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Instruction Manual –

MicroChem®2 Chlorine Probes


Series CL4000

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These instructions describe the installation, operation and maintenance of the subject equipment. Failure to strictly
follow these instructions can lead to an equipment rupture that may cause significant property damage, severe
personal injury and even death. If you do not understand these instructions, please call Severn Trent Water
Purification for clarification before commencing any work at 215-997-4000 and ask for a Field Service Manager.
Severn Trent Water Purification, Inc. reserves the rights to make engineering refinements that may not be described
herein. It is the responsibility of the installer to contact Severn Trent Water Purification, Inc. for information that
cannot be answered specifically by these instructions.

Any customer request to alter or reduce the design safeguards incorporated into Severn Trent Water
Purification equipment is conditioned on the customer absolving Severn Trent Water Purification from any
consequences of such a decision.

Severn Trent Water Purification has developed the recommended installation, operating and maintenance
procedures with careful attention to safety. In addition to instruction/operating manuals, all instructions given on
labels or attached tags should be followed. Regardless of these efforts, it is not possible to eliminate all hazards
from the equipment or foresee every possible hazard that may occur. It is the responsibility of the installer to ensure
that the recommended installation instructions are followed. It is the responsibility of the user to ensure that the
recommended operating and maintenance instructions are followed. Severn Trent Water Purification, Inc. cannot be
responsible for deviations from the recommended instructions that may result in a hazardous or unsafe condition.

Severn Trent Water Purification, Inc. cannot be responsible for the overall system design of which our equipment
may be an integral part of or any unauthorized modifications to the equipment made by any party other that Severn
Trent Water Purification, Inc.

Severn Trent Water Purification, Inc. takes all reasonable precautions in packaging the equipment to prevent
shipping damage. Carefully inspect each item and report damages immediately to the shipping agent involved for
equipment shipped “F.O.B. Colmar” or to Severn Trent Water Purification for equipment shipped “F.O.B Jobsite”. Do
not install damaged equipment.

SEVERN TRENT SERVICES, COLMAR OPERATIONS


COLMAR, PENNSYLVANIA, USA
IS ISO 9001: 2000 CERTIFIED

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TABLE OF CONTENTS
2
1 INTRODUCTION.................................................................................................................4
1.1 General Description.................................................................................................4
1.2 Safety .....................................................................................................................4
1.3 Chlorine Probes, Cables Accessories and Consumables .......................................5
1.3.1 Chlorine Probe Sensors ..............................................................................5
1.3.2 Cables .........................................................................................................5
1.3.3 Accessories .................................................................................................5
1.3.4 Consumables...............................................................................................5
1.4 Technical Data / Specifications ...............................................................................5
1.5 Principle of Operation..............................................................................................7

2 INSTALLATION..................................................................................................................8
2.1 General....................................................................................................................8
2.2 Mounting Dimensions..............................................................................................8
2.3 Chlorine Probes.......................................................................................................9
2.4 Flow Cell................................................................................................................12
2.5 Flow Regulation Components ...............................................................................12
2.6 Electrical................................................................................................................14

3 STARTUP ....................................................................................................... 15

4 MAINTENANCE................................................................................................................15
4.1 Periodic functional Check......................................................................................15
4.2 Electrode Maintenance..........................................................................................15
4.2.1 Electrode Membrane .................................................................................15
4.2.2 Cleaning the electrode surfaces ................................................................15

5 TROUBLE SHOOTING PROCEDURE.............................................................................16

FIGURES
1 Chlorine Probe ..................................................................................................................... 4
2 Mounting Dimension ............................................................................................................ 8
3 Chlorine Probe Components.............................................................................................. 11
4 Arrangement, Piping, CL4000 Sensor ............................................................................... 12
5 Probe Cable Connections ................................................................................................. 14

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1 INTRODUCTION

1.1 General Description

This manual describes the general description, installation, operation and maintenance of the
CL4000 Chlorine probes and accessories.

Chlorine is the most common chemical used in disinfection of municipal drinking water, swimming
pools, cooling towers and many industrial applications. Once added to water the chlorine will react
with chemicals already in the water forming combined chlorine or stay available as free chlorine.
Total chlorine is defined as the free chlorine and the combined chlorine.

A chlorine measuring system incorporating the CL4000 chlorine probes, connected to the
MicroChem®2 transmitter, provides automatic measurement/control of chlorine dosage in such
systems. Chlorine probes measure both free and combined chlorine.

The transmitter is part of the MicroChem®2 series, which is capable of supporting up to three of
the following measurements in all possible combinations: Dissolved Oxygen, Chlorine Dioxide,
Residual Chlorine, Bromine, Fluoride, Ozone, ORP, Temperature, pH, Iodine and Conductivity.
For a description and instructions regarding the transmitter see the MicroChem®2 transmitter
instruction manual.

The chlorine probes are 3 electrode amperometric cells covered with a permeable membrane.
The probe exterior is manufactured from a durable PVC and stainless steel and has a diameter of
25mm (1 inch). The probes are engineered to fit a specially designed flow cell.

Severn Trent Services chlorine probes can be used without the need for pH compensation.

All the CL4000 probes are designed to run without the need for reagents. The probes have no
moving parts and are designed to require minimal maintenance.

Figure 1 - Chlorine Probe

1.2 Safety
The recommended operating procedures have been designed with careful attention to safety.
Severn Trent Services has made formal safety reviews of the initial design and any subsequent
changes. This procedure is followed for all new products and covers areas in addition to those
included in applicable safety standards.

Observe the following safety precautions:


a. Observe all safety warnings marked on the equipment. These warnings identify areas of
immediate hazard, which could result in personal injury, or loss of life.
b. Do not use this equipment for any purpose other than described in this manual.
c. Disconnect power prior to making any terminal connections within the enclosure.
d. Use the recommended connection procedures described in Section 2 of this manual.

This equipment should only be installed by suitably qualified personnel.

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1.3 Chlorine Probes, Cables, Accessories and Consumables

Chlorine Probe 0-2 ppm, pH tolerable 4.0 - 9.5


(Note 1,2) 23183
Chlorine Probe 0-5 ppm, pH tolerable 4.0 - 9.5
(Note 1,2) 23184
Chlorine Probe 0-10 ppm, pH tolerable 4.0 - 9.5
(Note 1,2) 23185

4 Foot Cable (Note 3) 78-4001


12 Foot Cable (Note 3) 78-4002
40 Cable (Note 3) 78-4003
Sample/Drain Tubing, CLEAR, 3/16” ID X 5/16” OD R-376
Flow Through Cell with integral shut off valve (Note 4) 23411
Flow Through Cell and Flow Control Kit (Note 4, 6) 23449
T-Fitting (Note 5) R-240
Sample Valve (Note 5) 22897
Sample Flow Control Kit (Note 7) 23318
Flow Control Panel Kit (Note 6) 23451
Y Strainer 80 mesh, Max Inlet 75 PSIG 22901
Pressure Reducing Valve Kit, 0-25 PSIG, Max Inlet 300 PSIG w/15 PSIG Gauge & Bracket 23425
Flow Meter Assembly w/Rate Valve, 0-10 GPH 23426
Flow Switch (Note 8) 22896
Sulfite Dechlorinating Filter (Note 9) 1D617A004U01
Carbon Dechlorinating Filter (Note 9) 23450
Annual Maintenance Kit for:
01-4030 and 01-4031 Probes
Includes: PN 77-4005 and PN 94-2135 10-4001
23183, 23184, 23185, 01-4032 and 01-4033 Probes
Includes: PN 77-4004 and PN 94-2136 10-4002
01-4034 and 01-4035 Probes
Includes: PN 77-4004 and PN 94-2137 10-4003

M48 Membrane Cap to fit 23183, 23184, 23185, 01-4032, 01-4033, 01-4034 and 01-4035 Probes 77-4004
M20 Membrane Cap to fit 01-4030 and 01-4031 Probes 77-4005
G-Holder for 23183, 23184, 23185, 01-4032 and 01-4033 Probes 77-4017
Electrolyte Solution (100ml) for 01-4030 and 01-4031 Probes 94-2135
Electrolyte Solution (100ml) for 23183, 23184, 23185, 01-4032 and 01-4033 Probes 94-2136
Electrolyte Solution (100ml) for 01-4034 and 01-4035 Probes 94-2137
Handheld Chlorine Chlorometer 21885
Handheld Chlorine Dioxide Chlorometer 21884
DPD 1 Tablets, Qty 250, Chlorine, Free, 0-5.0 Range 22418
DPD 3 Tablets, Qty 250, Chlorine, Total, 0-5.0 Range 22419
DPD Tablets, Qty 250, Chlorine Dioxide, LR, 0-2.5 mg/L 21886
DPD Tablets, Qty 250, Chlorine Dioxide, HR, 0-20 mg/L 21887
Chlorometer Check Standards with Certificate (Chlorine Only) for P/N 21885 22420
Chlordiox Duo Check Standards (Chlorine Dioxide Only) for P/N 21884 22421

Notes:
1. The MicroChem2 Transmitter/Controller must be fitted with the expanded function board (P/N 1T686B129U12, U13 or U14)
in order to provide power to the probe and the software must be Version 2.8 or above. Consult factory on upgrading earlier
versions of microchem2 transmitter/controllers to the latest revision.
2. 23183, 23814, and 23815, probes with 3-electrode sensor for the measurement of free available chlorine,
combined chlorine and the “cyanuric acid chlorine” independent of the concentration of the cyanuric acid. Temperature
compensated (0 to 40°C). pH tolerable within the operating range 4 to 9.5.
3. Cable 78-4001, 78-4002 or 78-4003 must be used for probe to function properly.
4. Flow cell, 23411, includes a back pressure fitting to prevent the formation of air bubbles in probe chamber at sample
pressure of 8-15 PSIG (0.5 - 1 bar). Low pressure fitting is included.

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5. Tee Fitting and Sample Valve provides access for grab samples.
6. Flow Control Kit (P/N 23318) improves flow and pressure control of CL4000 probes. It includes a PRV Kit (P/N 23425), Flow Meter
Assembly (P/N 23426), T-Fitting (P/N R-240), Sample Valve (P/N 22897), 10 ft of tubing and connectors.
7. The Flow Control Panel Kit (P/N 23451) (26" H X 28” W X 0.5" thick) is predrilled and tapped for mounting the Microchem2 and 2
acrylic flow cells for chlorine or for use with pH, conductivity, or ORP 12mm probes and is supplied with mounting hardware.
8. Flow Switch provides 4-20 mA output for alarm when flow is not present.
9. Dechlorinating Filter provides a chlorine free sample stream, used for calibrating the MicroChem2.

1.4 Technical Data / Specifications


Quality Management The design & manufacturing process of Severn Trent
System: Services are certified to ISO9001.
Compliance: The unit complies with all relevant directives of the European Union and is
CE marked to indicate this.
Range: 0 - 2 mg/l, 0 -5 mg/l or 0 - 10 mg/l (probe dependant)
Type of measurement: Free and/or combined
Temperature
Compensation: Internal
Speed of Response: Ninety (90)% step change < 2 minutes.
Ambient/sample Temp: 32 °F - 104 °F (0 °C - 40 °C)
Limit of Detection: Probe, chlorine, 0-2 ppm : 0.01 ppm
Probe, chlorine, 0-5 ppm : 0.03 ppm
Probe, chlorine, 0-10 ppm : 0.05 ppm

Reproducibility: 0.05 mg/l


Accuracy: ± 2% of range
Sample Inlet Pressure: 0 to 15 psi (0 to 1 bar)
Sample Temperature: 32 °F - 104 °F (0 °C - 40 °C)
Sample Flow: 8 gph (30 liters per hour)
Electrodes: Working Electrode - gold
Counter Electrode - stainless steel
Reference Electrode: Silver/Silver-Chloride
pH: Chlorine:
independent of pH (pH 4 to pH 9.5)
Signal loss is 5% per pH unit (pH greater than 7)
Dimensions: In flow cell: 14.6” (h) x 2.25” (dia)
370mm x 55 mm
Probe alone 1” (dia) x 9” (l),
25mm (dia) x 230mm (l)
Weight: probe and flow cell 1lb (450g)
Connectors: 2 x compression fitting for flexible tubing
ID 3/16”, OD 5/16”
Cable: Various lengths available
Sample Limitations: Samples containing particles 100 microns (0.004 inches) in diameter and
larger may require pre-filtration. There should be no surfactants in the
water.

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Ammonia Interference: CL4000 probes in the presence of ammonia will measure free and/or
combined chlorine resulting in a total chlorine value.
Permanganate Interference: 1 ppm permanganate = 0.5 ppm chlorine

1.5 Principle of Operation


The chlorine probes are amperometric cells covered with a permeable membrane. The probes are
engineered to fit a specially designed flow cell with a built-in flow regulator.

A sample of liquid is delivered to the input (bottom) of the flow cell at an approximate rate of 500 mls/min.

The sample passes the membrane on the tip of the membrane cap. Chlorine diffuses through the
membrane and into the internal filling solution where a small DC current is generated between the stainless
steel counter electrode and gold working electrode in direct linear proportion to the amount of residual
present in the sample. A third reference electrode establishes a constant potential on the gold working
electrode to provide an accurate and stable residual signal.
®
The signal is amplified and transmitted to the MicroChem 2 transmitter/controller via the 3 conductor cable.
The probes need to be loop powered. This power is generated within the MicroChem®2 and supplied to the
probe in the same cable which transmits the residual signal.

All the CL4000 chlorine probes are designed to run without the need for reagents. The probes have no
moving parts and are designed to require minimal maintenance.

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2 INSTALLATION

2.1 General
Remove the instrument from its box and carefully inspect each item and report damages immediately. The
box will include the chlorine probe (electrode shaft, top cap and membrane cap), electrolyte bottle and a
sheet of blue abrasive paper.

The chlorine probes are designed for general duty indoor installation. Outdoor installation is possible if the
instrument is shielded from dripping water and not mounted in direct sunlight. Ensure that the process and
environmental conditions are within specified limits (see specification).
Excessive heat and vibration will affect the sensors.

2.2 Mounting Dimensions

Sample connectors are


compression fitting, requiring
flexible tubing 3/16” ID x 5/16” OD

Figure 2 - Mounting Dimensions

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2.3 Chlorine Probes

WARNING
Do not touch the electrode finger (see Figure 3)
Do not touch the bottom of the membrane cap (see Figure 3)

To assemble the probes for use:

When removing the membrane cap,


move the vent seal away from the
vent hole to allow air into the
membrane cap. Not doing so may
cause a vacuum to form and damage
Vent hole the membrane.
Vent Seal

Fill the membrane cap to the top with electrode filling solution (note each electrode has a
specially formulated filling solution which is unique to that sensor – see parts list for
details). Tap the side of the membrane cap to remove any air bubbles that may have
formed in the solution.

Reposition the vent seal, making sure that the vent hole is completely covered.

Fill up the G-holder with filling solution. Be careful that there


are no bubbles.

Hold the electrode shaft upright and push the electrode finger
carefully into the filled G-holder.

While holding the electrode shaft vertically with the G-holder


in place, screw the filled membrane cap back on to the
electrode shaft. Make sure not to press on the vent ring seal
or cover the area of the vent hole with a finger when installing
the membrane cap. Excess filling solution will escape from
top or the vent in the membrane cap. Rinse off any filling
solution that may have escaped during the installation with
clean water.

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Note: The G-holder is supplied and required for use with the chlorine probes and
with the annual maintenance kits containing the M48 membrane cap. See parts list
for details.

Note: When unscrewing the filled membrane cap from the electrode shaft, first
remove the vent seal and ensure that the vent is not covered by a finger (air needs to
be allowed through the vent hole to equalize the pressure).

Note: Make sure the membrane cap is tightly fastened to the electrode shaft
ensuring that no gap remains between the electrode shaft and the membrane cap.

Note: It is best to wait 1 - 4 hours before the first calibration is performed. After one
day repeat the calibration. See the MicroChem®2 electronics manual for calibration
instructions.

Note: Calibration must be made with a continuous flow of liquid at 500 mL/min
across the cell membrane.

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Figure 3 - Chlorine Probe Components.

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2.4 Flow Cell
The probe is inserted through a fitting which includes a slide ring and o-ring. Loosen or disassemble the
fitting to allow the probe to slide through the o-ring. The fitting may include a cap through which the probe
cable must be fed. Position the probe so it is about 1 inch (25 mm) from the bottom of the cell. Tighten the
fitting into the housing to compress the o-ring around the probe, providing a seal.

The inlet valve may be used to provide control the flow to the probe. It should be full open if the sample
stream is controlled by other components.

The adapter to be used on the outlet from the cell and is dependent on the sample supply. The sample flow
as noted in the section 1.4 is required. Excessive air in the sample may adversely affect the readings. The
small orifice adapter may be used to provide back pressure to keep the air from outgasing from the sample
stream.

2.5 Flow Regulation Components (See Figure 4)


To provide a sample to be measured for chlorine content with reduced potential for erratic readings and
calibration problems, it is highly recommended that some or all of the components in Figure 4 are
incorporated in the sample line. The Y-strainer is for particulate removal. The flow switch provides alarm
when flow is not present. The remaining components through the back pressure assembly will ensure that
you are providing the proper flow and pressure to allow optimum analysis. The back pressure assembly is
used in applications where air bubbles effervesce from the sample. The T-fitting and sample valve make for
easy sampling.

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Figure 4 – Arrangement, Piping, CL4000 Sensor

Key Part Number Description


1 22901 Y-strainer - (optional) for particulate removal
2 22832* Pressure Reducing Valve, 0-25 PSIG
3 23101* Pressure Gauge, 0-15 PSIG, ¼” NPT SS
4 22834* Flowmeter with Rate Valve, 0-10 GPH
5 22869 Flow Switch
6 23411 CL4000 Flow Cell
7 R-240 ½” NPT Tee Fitting
8 22897 ¼” Sample Valve
9 23102 Fitting, ¼ MNPT x 5/16 Tube
10 23104 Fitting, 1/8 MNPT x 5/16 Tube 90 Deg
11 23136 Fitting, 90 Deg, ¼ NPT x 5/16 Tube
12 23329 Assembly, Back Pressure with O-Ring
(included with 23411)
* Included in Flow Control Kit P/N 23068

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2.6 Electrical

The chlorine probes are connected to the transmitter analog board at pin 5 and 6 AND to the 24v
power supply terminals (see Figure 5). For more details on the analog board see the transmitter
manual.

WARNING
The transmitter power MUST be switched OFF before the probe is attached.

Terminals 9-12 are +24v


Terminals 13-16 are 0V

GREEN RED

BLUE BLUE

S4000 Cable Assembly


- + 1 meter 78-4001
probe 3 meter 78-4002
10 meter 78-4003

Figure 5 - Probe Cable Connections

WARNING
For proper operation of the chlorine probe, one of the above listed cable
Assemblies must be used.

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3 STARTUP
1. Check that the entire installation is connected properly. Check the electrode is properly
connected via the supplied cable.
2. Configure the transmitter channel that the probe is connected to for CL (Chlorine). Select CL
probe (mA) as the probe type. Set the probe range (0-2, 0-5 or 0-10 ppm) as indicated on the
chlorine probe label. Refer to the MicroChem®2 Transmitter instruction manual for additional
start-up information.
3. A calibration must be performed. Please find the instructions related to the procedure in the
MicroChem®2 instruction bulletin.
4. Output from CL4000 probes is never below 3.8 mA. At start-up, the probes may have an
output as low as 2 to 2.5 mA, but will rise to about 4 mA after half an hour. If output is less,
the electrolyte will need to be changed and the gold probe cleaned. Momentary power losses
will also result in low output, but will increase in about 30 minutes.

4 MAINTENANCE

4.1 Periodic Functional Check

The MicroChem®2 analyzer, like other analyzers, should be checked once per week to assure the
best measurement accuracy.

4.2 Electrode Maintenance

There is very little maintenance required on a chlorine electrode. Periodically the electrode should
be removed, and rinsed with de-ionised water.

CAUTION
Do not touch the tip of the electrode.

4.2.1 Electrode Membrane

The membrane cap needs to be replaced periodically (typically annually). The internal filling
solution needs to be replaced at the same time (section 2.3)
Note: pay particular attention to the notes on removing the membrane cap.

If the membrane gets coated it is possible to clean it. Very carefully swirl the membrane in a 1%
hydrochloric acid solution.

4.2.2 Cleaning the electrode surfaces

If the electrode has been stored for a long period of time the (gold) working electrode surface may
become tarnished and require polishing.

Empty out the internal filling solution – (section 2.3). Dry the electrode finger carefully using a
clean dry cloth .Holding the blue abrasive paper flat on a clean dry surface and holding the
electrode body vertically move the tip of the electrode across the paper two or three times. Refill
and reattach the membrane cap. (see section 2.3)

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5 TROUBLE SHOOTING PROCEDURE

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION


No indication No power supply to the transmitter Power the transmitter up or check the
power supply fuse. Check power supply
jumper setting.
Reading on Display is Faulty transmitter Verify transmitter (especially analogue
not in agreement with board)
the chlorine level The sensor is not continuously in Modify sensor installation
present in the sample contact with the sample
The connection between the sensor Make correct connections
and the transmitter is not correct.
Membrane is split or coated; internal Replace membrane and filling solution
filling solution contaminated or
depleted
The working electrode may be Clean the electrode surface
tarnished
The chlorine cell has been selected Reprogram the transmitter software
rather than the chlorine probe.
(RT Fault will be displayed with this
error)
The wrong chlorine range has been Reprogram the transmitter software
set up
Reading on Display is Not properly calibrated Recalibrate P2
fluctuating or erratic
Chlorine level is fluctuating Check the process
Sample flow rate is too low or Resolve flow problems. Add Pressure
variable Regulator and Flow meter for sample
control.
The sensor is not continuously in Modify sensor installation
contact with the sample
Air bubbles in the sample Eliminate the air bubbles or modify the
installation
“RTD” Fault displayed Incorrect chlorine channel definition – Refer to transmitter instruction manual.
Wrong chlorine input selected Select chlorine probe channel definition.

210.6405.10 - 16 -
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- 17 - 210.6405.10
Design improvements may be made without notice.
Represented By:

Severn Trent Services (UK) Severn Trent Services


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Sutton Coldfield, West Midlands, B76 9BL Tel: 215-997-4000 • Fax: 215-997-4062
Tel +44 (0) 121 313 2300 Web: www.severntrentservices.com
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09/07 Copyright 2007 Severn Trent Services

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