YOKOGAWA FC500G User manual

User’s
Manual
TM
Model FC500G
Free Available Chlorine
Analyzer
(Non-Reagent Type)
IM 12F5A2-01E
IM 12F5A2-01E
5th Edition

i
IM 12F5A2-01E
Introduction
This user’s manual describes the specications, installation, operation, maintenance, and
troubleshooting for Model FC500G Free Available Chlorine Analyzer. Read this manual
thoroughly to understand the contents before operating the equipment.
nNotes on Hardware
lAppearance and Accessories
Check the following when you receive the product:
• Appearance
• Standard accessories
Contact our sales representative or your local distributor if the product’s coating has come o󰀨, it
has been damaged, or there is shortage of required accessories.
l Model and Su󰀩x Codes
The name plate on the product contains the model and su󰀩x codes. Compare them with those in
the general specication to make sure the product is the correct one. If you have any questions,
contact our sales representative or your local distributor.
Media No. IM 12F5A2-01E 5th Edition : July 2018 (YK)
All Rights Reserved Copyright © 2007, Yokogawa Electric Corporation

ii
IM 12F5A2-01E
Safety Precautions
n Safety, Protection, and Modication of the Product
• In order to protect the system controlled by the product and the product itself and ensure
safe operation, observe the safety precautions described in this user’s manual. We assume
no liability for safety if users fail to observe these instructions when operating the product.
• If this instrument is used in a manner not specified in this user’s manual, the protection
provided by this instrument may be impaired.
• Be sure to use the spare parts approved by Yokogawa Electric Corporation (hereafter simply
referred to as YOKOGAWA) when replacing parts or consumables.
• Modication of the product is strictly prohibited.
nSignal Words
The following words are used in this manual.
CAUTION
This symbol gives information essential for understanding the operations and functions.
NOTE
This symbol indicates information that complements the present topic.
nNotes on Handling User’s Manuals
• Please hand over the user’s manuals to your end users so that they can keep the user’s
manuals on hand for convenient reference.
• Please read the information thoroughly before using the product.
• The purpose of these user’s manuals is not to warrant that the product is well suited to any
particular purpose but rather to describe the functional details of the product.
• No part of the user’s manuals may be transferred or reproduced without prior written
consent from YOKOGAWA.
• YOKOGAWA reserves the right to make improvements in the user’s manuals and product at
any time, without notice or obligation.
• If you have any questions, or you nd mistakes or omissions in the user’s manuals, please
contact our sales representative or your local distributor.
nWarning and Disclaimer
The product is provided on an “as is” basis. YOKOGAWA shall have neither liability nor
responsibility to any person or entity with respect to any direct or indirect loss or damage arising
from using the product or any defect of the product that YOKOGAWA can not predict in advance.
nTrademark Acknowledgments
• EXA FC is a trademark of Yokogawa Electric Corporation.
• All other company and product names mentioned in this user’s manual are trademarks or
registered trademarks of their respective companies.
• We do not use TM or ® mark to indicate those trademarks or registered trademarks in this
user’s manual.

iii
IM 12F5A2-01E
After-sales Warranty
nDo not modify the product.
n During the warranty period, for repair under warranty consult the local sales
representative or service o󰀩ce. Yokogawa will replace or repair any damaged
parts. Before consulting for repair under warranty, provide us with the model
name and serial number and a description of the problem. Any diagrams or
data explaining the problem would also be appreciated.
l If we replace the product with a new one, we won’t provide you with a repair report.
l Yokogawa warrants the product for the period stated in the pre-purchase quotation
Yokogawa shall conduct dened warranty service based on its standard. When the
customer site is located outside of the service area, a fee for dispatching the maintenance
engineer will be charged to the customer.
n In the following cases, customer will be charged repair fee regardless of
warranty period.
• Failure of components which are out of scope of warranty stated in instruction manual.
• Failure caused by usage of software, hardware or auxiliary equipment, which Yokogawa
Electric did not supply.
• Failure due to improper or insu󰀩cient maintenance by user.
• Failure due to modication, misuse or outside-of-specications operation which Yokogawa
does not authorize.
• Failure due to power supply (voltage, frequency) being outside specications or abnormal.
• Failure caused by any usage out of scope of recommended usage.
• Any damage from re, earthquake, storms and oods, lightning, disturbances, riots, warfare,
radiation and other natural changes.
n Yokogawa does not warrant conformance with the specic application at the
user site. Yokogawa will not bear direct/indirect responsibility for damage due
to a specic application.
n Yokogawa Electric will not bear responsibility when the user congures the
product into systems or resells the product.
n Maintenance service and supplying repair parts will be covered for ve years
after the production ends. For repair for this product, please contact the
nearest sales o󰀩ce described in this instruction manual.

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Toc-1
IM 12F5A2-01E
Model FC500G
Free Available Chlorine Analyzer
(Non-Reagent Type)
CONTENTS
IM 12F5A2-01E 5th Edition
Introduction..........................................................................................................i
Safety Precautions .......................................................................................ii
1. OVERVIEW ................................................................................................ 1-1
1.1 Standard Specications................................................................................... 1-2
1.2 Model and Su󰀩x Codes ................................................................................... 1-4
1.3 External Dimensions ........................................................................................ 1-5
1.4 Measuring Principle.......................................................................................... 1-6
2. COMPONENTS AND FUNCTIONS .......................................................... 2-1
2.1 Detector.............................................................................................................. 2-1
2.2 Converter ........................................................................................................... 2-2
3. INSTALLATION, PIPING, AND WIRING ....................................................3-1
3.1 Installation ......................................................................................................... 3-1
3.1.1 Location .............................................................................................. 3-1
3.1.2 Mounting ............................................................................................ 3-2
3.2 Piping ................................................................................................................. 3-2
3.2.1 Sample Water Piping ......................................................................... 3-2
3.2.2 Air Purge Piping ................................................................................. 3-2
3.3 Wiring ................................................................................................................. 3-3
3.3.1 Wiring for Power Supply and Grounding ........................................... 3-3
3.3.2 Analog Output Wiring ......................................................................... 3-3
4. OPERATION .............................................................................................. 4-1
4.1 Preparation for Operation ................................................................................ 4-1
4.1.1 Inspection of Piping and Wiring Status .............................................. 4-1
4.1.2 Fill with Glass Beads for Electrode Polishing .................................... 4-1
4.1.3 Measuring Range Setting .................................................................. 4-2
4.1.4 Setting of “Applied Voltage Compensation/Applied Voltage Fixation’’ Se-
lection Jumper .................................................................................... 4-3
4.2 Start-Up .............................................................................................................. 4-4
4.2.1 Supplying Sample Water ................................................................... 4-4
4.2.2 Conrmation of “Power Supply Voltage” and “Measuring Range” Selec-
tion Jumpers Setting Status ............................................................... 4-4
4.2.3 Supplying Power ................................................................................4-5
4.2.4 Operation Check ................................................................................4-5
4.2.5 Calibration .......................................................................................... 4-5
4.3 Steady State Operation .................................................................................... 4-5

Toc-2
IM 12F5A2-01E
5. CALIBRATION........................................................................................... 5-1
5.1 Zero Calibration................................................................................................. 5-1
5.1.1 Zero Calibration Procedure Using the Open Input Circuit Method .... 5-1
5.1.2 Zero Calibration Procedure Using Chlorine-Free Water Method ...... 5-1
5.2 Span Calibration ............................................................................................... 5-2
5.2.1 Span Calibration Procedure Using the Sampling Method ................. 5-2
5.2.2 Span Calibration Procedure Using Standard Solution Method ......... 5-2
6. INSPECTION AND MAINTENANCE ........................................................ 6-1
6.1 Mechanical System........................................................................................... 6-1
6.1.1 Indicator Electrode Polishing ............................................................. 6-1
6.1.2 Glass Beads and Measuring Tank Cleaning ..................................... 6-2
6.1.3 Brush and Slip Ring Checking ........................................................... 6-3
6.2 Electrical System .............................................................................................. 6-5
6.2.1 Span Calibration ................................................................................ 6-5
6.2.2 Converter Checking ........................................................................... 6-5
6.2.3 Fuse Replacement ............................................................................. 6-5
7. TROUBLESHOOTING .............................................................................. 7-1
8. AUXILIARIES AND CONSUMABLES...................................................... 8-1
8.1 Auxiliaries and Consumables List.................................................................. 8-1
8.2 Auxiliaries and Consumables ......................................................................... 8-1
8.2.1 Polisher (Part number: K9088PE) ..................................................... 8-1
8.2.2 Glass Beads (Part number: K9332ZJ)............................................... 8-1
8.2.3 Indicator Electrode (Part number: K9332MB) ................................... 8-1
8.2.4 Grease (Part number: K9044FX) ....................................................... 8-1
8.2.5 Counter Electrode (Part number: K9332MK) .................................... 8-1
8.2.6 Brush and Slip Ring (Part number: K9332JX, K9332JZ) .................. 8-2
Customer Maintenance Parts List.......................................... CMPL 12F5A2-01E
Revision Information ...............................................................................................i

<1. OVERVIEW> 1-1
IM 12F5A2-01E
1. OVERVIEW
Model FC500G Free Available Chlorine Analyzer (Non-Reagent Type) is used for continuous
measurement of free available chlorine in tap water distribution. This analyzer consists of a
detector and a converter as shown in Figure 1.1.
This chapter describes the FC500G free available chlorine analyzer specications and its
measuring principle.
Detector
Converter
Figure 1.1 Appearance of Model FC500G Free Available Chlorine Analyzer

<1. OVERVIEW>
1-2
IM 12F5A2-01E
1.1 Standard Specications
Measured Object: Free available chlorine contained in tap water
Measuring System: Polarographic method using rotating electrode
Measuring Ranges: 0 to 1 / 0 to 2 / 0 to 3 mg/L (Model FC500G-1)
0 to 5 / 0 to 10 mg/L (Model FC500G-5) (Air purge is necessary.)
Indication: Digital (3 1/2 LCD)
Output Signal: 4 to 20 mA DC (Load resistance: Maximum 500 Ω)
Operating pH Range of Sample Solution:
pH 6.5 to 7.5: For measured liquids whose pH exceeds the above limits,
error increases (refer to the following gure).
Sample Solution:
Temperature: 0 to 40°C (temperature compensation range 5 to 35°C).
Pressure: 1 to 30 kPa (for without VALVE)
1 to 150 kPa (with VALVE)
Flow Rate: 0.1 to 2.5 L/min (at tank inlet)
Conductivity: 100 to 300 μS/cm
SS (Suspended Solid): 10 mg/L or less
Air Purging (for only 0 to 5 / 0 to 10 mg/L Range)
Supply Air Pressure: About 50 to 140 kPa
Air Consumption: About 5 L/min
Electrode:
Indicator Electrode: Rotating gold electrode
Counter Electrode: Silver electrode (with Pt 1000 installed)
Electrode Cleaning: Glass beads used for cleaning
Wetted Part Materials:
Measuring Tank: Acrylic resin (molding)
Piping: Flexible PVC and PE
Color: Muncell 5Y7/1
Finish: Baked polyurethane resin coating
Mounting: On the wall or 2 inch pipe (OD 60.5 mm)
Ambient Temperature: -5 to 50°C
Power Supply: 100 or 110 V AC; or 200 or 220 V AC as per order ±10%, 50 or 60 Hz
Power Consumption: Approximately 15 VA (100 or 110 V), 20 VA (200 or 220 V)
Weight: Approximately 6.5 kg
EMC Regulatory Arrangement in Australia and New Zealand (RCM)
EN 55011 Class A, Group 1
Characteristics:
Reproducibility: 2% of full scale
Linearity: ±5% of full scale
Stability: Zero Drift: Within ±1% of full scale/month
Span Drift: Maximum -10% of full scale/month

<1. OVERVIEW> 1-3
IM 12F5A2-01E
Response Time: Approximately 2 minutes (time required to obtain a value within 90% of
nal value)
Ambient Temperature Inuence:
±0.5% of full scale/10°C
Power Voltage Fluctuation Inuence:
±0.5% of full scale/10% of rated voltage
Sample Solution Temperature Compensation Error:
±3% of full scale/5 to 35°C
345678910
pH
pH6.5 pH7.5
Operating range
0.5
0
1.0
Indicated value (mg/l)
Figure 1.2 Sensitivity characteristics of di󰀨usion current by pH value
Figure 1.3 Sensitivity characteristics of di󰀨usion current by conductivity
Note: If conductivity exceeds 300 μS/cm, default value of applied voltage should be changed.
nAccessories
Fuse (1 A) .........................4 pcs.
Glass Beads .....................1 (2 bags)
Allen Wrench ....................2 pcs.
Screwdriver (at blade) ...1 pc.
Polishing Powder ..............1 bottle

<1. OVERVIEW>
1-4
IM 12F5A2-01E
1.2 Model and Su󰀩x Codes
Model Su󰀩x Code Option Code Description
FC500G ���������������������������������� ���������������������� Free Available Chlorine Analyzer
Range -1
-5
����������������������
����������������������
0 to 1 / 0 to 2 / 0 to 3 mg/L Switchable
0 to 5 / 0 to 10 mg/L Switchable
Output signal 1���������������������� 4 to 20 mA DC
Power 3
4
5
6
����������������������
����������������������
����������������������
����������������������
100 V ±10%, 50/60 Hz
110 V ±10%, 50/60 Hz
200 V ±10%, 50/60 Hz
220 V ±10%, 50/60 Hz
Inlet valve 0
1
����������������������
����������������������
Without Valve
With Valve
Language -E ���������������������� English
nSpare Parts
Name Parts No. Note
Indicator Electrode K9332MB Rotating Electrore
Counter Electrode K9332MK Reference Electrode
Glass Beads K9332ZJ Washing Indicator Electrode (2 bags)
Polishing Powder K9088PE Polishing Indicator Electrode
Brush K9332JX
Slip Ring K9332JZ
Grease K9044FX

<1. OVERVIEW> 1-5
IM 12F5A2-01E
1.3 External Dimensions
(1) With Inlet Valve (FC500G-¨¨¨1-E)
0.50
mg/l
Unit: mm
(48)(154)
Mounting bracket
2-inch pipe (Ø60.5)
Approx.150 265
(209)56
Approx.160
Maintenance spaceMaintenance space
2.8
49.2
Approx.
50 154
Drain cock
Inlet
13.7
5.5 76
Cap
Outlet
22 22
(22)
22
108
Cable gland
3022 26
100
70
21
17.5
70
52.5 128.5 48
52.5
105 131
Wiring inlet
3-Ø23 holes
Approx.250
Maintenance
space
295
310
Approx.
150
Maintenance
space
Maintenance
space
240
Converter
Cap
Inlet
Ø6/Ø4 Union
Purge air inlet
1/4-18 NPT
(for only FC500G-5-E)
Outlet
Ø12 Nipple
Drain cock
Insert
Tub
4-Ø8.5 holes
for mounting
(U-bolt on bracket)
Driving
Box
35
33.4
17.3
(2) Without Inlet Valve (FC500G-¨¨¨0-E)
0.50
mg/l
Unit: mm
Approx.150 260
146.5 (5.5)108
Approx.160
Maintenance spaceMaintenance space
2.8
49.2
Approx.
50 154
Drain cock
Inlet
13.7
76
Cap
Outlet
22 22
(22)
22
Cable gland
3022
100
128.5
Wiring inlet
3-Ø23 holes
Approx.250
Maintenance
space
295
17830 Approx.
150
Maintenance
space
Maintenance
space
240
Converter
Cap
Outlet
Ø12 Nipple Drain cock
Insert
Tub
2-Ø8.5 holes
for mounting
Driving
Box
35
33.4
17.3
10
92
75
4
Inlet
Ø6/Ø4 Union
Purge air inlet
1/4-18 NPT
(for only FC500G-5-E)
Figure 1.4 Model FC500G Free Available Chlorine Analyzer External Dimensions

<1. OVERVIEW>
1-6
IM 12F5A2-01E
1.4 Measuring Principle
The FC500G free available chlorine analyzer (non-reagent type) is used for measuring
concentration of free available chlorine present in sample water, such as chlorine (Cl2)
hypochlorous acid (HClO), and hypochlorite ion (ClO-).
The measuring principle of this analyzer is analysis determination using the rotating electrode
polarographic method. Free available chlorine concentration is determined by measuring the
current (di󰀨usion current) which ows when free available chlorine is subjected to electrolytic
reduction by applying a voltage (applied voltage) between the indicator electrode (rotating
electrode) and the counter electrode. The applied voltage is set in a region where concentration
polarization occurs (plateau region) in polarography. In the plateau region, the di󰀨usion current
does not change even if the applied voltage changes.
In measurement practice, since the plateau region changes with free available chlorine
concentration, the applied voltage is compensated so that measurement can always be
performed in the plateau region. Also, since the di󰀨usion current is a󰀨ected by the sample water
temperature, temperature is compensated using a temperature sensor (Pt1000Ω) incorporated in
the counter electrode.
Figure 1.5 shows the block diagram for the FC500G free available chlorine analyzer (non-
reagent type) operation. The analyzer determines the free available chlorine concentration by
applying an applied voltage corresponding to the di󰀨usion current between the indicator and
counter electrodes and by applying temperature compensation to the di󰀨usion current.
Applied voltage
compensating
pulse circuiut
Free available
chlorine
detecting circuit
First stage
amplifier
Temperature
compensation
circuit
PWM circuit
isolator
Free available
chlorine/
conductivity
display
Voltage-current
conversion
circuit
4 to 20 mA DC
output
Diffusion current
Temperature
signal
Applied voltage
Indicator
electrode
Counter
electrode
(Pt 1000Ω)
Sample
water
Measuring
tank
Drain
F1-5.ai
Figure 1.5 Block Diagram for FC500G Free Available Chlorine Analyzer Operation

<2. COMPONENT NAMES AND FUNCTIONS> 2-1
IM 12F5A2-01E
2. COMPONENTS AND FUNCTIONS
2.1 Detector
Glass beads
Teflon (PTFE) ring
Beads case
Indicator electrode
(rotating elecrtrode)
Indicator electrode
(rotating elecrtrode)
Electrode assembly
Measuring tank
Measuring tank
Counter electrode
(Pt1000Ω sensor
incorporated)
F2-1.ai
Polishes the totating indicator
electrode to hold indicator
electrode in a clean state.
Drain cock
If loosened, this cock drains the
liquid in the measuring tank.
Cell motor
Air purge piping connection port
(for FC500G-5)
A motor for rotaing the
indicator electrode at a
constant speed.
Sample inlet
Figure 2.1 Component Names and Functions of the Detector

<2. COMPONENT NAMES AND FUNCTIONS>
2-2
IM 12F5A2-01E
2.2 Converter
Figure 2.2 shows the converter component names and their functions.
Figure 2.2 is a gure with the cover removed. Measuring range selection should be performed in
this state.
1A
FUSE
POWER
CHECK
MEAS. ON
SPAN
OFF
SG
ME RE T1 T2 GC1 C2
+-GGL1 L2
Zero calibrator
MEAS / CHECK selection switch
Display (liquid crystal)
Measuring range
setting switch
Converter cover
Fastener
Span calibrator
Terminal cover
Measuring range
selecting jumper
Applied voltage
compemsation/fixation
selection jumper Power switch
Fuse
External wiring
connection terminals
Power supply
voltage selection
jumper
Operated when
zero is to be
calibrated.
(To be operated
with the
terminal cover
removed.)
For converter checking,
select CHECK position.
Sets a measuring
range.
The terminal cover
should be attached
or detached with
this fastener grip
pulled out.
Operated when span
is to be calibrated.
mg/l
Figure 2.2 Converter Component Names and Their Functions
NOTE
The measuring range selection jumper and the power supply voltage selection jumper are
shipped with these set based on the desired specications.
The specications cannot be changed by jumper selection.

<3. INSTALLATION, PIPING, AND WIRING> 3-1
IM 12F5A2-01E
3. INSTALLATION, PIPING, AND WIRING
This chapter describes procedures for the FC500G free available chlorine analyzer installation,
piping, and wiring.
3.1 Installation
3.1.1 Location
Install the FC500G free available chlorine analyzer (non-reagent type) in a location which meets
the following conditions:
● Free from rain water such as an indoor location or in a cabinet
● Low vibration
● No exposure to direct sunshine
● Little dust
● Absence of corrosive gas
● Easy maintenance
Figure 3.1 shows maintenance spaces.
0.50
mg/l
Unit: mm
Approx.150 265 Approx.160
Maintenance spaceMaintenance space
Approx.
50
154
Approx.250
Maintenance
space
310
Approx.
150
Maintenance
space
Maintenance
space
240
Figure 3.1 Maintenance Spaces for the FC500G Free Available Chlorine Analyzer

<3. INSTALLATION, PIPING, AND WIRING>
3-2
IM 12F5A2-01E
3.1.2 Mounting
Mount the FC500G free available chlorine analyzer (non-reagent type) on a wall surface. For
mounting holes, see section 1.3.
3.2 Piping
3.2.1 Sample Water Piping
Connect a 6 mm OD X 4 mm ID polyethylene tube to the sample water inlet. Set the sample
water pressure at the sample water inlet to 1 to 30 kPa (ow rate: 0.1 to 2.5 l/min).
Note: If a sample water inlet valve is used, set the pressure at the valve inlet to 10 to 150 kPa.
Connect a hose of 12 mm lD to the sample outlet. Make piping so that no drain stagnates in the
hose.
3.2.2 Air Purge Piping
Make the air purge piping only when the FC500G-5 free available chlorine analyzer is used.
The air purge piping connecting port (1/8 NPT female) is located at the electrode assembly.
Exercise care in piping because the electrode assembly must be removed in implementing
inspection or maintenance (see Figure 3.2).
Inspection or
maintenance
Electrode
assembly
Measuring
tank
Detector
Pressure regulator
6 mm OD X 4 mm ID
polyyethylene tube
Air supply
Figure 3.2 Air Purge Piping

<3. INSTALLATION, PIPING, AND WIRING> 3-3
IM 12F5A2-01E
3.3 Wiring
Make wiring for power supply and output signal. Figure 3.3 shows the symbols on the converter
terminals and the types of wiring to be connected.
+
TM1
Power
supply
Detector signal
(Exclusively used cable: already wired)
Ground
to earth
4 to 20 mA DC
output
500Ω or less
Terminal board TM1 (M4 screw)
- G G L1 L2 ME RE T1 T2 SG G C1 C2
F3-3.ai
Note: Make grounding to earth (grounding resistance 100 Ω or less).
Figure 3.3 Symbols on the Converter Terminals and the Types of Wiring to be Connected
3.3.1 Wiring for Power Supply and Grounding
Use a three-conductor cable of 9 to 12 mm OD, each conductor having a cross section of 1 mm2
or more.
Make grounding to earth (grounding resistance 100 Ω or less).
3.3.2 Analog Output Wiring
Use a two-conductor shielded cable of 9 to 12 mm OD, each conductor having cross section of
0.5 mm2 or more. The shield should be connected to terminal ‘‘G”.

Blank Page

<4. OPERATION> 4-1
IM 12F5A2-01E
4. OPERATION
This chapter chiey describes the preliminary work to be performed prior to putting into operation.
4.1 Preparation for Operation
4.1.1 Inspection of Piping and Wiring Status
Conrm that wiring and piping are made properly.
4.1.2 Fill with Glass Beads for Electrode Polishing
Put glass beads (accessories) for cleaning the indicator (rotating) electrode into the beads case
in the measuring tank in the following procedure:
(1) As shown in Figure 4.1, mount the electrode assembly to the holding stud. The electrode
assembly is xed to the measuring tank assembly using two screws.
In doing this, exercise care so that the indicator (rotating) electrode and the counter
electrode are not struck by the measuring tank. Also, do not touch the surface of the
indicator electrode with the ngers.
Fixing screws
(2 pcs.)
Electrode
assembly
Measuring
tank
Holding stud
F4-1.ai
In maintenance position
Figure 4.1 Removal of Electrode Assembly
(2) Remove the beads case from the measuring tank. The new glass beads are normally lled
up to the bottommost notch of the beads case when the indicator electrode is inserted.
Taking care that glass beads do not drop from the beads case. Mount the beads case so
that its slits face the counter electrode.
Beads case
Glass beads
Rubber packing
F4-2.ai
Slits
Counter electrode
(reference electrode)
Indicator electrode
(rotating electrode)
Beads case
Glass beads
The bottommost notch
of the beads case
Figure 4.2 Amount of Glass Beads to be Put into the Beads Case