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Emerson IM-106-5500 manual

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Table of contents for the manual

  • Page 1

    http://www .raihome.com Instruction Manual IM-106-5500, Orignal Issue August 2005 CCO 5500 Carbon Monoxide (CO) Analyzer[...]

  • Page 2

    [...]

  • Page 3

    Instruction Manual IM-106-5500, Origina l Issue August 2005 CCO 5500 http://www .raihome.com CCO 5500 Carbon Monoxide (CO) Analyzer ESSENTIAL INSTRUCTIONS READ THIS P AGE BEFORE PROCEEDING! Rosemount Analytical desig ns, manufact ures and test s its product s to meet many national and international st and ards. Because these instrument s are sophis[...]

  • Page 4

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 ii PREFACE The purpose of this manual is to pro vide information concerning the components, functio ns, installation and mainten ance of the CCO 5500. Some sections may describe equipment not used in your configuration. The user should become thorou ghly familiar with the oper atio[...]

  • Page 5

    Instruction Manual IM-106-5500, Origina l Issue August 2005 CCO 5500 http://www .raihome.com T able of Content s Essential Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii Definitions . . . . . .[...]

  • Page 6

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 TOC -2 SECTION 3 Configuration and Startup Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Power Supply Voltage Selection .[...]

  • Page 7

    Instruction Manual IM-106-5500, Original Issue August 2005 TOC -3 CCO 5500 Routine Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Notes for Using a Rosemount Analytical Check Cell . . . . . . . . . . 4-21 Alarms and Emergency Conditions . . . . . . . . . . . . . . . . . . . . . . . 4-23 Emergency Shutd[...]

  • Page 8

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 TOC -4[...]

  • Page 9

    Instruction Manual IM-106-5500, Origina l Issue August 2005 CCO 5500 http://www .raihome.com Section 1 Description and S pecifications Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p age 1- 1 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p age 1- 1 Principles and Modes of Ope[...]

  • Page 10

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 1-2 Each of these units is designed to be rugged and durable. They are all fully sealed to I P65 standards and are suitable for outside mounting , without the need for further weat herproof enclosures. Figure 1- 1. T ypical System Layout Infrared T ransmitter Unit At the heart of t[...]

  • Page 11

    Instruction Manual IM-106-5500, Original Issue August 2005 1-3 CCO 5500 The radiation emitted by t he he ater is then 'chopped' b y a motor-driven di sc, and focused across the duct by a lens. The chopper disc is driven by a small DC motor . The phase and frequency of the chopper disc ar e monitored by a radiation detector to provi de a r[...]

  • Page 12

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 1-4 Signal Processor Unit The signal processor unit is house d in a fully-sealed cast-aluminum enclosure. It houses the microprocesso r to monitor the data from the receiver and produces a 4-20 mA output sign al for gas levels within the flue. A non-volatile RAM section - requiring[...]

  • Page 13

    Instruction Manual IM-106-5500, Original Issue August 2005 1-5 CCO 5500 The basic expression from which th e gas concentr ation in the gas is determined is: This p arameter Y is then smoothe d, linearized and compensated for effect s of path length and flu e gas temperature, to produce a measurement of gas concentrat ion in the flue gas. Error Comp[...]

  • Page 14

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 1-6 Calculation Sequence The calculations for one co mplete operat ing cycle of the instrument ar e given below: •m e a s u r e D 1 & D 2 • measure E1 & E2 • compute Y • smoot h Y • linearize and correct for p ath length • normalize m easureme nt • smooth to p[...]

  • Page 15

    Instruction Manual IM-106-5500, Original Issue August 2005 1-7 CCO 5500 Since the vpm measurement is alrea dy normalized for temperatur e and pressure, the only further normalization required is for the dilution effe cts of water vapor and oxygen. These are straigh tforward calculations as shown below: 20.9% is taken as the level of free oxygen in [...]

  • Page 16

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 1-8 Carbon Monoxide IR Absorption S pectrum Carbon mo noxide absorb s IR energ y in a band between wa velengths of approximately 4.5 and 4.9 µ m. The absorption spectrum is complex and is illustrated in Figure 1-3 below . Figure 1-3. CO IR Absorption Sp e c t r u m However , two o[...]

  • Page 17

    Instruction Manual IM-106-5500, Original Issue August 2005 1-9 CCO 5500 T ransmissivity of CO Within the 4.7 µ m Band The transmis sion through th e gas of the IR energ y at about 4.7 µ m is affected by the concentration of CO. Figure 1-5 illustrates how the en ergy within the selected band varies with CO concentration. Figure 1-5. T ransmissivit[...]

  • Page 18

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 1- 10 Calibration Figure 1-6 sh ows the parameter Y against the CO concentration. Figure 1-6. Calibration Curve This is the calibration curve for the inst rument and is opposite in shape to the transmissivity curve shown in Figure 1-5. Each is fixed by the characteristics of the 4.[...]

  • Page 19

    Instruction Manual IM-106-5500, Original Issue August 2005 1- 1 1 CCO 5500 SPECIFICATIONS NOTE: *The range of the output sp an is quoted in ppm.meters. T o obtain the minimum and maximum sp an for your applic ation, divide these figures by the path length in meters. CCO 5500 Specifications S pan* Select able from 0-100 ppm to 0-10 ,000 ppm, within [...]

  • Page 20

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 1- 12[...]

  • Page 21

    Instruction Manual IM-106-5500, Origina l Issue August 2005 CCO 5500 http://www .raihome.com Section 2 Inst allation Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . p age 2-2 Electrical Supply Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . p age 2-2 Unp acking the Equipment . . . . . . . . . . . . . . . .[...]

  • Page 22

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 2-2 SAFETY CONSIDERATIONS The mains power is supplied to th e whole system via the power supply . During installation, DO NOT connect th e system to the mains until all unit s are in place and fully wired up . Keep the isolating valves, if us ed, CLOSED. T he compressed air (to be [...]

  • Page 23

    Instruction Manual IM-106-5500, Original Issue August 2005 2-3 CCO 5500 NOTE For normal operatio n terminals PS1 and PS2 must not be linked together . CABLE REQUIREMENT S 1. Power supply to signal proc essor - 7-co re, shielded, multi-strand ed, 6/0.2 mm. 0.5 mm 2 . NOTE Although screened cable is specified for the interconnecting cable , it is not[...]

  • Page 24

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 2-4 1. The site must be accessible at bo th sides of the duc t for servicing the transmitter and rece iver . 2. The site should be as free from extremes of temperatur e and vibration as possible - permissible ambient temperatur e range -4 o F to 158 o F (-20 o C to +70 o C). 3. Flu[...]

  • Page 25

    Instruction Manual IM-106-5500, Original Issue August 2005 2-5 CCO 5500 A hole should be cut on either side of the duct to be measured; these holes should accept a 'slip fit' with the stand-of f pipe. The st and-of f pipe should now be welded into each hole and a mounting flange welded to each pipe with the tapped hole s positioned as sho[...]

  • Page 26

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 2-6 ISOLATING V ALVES If isolating va lves are used they mount directly onto the site mounting flange s. AIR PURGE The air purge mo unts on the isolating va lve. They are mounted b y separating the front flange from the air pu rge by unscrewing the four locking nut s. A 'snout[...]

  • Page 27

    Instruction Manual IM-106-5500, Original Issue August 2005 2-7 CCO 5500 Figure 2-3. Analyzer Head Arrangement AIR SUPPLY The purpose of the air pur ge is to keep the windows of the transmitter and the receiver clean. Air may be supplied by one of three methods: 1. Negative pressur e duct. If the duct across which the instrument is measuring operate[...]

  • Page 28

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 2-8 SIGNAL PROCESSOR UNIT Enough cable is supplied to mount the sig nal processor up to 33 ft (10 m) from the receiver . T o mount the sig nal processor (Figure 2-4), first remove the cover by loosening the four captive sc rews, un plug the ribbon cable at the connector on the lid [...]

  • Page 29

    Instruction Manual IM-106-5500, Original Issue August 2005 2-9 CCO 5500 POWER SUPPLY UNIT Enough cable is supplied to mount the power supply up to a maximum of 33 ft (10 m) from the transm itter . A maximum tot al cable length of 82 ft (25 m) may be used to link the power supply to the receiver . These are the maximum permitted lengths of cable and[...]

  • Page 30

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 2-10 Figure 2-5. System Cable Connections MOTOR DIRECTION MOTOR DRIVE REFERENCE W A VE 0V TO SOURCE 12V TO SOURCE SCREEN YELLOW PURPLE BLACK/WHITE RED/BROWN TRANSMITTER PVC COPPER BRAID SCREEN 0.5 mm 8 CORE 2 YELLOW PURPLE BLACK/WHITE RED/BROWN 8 9 10 11 12 BLUE GREEN/YELLOW BROWN [...]

  • Page 31

    Instruction Manual IM-106-5500, Original Issue August 2005 3-1 CCO 5500 Section 3 Configuration and S t artup Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p age 3-1 Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . p age 3-1 Power Supply V olt age Selection . . . . . . . . . . . [...]

  • Page 32

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 3-2 POWER SUPPLY V OLTAGE SELECTION With the mains supply switched OFF , un screw the four captive screws on the cover of the power supply and remove the cover . Select the correct supply voltage usin g the sliding switch. T URNING THE POWER ON Once the supply volta ge switch has b[...]

  • Page 33

    Instruction Manual IM-106-5500, Original Issue August 2005 3-3 CCO 5500 Figure 3-1. Adjusting Nuts for Alignment 3. Replace the re ceiver on its air purge. Th e next adjustme nt is done using the detector lev els as viewed from the sig nal process or . 4. T o change mode on the signal processor the MODE key needs to be pressed once to access each m[...]

  • Page 34

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 3-4 NOTE The alignment of the receiver unit is important. T ake time to ensure that maximum va lues of D1 a nd D2 are obtained. 1 1. T o 'fine tune' the alignment, retu rn once more and adjust the tran smitter flange, again observing the values of D1 and D2 as appr opriat[...]

  • Page 35

    Instruction Manual IM-106-5500, Original Issue August 2005 3-5 CCO 5500 Figure 3-2. Receiver Trim Pot s 4. T rim potentiomete r(s) set the gain with the receiver . Levels should be measured with a voltm eter set to AC V olts. Figure 3-3. Receiver T est Points 5. Connect the voltme ter to the S0V and S1 test point s, as in Figure 3-3. Increase the g[...]

  • Page 36

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 3-6 NOTE If the duct is operating and a high op acity may be present, reduce the set voltages to 2V rms maximum. This is to prevent saturation sh ould the opacity level drop. Signal Processor Gain Adjustment After the d etector level(s) at the receiver have been optimized if necess[...]

  • Page 37

    Instruction Manual IM-106-5500, Original Issue August 2005 3-7 CCO 5500 NOTE If the duct is operating and the op acity levels are high, redu ce the D2 level to about 8,500. This is to avoid satura tion should the opacity level within the duct reduce. 3. *T o ensure that the detecto r signal is not saturating, observe the saturation coun t signal di[...]

  • Page 38

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 3-8 NOTE All operating p arameters are entered in the se tup mode. Section 5, Normal Operatio n, lists all p arameters in full. Basic details are given here for configur ation purposes. T o aid configu ration and to recor d any subsequent changes to the op erating paramete rs, it i[...]

  • Page 39

    Instruction Manual IM-106-5500, Original Issue August 2005 3-9 CCO 5500 Any of the f our averagin g stacks (seconds, minutes, hours or days) may be used for the analog output. They are sele cted by the AR ROW keys and entered using the ENTER key . c. Output Unit s The analog output can repr esent the gas concen tration in units of e ither mg/m 3 , [...]

  • Page 40

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 3-10 The value is adjusted using the two arrow keys, the UP arrow will take the current output up, and th e DOWN arrow will take it down. Press the ENTER key when the corr ect output current is displayed on the ammeter . NOTE Zero mA should be set up no matter what has been se lect[...]

  • Page 41

    Instruction Manual IM-106-5500, Original Issue August 2005 3-1 1 CCO 5500 The transmissivity of a sampl e of any gas depends both on the concentrat ion and on the path length through which the radiatio n is transmitted. Similarly , the output of the CCO 5500 monitor also depends on the path length o f the flue gas through which the radiation is tra[...]

  • Page 42

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 3-12 NOTE As this value controls the calibration of the instrument do not chang e it without due consideration. f. Plant S tatus Input Used to determine whether the plant is operating under corre ct conditions. There is a ch oice of thre e controls f or plant statu s, only one can [...]

  • Page 43

    Instruction Manual IM-106-5500, Original Issue August 2005 3-13 CCO 5500 k. Oxygen Threshold Set and used in a similar m anner to t he temper ature thre shold. However , if the normalizing oxygen level rises above the threshold, plant status is OF F . For pla nt status ON, t he oxygen leve l must be below the threshold set. l. W ater V a por Thres [...]

  • Page 44

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 3-14 b. Set V alues The normalizing da ta can be brought in to the instrument in one of 3 ways: 1 By entering a fixed value via the keypad. This is su itable where the value is stable to about ±5%. 2 If an INPUT UNIT is being used, all normalizing data can be transmitted via the s[...]

  • Page 45

    Instruction Manual IM-106-5500, Original Issue August 2005 3-15 CCO 5500 NOTE If normalization is not required, the instrume nt must have the normalizing parame ters for oxygen set. With an integrated system the pressure da ta can be ta ken to the instrument via the serial dat a line. e. Pressure T o correct the dat a to a standa rd pressure - norm[...]

  • Page 46

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 3-16 9. Calibration From this option the two detector levels may be displayed a nd a basic calibration conducted. During Set Detectors the gas cells are not moved; this gives an immediate response for setting up the detector levels. The basic calibration of the instrument is set by[...]

  • Page 47

    Instruction Manual IM-106-5500, Original Issue August 2005 3-17 CCO 5500 Set the calibration ta rget either to a known value of the gas concentration or to zero, a nd set the desired number of cycles over which the calibration factor is determined (a minimu m of 30 is recommended). The calibration should now be run and the dis play will show a coun[...]

  • Page 48

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 3-18 T able 3-1. Instrument Settings Parameter Config. A verages Seconds Minutes Hours Days Output 0 or 4 m A base Unit s Average Fault conditio n Parameters Path Length Alarm source Alarm units Alarm levels Normalization Te m p e r a t u r e S tandard level o F ( o C) I/P o F ( o [...]

  • Page 49

    Instruction Manual IM-106-5500, Original Issue August 2005 3-19 CCO 5500 After the calibration has been c onducted, a CAL F ACTOR will be calculated; this determines the calib r ation of the instrument. The cal factor will be displayed for a few se conds after a calibration has been conducted, and it can also be interrogated from Mode 4 (diagnostic[...]

  • Page 50

    Instruction Manual IM-106-5500, Original Issue August 2005 3-20 CCO 5500[...]

  • Page 51

    Instruction Manual IM-106-5500, Original Issue August 2005 4-1 CCO 5500 Section 4 Normal Operation Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p age 4-1 Normal St artup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . p age 4-1 Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 52

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 4-2 MODES OF OPERATION The instrument has six mode s of operation identified by a number in the top left corner of the display: Mode 1 - Operating Mode Displays average gas concentration. Mode 2 - Parameter Mode Displays operating pa rameters. Mode 3 - Normalization Mode Displays n[...]

  • Page 53

    Instruction Manual IM-106-5500, Original Issue August 2005 4-3 CCO 5500 KEY OPERATION Each mode is accessed sequentially by each p ush of the MODE key . Figure 4-1 illustrates the display and ke ys of the signal processor . After a mode has been selected, the ARROW ke ys will s elect the various options within these modes. The ENTER key will input [...]

  • Page 54

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 4-4 Figure 4-2. Prog ram Operation Tr e e Enter Press Enter on Exit option or Enter on the final option Operating Mode - 1 Mode Concentration units Measured or normalized Averaging time Parameter Mode - 2 Mode Indentification Parameters Averages Output Alarm source & level Plan[...]

  • Page 55

    Instruction Manual IM-106-5500, Original Issue August 2005 4-5 CCO 5500 OPERATING MODE From this mode of operation the av erag ing time of the displayed gas concentrat ion may be altered to one of the other av eraging stacks, and the measured/normalized g as measurements ob served. When in this mode, the display will appear similar to that shown be[...]

  • Page 56

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 4-6 Alarm A changeover relay co ntact output is available to indicate a high gas concentrat ion. The lev el at which th is output is o perated, an d the aver aging stack from which the gas valu e is obtained, may be examined from this display . Plant St atus When plant status is of[...]

  • Page 57

    Instruction Manual IM-106-5500, Original Issue August 2005 4-7 CCO 5500 Figure 4-3. Diagnostic Mode Tr e e Detector Levels Detector levels from the detector are di splayed her e. D1 is the reference level and should always be less than D2. The level of D2 should be between 10,000 and 20,000. E2 and E1 are the detector levels with the gas cell withi[...]

  • Page 58

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 4-8 Chopper Motor Frequency The chopper blad e should 'chop' the IR radiation at a freq uenc y of about 37 Hz. This frequency is measured by the processor and can be displayed from this option. As the chopper blades interrupt s the IR b eam, the radiation is split into tw[...]

  • Page 59

    Instruction Manual IM-106-5500, Original Issue August 2005 4-9 CCO 5500 Fault Condition T o display the current fault condition, press the ENTER key while this is displayed. This display mode is automatically selected by the instrument, should a fault conditio n occur . The following faul t conditions are re cognized by the ins trument: 1. *ALL CLE[...]

  • Page 60

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 4-10 Setup Mode All operating p arameters - averaging ti mes, output settings , normalization paramete rs, path length, calibration, etc. - can be changed from this mode. T o prevent any unauthorized changes, the user must enter a four number code before the mode ca n be entered. N[...]

  • Page 61

    Instruction Manual IM-106-5500, Original Issue August 2005 4-1 1 CCO 5500 Figure 4-4. Set Up Mode T ree Set A verages Four sep arate averages are ca lculated within the instrument. Th ese are defined in units of seconds, minu tes, hours and days. Any of the four averaging stacks can be used to provide the analog output of the instrument. Each avera[...]

  • Page 62

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 4-12 1. Press the ENTER key when this display is shown; the display will now show one of the averages. Use the ARROW keys to select the average time th at requires changing, and press the ENTER key to change it. The value can now be changed using th e ARROW keys and input by pressi[...]

  • Page 63

    Instruction Manual IM-106-5500, Original Issue August 2005 4-13 CCO 5500 Output Sp an Select the required sp an using the ARROW keys for each digit. The ENTER key is pressed to enter the value of each digit. The units will be displayed in ppm, mg/m 3 or mg/Nm 3 , depending on what has been selected beforehand. The current value will be displayed fo[...]

  • Page 64

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 4-14 Parameters Select this option by pressing the ENTER key . The ARROW keys will now display the available options from within this sub-mode. When the option that requires c hanging is displa yed, press the ENTER key . When all requ ired changes have been made, select the EXIT op[...]

  • Page 65

    Instruction Manual IM-106-5500, Original Issue August 2005 4-15 CCO 5500 Alarm A contact output is available to warn of a high gas concentration. This cont act output may be triggered from any of th e four averaging sta cks. Select the source with the ARROW key and enter it with the ENTER key . Select the units for the alarm - the se may be diff er[...]

  • Page 66

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 4-16 Serial Input — If this option is selected th e criteria contro lling plant status are transmitted via the seria l data lin k. Select th is option by pressing ENTER when t he 'Plant S tatus - Serial' scr een is displaye d. Multiple — Four options are available her[...]

  • Page 67

    Instruction Manual IM-106-5500, Original Issue August 2005 4-17 CCO 5500 Normalization All of the normalization inputs and parameters are set up from this mode. Press ENTER to access the mode and the ARROW keys will select which of the normalizing input s are to be changed, they are: 1. T emperatur e 2. Oxygen 3. Pressure 4. Water V apor After sele[...]

  • Page 68

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 4-18 Setting the Normalizing Parameters After selecting the parameter to be set up, the ARROW keys will select between enterin g the standard levels an d how the normalization dat a is to be brought into the instrume nt. Set St andard Levels Each normalizing para meter normalizes t[...]

  • Page 69

    Instruction Manual IM-106-5500, Original Issue August 2005 4-19 CCO 5500 Oxygen T o correct the data to st andard levels of oxygen, an estimate of the oxygen at the point of meas urement is req uired. If the ox ygen level is being co ntinuously measured, connect the analog ou tput of the oxygen analyzer into the CCO 5500 analyzer and sele ct the an[...]

  • Page 70

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 4-20 NOTE If this option is selected , all data in the averaging stacks is reset and the dat a for as much as the last 30 days will be lost. Calibrate From this option the two detector levels may be displayed and a basic calibr ation conducted. While in this mode the gas cell is no[...]

  • Page 71

    Instruction Manual IM-106-5500, Original Issue August 2005 4-21 CCO 5500 The check cell must not be inserted before this screen is accessed. Refer to Notes for Using a Rosemount Analytical Check Cell. NORMAL SHUT DOWN PROCEDURE The system should not need shutting down un less maintenance is being carried out. In this case, power down the power supp[...]

  • Page 72

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 4-22 Figure 4-6. Check Cell Holder 5. Insert the check cell into the check cell holder and replace and tighten the screws. The cell can be inserted in either direction. Refer to Figure 4-7. Figure 4-7. Check Cell 6. Introducing the check cell may cause an initial major disturbance [...]

  • Page 73

    Instruction Manual IM-106-5500, Original Issue August 2005 4-23 CCO 5500 Alarms and Emergency Conditions The alarm thresholds for the system ar e set as described in the normal operating mode. When an al arm condition is obtained the re d LED on the signal processor will light up. This will go out when the al arm condition has cleared. If the analy[...]

  • Page 74

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 4-24[...]

  • Page 75

    Instruction Manual IM-106-5500, Origina l Issue August 2005 CCO 5500 http://www .raihome.com Section 5 Maintenance Routine (Preventive ) Maintenance . . . . . . . . . . . . . . . . . . page 5-1 Sp an Factor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . p age 5-3 ROUTINE (PREVENTIVE) MAINTENANCE The equipment is designed to ke ep le[...]

  • Page 76

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 5-2 T o replace an element proceed as fo llows: 1. Switch OFF power . 2. Remove the rear cover plate from th e transmitter by removing the four retaining screws. Note th at these screws are not captive. 3. Carefully remo ve the PCB now revealed by unscrewing the thre e retaining sc[...]

  • Page 77

    Instruction Manual IM-106-5500, Original Issue August 2005 5-3 CCO 5500 Receiver 1. T urn the power OFF and remove the receiver from it s air purge. 2. Remove the receiver cove r from the front flange. 3. Remove the four screws holding side detector PCB to the main body of the receiver (M4 x 16 screws). 4. Completely remove the four M6 bolt s from [...]

  • Page 78

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 5-4 An example of resetting the span factor is outlined be low: • Certified check cell of 2880 pp m is inserted into the check cell holder with the analyzer in Mode 6 a nd a reading take n. This reading is 3240. • Due to the value of the check cell exceeding 999 ppm a suitable [...]

  • Page 79

    Instruction Manual IM-106-5500, Original Issue August 2005 6-1 CCO 5500 Section 6 T roubleshooting Fault Finding with the Keypad . . . . . . . . . . . . . . . . . . . . . . page 6-1 T roubleshooting T ables . . . . . . . . . . . . . . . . . . . . . . . . . . . p age 6-2 Component T ests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 80

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 6-2 The following fault conditions are recognized by the instru ment. T able 6-1. Fault Conditions NOTE If a fault condition is recognized by the instrument the minute s, hours and days averages w ill not be updated. Further troubleshooting infor mation is provided in T able 6-2 an[...]

  • Page 81

    Instruction Manual IM-106-5500, Original Issue August 2005 6-3 CCO 5500 T able 6-2. Configuration Problems No display on signal proce ssor Possible Cause Te s t Result Action Mains input failure Check 1 10/220V selection sw itch in power supply Setting correct Proceed to next test Setting incorrect Change setting & proceed to next test Check po[...]

  • Page 82

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 6-4 Display message ‘Waiting for Reference’ Possible Cause Te s t Result Action Reference wave failure Checking wiring between power supply and signal processor and also between power supply and transmitter Wiring OK Proceed to next test Wiring incorrect Cor rect wiring Check r[...]

  • Page 83

    Instruction Manual IM-106-5500, Original Issue August 2005 6-5 CCO 5500 Low detector level Possible Cause Te s t Result Action Incorrect wiring Chec king wiring Fault clears No further action Fault continues Proceed t o next possible cause Dirty windows o r obstructed sight path Check and clean the Rx and Tx windows - clear sight path between Rx an[...]

  • Page 84

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 6-6 Modulation frequency o ut of range Possible Cause Te s t Result Action Chopper motor speed out of range Adjust chopper motor speed Mod. Frequency in range No further action Unable to adjust Proceed t o next test Monitor ref. waveform across 10 and 1 1 in power supply using osci[...]

  • Page 85

    Instruction Manual IM-106-5500, Original Issue August 2005 6-7 CCO 5500 T able 6-3. Operational Problems Output reading permanently zero or full scale Possible Cause Te s t Result Action Incorrect normalizing parameter setting Enter parameter mode and ensure all parameters are as required Parameters correct Proceed to next possible cause Parameters[...]

  • Page 86

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 6-8 COMPONEN T T EST S Some instrument component s/operation can be verified as follows: Heater Cartridge Perform the step s for Section 5, Replacement of the Heater Element within the transmitter up to step 4. Remove one lead from th e heater cartridge and measure the resist ance [...]

  • Page 87

    Instruction Manual IM-106-5500, Original Issue August 2005 6-9 CCO 5500 T EST POINTS If further checks on instrument operatio n are requir ed, there are various test points with in the instrument. Many of these are simple DC voltages a nd so may be checked using a vo ltmeter set to DC volts, otherwise may be investigated usin g an oscilloscope: Sig[...]

  • Page 88

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 6-10[...]

  • Page 89

    Instruction Manual IM-106-5500, Origina l Issue August 2005 CCO 5500 http://www .raihome.com Section 7 Returning Material If factory rep air of defective equipm ent is required, proceed as follows: 1. Secure a return authorization number from a Rosemount Analytical sales of fice or representative before r eturning the equipment. Equipment mu st be [...]

  • Page 90

    Instruction Manual IM-106-5500, Original Issue August 2005 7-2 CCO 5500[...]

  • Page 91

    Instruction Manual IM-106-5500, Origina l Issue August 2005 CCO 5500 http://www .raihome.com Section 8 Replacement Part s Recommended Sp are Part s . . . . . . . . . . . . . . . . . . . . . . . . p age 8-1 Part s List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p age 8-1 RECOMMENDED SP ARE PART S Items marked * are[...]

  • Page 92

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 8-2[...]

  • Page 93

    Instruction Manual IM-106-5500, Origina l Issue August 2005 CCO 5500 http://www .raihome.com Appendix A Safety Dat a Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p age A-2[...]

  • Page 94

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 A-2 SAFETY INSTRUCTIONS IMPORT ANT SAFETY INSTRUCTIONS FOR THE WIRING AND INST ALLA TION OF THIS APP ARA TUS The following safety instruct ions appl y specifically to all EU member st ates. They should be s trictly adhered to in ord er to assure compliance with the Low V olt age Di[...]

  • Page 95

    Instruction Manual IM-106-5500, Original Issue August 2005 A-3 CCO 5500 BELANGRIJK V eiligheidsvoorschrif ten voor de aansluiting en inst allatie van dit toestel. De hierna volgende veiligheidsvoorsc hriften zijn vooral bedoeld voor de EU lidst aten. Hier moet aan gehouden worden om de onderworpenheid aan de Laag S pannings Richtlijn (Low V olt age[...]

  • Page 96

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 A-4 VIG TIG T Sikkerhedsinstruktion for tilslut ning og inst allering af dette udstyr . Følgende sikkerhedsin struktioner gælder spec ifikt i alle EU-medlemslande. Instruktion erne skal nøje følges for overhold else af Lavsspændingsdirektive t og bør også følges i ikke EU-l[...]

  • Page 97

    Instruction Manual IM-106-5500, Original Issue August 2005 A-5 CCO 5500 BELANGRIJK V eiligheidsinstructies voor de bedrad ing en inst allatie van dit app araat. V oor alle EU lidst aten zijn de volgende veiligheidsinstr ucties van toep assing. Om aan de geldende richtlijnen voor laagsp anning te voldoen dient men zich hieraan st rikt te houden. Ook[...]

  • Page 98

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 A-6 TÄRKEÄÄ T urvallisuusohje , jota on noudatett ava tämän laitteen asent amisessa ja kaapeloinnissa . Seuraavat ohjeet pät evät erityisesti EU:n jäsenv altioissa. Niitä täytyy ehdottomasti nou dattaa jotta täyt ettäisiin EU:n mat alajännitedirektiivin (Low V olt age [...]

  • Page 99

    Instruction Manual IM-106-5500, Original Issue August 2005 A-7 CCO 5500 IMPORT ANT Consignes de sécurité concernant le raccordement et l' insta llation de cet app areil. Les consignes de sécurité ci-d essous s'adressent p a rticulièrement à tous les ét at s membres de la communauté européenne. Elles doiven t être strictement app[...]

  • Page 100

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 A-8 WICHTIG Sicherheit shinweise für den Anschluß und die Inst allation dieser Geräte. Die folgenden Sicherheit shinweise si nd in allen Mitgliederst aaten der europäischen Gemeinschaf t gültig. Sie müssen s trickt eingehalten werden, um der Niedersp annungsrichtlinie zu gen?[...]

  • Page 101

    Instruction Manual IM-106-5500, Original Issue August 2005 A-9 CCO 5500 IMPORT ANTE Norme di sicurezza per il cablaggi o e l'inst allazion e dello strumento. Le seguenti norme di sicurezza si applica no specificata mente agli stati membri dell'Unione Europea, la cui stre tta osse rvanza è richiest a per garantire conformità alla Dire tt[...]

  • Page 102

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 A-10 VIKTIG Sikkerhet sinstruks for tilkobling og inst allasjon av dette uts tyret. Følgende si kkerhetsinstruksjoner gj elder spesifik t alle EU medlemsl and og land med i EØS-avt alen. Instruksjo nene skal følges nøye slik at inst allasjonen blir i henhold til lavspenn ingsdi[...]

  • Page 103

    Instruction Manual IM-106-5500, Original Issue August 2005 A-1 1 CCO 5500 IMPORT ANTE Instruções de segurança p ara ligação e instalaç ão deste ap arelho. As seguintes instruções de segurança aplicam-se especific amente a todos os est ados membros da UE. Deve m ser observadas rigidamente por forma a garantir o cumprimento da Directiv a so[...]

  • Page 104

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 A-12 IMPORT ANTE Instrucciones de seguridad p ara el mont aje y cableado de este apar ato. Las siguientes instrucciones de s eguridad, son de aplicacion espe cifica a todos los miembros de la UE y se adjunt aran para cumplir la normativa europea de baja tens ion. 1. Se deben prevee[...]

  • Page 105

    Instruction Manual IM-106-5500, Original Issue August 2005 A-13 CCO 5500 VIKTIG T Säkerhetsföreskrifter för kablage och installation av denna ap p arat . Följande säkerhet sför eskrifter är tillämp liga för samtliga EU-medlemsländer . De skall följas i varje avs eende för att överensstämma med Lågs pännings direktivet. Icke EU medle[...]

  • Page 106

    Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 A-14[...]

  • Page 107

    W ARRANTY Rosemount Analytical warr ants that th e equipment manufacture d and sold by it will, upon shipment, be free of defe cts in workmanship or material. Should any failure to conform to this warranty become app arent during a period of one year after the date of shipment, Rosemount Analytical shall, upon prompt written notice from the pu rcha[...]

  • Page 108

    Emerson Process Management © 2005 Rosemount Analytical Inc. All rights reserved. Rosemount Analytical and the Rosemount Analytical logotyp e are registered trademarks of Rosemount Analytical Inc. All other marks are the property of their respective owners. Instruction Manual IM-106-5500, Original Issue August 2005 EUROPE, MIDDLE EAST , AFRICA Fish[...]