Thermo Scientific AquaSensors AquaChlor User manual

Thermo Scientific AquaSensors™
AquaChlor™Free Chlorine
Monitor
User Guide

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Thermo Scientific AquaSensors™AquaChlor™Free Chlorine Monitor User Guide 1
Preface
This instruction manual serves to explain the use of the Thermo Scientific AquaSensors Free Chlorine
Measurement System and is written to cover as many applications as possible. Please do not hesitate to
contact Thermo Fisher Scientific or an authorized representative with questions or concerns.
The information presented in this instruction manual is subject to change without notice as improvements are
made, and does not represent any commitment whatsoever on the part of Thermo Fisher Scientific.
Thermo Fisher Scientific cannot accept any responsibility for damage or malfunction of the sensor due to
improper use.
Contact Information
To contact Thermo Scientific AquaSensors Technical Support:
Within the United States call 1.800.225.1480 or fax [phone].
Outside the United States call 978.232.6000 or fax [phone].
In Europe, the Middle East and Africa, contact your local authorized dealer.
Visit us on the web at www.thermo.com/processwater

Thermo Scientific AquaSensors™AquaChlor™Free Chlorine Monitor User Guide 2
Safety Information
The Thermo Scientific AquaSensors Free Chlorine Measurement
System shall be installed and operated only in the manner specified.
Only a skilled, trained or authorized person should carry out
installation, setup and operation of the sensor system.
Before using the system, make sure that is connected as specified.
Failure to do so may result in permanent damage to the system of its
components.
Protection against electric shock will be achieved only by observance
of the corresponding installation rules.

Thermo Scientific AquaSensors™AquaChlor™Free Chlorine Monitor User Guide 3
TABLE OF CONTENTS
1. INTRODUCTION...............................................................................................................................4
1.1. GENERAL INFORMATION.................................................................................................................... 4
1.2. INTENDED USE.................................................................................................................................... 5
2. PRODUCT DESCRIPTION.............................................................................................................. 6
2.1. SENSOR CARE AND START-UP............................................................................................................ 9
2.2. SENSOR INSTALLATION............................................................................................................... 11
3. MOUNTING HARDWARE ............................................................................................................ 12
3.1. UNION TEE....................................................................................................................................... 13
3.2. AQUACHLOR™-CHLORINE SAMPLE CHAMBER ............................................................................. 14
4. WIRING.............................................................................................................................................17
5. AV38 LOCAL DISPLAY INTERFACE ........................................................................................19
5.1. MEASURE SCREEN OVERVIEW......................................................................................................... 19
5.2. MENU STRUCTURE........................................................................................................................... 21
5.3. 1-POINT (SPAN)CALIBRATION......................................................................................................... 24
5.4. TEMPERATURE CALIBRATION .......................................................................................................... 27
5.5. CONFIGURATION.............................................................................................................................. 29
5.6. CHLORINE CONFIG (PHCOMPENSATION)......................................................................................... 30
5.7. ANALOG OUTPUT OVERVIEW .......................................................................................................... 32
5.8. RELAY FUNCTION OVERVIEW.......................................................................................................... 32
6. AQUACOMM™ INTERFACE.......................................................................................................33
7. DIRECT PLC CONNECTIONS..................................................................................................... 34
8. SPECIFICATION............................................................................................................................. 35
9. FREE CHLORINE SYSTEM ORDER MATRIX AND ACCESSORIES..................................36
1. LIMITED WARRANTY.................................................................................................................. 38
10. TERMS AND CONDITIONS.......................................................................................................... 39

Thermo Scientific AquaSensors™AquaChlor™Free Chlorine Monitor User Guide 4
1. INTRODUCTION
1.1. General Information
The product is designed for continuous use in industrial process applications and complies with safety
regulations currently in force. Improper use could lead to hazards for the user or a third-party, and/or adverse
effects to the plant or other equipment.
Thermo Fisher Scientific does not accept any liability for damage that may arise if information in this
manual is not followed. Therefore, the operating instructions and specifications must be read and
understood by all persons involved in installation and operation of this equipment.
This manual identifies safety instructions and additional information by means of the following symbols:
This symbol draws attention to safety instructions and warnings of potential danger,
which if neglected, could result in injury to persons and/or damage to property.
This symbol identifies additional information and instructions, which if neglected, could
lead to inefficient operation and possible loss of production.
It is recommended that this manual be made accessible to everyone who may need it as a reference.
Please contact Thermo Fisher Scientific or an authorized representative with any questions.

Thermo Scientific AquaSensors™AquaChlor™Free Chlorine Monitor User Guide 5
1.2. Intended use
The Free Chlorine Measurement Systems are used for continuous monitoring of free chlorine in
applications where the chlorine concentration is between 0.05 ppm and 5ppm or 0.05 ppm and 20 ppm.
The systems also measure water temperature.
Any other use, or use not mentioned here, that is incompatible with the technical specifications is deemed
inappropriate. The operator is solely responsible for any damage arising from such use.
Other prerequisites for appropriate use include:
 Observing the instructions, notes and requirements set out in this instruction manual.
 Observing all local safety regulations.
 Observing all warnings and cautions in the documentation regarding all products used in this
measurement system, including the sensor, mounting hardware, AV38 electronics and
cabling.
 Observing the prescribed environmental and operational conditions.
 Observing chemical compatibility with all wetted materials.
1.3. Safety Instructions
The Chlorine Measurement System should be installed and operated only by
personnel familiar with the sensor and qualified for such work.
A defective Chlorine Measurement System should be returned to Thermo Fisher
Scientific for repair or replacement. Contact Thermo Fisher Scientific to obtain a
Return Material Authorization (RMA) number.
No modifications to the Chlorine Measurement System are allowed. The
manufacturer/supplier accepts no responsibility for damage caused by unauthorized
modifications. The risk is borne entirely by the user.
1.4. Removal from Service / Correct Disposal of the Chlorine Measurement System
Removal from Service
 Disconnect the cable wiring from the controller terminal block.
 Remove the Chlorine Measurement System from the mounting hardware.
Correct Disposal of Unit
 When the Chlorine Measurement System is taken out of service, observe the local
environmental regulations for correct disposal.

Thermo Scientific AquaSensors™AquaChlor™Free Chlorine Monitor User Guide 6
2. PRODUCT DESCRIPTION
The Free Chlorine Measurement Systems are used for continuous monitoring of free chlorine in
applications where the chlorine concentration is between 0.05 ppm and 5 ppm or 0.05 ppm and 20 ppm.
The system also measures temperature from 0°C to 100°C.
The sensor head is pre-calibrated for span and the zero is factory set. The sensor retains calibration
values and does not require a new calibration when the system is connected to a new AV38 Display Unit,
PC, or PLC.
Any communications protocol that Thermo Fisher Scientific supports can be configured in this system by
plugging in one of many types of cabled communications adapters. All Thermo Scientific AquaSensors
communications adapters support measurement, calibration, configuration and diagnostics functions,
which can be accessed locally or remotely without an analyzer or controller electronics box.
The sensor in this system uses an amperometric measurement method with a gold cathode and a silver
anode. The electrolyte and membrane are easily replaced with a pre-stretched screw-on membrane cap.
Measurements are stable below 5 pH and are maintained in the pH window between 5 pH and 9 pH.
When pH compensation is used in conjunction with an AV38 local display, Hypochlorous acid or free
chlorine concentrations are automatically available when a chlorine sensor is connected.
•Modbus RTU
• Modbus 232
• Modbus TCP
• DeviceNet
• CANopen
• Ethernet/IP
• PCCC
• Web Browser
• USB
• RS-232
Plug-in Communications Adapters
•Retained calibration
• Screw-on membrane cartridge
• Simple electrolyte fill procedure
Plug-in Free Chlorine Sensor Head

Thermo Scientific AquaSensors™AquaChlor™Free Chlorine Monitor User Guide 7
The free chlorine system can be connected directly to a digital network, an AV38 local display or a
personal computer running AquaComm™ software. The following schematic illustrates:
Communications Suggested Application Standard Interface Reference
USB ASCII Laboratory PC, Field Laptop AquaComm™, Hyper Terminal® USB Adapter Manual
RS-232 ASCII Laboratory PC AquaComm™, Hyper Terminal® ASCII Commands and Responses detailed
in the appendix of the DataStick manual.
Modbus RTU AV38 Local Display
PLC with Modbus Network
AV38 Local Display
Modbus PLC Tools
AV38 Local Display Manual
Modbus Communications Manual
DeviceNet PLC with DeviceNet Network DeviceNet PLC Tools DeviceNet Communications Manual
CANbus PLC with CANbus Network CANbus PLC Tools CANbus Communications Manual
Ethernet/IP DeviceNet over Ethernet PoE Switch with DeviceNet Tools Ethernet Manual
PCCC Allen-Bradley SL/C 500 Series PoE Switch with PCCC Tools Ethernet Manual
Modbus/TCP Modbus over Ethernet PoE Switch with Modbus Tools Ethernet Manual
TCP/IP PC PoE Switch with Internet Explorer Ethernet Manual
Profibus DP connections are made through Thermo Scientific AquaSensors Profibus DP gateway which
connects up to 30 DataSticks with integral Modbus RTU comms adapters.

Thermo Scientific AquaSensors™AquaChlor™Free Chlorine Monitor User Guide 8
The sensor is designed for continuous use and has 1-inch NPT mounting threads for union tee and sample
chamber hardware. The parts of the sensor system are show here:
Product Highlights:
 0.05 to 5 ppm and 0.05 to 20 ppm Measurement Ranges
 Calibration stored in Sensor (Does not require recalibration after connection to
Analyzer/Controller)
 0.01 ppm Resolution
 Fast Response
 Simple membrane and electrolyte replacement
 Provides measurement, calibration, configuration and diagnostic functions without
Analyzer/Controller
 Works with AV38 for local display, current output data reporting, and relay control
 Temperature measurement included
 Can be connected to Modbus, DeviceNet, Ethernet, USB, RS-232 and CANopen networks.

Thermo Scientific AquaSensors™AquaChlor™Free Chlorine Monitor User Guide 9
2.1. Sensor Care and Start-up
The chlorine sensor is shipped without electrolyte in the membrane cap and the end of the sensor is covered
to protect the sensor membrane from physical damage. Before the system is installed, prepare the sensor as
follows:
1: Remove the protective cover from the sensor head. Be careful
not to damage the sensor membrane while removing the cover.
2: Unscrew the membrane cap from the sensor head.
3: Wet the silicone rubber band near the end of the sensor with
clean water. Apply light pressure to the band while turning the cap
to break any adhesion between the band and cap. The band should
be seated tightly in the groove on the cap, but it should not stick or
adhere.
4: Fill the membrane cap with Free Chlorine Electrolyte (PN:
RDOK9). Fill it up to the step just below the internal threads inside
the membrane cap.

Thermo Scientific AquaSensors™AquaChlor™Free Chlorine Monitor User Guide 10
5: Assemble the membrane cap back onto the sensor head. Screw
the cap on slowly until it seats against the gasket at the base of the
sensor head. Some excess electrolyte will drip out of the top of the
cap as it is threaded onto the sensor head.
6: Rinse the sensor head with clean water and dry it carefully.
Inspect the sensor head to make sure the membrane is intact and
does not leak electrolyte.

Thermo Scientific AquaSensors™AquaChlor™Free Chlorine Monitor User Guide 11
2.2. Sensor Installation and Calibration
After preparing the sensor as noted above, install the chlorine sensor in the appropriate hardware. Refer to section
3.1 of this manual for information on installing the sensor in an in-line tee or section 3.2 for information on
installing the sensor in a bypass flow chamber. If necessary, refer to section 4 of this manual for instructions on
wiring the sensor electronics. Begin process water flow through the system and adjust the flow rate as necessary.
The chlorine sensor has been polarized and tested prior to shipment but it will require time to re-polarize. After
installation, leave the sensor powered for at least 12 hours in the process before calibration. The system should
be configured for the desired pH compensation (see section 5.6) before calibrating the chlorine measurement.
If the installation uses a dedicated pH sensor for measurement compensation, calibrate the pH sensor (refer to
user guide for the pH sensor for calibration instructions) and install it as required.
The chlorine sensor temperature measurement can be calibrated with a 1-point sample calibration. It is
recommended to calibrate the temperature measurement before calibrating the free chlorine measurement
because the chlorine reading is temperature compensated. Refer to section 5.4 of this manual for the temperature
calibration procedure.
The chlorine measurement is also calibrated with a 1-point sample. Calibration should be done with a measured
free chlorine reading (DPD colorimetric, etc.) that is in the normal measurement range. With this calibration, the
current sensor reading can be set to a known value. Refer to section 5.3 of this manual for the chlorine calibration
procedure.
Note: Be sure the AV38 is properly configured for either fixed or automatic pH compensation. If fixed
compensation is selected, make sure the correct pH value has been entered.

Thermo Scientific AquaSensors™AquaChlor™Free Chlorine Monitor User Guide 12
3. Mounting Hardware
The Free Chlorine Measurement System should be installed in a union pipe tee or in an AquaChlor-style
bypass sample chamber. In either case, care must be taken to insure constant flow and pressure at the
membrane surface for accurate readings.
When the sensor system is inserted into a Thermo Scientific AquaSensors bypass sample chamber,
pressure is automatically regulated through an overflow weir.
When using union tee mounting, care must be taken to regulate pressure for accurate measurement.
When configured with a plug-in communications adapter the sensor is 12.08 inches long from sensor tip to
the end of the communications adapter body. The largest diameter of the sensor head is 1.35 inches.

Thermo Scientific AquaSensors™AquaChlor™Free Chlorine Monitor User Guide 13
3.1. Union Tee
The Free Chlorine System is threaded into the Union Tee adapter. The adapter is then set into the tee and
the retaining ring is tightened down.

Thermo Scientific AquaSensors™AquaChlor™Free Chlorine Monitor User Guide 14
3.2. AquaChlor™ - Chlorine Sample Chamber
The AquaChlorTM sample chamber compensates for minor changes in sample pressure and flow. A flow
regulator is recommended to adjust the inlet flow to approximately 250 ml/min (see installation instructions
on pages 15 and 16). The chlorine sensor is inserted into the top of the flow chamber, into the port on the
left-hand side of the chamber. For applications that require pH measurement, the pH sensor is inserted into
the top of the flow chamber, into the port on the right hand side of the chamber.
The free chlorine sensor and optional pH sensor are connected to an AV38 local display. The AV38
calculates the concentration of free chlorine components. If an AV38 is not desired, the pH and chlorine
DataStick systems can be connected directly to a digital network without the AV38 display and the
compensation algorithm can be supplied and operated by a computer or PLC.

Thermo Scientific AquaSensors™AquaChlor™Free Chlorine Monitor User Guide 15
The AquaChlorTM measurement system is mounted on 12 inch x 12 inch panel with four ¼ inch mounting
holes. Use ¼ inch bolts with washers to mount the panel to a wall, making sure the sample chamber is
level and plumb. It is important to note that the system must be fixed securely to the wall to insure the
chamber does not move when handled or touched.
To obtain a stable chlorine measurement, the flow through the chamber should be adjusted with the inlet
valve. When properly adjusted, the right port (pH port) in the flow chamber should fill and overflow into the
center drain, while the left port (chlorine port) should partially fill and flow through a small side orifice into
the center drain. Note that the orifice connecting the chlorine port to the drain must be kept clear and not
obstructed. If debris builds up in the orifice it can be accessed for cleaning by removing the clean-out plug
in the side of the flow chamber.
.

Thermo Scientific AquaSensors™AquaChlor™Free Chlorine Monitor User Guide 16
Sample Chamber Mounting tools and equipment:
 ½ inch Drill with drill bit for appropriate wall anchor.
 Four ¼ diameter bolts – 1.5 inches long.
 Four ¼ inch ID flat washers
 Wrench to turn bolts
 Level to insure the system is level when mounted
General Sample Chamber Mounting Instructions:
1. Place the 12 inch x 12 inch panel on the wall where it is to be mounted and mark the placement of the
upper left hole.
2. Drill a mounting hole for the upper left corner with a masonry drill bit.
3. Mount the AquaChlor System with the upper left bolt.
4. Using a level, rotate the system until level, then mark the other three mounting holes.
5. Rotate the plate out of the way and drill the other three mounting holes.
6. Place all four bolts with washers and tighten. Use shims if necessary to insure the sample chamber is
level.
General Sample Chamber Plumbing Instructions:
1. The AquaChlor™ system has a water INLET and an OUTLET.
2. Barb fittings are provided for the INLET and OUTLET to accommodate 3/8 inch and 1/2 inch ID tubing
respectively.
3. When the INLET is to be directly plumbed rather than using tubing, remove the barb fitting and install
¼ inch NPT threaded pipe to the INLET.
4. When the OUTLET is to be directly plumbed rather than using tubing, remove the barb fitting and
install straight ½ inch NPT threaded pipe that extends to a vented drain. Pipe restrictions that result in
back pressure to the OUTLET are not allowed.
5. The sample supply must be between 250 to 750 ml/min (4 to12 gph). If the source is under pressure,
use an appropriate flow or pressure valve to obtain consistent flow.
6. Turn on water flow into the flow chamber.
7. Adjust the flow rate through the system with the inlet valve on the flow chamber. If the right port in the
flow chamber is not overflowing to the center drain, increase the flow through the system. If the left
port in the flow chamber is overflowing to the center drain, decrease the flow through the system.

Thermo Scientific AquaSensors™AquaChlor™Free Chlorine Monitor User Guide 17
4. Wiring
Each communications adapter has a label printed at the end of the cable that indicates the supported protocol
and the corresponding wiring chart. The standard cable length is 10 feet with the idea that the cable will
terminate in a junction box. It is however possible to order the communications adapter with any length of cable
up to the maximum allowed by the particular protocol being used. (Note: In the pre-packaged AquaChlor
System configuration, both the free chlorine and pH sensors are supplied with 30 inch cables.) In practice all
adapters have four wires and a shield. Any Class 2 DC power supply that provides 24VDC can be used.
For DeviceNet, Modbus and RS-232 cables, the RED and BLACK wires are for power, the BLUE and WHITE
wires are for communications, and a bare shield wire is connected to EARTH GROUND for safety and
electromagnetic immunity and emissions.
Color DeviceNet Modbus RTU RS-232
RED 24 VDC 12 to 30 VDC 12 to 30
VDC
BLACK Signal
Ground Signal Ground Signal Ground
BLUE CAN_L Comms (-) Rx
WHITE CAN_H Comms (+) Tx
SHIELD Earth Earth Earth
All Ethernet Adapters (Ethernet/IP, Modbus TCP, PCCC and TCP/IP) are terminated with an RJ45 connector
that plugs in to any PoE switch or power injector.
All USB Adapters are terminated with a USB connector that plugs into most PC’s. Power is supplied by the
host computer.
When an AV38 local display is used, the sensor must be configured with a Modbus RTU communications
adapter.

Thermo Scientific AquaSensors™AquaChlor™Free Chlorine Monitor User Guide 18
The communications adapters are keyed and plug into the end of the DataStick™ marked “Communication
Adapter”. Insert the communications adapter until it bottoms out. Rotate the adapter until it engages with the
connector. Push in gently and then tighten the retaining ring with a 15/16-inch wrench.
Communications adapters can be inserted into the “Sensor Head” end of the DataStick™ but the adapter is not
long enough to reach the internal connector. Likewise, any sensor head can be inserted into the
communications adapter end of the DataStick™ but it will be too long for the retaining ring to be engaged.
O-Ring seal should be free of
dirt when inserted in the free
chlorine sensor bod
y
.
Potted Serial number and Part number.
Retaining Ring:
Insert the Adapter into the DataStick™ and rotated
until it engages.
Tighten the retaining ring to lock down the adapter.
Use a 15/16 inch (24mm) wrench. Rotate clockwise
to tighten.