Rosemount 450 Free Residual Chlorine Sensor Owner's manual

Brand: Rosemount

Model: 450 Free Residual Chlorine Sensor

Type: Owner's manual

Model 450

Free Residual Chlorine Sensor Assembly

Instruction Manual

PN 51-450/rev.B

March 2006

CAUTION

SENSOR/PROCESS

APPLICATION COMPATIBILITY

The wetted sensor materials may not

be compatible with process com-

position and operating conditions.

Application compatibility is entirely the

responsibility of the user.

DANGER

HAZARDOUS

AREA INSTALLATION

Installations near flammable liquids or in haz-

ardous area locations must be carefully eval-

uated by qualified on site safety personnel.

This sensor is not

Intrinsically Safe or

Explosion Proof.

To secure and maintain an intrinsically safe

installation, the certified safety barrier,

transmitter, and sensor combination must

be used. The installation system must com-

ply with the governing approval agency (FM,

CSA or BASEEFA/CENELEC) hazardous

area classification requirements. Consult

your analyzer/transmitter instruction manual

for details.

Proper installation, operation and servicing

of this sensor in a Hazardous Area Instal-

lation is entirely the responsibility of the user.

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PRO-

CEEDING!

Rosemount Analytical designs, manufactures, and tests its

products to meet many national and international stan-

dards. Because these instruments are sophisticated tech-

nical products, you must properly install, use, and maintain

them to ensure they continue to operate within their normal

specifications. The following instructions must be adhered

to and integrated into your safety program when installing,

using, and maintaining Rosemount Analytical products.

Failure to follow the proper instructions may cause any one

of the following situations to occur: Loss of life; personal

injury; property damage; damage to this instrument; and

warranty invalidation.

• Read all instructions prior to installing, operating, and

servicing the product. If this Instruction Manual is not the

correct manual, telephone 1-800-654-7768 and the

requested manual will be provided. Save this Instruction

Manual for future reference.

• If you do not understand any of the instructions, contact

your Rosemount representative for clarification.

• Follow all warnings, cautions, and instructions marked

on and supplied with the product.

• Inform and educate your personnel in the proper instal-

lation, operation, and maintenance of the product.

• Install your equipment as specified in the Installation

Instructions of the appropriate Instruction Manual and

per applicable local and national codes. Connect all

products to the proper electrical and pressure sources.

• To ensure proper performance, use qualified personnel

to install, operate, update, program, and maintain the

product.

• When replacement parts are required, ensure that qual-

ified people use replacement parts specified by

Rosemount. Unauthorized parts and procedures can

affect the product’s performance and place the safe

operation of your process at risk. Look alike substitu-

tions may result in fire, electrical hazards, or improper

operation.

• Ensure that all equipment doors are closed and protec-

tive covers are in place, except when maintenance is

being performed by qualified persons, to prevent electri-

cal shock and personal injury.

Emerson Process Management

Liquid Division

2400 Barranca Parkway

Irvine, CA 92606 USA

Tel: (949) 757-8500

Fax: (949) 474-7250

http://www.RAuniloc.com

MODEL 450 TABLE OF CONTENTS

MODEL 450

FREE RESIDUAL CHLORINE SENSOR

TABLE OF CONTENTS

Section Title Page

1.0 DESCRIPTION AND SPECIFICATIONS ................................................................ 1

1.1 Features and Applications ....................................................................................... 1

1.2 Specifications........................................................................................................... 1

1.3 Ordering Information................................................................................................ 2

2.0 INSTALLATION....................................................................................................... 3

2.1 General.................................................................................................................... 3

2.2 Inspection and Unpacking ....................................................................................... 3

2.3 Application Requirements........................................................................................ 3

2.4 Preparation for Installation and Startup ................................................................... 3

2.5 Installation................................................................................................................ 4

3.0 TROUBLESHOOTING ............................................................................................ 6

3.1 General.................................................................................................................... 6

3.2 Troubleshooting the Model 450 Sensor .................................................................. 6

4.0 MAINTENANCE ...................................................................................................... 9

4.1 General.................................................................................................................... 9

4.2 Scheduled Preventative Maintenance..................................................................... 9

4.3 Sensor Disassembly, Rebuild and Assembly Procedure ........................................ 9

5.0 PARTS LISTS ......................................................................................................... 11

6.0 RETURN OF MATERIAL ........................................................................................ 15

MODEL 450 TABLE OF CONTENTS

MODEL 450

FREE RESIDUAL CHLORINE SENSOR

LIST OF FIGURES

Figure Title Page

1-1 Model 450 Dimensional Data 2

2-1 Model 450-01 and 450-02 Sensor Installation Diagrams 4

2-2 Handrail Mounting Installation for Model 450-03 and 450-04 Sensor Assemblies 5

5-1 Models 450-01 and 450-02 Free Residual Chlorine Flow Through Sensors 11

5-2 Model 450-03 Free Residual Chlorine Submersion Sensor 12

5-3 Model 450-04 Free Residual Chlorine Submersion Sensor/Agitator 13

5-4 Model 450 Free Residual Chlorine Sensor Assembly 14

LIST OF TABLES

Table Title Page

3-1 Temperature Resistance Chart 7

3-2 Model 1054A TFC Quick Troubleshooting Chart 8

MODEL 450 SECTION 1.0

DESCRIPTION AND SPECIFICATIONS

SECTION 1.0

DESCRIPTION AND SPECIFICATIONS

1.1 FEATURES AND APPLICATIONS

The Rosemount Analytical Model 450 Free Residual

Chlorine Sensor, used with the Model 1054A Total

Free Chlorine Analyzer and the Models 1181 or 853

free residual chlorine analyzer/transmitter, measures

the free residual chlorine level in a wide variety of

applications, such as: Potable water treatment,

sewage plant effluent, cooling tower chlorination con-

trol, swimming pools, and industrial waste treatment

plant effluent.

The Model 450 sensor is constructed of PVC with

polymer membrane, hardwood liquid junction*, and

stainless steel hardware. The sensor is designed for

flow (Codes 01 and 02), submersion in a flowing sam-

ple (Code 03), and submersion in a stagnant pond

(Code 04). All sensors are furnished with an integral

20-foot cable. The Code Option 04 incorporates an

agitator and impeller, with a 20-foot power cord, for

agitation of a stagnant solution so a fresh sample is

always present at the sensor membrane in submer-

sion applications.

The membrane retainer** is designed for ease of

installation, and provides adequate tension on the

membrane to insure an accurate measurement. In

addition, the electrolyte chamber incorporates a pres-

sure compensator to maintain equal pressure on both

sides of the membrane, despite sample pressure

changes. A thermistor or an RTD for automatic tem-

perature compensation is incorporated in the tip of the

sensor to adjust for temperature change effects on the

diffusion rate of free residual chlorine across the

membrane.

The sensor requires very little maintenance and

requires no special tools or fixtures.

1.2 SPECIFICATIONS

Temperature: 0 to 50°C (32 to 122°F)

Pressure: 0 to 345 kPa abs (0 to 50 psig)

Material: Housing: PVC

Hardware: Stainless steel

Liquid Junction: Hardwood

O-Rings: Buna-N

Membrane: Polymer

Cathode: Gold

Anode: Silver

Minimum Sample Flow Rate:

Code 01 & 02: 0.13 liter/sec (2 GPM)

Code 03: 0.3 meter/sec (1 ft/sec)

Code 04: None

Agitator Power Requirement:

(Model Code 04 only): 115 VAC ±10% 60Hz (0.2

amp)

Weight/Shipping Weight:

Code 01, 02 & 03: 0.9 kg/1.8 kg (2lbs/4 lbs)

Code 04: 2.3 kg/3.2 kg (5 lbs/7lbs)

• ELIMINATES THE NEED FOR WET CHEMICAL ANALYSIS.

• LOW MAINTENANCE with up to 12 months between rechargings.

• THREE CONFIGURATIONS AVAILABLE to meet most applications.

• COMPACT DESIGN provides for ease of installation and service.

*U.S. Patent No. 4,187,162

**U.S. Patent No. 3,887,194

Canadian Patent No. 1,025,496

MODEL 450 SECTION 1.0

DESCRIPTION AND SPECIFICATIONS

1.3 ORDERING INFORMATION

Model 450 Free Residual Chlorine Sensor Includes PVC sensor housing with integral chlorine permeable

membrane and temperature compensator.

MODEL

450 FREE RESIDUAL CHLORINE SENSOR (3 lbs./1.5 kg)

CODE MOUNTING HARDWARE

01 1-1/2 inch PVC cell, 90° flow

02 1-1/2 inch PVC cell, 180° flow

03 PVC union with 3/4 inch FNPT for submersion service

04 PVC union with 1 inch FNPT, and agitator with 20-ft. cable for submersions. Agitator motor requires 115 VAC power only.

450 01 17 EXAMPLE

CODE OPTIONS

11 Stainless steel tags (specify marking)

14 Handrail mounting bracket (P/N 1000857) for use with J-box (see Code 17 below)

15 Handrail mounting bracket (P/N 1000856) for use with Model 803

17 Weatherproof NEMA 4X junction box (P/N 22719-02)

54 For use with Models 1054A TFC

NOTE: Recommended cable from sensor to transmitter is Belden 8434 or equivalent, available from Rosemount Analytical (P/N 9200074).

Specify length.

FIGURE 1-1. MODEL 450 DIMENSIONAL DATA

*CODE 02 SAME AS CODE 01 EXCEPT SENSOR MOUNTED IN TOP OF TEE, WITH FLOW IN EITHER DIRECTION

MODEL 450 SECTION 2.0

INSTALLATION

SECTION 2.0

INSTALLATION

2.1 GENERAL. This section provides installation

instructions for the Model 450 Sensor Assembly.

2.2 INSPECTION AND UNPACKING. Inspect the ship-

ping container for any evidence of damage. If damage

is evident, notify the carrier immediately. If no damage

is evident, open the container and inspect the sensor.

Save the container for shipment to the factory for serv-

ice.

2.3 APPLICATION REQUIREMENTS. The Model 450

is designed for typical clean water application. It is

NOT designed for the following:

Processes containing ammonia (municipal waste water).

2. Processes containing sea water or bromine chem-

ical additions.

3. Low conductivity processes, less than 50 micro-

siemens (reverse osmosis).

4. Post-dechlorination processes (example: after

adding sodium bisulfite).

2.4 SENSOR PREPARATION FOR INSTALLATION

AND START-UP. The plumbing fittings provided on the

Model 450 Sensor differ slightly, depending on the piping

requirements. However, the main body, or chlorine sens-

ing portion of each of the different codes, is identical. Each

sensor is shipped from the factory dry and without a

membrane installed. The recharge kit which accompa-

nies the sensor contains one bottle of dry electrolyte and

five membranes. The sensor should be charged utilizing

the following procedure:

CAUTION

Clean rubber gloves should be worn during

sensor preparation and maintenance to

avoid skin contact and contaminating the

membrane and cathode.

1. Prepare sensor electrolyte by filling the bottle of

crystals supplied with the recharge kit (Ag Cl/KCI)

to the neck with distilled or deionized water. Stir or

shake to wet crystals thoroughly. Some crystals

should remain undissolved.

NOTE

Please see Figure 5-4 for Model 450 Free

Residual Sensor assembly exploded view.

2. Remove sensor “cover” and membrane “Retainer”

(remove 6 screws at sensor tip).

3. Sand the gold cathode with the 400 grit sandpa-

per, in one direction only

until it is shiny. Rinse

cathode with clean water.

4. Remove the fill-plug.

5. Fill the syringe (included in the recharge kit) with

the AgCl/KCl electrolyte solution. Fill the sensor

body with the electrolyte, shaking the sensor to

remove air. Ensure that about 1 cc (or 1 ml) of

crystals get inside the sensor body.

6. Install the fill plug (wrapped with one or two turns

of TEFLON

®1

tape in the side of the sensor. As the

plug is screwed into place, electrolyte will be

forced through the wood junction. This is impor-

tant, since the electrical continuity will not be

established unless the wood junction is thorough-

ly wetted.

Continue to screw the fill plug into place until it is flush

with the sensor body. Do not remove excess electrolyte

from the end of the sensor because it will wet the mem-

brane and help hold it in place during installation.

7. Place the O-ring in the groove and press it into posi-

tion around the wood junction. If there is no solution

remaining over the gold cathode after installing the O-

ring, add a few drops of electrolyte (no crystals).

IMPORTANT: No crystals underneath the mem-

brane or damage will occur.

8. Place the white-opaque “membrane” on top of the

cathode. Place the white-translucent “protector”

over the membrane. DO NOT use the blue-paper

protective separators found in the membrane kit!

9. Lay the membrane “retainer” over the membrane

and protector. Screw down the (6) screws applying

even pressure. The membrane should be taut, not

spongy, when the retainer is secure.

10. Keep the sensor tip in water if installation is delayed

over an hour. Membrane may adhere to the cath-

ode if allowed to dry out.

11. Sensor requires approximately (2) hours to polar-

ize and (12-24) hours to obtain a stable zero in

chlorine-free water.

NOTE

Water should be agitated for zeroing and

spanning (magnetic stirrer is recommended)

CAUTION

Insufficient zeroing time may cause diffi-

culties in calibration and readings that

drift.

Reg. U.S. Pat. Office for DuPont's fluorocarbon resins

MODEL 450 SECTION 2.0

INSTALLATION

12. Chlorine concentrations of 1 PPM or above are rec-

ommended for the most accurate chlorine calibration.

IMPORTANT: Process flow requirement is 1 ft./sec.

or if in a “Tee” 2.0-5.0 gal./min. If unable to adjust

process chlorine concentration to this level, perform

calibration in a beaker with a magnetic stirrer for agi-

tation. Adding a drop or two of chlorine bleach to

deionized water (buffered to 7 pH) will create a chlo-

rine residual.

13. Calibrate the chlorine reading to the titrated value

of the process or the chlorine residual sample.

14. The sensor is now ready to be installed.

2.5 INSTALLATION.

2.5.1 Mechanical Installation.

1. Model 450-01 and 450-02 Sensor Assemblies.

These sensors are available in two configurations:

Angle flow (Code 01) and straight flow (Code 02).

The PVC tee is for plumbing into 1-1/2 inch PVC

(SCH 80) tubing. Direction of flow should be as

shown in Figure 2-1.

2. Models 450-03 and 450-04 Sensor Assemblies.

These sensors are for submersion applications. If a

handrail mounting bracket (Code 14) is to be used,

refer to Figure 2-2 for installation details. The Model

450-03 Sensor Assembly should be installed in a

stream having a minimum flow of 1.5 ft./sec. to

obtain rated response time. Attach the union adapter

to a 3/4 inch FPT PVC (SCH 80) tube or metal pipe.

If PVC to metal connection is made, use RTV sili-

cone rubber adhesive/sealant (Rosemount

Analytical P/N 9220106 or 9220018). Check the con-

nection frequently for looseness, until no more loose-

ness is observed. The sensor may be submerged to

a depth of up to 6.1 meters (20 feet).

CAUTION

Use extreme care when attaching PVC tubing or

components to metal pipe. Over-tightening can

cause damage to the PVC or components, so

tighten only until pressure is felt.

3. Model 450-04 Sensor Assembly. The Model 450-04

Sensor Assembly is for installation in processes

where insufficient flow or agitation exists. Attach the

union adapter to a 1 inch FPT PVC (SCH 80) tube

or metal pipe. If PVC to metal connection is made,

refer to Paragraph 2 and the CAUTION which fol-

lows. The sensor may be submerged to a depth of

up to 6.1 meters (20 feet). The agitator cable is

water tight and should be fastened to the standpipe

with tiewraps every five feet.

2.5.2 Electrical Installation. All sensors are wired the

same. Connect the sensor wiring as follows:

NOTE

The sensor is supplied with 20 feet of cable. If

more is needed, use Belden 8434 cable or

equivalent, available from Rosemount

Analytical as P/N 9200074 (specify length).

Junction box (P/N 22719-02) may be used for

connection if extended length of cable is used.

FIGURE 2-1. Model 450-01 and 450-02 Sensor Installation Diagrams

Transmitter

1054RCI/

Sensor Lead 1054ARCI/

1054ATFC 1181RCI 853RCI

Shield (Guard) to TB2-6 TB2-2 TB1-15

White (TC) to TB2-5 TB2-1 TB1-18

Green (TC) to TB2-7 TB2-3 TB1-17

Red (Anode) to TB2-1 TB2-4 TB1-16

Black (Cathode) to TB2-3 TB2-3 TB1-14

MODEL 450 SECTION 2.0

INSTALLATION

FIGURE 2-2. Handrail Mounting Installation for Model 450-03 and 450-04 Sensor Assemblies

WHEN INCH AND METRIC DIMS

ARE GIVEN

MILLIMETER

INCH

DWG. NO. REV.

40045019 A

3.1 GENERAL. This section contains troubleshooting

data for the Model 450 Sensor Assembly.

3.2 TROUBLESHOOTING THE MODEL 450

SENSOR. The majority of problems encountered in

RCI systems are caused by improper maintenance, or

from internal leakage within the sensor.

Disassemble the sensor completely by removing the

membrane retainer and sensor body (see Section 4.3

and Figure 5-4). The membrane may have dried on to

the gold cathode. Soak this loose with water as scraping

will damage the gold tip. A wet wood junction will make

the sensor body very difficult to remove but a firm twist-

ing, pulling motion should loosen it.

Clean all parts with clean water and dry them. Check for

visible damage (i.e., cracks, deep cuts, broken silver

wires). Perform the following checks with an ohmmeter.

Check T.C. resistance between the green and white

wires. Check continuity between the red wire and the sil-

ver anode, and between the black wire and the gold

cathode (be careful not to scratch the gold). Perform a

high meg check between the following (100 megohms

minimum): Shield; Black; Red; Green or White. If every-

thing checks O.K., the sensor should function after a

proper recharge. If the silver anode appears oxidized, it

may be cleaned with wet or dry 400 sandpaper. Also

brush the gold tip two or three times with 400 sandpaper

in one direction only.

Assemble the body of the RCI sensor and calibrate per

Section 2.4.

NOTE

BENCH LOOP CHECK. A bench check of

the sensor in a beaker of distilled water,

with a capful of 7 pH buffer added to it.

Place beaker and sensor on a ring stand

with a magnetic stirrer to create flow. Allow

the sensor to zero for a minimum of 12-24

hours as specified. Caution: zeroing too

early will distort scaling and confuse the

calibration procedure

MODEL 450 SECTION 3.0

TROUBLESHOOTING

SECTION 3.0

TROUBLESHOOTING

WAIT FOR SENSOR TO ZERO OUT. It is

typical for the “Reverse Current Input (rci)”

message to come up while zeroing. When

the input current drops below zero it trig-

gers this message to be displayed. It is also

normal for the chlorine readings to rise and

fall, while zeroing. The input current from

the sensor may even be negative at times.

Add some drops of chlorine to check for a

response. To determine accuracy you

should maintain a pH of 7 and check the

chlorine level with a free chlorine test such

as DPD-50.

NOTE

Record the current that is developed by the

Model 450 sensor. If using a 1054A RC or

1054 A TFC, the input current can be

viewed by selecting “jo” under the “Set

Menu”. To access the “Set Menu” press the

ACCESS/ENTER key twice in rapid suc-

cession. Then press the up-arrow key until

“jo” is displayed then press SELECT key.

The current from the sensor will then be

displayed. NOTE: If using a 1054A RC the

reading is in microamps. If using a 1054A

TFC the reading is in nanoamps. (1000

nanoamps = 1 microamp). If using an 1181

RC, place an ammeter in series with the

sensor's black wire to read the current.

Convert the current reading to nanoamps.

Now divide the nanoamp reading, from the

sensor, by the chlorine ppm concentration

to determine the nanoamps per ppm value

of the sensor. Example:

200 nanoamps ÷ 2.0 ppm = 100 nanoamps

per ppm

A good nanoamp per ppm value is between

70 and 135. If value drops below 70, the

sensor should be rebuilt and the cathode

sanded.

CAUTION

Care should be taken not to damage the

TEFLON

®1

membrane.

450

Sensor

Magnetic

Stirrer

Ring

Stand

MODEL 450 SECTION 3.0

TROUBLESHOOTING

If the resistance as specified above cannot be

achieved, replace the sensor.

4. To check for shorted sensor leads, measure the

resistance between one temperature compensator

wire (green or white) and the cathode (black) lead

and anode (red) lead. The meter should indicate

an open circuit (100 megohms or more). Repeat

the measurement using the other temperature

compensator wire. If the sensor shows a short cir-

cuit, the sensor is defective and should be

replaced.

Reg. U.S. Pat. Office for DuPont's fluorocarbon resins

1. Low readings and inability to calibrate are gener-

ally the result of a coated membrane. Replace the

coated membrane and return the sensor to serv-

ice.

2. Readings offscale and inability to calibrate are

usually caused by a damaged membrane. If this is

the case, replace the membrane.

3. To check the resistance of the temperature com-

pensator (thermistor or PT100 RTD), connect an

ohmmeter to the green and white leads of the sen-

sor. The resistance should be as indicated at the

temperature listed below:

TABLE 3-1. Temperature Resistance Chart

Sensor Resistance (ohms)

Temp. PT 100 Thermistor

Mdl 450-54 Mdl 450

0°C 100.00 371.40K

10°C 103.90 214.50K

20°C 107.70 128.00K

25°C 109.62 100.00K

30°C 111.67 78.00K

40°C 115.54 49.80K

50°C 119.40 32.36K

NOTE

Allow enough time for the T.C. element to

stabilize to the surrounding temperature.

MODEL 450 SECTION 3.0

TROUBLESHOOTING

TABLE 3-2. Model 1054A TFC Microprocessor Analyzer Quick Troubleshooting Chart

Symptoms Action

Fault Code sdj 1. Typical message during the zeroing process; if sensor is wired correctly. Message

should go away as the sensor zeros out (12-24 hours).

Fault Code cbe 1. Too littIe current to calibrate to: verify that chlorine concentration is a minimum of

1-2 ppm. Increase the chlorine concentration if it is below I ppm.

2. Verify that the chlorine sensor is putting out at least 70 nanoamps per ppm;

check jo under the SEt menu.

3. Recharge the chlorine sensor, ensure the gold cathode is sanded and a new

membrane is installed.

Fault Code udI0udM 1. Check wiring between the sensor and analyzer.

2. Verify analyzer’s temperature reading has been standardized properly (250 may

have been entered instead of 25 degrees)

3. Use the MANUAL temperature compensation mode, to get by if the sensors T.C. is bad.

4. Replace the chlorine sensor, if the T.C is bad.

Fault Code Pso0Fdj 1. Remove sensor from process; clean & check membrane.

2. Replace membrane if suspected of being damaged.

3. Recalibrate.

Fault Code TFo 1. Check wiring at TB2-6 and TB2-7 particularly; sense wire and shield must be

connected correctly.

2. Check for bad lug crimps or open wires, from sensor.

Chlorine Sensor won’t zero

1. Check sensor membrane for damage (pin-hole).

2. Allow sufficient time for sensor to zero: 12-24 hrs.

3. Perform Sensor Electrical Checks.

4. Verify Analyzer: perform Electronic Bench Check.

Chlorine Sensor has little or

1. Verify proper flow rate past sensor minimum 1 ft/sec.

no response to chlorine

2. Clean and check sensor membrane: on the Model 450 Sensor make sure that

the

changes

blue paper separator has not been installed with the white membrane and/or the

translucent protector.

3. Verify electrolyte is fresh (change every 5-6 months).

4. Perform Chlorine Sensor Electrical Checks.

5. Rebuild sensor if Electrical Checks are OK.

6. If the Analyzer passes the Electronics Bench Check and sensor continues to fail

after rebuilding; replace sensor.

Chlorine reading is all 1. Reading will typically fluctuate when a sensor is charged and put in chlorine-free

over the place

water to polarize and zero out. A stable reading, near zero, should occur in 12-24

hours.

2. If using automatic pH correction, verify that the pH reading is not fluctuating, this

would cause the chlorine reading to fluctuate. Place analyzer in Manual pH cor-

rection mode and check for a stable chlorine reading.

3. Perform pH Checks if the pH reading is fluctuating.

4. Verify analyzer. Perform the Electronic Bench Check.

5. Perform Chlorine Sensor Checks.

6. Rebuild chlorine sensor, if Sensor Checks are OK

MODEL 450 SECTION 4.0

MAINTENANCE

SECTION 4.0

MAINTENANCE

4.1 GENERAL. This section provides maintenance

instructions for keeping the sensor assembly in good

operating condition.

4.2 SCHEDULED PREVENTATIVE MAINTENANCE.

For best results the sensor should be clean. Examine

the sensor at periodic intervals to make sure it is clean.

Determine this interval period by examining the sensor

after seven days service, and progressively longer

periods, until recalibration or cleaning of the sensor is

required.

Clean the sensor by washing with clean water, or if it is

coated, wipe gently with soft tissue or cloth.

CAUTION

Make sure the TEFLON membrane is not

damaged during cleaning.

4.3 SENSOR DISASSEMBLY, REBUILD AND

ASSEMBLY PROCEDURE. Recharge the sensor and

replace the membrane as follows:

CAUTION

Clean rubber gloves should be worn during

sensor preparation and maintenance to

avoid skin contact and contaminating the

membrane and cathode.

1. Prepare sensor electrolyte from sensor recharge

kit (P/N 2002402) by filling the bottle of crystals

supplied with the recharge kit (AgCl/KCl) to the

neck with distilled or deionized water. Stir or shake

to wet crystals thoroughly. Some crystals should

remain undissolved.

NOTE

Please see Figure 5-4 for Model 450 Free

Residual Sensor assembly exploded view.

2. Remove sensor “cover” and membrane “Retainer”

(remove 6 screws at sensor tip).

3. Sand the gold cathode with the 400 grit sandpa-

per, in one direction only

until it is shiny. Rinse

cathode with clean water.

NOTE

The gold element is very thin and care

must be taken that penetration through the

element does not occur.

4. Remove the fill-plug.

5. Fill the syringe (included in the recharge kit) with

the AgCl/KCl electrolyte solution. Fill the sensor

body with the electrolyte, shaking the sensor to

remove air. Ensure that about 1 cc (or 1 ml) of

crystals get inside the sensor body.

6. Install the fill plug (wrapped with one or two turns

of TEFLON

®1

tape in the side of the sensor. As the

plug is screwed into place, electrolyte will be

forced through the wood junction. This is impor-

tant, since the electrical continuity will not be

established unless the wood junction is thorough-

ly wetted.

Continue to screw the fill plug into place until it is flush

with the sensor body. Do not remove excess elec-

trolyte from the end of the sensor because it will wet

the membrane and help hold it in place during instal-

lation.

7. Place the O-ring in the groove and press it into posi-

tion around the wood junction. If there is no solution

remaining over the gold cathode after installing the O-

ring, add a few drops of electrolyte (no crystals).

IMPORTANT: No crystals underneath the mem-

brane or damage will occur.

8. Place the white-opaque “membrane” on top of the

cathode. Place the white-translucent “protector”

over the membrane. DO NOT use the blue-paper

protective separators found in the membrane kit!

9. Lay the membrane “retainer” over the membrane

and protector. Screw down the (6) screws applying

even pressure. The membrane should be taut, not

spongy, when the retainer is secure.

10. Keep the sensor tip in water if installation is delayed

over an hour. Membrane may adhere to the cath-

ode if allowed to dry out.

Reg. U.S. Pat. Office for DuPont's fluorocarbon resins

MODEL 450 SECTION 4.0

MAINTENANCE

11. Sensor requires approximately (2) hours to polar-

ize and (12-24) hours to obtain a stable zero in

chlorine-free water.

NOTE

Water should be agitated for zeroing and

spanning (magnetic stirrer is recommended)

CAUTION

Insufficient zeroing time may cause diffi-

culties in calibration and readings that

drift.

12. Chlorine concentrations of 1 PPM or above are rec-

ommended for the most accurate chlorine calibration.

IMPORTANT

Process flow requirement is 1 ft./sec. or if in a

“Tee” 0.5-5.0 gal./min. If unable to adjust process

chlorine concentration to this level, perform cali-

bration in a beaker with a magnetic stirrer for agi-

tation. Adding a drop or two of chlorine bleach to

deionized water (buffered to 7 pH) will create

a chlorine residual.

13. Calibrate the chlorine reading to the titrated value of

the process or the chlorine residual sample.

14. The sensor is now ready to be installed.

15. Refer to the Model 1054A TFC, 1181 RC or 853

instruction manual for standardization procedure.

Figure 5-1 Model or

Item No. Part No.

Description Qty.

Model 450 Sensor Assembly (Models 1181 RCl and 853 RCI)

Model 450-54 Sensor Assembly (Models 1054 RCl, 1054A RCl and 1054A TFC)

2 2002566 1¼ inch Tee Assy. - Angle Flow (Code 01) 1

3 2002567 1¼ inch Tee Assy. - Straight Flow (Code 02) 1

4 9320057 Union Assembly 1

5 9550090 O-ring (Buna-N, 2-029) 1

6 ––– 1¼ inch Tee (Straight Flow) 1

7 ––– 1¼ inch Tee (Angle Flow) 1

MODEL 450 SECTION 5.0

PARTS LISTS

SECTION 5.0

PARTS LISTS

GENERAL. This section contains the replacement parts

lists and illustrations for the Model 450 Sensor Assembly.

Parts are keyed with an item number. To locate a part,

look on the illustration for that parts next higher assembly

and look for the part. When you have found the part, fol-

low the arrow to the item number. This will give you the

part number, description and quantity of that part on the

accompanying parts list. The Usage Code column, where

used, identifies parts used on more than one assembly.

Determine which assembly you are concerned with and

then check its code letter in the Usage Code column. All

items with that code letter are used on that assembly. If

there is no code letter, the item is used on all assemblies

in that parts list.

Figure 5-1.

Models 450-01 and 450-02 Free Residual Chlorine Flow Through Sensors

Figure 5-2 Model or

Item No. Part No.

Description Qty.

Model 450 Sensor Assembly (Models 1181 RCl and 853 RCl)

Model 450-54 Sensor Assembly (Models 1054 RCl, 1054A RCl and 1054A TFC)

2 2002568 Union/Gasket Assy 1

3 3001617 Gasket 1

Figure 5-2.

Model 450-03 Free Residual Chlorine Submersion Sensor

MODEL 450 SECTION 5.0

PARTS LISTS

Figure 5-3 Model or

Item No. Part No.

Description Qty.

Model 450 Sensor Assembly (Models 1181 RCI and 853 RCl)

Model 450-54 Sensor Assembly (Models 1054 RCl, 1054A RCl and 1054A TFC)

2 2002569 Pump, submersible Assy. 1

3 Screw, SPH SS (#8-32 X 3/8) 4

4 Screw, SPH SS (#8-32 X 3/8) 2

5 Holder Assy 1

6 ––– Union 1

7 3001197 Gasket 1

Figure 5-3.

Model 450-04 Free Residual Chlorine Submersion Sensor/Agitator

MODEL 450 SECTION 5.0

PARTS LISTS

Figure 5-4 Model or

Item No. Part No.

Description Qty.

––– Screw (#4-40 X 1.0) 4

2 ––– Base Assy. Sensor (Model 450/450-54) 1

3 9550144 O-ring (Viton

®1

,2-222) 1

4 9550056 O-ring (Viton

®1

, 2-210) 1

5 3002010 Junction, wood 1

6 ––– Body, sensor 1

7 33209-00 Plug, fill 1

8 9550110 O-ring (Viton

®1

, 2-016) 1

9 2001996 Membrane kit contains five membrane, five polyester filter and

two O-rings (Item 8). Discard blue paper between mesh and membrane. 1

10 ––– Retainer, membrane 1

11 ––– Screw (#4-40 X 0.37) 6

12 ––– Cap, protective 1

2002402 Kit, recharge, chlorine sensor contains the following items: 1

3002010 Junction, wood (same as Item 5) 1

2001996 Membrane kit (same as Item 9) 1

9210001 Solution (AgCI/CKI) 1

––– Syringe (for filling sensor) 1

Figure 5-4. Model 450 Free Residual Chlorine Sensor Assembly

MODEL 450 SECTION 5.0

PARTS LISTS

Viton is a registered trademark of DuPont Performance Elastomers.

NOTE

blue protective separator between mem-

brane and mesh is to be discarded

Model 450 SECTION 6.0

RETURN OF MATERIAL

SECTION 6.0

RETURN OF MATERIAL

6.1 GENERAL. To expedite the repair and return of

instruments, proper communication between the cus-

tomer and the factory is important. A return material

authorization number is required. Call 1-800-654-

7768 or (949) 757-8500. The “Return of Materials

Request” form is provided for you to copy and use in

case the situation arises. The accuracy and complete-

ness of this form will affect the processing time of your

materials.

6.2 WARRANTY REPAIR. The following is the proce-

dure for returning products still under warranty.

1. Contact the factory for authorization.

2. Complete a copy of the “Return of Materials

Request” form as completely and accurately as

possible.

3. To verify warranty, supply the factory sales order

number or the original purchase order number. In

the case of individual parts or sub-assemblies, the

serial number on the mother unit must be sup-

plied.

4. Carefully package the materials and enclose your

“Letter of Transmittal” and the completed copy of

the “Return of Materials Request” form. If possi-

ble, pack the materials in the same manner as it

was received.

IMPORTANT

Please see second section of “Return of

Materials Request Form”. Compliance to

the OSHA requirements is mandatory for

the safety of all personnel. MSDS forms

and a certification that the instruments

have been disinfected or detoxified are

required.

5. Send the package prepaid to:

Rosemount Analytical Inc.

2400 Barranca Parkway

Irvine, CA 92606

Attn: Factory Repair

Mark the package:

Returned for Repair RMA No. _______________

Model No. ______________

6.3 NON WARRANTY REPAIR.

1. Contact the factory for authorization.

2. Fill out a copy of the “Return of Materials Request”

form as completely and accurately as possible.

3. Include a purchase order number and make sure

to include the name and telephone number of the

right individual to be contacted should additional

information be needed.

4. Do Steps 4 and 5 of Section 6.2.

NOTE

Consult the factory for additional infor-

mation regarding service or repair.

MODEL CFA 3000 RETURN OF MATERIAL

RETURN OF MATERIAL

GENERAL.

To expedite the repair and return of instruments, proper communication between the customer and the factory is

important. Before returning a product for repair, call 1-949-757-8500 for a Return Materials Authorization (RMA)

number.

WARRANTY REPAIR.

The following is the procedure for returning instruments still under warranty:

1. Call Emerson Process Management for authorization.

2. To verify warranty, supply the factory sales order number or the original purchase order number. In the case

of individual parts or sub-assemblies, the serial number on the unit must be supplied.

3. Carefully package the materials and enclose your “Letter of Transmittal” (see Warranty). If possible, pack the

materials in the same manner as they were received.

4. Send the package prepaid to:

Emerson Process Management

Liquid Division

2400 Barranca Parkway

Irvine, CA 92606

Attn: Factory Repair

RMA No. ____________

Mark the package: Returned for Repair

Model No. ____

NON-WARRANTY REPAIR.

The following is the procedure for returning for repair instruments that are no longer under warranty:

1. Call Emerson Process Management for authorization.

2. Supply the purchase order number, and make sure to provide the name and telephone number of the individ-

ual to be contacted should additional information be needed.

3. Do Steps 3 and 4 of the Warranty Repair section above.

NOTE

Consult the factory for additional information regarding service or repair.

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Rosemount 450 Free Residual Chlorine Sensor Owner's manual

Rosemount 450 Free Residual Chlorine Sensor Owner's manual

Rosemount 450 Free Residual Chlorine Sensor Owner's manual

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