Benutzeranleitung / Produktwartung PN 51-FCL-1056 des Produzenten Emerson
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FCL with 1056 Analyzer Instruction Manual PN 51-FCL-1056 rev .E March 2012.
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.
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 .
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.
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 .
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 Alarm.
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.
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 ................................................
Section Title Page 7.0 DIGIT AL COMMUNICA TIONS ............................................................................... 51 8.0 MAINTENANCE ...................................................................................................... 53 8.
LIST OF FIGURES Number Title Page 2-1 Model FCL-01 .................................................................................................... 7 2-2 Model FCL-02 ................................................................................
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 .
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).
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 .
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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 .
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.
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.
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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.
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.
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.
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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.
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.
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 .
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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).
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 .
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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 .
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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.
52 MODEL FCL-1056 SECTION 7.0 DIGIT AL COMMUNICA TIONS This page lef t blank intentionally.
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.
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.
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 assembl.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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 syste.
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.
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.
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.
73 NOTES.
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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.
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