Emerson IM-106-5500 - Manuals

Instruction Manual IM-106-5500, Original IssueAugust 2005 CCO 5500 http://www.raihome.com Section 1 Description and Specifications Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

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 IP65 standards and are suitable for outside mounting, without the need for further weatherproof enclosures. Figure 1-1. Typical System Layout...

Instruction Manual IM-106-5500, Original IssueAugust 2005 1-3 CCO 5500 The radiation emitted by the heater is then 'chopped' by a motor-driven disc, 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 are monitored by a r...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 1-4 Signal Processor Unit The signal processor unit is housed in a fully-sealed cast-aluminum enclosure. It houses the microprocessor to monitor the data from the receiver and produces a 4-20 mA output signal for gas levels within t...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 1-8 Carbon Monoxide IR Absorption Spectrum Carbon monoxide absorbs IR energy in a band between wavelengths 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 I...

Instruction Manual IM-106-5500, Original IssueAugust 2005 1-9 CCO 5500 Transmissivity of CO Within the 4.7 µ m Band The transmission through the gas of the IR energy at about 4.7 µ m is affected by the concentration of CO. Figure 1-5 illustrates how the energy within the selected band varies with CO...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 1-10 Calibration Figure 1-6 shows the parameter Y against the CO concentration. Figure 1-6. Calibration Curve This is the calibration curve for the instrument and is opposite in shape to the transmissivity curve shown in Figure 1-5....

Instruction Manual IM-106-5500, Original IssueAugust 2005 1-11 CCO 5500 SPECIFICATIONS NOTE: *The range of the output span is quoted in ppm.meters. To obtain the minimum and maximum span for your application, divide these figures by the path length in meters. CCO 5500 Specifications Span* Selectable...

Instruction Manual IM-106-5500, Original IssueAugust 2005 CCO 5500 http://www.raihome.com Section 2 Installation Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2Electrical Supply Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2Unpacking the ...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 2-2 SAFETY CONSIDERATIONS The mains power is supplied to the whole system via the power supply. During installation, DO NOT connect the system to the mains until all units are in place and fully wired up. Keep the isolating valves, ...

Instruction Manual IM-106-5500, Original IssueAugust 2005 2-3 CCO 5500 NOTE For normal operation terminals PS1 and PS2 must not be linked together. CABLE REQUIREMENTS 1. Power supply to signal processor - 7-core, shielded, multi-stranded, 6/0.2 mm. 0.5 mm 2 . NOTE Although screened cable is specifie...

Instruction Manual IM-106-5500, Original IssueAugust 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-off pipe. The stand-off pipe should now be welded into each hole and a mounting flange welded to each pipe with...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 2-6 ISOLATING VALVES If isolating valves are used they mount directly onto the site mounting flanges. AIR PURGE The air purge mounts on the isolating valve. They are mounted by separating the front flange from the air purge by unscr...

Instruction Manual IM-106-5500, Original IssueAugust 2005 2-7 CCO 5500 Figure 2-3. Analyzer Head Arrangement AIR SUPPLY The purpose of the air purge is to keep the windows of the transmitter and the receiver clean. Air may be supplied by one of three methods: 1. Negative pressure duct. If the duct a...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 2-8 SIGNAL PROCESSOR UNIT Enough cable is supplied to mount the signal processor up to 33 ft (10 m) from the receiver. To mount the signal processor (Figure 2-4), first remove the cover by loosening the four captive screws, unplug t...

Instruction Manual IM-106-5500, Original IssueAugust 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 transmitter. A maximum total cable length of 82 ft (25 m) may be used to link the power supply to the receiver. These a...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 2-10 Figure 2-5. System Cable Connections MOT OR DIRECTION MOT OR DRIVE REFERENCE W A VE 0V T O SOURCE 12V T O SOURCE SCREEN YELLOW PURPLE BLACK/WHITE RED/BROWN TRANSMITTER PVC COPPER BRAID SCREEN 0.5 mm 8 CORE 2 YELLOW PURPLE BLACK...

Instruction Manual IM-106-5500, Original IssueAugust 2005 3-1 CCO 5500 Section 3 Configuration and Startup Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-1Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-1Power Supply...

Instruction Manual IM-106-5500, Original IssueAugust 2005 3-3 CCO 5500 Figure 3-1. Adjusting Nuts for Alignment 3. Replace the receiver on its air purge. The next adjustment is done using the detector levels as viewed from the signal processor. 4. To change mode on the signal processor the MODE key ...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 3-4 NOTE The alignment of the receiver unit is important. Take time to ensure that maximum values of D1 and D2 are obtained. 11. To 'fine tune' the alignment, return once more and adjust the transmitter flange, again observing the v...

Instruction Manual IM-106-5500, Original IssueAugust 2005 3-5 CCO 5500 Figure 3-2. Receiver Trim Pots 4. Trim potentiometer(s) set the gain with the receiver. Levels should be measured with a voltmeter set to AC Volts. Figure 3-3. Receiver Test Points 5. Connect the voltmeter to the S0V and S1 test ...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 3-6 NOTE If the duct is operating and a high opacity may be present, reduce the set voltages to 2V rms maximum. This is to prevent saturation should the opacity level drop. Signal Processor Gain Adjustment After the detector level(s...

Instruction Manual IM-106-5500, Original IssueAugust 2005 3-7 CCO 5500 NOTE If the duct is operating and the opacity levels are high, reduce the D2 level to about 8,500. This is to avoid saturation should the opacity level within the duct reduce. 3. *To ensure that the detector signal is not saturat...

Instruction Manual IM-106-5500, Original IssueAugust 2005 3-9 CCO 5500 Any of the four averaging stacks (seconds, minutes, hours or days) may be used for the analog output. They are selected by the ARROW keys and entered using the ENTER key. c. Output Units The analog output can represent the gas co...

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 the DOWN arrow will take it down. Press the ENTER key when the correct output current is displayed on the ammeter. NOTE Zero mA s...

Instruction Manual IM-106-5500, Original IssueAugust 2005 3-11 CCO 5500 The transmissivity of a sample of any gas depends both on the concentration and on the path length through which the radiation is transmitted. Similarly, the output of the CCO 5500 monitor also depends on the path length of the ...

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 change it without due consideration. f. Plant Status Input Used to determine whether the plant is operating under correct conditions. There is a choice of thr...

Instruction Manual IM-106-5500, Original IssueAugust 2005 3-13 CCO 5500 k. Oxygen Threshold Set and used in a similar manner to the temperature threshold. However, if the normalizing oxygen level rises above the threshold, plant status is OFF. For plant status ON, the oxygen level must be below the ...

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

Instruction Manual IM-106-5500, Original IssueAugust 2005 3-15 CCO 5500 NOTE If normalization is not required, the instrument must have the normalizing parameters for oxygen set. With an integrated system the pressure data can be taken to the instrument via the serial data line. e. Pressure To corre...

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 and a basic calibration conducted. During Set Detectors the gas cells are not moved; this gives an immediate response for setting up the detector levels. ...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 3-18 Table 3-1. Instrument Settings Parameter Config. Averages SecondsMinutesHoursDays Output 0 or 4 mA baseUnitsAverageFault condition Parameters Path LengthAlarm sourceAlarm unitsAlarm levels Normalization Temperature Standard lev...

Instruction Manual IM-106-5500, Original IssueAugust 2005 3-19 CCO 5500 After the calibration has been conducted, a CAL FACTOR will be calculated; this determines the calibration of the instrument. The cal factor will be displayed for a few seconds after a calibration has been conducted, and it can ...

Instruction Manual IM-106-5500, Original IssueAugust 2005 4-1 CCO 5500 Section 4 Normal Operation Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-1Normal Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . page 4-1Modes of Operation . . ....

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 4-2 MODES OF OPERATION The instrument has six modes 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...

Instruction Manual IM-106-5500, Original IssueAugust 2005 4-3 CCO 5500 KEY OPERATION Each mode is accessed sequentially by each push of the MODE key. Figure 4-1 illustrates the display and keys of the signal processor. After a mode has been selected, the ARROW keys will select the various options wi...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 4-4 Figure 4-2. Program Operation Tree Enter Press Enter on Exit option or Enter on the final option Operating Mode - 1 Mode Concentration unitsMeasured or normalizedAveraging time Parameter Mode - 2 Mode IndentificationParametersAv...

Instruction Manual IM-106-5500, Original IssueAugust 2005 4-5 CCO 5500 OPERATING MODE From this mode of operation the averaging time of the displayed gas concentration may be altered to one of the other averaging stacks, and the measured/normalized gas measurements observed. When in this mode, the d...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 4-6 Alarm A changeover relay contact output is available to indicate a high gas concentration. The level at which this output is operated, and the averaging stack from which the gas value is obtained, may be examined from this displ...

Instruction Manual IM-106-5500, Original IssueAugust 2005 4-7 CCO 5500 Figure 4-3. Diagnostic Mode Tree Detector Levels Detector levels from the detector are displayed here. 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 ar...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 4-8 Chopper Motor Frequency The chopper blade should 'chop' the IR radiation at a frequency of about 37 Hz. This frequency is measured by the processor and can be displayed from this option. As the chopper blades interrupts the IR b...

Instruction Manual IM-106-5500, Original IssueAugust 2005 4-9 CCO 5500 Fault Condition To 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 condition occur. The following fault conditions ar...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 4-10 Setup Mode All operating parameters - averaging times, output settings, normalization parameters, path length, calibration, etc. - can be changed from this mode. To prevent any unauthorized changes, the user must enter a four n...

Instruction Manual IM-106-5500, Original IssueAugust 2005 4-13 CCO 5500 Output Span Select the required span 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 bef...

Instruction Manual IM-106-5500, Original IssueAugust 2005 4-15 CCO 5500 Alarm A contact output is available to warn of a high gas concentration. This contact output may be triggered from any of the four averaging stacks. Select the source with the ARROW key and enter it with the ENTER key. Select th...

Instruction Manual IM-106-5500, Original IssueAugust 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 inputs are to be changed, they are: 1. Temperature 2....

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 entering the standard levels and how the normalization data is to be brought into the instrument. Set Standard Le...

Instruction Manual IM-106-5500, Original IssueAugust 2005 4-19 CCO 5500 Oxygen To correct the data to standard levels of oxygen, an estimate of the oxygen at the point of measurement is required. If the oxygen level is being continuously measured, connect the analog output of the oxygen analyzer int...

Instruction Manual IM-106-5500, Original IssueAugust 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 SHUTDOWN PROCEDURE The system should not need shutting down unless maintenance is being carri...

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 ...

Instruction Manual IM-106-5500, Original IssueAugust 2005 CCO 5500 http://www.raihome.com Section 5 Maintenance Routine (Preventive) Maintenance . . . . . . . . . . . . . . . . . . page 5-1Span Factor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-3 ROUTINE (PREVENTIVE) MAINTE...

Instruction Manual IM-106-5500, Original IssueAugust 2005 5-3 CCO 5500 Receiver 1. Turn the power OFF and remove the receiver from its air purge. 2. Remove the receiver cover from the front flange. 3. Remove the four screws holding side detector PCB to the main body of the receiver (M4 x 16 screws)....

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 5-4 An example of resetting the span factor is outlined below: • Certified check cell of 2880 ppm is inserted into the check cell holder with the analyzer in Mode 6 and a reading taken. This reading is 3240. • Due to the value of th...

Instruction Manual IM-106-5500, Original IssueAugust 2005 6-1 CCO 5500 Section 6 Troubleshooting Fault Finding with the Keypad . . . . . . . . . . . . . . . . . . . . . . page 6-1Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-2Component Tests . . . . . . . . . . ...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 6-2 The following fault conditions are recognized by the instrument. Table 6-1. Fault Conditions NOTE If a fault condition is recognized by the instrument the minutes, hours and days averages will not be updated. Further troubleshoo...

Instruction Manual IM-106-5500, Original IssueAugust 2005 6-3 CCO 5500 Table 6-2. Configuration Problems No display on signal processorPossible Cause Test Result Action Mains input failure Check 110/220V selection switch in power supply Setting correct Proceed to next test Setting incorrect Change s...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 6-8 COMPONENT TESTS Some instrument components/operation can be verified as follows: Heater Cartridge Perform the steps for Section 5, Replacement of the Heater Element within the transmitter up to step 4. Remove one lead from the h...

Instruction Manual IM-106-5500, Original IssueAugust 2005 CCO 5500 http://www.raihome.com Section 7 Returning Material If factory repair of defective equipment is required, proceed as follows: 1. Secure a return authorization number from a Rosemount Analytical sales office or representative before r...

Instruction Manual IM-106-5500, Original IssueAugust 2005 CCO 5500 http://www.raihome.com Section 8 Replacement Parts Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . page 8-1Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8-1 RECO...

Instruction Manual IM-106-5500, Original IssueAugust 2005 CCO 5500 http://www.raihome.com Appendix A Safety Data Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page A-2

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 A-2 SAFETY INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONS FOR THE WIRING AND INSTALLATION OF THIS APPARATUS The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to ass...

Instruction Manual IM-106-5500, Original IssueAugust 2005 A-3 CCO 5500 BELANGRIJK Veiligheidsvoorschriften voor de aansluiting en installatie van dit toestel. De hierna volgende veiligheidsvoorschriften zijn vooral bedoeld voor de EU lidstaten. Hier moet aan gehouden worden om de onderworpenheid aan...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 A-4 VIGTIGT Sikkerhedsinstruktion for tilslutning og installering af dette udstyr. Følgende sikkerhedsinstruktioner gælder specifikt i alle EU-medlemslande. Instruktionerne skal nøje følges for overholdelse af Lavsspændingsdirektive...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 A-6 TÄRKEÄÄ Turvallisuusohje, jota on noudatettava tämän laitteen asentamisessa ja kaapeloinnissa. Seuraavat ohjeet pätevät erityisesti EU:n jäsenvaltioissa. Niitä täytyy ehdottomasti noudattaa jotta täytettäisiin EU:n matalajännite...

Instruction Manual IM-106-5500, Original IssueAugust 2005 A-7 CCO 5500 IMPORTANT Consignes de sécurité concernant le raccordement et l'installation de cet appareil. Les consignes de sécurité ci-dessous s'adressent particulièrement à tous les états membres de la communauté européenne. Elles doivent ê...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 A-8 WICHTIG Sicherheitshinweise für den Anschluß und die Installation dieser Geräte. Die folgenden Sicherheitshinweise sind in allen Mitgliederstaaten der europäischen Gemeinschaft gültig. Sie müssen strickt eingehalten werden, um d...

Instruction Manual IM-106-5500, Original IssueAugust 2005 A-9 CCO 5500 IMPORTANTE Norme di sicurezza per il cablaggio e l'installazione dello strumento. Le seguenti norme di sicurezza si applicano specificatamente agli stati membri dell'Unione Europea, la cui stretta osservanza è richiesta per garan...

Instruction Manual IM-106-5500, Original Issue August 2005 CCO 5500 A-10 VIKTIG Sikkerhetsinstruks for tilkobling og installasjon av dette utstyret. Følgende sikkerhetsinstruksjoner gjelder spesifikt alle EU medlemsland og land med i EØS-avtalen. Instruksjonene skal følges nøye slik at installasjone...

Instruction Manual IM-106-5500, Original IssueAugust 2005 A-13 CCO 5500 VIKTIGT Säkerhetsföreskrifter för kablage och installation av denna apparat. Följande säkerhetsföreskrifter är tillämpliga för samtliga EU-medlemsländer. De skall följas i varje avseende för att överensstämma med Lågspännings di...

WARRANTY Rosemount Analytical warrants that the equipment manufactured and sold by it will, upon shipment, be free of defects in workmanship or material. Should any failure to conform to this warranty become apparent during a period of one year after the date of shipment, Rosemount Analytical shall,...