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Emerson PN 51-FCL-1056 manual

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Table of contents for the manual

  • Page 1

    FCL with 1056 Analyzer Instruction Manual PN 51-FCL-1056 rev .E March 2012[...]

  • Page 2

    ESSENTIAL INSTRUCTIONS READ THIS P AGE BEFORE PROCEEDING! Y our purchase from Rosemount Analytical, Inc. has resulted in one of the finest instruments available for your particular application. These instruments have been designed, and tested to meet many national and international standards. Experience indicates that its performance is directly re[...]

  • Page 3

    QUICK ST ART GUIDE FOR FCL ANAL YZER 1. Refer to Section 2.0 for installation instructions and Section 3.0 for wiring instructions. 2. Once connections are secured and verified, apply power to the analyzer . 3. When the analyzer is powered up for the first time, Quick St art screens appear . Using Quick S tart is easy . a. A backlit field shows the[...]

  • Page 4

    12. The main display appears. The outputs and alarms (if an alarm board is present) are assigned to default values. 13. T o change outputs, alarms, and other settings go to the main menu and choose Program . Follow the prompts. A menu tree is on the following two pages. T o calibrate the sensor(s) refer to section 6.0. T emp Unit s o C o F S1 Manua[...]

  • Page 5

    MENU TREE Calibrate Sensor 1 (Free chlorine) Chlorine Zero In process T emperature Sensor 2 (pH) pH Buffer Cal Auto Select buffer (NIST , DIN19267, Ingold, Merck, or Fisher) Select stability criteria Manual S tandardize Enter slope or offset T emperature Output 1 Output 2 Hold Sensor 1 Sensor 2 Display Main format configuration Language selection W[...]

  • Page 6

    Program Output s Range (assign values to 4 and 20 mA) Configure Output 1 or 2 Assign sensor and measurement Range Scale Dampening Fault mode (fixed or live) Fault value (output current) Simulate Alarms Configure/Setpoint Alarm 1, 2, 3, or 4 Setpoint Assign sensor and measurement High or low logic Deadband Interval time On time Recovery time Simulat[...]

  • Page 7

    About This Document This manual contains instructions for inst allation and operation of the Model FCL-1056 The following list provides notes concerning all revisions of this document. Rev . Level Date Notes A9 /08 This is the initial release of the product manual. The manual has been reformatted to reflect the Emerson documentation style and updat[...]

  • Page 8

    i MODEL FCL-1056 T ABLE OF CONTENTS FCL-1056 T ABLE OF CONTENTS Section Title Page 1.0 DESCRIPTION AND SPECIFICA TIONS ................................................................ 1 1.1 Applications ............................................................................................................. 1 1.2 Features ......................[...]

  • Page 9

    Section Title Page 7.0 DIGIT AL COMMUNICA TIONS ............................................................................... 51 8.0 MAINTENANCE ...................................................................................................... 53 8.1 Analyzer ....................................................................................[...]

  • Page 10

    LIST OF FIGURES Number Title Page 2-1 Model FCL-01 .................................................................................................... 7 2-2 Model FCL-02 .................................................................................................... 7 3-1 Analog Output Connections ..............................................[...]

  • Page 11

    Model FCL-1056 SECTION 1.0 DESCRIPTION AND SPECIFICA TIONS SECTION 1.0. DESCRIPTION AND SPECIFICA TIONS 1 1.1 APPLICA TIONS The FCL free chlorine system is intended for the deter- mination of free chlorine in fresh water . Unlike free chlorine analyzers from other manufacturers, the FCL does not use expensive sample conditioning systems or messy re[...]

  • Page 12

    1.3 SPECIFICA TIONS — GENERAL Sample requirement s: Pressure: 3 to 65 psig (122 to 549 kPa abs) A check valve in the inlet prevent s the sensor flow cells from going dry if sample flow is lost. The check valve opens at 3 psig (122 kPa abs). If the check valve is removed, minimum pres- sure is 1 psig (108 kp a abs). T emperature: 32 to 122°F (0 t[...]

  • Page 13

    3 1.6 ORDERING INFORMA TION FCL Free Chlorine Measuring System. The FCL is a complete system for the determination of free chlorine in aqueous samples. It consists of the sensor(s), analyzer , and constant head overflow device to control sample flow . All components are mounted on a backplate. Model option -02 includes a pH sensor for continuous, a[...]

  • Page 14

    This page lef t blank intentionally 4 MODEL FCL-1056 SECTION 1.0 DESCRIPTION AND SPECIFICA TIONS[...]

  • Page 15

    5 SECTION 2.0. INST ALLA TION MODEL FCL-1056 SECTION 2.0 INST ALLA TION 2.1 UNP ACKING AND INSPECTION Inspect the shipping container . If it is damaged, contact the shipper immediately for instructions. Save the box. If there is no apparent damage, unp ack the container . Be sure all items shown on the p acking list are present. If items are missin[...]

  • Page 16

    6 MODEL FCL-1056 SECTION 2.0 INST ALLA TION 2.2 INST ALLA TION 2.2.1 General Information 1. Although the system is suitable for outdoor use, do not inst all it in direct sunlight or in areas of extreme temperature. 2. T o keep the analyzer enclosure watertight, install plugs (provided) in the unused cable openings. 3. Install the system in an area [...]

  • Page 17

    7 FIGURE 2-1. Model FCL-01 FIGURE 2-2. Model FCL-02 INCH MILLIMETER INCH MILLIMETER MODEL FCL-1056 SECTION 2.0 INST ALLA TION[...]

  • Page 18

    This page lef t blank intentionally 8 MODEL FCL-1056 SECTION 2.0 INST ALLA TION[...]

  • Page 19

    SECTION 3.0. WIRING MODEL FCL-1056 SECTION 3.0 WIRING 3.1 POWER, ALARM, AND OUTPUT WIRING 3.1.1 Power Wire AC mains power to the power supply board, which is mounted vertically on the lef t hand side of the analyz- er enclosure. The power connector is at the top of the board. Unplug the connector from the board and wire the power cable to it. Lead [...]

  • Page 20

    MODEL FCL-1056 SECTION 3.0 WIRING 3.2 SENSOR WIRING The Model FCL is provided with sensor cables pre-wired to the analyzer . If it is necessary to replace the sensor cable, refer to the instructions below . 1. Shut off power to the analyzer . 2. Loosen the four screws holding the front panel in place and let it drop down. 3. Locate the appropriate [...]

  • Page 21

    11 MODEL FCL-1056 SECTION 3.0 WIRING Figure 3-3. Wiring Diagram for Free Chlorine Sensor Figure 3-4. Wiring Diagram for 399VP-09 pH Sensor Figure 3-5. Wiring Diagram for 3900VP-10 pH sensor (gray cable) Figure 3-6. Wiring Diagram for 3900VP-10 pH sensor (blue cable) RED WHITE[...]

  • Page 22

    This page lef t blank intentionally 12 MODEL FCL-1056 SECTION 3.0 WIRING[...]

  • Page 23

    13 MODEL FCL-1056 SECTION 4.0 DISPLA Y AND OPERA TION SECTION 4.0 DISPLA Y AND OPERA TION When the analyzer is being programmed or calibrated, the display changes to a screen similar to the one shown in Figure 4-2. The live readings appear in small font at the top of the screen. The rest of the display shows programming and calibration information.[...]

  • Page 24

    14 MODEL FCL-1056 SECTION 4.0 DISPLA Y AND OPERA TION 4.2 KEYP AD Local communication with the analyzer is through the membrane keypad. Figures 4-4 and 4-5 explain the operation of the keys. FIGURE 4-4. Analyzer keypad. Four navigation keys move the cursor around the screen. The position of the cursor is shown in reverse video. The navigation keys [...]

  • Page 25

    4.3 PROGRAMMING THE ANAL YZER—TUTORIAL Setting up and calibrating the analyzer is easy . The following tutorial describes how to move around in the programming menus. For practice, the tutorial also describes how to assign ppm chlorine values to the 4 and 20 mA analog outputs . MODEL FCL-1056 SECTION 4.0 DISPLA Y AND OPERA TION 1. Press MENU. The[...]

  • Page 26

    16 4.4 SECURITY 4.4.1 How the Security Code Works Security codes prevent accidental or unwanted changes to program settings or calibrations. There are three levels of security . a. A user can view the default display and diagnostic screens only . b. A user has access to the calibration and hold menus only . c. A user has access to all menus. 4.4.2 [...]

  • Page 27

    17 4.5 USING HOLD 4.5.1 Purpose T o prevent unwanted alarms and improper operation of control systems or dosing pumps, place the alarms and outputs assigned to the sensor in hold before removing it for maintenance. Hold is also useful if calibration, for example, buffering a pH sensor , will cause an out of limits condition. During hold, outputs as[...]

  • Page 28

    18 1. Press MENU. The main menu screen appears. Move the cursor to Display and press ENTER. 2. The screen shows the present configuration. There are four items: Main Format, Language, W arning, and Contrast. T o make a change, move the cursor to the desired line and press ENTER. A screen appears in which the present setting can be edited. Press ENT[...]

  • Page 29

    19 SECTION 5.0 PROGRAMMING THE ANAL YZER 5.1 GENERAL This section describes how to make the following program settings using the local keypad. a. Configure and assign values to the analog current outputs. b. Configure and assign values to the alarm relays. c. Choose the type of chlorine measurement being made. This step is necessary because the ana[...]

  • Page 30

    20 MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANAL YZER T ABLE 5-1. DEF AUL T SETTINGS ITEM CHOICES DEF AUL T Sensor assignment 1. Sensor 1 chlorine chlorine 2. Sensor 2 pH pH Output s 1. Assignment s (if FCL-01) a. output 1 chlorine, temp chlorine b. output 2 chlorine, temp temp 2. Assignment s (if FCL-02) a. output 1 chlorine, pH, temp chlorine b[...]

  • Page 31

    21 MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANAL YZER T ABLE 5-1. DEF AUL T SETTINGS (continued) ITEM CHOICES DEF AUL T Measurement 1. Chlorine (sensor 1) a. units ppm or mg/L ppm b. resolution 0.01 or 0.001 0.001 c. input filter 0 to 999 sec 5 sec 2. pH (sensor 2) a. pre-amplifier location analyzer or sensor/junction box analyzer b. solution tem[...]

  • Page 32

    22 MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANAL YZER 5.3 CONFIGURING , RANGING , AND SIMULA TING OUTPUTS. 5.3.1 Purpose This section describes how to configure, range, and simulate the two analog current outputs. CONFIGURE THE OUTPUTS FIRST . 1. Configuring an output means… a. Assigning a sensor and measurement (chlorine, pH, or temperature) t[...]

  • Page 33

    23 MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANAL YZER 5.3.3. Procedure – Configure Output s. 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. 2. The cursor will be on Output s. Press ENTER. 3. Choose Configure. 4. Choose Output 1 or Output 2 . 5. The screen shows the present configuration. There are six i[...]

  • Page 34

    24 MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANAL YZER 5.3.4. Procedure – Ranging Output s. 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. 2. The cursor will be on Output s . Press ENTER. 3. Choose Range . 4. Choose Output 1 or Output 2 . 5. The screen shows the present settings for the outputs. O1 is ou[...]

  • Page 35

    25 MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANAL YZER 5.3.5 Procedure – Simulating Output s 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. 2. The cursor will be on Output s . Press ENTER. 3. Choose Simulate . 4. Choose Output 1 or Output 2 . 5. Enter the desired simulated output current. T o end the sim[...]

  • Page 36

    5.4.2 Definitions 1. ASSIGNING ALARMS. There are four alarms relays. The relays are freely assignable to any sen- sor and to either the measurement (for example, chlorine) or temperature. Alarm relays can also be assigned to operate as interval timers or as fault alarms. A fault alarm activates when the analyzer detects a fault in either it self or[...]

  • Page 37

    27 MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANAL YZER 5.4.3 Procedure – Configuring Alarms and Assigning Setpoints 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. 2. Choose Alarms. 3. Choose Configure/Setpoint. 4. Choose Alarm 1, Alarm 2, Alarm 3, or Alarm 4. 5. The screen summarizes the present configur[...]

  • Page 38

    28 MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANAL YZER 5.4.4 Procedure – Simulating Alarms 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. 2. Choose Alarms. 3. Choose Simulate. 4. Choose Alarm 1, Alarm 2, Alarm 3, or Alarm 4. 5. Choose Don’t simulate, De-energize, or Energize. Press MENU or EXIT to end [...]

  • Page 39

    29 MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANAL YZER 5.4.4 Procedure – Synchronizing Timers 1. Synch Timers is available only if two or more alarm relays have been configured as interval timers. 2. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. 3. Choose Alarms. 4. The summary display shows the current Sy[...]

  • Page 40

    30 MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANAL YZER 5.5 CONFIGURING THE MEASUREMENT . 5.5.1 Purpose This section describes how to do the following: 1. Program the analyzer to measure free chlorine (and pH). This step is necessary because the Model FCL ana- lyzer can be used with other sensors to measure other chlorine oxidants. It can also be u[...]

  • Page 41

    MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANAL YZER 5.5.4 Procedure – Configuring the Measurement 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. 2. Choose Measurement. 3. The screen at left appears only if you have an FCL-02. Choose Sensor 1 (chlorine) or Sensor 2 (pH). 4. The screen summarizes the prese[...]

  • Page 42

    MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANAL YZER 5.6 CONFIGURING TEMPERA TURE RELA TED SETTINGS 5.6.1 Purpose This section describes how to do the following: 1. Choose temperature units. 2. Choose automatic or manual temperature correction for membrane permeability (chlorine sensor). 3. Choose automatic or manual temperature compensation for pH[...]

  • Page 43

    MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANAL YZER 5.7 CONFIGURING SECURITY SETTINGS 5.7.1 Purpose This section describes how to set security codes. There are three levels of security . a. A user can view the default display and diagnostic screens only . b. A user has access to the calibration and hold menus only . c. A user has access to all men[...]

  • Page 44

    34 MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANAL YZER 5.8 SETTING UP DIAGNOSTICS 5.8.1 Purpose NOTE Diagnostic setup applies only to pH sensors. It appears only if you are using the FCL-02. This section describes how to do the following: 1. T urn pH sensor diagnostics on and off. 2. Set pH sensor diagnostic limits. 5.8.2 Definitions 1. DIAGNOSTIC[...]

  • Page 45

    35 MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANAL YZER 5.8.3 Procedure – Setting Up Diagnostics 1. Press MENU. The main menu screen appears. Move the cursor to Program and press ENTER. 2. Scroll to the bottom of the screen and continuing scrolling until Diagnostic Setup is highlighted. Press ENTER. 3. Diagnostics are available only for pH sensor[...]

  • Page 46

    36 MODEL FCL-1056 SECTION 5.0 PROGRAMMING THE ANAL YZER 5.9 RESETTING THE ANAL YZER 5.9.1 Purpose This section describes how to clear user-entered values and restore default settings. There are three reset s: 1. Resetting to factory default values clears ALL user entered settings, including sensor and analog output calibration, and returns ALL sett[...]

  • Page 47

    MODEL FCL-1056 SECTION 6.0 CALIBRA TION SECTION 6.0 CALIBRA TION 6.1 INTRODUCTION The calibrate menu allows the user to do the following: 1. Calibrate the temperature sensing element in the chlorine and pH sensors. 2. Calibrate the chlorine sensor . 3. Calibrate the pH sensor . Four methods are available. a. T wo-point calibration with automatic bu[...]

  • Page 48

    38 MODEL FCL-1056 SECTION 6.0 CALIBRA TION 3. Press MENU. The main menu screen appears. The cursor will be on Calibrate. Press ENTER. 4. Choose the sensor you wish to calibrate. Sensor 1 is the chlorine sensor . Sensor 2 (if present) is the pH sensor . 5. Choose T emperature . 6. Change the display to match the temperature read from the calibrated [...]

  • Page 49

    39 MODEL FCL-1056 SECTION 6.0 CALIBRA TION 6.3 CALIBRA TION — FREE CHLORINE 6.3.1 Purpose As Figure 6-1 shows, a free chlorine sensor generates a current directly proportional to the concentration of free chlorine in the sample. Calibrating the sensor requires exposing it to a solution containing no chlorine (zero standard) and to a solution cont[...]

  • Page 50

    40 MODEL FCL-1056 SECTION 6.0 CALIBRA TION 3. Choose the sensor you wish to calibrate. Sensor 1 is the chlorine sensor . Sensor 2 (if present) is the pH sensor . 4. Choose Free Chlorine . 5. Choose Zero Cal . The analyzer will automatically st art the zero calibration 6. If the zero calibration was successful, the screen at left appears. If the zer[...]

  • Page 51

    MODEL FCL-1056 SECTION 6.0 CALIBRA TION 6.3.3 Procedure-Calibrating the Sensor 1. Place the chlorine sensor in the chlorine flow cell. If continuous (live) pH correction is being used, calibrate the pH sensor (section 6.4) and place it in the pH flow cell. If manual pH correction is being used, measure the pH of the sample and enter the value. See [...]

  • Page 52

    42 6.4 CALIBRA TION – pH 6.4.1 Purpose A pH sensor consist s of a glass and reference electrode. Usually , the two electrodes are combined into a single body , called a combination pH sensor . When the sensor is placed in an aqueous solution, it produces a voltage proportional to pH. An ideal pH sensor has a potential of 0 mV in pH 7 solution and[...]

  • Page 53

    43 MODEL FCL-1056 SECTION 6.0 CALIBRA TION 3. Press MENU. The main menu screen appears. The cursor will be on Calibrate . Press ENTER. 4. Choose the sensor you wish to calibrate. Sensor 1 is the chlorine sensor . Sensor 2 is the pH sensor . 5. Choose pH . 6. Choose Buffer Cal 7. Choose Auto . 5. USER ENTERED SLOPE AND OFFSET . If the slope and offs[...]

  • Page 54

    44 MODEL FCL-1056 SECTION 6.0 CALIBRA TION 8. Choose St art Auto Cal . If you wish to change the stability criteria or the pH buf fer list from the default values, choose Setup instead and go to step 14. The default stability is defined as a less than 0.02 pH change in 10 seconds. The default buffer list is S tandard . See the t able in section 6.4[...]

  • Page 55

    45 MODEL FCL-1056 SECTION 6.0 CALIBRA TION 6.4.4 Procedure-Manual Calibration 1. Obtain two buffer solutions. Ideally , the buffer pH values should bracket the range of pH values to be measured. 2. Remove the sensor from the flow cell. If the process and buffer temperatures are appreciably different, place the sensor in a container of t ap water at[...]

  • Page 56

    46 MODEL FCL-1056 SECTION 6.0 CALIBRA TION 10. W atch the pH reading for sensor 2 (S2) at the top of the screen. Once the reading is st able, enter the pH value of the buffer at the buffer temperature and press ENTER. 1 1. The display returns to the screen shown in step 8. Choose Buffer 2. Remove the sensor from the first buffer . Rinse with water [...]

  • Page 57

    47 MODEL FCL-1056 SECTION 6.0 CALIBRA TION 6.4.5 Procedure-St andardization 1. The pH value measured by the analyzer can be changed to match the reading from a second or referee instrument. The process of making the two readings agree is called st andardization. 2. Place the sensor in the flow cell. W ait until pH readings are stable. 3. Press MENU[...]

  • Page 58

    48 MODEL FCL-1056 SECTION 6.0 CALIBRA TION 6.4.6 Procedure-Entering a Known Slope and Offset 1. Calibration data, i.e., slope and of fset at pH 7, can be entered directly into the analyzer if the data for the sensor are already known. 2. Press MENU. The main menu screen appears. The cursor will be on Calibrate . Press ENTER. 3. Choose the sensor yo[...]

  • Page 59

    MODEL FCL-1056 SECTION 6.0 CALIBRA TION 2. Press MENU. The main menu screen appears. The cursor will be on Calibrate . Press ENTER. 3. Choose the output you wish to calibrate. 4. The analyzer will simulate the low output current. Change the value in the display to match the reading from the milliammeter . 5. The analyzer will simulate the 20 mA out[...]

  • Page 60

    50 MODEL FCL-1056 SECTION 6.0 CALIBRA TION This page lef t blank intentionally[...]

  • Page 61

    51 MODEL FCL-1056 SECTION 7.0 DIGIT AL COMMUNICA TIONS SECTION 7.0 DIGIT AL COMMUNICA TIONS THE ANAL YZER SUPPLIED WITH THE FCL DOES NOT HA VE THE DIGIT AL COMMUNICA TIONS OPTION.[...]

  • Page 62

    52 MODEL FCL-1056 SECTION 7.0 DIGIT AL COMMUNICA TIONS This page lef t blank intentionally[...]

  • Page 63

    53 MODEL FCL-1056 SECTION 8.0 MAINTENANCE SECTION 8.0 MAINTENANCE 8.1 ANAL YZER The analyzer used with the FCL needs little routine maintenance. Clean the analyzer case and front panel by wiping with a clean sof t cloth dampened with water ONL Y . Do not use solvents, like alcohol, that might cause a buildup of st atic charge. Sensor circuit boards[...]

  • Page 64

    MODEL FCL-1056 SECTION 8.0 MAINTENANCE 54 8.2.1 General. When used in clean water , the chlorine sensor requires little maintenance. Generally , the sensor needs mainte- nance when the response becomes sluggish or noisy or when readings drift following calibration. For a sensor used in potable water , expect to clean the membrane every month and re[...]

  • Page 65

    MODEL FCL-1056 SECTION 8.0 MAINTENANCE 55 33523-00 Electrolyte Fill Plug 9550094 O-Ring, Viton 2-014 33521-00 Membrane Ret ainer 23501-08 Free Chlorine Membrane Assembly: includes one membrane assembly and one O-ring 23502-08 Free Chlorine Membrane Kit: includes 3 membrane assemblies and 3 O-rings 9210356 #4 Free Chlorine Sensor Fill Solution, 4 oz[...]

  • Page 66

    56 MODEL FCL-1056 SECTION 8.0 MAINTENANCE 8.4 CONST ANT HEAD FLOW CONTROLLER 8.4.1 General After a period of time, deposit s may accumulate in the constant head overflow chamber and in the tubing leading to the flow cell(s). Deposits increase the resist ance to flow and cause the flow to gradually decrease. Loss of flow may ultimately have an impac[...]

  • Page 67

    57 MODEL FCL-1056 SECTION 8.0 MAINTENANCE FIGURE 8-2. Replacement Part s for the Flow Controller Assembly used in Model FCL-01. Location in Shipping Figure 8-2 PN Description Weight 1 24039-00 Flow cell for chlorine sensor with bubble shedding nozzle 1 lb/0.5 kg 2 24040-00 O-ring kit, two 2-222 and one 2-024 silicone O-rings, 1 lb/0.5 kg with lubri[...]

  • Page 68

    58 MODEL FCL-1056 SECTION 8.0 MAINTENANCE FIGURE 8-3. Replacement Part s for the Flow Controller Assembly used in Model FCL-02. Location in Shipping Figure 8-3 PN Description Weight 1 24039-00 Flow cell for chlorine sensor with bubble shedding nozzle 1 lb/0.5 kg 2 24039-01 Flow cell for pH sensor 1 lb/0.5 kg 3 24040-00 O-ring kit, two 2-222 and one[...]

  • Page 69

    59 MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING SECTION 9.0 TROUBLESHOOTING 9.1 OVERVIEW The analyzer continuously monitors itself and the sensor(s) for problems. When the analyzer identifies a problem, the word warning or fault appears intermittently in the lower line of the main display . When the fault or warning message appears, press the DIAG (d[...]

  • Page 70

    MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING Fault message Explanation Section Main Board CPU Error Main board software is corrupted 9.3.1 Main Board Factory Data Main board factory eeprom data is corrupted 9.3.1 Main Board User Data Main board user eeprom data is corrupted 9.3.1 Sensor Hardware Error Missing or bad hardware component 9.3.2 Sensor Bo[...]

  • Page 71

    MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.3.4 Sensor Incomp atible This error message means that the sensor board software is not supported by the main board sof tware. Either the sensor board or the main board software is too old. Replace the main board with one compatible with the sensor board. Call the factory for assist ance. Y ou will be as[...]

  • Page 72

    62 MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.3.10 Sensor RTD Out of Range Both the chlorine and pH sensor contain a Pt 100 R TD (resistance temperature device) for measuring temperature. If the measured resistance is out side the expected range, the analyzer will display the out of range error message. 1. Check wiring connections. 2. Disconnect [...]

  • Page 73

    63 MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING W arning message Explanation Section Sensor No Solution Gnd pH sensor may be miswired. 9.4.1 Sensor Need Factory Cal The sensor board was not calibrated at the factory . 9.4.2 Sensor Out of Range The pH measurement is invalid. 9.4.3 Sensor Negative Reading The chlorine reading is less than -0.5 ppm. 9.4[...]

  • Page 74

    64 MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.4.6 Sensor T emperature High or Low The sensor RTD is most likely miswired. 1. Check wiring connections. 2. Check resistance between RTD in and return leads. The resistance should be close to the values given in Section 9.10.2. 3. Replace sensor . 9.4.7 Broken Glass Disabled The impedance of the pH gl[...]

  • Page 75

    MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.5.3 Sensor can be calibrated, but the current is too low 1. Is the temperature low or is the pH high? Sensor current is a strong function of pH and temperature. The sensor current decreases about 3% for every °C drop in temperature. Sensor current also decreases as pH increases. Above pH 7, a 0.1 unit i[...]

  • Page 76

    66 MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.5.6 Sensor does not respond to changes in chlorine level. 1. Is the grab sample test accurate? Is the grab sample representative of the sample flowing to the sensor? 2. Is sample flowing past the sensor? Be sure the liquid level in the const ant head sampler is level with the central overflow tube and[...]

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    67 MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.6 TROUBLESHOOTING WHEN NO ERROR MESSAGE IS SHOWING — pH. Problem See Section Calibration Error warning during two-point calibration 9.6.1 Offset Error warning during st andardization 9.6.2 Sensor does not respond to known pH changes 9.6.3 Calibration was successful, but process pH is slightly differ[...]

  • Page 78

    68 MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.6.2 Calibration Error during St andardization. During standardization, the millivolt signal from the pH cell is increased or decreased until the pH agrees with the pH reading from a referee instrument. A unit change in pH requires an offset of about 59 mV . The analyzer limit s the offset to ±60 mV .[...]

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    69 MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.6.5 Calibration W as Successful, but Process pH Is Grossly Wrong and/or Noisy . Grossly wrong or noisy readings suggest a ground loop (measurement system connected to earth ground at more than one point), a floating system (no earth ground), or noise being brought into the analyzer by the sensor cable[...]

  • Page 80

    MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING 9.7.1 Difference Between Analyzer and St andard Thermometer is Greater Than 3°C. 1. Is the standard thermometer , R TD, or thermistor accurate? General purpose liquid-in-glass thermometers, particularly ones that have been mistreated, can have surprisingly large errors. 2. Is the temperature element in th[...]

  • Page 81

    9.9 SIMULA TING INPUTS — pH 9.9.1 General This section describes how to simulate a pH input into the analyzer . T o simulate a pH measurement, connect a standard millivolt source to the analyzer . If the analyzer is working properly , it will accurately measure the input voltage and convert it to pH. 9.9.2 Simulating pH input. 1. Set automatic te[...]

  • Page 82

    72 MODEL FCL-1056 SECTION 9.0 TROUBLESHOOTING T emp. (°C) Pt 100 ( Ω ) 0 100.0 10 103.9 20 107.8 25 109.7 30 1 1 1.7 40 1 15.5 50 1 19.4 60 123.2 70 127.1 80 130.9 85 132.8 90 134.7 100 138.5 FIGURE 9-6. Simulating RTD Input s. 9.10 SIMULA TING INPUTS — TEMPERA TURE 9.10.1 General. The analyzer accepts a Pt100 R TD (for pH and chlorine sensors)[...]

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    73 NOTES[...]

  • Page 84

    A Worldwide Network of Sales and Service Emerson Process Management’s field sales of fices are your source for more information on the fill line of Rosemount Analytical products. Field sales personnel will work closely with you to supply technical dat a and application information. For more information, please contact your nearest Emerson Process[...]

  • Page 85

    W ARRANTY Seller warrants that the firmware will execute the programming instructions provided by Seller , and that the Goods manufactured or Services provided by Seller will be free from defects in materials or workmanship under normal use and care until the expira- tion of the applicable warranty period. Goods are warranted for twelve (12) months[...]

  • Page 86

    Credit Cards for U.S. Purchases Only . The right people, the right answers, right now . ON-LINE ORDERING NOW A V AILABLE ON OUR WEB SITE http://www .rosemount analytical.com Specifications subject to change without notice. 8 Emerson Process Management 2400 Barranca Parkway Irvine, CA 92606 USA T el: (949) 757-8500 Fax: (949) 474-7250 http://www .ro[...]