeTemperatureCalibrationintheC‐22manual.



TemperatureCalibrationScreenShots



#1EntertheConfigure/

TrimMenu

ScrolltotheConfigure

MenuusingtheMENU

SELECTkeyandenterthe

Menubysimultaneously

pressingbothHorizontal

CALIBRATEkeys.

#2Scrollthroughthe

PasswordsScreen

PresstheMENUSELECT

downKeyfourtimesto

thenextscreen.



#3Scrollthroughthe

RelayAssignScreen

PresstheMENUSELECT

downKeyfourtimesto

thenextscreen.



#4Choose°C/°F&temp

cal

SelecttheMenuby

Simultaneouslypressing

bothHorizontal

CALIBRATEkeys.



#5ChoosetheTrim°C

Menu

SelecttheMenuby

Simultaneouslypressing

bothHorizontal

CALIBRATEkeys.



#6AdjusttheTrimto

calibrate

thereading

Usingthevertical

CALIBRATEkeysadjust

thetrimtochangethe

Displayedtemperature



FCA‐22InstructionManual



Page9



#7Acceptthecalibration

PresstheMENUSELECT

downkeytoacceptthe

newvalue



#8ReturntoHome

Screen

PresstheCALIBRATE

downkeytoreturntothe

HomeScreen.



pHCalibration



ThePHS10pHsensorwascalibratedwithpH7.0andpH10.0buffersatthefactorybeforeshipping.

VerifythedisplayedpHagreeswiththeactualpH.IfthepHvaluedeviatesbymorethan0.2pHthen

adjustthevalueintheBuffer:#1pH:MenubysettingtheexistingpH7valuetotheactualsamplevalue

andthenacceptingthecalibration.ForadetaileddescriptionseeElectrodeStandardizationintheC‐22

manual.



pHCalibrationScreenShots



Calibration2point

(Zeropt.andSlope)

#1HomeScreen

PressMenuSelect

Upbutton



#2SelectionMenu

StatusScreen

PressMenuSelect

Upbutton



#3SelectionMenu

SetUpScreen

PressMenuSelect

Upbutton



#4SelectionMenu

BufferScreen

(calibration)

SelectBUFFERby

simultaneouslypressing

thehorizontalCALIBRATE

keys.



#5ZeroPointCalibration

Initiatethecalibrationby

simultaneouslypressing

thehorizontalCALIBRATE

keyswiththesensorina

7.00pHsolution,or…



#5aStandardizetothe

SamplepHvalue

Adjustthedisplayedvalue

toagreewiththesample

valueusingtheCALIBRATE

keys



FCA‐22InstructionManual



Page10



#6AccepttheCalibration

Acceptthecalibrationby

pressingtheMenuSelect

downkey.CalmVindicates

thesensorsoutputin7

buffer.



#7MovetoSecondBuffer

PressMenuSelect

Downbuttontwice.



#8SlopeCalibration

Initiatethecalibrationby

simultaneouslypressing

thehorizontalCALIBRATE

keyswiththesensorina

10.00pHsolutionoradjust

toadifferentbuffer.



#9AdjustBufferValue

Usethehorizontal

CALIBRATEkeytoselectthe

digittobeadjusted.



#10AdjustBufferValue

UsetheverticalCALIBRATE

keytoadjustthevalueand

thenusethehorizontal

CALIBRATEkeytoselect

thenextdigittobe

adjusted.



#11AdjustBufferValue

UsetheverticalCALIBRATE

keytoadjustthevalue



#12Acceptthe

Calibration

AccepttheCalibration

whentheCalValueis

stableforgreaterthan30

seconds.PressMenu

SelectDownbuttonto

accepttheCalibration.



#13ReturntotheHome

Screen

LeavetheCalibration

Screenandreturntothe

HomeScreenbypressing

theCALIBRATEdownkey.





ChlorineCalibration



TheFreeChlorineSensor(FCS)zeropointandtheslope(sensitivity)werecalibratedatthefactory

beforeshipping.AllowtheFCA‐22systemtorunforatleast1hourbeforeproceedingwiththe

calibrationcheck.Thispolarizationtimeisnecessaryforstablereadingsandanaccuratezeropotential.

Verifythedisplayedchlorineconcentrationagreeswiththeactualvalue.Iffurthercalibrationis

necessaryverifythetemperatureandpHreadingsarevalidbeforebeginningthestandardizing

procedure.



Theprimarycalibrationisanadjustmentoftheslopeofthesensor,mV/ppmCl

.TheamperometricFCS

generatesanAcurrentproportionaltothechlorineconcentrationwhichissenttothechlorineinput

card.ThechlorineinputcardsendsamillivoltsignaltotheC‐22proportionaltothechlorine

concentration.



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