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5.2

Corrective maintenance

The following maintenance procedures describe the necessary steps for removing and
replacing failed elements of the Rosemount

™

CCO 5500 Analyzer.

WARNING!

ELECTRIC SHOCK
Install all protective equipment covers and safety ground leads after equipment repair or
service. Failure to install covers and ground leads could result in serious injury or death.

5.2.1

Replace heater element

The heater element has a finite life and at some stage you will have to replace it.
Rosemount

™

designed the unit to give a minimum of two years continuous operation; you

can replace the heater element on site when necessary.
Replace a failed heater element according to the following procedure.

Procedure

Shut down and lock out power to the Rosemount CCO 5500 Analyzer.

Unbolt and remove the source unit from the air purge.

Loosen the source unit cable gland (

Figure 5-2

) so the cable can slip when the rear

cover plate is removed.

Source Rear Cover Plate

Figure 5-2:

A. Rear cover plate
B. Cable gland

Unsccrew and remove the rear cover plate.

Unscrew and remove the circuit board (

Figure 5-3

Maintenance

Rosemount CCO 5500

Summary of Contents for Rosemount CCO 5500

Page 1: ...Reference Manual 00809 0100 4550 Rev AA June 2018 Rosemount CCO 5500 Carbon Monoxide CO Analyzer ...

Page 2: ...s document is subject to change without notice Warranty RosemountTM 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 shall upon prompt written notice from the purchaser correct such nonconformity by r...

Page 3: ...N Highlights an operation or maintenance procedure practice condition statement etc that if not strictly observed could result in damage to or destruction of equipment or loss of effectiveness NOTICE Highlights an essential operating procedure condition or statement Symbols Earth ground terminal Protective conduit or terminal Risk of electrical shock Warning Refer to Instruction Manual ...

Page 4: ......

Page 5: ...it 15 2 5 7 Power supply unit 16 2 6 Electrical data 17 2 6 1 AC supplies 17 2 6 2 Outputs 17 2 6 3 Normalizing inputs 17 2 6 4 Plant status input 17 2 7 Electrical connections 18 2 7 1 Installation of cables 19 2 7 2 Cable connections 19 Chapter 3 Configuration and startup 25 3 1 Introduction 25 3 2 Safety considerations 25 3 3 Power up the Rosemount CCO 5500 Analyzer 25 3 4 Alignment 26 3 5 Dete...

Page 6: ... and CO ppm 59 4 9 4 Calibration data 60 4 9 5 Fault condition 60 4 10 Set up mode 61 4 10 1 Enter security code 61 4 10 2 Set averages 62 4 10 3 Configure O P 63 4 10 4 Parameters 65 4 10 5 Normalization 69 4 10 6 Reset averages 71 4 10 7 Calibrate 72 4 11 Check Cell mode 76 4 12 Shutdown procedure 76 4 13 Routine checks 76 4 13 1 Notes for using a Rosemount check cell 76 4 13 2 Alarms and emerge...

Page 7: ...nts 98 Chapter 7 Spare parts 101 Appendices and reference Appendix A Theory of operation 103 A 1 Infrared source unit 103 A 2 Infrared receiver unit 104 A 3 Control unit 105 A 4 Power supply unit 105 A 5 Air purge 105 A 6 Isolating valves 105 A 7 Principles and modes of operation 106 A 7 1 Calculation of gas concentration 106 A 7 2 Error compensation 106 A 7 3 Calculation sequence 107 A 7 4 Normal...

Page 8: ...Contents iv Rosemount CCO 5500 ...

Page 9: ...Component checklist A typical Rosemount CCO 5500 Carbon Monoxide Analyzer should contain the items shown in Figure 1 1 Record the part number serial number and order number for your system Description and specifications Reference Manual 1 ...

Page 10: ...ver F Interconnect cable G 33 ft 10 m cables H Source I Gaskets 4 Also use the product matrix in Section 1 5 to compare your order number against your unit Ensure the features and options specified by your order number are on or included with the unit Description and specifications 2 Rosemount CCO 5500 ...

Page 11: ...n between analyzers and a central data logging station User definable output in either mg m3 mg Nm3 or ppm Four rolling averages are held selectable from 10 seconds to 30 days Integral back lit 32 character LCD provides diagnostic and measurement information Plant status input to prevent emissions dilution during off periods 1 3 System description The Rosemount CCO 5500 Analyzer consists of four i...

Page 12: ...d by Rosemount I Control unit J Analog outputs normalizing inputs and serial data port K AC power in and relay contact outputs L Power supply unit NOTICE The maximum cable length allowed between the power supply and the receiver is 82 ft 25 m The maximum cable length allowed between the power supply and the transmitter is 33 ft 10 m Description and specifications 4 Rosemount CCO 5500 ...

Page 13: ...from 10 sec to 30 days Environmental Specifications Table 1 2 Material of construction Cast aluminum fully sealed to IP65 Ambient temperature limits 4 to 158 F 20 to 70 C Installation Specifications Table 1 3 Probe mounting 6 5 in 165 mm flange with 4 9 in 125 mm bolt circle Inputs Temperature 4 20 mA Pressure 4 20 mA Plant status dry contact relay Outputs Analog 4 20 mA isolated 500 Ω max Power r...

Page 14: ...00 Carbon Monoxide Analyzer across the stack Level 1 power requirements 01 110 220 Vac 50 60 Hz Level 2 control module display keypad 01 English Level 3 calibration options 00 None 01 Calibration check cell and holder Description and specifications 6 Rosemount CCO 5500 ...

Page 15: ...zer component tags 2 1 Unpack the equipment A typical Rosemount CCO 5500 Carbon Monoxide CO Analyzer should contain the following items Refer to Figure 1 1 for an illustration of each of these components Record the part number serial number and order number for each major component of your system 1 Source with 33 ft 10 m of cable and air purge 2 Receiver with 33 ft 10 m of cable and air purge 3 In...

Page 16: ...ded cable 6 Analog inputs any suitable two conductor cable Rosemount instruments have an internal impedance of 240 ohms for these inputs 2 4 Selecting location Rosemount designed the equipment for mounting on boiler ducting or stacks open to the weather The instrument is fully sealed and requires no further enclosures or protection The specific location of the instrument depends on the application...

Page 17: ...ertainty to be below 2 of range the minimum range would be 500 ppm meters NOTICE 10 ppm CO 12 5 mg m3 2 For increased sensitivity reduced uncertainty of measurement the path length must be maximized 3 Maximum range is 6 000 ppm meters NOTICE To correct ppm meters to effective ppm divide the path length in meters 2 5 Mechanical installation The transmitter and receiver units are mounted on a site m...

Page 18: ...e mounting flanges as shown in Figure 2 1 Site Mounting Flange Assembly Figure 2 1 A Duct wall B Lagging C Stand off pipe if used 2 95 in 75 mm dia nominal D ØM8 hole 4 92 in 125 mm BC 4 places E Site mounting flange F Bracing fillets 3 With the stand off pipes and site mounting flanges welded together insert the mounting flange assemblies into their mounting holes 4 Position the mounting flange a...

Page 19: ...ace To avoid vibration and movement you may need to fit spreader plates or bracing fillets on the mounting flange assembly as shown in Figure 2 1 2 5 2 Isolating valves To protect operators Rosemount recommends that you use customer supplied isolating valves Figure 2 2 for ducts that operate at higher than atmospheric pressure Valve selection and installation is your responsibility Isolating Valve...

Page 20: ...iring conditions you may simply leave the air purge inlets open and allow the negative draft in the duct to draw in ambient air You must supply the air purge units for positive pressure ducts with compressed air or blower air to prevent contamination of the source and receiver units Compressed air You may use compressed air to provide the air flow required An air supply of 14 7 psi 1 bar is requir...

Page 21: ...rge units Failure to flow purge air may allow the optical surfaces of the source and receiver units to become severely contaminated Procedure 1 Remove the four locking nuts holding the front flange to the rear flange Figure 2 3 2 Carefully work and pull the front flange from the air purge unit 3 Align the four holes on the front flange with the four holes on the site mounting flange 4 Fasten the f...

Page 22: ...d the source or receiver unit 2 Dowel pins Figure 2 4 ensure that the source and receiver units and the air purge units mount in a fixed rotary position Align the dowel pin and dowel pin hole Air Purge and Source Unit Mounting Features Figure 2 4 A Locking nut B Window plate C Source D Alignment dowel pin hole E Threaded screw hole F Rear face of air purge 3 Attach the source or receiver to the re...

Page 23: ...ableto locate the control unit up to 33 ft 10 m from the receiver Do not exceed the 33 ft 10 m cable length 1 Loosen the four captive cover screws and remove the cover 2 Unplug the ribbon cable connector on the cover side 3 Fasten the control unit to a firm vertical support Install four mounting screws in the mounting holes provided Refer to Figure 2 6 for mounting dimensions Install Reference Man...

Page 24: ...re located outside the seal You do not need to seal the mounting holes after installation or to remove the circuit boards from the unit prior to mounting 2 5 7 Power supply unit Rosemount supplies adequate cableto locate the power supply unit up to 33 ft 10 m from the source unit You may use a maximum cable length of 82 ft 25 m to connect the power supply unit to the receiver Do not exceed the 82 ...

Page 25: ...communication between the control unit and a distributed control system or other process control system 2 6 3 Normalizing inputs The analyzer can hold pressure temperature and oxygen values to normalize the calculated gas value to standard conditions The instrument may read these values using the following methods 1 Fixed value from the keypad 2 4 20 mA outputs from measurment transducers You can ...

Page 26: ...ll all protective covers and safety ground leads after installation Failure to install covers and ground leads could result in serious injury or death WARNING ELECTRIC SHOCK To meet the safety requirements of IEC 1010 EC requirement and ensure safe operation of this equipment connect to the main electrical power supply through a circuit breaker min 10 A which will disconnect all current carrying c...

Page 27: ...y Use common routing wherever possible and install leaving sufficient free end length to make final connections Install power cables separately using different routes if possible to reduce the risk of cross interference Leave sufficient free end length to make final connections Rosemount supplied cables are provided with ferrite beads fitted to all cores to protect against interference Do not modi...

Page 28: ...System Wiring Diagram Figure 2 7 Install 20 Rosemount CCO 5500 ...

Page 29: ...Wiring Connector Locations Power Supply Board Figure 2 8 A 110 220 Vac power in B Data valid relay contacts C Alarm relay contacts D Interconnect cable contacts Install Reference Manual 21 ...

Page 30: ...le port of the control unit enclosure Provide adequate free wire length for making connections to the control board terminals 16 through 22 Tighten the cable gland nut 2 Connect the receiver cable wires to the control board terminals 16 through 22 according to the wiring diagram Figure 2 7 Do not connect the receiver cable shield wire at the control unit Install 22 Rosemount CCO 5500 ...

Page 31: ...for making connections to the power supply board terminals 1 through 7 Tighten the cable gland nut 8 Connect the cable wires to the power supply board terminals 1 through 7 according to the wiring diagram Figure 2 7 Do not connect the cable shield wire at the power supply unit 9 Install the 110 220 Vac power cable in one of the left hand cable ports of the power supply unit enclosure Provide adequ...

Page 32: ...Install 24 Rosemount CCO 5500 ...

Page 33: ...pment covers lock out and tag out power to the supply unit WARNING ELECTRIC SHOCK Disconnect and lock out power before connecting power to the analyzer 3 3 Power up the Rosemount CCO 5500 Analyzer Use the following procedure to power up the analyzer 1 Make sure that the voltage and frequency of the AC power supply match the required power specifications 2 With the AC power supply locked out and ta...

Page 34: ...e about five minutes from cold startup When the reference frequency is within tolerance for 10 consecutive measurement cycles the instrument automatically changes to the OPERATING mode This is Mode 1 and is indicated by a number 1 appearing in the top left corner of the LCD display The display shows a reading in ppm this is not an accurate reading until all configuration and startup procedures are...

Page 35: ...en the other Note You can achieve receiver alignment by monitoring the output of the detector directly Use a voltmeter set to AC volts 10 V max to measure across test points S0V and S2 for D3 and S0V and S1 for D1 on the receiver control board Figure 3 3 This alignment method is useful when the receiver is not located near the control unit Alignment Features Figure 3 2 A Adjusting nuts B Locking n...

Page 36: ... 4 Install and tighten the receiver on its air purge using the four screws removed in Step 1 5 At the control unit keypad press MODE four times to select SET UP mode Mode 5 When 5 SET UP is displayed on the LCD press ENTER to access the SET UP mode Note The analyzer uses a security code to prevent unauthorized alteration of settings The default code set at the factory is 0000 The keypad cursor fla...

Page 37: ...t in one particular plane The D1 detector level is affected more by adjustment in the other plane 10 Make sure the maximum possible values of both D1 and D2 are reached After you achieve alignment tighten the locking nuts Note The alignment of the receiver unit is important Make sure to obtain the maximum values of D1 and D2 11 If the displayed detector level is below 5000 increase the gain at the...

Page 38: ...of 6 5 f t 2 m If the path length is above 13 ft 4 m or below 5 ft 1 5 m you may need to adjust to optimize the detector levels 1 Enter Mode 5 Calibrate Set Detectors and display the value of D2 D1 2 Loosen the receiver cable gland so the receiver cable can slip when you remove the window plate 3 Pull the window plate Figure 3 4 from the receiver to access the detectors Receiver Trim Pots Figure 3...

Page 39: ...um This should prevent saturation should the opacity level drop off 3 5 2 Control unit gain adjustment After you have optimized the detector level s at the receiver optimize the levels within the microprocessor Make the adjustment with two trim potentiometers in the control unit 1 Set the gain to a minimum by turning the D2 detector trim pot Figure 3 5 fully clockwise D2 is a 20 turn potentiometer...

Page 40: ...ay the values of D2 and D1 Turn the trim pot counterclockwise until the D2 level is between 12 000 and 15 000 Allow time between adjustments for the readings to settle Note If the duct is operating and the opacity levels are high reduce the D2 level to about 8 500 This should prevent saturation should the opacity level drop off Configuration and startup 32 Rosemount CCO 5500 ...

Page 41: ...or levels ar the receiver Refer to Section 3 5 1 3 6 Source adjustments Two trim potentiometers within the source unit allow adjustments to be made to the intensity of the source and to the frequency of the chopper motor Rosemount sets these at the factory and they rarely need adjustment Rosemount recommends that you consult the company before making any adjustments within the source unit CAUTION ...

Page 42: ...ps to adjust the analyzer s chopper frequency 1 Unscrew and remove the source from the air purge 2 Unscrew and pull the window plate from the front of the source unit See Figure 3 7 A trim pot VR1 allows you to adjust the frequency of the chopper motor Configuration and startup 34 Rosemount CCO 5500 ...

Page 43: ...he event of a power loss Even if the measured data is not going to be normalized you must set the normalizing parameters to ensure proper analyzer operation Note When you select SET UP mode the instrument suspends motor operations and the Data Valid LED goes dim If no key is pressed within five seconds after selecting SET UP mode the instrument control reverts to OPERATING mode Chapter 4 lists all...

Page 44: ...e six options and press ENTER when the desired option is displayed 3 7 1 Enter security code Complete the following steps to enter the security code 1 Once the display is as shown here press ENTER to gain access to SET UP mode The cursor flashes over the first digit of the security code number 2 Select the required first digit with the arrow keys and press ENTER 3 Repeat this procedure for the rem...

Page 45: ...o 60 seconds in 10 second intervals 4 Set the minutes averaging stack to the required value This is limited to within 1 to 60 minutes in 1 minute intervals 5 Set the hours averaging stack to the required value This is limited to within 1 to 24 hours in 1 hour intervals 6 Set the days averaging stack to the required value This is limited to within 1 to 30 days in 1 day intervals 3 7 3 Configure O P...

Page 46: ... You may use any of the four averaging stacks seconds minutes hours and days for the analog output You can select them with the arrow keys and enter them with the ENTER key Units The analog output can represent the gas concentration in units of mg m3 mg Nm3 or vpm The arrow keys toggle between these three options Press ENTER to enter the new value Output Span Select the required span using the arr...

Page 47: ...ect one of these options when the desired output is displayed press ENTER to confirm Set mA output Note This is set at the factory and should not be altered without due consideration From this option the current levels of the analog output are set up Press ENTER to select it and the instrument prompts you to set the current levels at 0 and 20 mA When this is displayed set the current output to 0 m...

Page 48: ...need to change is displayed press ENTER 3 When you have made all required changes select EXIT and press ENTER The six available options are a Security Number b Identity Number c Path Length d Alarm e Cal Factor f Plant Status Input Security Number To prevent any unauthorized tampering with the setup information it is important to change the security code from the factory setting Select each digit ...

Page 49: ... Similarly the output of the Rosemount CCO 5500 Analyzer gas monitor also depends on the path length of the flue gas through which the radiation is transmitted Refer to Section 2 4 1 The Rosemount CCO 5500 Analyzer is sensitive to the product of concentration and path length In order to obtain a true value of concentration of gas you must input the correct path length into the processor The proces...

Page 50: ...Since this value controls the calibration of the instrument only change if necessary Plant Status Input Use this to determine whether the plant is operating under correct conditions There is a choice of three controls for plant status Logic Input Serial Input and Multiple You can only use one to control plant status at any one time Logic Input If the PS1 and PS2 terminals are linked in the control...

Page 51: ...ON Temperature A value is set here for the temperature threshold While the temperature taken from the normalizing temperature is above the threshold value plant status is ON If the temperature drops below the threshold plant status is OFF and only the seconds averaging stack updates Oxygen Oxygen is set and used in a similar manner to the temperature threshold However if the normalizing oxygen lev...

Page 52: ...gas temperature is being measured continuously and accurately Connect the analog output of the temperatue transducer into the Rosemount analyzer and select the analog input option This value is used to normalize the gas concentration measurement and to correct for the effects of temperature on the IR absorption spectrum If you use the Keypad Input and the gas temperature is higher than 572 F 300 C...

Page 53: ...en analyzer into the Rosemount CCO 5500 Analyzer and select Analog Input You must define this input as either WET or DRY depending on how the measurement is made After you define the wet or dry you need to define the Analog Input values set the 4 mA and 20 mA values If the oxgyen level is relatively constant through all firing conditions you may use a fixed keypad input With an integrated system y...

Page 54: ...instrument via the serial data line 3 7 6 Reset averages Note Resetting averages causes the rolling average data to be cleared from memory You can reset the average values that are currently held in the four averaging stacks using this option this ereases the current average that is held in all of the averaging stacks Select this option by pressing ENTER and using the arrow keys The instrument req...

Page 55: ...fore making adjustments You can adjust instrument sensitivity if a known concentration of gas exists between the source and receiver units and instrument sensitivity is supsected If a problem arises consult Rosemount You may need to adjust the span factor if you have fitted new gas cells or filters Calibrate Re enter the Mode 5 CALIBRATE menu and proceed to the Calibrate option You can calculate t...

Page 56: ...ine during commissioning otherwise the instrument will not be able to calculate the true level of gas within the duct Do not run the calibration routine unless reasonable conditions exist in the duct If it is not the initial calibration record the Cal Factor from the Parameters option before running the calibration To aid configuration and to record any subsequent changes to the operating paramete...

Page 57: ...essure Standard level psi kPa I P psi kPa 4 mA I P psi kPa 20 mA Keypad input Serial input Water vapor Standard level wet dry Keypad input Measured value After the instrument calibrates it calculates a cal factor this determines the calibration of the instrument The instrument displays the cal factor for a few seconds after calibrating and you can also interrogate the cal factor from Mode 4 DIAGNO...

Page 58: ...re as follows Note Rosemount sets the current output at the factory do not alter it Procedure 1 Connect the multimeter to the output terminals within the control unit terminals mA and mA 2 Enter Mode 5 Configure Output Fault Condition Set Zero and adjust the level using the arrow keys until 0 mA is recorded Record the value in brackets on the display in Table 3 2 3 Enter Mode 5 Configure Output Fa...

Page 59: ...errogate the microprocessor to observe the system parameters and to change them if required The Rosemount CCO 5500 uses a menu based program you can gain access to it by the key panel mounted on the lid of the control unit Figure 4 1 Control Unit Keypad Figure 4 1 A 32 character liquid crystal display B Keypad C Data valid and alarm LEDs 4 1 1 Measurement Once the analyzer has completed configurat...

Page 60: ...a signal you will see a reading on the control unit display This should be in normal OPERATING mode Mode 1 shown by a number 1 at the top left corner of the LCD the display also shows a reading in vpm mg m3 or Nmg m3 If this appears the system is functioning properly 4 3 Modes of operation The instrument has six modes of operation identified by a number in the top left corner of the display Mode 1...

Page 61: ...e next mode of operation or back to the OPERATING mode if pressed from within a mode 2 Arrow keys Press the arrow keys to do one of two things depending on the position in the program It increases or decreases the displayed value If you hold down the key it scrolls quickly to the desired value It steps through the available options within a mode or submode 3 ENTER key Press the ENTER key to do one...

Page 62: ...ure threshold Oxygen threshold Water vapor threshold Temperature Oxygen Pressure Water vapor Exit Detector outputs Mod Frequency Yval CO ppm Calibration data Fault condition Exit Security code Set averages Configure O P 0000 to 9999 Seconds Minutes Hours Days Exit 10 to 60 s 10 s intervals 01 to 60 m 01 m intervals 01 to 24 h 01 h intervals 01 to 30 d 01 d intervals Output Average Units Set span F...

Page 63: ...nput Exit Set std levels Set values Exit Set std levels Set values Exit Set std levels Set values Exit Analog input Serial input Keypad input Exit Analog input Serial input Keypad input Exit Serial input Keypad input Exit Yes No Set detectors Span adjust Calibrate Exit Yes No 4 6 Operating mode From this mode of operation you may alter the averaging time of the displayed gas concentration to one o...

Page 64: ...ET UP mode but you cannot change them Press MODE until the number 2 appears in the top left corner of the display then press ENTER Use the arrow keys to scroll through the available options press ENTER to display one of the selected options below 1 Identification 2 Parameters 3 Averages 4 Output Alarm 5 Plant Status Press ENTER again to exit from each option Refer to Section 4 10 for further detai...

Page 65: ... hours and days averaging stacks do not update Note When the plant status is OFF pollutant levels are zero It is not normally permitted to use plant OFF zero levels to reduce the recorded mean entitled pollutant levels You can use this function to ensure data is only collected when the plant is fully operational You can use three options to determine plant status ON or OFF Logic Input Serial Input...

Page 66: ...rce k keypad input a analog input s serial data input m measured input 4 9 Diagnostic mode You may examine the detector levels chopper blade frequency Y parameter and the fault condition from this mode Press MODE until the number 4 appears in the top left corner of the display and press ENTER to access this mode Once in Diagnostics the five suboptions are as follows 1 Detector outputs 2 Modulation...

Page 67: ...es this frequency and displays it from this option As the chopper blades interrupt the IR beam they split the radiation into two Half the time the blade obscures the beam and half the time the beam radiates across the duct The value of Mark space should be between 0 9 and 1 1 where Mark space Time IR beam obscured Time IR beam clear 4 9 3 YVals and CO ppm A parameter Y determines the calculation o...

Page 68: ...s is displayed The instrument automatically selects this display mode if a fault condition occurs The instrument recognized the following fault conditions 1 ALL CLEAR No fault condition 2 Det Saturated The detector level gain within either the receiver or the control unit is too high for the current duct conditions 3 Low Det Level Detector levels are too low 3 000 4 Mod Freq O R Chopper motor freq...

Page 69: ...hese six submodes are listed below 1 Set Averages You may set the four averaging stack times seconds minutes hours and days as required 2 Configure O P Analog output setup origin units span rolling average and fault condition 3 Parameters You may set the following from this mode security code identity number path length alarm level cal factor and plant status 4 Normalization You may set up all nor...

Page 70: ...ime within predefined limits 1 Press ENTER when this display is shown The display now shows one of the averages 2 Use the arrow keys to select the average time that you need to change and press ENTER to change it You can now change the value using the arrow keys and confirm it by pressing ENTER 3 Set the seconds averaging stack to the required value This is limited to within 10 to 60 seconds in 10...

Page 71: ...parameters of each of the six available options listed below a Output b Averages c Units d Output Span e Fault Condition f Set mA Output Output You can set an origin of 0 or 4 mA for the current loop output The arrow keys toggle between these two options Press ENTER to enter the new value Average You may use any of the four averaging stacks seconds minutes hours and days for the analog output You ...

Page 72: ...splay then defaults to zero thus you must re enter the span value for the unit to function correctly Fault condition If a fault condition occurs you may set the current output of the instrument to one of the following options Procedure 1 Set the output at 0 mA ZERO 2 Adjust the output to the calculated gas concentration even though a fault condition exists MEAS 3 Hold the last selected gas concent...

Page 73: ...he correct output is displayed on the ammeter Note Zero mA should be set up no matter what has been selected as the base of the current output This is factory set In a similar manner to the above set the current output level to 20 mA 4 10 4 Parameters Complete the following steps to set the parameters 1 With this option displayed press ENTER to access the list of six available options The arrow ke...

Page 74: ... second The first value of the display then defaults to zero therefore you must re enter the value to calculate the gas concentrations correctly The transmissivity of any gas depends both on the concentration and on the path length through which the radiation is transmitted Similarly the output of the Rosemount CCO 5500 Analyzer gas monitor also depends on the path length of the flue gas through w...

Page 75: ...original Cal Factor before entering this mode as displayed in Mode 4 Calibration Data The Cal Factor is lost when the menu option is entered During the calibration routine the instrument calculates a Cal Factor which sets the basic calibration of the instrument You may change this value from this mode Note Since this value controls the calibration of the instrument only change if necessary Plant S...

Page 76: ...isplay below Configure the instrument for temperature threshold Press ENTER when it is correctly configured and the display moves to the next option Oxygen After you set the last option the Logic Input display returns to the PARAMETERS Plant Status I P option Use the DOWN arrow to scroll down to EXIT and press ENTER The plant status is now full configured Plant status is only OFF if all options se...

Page 77: ...mperature b Oxygen c Pressure d Water Vapor Once selected each of the above normalizing parameters have the same suboptions Set Standard Levels and Set Values Under Set Values are three more suboptions that determine how the instrument reads the data Analog Input Serial Input and Keypad Input Set Standard Levels Each normalizing parameter normalizes the measured gas concentration to standard condi...

Page 78: ...ata The values at 4 mA and 20 mA will be requested should this option be selected Serial Input If you use an input unit all normalizing data can be transmitted via the serial data line You can enter a fixed value via the keypad This is suitable where the value is stable to about 5 With an integrated system set the lead analyzer s normalizing parameters to the 4 20 mA inputs Then set all the other ...

Page 79: ...e processor Note If normalization is not required set the normalizing parameters for pressure in the instrument to 14 7 psi 101 kPa Standard Level and Keypad Input With an integrated system you can take the pressure data to the instrument via the serial data line Water Vapor An across the duct monitor measures the gas concentration under wet conditions Unlike a sampling system the gas has not been...

Page 80: ... for setting up the detector levels A Cal Factor that is calculated during a calibration routine sets the basic calibration of the instrument Press ENTER while this is displayed to see the following options 1 Set Detectors 2 Span Adjust 3 Calibrate Set detectors You can display both the D1 and D2 levels you can also display saturation counts To give an immediate response to any alterations that ar...

Page 81: ... the duct If this is not possible the instrument can calibrate to a known value of the gas concentration the calibration target Set the calibration target either to a known value of the gas concentration or to zero Then set the desired number of cycles over which the calibration factor is determined Rosemount recommends a minimum of 30 Now run the calibration and the display will show a countdown ...

Page 82: ... table_jlb_4y5_b2b lists all of the options available and can be used as a record of the operating parameters Instrument Settings Table 4 1 Parameter Config Averages Seconds Minutes Hours Days Output 0 or 4 mA base Units Average Fault condition Parameters Path length Alarm source Alarm units Alarm levels Normalization Temperature Standard level F C I P F C 4 mA I P F C at 20 mA Keypad input C not ...

Page 83: ...instrument The cal factor is displayed for a few seconds after a calibration has been conducted and you can aslo interrogate it from Mode 4 DIAGNOSTIC mode Enter the cal factor into the table below as a record of instrument operation Note Rosemount obtained factory settings under the following conditions 2 m path length Clean conditions Calibration Data Table 4 2 Detector outputs Factory Config D2...

Page 84: ...shut down the system unless you are performing maintenance 1 In this case power down the power supply and thus the control unit and analyzer heads 2 Close the manually operated isolating valves on the analyzer heads 3 Proceed with service 4 When completed open the valves and power up the system Postrequisites You may need to calibrate the system depending on the type of maintenance you are doing F...

Page 85: ...o Do not insert the check cell in any other mode than Mode 6 The analyzer does not update rolling averages while in Mode 6 Procedure 1 Enter Mode 6 on the control unit before inserting the check cell into the analyzer Press ENTER when Mode 6 is displayed 2 Use an arrow key to toggle from NO to YES and press ENTER to access the check cell function If you don t select this within five seconds the in...

Page 86: ...w Introducing the check cell may cause an initial major disturbance to the instrument operation 6 Wait for the instrument reading to settle five to ten minutes and record the gas measurement with the cell in position 7 Remove the check cell and wait for the analyzer to return to zero another five to ten minutes 8 Replace the cover on the check cell holder and place MODE on the control unit The ins...

Page 87: ... system are set as described in the normal OPERATING mode When an alarm condition occurs the red LED on the control unit lights up This goes out when the alarm condition has cleared When the condition has cleared the software records the fact that an alarm condition occurred The 4 to 20 mA output from the analyzer will also alter according to the pollution levels detected 4 13 3 Emergency shutdown...

Page 88: ...Operation 80 Rosemount CCO 5500 ...

Page 89: ...w Figure 5 1 every six months and more frequently for dirty processes Optical Window Figure 5 1 A Air purge B Source C Window WARNING HIGH TEMPERATURE AND DANGEROUS VAPORS Take great care when removing the Rosemount CCO 5500 Analyzer from a positive pressure stack or duct The source may be very hot and there may be dangerous vapors present Observe all required safety practices Procedure 1 Unbolt a...

Page 90: ... will have to replace it Rosemount designed the unit to give a minimum of two years continuous operation you can replace the heater element on site when necessary Replace a failed heater element according to the following procedure Procedure 1 Shut down and lock out power to the Rosemount CCO 5500 Analyzer 2 Unbolt and remove the source unit from the air purge 3 Loosen the source unit cable gland ...

Page 91: ...terminal nuts Figure 5 4 and remove the heater wires Heater Element Figure 5 4 A Terminal nuts B Captive screw C Heater 7 Unscrew the three captive screws 8 Remove and discard the heater assembly 9 Install the new heater assembly and tighten the three captive screws Maintenance Reference Manual 83 ...

Page 92: ...itor the gas levels 5 2 2 Replace chopper motor assembly Complete the following steps to replace the chopper motor assembly in the analyzer 1 Shut down and lock out power to the Rosemount CCO 5500 Analyzer 2 Unbolt and remove the source unit from the air purge 3 Remove the window plate Figure 5 5 from the source unit Source Unit Circuit Board and Center Plate Assembly Figure 5 5 A Black wire M B R...

Page 93: ... 7 9 Solder the chopper motor power wires to the circuit board Solder the red wire to the M terminal and the black wire to the M terminal 10 Install the center plate and circuit board assembly Secure the assembly with the three brass crews removed in Step 4 11 Line up and install the window plate onto the source unit Fully seat the window plate flange in the source unit 12 Secure the source unit t...

Page 94: ...ft the circuit board and center plate assembly out of the source unit 6 Loosen the setscrew at the end of the gas cell assembly Figure 5 7 Source Gas Cell Figure 5 7 A Gas cell B Setscrew 7 Pry the gas cell from the stepper motor shaft 8 Insert a new gas cell onto the stepper motor shaft and tighten the setscrew 9 Install the center plate and circuit board assembly and secure with the three brass ...

Page 95: ...lyzer 2 Unbolt and remove the receiver unit from its air purge 3 Loosen the receiver unit cable gland so the cable can slip when the window plate is removed 4 Unscrew and pull the window plate Figure 5 8 from the front of the receiver unit Receiver Gas Cell Figure 5 8 A End detector PCB B Window plate C M6 bolts D M4 x 16 screws E Side detector PCB F Gas cell assembly 5 Use a marker pen to match m...

Page 96: ...d install the window plate onto the receiver unit Fully seat the window plate flange in the receiver unit 15 Secure the receiver unit to the air purge using the four screws removed in Step 2 Tighten the screws evenly 16 Power up and recalibrate the Rosemount CCO 5500 Analyzer Refer to Calibrate 5 2 5 Electronics The electronics require no routine maintenance They are all solid state and undergo a ...

Page 97: ...in Step 6 8 Using the up and down arrow keys adjust the span factor until the second reading agrees with the certified check value divided by the path length if appropriate 9 Record the span factor and press ENTER 10 Confirm the span factor by selecting Mode 2 Parameters Span Factor and checking the value 5 3 1 Reset span factor An example of resetting the span factor is outlined below 1 You inser...

Page 98: ...Maintenance 90 Rosemount CCO 5500 ...

Page 99: ...e analog outputs of the equipment As an initial guide to equipment performance typical values for instrument operation are given below D2 min D2 max D1 min D1 max Set Cal min Set Cal max Rosemount CCO 5500 3 000 20 000 3 000 20 000 2 000 2 900 where Modulation frequency 30 to 45 Hz Mark space ratio 0 9 to 1 1 Saturation count 50 maximum for all analyzers If the values are outside of the above rang...

Page 100: ...per motor fails Note If the instrument recognizes a fault condition it does not update the minutes hours and day averages 6 2 Troubleshooting tables The troubleshooting tables provide fault diagnosis possible causes and the appropriate actions if you suspect an instrument fault Note the symptoms and when the fault has occurred Refer to the appropriate tables Note Be sure to use the tables from the...

Page 101: ...ext text Incorrect wiring Correct wiring Check ribbon cable connec tions in control unit Connections OK Go to next possible cause Connections loose Secure connections Control unit failure Contact Rosemount Display nonsense on control unit Microprocessor fault Reset by interrupting mains supply Fault clears No further action Fault continues Go to next possible cause Program corruption failed micro ...

Page 102: ...check the Rx and Tx windows clear sight path between receiver unit and source unit Detector levels in range No further action Fault continues Go to next possible cause Misalignment Realign receiver and source units Detector levels in range No further action Fault continues Go to next possible cause Incorrect gain settings Adjust gains in control unit and or receiver unit Detector levels in range N...

Page 103: ... Cal factor in range No further action Cal factor out of range Go to next possible cause D2 detector circuit failure Check D2 signal level OK Go to next possible cause Not OK Go to next test Monitor D2 signal from Rx OK Not OK Contact Rosemount Source gas cell failure Replace source unit gas cell Cal factor in range No further action Cal factor out of range Go to the next possible cause Receiver g...

Page 104: ...ext possible cause Plant status contact in con trol unit has been made Check plant status input LED in control unit LED off Operation correct stable gas level LED on Plant status in use instru ment will not update until plant on 6 3 Component tests Some instrument components operation can be verified as follows 6 3 1 Heater cartridge Complete the following steps to check the analyzer s heater cart...

Page 105: ...4 seconds SOL_MDRV Supply to the solenoid that drives the filter into the optical path within the receiver pulses every time the M DIR changes approximately every 2 seconds V1 V1 and 12 V Middle bottom left of board All should be ON Power supplies to the isolated analog current output 12 V Bottom left of board Should be ON Indication of the isolated supply for the plant status input PS Bottom left...

Page 106: ...maximum centered on 0 V You can take 0 V to T1 to T6 from the 0 V test point top left of board Test points T1 to T6 are in the center of the board T2 D1 signal after amplification in the processor Flattened saw tooth 32 to 45 Hz 3 5 V peak to peak maximum centered on 0 V Amplitude may vary by a trim put Refer to Section 4 9 1 T3 D1 output to the A D converter within the mi cro processor offset by ...

Page 107: ...ce unit via the power supply Square wave 30 to 45 Hz 5 V peak to peak centered on 2 5 V Power supply Description 0 V and 12 V Power supply for the instrument Receiver Description 0 V 0 V for the receiver T1 Detector output without conditioning T2 Detector output after first stage of gain T3 Detector output after both stages of gain Source Description S 0 V supply to the heater cartridge S 12 V sup...

Page 108: ...Troubleshooting 100 Rosemount CCO 5500 ...

Page 109: ...Control unit assembly 1A99995H05 Purge assembly 1A99995H06 Site mounting flanges set of 2 6 5 in 165 mm OD 4 M8 holes on 4 9 in 125 mm BC 1A99995H07 Heater cartridge 1A99995H08 Protection window 1A99995H09 Gasket source receiver to air purge assembly 1A99995H10 Gasket source receiver to site flange 1A99995H11 Chopper motor and disk 1A99995H12 Stepper motor and gearbox 1A99995H20 IR detector 1A9999...

Page 110: ...Spare parts 102 Rosemount CCO 5500 ...

Page 111: ...n site A motor drive disc then chops the radiation emitted by the heater and a lens focuses the radiation across the duct A small DC motor drives the chopper disc A radiation detector monitors the phase and frequency of the chopper disc to provide a reference signal that the control unit uses A stepper motor and gear box assembly swing a small calibration cell containing pure reference gas CO into...

Page 112: ... precision interference filter to limit the band wave of energy used This filter s tolerance is strictly controlled since it alone determines the instrument scale shape and calibration The radiation then passes to an optical beam splitter where approximately half the radiation is reflected at right angles directly onto a radiation detector The beam splitter transmits the other half of the radiatio...

Page 113: ...ment to communicate with other Rosemount analyzers and a central data logging unit A 4 Power supply unit The power supply unit is housed in a fully sealed cast aluminum enclosure A supply voltage switch allows you to select from either 110 or 220 V This provides an extremely stable power source able to cope with large fluctuations in the supply voltage Also the data valid and high gas alarm contac...

Page 114: ...is zero measurement gas in the duct Y 0 thereby K G D10 D20 The analyzer then smooths linearizes and compensates the parameter Y for effects of path length and flue gas temperature to produce a measurement of CO gas concentration in the flue gas A 7 2 Error compensation The accurate determination of gas concentration depends on the measurement of the radiation levels received by the detectors Any ...

Page 115: ...ected by the analyzer is essential to compare emission levels of pollutants into the atmosphere Software in the Rosemount CCO 5500 Analyzer performs all calculations and provides results in various units vpm mg m3 and mg Nm3 The following paragraphs describe the derivation of these results The Rosemount CCO 5500 Analyzer is a cross duct type that measures the quantity number of molecules of gas wi...

Page 116: ...her normalization is required only for the dilution effects of water vapor and oxygen These are straightforward calculations 20 9 is taken as the level of free oxygen in dry air When the measured O2 is a wet measurement the instrument must correct it to a dry measurement When the measured O2 concentration is defined as a wet measurement in the analyzer software the software automatically performs ...

Page 117: ...that infrared IR energy is absorbed by particular gases in a manner very specific to that gas Although cross duct analysis will differ from gas to gas the basic principles are similar for all measured gases This section examines the analysis of carbon monoxide in detail Carbon monoxide infrared absorption spectrum Carbon monoxide absorbs infrared energy in a band between wavelengths of approximate...

Page 118: ...sses IR energy at wavelengths around 4 7 µm By using this filter correctly designed CO analyzers are able to ignore the effects of water vapor and CO2 No other flue gases absorb IR energy in the band The filter characteristics are shown in Figure A 3 Comparison of Spectra Figure A 3 Transmissivity of CO within the 4 7 µm band The concentration of CO affects the IR energy s transmission through the...

Page 119: ...oth measurements after the beam has passed through the gas to be measured One beam however also passes through a cell containing pure CO the gas cell shown in Figure A 1 The beam absorbs all the energy capable of being absorbed by CO and provides a reference that is unaffected by any CO in the duct However any other material e g dust which reduces the energy received from the source unit will affe...

Page 120: ...ut if we consider the calibration curve we can see that if Y 0 when CO 0 then Y a when CO b We can also see from Figure A 5 that at high CO levels the parameter Y becomes completely insensitive to changing CO levels in the duct such that Y a when CO b By making Y a when CO b and Y 0 when CO 0 you can eliminate all errors You can introduce a gas cell containing pure carbon monoxide can be introduce...

Page 121: ...h equipment was removed d Whether warranty or non warranty service is requested e Complete shipping instructions for return of equipment f Reference the return authorization number 4 Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided in Rosemount Return Authorization prepaid to Rosemount Inc PAD Repair Center C O Rosemount Analytical Inc 1...

Page 122: ...Return equipment to the factory 114 Rosemount CCO 5500 ...

Page 123: ...Return equipment to the factory Reference Manual 115 ...

Page 124: ...utomation Solutions Emerson FZE Jebel Ali Free Zone Dubai United Arab Emirates P O Box 17033 971 4 811 8100 971 4 886 5465 gas csc emerson com ASIA PACIFIC Emerson Automation Solutions 1 Pandan Crescent Singapore 128461 Singapore 65 777 8211 65 777 0947 gas csc emerson com Linkedin com company Emerson Automation Solutions twitter com rosemount_news Facebook com Rosemount youtube com RosemountMeasu...

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