GF 4630 User manual

The Signet Chlorine Analyzer System is an integrated, all-in-one chlorine panel system designed to measure free chlorine in
drinking water and clean fresh water treatment applications.
Features:
Complete chlorine analyzer system allows quick setup and easy•
installation. Connect to a water source and plug it in.
Unique integrated clear flow cell combines sensors, flow regulator,•
filter and rotameter in one compact unit.
Built-in rotameter facilitates flow rate confirmation at a glance.•
Integrated flow regulator with removable filter accepts inlet pressures•
of 15 to 150 psi while maintaining constant flow and minimal pressure
to the sensors.
Water flows vertically into sensor tip, eliminating bubble entrapment.•
Raised exit in flow cell sensor chamber ensures sensors stay
submerged even when system and flow is turned off.
System is supplied with pre-wired electronics, power cable, 4 to 20 mA•
current loop and relay output capability.
Flow cell accommodates two sensors; one chlorine and an optional•
pH sensor.
Automatic pH and temperature compensation or manual pH value•
input capability for chlorine reading accuracy.
Easy viewing of the transmitter via the bright backlit LCD display.•
Moisture proof NEMA 4X wiring enclosure.•
Exterior panel enclosure available for outdoor mounting applications.•
Refer to the individual component manuals for detailed component
information.
8630-3 Chlorine Transmitter Manual•
2630-2 Amperometric Chlorine Electrode Manual•
2650 Amperometric Electronics Manual•
2724 pH/ORP Electrode Manual•
2750-7 pH Electronics Manual•
*3-4630.090*
3-4630.090 Rev A 09/10 English
English
CAUTION!
Follow instructions carefully to avoid personal injury.1.
Do not exceed the maximum pressure or temperature specifications.2.
Mounting the Chlorine System in an outdoor box, in areas with elevated temperatures, may3.
cause damage to the system if the enclosure's internal temperature exceeds the temperature
specification of the Chlorine Analyzer.
Do not alter product construction.4.
For use with clean fresh water only.5.
Disconnect AC power before opening wiring enclosure.6.
This panel system uses AC voltages. Wiring should be done by qualified personnel only.7.
1. Description
Signet 4630 Chlorine Analyzer System
1. Description p.1 6. System Setup p.5 11. O-rings p.11
2. Dimensions p.2 7. Wiring p.7 12. Flow Cell Assembly p.12
3. Component Identification p.3 8. Water Flow p.8 13. Troubleshooting p.13
4. Mounting p.4 9. Flow Cell Components p.9 14. Ordering p.14
5. Tubing Connections p.4 10. Cleaning p.10 15. Specifications p.16

2 4630 Chlorine Analyzer System
2. Dimensions
165 mm
(6.5 in.)
305 mm (12 in.)
254 mm (10 in.)
330 mm (13 in.) 76 mm
(3 in.)
171 mm (6.75 in.)
578 mm (22.75 in.)
Ø 7 mm
(0.27 in.)
25 mm
(1.0 in.)
Ø 13 mm
(0.52 in.)
79.3 mm (3.12 in.)

34630 Chlorine Analyzer System
3. Component Identification
Power cable conduit
Chlorine sensor
with electronics
Flow cell block
Flow cell O-rings
Knurled thumb nut
Vent
Cap
Output conduits
Transmitter
Wiring enclosure
Flow rate indicator
Flow range limits
Plug
Flow regulator with strainer
Hex bolt
Inlet port
(3/8 inch hose)
Drain port
(3/8 inch hose)
Sampling port
(3/8 inch hose)
pH Sensor
with electronics
DryLoc®connection to the sensor electronics

4 4630 Chlorine Analyzer System
Inlet Drain
(to atmosphere)
Sampling port
(flow off)
4. Mounting
Mount the panel according to electrical, building, and or plumbing codes and•
seismic requirements.
The panel must be mounted vertically in an upright position.•
Use four 6 mm (¼ in.) diameter screws or bolts of sufficient length to mount•
the panel to a sturdy vertical surface. A mounting template is provided.
Allow clearance on the sides and bottom for service to the unit.•
Mount in a shaded location out of direct sunlight. Indoors is recommended.•
Bright light can promote algae growth.
Keep panel system electronics and enclosure away from dripping water.•
If the system is mounted outdoors, an outdoor enclosure for the whole•
system must be used to protect the electronics and flow cell from light,
rodents, insects and dirt. A suitable outdoor box is available from Georg
Fischer Signet.
5. Tubing Connections
Use suitable tubing that is rated for your inlet pressure. Use hose clamps.•
NO
Valve position for start up and normal use
Note: Turn off inlet valve first when stopping
water flow.
• The drain tube must be positioned lower than
the influent water source to allow proper flow
through the flow cell. The flow cell must drain by
gravity, not system pressure.
Inlet Quick Release Connection
Press down gray plunger to release. Water flow
is automatically shut off when disconnected.

54630 Chlorine Analyzer System
Step 1. Mount the panel on a vertical flat surface using appropriate hardware.
Step 2. Install the influent water source to the "Inlet Port" nipple assembly of the flow cell. Use tubing
that is properly rated for the system pressure and secure with hose clamps.
Step 3. Install tubing on the "Drain" port and direct the tube to a proper drain.
Step 4. Open the wiring enclosure and wire any 4 to 20 mA and relay outputs. (See section 7: Wiring)
Step 5. Remove sensor access plugs from the flow cell. If the optional pH sensor is NOT used, only remove the
right plug from the flow cell.
Step 6. Remove the protective cap from the chlorine electrode tip and install the electrode into the flow cell.
(Keep the electrode tip cap in a safe place for future use. It is recommend to use the cap to protect the
sensor during the removal of the electrode for cleaning or maintenance of the flow cell.)
Step 7. Repeat step 6 if the optional pH sensor is being used.
Step 8. Verify the inlet and drain ball valves are in the open position and the sample port is in the off position.
(See section 5: Tubing Connections)
Step 9. Turn on the influent water source and check the system for leaks.
Step 10. Plug in or apply input power to the system.
NOTE: A new chlorine sensor requires a 4 hour conditioning period with power on and water flowing past the
sensor prior to calibration. All new chlorine and pH sensors require calibration during the start up of a system
and also throughout the life of the sensor. See the 3-8630-3P transmitter manual for the proper calibration
procedure.
6. System Setup Overview
Follow the steps below to set up a new Chlorine Analyzer System.
Refer to the individual component manuals for detailed information.
Sensor access plugs

6 4630 Chlorine Analyzer System
7. Wiring
Follow all local and government recommendations and methods
for installation of electrical connections to and between the
system and other devices.
System Input Power
The panel system is pre-wired with an auto switching power•
supply that is rated for 100 to 240 VAC 50/60 Hz input.
The supplied plug is a standard North American Type B. If•
the source is 220 to 240 VAC, use an adapter plug.
Install in a properly grounded circuit.•
Install a circuit breaker in the AC line for easy maintenance•
and short circuit protection.
If wiring via conduit connection, include a disconnect device•
(switch) to power down the system.
Output Connections
Use the wiring enclosure terminal block for output wire•
connections. Do not wire directly to the transmitter.
• Do not run 4 to 20 mA loop cables in the same conduit as the
power or other high voltage wiring.
Remove one installed jumper wire (from both of its terminals)•
on the terminal block in the enclosure for each loop device
connected. Replace the jumper if you later remove your loop
device. If only one loop device is connected, remove just one
jumper wire from its two terminals.
The panel system uses an active loop output wired to the•
enclosure terminal block.
If connecting to a PLC, use the PLC's passive input.•
The transmitter must have a jumper wire or loop device•
always connected to Loop 1.
Use Loop 2 when using only one loop output.•
WARNING
This panel system is wired for AC voltages that can injure
or kill. Wiring should be done by qualified personnel only.
Disconnect AC power before opening wiring enclosure.
Wiring Label Legend
Ground Earth Ground. Attach 4 to 20 mA loop cable
shield wire here to help eliminate possible noise.
Loop 1 4 to 20 mA Loop #1
Loop 2 4 to 20 mA Loop #2
Relay 1 Relay Output #1
NC Relay Normally Closed when un-energized
(contact)
C Common
NO Relay Normally Open when un-energized (no
contact)
Relay 2 Relay Output #2 (terminals same as Relay #1)
PLC Terminals
Channel 2
4 to 20 mA
Channel 1
4 to 20 mA
+
-
+
-
1 2 3 4 5 6 7 8 9 10
+ - + -
NC C NO NC C NO
LOOP 1
LOOP 2
GROUND
RELAY 1
RELAY 2
GND
PLC dual channel connection
Jumper wire removed
to 4 to 20 mA
loop device
Wiring a 4 to 20 mA loop device

74630 Chlorine Analyzer System
Wiring - continued
12 to 24 VDC Input Wiring Conversion
If the power source supplied to the system will be 12 to 24•
VDC instead of 100 to 240 VAC, remove the AC wires from
the system. Disconnect the red and black output wires from
the power supply and connect your DC power source to
them.
If the AC wires are removed from the system, the earth•
ground connection on the green terminal block will be lost as
well. Run a separate ground wire into the wiring enclosure if
grounding is needed for the loop shield wire.
100 to 240 VAC input
Standard AC configuration
12 to 24 VDC input
User supplied wiring
WARNING
This panel system is wired for AC voltages that can injure
or kill. Wiring should be done by qualified personnel only.
Disconnect AC power before opening wiring enclosure.
+
–
Power Supply Terminal Identification
Terminal Name Description
V. ADJ Voltage
adjustment
Adjusts within ±10%; turning
clockwise increases output
voltage
DC ON Operation
indicator
Green LED is lit when output
voltage is on
+V, –V DC output
terminals
+V: Positive output terminal
–V: Negative output terminal
Frame ground Ground terminal to reduce high-
frequency currents caused by
switching
L, N Input terminals Accepts a wide range of
voltages and frequencies (no
polarity at DC input)
NC No connection Do not insert wires here, as this
may damage the power supply

8 4630 Chlorine Analyzer System
8. Water Flow
IN
OUT
pH Cl
OK
Sensor Removal
Caution
Over time, a sensor can get tight in the flow cell fitting. When
removing the sensor, avoid hitting the sensor electronics into the
bottom of the wiring enclosure if the sensor suddenly releases.
While holding the flow cell, grasp the yellow electronics as a
whole unit and carefully pull upwards, gently rocking back and
forth if necessary. Once the sensor is loose, disengage the
electronics, then remove the sensor.
TIP: A tool can be used to carefully pry the sensor electronics up
and out if it is difficult to remove.
Take care not to damage the components.
Flow Rate
The flow rate is in the proper range when the center line on the
float is within the Min. and Max. markers on the flow cell. The flow
range limits are 30.24 to 45.36 L/h (8 to 12 gal/h).

94630 Chlorine Analyzer System
Flow cell front block
Disc spring
Spacer ring
Stainless steel filter
Pressure regulator
Pressure regulator outer O-ring (large)
Pressure regulator outer O-ring (small)
Flow cell O-rings (4 segments)
Flat washer
Flat washer
Disc spring (curved washer)
Knurled thumb nut
Flow cell bolt
Included in kit 3-4630.390
Item Quantity
Flow cell nut 6
Flat washer 15
Disc spring 9
Knurled thumb nut 3
Flow cell bolt 6
9. Flow Cell Components
Flow cell nut
Flat washer
Flow cell back block
(1700-2501)
(3200-2578)
(3-4630.150)
(3-4630.391)
(3-4630.150)
(3200-2578)
(2700-0003)
(1700-2512)
(2490-0554)
(3-4630.390)

10 4630 Chlorine Analyzer System
10. Cleaning
Under certain conditions, a dirty flow cell and filter can create a
chlorine demand which could lower the chlorine concentration in
the water flowing past the chlorine sensor. Because of this, it is
recommended to clean the filter and flow cell on a regular basis.
The frequency of necessary cleaning will depend on the application
in which the system is being used and the level of accuracy required.
Step 1. Keep the system powered on.
Step 2. Disable the relays and any output loops.
Step 3. Turn off the water flow.
Step 4. Remove the sensors and reattach their electronics
after removal.
Step 5. Install the vinyl caps on to the sensor tips or place
the tips of the removed sensors in a cup of sample
water for temporary storage while cleaning the flow cell.
Keep the sensor tips wet and the sensors energized.
Step 6. Remove the flow cell from the panel by removing the
knurled nuts. (Figure 1)
Step 7. Remove the remaining hardware from the flow cell.
(Figure 2)
Wash the surfaces with water or soapy water only.•
Use gentle, liquid dishwashing soap if necessary.•
Do not use commercial glass cleaning fluids.•
Use a soft, lint-free cloth.•
If your inlet pressure is less than 1 bar
(15 psi), remove the flow regulator.
WARNING: Do not disassemble the flow
regulator. There are no user serviceable
parts inside.
Remove filter screen to clean. If the filter
is not desired, it may be removed from the
system.
Flow Regulator
Service the flow cell on a clean, dirt free surface to avoid
scratches or damage to the flow cell.
Servicing the Flow Regulator and Filter
Figure 1
Figure 2

114630 Chlorine Analyzer System
11. O-rings
The sealing of the flow cell is accomplished by four cut•
O-ring segments and two round O-rings sealing the flow
regulator. Refer to the illustration below for special O-ring
fitting instructions. Butt all O-ring joints together so there is
no gap.
Remove the O-rings during flow cell disassembly. Both the•
O-rings and all sealing grooves should be examined for
cleanliness.
Wipe all surfaces carefully with a soft, lint-free cloth to ensure•
good sealing.
The cross section of the O-rings should be round and•
smooth. If they are flattened, their ability to seal is reduced.
Do not use liquid or paste sealant.•
Do not scratch the sealing surfaces of the flow
cell block. Scratches to the sealing surfaces
can cause irreparable leaks.
1
2
3
6
5
4
New O-ring
cross section
Old flattened O-ring
cross section
(Replace)
Individual O-rings shown.
Butt all segment joints together in final assembly.
Fit all O-ring joints so there is no gap in final assembly.
Fit flush with no gap
Straight cut
Angle cut O-ring
Fit flush with no gap
Angle cut O-ring
Fit flush with no gap
Straight cut
Butt ends together

12 4630 Chlorine Analyzer System
Tighten the nut just enough to hold
the block together and keep the
O-rings in place.
6
Tighten the bolts in three passes to
specification.
8
12. Flow Cell Assembly
WARNING!
Do not over tighten flow cell bolts. Maximum torque is 8.1 Nm (72 Lb-In).
Over tightening the bolts can damage the flow cell.
Do not over tighten the bolts in an attempt to stop a leak.
Install the nut and washers.
5
Install the remaining bolts, washers
and nuts.
7
1
2
3
6
5
Torque
8.1 Nm
(72 Lb-In)
MAX!
4
Tighten bolts in 3 passes
Install the assembled pressure
regulator and the two round
O-rings into the flow cell.
1
Install the four O-ring
segments.
2
Insert the center bolt into the
block.
3
4
Align and place the back block
onto to flow cell. Check to be
sure that the O-rings are seated
correctly.
9
Install the flow cell on the panel.
Screw on the thumb nuts finger tight.
Do not use tools on the thumb nuts.

134630 Chlorine Analyzer System
The troubleshooting table below outlines possible causes and remedies related to the flow cell panel system. Refer to the transmitter
and sensor manuals for specific component troubleshooting.
Problem Possible Cause Remedies
No water flow • Inlet pressure below 1 bar (15 psi)
• Clogged filter
• Damaged flow regulator
• Check source pressure
• Clean filter or remove pressure regulator if
inlet pressure is below 1 bar (15 psi)
• Replace flow regulator
Low water flow • Clogged filter
• Insufficient inlet pressure
• Damaged flow regulator
• Clean filter
• Increase inlet pressure to specification
or remove flow regulator
• Inspect or replace
Excessive flow • Excessive pressure over 10 bar (150 psi)
• Damaged flow regulator
• Ensure inlet pressure does not exceed
10 bar (150 psi)
• Replace flow regulator
Flow cell leaks • Incorrect assembly
• Loose bolts
• Defective or missing O-rings
• Damaged sealing surfaces
• Inspect, clean, and reassemble
• Tighten bolts (8.1 Nm, 72 Lb-In Max)
• Replace O-rings
• Replace flow cell
Leaks around sensor • Damaged sensor O-ring
• Damaged flow cell
• Inspect or replace O-ring
• Inspect flow cell
Water leaks out of top vent hole • Drain valve closed or plugged
• Hose connections are backwards
• Outlet drain not below flow cell
• Inspect
• Connect water source correctly
• Route drain line below flow cell and
vented to atmosphere
Algae growth in flow cell • Low chlorine concentration in water
• Exposure to light
• Locate flow cell away from light
Excessive small bubbles in flow cell
accumulating on sensors
• Water source contains bubbles
• Water source is saturated with dissolved
gasses
• Check water source
Transmitter does not turn on • No power or external circuit breaker is
switched off
• Loose or incorrect wire connections
• Open loop wiring or missing jumper wire on
terminal 1 (Loop 1) on the wiring enclosure
terminal block
• Inspect power and wiring connections
• Check connections
• Replace jumper wire to terminal 1 or
connect a loop device if the jumper wire to
terminal 1 is removed
Chlorine reading too high • Breached membrane • Replace membrane and fill solution
Chlorine reading too low • Low flow rate
• Filter clogged
• Sensor conditioning not long enough
• Check source pressure
• Clean the filter
• Allow the sensor to condition for 4 hours
(See 2630 sensor manual for details)
Sensor output drifts • Variable flow rate
• Clogged filter
• Contaminated fill solution
• Check flow rate
• Clean the filter
• Change electrolyte fill solution
Chlorine Electrode Troubleshooting (see 2630-2 electrode manual)
Transmitter Troubleshooting (see 8630-3 transmitter manual)
pH Electrode Troubleshooting (see 2724 electrode manual)
13. Troubleshooting

14 4630 Chlorine Analyzer System
14. Ordering Information
Mfr. Part No. Code Description
3-4630-20 159 001 691 Chlorine panel, transmitter, free chlorine sensor (0 to 5 ppm) with electronics, no
pH sensor
3-4630-21 159 001 692 Chlorine panel, transmitter, free chlorine sensor (0 to 5 ppm) with sensor
electronics, pH sensor with electronics
3-2630-2 159 001 662 Free Chlorine sensor, 0 to 5 ppm (mg/l)
3-2724-00 159 001 545 pH electrode, flat glass, PT1000 temp element, ¾ in. MNPT
3-2650-7 159 001 670 Chlorine - Inline Amperometric Electronics, Digital (S3L), 4.6 m (15 ft) cable
3-2750-7 159 001 671 pH - Inline Electronics, Digital (S3L), 4.6 m (15 ft) cable
3-8630-3P 159 001 673 Panel mount chlorine and pH transmitter
Accessories and Replacement Parts
Mfr. Part No. Code Description
3-4630.390 159 001 688 Rebuild kit, O-rings, boots, screws, 1 filter screen
3-4630.391 159 001 689 Pressure regulator with 1 spare filter screen
3-4630.392 159 001 690 Acrylic flow cell complete with all components and connections
7300-7524 159 000 687 24 VDC Power Supply 7.5 W, 300 mA
3-2630.391 159 001 674 Free Chlorine electrolyte, 30 ml
3-2630.392 159 001 675 Free Chlorine replacement membrane (1)
3-2630.396 159 001 676 Free Chlorine replacement kit - (2) electrolyte and (2) membranes
3-0700.390 198 864 403 pH Buffer Kit (1 each 4, 7, 10 pH buffer in powder form, makes 50 ml of each)
3822-7004 159 001 581 pH 4.01 buffer solution, 1 pint (473 ml) bottle
3822-7007 159 001 582 pH 7.00 buffer solution, 1 pint (473 ml) bottle
3822-7010 159 001 583 pH 10.00 buffer solution, 1 pint (473 ml) bottle
3-2700.395 159 001 605 Calibration kit: included 3 polypropylene cups, box used as cup stand,
1 pint pH 4.01, 1 pint pH 7.00

154630 Chlorine Analyzer System
Notes

Georg Fischer Signet LLC, 3401 Aerojet Avenue, El Monte, CA 91731-2882 U.S.A. • Tel. [phone] • Fax [phone]
For Worldwide Sales and Service, visit our website: www.gfsignet.com • Or call (in the U.S.): [phone]
For the most up-to-date information, please refer to our website at www.gfsignet.com
3-4630.090 Rev A 09/10 English © Georg Fischer Signet LLC 2010
15. Specifications Signet 4630 Chlorine Analyzer System
Environmental Requirements
Storage Temperature:
0 °C to 65 °C (32 °F to 149 °F)
Operating Temperature:
0 °C to 45 °C (32 °F to 113 °F)
Relative Humidity:
0 to 95%
Maximum Altitude:
2000 m (6562 ft)
Enclosure:
NEMA 4X (with output wire glands sealed)
Standards and Approvals
CE
China RoHS (Go to www.gfsignet.com for details)
Shipping Weight
10 kg (22 lbs)
General
Compatible Sensors:
Signet 3-2630-2 Free Chlorine Sensor
Signet 3-2724-00 Flat pH Electrode
Materials:
Panel: ABS
Wiring Enclosure: Polycarbonate
Wetted Materials:
Acrylic (flow cell, spacer rings)
Polycarbonate (flow regulator housing)
Stainless steel (strainer, e-clip, regulator spring,
float)
Polypropylene (valves, vent )
EPDM, FKM (flow cell O-rings, diaphragm)
PVC, PVDF, FPM (Chlorine electrode)
PPS, Glass, UHMW, PE, FPM (pH electrode)
PTFE (sealing tape on valves, plug and vent)
Polyethylene (plug)
Performance
System Inlet Pressure Rating:
1 to 10 bar (15 to 150 psi)
Pressure Regulator:
< 0.69 bar (10 psi) variation over all ranges of
flow and pressure
Flow Tolerance:
± 15% or rated specification above
Flow Rate Limits:
37.8 to 75.7 L/h (10 to 20 gal/h)
Electrical
AC Input - Standard Configuration:
100 to 240 VAC nominal (85 to 264 VAC),
50 to 60 Hz (47 to 63Hz), 0.17 A at 100 VAC
DC Input - Optional Configuration:
12 to 24 VDC ±10% regulated, 250 mA max
Material Safety Data Sheets (MSDS) are available online at www.gfsignet.com.