Emerson Rosemount MCL-220 User manual

Manual
LIQ-MAN-MCL, Rev E
July 2017
Rosemount™ MCL-220
Monochloramine System with Rosemount 1056 Transmitter

Essential instructions
Read this page before proceeding!
Your purchase from Rosemount has resulted in one of the finest instruments available for your particular application. These
instruments have been designed and tested to meet many national and international standards. Experience indicates that the
instrument's performance is directly related to the quality of the installation and knowledge of the user in operating and
maintaining the instrument. To ensure continued operation the the design specifications, read this manual thoroughly before
proceeding with installation, commissioning, operation, and maintenance of this instrument. If this equipment is used in a manner
not specified by the manufacturer, the protection provided by it against hazards may be impaired.
•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.
•Ensure that you have received the correct model and options from your purchase order. Verify that this manual covers your
model and options. If not, call 1 800 999 9307 to request the correct manual.
•For clarification of instructions, contact your Rosemount representative.
•Follow all warnings, cautions, and instructions marked on and supplied with the product.
•Use only qualified personnel to install, operate, update, program, and maintain the product.
•Install your equipment as specified in the installation instructions of this manual. Follow appropriate local and national
codes. Only connect the product to the electrical and pressure sources specified in this manual.
•Use only factory documented components for repair. Tampering or unauthorized substitution of parts and procedures can
affect the performance and cause unsafe operation of your process.
•All equipment doors must be closed and protective covers much be in place unless qualified personnel are performing
maintenance.
•If this equipment is used in a manner not specified by the manufacturer, the protection provided by it against hazards may
be impaired.
WARNING!
RISK OF ELECTRICAL SHOCK
Equipment protected throughout by double insulation.
•Installation of cable connections and servicing of this product may require access to shock and high voltage levels.
•Main power and relay contacts wired to separate power sources must be disconnected before servicing.
•Do not operate or energize instrument with the case open!
•Signal wiring connected in this box must be rated at least 240 V.
•Non-metallic cable strain reliefs do not provide grounding between conduit connections! Use grounding type bushings and
jumper wires.
•Unused cable conduit entries must be securely sealed by non-flammable closures to provide enclosure integrity in
compliance with personal safety and environmental protection requirements. Unused conduit openings must be sealed with
NEMA 4X or IP65 conduit plugs to maintain the ingress protection rating (NEMA 4X).
•Electrical installation must be in accordance with the National Electrical Code (ANSI/NFPA-70) and/or any other applicable
national or local codes.
•Operate only with front and rear panels fastened and in place over terminal area.
•Safety and performance require that this instrument be connected and properly grounded through a three-wire power
source.
•Proper relay use and configuration is the responsibility of the user.
WARNING!
This product is not intended for use in the light industrial, residential, or commercial environments per the instrument's certification
to EN50081-2.
CAUTION!
This product generates, uses, and can radiate radio frequency energy and thus can cause radio communication interference.
Improper installation or operation may increase such interference. As temporarily permitted by regulation, this unit has not been
tested for compliance within the limits of Class A computing devices, pursuant to Subpart J of Part 15 of FCC rules, which are
designed to provide reasonable protection against such interference. Operation of this equipment in a residential area may cause
interference, in which case the user at his own expenace, will be required to take whatever measures may be required to correct the
interference.

About this document
This manual contains instructions for installation and operation of the Rosemount
MCL-220 monochloramine system.
The following list provides notes concerning all revisions of this document.
Rev level Date Notes
A 09/08 This is the initial release of the product manual. This manual has been reformatted to
reflect the Emerson documentation style and updated to reflect any change in the prod-
uct offering.
B 08/09 Updated ISO/DNV approval.
C 09/11 Updated Chapter 2, Table 8-2, and Figure 8-2. Updated Troubleshooting sections
Section 9.5.5, Section 9.5.6, Section 9.6, and Section 9.7.
D 03/12 Updated addresses - mail and web.
E 07/17 Changed instances of analyzer to transmitter. Updated formatting to align with new
branding guidelines. Updated addresses on back page.

Contents
Chapter 1 Quick Start guide ............................................................................................................. 1
Chapter 2 Description and Specifications ..........................................................................................5
2.1 Features ......................................................................................................................................... 5
2.2 Specifications .................................................................................................................................6
2.3 Ordering information ..................................................................................................................... 7
Chapter 3 Installation .......................................................................................................................9
3.1 Unpacking and inspection .............................................................................................................. 9
3.1.1 Rosemount MCL-220 .......................................................................................................9
3.2 Installation ..................................................................................................................................... 9
3.2.1 General information ........................................................................................................ 9
3.2.2 Sample requirements .................................................................................................... 10
3.2.3 Mounting, inlet, and drain connections ......................................................................... 10
3.2.4 Electrical connections ....................................................................................................11
3.2.5 Installing the sensor .......................................................................................................11
Chapter 4 Wiring ........................................................................................................................... 13
4.1 Power, alarm, and output wiring .................................................................................................. 13
4.1.1 Power ............................................................................................................................ 13
4.1.2 Analog output wiring .....................................................................................................13
4.1.3 Alarm wiring .................................................................................................................. 14
4.2 Sensor wiring ............................................................................................................................... 15
Chapter 5 Display and operation .................................................................................................... 17
5.1 Display ......................................................................................................................................... 17
5.2 Keypad .........................................................................................................................................18
5.3 Programming the transmitter - tutorial ........................................................................................ 20
5.4 Security ........................................................................................................................................22
5.4.1 How the security code works ......................................................................................... 22
5.4.2 Assigning security codes ................................................................................................22
5.4.3 Bypassing security codes ............................................................................................... 22
5.5 Using hold ....................................................................................................................................23
5.5.1 Purpose ......................................................................................................................... 23
5.5.2 Using the hold function ................................................................................................. 23
5.6 Configuring the main display ........................................................................................................24
Chapter 6 Programming the transmitter ........................................................................................ 27
6.1 General ........................................................................................................................................ 27
6.2 Default settings ............................................................................................................................27
6.3 Configuring, ranging, and simulating outputs .............................................................................. 29
6.3.1 Purpose ......................................................................................................................... 29
6.3.2 Definitions .....................................................................................................................29
6.3.3 Procedure - configure outputs ....................................................................................... 30
6.3.4 Procedure - ranging outputs .......................................................................................... 31
6.3.5 Procedure - simulating outputs ......................................................................................32
6.4 Configuring alarms and assigning setpoints ................................................................................. 34
6.4.1 Purpose ......................................................................................................................... 34
6.4.2 Definitions .....................................................................................................................34
Contents
Instruction Manual i

6.4.3 Procedure - configuring alarms and assigning setpoints ................................................ 36
6.4.4 Procedure - simulating alarms ....................................................................................... 37
6.4.5 Procedure - synchronizing timers ...................................................................................39
6.5 Configuring the measurement ..................................................................................................... 40
6.5.1 Purpose ......................................................................................................................... 40
6.5.2 Definitions - chlorine ..................................................................................................... 40
6.5.3 Procedure - configuring the measurement .................................................................... 40
6.6 Configuring temperature related settings .................................................................................... 41
6.6.1 Purpose ......................................................................................................................... 41
6.6.2 Definitions .....................................................................................................................41
6.6.3 Procedure - configuring temperature related settings ................................................... 42
6.7 Configuring security settings ........................................................................................................43
6.7.1 Purpose ......................................................................................................................... 43
6.7.2 Procedure - configuring security settings .......................................................................43
6.8 Resetting the transmitter ............................................................................................................. 44
6.8.1 Purpose ......................................................................................................................... 44
6.8.2 Procedure - resetting the transmitter ............................................................................ 44
Chapter 7 Calibration ..................................................................................................................... 47
7.1 Introduction .................................................................................................................................47
7.2 Calibrating temperature ...............................................................................................................47
7.2.1 Purpose ......................................................................................................................... 47
7.2.2 Procedure ......................................................................................................................47
7.3 Calibration - monochloramine ......................................................................................................49
7.3.1 Purpose ......................................................................................................................... 49
7.3.2 Procedure - zeroing the sensor ...................................................................................... 50
7.3.3 Procedure - calibrating the sensor ..................................................................................52
7.4 Calibration - analog outputs ......................................................................................................... 54
7.4.1 Purpose ......................................................................................................................... 54
7.4.2 Procedure ......................................................................................................................54
Chapter 8 Maintenance .................................................................................................................. 57
8.1 Transmitter .................................................................................................................................. 57
8.2 Monochloramine sensor ...............................................................................................................57
8.2.1 General ..........................................................................................................................57
8.2.2 Cleaning the membrane ................................................................................................ 58
8.2.3 Replacing the electrolyte solution and membrane .........................................................58
8.3 Constant head flow controller ...................................................................................................... 60
8.3.1 General ..........................................................................................................................60
8.3.2 Cleaning the flow controller ...........................................................................................60
8.3.3 Other maintenance ....................................................................................................... 60
Chapter 9 Troubleshooting ............................................................................................................ 63
9.1 Overview ......................................................................................................................................63
9.2 Using the diagnostic feature .........................................................................................................63
9.3 Troubleshooting when a Fault message is showing ...................................................................... 64
9.3.1 Main Board CPU, Main Board Factory Data, and Main Board User Data errors .................65
9.3.2 Hardware Error .............................................................................................................. 65
9.3.3 Sensor Board Unknown, Sensor Board HW (Hardware) or SW (Software) Mismatch, or
Sensor Board Not Communicating .................................................................................65
9.3.4 Sensor Incompatible ......................................................................................................65
9.3.5 Sensor CPU Error ............................................................................................................66
9.3.6 Sensor RTD Open ...........................................................................................................66
Contents
ii Rosemount MCL

9.3.7 Sensor 1 Not Detected ...................................................................................................66
9.3.8 Sensor Factory Data, Sensor Board User Data, and Sensor EEPROM Write errors ............ 67
9.3.9 Sensor ADC error ........................................................................................................... 67
9.3.10 Sensor RTD Out of Range ...............................................................................................67
9.4 Troubleshooting when a Warning message is showing .................................................................68
9.4.1 Sensor Need Factory Cal ................................................................................................ 68
9.4.2 Sensor Negative Reading ............................................................................................... 68
9.4.3 Sensor RTD Sense Open .................................................................................................68
9.4.4 Sensor Temperature High or Low ...................................................................................69
9.5 Troubleshooting when no error message is showing .................................................................... 69
9.5.1 Zero current is too high. ................................................................................................ 69
9.5.2 Zero current is unstable. ................................................................................................ 70
9.5.3 Sensor can be calibrated, but the current is too low. ...................................................... 70
9.5.4 Process readings are erratic. .......................................................................................... 71
9.5.5 Readings drift. ............................................................................................................... 71
9.5.6 Sensor does not respond to changes in monochloramine level. ..................................... 72
9.5.7 Readings are too low. .................................................................................................... 72
9.6 Troubleshooting when no error message is showing - general ......................................................73
9.6.1 Difference between transmitter and standard thermometer is greater than 3 °C. .......... 73
9.6.2 Current output too low ..................................................................................................74
9.6.3 Alarm relays don't work. ................................................................................................ 74
9.6.4 Bubbles trapped against membrane. ............................................................................. 74
9.7 Simulating inputs ......................................................................................................................... 74
9.8 Simulating temperature ...............................................................................................................75
9.8.1 General ..........................................................................................................................75
9.8.2 Simulating temperature ................................................................................................ 75
Contents
Instruction Manual iii

Contents
iv Rosemount MCL

1 Quick Start guide
For Rosemount MCL-220 Monochloramine System
Prerequisites
Refer to Chapter 3 for installation instructions and Chapter 4 for wiring instructions.
Procedure
1. Once connections are secured and verified, apply power to the transmitter.
When the transmitter is powered up for the first time, Quick Start screens appear..
Using Quick Start is easy.
a. A backlit field shows the position of the cursor.
b. To move the cursor left or right, use the keys to the left or right of the ENTER key.
To scroll up or down or to increase or decrease the value of a digit, use the keys
above and below the ENTER key. Use the left and right keys to move the decimal
point.
c. Precc ENTER to store a setting. Press EXIT to leave without storing changes.
Pressing EXIT also returns the display to the initial Quick Start screen.
d. A vertical black bar with a downward pointing arrow on the right side of the
screen means there are more items to display. Continue scrolling down to
display all the items. When you reach the bottom of the list, the arrow points up.
2. Choose the desired language. Scroll down to display more choices.
3. The next step is to configure sensor 1. Sensor 1 is the total chlorine sensor. The
screen has two control boxes.
a. For measurement, choose Total chlorine.
b. Choose the desired units, mg/L or ppm.
4. Choose Monochloramine for sensor 1 (S1).
Quick Start guide
Instruction Manual 1

5. Choose the desired units for chlorine.
6. Choose the desired temperature units.
The main display appears. The outputs and alarms (if an alarm board is present) are
assigned to default values.
7. To change outputs, alarms, and other settings, go to the main menu and choose
Program. Follow the prompts.
A menu tree is on the following page. To calibrate the sensor, refer to Section.
Quick Start guide
2 Rosemount MCL

Quick Start guide
Instruction Manual 3

Quick Start guide
4 Rosemount MCL

2 Description and Specifications
2.1 Features
The Rosemount MCL monochloramine system is intended for measuring monochloramine
in fresh water.
This system uses a membrane-covered amperometric sensor. A polarizing voltage applied
to a gold mesh cathode behind the membrane destroys the monochloramine diffusing
through the membrane and keeps the concentration of monochloramine in the sensor
equal to zero. The current generated by the cathode reaction is proportional to the rate of
diffusion of monochloramine through the membrane. Because the concentration of
monochloramine in the sensor is zero, the diffusion rate and the current are proportional
to the concentration of monochloramine in the sample.
Diffusion rate also depends on membrane permeability, which is a function of
temperature. An RTD in the sensor continuously measures the temperature of the sample,
and the transmitter automatically corrects the raw sensor current for temperature
changes.
Maintenance is fast and easy. Replacing a membrane requires no special tools or fixtures. A
screw cap holds the pre-tensioned membrane in place. Replacing the electrolyte solution
takes only minutes.
The Rosemount MCL-220 system includes an easy-to-use Rosemount 1056 transmitter
that features two fully programmable 4-20 mA outputs and four fully programmable
relays. The large back-lit display allows you to read monochloramine concentration at a
glance.
A constant head overflow sampler ensures correct sample flow to each sensor.
Stable monochloramine standards do not exist. The monochloramine sensor must be
calibrated using the results of a laboratory test run on a grab sample.
Description and Specifications
Instruction Manual 5

2.2 Specifications
General SpecificationsTable 2-1:
Physical characteristics Specifications
Sample requirements •Pressure: 3 to 65 psig (122 to 549 kPa abs). A check
valve in the inlet prevents the sensor flow cells from
going dry if sample flow is lost. The check valve opens
at 3 psig (122 kPa abs). If the check valve is removed,
minimum pressure is 1 psig (108 kPa abs).
•Temperature: 0 to 50 °C (32 to 122 °F)
•Minimum flow: 3 gal/hr (11 L/hr)
•Maximum flow: 80 gal/hr (303 L/hr); high flow causes
the overflow tube to back up.
Sample conductivity > 10 µS/cm at 25 °C (77 °F)
Process connection 1/4 in. OD tubing compression fitting (can be removed and
replaced with barbed fitting for soft tubing).
Drain connection 3/4 in. barbed fitting. Sample must drain to open atmos-
phere.
Wetted parts Overflow sampler: acrylic, nylon, polycarbonate, polyester,
silicone
Monochloramine sensor: Noryl(1), Viton(2), silicone, and Zi-
tex(3). PFTE gold mesh cathode (not normally wetted)
Response time to step change in monochloramine concen-
tration
<60 sec to 95% of final reading for inlet sample flow of 17
gph (64 L/hr)
Weight/shipping weight 10 lb/13 lb (4.5 kg/6.0 kg) (rounded to the nearest 1 lb
[0.5 kg])
(1) Noryl is a registered trademark of General Electric.
(2) Viton is a registered trademark of E.I. duPont de Nemours & Co.
(3) Zitex is a registered trademark of Performance Plastic Corp.
Sensor SpecificationsTable 2-2:
Physical characteristics Specifications
Range 0 to 6 ppm as Cl2. For higher ranges, consult the factory.
pH range Response is practically independent of pH between pH 7.0
and 10.0. Sensor current at pH 10.0 is within 5% of sensor
current at pH 7.0.
Accuracy Accuracy depends on the accuracy of the chemical test
used to calibrate the sensor.
Linearity 2% (typ.)
Electrolyte volume 25 mL (approx.)
Electrolyte life 2 months (approx.)
Description and Specifications
6 Rosemount MCL

Rosemount 1056 Transmitter SpecificationsTable 2-3:
Physical characteristics Specifications
Case Polycarbonate NEMA 4X/CSA 4 IP65)
Conduit openings Accepts PG13.5 or 1/2 in. conduit fittings
Languages English, French, German, Italian, Spanish, Portuguese, and
Chinese
Ambient temperature and humidity 0 to 55 °C (321 to 131 °F); relative humidity 5 to 95% (non-
condensing)
Storage temperature -20 to 60 °C (-4 to 140 °F)
Power 84 to 265 Vac, 47.5 to 65.0 Hz, switching, 15 W.
Equipment protected by double insulation.
RFI/EMI EN-61326
LVD EN-61010-1
Outputs Two 4-20 mA or 0-20 mA isolated outputs. Continuously
adjustable. Linear or logarithmic. Maximum load 550 Ω.
Output dampening is user-adjustable.
Alarms Four alarm relays. Any relay can be configured as a fault
alarm instead of a process alarm. Each relay can be config-
ured independently, and each can be programmed with in-
terval timer settings.
Relays Form C, SPDT, epoxy sealed
Relay contact ratings
5A at 28 Vdc or 300 Vac (resistive)
1/8 HP at 120/240 Vac
Terminal connections rating Power connector (3 leads): 18-12 AWG wire size. Current
output connectors (2 leads): 24-16 AWG wire size. Alarm
relay terminal blocks: 18-16 AWG wire size.
Hazardous location approvals For more information, refer to the Rosemount 1056 prod-
uct data sheet. Approvals apply to the transmitter only.
The MCL is not suitable for use in hazardous areas.
2.3 Ordering information
The Rosemount MCL-220 is a complete system for the determination of monochloramine
in water. It consists of a monochloramine sensor, Rosemount 1056 transmitter, Variopol
cable, and constant head overflow cup to control sample flow. All components are
mounted on a backplate, and the cable is pre-wired to the transmitter. Three replacement
membranes and a 4-oz bottle of electrolyte solution are shipped with the sensor.
Description and Specifications
Instruction Manual 7

Component PartsTable 2-4:
Transmitter model Description
1056-03-24-38-AN Rosemount 1056 transmitter, single input (monochlora-
mine), alarm relays, analog output, 115/230 Vac
Sensor model Description
499ACL-03-54-VP Monochloramine sensor with Variopol connector
Sensor cable Description
23747-04 Interconnecting cable, Variopol for Rosemount 499ACL
sensor, 4 ft
AccessoriesTable 2-5:
Part number Description
9240048-00 Tag, stainless steel (specify marking)
Description and Specifications
8 Rosemount MCL

3 Installation
3.1 Unpacking and inspection
Complete the following steps when you unpack your instrument.
1. Inspect the shipping container. If there is damage, contact the shipper immediately
for instructions.
2. Save the box.
3. If there is no apparent damage, unpack the container.
4. Ensure that all items shown on the packing list are present. If items are missing,
notify Rosemount immediately.
3.1.1 Rosemount MCL-220
The Rosemount MCL-220 consists of the following items mounted on a back plate.
1. The Rosemount 1056-03-24-38-AN with sensor cable attached.
2. Constant head overflow sampler with flow cell for monochloramine sensor.
3. The monochloramine sensor (Rosemount 499ACL-03-54-VP), three membrane
assemblies, and a bottle of electrolyte solution are in a separate package.
3.2 Installation
3.2.1 General information
1. Although the system is suitable for outdoor use, do not install it in direct sunlight or
in areas of extreme temperature.
CAUTION!
HAZARDOUS AREAS
The Rosemount MCL is not suitable for use in hazardous areas.
2. To keep the transmitter enclosure watertight, install plugs (provided) in the unused
conduit openings.
3. Install the system in an area where vibrations and electromagnetic and radio
frequency interference are minimized or absent.
4. Keep the transmittter and sensor wiring at least one foot from high voltage
conductors. Be sure there is easy access to the transmitter and sample conditioning
system.
5. Be sure there is easy access to the transmitter and sensor.
Installation
Instruction Manual 9

3.2.2 Sample requirements
Be sure the sample meets the following requirements:
1. Temperature: 0 to 50 °C (32 to 122 °F)
2. Pressure: 3 to 65 psig (122 to 549 kPa abs)
3. Minimum flow: 3 gal/hr (11 L/hr)
3.2.3 Mounting, inlet, and drain connections
The Rosemount MCL-220 is intended for wall mounting only. Refer to Figure 3-1 for details.
The sensor screws into the flow cell adapter.
Rosemount MCL-220 Monochloramine SystemFigure 3-1:
A 1/4 in. OD tubing compression fitting is provided for the sample inlet. If desired, the
compression fitting can be removed and replaced with a barb fitting. The inlet fitting
screws into a 1/4 in. FNPT check valve. The check valve prevents the sensor flow cell from
going dry if sample flow is lost.
The sample drains through a 3/4 in. barbed fitting.
1. Attach a piece of soft tubing to the fitting and allow the waste to drain to open
atmosphere. Do not restrict the drain line.
Installation
10 Rosemount MCL

2. Remove the foam packing insert between the outer tube and the inner overflow
tube.
3. Adjust the sample flow until the water level is even with the central overflow tube
and excess water is flowing down the tube.
3.2.4 Electrical connections
Refer to Section 4.1 for details.
3.2.5 Installing the sensor
The Rosemount MCL is provided with the sensor cable pre-wired to the transmitter. The
terminal end of the sensor is keyed to ensure proper mating with the cable receptacle.
1. Once the key has slid into the mating slot, tighten the connection by turning the
knurled ring clockwise.
2. Screw the sensor into a plastic fitting, which is held in the flow cell by a union nut.
Do not remove the protective cap on the sensor until ready to put the sensor in
service.
Installation
Instruction Manual 11

Installation
12 Rosemount MCL