Turtle Tough TT-CL2 User manual

TURTLE
TOUGH
®

OPERATION MANUAL
TT-CL2 FREE CHLORINE SENSOR
Ion Specic Chlorine Analyser
turtletoughsensors.com

CONTENT
SAFETY PRECAUTIONS 3
THEORY OF OPERATION 3
SPECIFICATIONS 4
Residual Chlorine sensor probe 4
Flow cells 4
Electrochemical Probe Simulator 4
INSTALLATION 5
Site selecon 5
Unpacking 5
Mounng 6
Water connecons 6
OPERATION 6
Calibraon 6
SENSOR 7
Installaon 8
Setup 8
Maintenance 11
4.0.3.1 Roune maintenance 11
4.0.3.2 Diagnosc maintenance 11
Storage 11
Spares 11
Single owcell 11
4.0.6.1 Inseron 12
Double owcell 13
COMMISSIONING 13
TROUBLESHOOTING GUIDE 13
Further help 13
APPENDICES 14
General layout drawings 14
Cercates and approval statements 15
Returns Procedure and ‘Free of Contaminaon Sheet’ 16
Warranty 17
MSDS safety data sheets for Free Chlorine Electrolyte (ECS2.1/GEL) Electrolyte (ECS2.1/GEL 18
Calibraon informaon and sensor setup 21

T T-CL2
Free Chlorine Sensor
SAFETY PRECAUTIONS
• Before aempng to unpack, set up, or operate this instrument, please read this enre manual.
• Make certain the unit is disconnected from the power source before aempng to service or remove any
component.
Make certain the unit is disconnected from other sources of force or pressure (for example, pneumac or hydrau-
lic), before aempng to service or remove any component.
• Failure to follow these precauons could result in personal injury and damage to the equipment.
1. THEORY OF OPERATION
The free chlorine sensor has been designed to measure the concentraon of dissolved free residual chlorine.
It does this using a Potenastac 3-electrode chronoamperometric sensor insulated from the water supply
by a hydrophilic membrane. The free chlorine diuses through the membrane and is reduced at the cathode
generang a small current that is proporonal to the concentraon of free chlorine. In potable, process, or
swimming pool water this means HOCl (hypochlorous acid) and OCl- (hypochlorite ion). The relave amount of
these two species is dependent on the pH of the soluon. At low pH’s the predominant species will be HOCl.
At higher pH's the predominant species will be OCl-. Tradional amperometric measurement systems need to
be buered to an exact pH in order that changes in the pH of the sample water do not aect the Free Chlorine
measurement. The probe supplied for Free Chlorine measurement with this instrument is not aected by changes
in pH to the same degree. This means that on many plants it will not be necessary to buer the sample water at
all. If it is necessary to buer the sample water, because the pH is both high and variable it will only be necessary
to reduce the pH to below 6.5. This is best done using the CO2 Buer accessory. The probes are available for a
variety of ranges which are specied at the me of purchase.
The sensor incorporates automac temperature compensaon (ATC).
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TURTLETOUGH
IPM19 HaloSense Free Chlorine Probe
Manual date 12/1/2011 Page 4of 29
1.0 Theory of Operation
The free chlorine sensor has been designed to measure the concentration of dissolved free residual
chlorine. It does this using a Potentiastatic 3-electrode chronoamperometric sensor insulated from the water
supply by a hydrophilic membrane. The free chlorine diffuses through the membrane and is reduced at the
cathode generating a small current that is proportional to the concentration of free chlorine. In potable,
process, or swimming pool water this means HOCl (hypochlorous acid) and OCl-(hypochlorite ion). The
relative amount of these two species is dependent on the pH of the solution. At low pH’s the predominant
species will be HOCl. At higher pH's the predominant species will be OCl-. Traditional amperometric
measurement systems need to be buffered to an exact pH in order that changes in the pH of the sample
water do not affect the Free Chlorine measurement. The probe supplied for Free Chlorine measurement
with this instrument is not affected by changes in pH to the same degree. This means that on many plants it
will not be necessary to buffer the sample water at all. If it is necessary to buffer the sample water, because
the pH is both high and variable it will only be necessary to reduce the pH to below 6.5. This is best done
using the CO2Buffer accessory. The probes are available for a variety of ranges which are specified at the
time of purchase.
The sensor incorporates automatic temperature compensation (ATC).
Typical Probe Response to pH
(Unbuffered)
0
20
40
60
80
100
120
6
6.5
7
7.5
8
8.5
9
9.5
10
Chlorine Probe Response
Typical Amperometric Probe Response

T T-CL2
Free Chlorine Sensor
1.1 SPECIFICATION
1.1.1 Sensor
Type Membrane covered amperometric potenostac three-electrode system
Measurand Free Residual Chlorine
Range 0-2, 0-5, 0-10mg/l (ppm)
Resoluon 0.01mg/l (ppm)
Reproducibility ±5 %
Stability -2 % per month (without calibraon)
Working electrode Cathode made of gold
Counter electrode Anode made of stainless steel
Reference electrode Silver / silver halide
Membrane material Micro-porous hydrophilic membrane
Flow rate 0.5 l/min (0.13 gallon/minute [US])
Temperature range >5 and <45°C
Temperature compensaon Automacally by an integrated thermistor (ATC)
pH-range pH 4 up to pH 9.5
Permissible overpressure 0.5 bar
First-polarisaon me 120 min
Re-polarisaon me 30 min
Response me T90: approx. 2 min
Zero-point adjustment Not necessary
Zero running Running at zero de-polarises the probe
Calibraon Manual using DPD or Automac (Autocal)
Housing material PVC, silicone, polycarbonate, stainless steel, perspex
Dimensions Diameter approx. 25mm (1”), length 175mm (7”)
Maintenance intervals
Calibraon On control applicaons it is a week to a month & on non-control it is 1 to 3 months.
Electrolyte Quarterly
Calibraon reagent Six monthly (Autocal unit only)
Membrane Yearly
Interferences High levels of other oxidants such as Ozone and Chlorine Dioxide
1.1.2 Flow cell
Inlet ¼” or 6mm barb ng, or 8mm pipe push-ng
Outlet ½” or 12mm barb ng
No. of probes Single and double ow cells available
Service isolaon Ball valve
Flow 0-1.4 l/min (preferred ow rate 0.5 l/min)
Inlet pressure 0.5 bar
Flow cell pressure Eecvely zero, cell open to atmosphere
Weight 1kg (single), 1.5kg (double)
Filter (if ed) 100um
Flow switch available as an opon to give a low ow alarm if sample ow is lost.
1.1.3 Electrochemical probe simulator
Supplied with your instrument, if ordered. It simulates a constant output from a sensor and allows for easier
troubleshoong.
4
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T T-CL2
Free Chlorine Sensor
2.0 INSTALLATION
As with all instrumentaon the installaon and commissioning of this instrument is crucial to its safe and accurate
funcon. This instrument must be used only for its purpose as outlined in this manual and must be installed and
commissioned in accordance with this manual and by trained and qualied personnel.
2.1 Site Selecon
Please choose a suitable locaon for the installaon of the probe and the electronics. The choice of installaon
point on any site is a compromise and is best undertaken by experienced installaon personnel. The following is
a list of the factors that need to be taken into consideraon. This list is not intended as a checklist neither is it
implied that the list is complete.
• Ensure that the mounng allows access to all serviceable parts.
• Try to mount the electronics in a posion where they are not habitually hosed down in a cleaning process.
• Consider the length of wiring runs when mounng the instrument.
• Try to keep the electronics away from substaons or other large EMI emiers.
• Consider whether the sample will be representave and well mixed.
• Consider sample return points.
• In a plasc run, with a low conducvity sample consider earthing the sample.
2.2 Unpacking
Please have a copy of your order with you when you unpack your instrument. All orders are checked when they
leave the factory. Please double check that you have all the parts that were ordered as soon as you open the box.
This may include (but not necessarily);
 Probe
 Probe mounng overow cell.
 Electrolyte
 Membranes
 Abrasive paper (blue)
 Manual
 CO2 Buer kit - opon
 Acid buer unit - opon
If anything is missing, or damaged, please contact your sales outlet immediately. If the instrument needs to be
returned for any reason please follow the instrucons given in Appendix C of this manual.
TURTLETOUGH
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T T-CL2
Free Chlorine Sensor
2.3 Mounng
For mounng of the ow cell (single or double), with its backplate (9mm thick), please refer to the drawings below.
2.4 Water connecons
The incoming water sample connecon is to the owcell lower barb or push ng.
In all cases the incoming water sample should be regulated to 0.5 l/min (0.13 gallon/minute [US]).
The ow cell is open to atmosphere, large changes in water pressure can cause water leaks.
If the pressure within the owcell exceeds 0.5 bar, there is a possibility of unstable readings.
The incoming ng is a ¼” or 6mm barb ng, or an 8mm pipe push-ng.
The outlet ng is a ½” or 12mm barb ng.
TURTLETOUGH
IPM19 HaloSense Free Chlorine Probe
Manual date 12/1/2011 Page 7of 29
2.3 Mounting
For mounting of the flow cell (single or double), with its backplate (9mm thick), please
refer to the drawings below.
2.4 Water connections
The incoming water sample connection is to the flowcell lower barb or push fitting.
In all cases the incoming water sample should be regulated to 0.5 l/min (0.13 gallon/minute [US]).
The flow cell is open to atmosphere, large changes in water pressure can cause water leaks. If the pressure
within the flowcell exceeds 0.5 bar, there is a possibility of unstable readings.
The incoming fitting is a ¼” or 6mm barb fitting, or an 8mm pipe push-fitting.
The outlet fitting is a ½” or 12mm barb fitting.
3.0 OPERATION
Refer to the instrument menu structure.
3.1 Calibraon
In order to perform a span of the sensor it is necessary to have an independent method of determining the level
of the measurand, e.g. a DPD test kit to measure free chlorine in the sample water. Refer to the appendix of this
manual for further calibraon informaon. Zeroing of this sensor is not required.
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T T-CL2
Free Chlorine Sensor
4.0 SENSOR
WARNING!WARNING!WARNING!WARNING!
PLEASE READ THE INSTRUCTIONS BELOW BEFORE DOING ANYTHING WITH THIS
PROBE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN DAMAGE TO
THE MEMBRANE CAP AND WARRANTIES FOR THIS DEVICE MAY BE VOIDED.
You will nd a membrane cap that is loosely screwed onto the end of your probe.
DO NOT REMOVE OR TIGHTEN THIS MEMBRANE CAP UNTIL YOU HAVE READ THESE INSTRUCTIONS!
There is an elasc seal around the membrane cap which is used to seal the vent hole on the membrane cap during
normal operaon. Prior to servicing the probe the elasc seal must be slid down to expose this vent hole. Do not
loosen the membrane cap without having the vent hole exposed and unobstructed. If the vent hole is blocked
o when the membrane cap is removed, then the membrane may rupture (i.e. develop a ny tear) and the probe
may not produce accurate readings.
When the membrane cap is lled with electrolyte and fastened onto the probe (in accordance with
instrucons in the operaons manual), you will noce some electrolyte bleed out from the vent hole. This is normal.
NOTE: DO NOT INSERT THE PROBE INTO THE FLOW CELL, OR GET IT WET, WITHOUT HAVING THE
VENT HOLE COVERED WITH THE ELASTIC SEAL!
The purpose of the vent hole is to protect the membrane from being exposed to internal pressure or vacuum
when the membrane cap is screwed onto or o of the probe p.
For further assistance please contact turtetough.com.au
TURTLETOUGH
IPBI08 – Probe Warning
Elasc Seal
This is the posion
the seal should be
in when the probe
is inserted into the
ow cell.
Vent Hole
This vent hole must
be exposed prior
to unscrewing the
membrane cap from
the probe p.
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T T-CL2
Free Chlorine Sensor
TURTLETOUGH
The chlorine sensor is a membrane covered potenostac 3-electrode system. The measuring electrode is
membrane covered and is in the electrolyte area together with the reference electrode. This electrolyte area
contains a special electrolyte and is separated by a second membrane from the sample water.
In this measuring method chlorine diuses out of the sample water, through the membranes and causes an
electrical signal at the measuring electrode. The electrical signal at the measuring electrode is proporonal to the
chlorine concentraon and is amplied by the electronics in the sensor. The measuring signal is independent from
the temperature of the measuring water due to an integrated temperature compensator.
4.0.1 Installaon
• Please refer to Site Selecon, secon 2.1
• Ensure the probe housing is mounted vercally, to ensure correct water ow over the sensor
• Ensure the installaon is stable, secure and away from vibraon
• Ensure the sample is free from bubbles and is well mixed
4.0.2 Setup
CAUTION:
When you unscrew the lled (or unlled) membrane cap, ensure
the vent band has been removed from the vent hole, to allow
air to enter, otherwise the membrane will be destroyed by the
vacuum.
• Unscrew the membrane cap from the electrode sha.
• Place the membrane cap and the G-holder onto a clean and
non-absorpve bench.
CAUTION: Never polish this area of the probe.
8

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Free Chlorine Sensor
9
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• Fill the membrane cap up to the edge with the enclosed electrolyte.
• Be careful, so that there are hardly any bubbles.
• Then replace it onto the bench.
NOTE: Read the electrolyte MSDS sheet.
• Fill up the G-holder with electrolyte.
• Be careful that there are no bubbles.
• Hold the electrode sha upright and push the electrode nger carefully
into the lled G-holder.

T T-CL2
Free Chlorine Sensor
10
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• Hold the electrode sha (with the G-holder) upright and put it on the
lled membrane cap.
• Then screw the membrane cap onto the electrode sha.
• Turn it anclockwise unl the thread engages, then screw slowly the
electrode sha clockwise (by hand) onto the membrane cap.
• Excess electrolyte will escape through the vent hole in the membrane cap.
• Do not close this vent with your nger.
WARNING: Electrolyte may spurt from the vent hole.
Excess electrolyte, or electrolyte on your skin or in your eye,
should be washed o immediately with water.
The electrolyte contains potassium halide.
• Check that the membrane cap is completely screwed in up to the stop.
• There is initial resistance from the o-ring, continue past this to the
electrode body.
• Ensure the vent band is seated correctly.
• Wash o the excess electrolyte with water.
• Inial run-in is 1 hour prior to calibraon.
• Calibraon should be repeated aer 24 hours.
Roune calibraon should be weekly.
CAUTION: When you unscrew the lled
membrane cap, ensure the vent band has
been removed from the vent hole, to allow
air to enter, otherwise the membrane will be
destroyed by the vacuum.

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Free Chlorine Sensor
11
TURTLETOUGH
4.0.3 Maintenance
Cauon: The coang of the electrode nger must not be cleaned with emery cloth or other polishing agents!
Do not unscrew the metal end ring of the membrane cap, as this will destroy the membrane.
4.0.3.1 Roune maintenance
The electrolyte should be changed every three months, although it may be possible to extend the period if low
levels of chlorine are measured. It may be necessary to use a new membrane cap when changing the electrolyte.
In any event, the membrane cap should be changed every 12 months. If your unit has been ordered with the auto
calibrator then the calibraon reagent should be changed every six months.
4.0.3.2 Diagnosc maintenance
4.0.4 Storage
To store the probe the membrane cap is unscrewed (note previous warning). The membrane G-holder must
be removed and discarded. The membrane cap and electrode nger should be rinsed in clean water and dried
in a place free of dust with a so paper towel (do not damage the electrode areas). The dry membrane cap is
then loosely screwed onto the electrode sha. The membrane must not rest against the measuring electrode.
Do not fully ghten the membrane cap.
When pung the probe back into use aer storage, the electrode p must be cleaned with the special abrasive
paper supplied (see 4.0.3.2) and a new membrane cap and G-holder must be used (follow 4.0.2).
4.0.5 Spares
Free Chlorine Membrane cap M48 G
Free Chlorine Electrolyte ECS2.1/GEL
Please contact us regarding any other spares.
4.0.6 Single owcell
The o-ring is rst inserted in the 1” opening of the adaptor followed by the PVC shim. Then the 1” PVC threaded
end cap is screwed in loosely. The probe is inserted into this prepared probe housing. Then the probe is xed
in place by ghtening (hand ght only) the threaded end cap, so the probe cannot move away from its posion.
If calibraon is impossible due to unstable or low output,
remove the sensor, displace the vent seal so that the vent hole
opening is free. The membrane cap can then be unscrewed. The
electrode nger is cleaned with a clean, dry, so paper towel.
With the special abrasive paper supplied (blue) just the p of
the dry electrode (the working electrode) is cleaned. Place the
special abrasive paper on a paper towel (on a at, dry surface), hold
it at the corners and rub the electrode p of the perpendicularly
held probe two or three mes across the abrasive paper. Then
rell with electrolyte (see secon 4.0.2). If necessary, use a new
membrane cap.
Recommendaon: Change the electrolyte every 3 months.

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Free Chlorine Sensor
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4.0.6.1 Inseron
There should be 25mm (1”) of clear space between the p of the sensor and the conical base of the owcell tube.

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Free Chlorine Sensor
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4.0.7 Double owcell
The sensor ts into the right-hand entry (if used with a pH or ORP probe). The o-ring is rst inserted in the 1”
opening of the adaptor followed by the PVC shim. Then the 1” PVC threaded end cap is screwed in loosely. The
probe is inserted into this prepared probe housing, so the ow passes directly over the probe p. Then the probe
is xed in place by ghtening (hand ght only) the threaded end cap, so the probe cannot move away from its
posion.
As with the single owcell, there should be 25mm (1”) of clear space between the p of the sensor and the conical
base of the owcell tube (refer to 4.0.6.1) if using the le-hand entry.
5.0 Commissioning
It is recommended that the instrument is commissioned by a trained commissioning engineer. During
the commissioning the engineer can train the operators in the correct operaon of the instrument.
The installaon and commissioning should proceed in the following manner:
1) Install the unit
2) Check the sensor for damage
3) Make up the sensor
4) Ensure that water ows through the owcell and over each sensor’s measuring end.
5) Calibraon
Aer the Cl2 sensor has completely polarized (from 2-12 hours of water ow with the electronics turned on
and chlorine in the water), calibrate the sensor using a suitable test kit (eg DPD for Cl2).
6.0 Troubleshoong Guide
Sensor faults will usually show themselves as unexpected readings. Unexpected readings can also be caused
by the electronics, so when troubleshoong it is important to determine the cause of the variable readings.
Cl2 sensors can be supplied with an electrochemical probe simulator. If the instrument displays unexpected
readings, unplug the probe and plug in the probe simulator. This supplies a xed constant reading to the analyser.
If the reading is not constant, please contact your supplier.
Symptom Possible cause Possible soluon
Chlorine
incorrect
Sensor disconnected Check sensor connected
Probe depolarised aer
extended zero period
Probe will re-polarise aer
2-12 hours
Sensor connected
incorrectly
Check sensor connected to
correct channel
6.1 Further help
For more troubleshoong, please visitt www.turtletoughsensors.com

T T-CL2
Free Chlorine Sensor
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Appendix A
General Layout Drawing - Flowcell

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Free Chlorine Sensor
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Appendix B
CERTIFICATES AND APPROVALS
Declaraon of conformity
The product meets the legal requirements of the harmonised European standards.
Process Instruments (UK) conrms compliance with the standards by axing the CE
symbol.
Waste electrical and electronic equipment (WEEE) Important informaon.
Disposal of old electrical & electronic equipment
This symbol on the product or on its packaging indicates that this product
shall not be treated as household waste. Instead, it shall be handed over to the
applicable collecon point for the recycling of electrical and electronic equipment. By
ensuring this product is disposed of correctly, you will help prevent potenal negave
consequences for the environment and human health, which could
otherwise be caused by inappropriate waste handling of this product. The recycling of
materials will help to conserve natural resources. For more detailed informaon about
recycling of this product, please contact your local council or city oce, your waste
disposal service or the organisaon from which you purchased the product.
Appendix C
RETURNS PROCEDURE AND ‘FREE OF CONTAMINATION SHEET’
If the analyser has to be repaired, please return it cleaned to your local sale organisaon or Turtle Tough.
Please use the original packaging, if possible. Please enclose the completed Contaminant sheet
(copy the Contaminants page, on the following page) with the packaging and shipping documents.
No repair will be undertaken without a completed contaminant sheet!

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Free Chlorine Sensor
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CONTAMINATION SHEET
Dear customer
Because of legal requirements and for the safety of our employees, we need this “Contaminaon sheet” lled
in (with your signature) before your instrument can be handled. Please put the completely lled in declaraon
with the instrument and the shipping documents. Add any safety data sheets (MSDS) and/or specic handling
instrucons if necessary.
Type of instrument / sensor:
Serial number:
Medium / concentraon:
Temperature: Pressure: Conducvity: Viscosity:
Cleaned with:
Please mark the appropriate warnings.
 Radioacve
 Explosive
 Causc
 Poisonous
 Harmful to health
 Biologically hazardous
 Inammable
 Safe
Company:
Contact name:
Address:
Telephone/fax no:
Email:
Order no.:
I hereby cerfy that the returned equipment has been cleaned and decontaminated according to good pracces
and is in compliance with all regulaons. This equipment poses no health or safety risks due to contaminaon.
Company stamp (if available) and
legally binding signature
Date: / /
For more informaon about service and repair go to www.turtletoughsensors.com

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Free Chlorine Sensor
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Appendix D
WARRANTY
Turtle Tough warrants its product to be free of defects in material and workmanship for a period of one (1) year
from date of shipment to the original customer. Upon receipt of wrien noce from the customer, Turtle Tough
shall repair or replace (at the discreon of Turtle Tough) the defecve equipment or components. Turtle Tough
assumes no responsibility for equipment damage or failure caused by:
A. Improper installaon, operaon, or maintenance of the equipment.
B. Abnormal wear and tear on moving parts caused by some processes.
C. Acts of nature (i.e. lightning, ooding, etc.)
This warranty represents the exclusive remedy of damage or failure of the equipment.
Under no circumstances shall Turtle Tough be liable for any special, incidental, or consequenal damage, such as
loss of producon, prots or product quality. The warranty cannot be guaranteed if the customer fails to service
and maintain the equipment in accordance with Turtle Tough wrien instrucons and policies, as stated in the
Operaons Manual.

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Free Chlorine Sensor
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Appendix E
Safety Data Sheet
Electrolyte ECS2.1/GEL/Electrolyte FC1 for Membrane Free Cl2- Sensor
IPM19 HaloSense Free Chlorine Probe
Manual date 12/1/2011 Page 25 of 29
Appendix E

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Free Chlorine Sensor
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Appendix E
IPM19 HaloSense Free Chlorine Probe
Manual date 12/1/2011 Page 26 of 29

T T-CL2
Free Chlorine Sensor
IPM19 HaloSense Free Chlorine Probe
Manual date 12/1/2011 Page 27 of 29
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