Emerson Rosemount FCL Reference Manual Download Page 108

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00809-0100-3412

Rev. AA

2019

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Summary of Contents for Rosemount FCL

Page 1: ...Reference Manual 00809 0100 3412 Rev AA May 2019 Rosemount FCL Free Chlorine System with Rosemount 1056 Transmitter ...

Page 2: ...tion instructions of the appropriate Reference Manual and per applicable local and national codes Connect all products to the proper electrical and pressure sources To ensure proper performance use qualified personnel to install operate update program and maintain the product When replacement parts are required ensure that qualified people use replacement parts specified by Rosemount Unauthorized ...

Page 3: ... operator s responsibility No external power to the instrument of more than 69 Vdc or 43 V peak is allowed with the exception of power and relay terminals Any violation will impair the safety protection provided Do not operate this instrument without the front cover secured Refer installation operation and servicing to qualified personnel WARNING This product is not intended for use in the light i...

Page 4: ...4 ...

Page 5: ...0 4 3 Program the transmitter 32 4 4 Security 34 4 5 Using hold 35 4 6 Configure the main display 36 Chapter 5 Programming the transmitter 39 5 1 Programming overview 39 5 2 Default settings 39 5 3 Configuring ranging and simulating outputs 42 5 4 Configuring alarms and assigning setpoints 46 5 5 Configuring the measurement 53 5 6 Configuring temperature related settings 56 5 7 Configuring securit...

Page 6: ...ic feature 85 9 3 Troubleshooting when a Fault message is showing 86 9 4 Troubleshooting when a Warning message is showing 91 9 5 Troubleshooting when no error message is showing 93 9 6 Troubleshooting when no error message is showing pH 97 9 7 Troubleshooting when no error message is showing general 101 9 8 Simulate inputs chlorine 102 9 9 Simulate pH input 103 9 10 Simulating temperature 104 Con...

Page 7: ... C Process connection in OD tubing compression fitting can be removed and replaced with barbed fitting for soft tubing Drain connection in barbed fitting Sample must drain to open atmosphere Wetted parts Overflow sampler and flow cell acrylic polycarbonate Kynar nylon and silicone Chlorine sensor Noryl Viton wood silicone polyethersulfone polyester and platinum pH sensor Rosemount 3900VP Stainless...

Page 8: ... overflow device to control sample flow All components are mounted on a backplate The factory ships three replacement membranes and a 4 oz 118 mL bottle of electrolyte solution with the system Free Chlorine System Table 1 3 Free Chlorine System Code Measurement option 01 Without pH sensor 02 With pH sensor Code Transmitter option 220 Rosemount 1056 03 24 38 AN 115 230 Vac 50 60 Hz alarm relays ana...

Page 9: ...sor cable Description 23747 04 Interconnecting cable Variopol for Rosemount 499ACL sensor 4 ft 1 2 m 24281 05 Interconnecting cable Variopol for Rosemount 3900VP sensor 4 ft 1 2 m Accessories Table 1 7 Tag Part number Description 9240048 00 Tag stainless steel specify marking Reference Manual Description and specifications 00809 0100 3412 May 2019 Rosemount FCL 1056 9 ...

Page 10: ...Description and specifications Reference Manual May 2019 00809 0100 3412 10 Emerson com Rosemount ...

Page 11: ...e membrane assemblies and a bottle of electrolyte solution are in a separate package 2 1 2 Rosemount FCL 02 free chlorine with continuous pH correction The Rosemount FCL 02 consists of the following items mounted on a back plate 1 Rosemount 1056 03 24 32 AN transmitter with sensor cables attached 2 Constant head overflow sampler with flow cells for pH and chlorine sensors 3 Stand to hold pH buffer...

Page 12: ...3 Sample requirements Be sure the sample meets the following requirements 1 Temperature 32 to 122 F 0 to 50 C 2 Pressure 3 to 65 psig 122 to 549 kPa abs 3 Minimum flow 3 gal hr 11 L hr 2 4 Mounting inlet and drain connections The Rosemount FCL is intended for wall mounting only Refer to Figure 2 1 or Figure 2 2 for details The sensor s screw into the flow cell adapters as shown in the figures For ...

Page 13: ...Figure 2 1 Rosemount FCL 01 A Chlorine sensor B Inlet C Drain Reference Manual Install 00809 0100 3412 May 2019 Rosemount FCL 1056 13 ...

Page 14: ...with a barbed fitting The fitting screws into a in FNPT check valve The check valve prevents the sensor flow cell from going dry if sample flow is lost The sample drains through a in barbed fitting 1 Attach a piece of soft tubing to the fitting and allow the waste to drain to open atmosphere Important Do not restrict the drain line Install Reference Manual May 2019 00809 0100 3412 14 Emerson com R...

Page 15: ... VP to the cable labeled CL 2 Connect the pH sensor Rosemount 3900 VP 02 10 to the cable labeled pH The terminal end of the sensor is keyed to ensure proper mating with the cable receptacle 3 Once the key has slid into the mating slot tighten the connection by turning the knurled ring clockwise 4 Screw the sensor s into the plastic fitting s which are held in the flow cell s by the union nut Do no...

Page 16: ...Figure 2 3 Rosemount FCL 01 A Chlorine sensor B Inlet C Drain Install Reference Manual May 2019 00809 0100 3412 16 Emerson com Rosemount ...

Page 17: ...Figure 2 4 Rosemount FCL 02 A pH sensor B Chlorine sensor C Inlet D Drain Reference Manual Install 00809 0100 3412 May 2019 Rosemount FCL 1056 17 ...

Page 18: ...Install Reference Manual May 2019 00809 0100 3412 18 Emerson com Rosemount ...

Page 19: ... connection has the standard symbol 2 Run the power wiring through the conduit opening nearest the power terminal AC power wiring should be 14 gauge or greater 3 Provide a switch or breaker to disconnect the transmitter from the main power supply 4 Install the switch or breaker near the transmitter and label it as the disconnecting device for the transmitter 3 2 Wire analog outputs Two analog outp...

Page 20: ...ed in earth grounded metal conduit Keep output signal wiring separate from power wiring Do not run signal and power or relay wiring in the same conduit or close together in a cable tray 3 3 Alarm wiring The alarm relay terminal strip is located just below the power connector on the power supply board See Figure 3 2 Wire Reference Manual May 2019 00809 0100 3412 20 Emerson com Rosemount ...

Page 21: ...ns to the terminals strip 3 Replace the cover The two tabs on the back edge of the cover fit into slots at the rear of the enclosure and the three small slots in the front of the cover snap into the three tabs next to the relay terminal strip See Figure 3 2 Once the tabs are lined up push the cover to snap it in place Keep alarm relay wiring separate from signal wiring Do not run signal and power ...

Page 22: ...and fitting and carefully push the sensor cable up through the fitting as you pull the board forward to gain access to the wires and terminal screws 5 Wire the sensor to the signal board Refer to the wiring diagrams in Figure 3 3 and Figure 3 4 Figure 3 3 Wiring Diagram for Free Chlorine Sensor A White B Resistance temperature device return C White red D Resistance temperature device sense E Red F...

Page 23: ...Green connect to green grounding screw at bottom of enclosure 6 Once the cable has been connected to the board slide the board fully into the enclosure while taking up the excess cable through the cable gland 7 Tighten the gland nut to secure the cable and ensure a sealed enclosure 3 5 Quick Start Procedure 1 Once connections are secured and verified apply power to the transmitter When the transmi...

Page 24: ... A vertical black bar with a downward pointing arrow on the right side of the screen means there are more items to display Continue scrolling down to display all the items When you reach the bottom of the list the arrow points up 2 Choose the desired language Scroll down to display more choices 3 Choose Free Chlorine for sensor 1 S1 4 Choose the desired units for chlorine The screens in Step 5 and...

Page 25: ...ocess liquid 9 Choose the desired temperature units The main display appears The outputs and alarms if an alarm board is present are assigned to default values 10 To change outputs alarms and other settings go to the Main Menu and choose Program Follow the prompts Reference Manual Wire 00809 0100 3412 May 2019 Rosemount FCL 1056 25 ...

Page 26: ...Wire Reference Manual May 2019 00809 0100 3412 26 Emerson com Rosemount ...

Page 27: ...Reference Manual Wire 00809 0100 3412 May 2019 Rosemount FCL 1056 27 ...

Page 28: ...Wire Reference Manual May 2019 00809 0100 3412 28 Emerson com Rosemount ...

Page 29: ...en The rest of the display shows programming and calibration information Programming items appear in lists The screen can only show four items at a time and the arrow bar at the right of the screen indicates whether there are additional items in the list See Figure 4 3 for an explanation of the arrow bar Figure 4 2 Programming Screen Showing Item List A Live measurement B Item list C Arrow bar The...

Page 30: ...u are in the middle of the list There are more items for viewing Scroll up or down The arrow bar shows whether additional items in a list are available 4 2 Keypad Local communication with the transmitter is through the membrane keypad Figure 4 4 and Figure 4 5 explain the operation of the keys Display and operation Reference Manual May 2019 00809 0100 3412 30 Emerson com Rosemount ...

Page 31: ... a change or select an item The display changes to the next screen Four navigation keys move the cursor around the screen The position of the cursor is shown in reverse video The navigation keys are used to increase or decrease the value of a numeral Press ENTER to select an item and store numbers and settings Press EXIT to return to the previous screen without storing changes Pressing MENU always...

Page 32: ...own 4 3 Program the transmitter Setting up and calibrating the transmitter 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 Procedure 1 Press MENU The main Menu screen appears There are four items in the main menu Calibrate is in reverse video meaning tha...

Page 33: ...ttom the arrow will point up Move the cursor back to Outputs and press ENTER The Outputs screen appears The cursor is on Range Output range is used to assign values to the low and high current outputs 4 Press ENTER The Output Range screen appears The screen shows the present values assigned to output 1 O1 and output 2 O2 The screen also shows which sensors the outputs are assigned to S1 is sensor ...

Page 34: ...en shown below Note that the 20 mA setting for output 1 has changed to 8 50 ppm 6 To return to the main menu press MENU To return to the main display press MENU and then EXIT 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 1 A user can view the default display and diagnostic ...

Page 35: ...tion 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 will cause an out of limits condition During hold outputs assigned to the sensor remain at the last value and alarms assigned to the sensor remain in their present state Once in hold the sensor remains in hold until hold is turned...

Page 36: ...choose No 4 6 Configure the main display You can configure the main display to meet your requirements Procedure 1 Press MENU The main Menu screen appears 2 Move the cursor to Display and press ENTER The screen shows the present configuration There are four items Main Format Language Warning and Contrast Display and operation Reference Manual May 2019 00809 0100 3412 36 Emerson com Rosemount ...

Page 37: ...wice to return to the Display menu 8 Press MENU and then EXIT to return to the main display The following abbreviations are used in the quadrant display O output T temperature live Tm temperature manual M measurement mV mV pH I sensor current Cl Slp slope Gl glass impedance pH RZ ref impedance pH If you have a dual input Rosemount 1056 Transmitter other abbreviations might appear Consult the Rosem...

Page 38: ...the contrast choose either lighter or darker and press ENTER Every time you press ENTER the display becomes lighter or darker Display and operation Reference Manual May 2019 00809 0100 3412 38 Emerson com Rosemount ...

Page 39: ...c warnings applies only if a pH sensor is installed 7 Reset the transmitter to factory default settings 5 2 Default settings The transmitter leaves the factory with the default settings shown in Table 5 1 You can change the settings to any value shown in the column labeled Choices Table 5 1 Default Settings Item Choices Default Sensor assignment 1 Sensor 1 Chlorine Chlorine 2 Sensor 2 pH pH Output...

Page 40: ...99 0 4 Interval timer settings a Interval time 0 0 to 999 9 hr 24 0 hr b On time 0 to 999 sec 10 sec c Recovery time 0 to 999 sec 60 sec Measurement 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 temperature correction on or off off c resolution 0 01 or 0 1 0 01 d ...

Page 41: ...ss fault high impedance 0 to 9999 MΩ 1500 MΩ 6 Reference fault high impedance 0 to 9999 kΩ 40 kΩ Calibration pH 1 Stabilization criteria a Time interval 0 to 99 sec 10 sec b pH change 0 01 to 1 00 pH 0 02 pH 2 User entered slope 0 00 to 99 99 mV pH 59 16 mV pH 3 User entered offset 999 to 999 mV 0 mV Calibration analog outputs 1 4 mA 0 000 to 22 000 mA 4 000 mA 2 20 mA 0 000 to 22 000 mA 20 000 mA...

Page 42: ... output Outputs can be assigned to any sensor and to either free chlorine or temperature Linear output Linear output means the current is directly proportional to the value of the variable assigned to the output chlorine pH or temperature Logarithmic output Logarithmic output means the current is directly proportional to the common logarithm of the variable assigned to the output chlorine pH or te...

Page 43: ...omplete the following steps to configure the analog current outputs Procedure 1 Press MENU The main Menu screen appears 2 Move the cursor to Program and press ENTER The cursor is on Outputs 3 Press ENTER 4 Choose Configure 5 Choose Output 1 or Output 2 The screen shows the present configuration There are six items Assign S1 is sensor 1 S2 is sensor 2 Range Scale Dampening Fault Mode and Fault Valu...

Page 44: ...n of terms see Purpose of configuration and Definitions 8 To return to the main display press MENU and then EXIT 5 3 4 Range outputs Complete the following steps to range the outputs by assigning values to the low and high outputs Procedure 1 Press MENU The main Menu screen appears 2 Move the cursor to Program and press ENTER The cursor is on Outputs 3 Press ENTER 4 Choose Range Programming the tr...

Page 45: ... For an explanation of terms see Purpose of configuration and Definitions 8 To return to the main display press MENU and then EXIT 5 3 5 Simulate outputs Complete the following steps to simulate an output by making the transmitter generate an output current equal to the value you enter Procedure 1 Press MENU The main Menu screen appears 2 Move the cursor to Program and press ENTER The cursor is on...

Page 46: ...onfigure and assign setpoints to the alarm relays simulate alarm action and synchronize interval timers Important Configure the alarms first 1 Configuring an alarm means a Assigning a sensor and measurement chlorine pH or temperature to an alarm An alarm relay can also be used as a timer b Selecting high or low logic c Choosing the deadband Programming the transmitter Reference Manual May 2019 008...

Page 47: ...en the transmitter detects a problem with the sensor or with the transmitter itself that is likely to cause seriously erroneous readings If an alarm was programmed as a fault alarm the alarm activates At the same time a fault message appears in the main display Alarm logic setpoints and deadbands See Figure 5 1 and Figure 5 2 Figure 5 1 High Alarm Logic A Chlorine ppm B Alarm activates C Deadband ...

Page 48: ...the reading increases above the value determined by the deadband Interval timer Any alarm relay can be used as an interval timer Figure 5 3 shows how the timer operates While the interval timer is operating the main display analog outputs and assigned alarms for the sensor s can be put on hold During hold the main display remains at the last value Programming the transmitter Reference Manual May 2...

Page 49: ... The Rosemount FCL has an optional alarm relay board This section describes how to configure and assign setpoints to the alarm relays simulate alarm action and synchronize interval timers Important Configure the alarms first 1 Configuring an alarm means a Assigning a sensor and measurement to an alarm An alarm relay can also be used as a timer b Selecting high or low logic c Choosing the deadband ...

Page 50: ...Setpoint 5 Choose Alarm 1 Alarm 2 Alarm 3 or Alarm 4 The screens summarizes the present configuration and setpoints There are eight items Setpoint Assign S1 is sensor 1 and S2 is sensor 2 Logic Deadband Interval time Programming the transmitter Reference Manual May 2019 00809 0100 3412 50 Emerson com Rosemount ...

Page 51: ...he present setting can be edited 7 Press ENTER to store the setting For an explanation of terms see Purpose and Definitions 8 To return to the main display press MENU and then EXIT 5 4 4 Simulate alarms Complete the following steps to make the transmitter energize or de energize an alarm relay Procedure 1 Press MENU The main Menu screen appears 2 Move the cursor to Program and press ENTER 3 Choose...

Page 52: ... 5 4 5 Synchronize timers Synch Timers is available only if two or more alarm relays have been configured as interval timers Procedure 1 Press MENU The main Menu screen appears 2 Move the cursor to Program and press ENTER 3 Choose Alarms Programming the transmitter Reference Manual May 2019 00809 0100 3412 52 Emerson com Rosemount ...

Page 53: ...om the chlorine and pH sensors 4 Make various pH measurement settings The transmitter supplied with the Rosemount FCL is designed to be as versatile as possible The pH settings below are needed in some applications but are not used when pH is measured for the purpose of correcting free chlorine readings a Solution temperature correction b Transmitter isopotential point c Reference impedance 5 5 2 ...

Page 54: ...the transmitter uses the pH you enter for the pH correction Generally if the pH changes more than about 0 2 units over short periods of time Emerson recommends continuous live pH correction If the pH is relatively steady or subject to only seasonal changes manual pH correction is adequate Resolution If the chlorine concentration is less than 1 00 ppm mg L the display resolution can be set to 0 XX ...

Page 55: ...3 Choose Measurement The screen below appears only if you have a Rosemount FCL 02 Choose Sensor 1 chlorine or Sensor 2 pH The screen summarizes the present configuration for sensor 1 chlorine If you have a Rosemount FCL 02 the items are Measure Units Filter Free Cl Correct and Resolution If you have a Rosemount FCL 01 the items are Measure Units Filter Manual pH and Resolution Only four items are ...

Page 56: ...e Filter at the default value unless readings are noisy For an explanation of terms see Definitions chlorine and Definitions pH ORP 8 To return to the main display press MENU and then EXIT 5 6 Configuring temperature related 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 ...

Page 57: ...uracy use automatic temperature compensation Manual temperature compensation In manual temperature compensation the transmitter converts measured voltage to pH using the temperature you enter It does not use the actual process temperature Do not use manual temperature compensation unless the process temperature varies no more than about 2 C Manual temperature correction is useful if the sensor tem...

Page 58: ... security settings 5 7 1 Purpose This section describes how to set security codes There are three levels of security 1 A user can view the default display and diagnostic screens only 2 A user has access to the calibration and hold menus only 3 A user has access to all menus The security code is a three digit number The table shows what happens when different security codes XXX and YYY are assigned...

Page 59: ...YY are assigned to Calibration Hold and All 000 means no security Procedure 1 Press MENU The main Menu screen appears 2 Move the cursor to Program and press ENTER 3 Scroll to the bottom of the screen and continue scrolling until Security is highlighted Press ENTER The screen shows the existing security codes 4 To make a change move the cursor to the desired line and press ENTER A screen appears in...

Page 60: ...he transmitter also continuously measures the impedance of the reference junction The Rosemount 3900VP pH sensor supplied with the FCL 02 has a solution ground The Rosemount 399VP sensor supplied with earlier versions of the FCL 02 did not have a solution ground If you are using a Rosemount 399VP sensor reference impedance diagnostics will not be available Glass and reference impedance measurement...

Page 61: ... the settings to the values in the table Setting Default Ref Offset 60 mV Diagnostic On Z Temp Correct n On GI Fault High 1000 MΩ Ref Fault High 20 KΩ 5 To return to the main display press MENU and then EXIT 5 9 Resetting the transmitter 5 9 1 Purpose This section describes how to clear user entered values and restore default settings There are three resets 1 Resetting to factory default clears AL...

Page 62: ... is highlighted Press ENTER 4 Choose whether to reset all user entered values Factory Defaults sensor calibration Sensor Cal Only or output calibration Output Cal Only If you choose Sensor Cal Only or Output Cal Only a second screen appears in which you can select which sensor or output calibration to reset 5 To return to the main display press MENU and then EXIT Programming the transmitter Refere...

Page 63: ...ent changes if the temperature changes To account for changes in sensor current caused by temperature alone the transmitter automatically applies a membrane permeability correction The membrane permeability changes about 3 per C at 77 F 25 C so a 1 C error in temperature produces about a 3 error in the reading Temperature is also important in pH measurements 1 The transmitter uses a temperature de...

Page 64: ...f present is the pH sensor 6 Choose Temperature 7 Change the display to match the temperature read from the calibrated thermometer Press ENTER If the present temperature is more than 5 C different from the value entered an error message appears 8 To force the transmitter to accept the calibration choose Yes To repeat the calibration choose No For troubleshooting assistance see Troubleshooting when...

Page 65: ...er the flow of the sample to the unit It is best to install the sample tap just downstream from the tap for the FCL Chlorine solutions are unstable Run the test immediately after taking the sample Try to calibrate the sensor when the chlorine concentration is at the upper end of the normal operating range Free chlorine measuremetns also require a pH correction Free chlorine is the sum of hypochlor...

Page 66: ...electrolyte solution has been replaced may require several hours occasionally as long as overnight to reach a minimum zero current Important Do not start the zero routine until the sensor has been in the zero solution for at least two hours 4 Press MENU The main Menu screen appears The cursor is on Calibrate 5 Press ENTER 6 Choose the sensor you wish to calibrate Sensor 1 is the chlorine sensor Se...

Page 67: ... Procedure 1 Place the chlorine sensor in the chlorine flow cell 2 If continuous live pH correction is being used calibrate the pH sensor Section 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 Configuring the measurement 3 Adjust the chlorine concentration until it is near the upper end of the operating range Wait until t...

Page 68: ...resent sensor current and temperature and uses those values in calibration 10 Determine the free chlorine concentration in the sample and enter the value in the screen below See Purpose for sampling and testing precautions If the calibration was successful the live reading changes to the value entered in step 9 and the display returns to the screen in step 6 If the sensitivity is too far outside t...

Page 69: ...e decreases For these reasons a new pH sensor should be calibrated before use and the sensor should be recalibrated at regular intervals A pH sensor is calibrated by exposing it to standard solutions having known pH values The standard solutions are called buffers 6 4 2 Definitions Automatic buffer calibration In automatic buffer calibration the transmitter recognizes the buffer and uses the tempe...

Page 70: ...t is added to all subsequent measured sensor voltages before they are converted to pH If a pH sensor is buffered then standardized and placed back in the buffer solution the measured pH will differ from the buffer pH by an amount equivalent to the standardization offset User entered slope and offset If the slope and offset are known from other measurements they can be directly entered into the tra...

Page 71: ...ts the stability requirements the screen changes to show the nominal pH of the buffer The nominal pH is the pH value at 25 C 77 F 12 If the displayed value is not correct press Up or Down until the correct value is showing 13 Press ENTER Once the pH reading meets the stability requirements the screen changes to show the nominal pH of the buffer 14 If the displayed value is not correct press Up or ...

Page 72: ...e sensor 11 Watch the pH reading for sensor 2 S2 at the top of the screen Once the reading is stable enter the pH value of the buffer at the buffer temperature and press ENTER The display returns to the screen shown in step 9 12 Choose Buffer 2 13 Remove the sensor from the first buffer 14 Rinse with water and place it in the second buffer Be sure the glass bulb and reference junction are complete...

Page 73: ...ing of the referee instrument If the calibration is successful the screen below is displayed for five seconds The display then returns to the screen in step 3 If the calibration is not successful the existing calibration data is not changed A screen appears identifying the error high slope low slope or offset error For troubleshooting see Troubleshooting when no error message is showing 8 To retur...

Page 74: ...ange the value in the display to match the reading from the milliameter If the calibration was successful the screen below appears If the user entered value is more than 1 mA different from the nominal value a possible error screen appears 7 To force the transmitter to accept the calibration choose Yes 8 To return to the main display press MENU and then EXIT Calibrate Reference Manual May 2019 008...

Page 75: ...igital communications The transmitter supplied with the Rosemount FCL does not have the digital communications option Reference Manual Digital communications 00809 0100 3412 May 2019 Rosemount FCL 1056 75 ...

Page 76: ...Digital communications Reference Manual May 2019 00809 0100 3412 76 Emerson com Rosemount ...

Page 77: ... the board Procedure 1 Turn off power to the transmitter 2 Loosen the four screws holding the front panel in place and let the front panel drop down 3 Loosen the gland fitting and carefully push the sensor cable up through the fitting as you pull out the circuit board 4 Once you have access to the terminal strip disconnect the sensor 5 Unplug the sensor board from the main board See Figure 3 2 6 S...

Page 78: ...water containing large amounts of suspended solids for example open recirculating cooling water membrane cleaning or replacement will be more frequent 8 2 2 Cleaning the membrane Clean the membrane with water sprayed from a wash bottle Important Do not use tissues to clean the membrane 8 2 3 Replacing the electrolyte solution and membrane WARNING HARMFUL SUBSTANCE Fill solution may cause irritatio...

Page 79: ...umina intended for metallographic polishing of medium and soft metals b Rinse thoroughly with water 7 Wrap the plug with two turns of pipe tape and set aside 8 Prepare a new membrane a Hold the membrane assembly with the cup formed by the membrane and membrane holder pointing up b Fill the cup with electrolyte solution 9 Hold the sensor at about a 45 angle with the cathode end pointing up 10 Add e...

Page 80: ...base of the cathode stem Keep pressing the bladder until no air bubbles can be seen leaving the holes Be sure the holes remain covered with electrolyte solution 19 Place a drop of electrolyte solution on the cathode then place the membrane assembly over the cathode 20 Screw the membrane retainer in place The sensor may require several hours operating at the polarizing voltage to equilibrate after ...

Page 81: ...3 Rinse the sensor thoroughly with water and soak in pH buffer for several hours 4 Recalibrate the sensor in buffers before returning it to service 8 3 3 Other maintenance The 3900VP 02 10 sensor supplied with the Rosemount FCL 02 is disposable It has no replaceable parts 8 4 Constant head flow controller 8 4 1 General head flow controller information After a period of time deposits may accumulate...

Page 82: ...or the flow controller assembly used in the Rosemount FCL 01 Table 8 3 and Figure 8 3 show replacement parts for the flow controller assembly used in the Rosemount FCL 02 Table 8 2 Rosemount FCL 01 Constant Head Flow Controller Assembly Replacement Parts Location in Figure 8 2 PN Description 1 24039 00 Flow cell for chlorine sensor with bubble shedding nozzle 2 24040 00 O ring kit two 2 222 and on...

Page 83: ...cell for chlorine sensor with bubble shedding nozzle 2 24039 01 Flow cell for pH sensor 3 24040 00 O ring kit two 2 222 and one 2 024 silicone O rings with lubricant 4 33812 00 Dust cap for constant head flow controller 5 9322032 Elbow 1 4 in FNPT x 1 4 in OD tubing 6 9350029 Check valve 1 4 in FNPT 7 33823 00 Outside tube for constant head device Reference Manual Maintenance 00809 0100 3412 May 2...

Page 84: ...Figure 8 3 Rosemount FCL 02 Constant Head Flow Controller Assembly Replacement Parts Maintenance Reference Manual May 2019 00809 0100 3412 84 Emerson com Rosemount ...

Page 85: ...to 22 00 mA or to the value programmed in Configure outputs The transmitter also displays warning messages if a calibration is seriously in error For more information see Use the diagnostic feature 9 2 Use the diagnostic feature Complete the following steps to troubleshoot your transmitter with the diagnostic feature Procedure 1 To read diagnostic messages press DIAG The screen below appears 2 To ...

Page 86: ... Transmitter does not recognize sensor board Sensor Board Unknown Sensor Board HW Hardware or SW Software Mismatch or Sensor Board Not Communicating Sensor HW SW Mismatch Sensor board hardware and software do not match Sensor Board Unknown Sensor Board HW Hardware or SW Software Mismatch or Sensor Board Not Communicating Sensor Incompatible Sensor board software is not supported by main board soft...

Page 87: ...High Sensor Broken Glass The impedance of the pH sensing glass membrane is very low suggesting a broken glass membrane Broken Glass 9 3 1 Main Board CPU Main Board Factory Data and Main Board User Data errors These error messages mean the main board is corrupted or the eeprom data on the main board is corrupted Procedure 1 Cycle the power off and then on 2 If cycling the power does not help call t...

Page 88: ...for the main and sensor board revision numbers To read the main board revision press DIAG and scroll down until Inst SW Ver is showing To view the sensor board software revision press DIAG choose the appropriate sensor and scroll down until Board SW Ver is showing The main board can be replaced only at the factory 9 3 5 Sensor CPU Error This message means the sensor board software is corrupted Pro...

Page 89: ...oblem is with the VP cable and it must be replaced 9 3 7 Sensor 1 Not Detected The ribbon cable from sensor 1 chlorine board must be plugged into the sensor 1 plug See Figure 3 2 for the location of the sensor board connectors Procedure 1 Confirm that the ribbon cable connecting sensor 1 chlorine board to the main board is plugged into the Sensor 1 connector on the main board 2 Confirm that the ri...

Page 90: ... of the glass membrane is about 80 100 MΩ As the glass membrane ages the impedance increases A large increase in glass impedance suggests the sensor is near the end of its useful life 9 3 12 Reference Impedance Too High The Rosemount 3900VP pH sensor supplied with the Rosemount FCL 02 has a porous reference junction so the normal reference impedance is low less than 5 kΩ High reference impedance s...

Page 91: ...sensor may be miswired Sensor No Solution Gnd Sensor Need Factory Cal The sensor board was not calibrated at the factory Sensor Need Factory Cal Sensor Out of Range The pH measurement is invalid Sensor Out of Range Sensor Negative Reading The chlorine reading is less than 0 5 ppm Sensor Negative Reading Sensor RTD Sense Open RTD sensor line is broken or not connected Sensor RTD Sense Open Sensor T...

Page 92: ...g sensor should generate between 250 and 350 nA for every 1 ppm free chlorine at pH 8 3 Recalibrate the sensor If necessary clean or replace the membrane and check the fill solution 4 Replace the sensor 9 4 5 Sensor RTD Sense Open The transmitter measures temperature using a three wire resistance temperature device RTD See Figure 9 5 The transmitter uses the in and return leads to measure the resi...

Page 93: ...ent is substantially greater than 10 nA Zero current is too high Error or warning message appears while zeroing the sensor zero current is too high Zero current is too high Zero current is unstable Zero current is unstable Sensor can be calibrated but the sensitivity is significantly different from 350 nA ppm Sensor can be calibrated but the current is too low Process readings are erratic Process ...

Page 94: ...mbly Be sure the wood ring remains with the membrane assembly Use the end of a straightened paper clip to clear the holes at the base of the cathode stem Replace the membrane 5 Verify that the sensor is filled with electrolyte solution Refer to for details 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 ...

Page 95: ...n good condition and is the sensor filled with electrolyte solution Replace the fill solution and electrolyte Refer to Monochloramine sensor for details 9 5 5 Readings drift Recommended actions 1 Check to see if the sample temperature is changing Membrane permeability is a function of temperature The transmitter automatically corrects for changes in sensor current caused by temperature changes The...

Page 96: ...en the end of the nozzle and membrane retainer 6 If the sensor is new or has been recently serviced wait a few hours New or rebuilt sensors may require several hours to stabilize 9 5 6 Sensor does not respond to changes in chlorine levels Recommended actions 1 Make sure the grab sample test is accurate and that the grab sample is representative of the sample flowing to the sensor 2 Make sure that ...

Page 97: ...e the current is a minimum can lead to low results Example The true residual current for a free chlorine sensor is 4 nA and the sensitivity is 350 nA ppm Assume the measured current is 200 nA The true concentration is 200 4 350 or 0 56 ppm If the sensor was zeroed prematurely when the current was 10 nA the measured concentration will be 200 10 350 or 0 54 ppm The error is 3 6 Now suppose the measu...

Page 98: ...e from the atmosphere which lowers the pH If a high pH buffer was used in the failed calibration repeat the calibration using a fresh buffer If a fresh buffer is not available use a lower pH buffer For example use pH 4 and 7 buffer instead of pH 7 and 10 buffer 2 Was adequate time allowed for temperature equilibration If the sensor was in a process substantially hotter or colder than the buffer pl...

Page 99: ...3 Is the sensor fouled The sensor measures the pH of the liquid adjacent to the glass bulb If the sensor is heavily fouled the pH of liquid trapped against the bulb may be different from the bulk liquid 4 Has the sensor been exposed to poisoning agents sulfides or cyanides or has it been exposed to extreme temperature Poisoning agents and high temperature can shift the reference voltage many hundr...

Page 100: ...ers and the process liquid or piping b Strip back the ends of a heavy gauge wire Connect one end of the wire to the process piping or place it in the process liquid Place the other end of the wire in the container of buffer with the sensor The wire makes an electrical connection between the process and sensor If offsets and noise appear after making the connection a ground loop exists 2 Ground the...

Page 101: ...islodge the bubbles If bubbles remain a problem contact the factory 9 7 Troubleshooting when no error message is showing general Problem See Section New temperature during calibration more than 2 3 C different from the live reading Difference between transmitter and standard thermometer is greater than 3 C Current output is too low Current output too low Alarm relays do not operate when setpoint i...

Page 102: ...gure 9 2 Figure 9 2 Simulating Chlorine A Anode shield B Anode C Cathode shield D Cathode It is not necessary to disconnect the RTD leads 2 Set the decade box to 2 8 MΩ 3 Note the sensor current It should be about 500 nA The actual value depends on the voltage of the battery To view the sensor current go to the main display and press DIAG Choose sensor 1 The input current is the second line in the...

Page 103: ...displayed pH may not be exactly 7 00 5 If a standard millivolt source is available disconnect the jumper wire between IN REFERENCE and IN pH and connect the voltage source as shown in Figure 9 3 Figure 9 3 Simulating pH input Be sure to jumper the IN REFERENCE and GND SOL terminals 6 Calibrate the transmitter using the procedure in Procedure manual calibration Use 0 0 mV for Buffer 1 pH 7 00 and 1...

Page 104: ...stance temperature device sense D Resistance temperature device return Although only two wires are required to connect the resistance temperature device to the transmitter using a third and sometimes fourth wire allows the transmitter to correct for the resistance of the lead wires and for changes in the lead wire resistance with temperature 9 10 2 Simulate temperature To simulate the temperature ...

Page 105: ... is measuring temperature correctly if the difference between measured temperatures equals the difference between the values in the table to within 0 1 C For example start with a simulated resistance of 103 9 Ω which corresponds to 10 0 C Assume the offset from the sensor calibration was 0 3 Ω Because of the offset the transmitter calculates temperature using 103 6 Ω The result is 9 2 C Now change...

Page 106: ...Temp C Pt 100 Ω 60 123 2 70 127 1 80 130 9 85 132 8 90 134 7 100 138 5 Troubleshoot Reference Manual May 2019 00809 0100 3412 106 Emerson com Rosemount ...

Page 107: ...Reference Manual 00809 0100 3412 May 2019 Rosemount FCL 1056 107 ...

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